RPB Z3 User manual

INSTRUCTION MANUAL
®
Z3 WELDER
™


3
CONTENTS
INTRODUCTION 4
RESPIRATORY COMPONENT CONCEPT 5
!WARNINGS! 6
CAUTIONS AND LIMITATIONS 8
RESPIRATOR OPERATION 9
SPECIAL OR CRITICAL USERS INSTRUCTIONS
- BREATHING AIR PRESSURE TABLE 10
RESPIRATOR SETUP AND USE 11
IMPACT LENS AND PROTECTION SCREEN REPLACEMENT 11
FACE SEAL REPLACEMENT 12
AUTO DARKENING WELDING PROTECTION FILTER 17
RECOMMENDED SHADE LEVELS AND LIGHT TRANSMISSION CURVE 19
DESCRIPTION OF RPB®FILTER FEATURES & TECHNICAL DATA 20
PARTS LIST 21
APPENDIX A 24
Z3 WELDER
™
RPB®Safety Global Headquarters
2807 Samoset Rd, Royal Oak, MI 48073, USA.
RPB® Safety Asia Pacic Headquarters
652 Halswell Junction Road, Hornby South 8042 New Zealand.
RPB®, Advancing Your Safety®, Nova®, Nova 3®, Radex®, Zytec®, Z-LINK®and T-LINK®are
registered trademarks of RPB®Safety LLC
For technical assistance contact our Customer Service Department at 1-866-494-4599 or email:
FORM #: 7.20.517
REV: 2
Read all instructions and warnings before using this product.
Keep this manual for future reference.

4
Z3 WELDER
™
INTRODUCTION
The RPB®Z3™ is approved by NIOSH in two
categories as follows:
Type C Supplied Air Respirator - When
used with RPB®Supplied AIr Hose and Flow
Device Systems.
Powered AIr Purifying Respirator - When
used with the PX4 AIR®PAPR unit.
It is designed for use in welding applications
where there is a need for protection from
Airborne Contaminants and UV or IR eye
protection, such as welding.
The Z3™ has been designed for use in
atmospheres that are NOT IMMEDIATELY
DANGEROUS TO LIFE OR HEALTH (IDLH).
The Z3™ is approved for use with any one of
the following ow control devices:
03-101 Constant Flow Valve
NV2016 Flow Control Valve
03-901 RPB®PX4 AIR®Powered Air
Purifying Respirator (refer to PX4
AIR®PAPR Instruction Manual for
instructions on setting up for use
with the PAPR)
WARRANTY
All RPB®products are covered by a
manufactures warranty of 3 months. The
manufacturer warranty covers defects in
material, workmanship and does not cover
damage caused by misuse or abuse. RPB®’s
only obligation and your exclusive remedy
shall be to repair, replace or refund the
purchase price of such parts or products
upon the presentation of proof of purchase.
Maximum liability is in no case to exceed the
value of the RPB®product involved.

5
RESPIRATORY COMPONENT CONCEPT
The RPB®Z3™ consists of 3 main components:
2. Breathing Tube Assembly
1. Z3™ Helmet
3. Air Supply Hose Assembly
or PX4 AIR®PAPR
FIGURE 1.1
!WARNING! Failure to use genuine parts and components that are part of the NIOSH
approved respirator assembly will void the approval of the entire respirator assembly.

