bohler 64255 Guardian Air Papr System Instruction Manual

: June 13, 2024
: BOHLER

bohler 64255 Guardian Air Papr System

bohler-64255-Guardian-Air-Papr-System-PRODUCT

Product Information

The Guardian Air PAPR System is a respiratory protective device that delivers circulated over pressured air in the helmet to protect the user’s breathing zone. It is designed to meet the EN12941 certification standards and is suitable for a range of applications.

Product Usage Instructions

Preconditions for use: Before using the Guardian Air PAPR system, it is important to ensure that it is not used for welding in confined spaces. Refer to section 4 of the user manual for more information.
Unpacking / Assembly: Follow the instructions provided in section 6 of the user manual for unpacking and assembling the PAPR system.
Before Use: Before using the PAPR system, it is crucial to read and fully understand the user instruction manual. Retain the manual for future reference.
Usage: Once the PAPR system is assembled, follow the guidelines in section 8 of the user manual for proper usage.
Maintenance / Cleaning: Regular maintenance and cleaning of the PAPR system are essential. Refer to section 9 of the user manual for instructions on maintenance and cleaning.
Fault finding: In case of any issues or faults with the PAPR system, consult section 10 of the user manual for guidance on fault finding.
Storage and transportation: Proper storage and transportation of the PAPR system are important to ensure its longevity. Follow the instructions in section 11 of the user manual for storage and transportation guidelines.

Please refer to the complete user manual for detailed instructions on the remaining sections, including the list of certified helmet systems, parts and assembly drawing, technical data, and warranty information.

USER INSTRUCTION MANUAL FOR PAPR SYSTEMS
Approved to BS EN 12941 : 1998 – A1:2003+A2:2008 TH3
RESPIRATORY PROTECTIVE DEVICE – POWERED FILTERING DEVICE, INCORPORATING A SERIES OF WELDING HELMETS
CLASS TH3 P R SL

USER INSTRUCTION

The manufacturer reserves the right, at any time and without prior notice, to make such changes and amendments to these user instruction as become necessary due to misprints, inaccuracies or product enhancements. Such changes will, however, be incorporated into subsequent editions of the instruction manual.
Our latest product documents as well as all contact details for the voestalpine Böhler Welding can be found on our website at: www.voestalpine.com/welding.

IMPORTANT !

This user instruction manual must be read and fully understood before using the equipment.
The user instruction manual must be retained for future reference.

COMPULSORY INFORMATION FOR THE USE OF A POWERED AIR PURIFYING RESPIRATOR WITH WELDING HELMETS

It is imperative that these user instructions are strictly followed when using/operating a Guaridan Air PAPR (powered air purifying respirator) system. Failure to follow these instructionsmay invalidate any warranty protection that is offered or available to you in respect of the product(s). Please refer to the terms of your purchase contract in respect of the product(s) for the specific details of such warranty cover.
The product(s) are designed to protect your health and wellbeing.
Failure to comply with these user instructions may also adversely affect your health/well-being.

Please read these user instructions carefully before unpacking your product(s).
No recommendation is given as regards the suitability of this product for your needs. If you have any questions regarding the suitability of this product to your task, please contact an occupational hygienist.
Address contact information is printed on page 2.

INTRODUCTION

Guardian Air is a respiratory protective system which is based on the principle of circulated over pressured air in the helmet.
The belt-mounted blower unit delivers air through a filter and via an air hose into a helmet. The supply of filtered air creates positive pressure inside of the helmet, which prevents the external contaminated air from entering the user‘s breathing zone.

RANGE OF APPLICATION

The PAPR system is suitable for all applications where EN12941 certification is acceptable. The unit is not suitable for welding in confined spaces. (See 4. PRECONDITIONS OF USE)

APPROVALS

Guardian Air has been designed and manufactured to comply with EN12941: 1998 – A1:2003+A2:2008 as a TH3 P R SL device.
BS4275 (Guide to implementing an effective respiratory protective device program), which the user is advised to read,defines an EN12941 TH3 P R SL device as offering an Nominal Protection Factor of 500.
The PAPR system can only provide this level of protection when used with filters provided by the manufacturer marked “Böhler“ and “EN12941:1998 TH3P R SL”.
Welding helmets are certified to EN 175B
The PAPR Systems are manufactured under ISO 9001:2000 Quality System.

