We’ve all been there—right in the middle of a weld when your auto-darkening lens flickers or stops working. Your visibility drops, your eyes feel the strain, and you realize: your hood’s BATTERY IS DYING.
With the ESAB Sentinel A60 welding helmet, you get a low-battery warning light to alert you before the auto-darkening filter (ADF) fails. It’s a great improvement over older models, but do you know what to do when that light starts blinking?
This guide will cover everything you need to know:
When to replace the cell of ESAB’s A60
How to do it safely and correctly
Common mistakes to avoid
Tips to extend battery life
Let’s make sure your helmet is always ready when you need it.
Signs That Your ESAB Sentinel A60 Needs a Battery Replacement
Earlier models of auto-darkening welding helmets didn’t provide a clear warning before their cells died. Even the widely popular Sentinel A50 only offers a digital display to check battery levels, which can be inconvenient—especially if you tend to forget to check.
FORTUNATELY, ESAB listened to welders’ concerns and introduced a workaround. The all-new Sentinel A60 now features a low-battery warning light that flashes to grab your attention—a fantastic addition! You can also check the digital display for the power status. Full review here.
While these are the most obvious indicators, there are other signs to watch for.
ADF Flickering Intermittently: If the lens goes dark and then suddenly flashes bright, your battery is struggling.
Slow Reaction Time: The ADF isn’t switching as fast as it should when you start welding.
Dim Auto-darkening Filter: The display appears faint or inconsistent.
Completely Unresponsive ADF: The lens no longer darkens, leaving you exposed.
If you ignore these signs, you risk eye strain or even arc eye (welder’s flash). So, always replace the battery as soon as possible. This is why I always recommend keeping spare cells handy and never waiting until they die completely. As soon as the power level drops to the last indicator, install a fresh pair.
What Type of Battery Does the Sentinel A60 Welding Helmet Use?
The ESAB Sentinel A60 auto-darkening welding hood is powered by solar cells along with two CR2450 lithium-ion batteries, just like its predecessor, the A50. These cells are NOT RECHARGEABLE, so once they run out, they must be replaced.
How Long Do the Batteries Last?
CR2450 Li-ion cells provide approximately 600 mAh of power and typically last around 8–9 months, depending on usage. I’ve been using my Sentinel A60 welding mask for over a year, and my first battery change was just recently—so in my case, they lasted nearly a year, which is impressive!
However, battery life varies based on:
Frequency Of Use: If you weld daily, expect faster drain.
Lighting Conditions: Bright environments keep the ADF sensor active, draining power.
Battery Removal When Not In Use: Leaving cells inside the hood can cause slow discharge, even when stored.
To extend their lifespan, I ALWAYS remove the batteries off the welding helmet after use. If you leave them inside the mask for long periods without use, they may last less than two months. This is because the ADF of the A60 is highly sensitive and continuously reacts to changes in ambient lighting, which slowly drains the cells. Here is how to use it properly.
I’ve used many other auto-darkening helmets with CR2450 batteries, and proper storage can extend their life up to two years!
MYTH: Can The ESAB A60 Helmet’s Solar Panel Recharge The Battery?
NO—the solar panel only assists the ADF and slightly extends battery life. It does NOT charge the cells, meaning you must replace it when it runs out.
Step-by-Step: How to Replace the Batteries in the ESAB Sentinel A60?
Replacing the battery of this welding helmet is QUICK and EASY—all you need is a small screwdriver and about five minutes.
Tools And Materials Required
Small Phillips-head screwdriver
Two CR2450 lithium-ion cells (high-quality brands recommended)
Clean cloth or gloves (to avoid touching battery terminals)
Battery Replacement Process
Turn off the ESAB Sentinel A60 welding helmet and place it on a flat, stable surface.
Locate the battery compartment inside the mask (usually near the ADF unit).
Use the screwdriver to remove the small screw securing the cover.
Gently slide off the cover and remove the old cells .
Clean the battery contacts with a dry cloth to remove dust or corrosion.
Insert the new CR2450 cells, ensuring the positive (+) side is facing up.
Reattach the battery cover and tighten the screw securely.
