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Practical answers on choosing and fitting spare lenses, headgear, sweatbands, batteries and magnifiers for an auto-darkening welding helmet.
Welding-equipment makers' manuals describe a quick test before use. Point the front of the filter at a bright light source, then use your fingers to rapidly cover and uncover the sensors. The filter should darken as the sensors are exposed. Some manuals also allow a torch striker.If the filter does not darken when an arc is struck, or the filter is cracked, stop using the helmet: the UV and IR protection may be compromised, which can burn the eyes and skin. Keep the sensors clean and unblocked, and inspect the helmet and cover lenses before each use.
The outer cover lens sits at the front and takes spatter and scratches so the auto-darkening filter behind it does not. The inner lens sits between the filter and your face. Neither is a substitute for the filter.Maker manuals say to replace a cover lens if it is damaged, cracked, scratched, pitted, or spattered or dirty enough to impair vision. This is a condition-based decision, and no fixed interval is given. Do not use the helmet without the cover lenses properly fitted, and check your manual for how to remove and refit them.
It is better not to. Maker manuals say to use only the replacement parts specified for the helmet, and one warns that cover lenses from other suppliers should be avoided because the lenses supplied are sized to work with that helmet. Using non-specified parts can also affect the warranty.Choose lenses listed for your helmet and compare against the old one before fitting. The lens should be clean, secure and seated properly. If anything feels loose, do not weld until it is corrected.
Wipe with a soft cloth and keep the sensors and solar cell clean, because dirt can stop the filter seeing the arc. Dry with a lint-free cloth. Never use abrasive cleaners, and do not submerge the filter cartridge in water or any other liquid.Makers do not agree on the cleaning fluid. One manual says to use a damp, not saturated, cloth with a soapy water solution and no solvents, while others name alcohol or methylated spirits for the sensors. Follow the manual for your helmet. If marks will not clean off a cover lens, replace the cover.
Not always. Maker manuals show two designs: some helmets run on solar cells alone with no battery to replace, while others use a solar cell with battery assist, for example two lithium coin cells. Check your manual or helmet specification to see which you have.On a battery-assist helmet, replace the cells when the low-battery indicator appears or the helmet signals low power. Always run the test before welding. Some manuals also say to test that the filter is charged before welding, particularly after long storage in the dark.
Many helmets use a lithium coin cell, but the type and the number of cells differ between models, so check the manual or the old cell. Some manuals say to slide open the battery cover when the low-battery light comes on, then fit the new cell the right way up. Others use a cover plate or need the filter opened, so follow your manual and never force it.If the manual does not describe user battery replacement, do not open the filter cartridge. Test that the lens darkens before welding, and keep spare cells away from children.