North Honeywell 5400 Series Full Face Respirator

The Honeywell North 5400 Series: Full APF 50 Protection at the Lowest Entry Cost

NIOSH TC-14C | APF 50 | TPE Facepiece | ANSI Z87.1 Integrated Eye Protection | North Bayonet Cartridge | Fit Test Required

The North 54001S is the best-value Honeywell North full-face respirator for workers with a small fit — NIOSH TC-14C, APF 50, integrated ANSI Z87.1 eye protection, and full North bayonet cartridge compatibility at roughly $60 less than the silicone 7600 series. The 54001 is the same facepiece in medium/large. For welding and cutting environments that require simultaneous arc-flash eye protection, the 54001SW and 54001W add an integrated shade-5 welding lens to the same 5400 TPE platform. All four models deliver identical NIOSH-approved APF 50 protection to the 7600 series — the trade-off is facepiece material (TPE vs. silicone) and long-term service life in daily-wear programs. Three decisions apply: material (already resolved — TPE), size (S or M/L), and lens (standard or welding).

→ Expert Rankings: Best Honeywell North Full Face Respirators 2026 — 5400 & 7600 Series Compared

All Four 5400 Series Configurations

All four: NIOSH TC-14C | APF 50 | TPE facepiece | ANSI Z87.1 integrated eye protection | North bayonet dual cartridge | Fit test required.

Decision 1 — When to Choose 5400 TPE Over 7600 Silicone

Both the 5400 and the 7600 series carry identical NIOSH TC-14C approval, APF 50 protection, ANSI Z87.1 integrated eye protection, and North bayonet cartridge compatibility. The 5400 costs roughly $60 less per unit. The difference is facepiece material:

The 5400 series is the right choice when: per-unit cost is the primary budget constraint; facepieces are replaced on a scheduled interval (annually or more frequently) rather than cleaned and reused indefinitely; the work environment does not involve daily exposure to solvents or UV radiation that accelerates TPE degradation; or safety managers are outfitting a large workforce where the $60-per-unit price difference represents a meaningful program cost. Protection level and cartridge compatibility are identical to the 7600 — the savings come entirely from facepiece material. See the 5400 vs. 7600 comparison collection for a direct side-by-side.

Decision 2 — Size: Small or Medium/Large?

The 5400 series offers two fit ranges. M/L (54001 / 54001W) fits most adult male workers. Small (54001S / 54001SW) is designed for workers with shorter face length or narrower cheekbones — commonly including many women workers, younger adults, and smaller-statured individuals. There is no separate medium size in the 5400 or 7600 full-face line; M/L covers both. OSHA 29 CFR 1910.134(f)(2) requires a successful fit test before any occupational use — start with M/L for most workers; evaluate small when M/L fails fit testing or workers report discomfort at the temples or chin.

Decision 3 — Lens: Standard Polycarbonate or Integrated Welding?

Standard models (54001S, 54001) use a clear ANSI Z87.1 polycarbonate lens rated for chemical splash, vapor, dust, and particulate environments — not arc-rated. Welding models (54001SW, 54001W) add an integrated shade-5 welding lens assembly for arc-flash and UV/IR protection, combining a welding helmet and a full-face APF 50 respirator in a single unit. Both types accept identical North bayonet cartridges. If the application involves welding or plasma cutting in environments with simultaneous fume, gas, or particulate hazards, the welding variants eliminate the conflict between a welding helmet and a standalone respirator — at a lower total cost than the equivalent 7600 welding models.

Cartridge Compatibility: All four 5400 models use the same North bayonet dual-cartridge mount as every other Honeywell North respirator. Every North 75-series cartridge — N75001 (OV), N75002 (AG), N75003 (OV/AG), 75FFP100 (P100), N750014 (OV/P100), N75021 (OV/AG/P100) — fits the 54001, 54001S, 54001W, and 54001SW without adapters. If your facility already stocks North cartridges for North half-mask respirators, those same cartridges work in the 5400 series. North bayonet cartridges are not compatible with 3M, MSA, Moldex, or any other brand. Full selection at Honeywell North Respirator Cartridges & Filters.

Frequently Asked Questions — North 5400 Series Full-Face Respirators