51 WELDING HELMETS ONLY HIGH-TECH EQUIPMENT PROTECTS AGAINST HIGH RISKS
53
WELDING THE VARIOUS ELECTRIC WELDING PROCESSES Arc welding is a generic term for a process during which an electric arc is created between an electrode and the parts to be assembled. • Electric welding, a trade for experts Welders carry out assembly by melting or applying filler metal to sections or elements of various parts using an electric arc or other welding processes (coated electrode, TIG, MIG, MAG) and the appropriate equipment (welding station, welding set, etc.). Manual skill is one of the most important factors of the process. • Electric arc welding with coated electrodes This is the best known welding process. When the coated electrode approaches the parts to be assembled, an electric arc is created which releases strong heat causing the electrode to melt. Coated electrodes: for welding carbon steels or light alloy steels - for welding stainless steels. • Arc welding with non-consumable electrodes: TIG welding The electric arc is created between the sheet metal to be welded and a non-consumable W electrode protected by an inert gas (Argon or Helium). TIG stands for "Tungsten Inert Gas" where "Tungsten" refers to the electrode and "Inert Gas" the type of plasma gas used. This welding process falls into the category of arc welding processes with a non-consumable electrode. The arc is created between the refractory electrode (- of the generator) and the part (+ of the generator) under a gaseous flux; generally, it is a rare gas or a mixture of rare gases. T.I.G. welding is especially used for welding thin sheet metals, but more particularly for all metals that are difficult to weld. These metals include aluminium, magnesium, stainless steel, copper and its alloys, and carbon steels of various thicknesses. • Tungsten electrodes with a 1% to 2% thorium content are particularly used for welding light alloy steels (soft steel). This type of electrode requires lower amperage. • Tungsten-zirconium electrodes have the highest melting point and are most frequently used for welding aluminium.
GUIDE TO WELDING SHADES Equivalents: • GTAW Gas Tungsten Arc Welding according to American standards • Process 141 according to ISO 4063 • Arc welding with consumable electrode wire: MIG-MAG welding MIG-MAG welding is a semi-automatic welding process. The protective atmosphere differs according to the type used, i.e. MIG or MAG: • for MIG Metal Inert Gas, helium, argon or a mixture of both is used • for MAG Metal Active Gas, a mixture of argon and carbon dioxide is used. Only steels can be welded with this type of active protection. For MIG, the gas is inert, i.e. it does not react with the metal. For MAG, however, the gas must react with the metal and therefore be active. Equivalents: • Metal Inert Gas • Metal Active Gas • GMAW: Gas Metal Arc Welding (uses a solid electrode wire) according to American standards • FCAW: Flux Core Arc Welding (uses tubular wire, a so-called "flux-cored" wire) according to American standards • Process 131 (MIG) or 135 (MAG) according to ISO 4063 • Plasma welding Plasma welding is an automatic welding process. Plasma defines the high energy state generated by the creation of an electric arc with an orifice or nozzle. The Plasma process is a major technological breakthrough involving constricted arc welding with inert gas (TIG process). Plasma welding is essentially used for stainless steels, metals and noble alloys. PAW: Plasma Arc Welding according to American standards
FUSION
Amperage (A)
1.5
6
10
15
30
40
60
70
100
PLASMA / Plasma arc cutting
125
9
Coated electrodes
8 8
T.I.G on metals or metal alloys
10
9
M.A.G. 8
150
9
9
Amperage (A)
1.5
6
10
6 15
30
7 40
8 60
70
100
PLASMA / Plasma arc cutting
125
9
Coated electrodes
8
M.A.G.
8
T.I.G on metals or metal alloys
10
9
8
9
200
B800V
5
6
7
8
350
400
450
13
600
14 13
12
13
12 12
13
14 14
13
11
14
13
11
11
500
13
11
10
15
12
10
9
300
12
10 4
250
11
ARC-AIR / Arc Air gouging
14
12
10
14 14
13
225
11
9
13 13
12
10
14
12
11
M.I.G. on light alloys
MICRO-PLASMA / Micro plasma welding
12
11
10
M.I.G. on heavy metal
14
15
12
B800F Amperage (A)
1.5
6
10
15
30
40
60
70
100
PLASMA / Plasma arc cutting
125
9
Coated electrodes
8 8
T.I.G on metals or metal alloys
8
200
11
10
9
10
BL300F
5
6
7
8
9
10
350
400
450
13 13
14
13
11
12
11
12 12
11
600
14
12 12
11
500
13
11
10
4
300
12
10
ARC-AIR / Arc Air gouging
250
12
11
M.I.G. on light alloys
MICRO-PLASMA / Micro plasma welding
225
11
10
M.I.G. on heavy metal
175
10 9
9
150 10
9
M.A.G.
