Welding Helmet Troubleshooting Guide

Date: 17-07-2023
The Inside Tack

 

Tips and tricks to help with electronic / auto-darkening welding helmet troubleshooting issues.

While this article is firstly intended to assist owners of Weldclass branded helmets, most of the tips suggested will apply to other brands too.

 

Top Tips

  • Sensors: On the front of the auto-darkening lens are 2-4 sensors. These detect the welding arc and therefore need to have an unobstructed 'view', for the lens to operate.
  • It is critical that front cover lenses are kept clean: If the cover lens is dirty or scratched, this will obstruct the sensors and the helmet cannot be expected to function correctly. 
  • Try increasing delay adjustment: This is not an obvious hack, but a very useful remedy once you understand how it works. Increasing delay time adjustment can help overcome 'intermittant failure to darken' issues. If there is a sensing disruption, a longer delay time will temporarily keep the lens 'locked' in dark mode until sensing recovers... and thus prevent the lens from switching light mode during this disruption.

 

Troubleshooting Checklist

Fault

Possible Cause

Applicable Weldclass Promax Helmet / Lens Model

Possible Remedy
Intermittent failure to darken (sometimes does not switch to dark when welding starts)   

Momentary disruption to sensing of the arc
This can occur for a number of reasons, for example a change in the arc or weld position.

 All Increase delay time adjustment
Note: While the delay adjustment does not directly impact the sensors - if there is a momentary / brief sensing disruption, a longer delay time can 'lock' the lens in dark mode for sufficient time until sensing recovers proper detection of the arc.
Front cover lens is dirty or scratched and is obstructing the sensors All Replace front cover lens 
Sensitivity level is too low All Increase sensitivity level setting
Sensors are dirty All Clean surface of the sensors with the corner of a tissue or soft cloth

Lens is staying dark when no welding arc is present

Sensitivity too high

 All

Reduce sensitivity level setting
Ambient light level is too bright All Reduce the ambient light level / other light sources
Shade Lock is activated 600, 650, 680 Shade Lock will lock the lens into dark mode. To unlock, press both UP & DOWN adjustment buttons together. See more info here.
Lens will not switch/darken at all (no power / completely dead) Grind mode is activated 200, 350, 500, 600, 650, 680 Switch to weld mode
Batteries are discharged 350, 500, 600, 650, 680 Replace batteries
100, 150, 200
These models are solar-powered only, with non-removable rechargable battery

Place helmet/lens in direct sunlight (with solar panel facing the sun) for at least 4 hours, longer if possible
Batteries not fitted correctly, or Battery or terminals are dirty 350, 500, 600, 650, 680 Double check batteries are fitted correctly. Clean battery and/or terminals with soft dry cloth, if they are visibly dusty or dirty.
       

 

 

View the Weldclass Helmet Range

           

  

 

 

Tags
Welding Helmets
Comments

  • Date: 02-08-2023
    Rickys Welding Equipment Rickys Welding

    This troubleshooting guide for welding helmets is incredibly helpful for both Weldclass branded helmets and other brands as well. The article provides valuable tips and tricks to address common issues that welders may encounter with their electronic/auto-darkening welding helmets. I appreciate the specific fault scenarios listed, along with the possible causes and suggested remedies for each. From momentary disruptions in sensing the arc to intermittent failure to darken, the article covers a range of troubleshooting situations. It's great to see that adjustments like delay time, sensitivity levels, and even cleaning the sensors can help resolve these issues. The guide also addresses more serious problems like the lens staying dark when no welding arc is present or when the helmet fails to switch/darken at all. The recommended solutions, such as adjusting sensitivity levels, reducing ambient light, and replacing batteries, are practical and easy to follow. The inclusion of the Weldclass Helmet Range and handy tools like the MIG Torch ID Guide and TIG Torch Selection Guide add further value to the article. Overall, this troubleshooting guide is a valuable resource for welders, providing practical solutions to address common issues with welding helmets. Weldclass continues to demonstrate their commitment to providing useful knowledge and support for the welding community. Rick Tillman rickyswelding.com