PRECONDITIONS FOR USE

Guardian Air must be used strictly in accordance with this user instruction manual and the instructions supplied with the corresponding helmet.
The user must read and understand all the following „Instructions for Use“ well to be able to use the respiratory protective system correctly. Any questions should be directed to the manufacturer contact points noted on page 2.
When the PAPR is switched off, little or no respiratory protection is to be expected. When the PAPR system is switched off a rapid build up of carbon dioxide and depletion of oxygen within the helmet may occur and so it is essential not to use the blower unit when it is switched off.

GUARDIAN AIR MUST NOT BE USED:

In an atmosphere that is immediately hazardous to user hygiene or health and or has oxygen content of less than 19.5% or contains unknown substances.
In confined spaces or unventilated areas such as tanks, pipes, canals etc.
Near to flames and/or sparks
In areas with danger of explosion.
In an area where there are high winds.
If the blower unit stops working due to any reason, the user must leave the contaminated area immediately.

IT IS ALSO ESSENTIAL THAT:

Nothing is allowed to touch the moving parts.
There is no attempt to modify or alter the PAPR system or filter in any way.
Water or other liquids does not enter the unit in any way – in particular the motor and fan, the filter or the battery.

Make sure that helmet fits the user‘s face perfectly. Only then is the efficiency of the system sufficient. The protective factor of the complete system is reduced if the seal of the helmet is not fitted properly, for example due to beards or long hair intervening into the seal line.
There is a possibility that the hose to helmet may become caught up in use. The PAPR system should be positioned on the person in such a way as to reduce this possibility.

Filters cannot be fitted directly to helmet and should not be adapted to do so.
Correct respiratory protection will not be provided if any parts of the equipment are modified in any way.
At very high work rates the pressure in the PAPR system may become negative at peak inhalation flow. If in any doubt the user should consult local Health and Safety personal and acceptable risk assessments taken.

The PAPR systems are for use only by competent, trained personnel.

ATTENTION!
If any of these conditions is not kept or followed, the warranty is automatically invalid.

THE USER IS ADVISED TO LEAVE THE CONTAMINATED AREA IMMEDIATELY IF:

The Manufacturer’s Minimum Design Flow (MMDF) warning Alarm sounds
Breathing becomes difficult
Dizziness or distress occurs
Any part of the system becomes damaged
Airflow into the helmet decreases or stops
Contaminant can be smelt or tasted inside the helmet
Materials that may come into contact with the user’s skin are not known to cause allergic reactions to the majority of individuals but in the unlikely event of a reaction, the user should immediately leave the contaminated area, remove the unit and seek medical advice.

SYSTEM OVERVIEW

Guardian Air is a belt mounted powered respirator with a replaceable, disposable high efficiency particle filter system. The system is certified with the helmets covered in section 10 and they cover head sizes from 535 to 600 mm circumference.
The PAPR system contains a removable 8-hour rechargeable battery pack. (8 hours in a clean environment – in a workshop the time can be significantly reduced depending on the particulate levels in the atmosphere)
Guardian Air will warn the user when the MMDF of 170 L/min, is not achieved with its audible alarm and flashing LED’s.
In operation once the alarm sounds, the user must immediately leave the work area and reach an area nominated to be safe.
The PAPR system has visual alarm for a low battery and a multiple alarm – audible and visual for a blocked filter. Depending on the fault, the user should replace the filter with a new one (In very dusty environments the filter will need changing frequently) and or re-charge or change the battery for a fully charged one. Only when the PAPR system will function with the alarm switched off and the flow rate has been tested to be acceptable, should the user return to the work place.
The filter has been developed especially for this unit. It is used to filter the air the user will breathe. It is essential that the user checks the filter for any signs of damage or deformation that could potentially let contaminated air into the system. The filter must be disposed of if the filter is damaged or if clogged to the point of triggering the systems alarm mechanism.
The removable rechargeable battery used is a Lithium-ion cell.
When supplied the battery may hold a small charge, the PAPR system should be run flat and then charged for sixteen hours before the first use.

