Mostly the power source of auto-darkening helmets is with a battery or solar cells. You need to verify also the batteries are replaceable or not. Different models and brands manufacture helmets with varying sources of power. Due to the technology advancement mostly helmets use both the battery and solar cells as a power source to increase battery life and life span.
Now the question is how to change the battery in a welding helmet? This task looks quite difficult, and you think rocket science will be involved in it. But do not worry, it is just a simple task, and anyone can do it easily. Here, we will give you a complete guide about changing the battery of an auto-darkening helmet easily and quickly? Which steps you have to follow. Just read the entire article to get the full information.
Let’s discuss the indications from where you will know that now it’s time to replace the batteries of the helmet.
How to know when the helmet’s batteries need replacement?
Following are the details that will tell you about the battery replacement time.
System Alerts:
In the past, the helmets came without any indication or alert. But with the advancement of technology, companies are manufacturing helmets that have a specific alert system to give you an indication about the drained battery. The accuracy of the signal is 99%. So, if you get such an alert, first check the user manual that comes with that helmet and checks whether your helmet has such a system or this indication is for battery discharge or die battery alert.
Check with welding on variable intensities:
The auto-darkening helmets have the characteristic to darken lighten the intensity of light automatically according to the welding light intensity or the light available in the environment. To check the batteries, it a better way to check it at different welding intensities or, in other words, with varying intensities of light.
Try to produce more spark at different intensities. If you feel more light than usual while viewing from the helmet, then it’s an indication that there is something wrong with the helmet. Check the light level adjustment. If the battery is to die soon, it will not set the light levels properly.
Remember, don’t neglect the probability to set the sensitivity at too high or low levels. If you set it to too high, it will keep the helmet too darkening because of sensitivity. Keep the sensitivity normal. If you set the intensity too low, it will keep the helmet’s darkening the same even if you are viewing a higher intensity light.
Check these settings before deciding to replace the batteries
Sun Test:
It’s an old and common method to test your auto-darkening helmet. Wear the helmet on your face, go outside and view the sun from the helmet when the sun shines with full brightness. Now all light will be coming to the helmet, and the helmet will adjust the auto-darkening due to the high amount of light.
Now, wave your hand in front of the helmet screen to and fro. It will block and allow the sunlight immediately and test the response of the helmet. Try to adjust the settings, and if it does not work properly, then there is an issue with the battery of the auto-darkening helmet. Remember, try the methods as mentioned above first.
First, make sure to test all the mentioned methods. Then you may decide it’s time to replace the battery or not. Each helmet has a different manufacturing company, and also they keep its design. So, the previously shared methods can be other for individual companies. But changing a battery is not much difficult task.
You May Also Like
Directions to change the welding helmet battery:
Battery changing can be a problem for those who are going to change it the first time. And thinking about how to change the battery. Don’t worry! I am sharing the steps to replace the battery easily and quickly.
Select a Battery:
The auto-darkening helmets are equipped with lithium-ion batteries or the union of lithium-ion cells and solar cells. One more difference is that these batteries can be replaceable or non-replaceable with the combination of solar cells. In our opinion, an auto-darkening helmets with replaceable batteries is better.
To cut a long story short, read the instruction manual and find out the battery specifications of the helmet. Usually, four AAA or AA size batteries are required.
Pick up the Tool Kit:
It is a common sense that some sort of tools will need to replace the battery. Following are some essential tools that you have to gather:
- Glue Gun
- A diamond wheel
- A small screw deiver
- A solder
- Cell holers
After gather the above mention tools, now its time to locate the battery location that can be varied with the brand and model of auto-darkening helmet.
Locate the Battery:
Most of the helmets have batteries on their fron face. Try to inspect nearer to the lens. You must look for the solar cells also. Cut up the battery with dremel tool. It will not take more than a minute to do it.
Bring your helmet on a clean place like a table for working support. Use dremel tool to cut out the small battery area (usually small sized and square shape). Keep the cutted part of plastic that we will have to place after battery replacement.
After locating battery, note down the battery polarity, location and some necessary information.
Detach the Battery:
Its an important step where you have to concentrate. Loosen all the taps that are placed to secure the battery. Don’t loose much that they get broken. Do it just to get out the battery. Don’t apply too much force because there is a risk of breaking.
Battery Installation:
Now, connect the battery holder with the wires with the help of solder. Keep the wires according to the polarity (red wire to positive sign and black wire to negative sign). After that make a small hole to keep the wires externally. You can connect remaining wires to the helmet via that hole.
Now, replace the old batteries with the new one. Its time to place all the thing again on their places. Use a glue gun to seal the cutout area of plastic.
Battery Test:
After all, you need to repeat the above mention processes that we learned about checking of the battery for replacement. Read and apply the steps mentioned in “How to Know when the helmet’s batteries need replacement?”
Tip: If you are using the well-known brands helmet like Hobart, Millen or Lincoln then you need to remove the lens assembly before placing the new batteries.
Battery Replacement of Helmets from Different Brands?
You have to check the design of the helmet before new battery placement. In some brands, you need to remove both internal and external lens cover. Read the instruction manual and locate the exact place before doing anything.
Final Words
We have described about how to check the battery whether it needs to be replace or not? If you found battery is dead, follow the simple step to easy replacement of the battery.
In case, if you still unable to locate the place or any problem contact to some professional.
Enjoy!