6
Z3 WELDER
™
metals, corrosive liquids or hazardous
gases.
8. Materials which may come into
contact with the wearer’s skin could
cause allergic reactions to susceptible
individuals.
9. Welding helmet worn over standard
spectacles may transmit impact, thus
create a hazard to the wearer.
10. The RPB®Z3™ Welding Helmet does
not provide hearing protection. Earplugs
or earmuffs must be properly tted when
exposed to noise levels that exceed the
OSHA permissible exposure levels.
11. Do not use this respirator until you
have been trained in the respirators
use, maintenance and limitations by
a qualied individual (appointed by
your employer) who has extensive
knowledge on the RPB®Z3™
Respirator. All training must be in
accordance with this Users Instruction
Manual.
12. Before using this respirator ensure your
employer has determined that airborne
contaminant concentrations do not
exceed those allowed by applicable
OSHA, EPA or NIOSH regulations and
recommendations for continuous ow
supplied air respirators. Federal law
requires that the employer measures
and monitors airborne contaminant
levels in the work area.
13. If this respirator is used in conned
spaces ensure the area is well ventilated
and that all contaminate concentrations
are below those recommended for this
respirator. Follow all procedures for
conned space entry, operation and exit
BEFORE WELDING
1. Ensure that the helmet is correctly
assembled and that it completely
blocks any accidental light. In the front,
light may enter the helmet only through
the viewing area of the autodarkening
welding lter.
2. Check the prescribed shade level for
your welding application and adjust
your autodarkening lter accordingly
(see the table with recommended shade
levels Pg 20).
3. Never place the helmet or the
autodarkening welding lter on hot
surfaces.
4. Scratched or damaged protection
screens should be regularly replaced
by genuine RPB®replacement parts.
Before using the new protection screen,
make sure to remove any additional
protection foil from both sides.
5. Use the RPB®Z3™ only within the
temperature range of 14°F to 140°F
(-10°C to +60°C).
6. Do not expose the autodarkening
welding lter to liquids and protect it
from dirt.
7. Improper use of this respirator or
use not in accordance with this User
Instruction Manual may cause injury
or death. Improper use may also cause
life threatening delayed lung, skin and
eye disease. The RPB®Z3™ Welding
Helmet is manufactured to protect
the welder’s face against spatters and
hazardous ultraviolet and infrared rays
emitted during the welding process. It is
not intended to be used as a protection
against impact, ying particles, molten
!WARNINGS!

7
as dened in applicable regulations and
standards.
14. DO NOT wear this respirator if any
of the following conditions exist:
Atmosphere is immediately
dangerous to your life or health
You CAN NOT escape without
the aid of the respirator
Atmosphere contains less
than 19.5% oxygen
Work area is poorly ventilated
Contaminants are in excess of
regulations or recommendations
15. Do not modify or alter this respirator.
Use only parts and components that are
part of the NIOSH approved respirator
assembly. The use of non RPB®parts
voids the NIOSH approval of the entire
respirator assembly.
16. Inspect all components of the respirator
daily for signs of damage or wear
and tear that may reduce the level of
protection originally provided.
1 7. Do not wear this respirator until you
have passed a complete physical exam
including a lung X-ray conducted by
qualied medical personnel.
18. This respirator, when properly tted and
used, signicantly reduces but does not
completely eliminate the breathing of
contaminates by the respirator wearer.
19. Be certain your employer has
determined that the breathing air source
provides at least a Grade D breathable
air as specied in the compressed gas
association commodity specication
G-7.1. The respirator must be supplied
with clean breathable air at all times.
A carbon monoxide monitor must be
used at all times. Contact your RPB®
distributor for a Radex 08-200 CO
Monitor. Do not connect the respirator’s
air supply hose to nitrogen, toxic gases,
inert gases or other unbreathable non
Grade D air sources. Check the air
source before using the respirator. This
apparatus is not designed for use with
mobile air supply systems i.e. cylinders.
Failure to connect the supply hose to
the proper air source could result in
serious injury or death.
20. RPB®Safety cannot accept any liability
of whatsoever nature arising directly
or indirectly from the use or misuse
of RPB®Safety products, including
purposes that the products are not
designed for. RPB®Safety is not liable
for damage, loss or expense resulting
from the failure to give advice or
information or the giving of incorrect
advice or information, whether or
not due to RPB®Safety’s negligence
or that of its employees, agents or
subcontractors.
21. Leave work immediately if:
Any respirator component
becomes damaged
Airow stops or slows down
Breathing becomes difcult
You become dizzy, nauseous,
too hot, too cold or ill
Vision is impaired

