Respirator Welding Helmet | Welding Mask With Respirator

Weldclass PAPR Welding Helmet and Air Fed Welding Helmet

The complete guide to the Respirator Welding Helmet, or PAPR Welding Helmet, plus comparisons with other welding fume control and safety methods.

In this guide we cover; Weldclass PAPR range, What to look for in a PAPR helmet, Welding helmet with respirator vs other fume protection methods, What is PAPR, PAPR Components and functions, PAPR Maintenance, Video review of Weldclass air fed helmets.

 

Explore The Range Of PAPR Welding Helmets by Weldclass 

Click through to each product for more product details, RRP prices, and info on where to buy.

 

What to look for in a Welding Helmet With Respirator

Here's some key features and differences to be aware of, when shopping for Welding helmets with PAPR respirator / air fed systems:

1. Standard vs Flip-Up

Because air fed welding masks need to incorporate air ducts, face seals, etc, they are more cumbersome to fit and remove vs a standard welding helmet. This can be an inconvenience where the operator would traditionally lift up, or remove, the helmet to adjust the auto-darkening lens controls, or for better vision when grinding, etc. To address this, some PAPR welding helmet models now offer external controls, and/or a flip-up welding lens.  Here's a comparison between different helmet designs:

PAPR Helmet Design

Pros ✅

Cons ❌

Standard with Internal Controls

Welding helmet with respirator and basic internal controls
  • Typically lowest cost option
  • Typically simpler design, lightest weight option
  • Operator has to remove helmet to change lens settings and/or when grinding etc
  • With helmet removed, there is no respiratory protection and operator is exposed to fume hazard

Standard with External Controls / Grind Mode

Welding helmet with respirator and External Controls

Example: Weldclass Promax 680R
  • External control allows grind mode to be activated easily, without removing helmet
  • Typically lower cost vs flip-up
  • Typically lighter weight vs flip-up
  • Simpler design with fewer moving parts and fewer spares (cover lenses) to replace
  • Smaller viewing area (using grind mode with helmet on) vs grinding visor on flip-up models
  • Grind mode is typically around shade 3, vs clear visor on flip-up models

Flip-Up with large grinding visor

Respirator Welding Helmet With Flip-Up Grinding Visor

Example: Weldclass Promax 850R
  • Fast and easy change from welding to grinding configuration, without removing helmet
  • Easy acces to lens controls, without removing helmet
  • In flip-up position, grinding visor offers a clear, and wider, field of view
  • Typically higher cost
  • Additional weight, and centre of gravity is further forwards
  • More moving parts and spares (eg grinding visor lens)

 

2. Cost Of Consumables

This factor is often overlooked during the initial purchase decision. Over the lifetime of a welding helmet with respirator, the accumulated cost of replacement filters can easily exceed the original cost of the helmet. Replacement filters for the Weldclass PROMAX R50 PAPR respirator unit are priced very competitively (up to 50% lower than some other brands), to reduce operating costs and maximise ROI on your helmet investment. 

 

3. Filter Size vs Battery Size

The size of the replaceable filter (eg surface area of the filter in cm2) can have an impact on the performance, and ongoing maintenance cost, of the respirator unit.  A larger filter will typically absorb more fume dust and therefore last longer before needing to be replaced, however this places more demand on the battery and shortens battery charge life. Conversely, a smaller filter will need to be replaced more frequently, but will reduce battery load. 

The Weldclass PROMAX R50 PAPR respirator unit (supplied with PROMAX 680R and PROMAX 850R PAPR helmets) features a high quality battery to provide an operating time of up to 10 hours, whilst also allowing generous filter size to be used to maximise filter life and lower maintenance cost. 

 

4. Compliance to Australian Standards 

Not all welding helmet respirator systems are tested to, or compliant with, Australian standards.  The applicable standards include AS/NZS 1716 (respirator), AS/NZS 1337.1 (welding helmet), and AS/NZS 1338.1 (auto-darkening lens). 

Weldclass PROMAX 680R and PROMAX 850R PAPR helmets comply with these standards, giving you peace of mind that your investment will provide the protection that you need and expect. 

 

5. Weight and Ergonomics

A welding helmets with respirator system includes a lot more components than a standard helmet, so it's no suprise that they are higher in weight and more cumbersome.  That said, some PAPR welding helmets are better than others when it comes to weight and ergonomics.  Weldclass PAPR helmets incorporate thousand of hours of design, testing, re-design, and live trials with Aussie welders to achieve the best possible combination of; minimal weight, weight balance and comfort - without compromising safety and durability. A common response from first-time users of Weldclass PAPR helmets is "wow, that feels so much lighter than the other brand we have been using". 

 

6. Viewing Area

While standard helmets are very easy to flip-up and/or remove, this is not quite the case with PAPR units which have additional componentry including face seals, air ducts, and hoses. Also to protect the user, a PAPR helmet should not be removed while the user is in a fume-contaminated area.  This means that the helmet is likely to remain worn for longer periods, and helmets with a larger viewing area are a definite advantage. 

