Auto-darkening welding helmets have reshaped the welding industry. It helped to make welding an easy occupation by ensuring the safety of the welders. These welding helmets protect the skin and eyes of the operator. It fetches all of the power required for auto-darkening from the batteries. Sooner or later, these batteries have to drain out empty. When these batteries are fully drained, then it’s time to change the battery. So, if you are a professional welder, then you must know how to change the battery in a welding helmet. It will help a lot in your welding operations. 

This article will teach you about the following main aspects. 

  • Why use batteries in a welding helmet?
  • Time to replace the batteries
  • How to Change Battery in Welding Helmet?
  • How to change the battery in the Hobart welding helmet?

Let’s dive into the guide to learn more about the above-discussed headings. 

Why Use Batteries in Welding Helmet?

Welding is a game of fire, flash, and spatters. It’s a dangerous but inevitable occupation. Because there is always a need to join or cut a metal piece, all of this is usually done with the welding torch. To play the action, personal safety is much required. In the old days, this was done with the help of passive welding helmets. There is a fixed shade lens supported with the transparent lens present in these welding helmets.

Over time, in 1981 first active or auto-darkening welding helmets appeared in the market. When the welding torch touches the ground of welding, then sensors detect the lightning and darken the screen. All of the procedures are completed within a fraction of one second, which is now on average 1/25,000 seconds. This procedure is only possible just due to the presence of the batteries.   

Time has changed and present welding helmets are equipped with solar power. But the importance of batteries is evergreen like in the past. These batties support the solar system to carry on the welding operation properly. It is vital for a welder to know how does an auto-darkening welding helmet works because it helps the user to get the maximum out of it.

Time to Replace the Batteries

There are different types of welding helmets present in the market. Some welding helmets have built-in batteries. On the other hand, some welding helmets are equipped with replaceable batteries. There is a common thing between both types of welding helmets, that is, you have to replace the battery. In the case of a built-in or fixed battery, it works for a long time like 2 to 3 years. On the contrary, the second one has to be replaced sooner than the previous one.

By following proper guidelines, you can replace a battery easily. It requires both your precious time and money. So, you don’t have to throw away your old one although it’s properly working. In the following, there are a few tests that will teach you this is the right time to replace the battery. 

Take Alert System Seriously

As previously mentioned, there is an epic advancement in welding manufacturing. Helmets that are manufactured within the last few years are equipped with a signal, which alerts the user about the battery. This signal only buzzes up if the battery of your welding helmet is about to die or the course of life has ended.

One thing is that you must care about these signals. Within the past few years, there are many advanced-level welding helmets designed with low battery signals. So, check the manual to get a clear picture about the battery life, whether it is about to die or there is a need for a plugin. 

Variable Intensities

The key feature of an auto-darkening welding helmet is the adjustment of shade for different welding operations, according to the intensity of light. The reason behind the adjustment is the presence of sensors in the forehead of the welding helmet. The efficiency of bright and dark shade depends upon the strength of the welding helmet’s battery as well. Checking the welding helmet at variable intensities of light is an excellent way to check the condition of battery life.

For this test, deliberately spark up and carry on this operation. If there are many spark flashes received, then there is something wrong with the welding helmet because it is supposed to activate the auto-darkening option according to the light’s intensity. An excessive flash to your eyes is a sign of a weak battery. It means that the batteries are not responding to arc flash properly. 

Before making the final decision, you must check the sensitivity level of your welding helmet. It may be possible that you haven’t adjusted the sensitivity properly. If the sensitivity is too high then there is prolonged darkening. On the other, if the sensitivity is too low, then there is late darkening in response to high intensity of light. So, you should consider this option before making up your mind to change the battery of your welding helmet.

The Sun Test

Wear your welding helmet and go outside under the sun. This one is natural as well as easy to check. Face the sun, wave your hand between your face and sun as well back and forth on the path of your eye-sight. This one will block the sunlight intermittently, and it’s enough to trigger up the auto-darkening feature of your welding helmet. 