8
Z3 WELDER
™
A) Not for use in atmospheres containing
less than 19.5 percent oxygen.
B) Not for use in atmospheres immediately
dangerous to life or health.
C) Do not exceed maximum use
concentrations established by regulatory
standards.
D) Air-line respirators can be used only
when the respirators are supplied with
respirable air meeting the requirements
of CGA G-7.1 Grade D or higher quality.
E) Use only the pressure ranges and
hose lengths specied in the user’s
instructions.
F) Do not use powered air-purifying
respirators if airow is less than 4CFM
(115lpm) for tight tting facepieces
or 6CFM (170lpm) for hoods and/or
helmets.
H) Follow established cartridge and canister
change schedules or observe ESLI to
ensure that cartridge and canisters are
replaced before breakthrough occurs.
I) Contains electrical parts which have not
been evaluated as an ignition source in
ammable or explosive atmospheres.
J) Failure to properly use and maintain this
product could result in injury or death.
L) Follow the manufacturer’s User’s
Instructions for changing cartridges,
canister and/or lters
M) All approved respirators shall be
selected, tted, used and maintained in
accordance with MSHA, OSHA, and other
applicable regulations.
N) Never substitute, modify, add or omit
parts. Use only exact replacement parts
in the conguration as specied by the
manufacturer.
O) Refer to user’s instructions, and/or
maintenance manuals for information
on use and maintenance of these
respirators.
P) NIOSH does not evaluate respirators for
use as surgical masks.
S) Special or critical user’s instructions and/
or specic limitations apply. Refer to
user’s Instruction page 9 (breathing air
pressure table) before donning.
NIOSH - CAUTIONS AND LIMITATIONS

9
RESPIRATOR OPERATION
AIR QUALITY
This respirator must be supplied with clean
breathable air at all times. Breathable air
must at least meet the requirements for Type
1 gaseous air described in the Compressed
Gas Association Commodity Specications
G.7.1 (Grade D or higher) and as specied by
Federal Law 42 CFR 84, subpart J.84.141(b)
and 29 CFR 1910.134 (i) the RPB®Z3™
Welding Helmet does not purify air or lter
contaminants.
When using a RPB®Z3™ Welding Helmet
Supplied Air Respirator. It is recommended to
use a Radex Airline Filter (p/n: 04-900) and
a GX4®Gas Monitor (p/n: 08-400).
AIR SOURCE
Supplied air
Locate the air source in a clean air
environment, always use a lter on the inlet
of your air source. Do not park vehicles
beside your air inlet as this will cause carbon
monoxide to be drawn into your air supply.
Always use suitable after coolers/dryers
with lters and carbon monoxide alarms to
ensure clean breathable air is supplied at all
times. The air should be regularly sampled to
ensure that it meets Grade D requirements.
Powered Air
Check that the contaminated area is within
the limits of the use of a Powered Air
Purifying Respirator and determine the type
of contamination. Once the contamination
level has been conrmed then you can
determine the lter cartridge to be used for
the application, to make sure that you are
sufciently protected. Make sure that the
area is well ventilated and that regular air
samples are taken to conrm the atmosphere
stays within the levels recommended by
OSHA and other governing bodies. Follow
the PX4®PAPR Instruction Manual for more
details.
BREATHING AIR SUPPLY
HOSES AND FITTINGS
RPB® Safety air supply hoses and ttings
must be used between the point of
attachment and the respirator breathing air
connection at the wearer’s belt. The hose
sections must be within the correct length
and the amount of sections must be within the
number specied in the breathing air pressure
table on page 10.
BREATHING AIR PRESSURE
The air pressure must be continually
monitored at the point of attachment. Air
pressure must be read from a reliable
pressure gauge whilst the respirator has air
owing through it.
!WARNING!
Failure to supply the minimum required air
pressure at the point of attachment for the
length of air supply hose could result in
contaminants being inhaled as the pressure
in the helmet may become negative due to
peak inhalation ow when working at very
high work rates. The RPB®Z3™ Breathing
Air Pressure table on page 9 denes the
air pressure ranges needed to provide the
respirator with a volume of air which falls in
the required range of 6-15cfm or 170-425
Its/min.

