While auto-darkening welding helmets offer clear visibility, enhancing productivity and work efficiency, new users might find various adjustments daunting, especially the shade, sensitivity, and delay settings.
Mastering these CONTROLS will help you make the most of your hood and leverage its features fully. Having used numerous self-darkening hoods in different welding processes, I understand the struggle and have sorted out the right process to set them. And hey, don’t worry, I will share everything in this article.
So, let’s dive in and find out how to adjust an auto-darkening helmet with the best setups.
Exploring Welding Helmet Shade Settings
In a welding hood, the shade configuration or DIN is the most crucial setup. It’s important to distinguish between auto-darkening helmets, which allow you to modify the darkness, and fixed-shade designs, which do not offer this flexibility.
Where To Find The Shade Configurations?
The shade adjustment knob is typically located on the side of your hood, encircled by number markings, resembling a speed regulator. However, instead of a knob, some advanced welding helmets feature a digital control panel attached to the ADF.
Auto-darkening welding helmets usually offer shade numbers (DIN) ranging from #9 to #13, with some models also including from #5 to #8. The additional range of lighter settings proves extremely useful, especially when working at low amperages, such as with a TIG welder.
How To Configure Shade Number?
I recommend checking the Helmet Lens Shade Chart to find the right dimness for any welding task. Start with the lowest number based on the arc current (amps) and gradually darken it as needed. Configuring the DIN is simple: turn the knob clockwise for a higher number or counterclockwise for a lower shade.
For instance, my Lincoln helmet includes a knob next to the shade knob, allowing me to toggle the DIN number. When MIG welding at 240 amps, I begin with DIN 10 (as per OSHA recommendation) and then fine-tune up to DIN 12 (ANSI standard) to achieve the desired darkness. It’s a straightforward process that ensures optimal protection!
Adjusting Sensitivity Levels
The sensitivity level determines how easily your welding helmet’s self-darkening feature responds to bright lights. The more sensors there are and the higher the sensitivity, the more prone it is to trigger, and vice versa. So, should you set it to the maximum limit for the best protection? Not exactly. Let me explain.
Why Does Sensitivity Settings Matter?
If you’re welding alone with a low arc current, feel free to adjust the sensitivity all the way up as long as the process permits. However, in a bustling environment like mine, where SEVERAL welders are working simultaneously, setting it to a high range can cause more issues than it solves.
With the sensitivity at its HIGHEST, the sensors in your auto-dimming helmet would be constantly triggered by welding flashes from others around you- not only your subject. This means your visibility can be compromised even when you’re inspecting the weld after striking the arc, making it challenging to work.
In such a condition, or when welding outdoors in bright sunlight, using a lower sensitivity on your hood is more practical. If you’re unsure, it’s best to start with a lower value and upgrade it as much as necessary based on your requirements.
How To Adjust The Sensitivity Of Your Welding Hood?
There aren’t any official standards on the sensitivity levels of auto-darkening welding helmets, and it mostly depends on the environment you’re in. In my experience, mid to low-values work for most welding and cutting processes.
However, for techniques that require a low shade number, such as low-amperage TIG welding, I recommend setting a higher sensitivity. The arc won’t be as bright, which means the sensors might fail to detect it if the responsiveness is too low.
Understanding Delay Time Settings
Delay time refers to the duration for which the lens remains dark after the welding arc stops. Some helmets offer this adjustment as knobs on the side, while others have switches or digital controls on the ADF.
Why Does Delay Time Matter?
Like sensitivity, the ideal delay time depends on your requirements. When welding at high amperages, the weld pool might remain very bright for a few seconds after the arc stops, requiring a longer delay. However, an unnecessarily long buffer time can be inconvenient and disorienting. So, setting it to low and tuning as needed is a good approach.
How To Tweak Delay Configurations?
Just like shade and sensitivity options, auto-darkening welding helmets also have a separate knob for delay time with usually 3 options/ranges: short, medium, and long, typically ranging from 0.1s to 1s.
The more POWERFUL the arc, the LONGER the delay setting should be. This is because heavy welding processes, like FCAW at high amperage, cause the weld pool to grow extremely hot and glow brightly, making it difficult to look at if the lens lightens up right away.
Additional Configurations
Going beyond the basics, advanced welding helmets bring a range of features to the table, designed to elevate your productivity and simplify your work. These include:
Switch Speed: This setting controls how quickly the lens switches to a darker shade when exposed to welding arcs. Faster switch speeds, typically ranging from 1/3,600 to 1/25,000 of a second, provide better protection and reduce eye fatigue.
Grind Mode: While grinding still requires eye protection, the light generated is much dimmer than an arc generated during welding. Even shade #5 would be too dark for grinding. Some helmets have a special grinding mode with a very low DIN number to prevent excessive darkening of the view.
Cutting Mode: Unlike most welding processes, gas or air carbon arc cutting processes require higher DIN settings. Activating the cutting mode adjusts the lens for such tasks, optimizing visibility for this specific application.
X-Mode: Miller Helmets introduced the innovative X-mode feature, a game-changer for welders in bright environments. X-mode uses electromagnetic sensors to detect welding arcs, eliminating issues with sunlight. This ensures reliable auto-darkening even in challenging lighting conditions.
Test Button: Helmets from brands like Lincoln Electric include a TEST button for checking the battery power and functionality of the automatic dimming mechanism. This feature eliminates the need for additional tools like a torch striker, making the testing process more accessible.
Memory And Lock Buttons: ESAB welding helmets, such as the Sentinel A50, offer advanced features like programmable memory and shade-lock for the auto-darkening filter. This allows you to save welding profiles for specific tasks easily. Press the memory button to load the correct setup- easy peasy!
It’s important to note that not all hoods use traditional knobs or switches. Helmets like the Miller T94 Series use fully digital control panels with buttons and LCD displays for a more sophisticated user experience.
As the settings slightly vary from one hood to another, I am writing specific adjustment processes:
Welding Helmet Settings For Different Processes
I have compiled the minimum settings to adjust in an auto-darkening welding helmet in the following table. The shade number is based on OSHA and ANSI standards, and the delay and sensitivity are from my own experience. Please remember that with the arc current increasing, the shade number and delay time should also usually increase, while sensitivity should decrease.
| Welding Process | Arc Current | Shade Number | Sensitivity | Delay |
|---|---|---|---|---|
| Shielded Metal Arc Welding (SMAW) | Below 60A to 550A | 7 to 11 | Medium to High | Middle |
| Flux Cored Arc Welding (FCAW) | Below 60A to 500A | 7 to 10 | Medium | Middle |
| Gas Metal Arc Welding (GMAW) | Below 50A to 500A | 7 to 10 | Medium to High | Middle |
| Plasma Arc Welding (PAW) | Below 20A to 800A | 6 to 11 | High to Low | Short to Long |
| Air Carbon Arc Cutting (CAC-A) | 0A to 1000A | 10 to 11 | High to Low | Short to Long |
| Plasma Arc Cutting (PAC) | 300A to 800A | 8 to 12 | Medium to Low | Short to Long |
Now that I’ve given you a rundown of the BEST CONFIGURATIONS, I hope you won’t have any trouble adjusting your auto-darkening welding helmet. I have written a separate article on assembling different parts of a welding helmet, read it here.
Feel free to tinker with the settings to figure out what works best for you. You can also watch this video to tweak the options:
Key Takeaways
Your helmet may have knobs, a mix of knobs and switches, or a digital control panel for adjusting the settings.
The shade configuration is important in an auto-dimming welding helmet. It’s like choosing the right sunglasses for different levels of sunlight. Start with a LOWER shade number and increase it based on the welding process and amperage. This ensures you have clear visibility while protecting your eyes from harmful rays.
Sensitivity levels determine how QUICKLY your helmet reacts to bright light. In a busy workshop or under bright sunlight, lower sensitivity prevents the welding hood from darkening too often. However, in a quieter environment, higher sensitivity ensures quick darkening for better eye protection.
The delay setting controls how long the lens stays dark after striking the arc. For high-amperage welding, a longer delay is beneficial as it keeps the lens dark for a few extra seconds, protecting your eyes from the bright flash. But for LOWER amperages, a SHORTER cool-off period is more practical.
Some auto-tint welding helmets offer advanced features like switch speed, grind mode, X-mode, test button, memory function, and cutting mode. These are like bonus features on a gadget, enhancing your experience. Experiment with these options to find what suits your style and environment best.
Finding the perfect configurations for your auto-darkening helmet takes some experimentation and practice. Don’t be afraid to tweak the settings to suit your comfort and working conditions better.
