Battery Replacement: How to Change Battery in Welding Helmet within 8 Minutes

Welding Helmet is one of the best welding safety equipment, which helps to increase productivity. As a welding professional, You should have skill on how to change the battery in the Welding Helmet. The best welding helmet is your best friend because it ensures your safety during the welding process, and you don’t need to take off the helmet a thousand times to view the result of the welding process. The auto-adjustment of light intensity is a great feature. But. This feature plays a negative role sometimes. The auto-darkening feature is the reason for most of the helmet are battery-powered. So, it would be best if you changed batteries in a definite schedule.

Battery replacement is not a very mundane task. Following some steps, you can do it by yourself, even if you are a beginner. With some basic knowledge with few practices, the job can be manageable.

Change Battery in Welding Helmet

How to Ensure Battery is Drained or Not?

Not all helmets are battery-powered. Some welding helmets are solar-powered. In that case, you need to purchase a new one because the older one is run out of juice.

Fortunately, most of the cases we got are the problem of drainage in the battery. Battery changing can be a little bit expensive and causes some pain in the ass. So, it would be beneficial to check some signs that indicate the battery need to be changed.

Red Light Signal

To install the battery before first use or when the low battery led begins to turn red, indicating Battery needs replacement. You can consider yourself lucky enough if you have a pre-installed sensor that alerts you when the battery is down.

Failure of Intensity Change with Environment

When you are exposed to more sunlight, your welding helmet auto darkening feature changes its strength in intensity. It will automatically become darker or lighter, depending on the environment. If you see a lot of flashes, it indicates that the auto darkening feature is not responding quite well. You can be sure that it needs more batteries.

No, you shouldn’t look towards sunlight directly. Alternatively, you should overlook the welding helmet and face the sun. Take care as this may strain your eyes. After that, consider waving your hands back and forth through the welding helmet. The purpose here would be to interrogate the sun to check the way the welding helmet is reacting. If this is true, you’ll need to replace batteries.

How to Change the Battery?

First, you take all the mental preparation that you can do it by yourself. Before doing this, you shouldn’t have to read the manual. We have done this task easy for you. You don’t have to read anything or don’t need any theoretical knowledge. Just make sure the battery you want to replace you buy the same model battery. The first thing is first. Let’s discuss step by step point to do this task.

  1. Battery Selection

Different welding helmet companies use different types of batteries. So, according to your battery model, you need to buy a new battery. To identify your battery, you need to open your welding helmet. We will discuss it in the next section.

 Most of the welding helmet use Lithium CR2450 and the CR330. You will need four batteries (these are AA or AAA type).

2.Get Your Hands Dirty

Before entering the specifics, you need to realize that even though there are specific guidelines related to welding helmets. There can also be special instructions on your welding helmet make and design.

So, ensure you read the user manual which came with your auto darkening welding helmet. Some items are required to do the task.

  • Soldering Iron
  • Dremel Tool
  • One screwdriver
  • Glue Gun
  • 3V DC cell holders (Quantity 2)

3.  Exposing the Battery at First Glance

 In front of the lens casing, on the top of it, there is a solar panel. There are two extra photo sensors you will find. Inside of the dead lens, you will see a battery or storage supercapacitor. As the thickness of the plastic casing is almost 3/8 inches, the coin cell type location is used to contain the battery.

4.  Dissecting the Battery Case

 Once you are able to locate this area, your next task is to dissect the battery using your Dremel with two pinky fingers cut out a shallow square shape plastic area. Keep it aside. We will use it later. A coin-type battery will be exposed. Take a picture or remember the polarity sign. The polarity sign indicates the plus voltage or negative voltage terminal on which side of the battery.

5. Disconnect from the Battery Holder

 It would help if you were super careful on this step. To uproot the battery from the holding, use a screwdriver to loosen the tabs. If you put a lot of pressure on the labs, it might be broken. You can feel when the tabs are loosened to an optimum and then put a small force upwards to remove the battery from its position. We suggest you use a bladed screwdriver so that the PCB (printed circuit board) remains unbroken.

If you are fortunate enough, you’ll have the ability to find the battery within minutes. After cutting the region, you ought to be left with a sheet of plastic. Don’t throw this bit of plastic off. Rather, keep it in a secure place since you’re likely to have to replace it. By this time, you should have the ability to observe the battery. It is important to take note of several types where your battery is just located, in addition to some other facets of it, such as its polarity.

6. Installation of the New Battery

In this section, you have to do the technical part of the process. Be careful when you execute every step. Otherwise, you might end up destroying your welding helmet. Here are the steps that are given below:

  • Replace the old battery with a new one in the battery holder
  • Using soldering iron solder, the 2xAA battery holder leads. Connect red leads to the positive sign where the CR3023 battery was connected.
  • Repeat the same process for the black leads and connect it to the minus marks(ground) where the battery was connected.

Next, use the hot glue to put in the slot and cable contributes to their location. You must notice two things: when you’re installing two bolts, the first is for attaching the analog circuits which control the processing of these light amounts, and the next takes good care of contrasting the voltage of this lens and ascertaining just how dark it’ll be.

7.  Double Battery for Better Performance

With a decent amount of training, you’ll have the ability to repeat this process without a lot of issues. Should you’re feeling the initial steps weren’t too challenging, then that’s a fantastic thing as you’ll need to repeat the very same steps the same manner for the next battery.

Some folks had discovered the 2nd battery across another side of the lens. However, they could not explain its function or why it generally still had a useful life in battery life. I can clean this up. 

The battery powers the analog circuitry (op-amps, etc.) that procedure the mild amounts a then command the push into the LCD of this lens, which darkens. The 2nd battery would be that the comparison voltage for the LCD and can be accountable for just how dark the lens may proceed.

The contrast voltage into LCDs is a shallow current draw so that this battery is still useable.

Two batteries are connected in series. The first batteries negative terminal is connected to the positive terminal. They create a bi-polar connection of +3v dc/-3v dc for both the analog processing and contrast circuits. Now, take out the 2nd battery, with the exact same process as the battery revamp, I set in the 2nd pair of AAs to the 2nd holder and mounted on them within the helmet over the lens.

 8.  Recheck the Battery is Working or Not

As soon as you’ve securely set up the two batteries, you’ll have to place your welding helmet into the test. In this manner, you can confirm it is functioning properly. There are lots of techniques to check when the batteries are functioning fine. The most convenient method to test for this would be to perform the sunlight testing process mentioned previously. It is possible to glimpse in the sun when sporting the welding helmet then wave your hands before your eyes.


Changing the battery at a welding helmet needs to be a very simple undertaking, but occasionally even the simplest things may look complicated when you are unfamiliar with everything you are doing. Follow these instructions, along with your automatic darkening welding helmet, ought to be good as new in no time. Just make sure you look after the technical and electrical mechanics and make sure each the wires are set up.

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