10
Z3 WELDER
™
!WARNING!
Make sure you understand the Breathing Air Pressure table (Figure 1.1) before using this
respirator.
BREATHING AIR PRESSURE TABLE Figure 1.1
This table lists air pressure ranges needed to provide the RPB®Z3™ with the volume of air that
falls within the required range of 6-15cfm or 170-425 lts/min according to U.S. government
regulations.
SPECIAL OR CRITICAL USERS INSTRUCTIONS
1. Determine your air source (column 1).
2. Identify your breathing tube assembly
(column 2).
3. Conrm the part number of the air
supply hose you are using(column 3).
4. Check your RPB®Safety Air Supply
Hose is within the correct length
(column 4).
5. Set the air pressure at the point of
attachment within the range specied
(column 6) for your breathing tube
assembly, hose length and number of
hose sections (column 5).
Make sure air is owing through your respirator when setting the air pressure.
!WARNING! The RPB®Z3™ Supplied Air Respirator must be supplied with respirable air
meeting the requirements of CGA G-7.1 Grade D or higher quality.
1. AIR
SOURCE
2. BREATHING TUBE
ASSEMBLY AND FLOW
CONTROL DEVICES
3. AIR
SUPPLY HOSE
4. SUP-
PLY HOSE
LENGTH (FT)
5.
MAX
NUMBER
OF SEC-
TIONS
6.
PRESSURE
RANGE
(PSIG AIR)
Portable or
Stationary
Compressor
03-031/03-101
Constant Flow Valve
Assembly (High Pressure)
NV2028 (25ft)
NV2029 (50ft)
NV2027 (100ft)
25
50
100
150
200
250
300
1
1
2
3
4
5
6
10 - 14
12 - 14
17 - 19
21 - 23
25 - 27
28 - 31
31 - 34
Portable or
Stationary
Compressor
03-031/NV2016
Flow Control
Valve assembly
NV2028 (25ft)
NV2029 (50ft)
NV2027 (100ft)
25
50
100
150
200
250
300
1
1
2
3
4
5
6
27 - 28
28 - 29
30 - 31
33 - 34
36 - 37
38 - 39
41 - 43

11
Remove the clear Impact Lens by
squeezing together the two tabs on
either side. If you are just wanting to re-
place the Impact Lens then now put the
new Impact Lens in and reverse steps
starting at 2.3 to 2.1
IMPACT LENS, ADF LENS AND PROTECTION SCREEN REPLACEMENT
Squeeze the tabs inside the Helmet to
release the outer shell.
Remove the outer (green) shell.
To remove the Auto darkening lter, lift
the tab at the top of the to release it.
RESPIRATOR USE AND SETUP
FIGURE 2.1 FIGURE 2.2
FIGURE 2.3 FIGURE 2.4

12
Z3 WELDER
™
FACE SEAL REPLACEMENT
Pull the lower part of the face seal holder to
release it from the airduct.
Pull the face seal holder from the two inside
upper latches.
Remove the Autodarkening Filter completely.
With the lter removed you can clean the
visor to remove any contaminants.
Slide out the Protection Screen and replace
with a new one. Make sure you use genuine
RPB®Z3™ parts or this will no longer be
covered by the warranty.
NOTE
To put the RPB®Z3™ Welding Helmet back together reverse this process starting at 2.6 and
nishing at 2.1
RESPIRATOR USE AND SETUP CONTINUED
FIGURE 2.5 FIGURE 2.6
FIGURE 3.1
FIGURE 3.2

13
Release the face seal holder from the two
outside upper latches.
Take the new face seal and push the inner
upper side of the face seal holder into the two
upper inside latches.
Push the outside upper part of the face seal
holder into the two outside upper latches.
Slide the lower part of the face seal holder
into the gap between the helmet and airduct.
NOTE
In order to be able to observe the details better, the assembly pictures show the face seal holder
without the face seal in place (fabric part).
FIGURE 3.3 FIGURE 3.4
FIGURE 3.5
FIGURE 3.6

14
Z3 WELDER
™
MOUNTING OF THE HOSE
Screw in the running nut tting of the
breathing air tube as shown on the scheme.
Adjust the length of the hose between the
hose connector and the hose holder so
you achieve the maximum comfort. We
recommend this length to be 9-11 inches of
non stretched hose, so the upper loop would
not be too long, as the length should allow
comfortable lifting of the helmet.
FOR USE WITH RPB®PX4 AIR®- SEE THE PAPR USER MANUAL
When the Z3™ Welding Helmet Respirator is being used in conjunction with the RPB®PX4
AIR®PAPR, please refer to the RPB®PX4 AIR®PAPR for instruction of use and setting up the
assembly.
Note: The RPB®PX4 AIR®is a Powered Air Purifying Respirator, therefore care must be taken
when selecting the correct lter for the application the respirator will be used in.
FIGURE 4.1 FIGURE 4.2
It is recommended that the length of the hose
from the hose connector to the Flow control
device is adjusted, so that the hose follows
the user’s back without being stretched.
Once the hose is placed into the hose holder,
adjust the height of the hose by simply pulling
the hose trough the hose holder upward or
downwards. Fine adjustment of shape of the
loop can be achieved by turning the hose left
or right.