Now, focus on the results. If the auto-darkening is working appropriately, then carry on to your work with these batteries. Otherwise, it’s time to replace the battery of your welding helmet. You must also check another testing method for welding helmets because it will help you to make a true opinion about welding helmets.

There are two main things you must consider while performing this test. The first thing that you must have is to check the sensitivity of your welding helmet. As discussed in the previous section, too high causes prolonged darkening and too low late darkening. The second thing you must consider should be the last option to check the battery condition. 

Once all set and you are clear about the battery health. It’s time to get a replacement. Initial steps for the replacement vary from model to model. The reason behind this is the battery presence. 

How to Change Battery in Welding Helmet 

In the following, you will find the common steps to replace the battery of your welding helmet. If you are worried about reading, these steps vary from model to model. Then don’t worry about it, in the later section, you will also learn about how to change the battery in some famous brands.

Let’s see a few general steps to replace a battery in an auto-darkening welding helmet. 

Battery Selection 

You can find two situations here in regards to battery selection. One is that you will find auto-darkening with the help of only the battery. Usually, Lithium-Ion Metal batteries are used in welding helmets. The second situation is that you find a welding helmet powered with both solar system and Lithium-ion metal batteries. In some situations, you can find a welding helmet powered by a solar system but accompanied by fixed or non-replaceable batteries. Yes, batteries can be both fixed or replaceable. Replaceable is mostly preferred over non-replaceable. But to discuss the fixed or replaceable is out of context here. Let’s get back to our topic.

For the proper selection of a battery for your welding helmet, you should have a concern with the user manual that you have along with the welding helmet. Typically, AAA or AAAA batteries are required to empower the welding helmet. 


The second most important thing that you have to consider is, you have to gather all of the requirements for the replacement. In the following, there is a checklist of tools required.

  • Screwdriver
  • Solder along matching iron
  • Dremel diamond wheel
  • 3VDC cell holder

After you’ve gathered all of these things, it’s time to take action. As you get from the previous section, the place of the battery may vary from model to model. 

Locate the Battery

In most of the welding helmets battery is present besides the front lens. Therefore, examine the front portion of the welding helmet, which is located near the lens. After finding the location, the next thing is to dissect the battery. Use the Dremel tool to remove it from the place. This will not take more than a minute.

To go through a smooth and supported the operation, put your helmet on the table to get some support. A Dremel tool is required to cut an area that is a small square just like the size of a post stamp. Keep the part of cut plastic to use it on later. After watching the battery, take a pen and pencil to note down the information like the exact place of battery and polarity. 

Battery Removal 

This one is the most important step where you must have focused as much as possible. Take the screwdriver to lose the tabs that secure the battery at the spot. Lose them but be careful while losing them. Gentle force can break them down. Lose them according to the requirement. Apply gentle force, which is required to remove the battery, not apply brute force.

Battery Installation

Connect the battery holder with the desired leads with the help of solder. While making the connection, you must make sure to make the right connection. Join the red lead with the positive side, and black leads with the negative side. After that, you have to make a small incision that allows the wire to run externally. 

Place the battery at the desired palace in the holder. It’s time to rebuild the dissected welding helmet. For this, you have to follow the procedure that you have written on the paper. Place the holder at the desired place. Use hot glue to seal the dissected small plastic piece on the welding helmet. 


You have to test the welding helmet before putting it into operation. Follow the three tests that you have read at the top of this article, under the section of time to replace the battery. But at this time, you will feel a difference. The difference is that this time you are just checking it to put it into action, not for the sake of information about the battery condition. 

How to change the battery in the Hobart welding helmet?

Some of the advanced welding helmets, like the Hobart welding helmet, have a few unique steps for replacing the battery. For this welding helmet, you have to push the front lens inside of the welding helmet. When the front comes out from the place, you have to remove the tabs from it. After that, you will get lens assembly. If you look at the upper side of the lens, you can find a battery holder. Push it out with the help of your hand but requires gentle force. Remove the old one and place the new battery inside of the holder. Reverse the operation to regain its original shape.

Pin It on Pinterest