UNPACKING / ASSEMBLY

Unpacking
Check that the package is complete and that no part is damaged due to the transport or for other reasons.
A package with the complete PAPR system including accessories contains:

Guardian Air incl. battery and P R SL filter and pre-filter
Belt
Air hose
Air flow tester
Battery charger
User Instruction

Assembly
Attach the blower unit onto the belt: Pass the inner strap through the back of the blower loops. The pass through the belt loops and then through the buckle. (Fig. 1 / p. 4)
Fit the battery to the blower unit. (Fig. 3 / p. 4)

Waist-belt adjustment:
Put the belt around your waist with the PAPR system to the back and fasten the two ends together.
If the belt is too loose, slide the male adjuster down the belt, towards the female half. If the belt is too tight. Slide the male adjuster away from the female half.
Repeat the above processes until a comfortable and secure fit is achieved. Once the belt fits correctly, secure any excess belt material through the belt loops. (Fig. 5 / p. 4)
Particulate filter
Use only Böhler marked filters as supplied by voestalpine
Böhler Welding. Using any other filters will cause invalidation of any warranty protection and/ or a serious risk to the health of the user operating the product(s).
It should first be ascertained by consulting an occupational hygienist or by calling the manufacturers technical help line as to whether the Böhler marked filters will offer suitable protection from the hazard.
Guardian Air is equipped with a high efficiency particle filters of class P R SL.
As soon as the warning alarm sounds, the pre-filter should be exchanged or checked. In very dusty area‘s this can be necessary on a frequent basis.
The filters must be regularly checked (see 7.2. Airflow Test) and replaced. Filters are intended to be replaced and must not cleaned/re-used.
Make sure that the new filters are within their expiry date, unused and not evidently damaged.
From the hygienic point of view, the maximum working time of a main filter is 2 weeks or 90 hours whichever is the greater and should not be exceeded.
WARNING!
It is essential that the user must not confuse the markings on the filter relating to any other standard other than EN12941 1998 -A1:2003+A2:2008 with the classification of the device when used with this filter.
Removing the filters and fitting new ones
Open the filter cover by pulling the cover outward from the right side of the blower. (Fig. 6 / p. 4)
ATTENTION! It is strictly forbidden to use any tools to open the filter cover.
To remove the filter, pull it out of the unit. Clean the unit from dust ensuring no dust enters the air inlet.
Insert the new filter back into position. (Fig. 7 / p. 4) Push it gently in until it fits well on the body of the unit.
Put the pre-filter and spark guard in place. Close the filter cover.
Pay special attention, the filter cover will snap in place when properly closed. Do not attempt to use the blower unit without the cover fitted correctly.
Changing the pre-filter (Fig. 7 / p. 4)
The pre-filter is a fleece fabric which is fitted over the main filter.
To remove / replace simply pull off the old filter and stretch the new one into position. It is important to ensure that the filter media of the main filter is completely covered by the pre filter.
Attaching the hose to the PAPR system:
Align the pins of the hose bayonet connector with the slots in the air outlet of the PAPR system. Push the bayonet connector into the blower until it reaches the bottom of the hole and then twist in a clockwise direction until the locating pins clips into place.
Fitting the hose to the helmet is the same procedure.
Donning the Böhler Guardian Air helmets:
Set the welding helmets rake and adjust the welding filter to suit. (See the helmet’s user instructions)
Lift the helmet to it’s upper position.
Place over the head and adjust the headgear ratchet wheel by pushing it in and twisting until a satisfactory tightness is achieved.
Pull the elasticated chin guard downwards and at the same time pull the helmet down. Ensure the elasticated chin guard fits comfortably under the chin.
The Welding helmet is now ready for use.

BEFOR USE

Inspection before use:
Each and every time before starting work, check that:

All components are in good condition with no visible damage (like holes, tears etc.). Replace any damaged or worn parts. Carefully examine the air hose, seals and the face piece.
There is a good connection between the air hose and the helmet as well as the PAPR system.
There is sufficient air flow. (see 7.2. Airflow Test)
The air is supplied through the whole PAPR system from the blower to the helmet.
Charge the battery before the first use and check that the battery has sufficient charge prior to every subsequent use. (see 7.3. Batteries)
Ensure the alarms are working correctly (see 8. Usage) 7.2. Airflow test: (Fig. 4 / p. 4)
Disconnect the air hose from the blower unit.
Insert the airflow indicator into the air hose connector and keep the hose in vertical position at about the eye level.
Switch the power unit on. The airflow is sufficient only if the ball indicator reaches the minimum flow rate level. If the indicator sinks is below the minimum flow rate level, it is necessary to charge the battery or change the filter. If the problem still persists, see chapter 10 for additional suggestions.