15
Connect the Flow Control Device
Thread the loose running nut of the 03-031
Breathing Tube on to the Flow Control Device
(03-101, 03-106 or NV2016). Screw the
running nut in a clockwise direction until tight.
CONNECTING THE AIR SUPPLY
Adjust Air Pressure
Adjust the air pressure at the point of
attachment according to the Breathing Air
Pressure Table on page 10.
Connect air supply hose
Connect a RPB®Air Supply Hose insuring the
maximum sections and lengths are within the
specications on page 10.
2.
1.
FIGURE 5.1
FIGURE 5.2 FIGURE 5.3

16
Z3 WELDER
™
CLEANING / REPLACING COMFORT PADDING
ADJUSTING THE HEAD HARNESS
The Comfort Padding can be washed in a
normal Washing Machine. First remove the
Comfort padding from the front of the Head
Harness by undoing the Domes.
To adjust the Head Harness, push in the dial
on the back and then turn Right to tighten.
Or push in and turn left to loosen. A tight but
comfortable t is ideal.
Next remove the Comfort padding from the
back of the Head Harness by undoing the
Velcro.
FIGURE 6.1
FIGURE 6.2
F I G U R E 7. 1 F I G U R E 7. 2

17
USAGE
An autodarkening welding protection lter
built into a welding helmet is considered to
be Personal Protection Equipment (PPE)
protecting the eyes, face, ears and neck
against direct and indirect hazardous light of
the welding arc. In case that you have only
bought a lter without the helmet, you need
to select the appropriate helmet designed to
be used in combination with an autodarkening
welding protection lter. It has to allow the
lter, including the internal and external
protection screens, to be adequately mounted
into the helmet. There should be no tension
on the ADF Lens caused by the mounting
frame or mounting system, as it could cause
severe damage to the lter. Make sure that
solar cells and photo-sensors are not covered
by any part of the helmet, as this could
prevent the proper operation of the lter. If
any of these conditions occur, the lter may
not be suitable for use.
FIELD OF APPLICATION
RPB® Auto darkening lters are suitable
for all types of electro-welding: covered
electrodes, MIG/MAG, TIG/WIG, plasma
welding, cutting and laser welding, except for
gas welding.
FUNCTIONS
RPB® lters are supplied ready for use.
Check the degree of required protection for
specic welding procedure and select the
recommended shade, light sensitivity as well
as opening time delay.
OPERATION
RPB®autodarkening welding protection
lters operate on the basis of a liquid crystal
light shutter that protects the welder’s eyes
against intense visible light emitted during
the welding process. In combination with the
permanent passive IR/UV lter, it protects
against hazardous infrared (IR) and ultraviolet
(UV) light. The protection against harmful
radiation is present regardless of the shade
level or potential malfunction of the lter,
beyond the darkest shade number marked on
each specic model.
RPB®autodarkening welding protection
lters are manufactured according to ANSI
Z87.1, EN 379 requirements and are CE, DIN
as well as DIN Plus certied. They are not
intended to be used as a protection against
impacts, ying particles, molten metals,
corrosive liquids or hazardous gases.
Replace potentially malfunctioned or
physically damaged autodarkening welding
lters (check that the autodarkening lter
turns dark if you strike the welding arc).
AUTODARKENING WELDING PROTECTION FILTER
!WARNING!
Protection screens, both internal
and external, must be used in
conjunction with the autodarkening
lter in order to protect it against
permanent damage.