BL300V
175
10
9
12
11
150
600
14 13
12
11
500
13
11 11
10
450
12 12
10
9
400
13
11
10 5
350 13
11
ARC-AIR / Arc Air gouging
300
12
10
4
250
12
10 10 9
MICRO-PLASMA / Micro plasma welding
225
11
M.I.G. on light alloys
BL300
200
11
10
M.I.G. on heavy metal
B800
175
13 12
13 13
14 14
14
15
55
WELDING Bollé Safety protects all eyes The eye is a delicate and sensitive organ. There are many types of eye injury with severity ranging from simple irritation to total blindness. This is why it is so important to be aware of all potential risks in the workplace. Protecting eyes is our business; ensuring unbeatable product quality is our motto! Unprotected electric arc welding is dangerous It can lead to painful inflammation of the cornea and irreversible opacity of the eye’s crystalline lens, known as a cataract. Our line of products is entirely researched and designed to meet current standards and your expectations in terms of comfort and style. Our team of specialists will help you find the best solution for your risks. Bollé Safety traceability Product and batch identification ensures product quality control upstream in the distribution chain. This tracking is part of the Bollé Safety approach to constantly improve its product offering, quality, service and overall company efficiency. Bollé Safety guarantees reliable and comfortable products All products marketed by Bollé Safety comply with current European standards. Helmets from the range are guaranteed on average between one and three years. For safety and standard requirements, the auto-darkening filters must be protected by an inner and outer screen guard. No warranty will be given for damaged filters, used without protective screen guards. The consequences of incorrect use are not covered by the warranty. Products certified for your safety All Bollé Safety products comply with European directive 89/686/ EEC, EN175 and EN379.
EN379, standard for filters EN379 belongs to a series of European standards drafted by the European Standardization Committee (ESC) within the scope of the application of the European Directive on Personal Protective Equipment (PPE). It specifies the requirements relating to welding filters which automatically switch their transmission factor in the clear zone to a lower value when a welding arc is struck (known as welding filters with switchable scale numbers). The specifications of the standard apply if such a filter is to be used for continuous observation of the welding process and if it is only used during the period when the arc is struck. The standard also specifies the requirements for welding filters with different welding scale numbers in the clear zone (called welding filters with a double scale number). These filters are used for welder protective eyewear or system-mounted protection. EN175, standard for helmets EN175 specifies safety requirements and test methods related to eye and face protective equipment used for welding and associated techniques. This European standard specifies the requirements and test methods related to personal protective equipment used to protect the operator’s eyes and face against harmful optical radiation and other specific risks due to customary welding or cutting processes or other associated techniques. The standard specifies protection, including ergonomic aspects, against various risks or hazards including radiation, fire, mechanical and electrical risks. This standard defines the terms used and specifies the requirements related to materials, design and manufacture.
ACTIVE FILTERS, "INTELLIGENT" TECHNOLOGY Active welding filters provide reliable protection. Whether in a clear or darkened state, they ensure permanent protection against UV/ IR emissions, heat, sparks and projections. The filter’s degree of protection is defined to avoid "blinding" by the electric arc. Active welding filters must always be used with a welding helmet. When an electric arc is struck, the active welding filters automatically darken and when the arc is extinguished, they return to their initial clear state. So the active welding filters free up the welder’s hands and therefore save time, reduce fatigue and greatly improve quality thanks to better arc positioning. These filters must be protected by an outer and inner polycarbonate screen guard. Active Technology, high-tech filers for optimum protection.
UV/IR Filter Outer protective lens Liquid Crystals (LCD) Liquid Crystals (LCD) Glass Filter C
B
4
3
2
A
1
Inner protective lens
57 WELDING HELMETS FINISH AND STURDINESS
B800
FUSION
Permanent protection against UV/IR emissions, heat, sparks and splashes.
Delay adjustment
Four independent sensors
B800V
8 mm filter
Thanks to its new thinner, more resistant, lighter and faster filter, its sporty design and high strength, the FUSION helmet offers an array of advanced technology. The latest addition to the welding range, FUSION offers unbeatable advantages, four independent sensors, super fast reaction time, reinforced permanent protection and extreme comfort.