NOTE ! Batteries are delivered only partially charged. All batteries must be charged before they are used for the first time. The battery can be charged separately or on the blower unit.

WARNING
It is imperative that the battery charger used to charge the product(s) is the one that was delivered to you at the time of receipt of the product(s) and is a manufacturer approved battery charger. Using any other battery charger will cause invalidation of any warranty protection and / or a serious risk to the health of the user operating the product(s) from fire or explosion.
The charger must not be used for any other purpose than that for which it was manufactured. Do not charge the battery in a potentially explosive atmosphere. The battery charger is intended for indoor use. It must be protected against damp. The charger controls the charging automatically. After the battery has been charged, the charger switches to the trickle charging regime and keeps the battery fully charged. The charging time is 4 to 6 hours.

WARNING

Check that the voltage of the electrical power supply is correct.
Check that the battery charger being used to charge the product(s) is the one that was delivered to you at the time of receipt of the product(s) and is a manufacturer approved battery charger. It is essential that only the supplied charger is used. Failure to do so may cause a serious risk of fire or explosion.
Plug the charger into the socket. Either direct into the blower when the battery is fitted or into the battery directly.
Connect the battery to the charger. The socket of the battery is positioned on the back side.
The charging state is indicated by a red LED diode light.
After charging has been completed, the trickle charging regime is activated: – red LED diode goes out, the green LED diode comes on at the moment of trickle charging.
Disconnect the charger from the power supply.
Do not leave the battery charger in the power supply if not in use!

Battery changing

Removing the battery:
Locate the battery catch. Pull back the battery catch and at the same time the battery can be removed by lifting upwards.

Fitting the battery:
Make sure the battery is the correct way up (as per 6.2) and then slide into the blower unit until the battery catch engages.
It is essential that the battery catch is fully locked. (Fig. 3 / p. 4)

USAGE

Switch on the blower unit by pressing the ON/OFF button on the control panel. The airflow can be adjusted by pressing the + /- buttons from 180 l/min up to 220 l/min in six speeds. The Green LED diodes shows the actual airflow level. Please note that for every press of the buttons, it is necessary to hold the press for 2 seconds for the action to occur. This is to avoid accidental changes. (Fig. 2 / p. 4)

Guardian Air ensures a constant supply of air. The microprocessor inside the unit automatically regulates the motor speed to compensate the filter clogging and the battery state. If the microprocessor cannot keep the adjusted airflow, the unit will sound a ‚beeping‘ alarm (an acoustic signal can be heard), at which point the user must check the PAPR system. If possible, the microprocessor automatically reduces the airflow to the next lower level, if it fails to meet the lower level, the alarm will still sound. When the airflow falls below the minimum safe operating level, a second audible alarm joins the first. At this point, the user must stop working at once, leave the working environment and reach an area nominated to be safe and change the filter or recharge/change the battery.
To check the alarms it is necessary to block off the air outlet with the palm of a hand or by another suitable means. Then with PAPR system switched on, the motor will try to compensate by increasing the speed until the microprocessor sounds the alarm as described above.
To check the battery: When first starting the unit, the battery LED‘s will flash red on the control panel then go out if light stays on this indicates low battery and should be charged. It is recommended that only a fully charged battery should be used when starting a work shift.
With a fully charged battery in place, the unit should function normally, but if the audible alarm still sounds, the user must change the filter. If the problem still persists, see chapter 10 for additional suggestions.

MAINTENANCE / CLEANING

The blower unit, filter housing and helmet must all be regularly cleaned to keep them in good working order.
For single users, the units can all be cleaned with a cloth moistened with luke-warm water and soap.
For multiple users, the units should be disinfected when passed from one user to another.
Liquids must not be allowed to enter the workings of the PAPR system or get on to the element of the filter.
Parts should be allowed to air dry. Under no circumstances should any solvents or abrasive cleaning agents be used. The unit must not be dried using hot air or radiant heat.
The PAPR system should continue to provide protection to the designed specification for 2 to 3 years, when maintained in accordance with these instructions. Prior to each use the user should check that the PAPR system is free from defects, such as cracks, split filters and hoses, cracked visors and helmet components as appropriate.