18
Z3 WELDER
™
SHADE ADJUSTMENT
Our models (PLUS and ULTRA) enable
shade adjustment range from 9 to 13. It can
be adjusted by the knob »Shade« which is
located on the lter.
ADJUSTMENT OF SENSITIVITY
Most welding applications can be performed
with welding light sensitivity set to maximum.
The maximum sensitivity level is appropriate
for low welding current work, TIG, or special
applications. The welding light sensitivity
has to be reduced only in some specic
surrounding lighting conditions in order to
avoid unwanted triggering. As a simple rule
for optimum performance, it is recommended
to set sensitivity to the maximum at the
beginning and then gradually reduce it,
until the lter reacts only to the welding
light ashes and without annoying spurious
triggering due to ambient light conditions
(direct sun, intensive articial light,
neighboring welder’s arcs etc.)
OPENING TIME DELAY ADJUSTMENT:
The opening time delay can be adjusted from
0.1 to 1.0 seconds. It is recommended to use a
shorter delay with spot welding applications
and a longer delay with applications using
higher currents and longer welding intervals.
Longer delay can also be used for low current
TIG welding in order to prevent the lter
opening when the light path to the sensors is
temporarily obstructed by a hand, torch, etc.
STORAGE
When not in use the Auto Darkening Filter
should be stored in a dry place within the
temperature range of -4°F (-20°C) to +149°F
(65°C). Prolonged exposure to temperatures
above 113°F (45°C) may decrease the battery
lifetime of the autodarkening welding lter.
It is recommended to keep the solar cells of
the autodarkening welding lter in the dark
or not exposed to light during storage in order
to maintain power down mode. This can be
achieved by simply placing the lter face
down on a storage shelf.
MAINTENANCE AND CLEANING
It is always necessary to keep the solar cells
and the light sensors of the autodarkening
welding lter free of dust and spatters:
cleaning can be done with a soft tissue or a
cloth soaked in mild detergent (or alcohol).
Never use aggressive solvents such as
acetone. RPB® lters should always be
protected from both sides by protection
screens, which should also be only cleaned
with a soft tissue or cloth. If protection
screens are in any way damaged, they must
be immediately replaced.
WARRANTY
The warranty period of RPB®Z3™ ADF
Lens is three years. Failure to follow these
instructions may invalidate the warranty.
RPB®does not accept responsibility for any
issues, which may arise from applications
other than welding.
AUTODARKENING WELDING PROTECTION FILTER
CONTINUED

19
LIGHT TRANSMISSION CURVE Figure 8.2
RECOMMENDED SHADE LEVELS FOR VARIOUS WELDING
APPLICATIONS Figure 8.1
Welding Process
CURRENT IN AMPERES
6 10 15 30 40 60 70 100 125 150 175 200 225 250 300 250 400
MMA
8 9 10 11 12 13
PLUS, ULTRA
MAG
8 9 10 11 12
PLUS, ULTRA
TIG
8 9 10 11 12 13 14
PLUS, ULTRA
MIG heavy metals
9 10 11 12 13
PLUS, ULTRA
MIG light metals
Stainless, AI
10 11 12 13
PLUS, ULTRA
Plasma Cutting
9 10 11 12 13
PLUS, ULTRA
Micro plasma
welding
4 5 6 7 8 9 10 11 12 13
PLUS, ULTRA
Shade 3
Shade 4
Shade 6
Shade 7
Shade 8
Shade 9
Shade 10
Shade 11
Shade 12
Shade 13
100
10
1
0,1
0,01
0,001
0,0001
T %
LIGHT STATE
DARK STATE
WAVELENGTH
TRANSMISSION
300 400 500 600 700 800 900 1000 1100 1200 1300 1400
[nm]

20
Z3 WELDER
™
Sensitivity Shade Delay
1
3
1
2
1
1
1
0
9
6.
5.
7.
3.
4.
Model ULTRA PLUS
Viewing Area 3.77 x 2.69 inches 3.77 x 1.83 inches
Weight 4.4oz 3.8oz
Open state shade 4 4
Closed state shade 9-13 9-13
Shade adjustment yes / internal yes / internal
Sensitivity adjustment yes / internal yes / internal
Delay adjustment yes / internal yes / internal
Grinding Mode no no
Switching time at 23°C 0.15ms 0.15ms
Clearing time 0.1-1.0 s 0.1-1.0 s
UV / IR protection UV16 / IR 16 UV16 / IR 16
Temperature range 14°F - 140°F 14°F - 140°F
TIG detection enhanced enhanced
Energy supplied solar cells / no battery charge
TECHNICAL DATA Figure 8.4
DESCRIPTION OF RPB®FILTER FEATURES Figure 8.3
1. Solar Cells
2. Photo-sensors (Photo diodes)
3. Filter housing
4. Liquid crystal shutter viewing area
1.
2.
3.
4.
5. Shade adjustment
6. Sensitivity adjustment
7. Opening time delay adjustment
Other manuals for Z3
1
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