Turn on the welding hood and check the power level indicator on the digital display.
Test the ADF by pointing it at a bright light (or striking an arc) to ensure it responds properly.
Common Mistakes to Avoid
Installing The Batteries Incorrectly: The wrong polarity can prevent the ADF from working.
Using Cheap Or Expired Cells: They won’t last as long and may cause flickering issues.
Touching The Terminals With Bare Hands: Oils from your fingers can cause poor connections.
Over-tightening The Cover Screw: This could damage the plastic casing of the welding helmet.
Troubleshooting: What If Your Hood Still Doesn’t Work?
If your Sentinel A60 auto-darkening welding helmet isn’t functioning properly after replacing the batteries, try these steps:
Check The Cell Orientation: Make sure the positive (+) side is facing up.
Clean The Battery Contacts: Dirt or corrosion can prevent a good connection.
Try A Different Brand For CR2450: Some brands last longer than others.
Reset The Helmet: Remove the batteries for 10 minutes before reinstalling them.
Ensure The ADF Sensor Isn’t Obstructed: If it’s dirty, wipe it clean.
If none of these solutions work, there may be an issue with the ADF unit itself, and you might need to contact ESAB support.
How to Extend the Battery Life of Your ESAB Sentinel A60 Welding Helmet
A few simple habits can make a big difference in how long your batteries last. Follow these tips to keep your helmet powered up and ready to go:
Use High-Quality CR2450 Batteries: Using the wrong type can damage the helmet or cause inconsistent performance. Stick to reputable brands for the best longevity.
Remove Cells If Storing The Hood For A Long Time: Even when turned off, your welding helmet slowly drains power. Taking them out prevents unnecessary discharge.
Keep The Battery Surfaces Clean: Use a dry, lint-free cloth to wipe the terminals before inserting them. Dirt or oil can reduce contact and affect performance.
Avoid Liquid Cleaning Agents: Never use solvents or liquid cleaners on the battery compartment, as moisture can cause corrosion and interfere with proper function. If you’re interested, here’s more details on cleaning and maintaining methods.
Store Your Mask In A Cool, Dark Place: Heat and constant exposure to bright light can keep the ADF sensors active, draining the cells faster. So, proper storage of the helmet is necessary.
Turn Off The Welding Helmet When Not In Use: While the Sentinel A60 has power-saving features, manually turning it off helps extend life even further.
Test The ADF After Replacing Batteries: Once you insert new cells, always check that the auto-darkening filter (ADF) responds correctly before starting a weld. I have written a detailed guide particularly on this topic.
By following these steps, you can extend your battery life significantly, saving time, money, and the hassle of unexpected failures.
Final Thoughts: Why Battery Maintenance Matters
A dead cell inside the ESAB A60 welding helmet isn’t just an inconvenience—it can be a safety issue. A delayed ADF reaction or a flickering lens exposes your eyes to bright flashes that can lead to strain or even arc eye.
By staying on top of battery maintenance and timely replacements, you ensure:
Consistent ADF Response: No flickering or delays.
Maximum Eye Protection: No risk of accidental flashes.
Uninterrupted Workflow: No stopping mid-weld to troubleshoot issues.
Welding demands focus. It requires precision. And when you’re in the zone, the last thing you need is your hood failing you. Now that you know how to handle it, you’ll never be caught off guard again.
Stay sharp, stay safe, and keep welding.
Key Takeaways
Watch for flickering ADF, slow response times, dim display, or a completely unresponsive ADF, indicating it’s time to replace the battery.
The ESAB Sentinel A60 uses two non-rechargeable CR2450 lithium-ion cells, typically lasting 8-9 months depending on usage. Removing them when not in use helps extend their lifespan.
To replace the cells, use a small screwdriver to open the battery compartment, remove old ones, clean contacts, insert new ones, and secure the cover.
Ensure the correct battery orientation, avoid cheap or expired products, and never touch terminals with bare hands.
If the helmet doesn’t work after replacement, check the cell orientation, clean contacts, try a different brand, or reset the helmet.
Use high-quality batteries, remove them for long-term storage, keep terminals clean, avoid liquid cleaners, and turn off the helmet when not in use.
