Like most electronic equipment, the heart of an auto-darkening helmet is the BATTERY. I have often been approached by new welders seeking a better understanding of their welding helmet batteries, often with queries for identification, replacement, and troubleshooting.
If you’re in the same boat, don’t worry. This article will give you a comprehensive rundown of batteries for welding hoods, covering everything you need to know. So, let’s get started right from the basics.
Why Do Some Welding Helmets Need Batteries?
While fixed-shade hoods operate without batteries, auto-darkening welding helmets work entirely on electronics, powered by batteries. Each step of the process, from the sensors relaying signals to the Electronic Control Unit (ECU) to the auto-darkening filter (ADF) dimming to filter the welding flash, requires power.
What’s more interesting? Even in solar-powered welding helmets, batteries or cells are ESSENTIAL to initiate the process. Despite their name and inclusion of solar panels, they can draw power from sources beyond the sun. The welding arc emits large amounts of UV and IR radiation, similar to sunlight, enabling solar panels to generate power even indoors.
So, guess what? Batteries are crucial to activating the auto-darkening helmet when you start welding, safeguarding your eyes from the first flash that begins powering up the solar panels.
Types Of Battery Used In Welding Hoods
Due to their compact design, welding hoods can only accommodate coin batteries. The most common type is the CR2450, which is compatible with auto-darkening welding helmets from brands such as Miller, Lincoln Electric, Hobart, Vulcan, and ESAB. On the other hand, masks from 3M Speedglas, Harbor Freight, and Optrel usually use CR2032 cells.
In my experience, most of the best welding helmets also use CR2025 coin batteries. Respirator helmets require a larger rechargeable battery, which is necessary only if you need a respirator.
So, Where Are Those Cells Located?
The exact placement of the batteries may vary from one helmet to another. However, its chamber/tray is typically located adjacent to the ADF control panel responsible for lens adjustment, usually housing two coin batteries. This arrangement makes sense, as the control panel contains most of the electronics.
Some auto-darkening helmets have removable batteries, covered by a lid that can be removed to reveal and access them. On the other hand, the cells are usually sealed for life in solar-powered hoods.
Can They Get Damaged During Welding?
The location of the helmet batteries inherently SAFEGUARDS them from damage while welding. Positioned on the inside, they are shielded from welding sparks and flying metal debris. Additionally, the batteries remain encased within their dedicated chamber, further enhancing their protection.
However, it’s important to note that in very humid or corrosive environments, MOISTURE seeping into the battery tray can potentially damage both the chamber and the cells over time. Therefore, it’s essential to take proper precautions.
Also Read: Are Auto-Darkening Helmets Really Safe?
How Long Do Welding Helmet Batteries Last?
In auto-darkening welding helmets, it’s a no-brainer that BATTERY LIFE DEPENDS DIRECTLY ON USAGE. The longer and more frequently you use it, the quicker the power drains.
In the early stages of my career, I relied on a hood that required a battery replacement every 3 to 4 months. Given my daily use and extensive welding hours, this frequency serves as a practical estimate in the field.
In solar-powered helmets, however, you don’t have to worry about battery life – not for a FEW YEARS, at least. These hoods constantly trickle charge the cells using sunlight or UV light from the welding arc, generating power with their built-in solar panels.
It all comes down to how long you can keep using the batteries before they are too worn out to hold any charge. Depending on the quality and usage of your welding helmet, this can range anywhere between 3 months to 3 years.
But, How Do You Know If The Battery Is Working?
Many auto-darkening welding helmets include a BATTERY INDICATOR LED, which should alert you when the batteries are low, providing you with ample time to replace them before the mask stops working entirely. Some high-end hoods even feature a battery health display just like a smartphone for a more precise indication of the remaining charge.
And here is the kicker: if your helmet lacks a battery life indicator or if you’re unsure, you can still test its functionality. Simply expose the sensors to a sudden bright light source and check if the lens darkens.
Dead Battery? Here Is What To Do
If the welding helmet batteries are not working, first, ensure that no one uses them unknowingly. As for the solution, well, you’ve probably guessed it already – you’ll need a new pair of cells. This shouldn’t be an issue at all if the welding mask uses replaceable batteries.
However, if they’re sealed for life, you’ll have to either take the helmet to a repair shop or pry open the battery tray yourself. Make sure to get the same type of batteries that were originally in the helmet to prevent any compatibility issues.
Also Read: Welding Helmet Troubleshooting Guide
How To Change Batteries In Your Auto-Darkening Welding Helmet?
Auto-darkening welding helmets come with either removable or fixed batteries, so there are typically two approaches to replacing them.
A. Replacing Removable Batteries
What You Need
A new pair of batteries
Tweezers (optional)
A screwdriver
The user manual
Step-By-Step Guide
UNCLIP the main panel from the lens covers and remove it.
LOCATE the battery holder/tray, referring to the user manual if needed.
Carefully REMOVE the battery holder with your fingers or a pair of tweezers. You may need to unscrew it first.
PUT BACK the old cells in the chamber with the new ones. Put the holder back in place and screw it securely if it was previously screwed in position.
FIT the panel and secure it in position.
This process is pretty straightforward, however, it may require a slightly different approach, depending on the model of the helmet. For example, to change the battery in the Lincoln Viking 3350, you have to detach the grinding cable and the ADF itself. On the other hand, the battery slot in ESAB Sentinel A50 is separated from the main ADF unit, and it requires two batteries, instead of one. (learn more)
In addition to this, you may also like to see this video to know how easy the process is:
B. Changing Non-removable Batteries
Before we begin, I want to clarify that I don’t recommend beginners replace the non-removable batteries of a new helmet, as doing so could potentially damage it and/or the ADF and void its warranty.
In this method, along with the screwdriver and tweezers, you will also need:
A rotary tool or another similar cutting tool
Soldering iron
Superglue
Step-By-Step Guide
Refer to the USER MANUAL or search for similar welding helmets online to locate the battery chamber. Since the cells aren’t meant to be removed, they won’t be clearly marked on the outside. If you find a hood with a similar panel, you could try cutting it in the same area on your helmet’s panel.
Use a sharp rotary tool (I used Dremel) to cut over the area where you expect to find the battery. Be very slow and careful, as even a slight mistake can damage internal wiring or PCB boards. Alternatively, check if it’s possible to pry open the panel – this would be less risky.
Once you have cut or pried open the panel, take a PICTURE so that you can put everything back in place later. You’ll likely find the batteries soldered to a wire or securely housed. These wires and connectors are delicate, so handle them carefully as you remove the old batteries.
Put the new cells in place and replicate the connections of the old batteries. You may need to SOLDER the battery holder leads, but be careful, as excessive heat can damage the darkening system and delicate components inside the panel. Factories use advanced soldering technology during manufacturing to avoid exposing the electronics to high heat.
Use super glue or a similar adhesive to stick the small piece of plastic back in place that you cut off with the rotary tool to access the welding helmet battery tray.
That’s it! Once the adhesive dries out, store your auto-darkening helmet properly. You can also watch this video for a similar modification with non-removable batteries:
Once again, I wouldn’t recommend attempting these modifications if you’re just a hobbyist. Unless you are experienced in DIY and know what you’re doing, it’s not worth risking damage to such a crucial piece of safety gear. It’s better to invest in the best quality welding helmet with removable batteries or a longer lifespan.
Key Takeaways
Auto-darkening welding helmets require batteries for their operation, as they rely entirely on electronics. They are crucial even in solar-powered hoods.
The most common welding helmet batteries are CR2450 and CR2032 coin batteries. CR2025 and CR2450 are also used in some hoods.
They are typically located in a chamber adjacent to the ADF control panel and are shielded from damage during welding.
Many welding helmets include a battery indicator LED to alert users when batteries are low.
Replacing batteries in welding helmets can vary depending on whether they are removable or fixed, with removable batteries being easier to change for beginners.