FAULT FINDING

If there is a sudden change in air supply while using the system,it is necessary to check the following:

That all parts of the air-supply system are assembled properly.
The battery and its connector
Whether the battery is not faulty or malfunctioning
Filters and their clogging
That there is not a hole in the air hose.
Whether the helmet seal is not damaged.
Whether the working time after a full recharging of the battery has not decreased (if so, it is necessary to replace the battery).

STORAGE AND TRANSPORTATION

When not in use or during transportation the blower and head units should be stored in the container in which they were provided, or other similar container, such that it is out of direct sunlight, not in contact with solvents and cannot be damaged by physical contact with hard surfaces/items. Do not store outside the temperature range of +0°C to +40°C or with humidity above 75% RH.

HELMETS SYSTEMS CERTIFIED

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13 – Guardian 50M Air – 86669
13 – Guardian 50FM Air – 86682
13 – Guardian 62 Air – 57007
13 – Guardian 62F Air – 57029
14 – Big Vision Air – 73314

LIST OF PARTS AND ASSEMBLY DRAWING

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Guardian Air (complete blower kit) – 86692
Motor unit – 86668
Particle filter P R SL (4 pcs.) – 86645
Pre-filter (10 pcs.) – 86655
Spark guard – 86704
Filter cover – 86657
Standard battery (5.200mAh) – 86660
Heavy duty battery (7.800mAh) – 57075
Universal charger – 57081
Flexible air hose incl. air hose protection – 57065
Comfort belt – 57144
Shoulder harness – 57146
Airflow tester – 57184
Face-seal – 57182
Böhler bag (blue) – 57186
Böhler bag (black) – 86702

TECHNICAL DATA

Guardian Air is a light-weight and easy to handle PAPR system.
It is equipped with a replaceable particulate filter. The system affords reliable protection against particulates and aerosols.

Air flow: 180 to 220 l/min. with a minimum flow rate of 170 l/min for the alarm to sound.
Weight with filter and battery: 870 grams
Operating temperature between 0 °c and +40 °c
Type of filter: P R SL
Type of battery: Replaceable and rechargeable Li-Ion 7.4 V / 5.200 mAh
Charging cycles >350 r
Visual alarm for low battery voltage
Visual and audible alarms for insufficient flow rate (below 170 l/min)
Nominal Protection Factor (NPF) 500
Noise level: 65 dB
Operating time greater than 8 hours on minimum flow rate with a new filter and fully charged battery in a clean environment. (6 hours on maximum flow rate.). In actual use, operating times can be significantly reduced depending on the level of contaminants in the environment
Note! Operating time can be shortened in case of clogged filter under charged battery

WARRANTY

The Guardian Air is guaranteed for a period of 12 months from date of purchase against mechanical or electrical defects.
The Böhler battery is guaranteed for a period of 12 months from the date of manufacture.

voestalpine Böhler Welding undertakes to exchange or repair without charge, any part found to be defective within this period.
Alternatively, and at its discretion voestalpine Böhler
Welding may replace the part.

This guarantee is subject to:

Guardian Air has been used solely for the purpose for which it is intended.
Guardian Air has not been subject to misuse, accident, modification or repair.
N.B. In the event of a claim, contact the retailer from which the Guardian Air was purchased.
This guarantee does not cover normal wear and tear.
This guarantee does not affect your legal rights.

Certification EN 12941:1998+A1:2003+A2:2008
Certified by: APAVE SUDEUROPE SAS Notified Body 0082
13322 MARSEILLE
CEDEX 16
France
This PPE device complies with the following applicable EU standards:
EN 12941:1998+A1:2003+A2:2008
EN166B:2001
EN379:2003 +A1:2009 EN175B

Symbols:

Refer to the manufacturer‘s instruction manual:

Store between 0-40°C (Degrees Celsius):

Storage until:

Maximum storage Humidity <75%:

Filter Symbols: