Kemppi S1065 Welding Helmet and PAPR System
This document provides comprehensive user and maintenance information for the Kemppi S1065 welding helmet and the S1005 Powered Air-Purifying Respirator (PAPR) system. When used together, they form the S1065 respiratory protection system, designed to protect the welder's eyes, face, and respiratory system.
Product Overview
The S1065 welding helmet is an Individual Protective Equipment (EPI) for welders and fabrication personnel, suitable for arc welding (MMA, MIG/MAG, TIG), spraying, gouging, and cutting. It features an automatic darkening filter (ADF) for eye and face protection.
The S1005 PAPR system provides filtered air to the welding mask, enhancing safety and comfort during welding operations. The combined system (S1065) complies with relevant safety regulations.
System Components
The system comprises the following main components:
- 1. Welding Helmet Shell with Facial Joint
- 2. Facial Joint
- 3. Headgear with Air Duct
- 4. Outer Protection Plate (114x133x1mm)
- 5. Automatic Darkening Filter (ADF) S006
- 6. Inner Protection Plate (106x66x1mm)
- 7. Filter Cover
- 8. Spark Arrestor
- 9. Pre-filter (10 pcs)
- 10. Particle Filter (4 pcs)
- 11. PAPR Ventilation Unit
- 12. Belt with Shoulder Harness
- 13. Rechargeable Li-ion Battery
- 14. Battery Charger (240V)
- 15. Air Hose with Cover
- 16. Airflow Meter
- 17. Tool Bag
Features and Operation
Headgear Adjustment
The headgear can be adjusted for depth, tightness, distance from the face, and angle to ensure a secure and comfortable fit.
Automatic Darkening Filter (ADF) Controls
The ADF filter (S006) features:
- Shade Selection: Adjustable shade range from DIN 4/9-13, selectable via the "SHADE" button for different welding processes.
- Delay Selection: Adjustable delay time from 0.1 to 0.9 seconds via the "DELAY" button.
- Sensitivity Adjustment: Adjustable sensitivity via the "SENSITIVITY" button to adapt to ambient light conditions. Turning towards '1' decreases sensitivity (for high amperage/bright light), while turning towards '5' increases it (for TIG/regular arc).
- Grinding Function: A dedicated "WELD/GRIND" button allows switching to grinding mode. Note: Do not perform welding in grinding mode.
PAPR System Operation
The PAPR unit provides a constant flow of filtered air. The system has multiple airflow settings (levels 1-3, approx. 170-230 L/min) selectable via the ON button.
Airflow Test: Before use, connect the airflow meter to the hose and operate the PAPR unit. Ensure the indicator ball reaches the minimum flow level.
Alarms: The system includes alarms for low airflow, filter blockage, and low battery.
Power and Battery
The system is powered by a rechargeable Li-ion battery (4400 mAh) and features solar cells to assist charging. The battery life is up to 8 hours on the lowest setting. A low battery indicator is present.
LCD Display
The PAPR unit features an LCD screen indicating:
- [Airflow Indicator] Current airflow data.
- [Airflow Level Indicator] Selected airflow level.
- [Filter Status Indicator] Filter condition.
- [Battery Charge Indicator] Battery charge level.
- [Battery Temperature Indicator] Battery temperature.
All indicators flashing signify a system malfunction.
Technical Specifications
Helmet Shell
| Specification | Value |
|---|---|
| Standard Reference | 16321 KMP W15 E 1-M CE |
| Impact Level | E |
| Average Medium Head Size | 1-M |
| European Conformity Marking | CE |
ADF Filter
| Specification | Value |
|---|---|
| Model | S006 |
| Filter Dimensions | 114 x 133 x 9.5 mm |
| Viewing Area | 100 x 60 mm |
| Optical Class | 1/1/1/1 |
| Shade Range | DIN 4/9-13 |
| UV/IR Protection | Permanent |
| Reaction Time | < 0.1 ms |
| Delay Time | 0.1-0.9 s |
| Operating Temperature | -5°C to +55°C |
| Standard Reference (Filter) | 4/9-13KMP 1/1/1/1/379 CE |
PAPR Unit
| Specification | Value |
|---|---|
| Code | 9875065 |
| Norm | EN 12941: 1998+A1:2003+A2:2008 TH3 R SL / AS/NZS 1716:2012 |
| Filter Type | PAPR-P3 |
| Airflow (Speed 1/2/3) | 170 / 200 / 230 L/min |
| Noise Level | Max 75 dB |
| Belt Length | 900 - 1300 mm |
| Unit Dimensions | 240 x 165 x 70 mm |
| Unit Weight | 1.1 kg |
| Battery Model | Li-ion rechargeable 4400 mAh |
| Battery Life (Speed 1/2/3) | > 8h / > 6h / > 4h |
| Battery Charge Time | 3.5 h |
| Battery Recharge Cycles | 500 |
| Storage Temperature | -10°C to +60°C |
Shade Number vs. Amperage Table (EN 379)
This table indicates the recommended shade number for different welding processes and amperage ranges.
| Welding process | Amperes | |||||||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 0.5 | 1 | 2.5 | 5 | 10 | 15 | 20 | 30 | 40 | 60 | 80 | 100 | 125 | 150 | 175 | 200 | 225 | 250 | 275 | 300 | 350 | 400 | 450 | 500 | 550 | ||
| Covered electrodes | 9 | 10 | 11 | 12 | 13 | 14 | 14 | |||||||||||||||||||
| MIG (steel) | 10 | 11 | 12 | 13 | 14 | 14 | ||||||||||||||||||||
| MIG (light alloys) | 10 | 11 | 12 | 13 | 14 | 15 | ||||||||||||||||||||
| TIG | 9 | 10 | 11 | 12 | 13 | 14 | 14 | |||||||||||||||||||
| MAG | 10 | 11 | 12 | 13 | 14 | 15 | ||||||||||||||||||||
| Plasma welding | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12 | 13 | 14 | 15 | |||||||||||||||
| Plasma cutting | 11 | 12 | 13 | |||||||||||||||||||||||
Safety Precautions
[Warning] Use only genuine Kemppi parts and accessories. Using non-approved parts can lead to serious health damage.
Lifespan: A service life of 5 years is recommended. This depends on usage, cleaning, storage, and maintenance. Inspect the helmet before each use and replace any damaged or worn parts.
General Usage:
- Ensure all adjustments are correctly set for maximum protection.
- Never weld with the visor raised or without the welding filter.
- If the ADF fails to darken upon arc strike, stop welding immediately. Inspect the ADF and power supply, and replace if necessary.
- Always use ADF filters with appropriate protection plates.
- Never use an ADF filter without the inner protection plate.
- Do not use damaged or scratched filters or oculars.
- Be aware that materials in contact with skin may cause allergic reactions in sensitive individuals.
- Operating temperature range: -5°C to +55°C.
- This product is not intended for use in explosive environments.
- The mask does not protect against explosives or corrosive liquids.
- Not suitable for laser welding/cutting or oxy-acetylene welding/cutting.
- Particle protection is effective at ambient temperature when all components are correctly fitted.
- Wearing the mask over prescription glasses may transmit high-velocity particle impact, posing a risk.
- If impact level symbols differ between the lens/filter and the frame, the lower level applies to the complete protector.
- Protectors subjected to impact must be discarded and replaced.
- The protector may affect color perception and/or light signal detection.
- Not suitable for driving or road use.
PAPR System Specific Warnings:
- Before each use, check the fresh air system for damage and proper function. Test airflow to ensure adequate volume.
- Always wear the fresh air system. Do not remove the mask or turn off the unit until you are outside the contaminated area. Failure to do so can lead to high CO2 concentrations and reduced oxygen levels within the mask.
- Consult a safety engineer if unsure about pollution concentration or equipment performance.
- Only use the system with approved Kemppi parts.
- Only use the specified particle and pre-filters.
- Ensure the system is used by trained and qualified personnel.
- Be aware of potential hose or cable entanglement.
- If the system is powered off, respiratory protection is significantly reduced or absent. Leave the work area and remove the mask.
- Do not use if the oxygen content is below 19.5% or in atmospheres with unknown substances.
- Do not use in explosive atmospheres, confined spaces, or poorly ventilated areas.
- Do not use in high winds.
- Do not alter or modify the system.
- Keep water and liquids away from the fan housing, filter, and battery compartment.
Maintenance and Storage
Maintenance
The PAPR unit should be checked regularly and replaced if damaged or leaking.
Replace the filter if it is broken, blocked, or provides insufficient airflow. Replace the air hose if it is broken or cracked.
Clean external surfaces with a soft, dry cloth. Do not use water.
The filter should be replaced along with the pre-filter.
Storage
Store the PAPR unit in a dry, clean environment between -10°C and +60°C. Protect from dust and contamination.
If stored for extended periods (over 15 days), charge the battery. For storage over 3 months, charge and discharge the battery twice to achieve nominal capacity.
For long-term storage, fully charge the battery, remove it from the unit, and store it separately. Transport the unit in its original tool bag, away from direct sunlight.
Troubleshooting
| Problem | Probable Cause | Action |
|---|---|---|
| Error Code "E01" ([Flashing Warning Light]) | 1. Motor blocked 2. Motor damaged 3. Ventilation structure failure 4. Circuit failure | Inspect and clear physical fault, restart. Return to dealer if error persists. |
| Error Code "E02" ([Flashing Warning Light]) | 1. Motor damaged 2. Motor impeller rubbing ventilation housing 3. Excessive circuit current | Inspect and clear physical fault, restart. Return to dealer if error persists. |
| [Battery Low Icon] + [Flashing Warning Light] + Alarm Sounds | Low battery | Charge the battery. |
| [Flashing Icon] + [Flashing Warning Light] + Alarm Sounds | Filter blocked / Air hose blocked | Remove obstruction, change filter, clean air hose. |
| [Flashing Icon] + Alarm Sounds | High battery temperature | Stop work and let the battery cool down. |
| No airflow, no alarm | 1. No power 2. Damaged battery contact | Charge the battery. Check battery contact. |
| Short battery life | 1. Battery not fully charged 2. Filter blocked 3. Battery damaged | Charge the battery. Clear obstruction, change filter. Replace battery. |
| Facial joint air supply has unusual odor | 1. Ventilation filter broken 2. Air hose broken 3. ADF mask broken | Immediately leave the area. Replace ventilation filter, air hose, or ADF mask. |
| Insufficient airflow to facial joint | 1. Air hose broken 2. Air hose broken 3. Ventilation filter blocked | 1. Check air hose connection to mask and PAPR unit. 2. Replace air hose. 3. Remove obstruction, change filter. |
Certifications and Compliance
The S1065 system is a respiratory protection system compliant with EN 12941:1998+A1:2003+A2:2008 TH3 R SL and AS/NZS 1716:2012.
It is tested against solid and liquid particles (P/R) and offers TH3 protection level.
The CE marking (CE 2797) indicates conformity with the European Union's essential health and safety requirements.