100 x 49 mm field of vision
Variable shades 4/9 - 13
Selection of welding shades
Reaction time: 0.25 ms
Reaction time: 0.10 ms
Permanent UV and IR protection
NEW
Permanent DIN 16, UV and IR protection
2 independent photoelectric sensors
Two year warranty
Sensitivity adjustment Two year warranty
525 g
329 g
MODEL
B800V
VERSIONS
DESCRIPTION
STANDARDS
B800V
Full electro-optical helmet with variable shade 4/9 - 13
EN379/EN175
B8V
Electro-optical filter with variable shade 4/9 - 13
EN379
COVERPLATE 500
10 x 90 mm outer screen guard
EN166
COVERPLATE 400
105 x 50 mm inner screen guard
EN166
ST3C
Adjustable headband
BESM
Sweatband
B800F
Delay adjustment 8 mm filter Fixed shade 3/11 Reaction time: 0.25 ms Permanent UV and IR protection 2 independent photoelectric sensors
WIDE field of vision: 100 x 49 mm
Two year warranty
4 sensors
Sensitivity adjustment
Off-delay adjustment
Selection of shades
Grinding
380 g
MODEL
B800F
DESCRIPTION
STANDARDS
B800F
VERSIONS
Full electro-optical helmet with fixed shade 3/11
EN379/EN175
B8F
Electro-optical filter with fixed shade 3/11
EN379
COVERPLATE 500
10 x 90 mm outer screen guard
EN166
COVERPLATE 400
105 x 50 mm inner screen guard
EN166
ST3C BESM
MODEL
DESCRIPTION
STANDARDS
FUSV
Electro-optical helmet with variable shade 6/8 - 9/13
EN379/EN175
B7V
Electro-optical filter with variable shade 6/8 - 9/13
EN379
COVEXTFUS
114 x 91 mm outer screen guard
EN166
COVINTFUS
103 x 52 mm inner screen guard
EN166
Adjustable headband
ST3C
Adjustable headband
Sweatband
BESM
Sweatband
FUSION
VERSIONS
59 WELDING HELMETS
B-LINE Delay and sensitivity adjustment
Unprotected electric-arc welding is dangerous. It can lead to painful inflammation of the cornea and irreversible opacity of the eye’s crystalline lens, called cataracts. The BLOCUS range is entirely researched and designed to meet current standards.
BLOCUS
Available in fixed and variable shades, the B-LINE range of helmets is designed for all and demonstrate Bollé Safety expertise.
Fixed (B105) or flip-up (B105R) shield
BL300V
Zytel head helmet
B105
97 x 42 mm field of vision Variable shade: 4/9 - 13 435 g
Reaction time: 0.1 ms Permanent UV and IR protection 2 sensors
B105R
One year guarantee
544 g MODEL
VERSIONS BL300V
BL300V
COVERPLATE 500
DESCRIPTION Full electro-optical helmet with variable shade 4/9 - 13
STANDARDS
VERSIONS
Description Helmet only with 105 x 50 mm fixed shield
EN175 EN175
EN379
B105R
Helmet only with 105 x 50 mm flip-up shield
Welding helmet with adjustable headband
EN175
ST3C
Adjustable headband (3 positions)
10 x 90 mm outer screen guard
EN166
CR39I10550
Screen guard - CR39 - 105 x 50 mm - clear anti-splatter
104 x 46 mm inner screen guard
EN166
MI10550
Screen guard - clear toughened glass - 105 x 50 mm
B105 B105R
ST3C
Adjustable headband
MP (9 - 13 ) 10550
Welding filter - toughened glass shade 9 - 13 - 105 x 50 mm
BESM
Sweatband
BESM
Sweatband
EN169
B100F
Flip-up shield Nylon hand-held shield
8 mm filter
Standards
B105
Electro-optical filter with variable shade 4/9 - 13
BL300F
Delay and sensitivity adjustment
MODEL
EN379/EN175
Handle
Fixed shade 3/11 Reaction time: 0.3 ms 392 g
Permanent UV and IR protection
B100R
2 sensors One year guarantee
524 g
MODEL
VERSIONS BL300F
BL300F
COVERPLATE 500
DESCRIPTION Full electro-optical helmet with fixed shade 3/11
B100F
STANDARDS EN379/EN175
MODEL
VERSIONS
Description
Standards
Electro-optical filter with fixed shade 3/11
EN379
B100R
Helmet only with 105 x 50 and/or 110 x 90 mm flip-up shield
EN175
Welding helmet with adjustable headband
EN175
B100F
Helmet only with 105 x 50 and/or 110 x 90 mm fixed shield
EN175
10 x 90 mm outer screen guard
EN166
MP (9 - 13) 10550
Welding filter - toughened glass shade 9 - 13 - 105 x 50 mm
EN169
98 x 46 x 46 mm inner screen guard
EN166
CR39I10550
Screen guard - CR39 - 105 x 50 mm
-
B100F B100R
ST3C
Adjustable headband
CR39I11090
Screen guard - CR39 - 110 x 90 mm
-
BESM
Sweatband
MI10550
Screen guard - clear toughened glass - 105 x 50 mm
-