Both the Weldclass Promax 680R and 850R PAPR helmets boast a super-size 95mm2 viewing area that is up to 55% larger than other well-known PAPR helmets on the market. In addition, the Promax 850R offers a flip-up lens with large clear grinding visor and shade 5 side windows for extended peripheral vision when welding.

 

 

Welding Mask With Respirator vs Other Fume Control Methods

Here we cover some of the key pros and cons of welding helmets with respirators (or PAPR welding helmets), vs other methods of welding fume control.

Fume Control System

Pros ✅

Cons ❌

Welding Helmet with PAPR Respirator

Respirator Welding Helmet With Flip-Up Grinding Visor
  • Relatively low cost for initial purchase
  • Very mobile and allows for unrestricted movement
  • Quickly & easily deployed
  • Powered air provides additional operator comfort
  • Suitable for most welding, cutting & grinding processes, inclduing MIG, Stick, TIG, Plasma, Oxy, Grinding, Gouging
  • Only protects the user / individual
  • Does not remove fumes from the environment, or protect others in the environment
  • Depends on battery power
  • Requires frequent filter replacement
  • Operator carries additional weight & bulk

Fume Extraction MIG or TIG Welding Torch

Fume Extraction MIG Torch
  • Extracts fumes directly at the point of generation for high efficiency removal
  • Eliminates need for additional set up / movement, with extraction point always at the fume source
  • High set up cost: Fume torches costs substantially more than standard torches & each torch requires a dedicated extraction & filtration unit
  • Torch is bulkier, heavier and more cumbersome than standard torches
  • Torch cannot be used in some applications where there there is confined space at the weld joint
  • More complex with additional components to service / repair
  • Not suitable for Stick/MMA welding

Mobile Welding Fume Extractor

Portable Weld Fume Extractor Example
  • Extracts fumes at the source
  • Can be moved to different locations
  • Versatile: can be easily deployed, and utilised only where/when needed by each operator
  • Easy to maintain
  • Does not interfere with operator ergonomics or comfort 
  • ALLCLEAR extractors are suitable for most welding, cutting & grinding processes, inclduing MIG, Stick, TIG, Plasma, Oxy, Grinding, Gouging
  • Need to be manually moved to the fume source / welding location
  • In very confined spaces, wall mounted, or other systems may be better option
  • May not suit robotic use / non-stop welding

Ducted / Central Fume Extraction System

Ducted Welding Fume Extraction Example
  • Extracts fumes at the source
  • Suited to large-scale workshops, especially if all workstations are typically active at the same time
  • Minimal maintenance, or down time for operators
  • High cost
  • Time consuming to procure and install
  • Can be inefficient if workstations are used at different times, and/or some workstations are not always utilised
  • Not suitable where portability & flexibility is required

 

 

What is PAPR Welding Helmet?

A PAPR (Powered Air Purifying Respirator) welding helmet is an advanced protective device designed for welders, combining respiratory protection with eye and face shielding. This type of helmet incorporates a battery-powered 'blower' that pulls air through a filter, removing contaminants such as dust, fumes, and particles before delivering clean air into the helmet's breathing zone. The continuous flow of positive-pressure purified air not only helps in preventing inhalation of harmful substances but also keeps the welder cool and comfortable. PAPR welding helmets are particularly beneficial in environments with high levels of airborne pollutants, ensuring enhanced safety and compliance with health regulations while allowing welders to perform their tasks with improved visibility and reduced fatigue.

 

 

Air Fed Welding Helmet Parts and Components

All PAPR welding helmets typically include the following components:

  1. Welding helmet: Fitted with face seal to keep contaminated air out of the users breathing zone.
  2. Breathing tube or hose: Transports purified air from the respirator to the welding helmet.
  3. Respirator blower unit: Incudes motor and fan, and houses filter components.
  4. Waist Belt: On some models this may include shoulder harness to improve operator comfort.
  5. Battery: Powers the blower unit.
  6. Main particle filter: Filters harmful particles, such as welding fume dust, from contaminated air.
  7. Pre-Filter: Filters out larger particles before contaminated air reaches the main filter, to reduce clogging and maximise filter life. Some prefilter are available with activated carbon to eliminate odours for improved operator comfort.
  8. Spark arrestor: Thin metal mesh that prevents sparks from entering filter components, which would otherwise present risk of fire or damage.
  9. Filter cover: Holds all filter components in place.

 Parts and Components of Air Fed Welding Helmet

 

Maintenance of Respirator Welding Helmets

PAPR welding helmets are typically easy to use and maintain, however it is important to follow a regular maintenance schedule so that the respirator and helmet continue to function correctly and protect the operator.  This article outlines recommended maintenance proceedures for Weldclass PAPR welding helmets. 

 

Video Review: Weldclass PAPR Welding Helmets

Join Tim Thompson at Trigger Engineering (aka Fencestay), Heidelberg West Victoria as he trials and reviews the Weldclass PROMAX 850R welding helmet with respirator: