Spares and consumables for a powered air helmet system: filters, spark protectors, hoses, batteries and soft hood parts, and how to choose the right ones.
How do I work out which replacement part my powered air system needs?
Start with the data plate and the parts list in the user manual. They show the correct type for each item, such as pre-filter, main filter, spark protector, hose, battery or charger. Note any part number printed on the old part and match it against the manual.
The HSE advises that replacement parts ideally come from the original manufacturer, so the equipment still performs as the maker intended. Parts for one blower and helmet combination are often not interchangeable with another, so do not guess from appearance. If you are unsure, our team can help you check the details before you order.
When should I replace the pre-filter, and when the main filter?
Follow the manufacturer's instructions first. Powered systems usually have a clogged-filter alarm. On many units the pre-filter is changed first when that alarm sounds, because it catches the coarse dust and wears out sooner.
If the time between alarms keeps getting shorter, that suggests the main filter is also loading up and should be changed. Change any filter that is damaged, visibly contaminated or harder to breathe through, and never use one past its shelf-life date. Fitting the date to the filter when you open it is good practice.
Can I clean a clogged filter and use it again?
No. Filters of this type cannot be cleaned or reprocessed. Maker instructions say filters must not be washed or cleaned with compressed air, and a dirty filter must never be reused, because this can damage the filter material. The HSE says filters have limited capacity and should be replaced when necessary.
A clogged filter makes the blower work harder and, on many systems, triggers an alarm. If the alarm sounds or the airflow falls, leave the work area and fit a new filter rather than trying to revive the old one.
How do I look after the battery and charger?
Charge the lithium-ion battery only with the charger specified by the manufacturer. Other chargers can overheat the cells. Charge indoors in a clear, dry place away from flammable material and away from the welding area, and stay inside the temperature range given in the manual.
Before use, look the battery over for damage, leaking or swelling, and do not use it if you find any. Do not open it, short it or let the cells get wet. If run time becomes noticeably shorter, the battery is wearing out and should be replaced. Dispose of old batteries through a proper recycling route, not general waste.
What should I check on the air hose and hose cover?
Look along the whole hose before each use for holes, cuts, scratches, kinks and damaged end fittings, and make sure it connects firmly at both the blower and the helmet. A damaged hose can let unfiltered air in or reduce the flow, so replace it.
Where a protective hose cover is fitted, heat, sparks and ultraviolet from welding can wear and weaken it, and it may stop protecting the hose as intended. Replace a cover that is burnt, worn, faded or damaged, and follow your manual for any replacement interval it gives. Use only the hose and cover listed for your system, and keep the hose clear of sparks and hot work.
How do I check the airflow is high enough before I start work?
Check before every session that the unit works as the manual describes. The HSE says to always check the fan is providing enough airflow before using the device, and never to keep working if the fan stops or the flow rate falls.
Many systems have a built-in flow indicator or alarm, and the manual describes how to use it to check airflow. The method varies, so follow your manual. If an alarm sounds or the airflow drops, leave the work area immediately, and only then change the filter or battery.