Do modern, auto-darkening welding helmets "go bad"?

[mark-NJ]

I've already e-mailed Lincoln, and I await their reply, but I'll ask here anyway: Do modern, auto-darkening welding helmets suddenly "go bad"?

My first helmet was a "Lincoln" (I suspect "in name only") that I bought at Home Depot. No batteries needed, kinda small window, cheap headgear, everything looks green. But it worked.

I decided to upgrade to a better helmet. A little over a year ago, I bought a Lincoln 2450. 4 sensors, super clear, very adjustable in settings & fit. And it works flawlessly! Well, until today.

Three days ago it worked as it always has flawlessly. This morning I tried to do some more work on my project, but I couldn't. The helmet flashed me constantly. No settings (welder or helmet) were different from the other day. The low-bat light was not lit. The test button functioned as it should. The batteries were 2.94V each, but I put new ones in anyway (new ones were 3.2V each). No change. I played with some settings...no change. While the helmet has never cared about ambient light, I shut off the lights in my shop...no change. I tried welding steel, ss, alum....no change.

The only thing I can figure is that the sensor module has simply "gone bad". Is that a possibility? Do these things just fail abruptly without warning after 3 days in its storage bag?

I welcome your thoughts,

ps: I grabbed my cheap Home Depot helmet (untouched for > 1 year), put it on, and it worked perfectly. Kinda dark, and colors look weird, but it worked.

 

[isb cornbinder]

My first auto-dark helmet was a Speedglas. It lasted for only a few days and died. I took it back to Air Liquide Canada dealer and I was told the fail was my fault. I was asked where I stored the helmet. I said that I had a metal cabinet. I was told that darkness will kill the sensors. I asked how the darkness in the box the helmet was shipped in might cause damage. The dealer offered to send the less than a week old helmet in for repair. I was called to pick up the helmet. What was returned to me was a totally destroyed lens in a ZipLoc bag in the helmet shell in an original box.
Back then these auto dark helmets were expensive. I can buy a better unit, 30 years later, for $100 in 2023.
I have two MILLER auto dark helmets in the shop. I have not been in the shop for over 2 years. I am sure I will be replacing batteries on a few tools when I get out to the shop. I will be making a list.

 

[MadeByMiller]

Have you tried replacing your outside lens cover? If it is too dirty/pitted it can definitely block the sensors from detecting the arc.

 

[American Locomotive]

Any electronics can fail/die. As mentioned, make sure the outside lens is clean. The Lincoln Vikings are pretty much an "industry standard" as far as welding masks go, so it's pretty unusual to have one fail.

Also as FYI: Auto-dimming welding helmets always provide UV protection, even when un-dimmed. So there is no risk of UV eye damage even if the helmet doesn't dim. It will just be uncomfortably bright.

 

[blairjw]

I had a cheapie Northern Tool helmet fail. Since then, I bought an ESAB and I keep it in a window to keep the charge on the battery.

 

[ObnoxiousFumes]

I was told that darkness will kill the sensors

Hmm. What happens when the sun goes down...

 

[Wamsutta]

I had to replace the cassette on my ESAB under warrantee. They sent me a new cassette overnight mail.

 

[kaymccampbell]

They die. The dealers will lie to you to keep from warranting them. The factory can't fix them, because there are no parts. It's all so sad. I have a nice gold fixed lens, and a HF auto darkening POS. Both serve me appropriately.

Since you changed the battery, try changing the cover lens. After that buy another, and learn from your experience.

 

[kaymccampbell]

I had to replace the cassette on my ESAB under warrantee. They sent me a new cassette overnight mail.

Lucky you.

 

[Ricky Joe]

They do die. I was teaching my son to weld. I put an auto dark helmet on him and proceeded to show him how to strike and run a bead. I did not realize that his helmet had gone bad. Fortunately, no long term harm, but I learned a lesson. He didn’t know enough to say anything, and I trusted the helmet. Student gets vintage helmet now.

 

[mark-NJ]

I didn't mention it in my post, but...yes...I changed the front lens while I had the module out for the battery change.

No difference.

I was told that darkness will kill the sensors.

One wonders, then: why do they provide an opaque black bag to keep the helmet in?

 

[Mr.N]

Do modern, auto-darkening welding helmets suddenly "go bad"?

Good question, can't wait to see more input.

I've an HF, HD Lincoln's, old school 2" and 4" with several shades and a newer Lincoln 3350. I've only been flashed with the HF and it was because the batteries went bad. There is a chance it was they HD ones, but which ever ones had replaceable AAA batteries.

 

[mark-NJ]

Short update:

When I said that I had e-mailed Lincoln, in actuality I had filled out their "contact us" questionnaire portal on their website. There's a note that said "all inquiries are responded to within 24 hours". I was optimistic, but realistically didn't expect an immediate response.

I received their response at 7:51AM this morning saying "what's your address?...we'll ship you a replacement" Wow!

I still don't know if my unit failure is an anomaly or if these trend bad over time, but as for Lincoln's customer service? Outstanding! Simply outstanding.

 

[Jswain]

Could try cleaning the sensors with a qtip as well

 

[mark-NJ]

Conversing with Lincoln via e-mail, I asked why a helmet would go bad like this. While I haven't dropped or banged my helmet, I was told that failures like this...while rare in the Viking line...are usually board-level solder joints that have failed.

Anyway, a replacement module is on its way to me. Lincoln surely wins the "customer service gold medal" as far as I'm concerned!

 

[dnschmidt]

Lincoln has ALWAYS been a stand up company. It pains me to say that since they are based in Cleveland and I'm from Pittsburgh so it's tough for me to admit this but it is true. I've never dealt with Miller so I've got no frame of reference but my interactions with Lincoln have always gone well. Harris, which Lincoln owns is just as nice.

 

[mark-NJ]

It pains me to say that since they are based in Cleveland and I'm from Pittsburgh so it's tough for me to admit...

As a long-suffering Browns fan, let me say: "see ya next week!"

 

[aka Larry]

I started with an Auto-Darkening from HF, and it worked just fine. I wanted something nicer with a larger viewing window, and more comfortable to wear, so I got a Miller Elite model.

The Miller is indeed nicer and more comfortable, but the batteries don't seem to last for sh*t. I'm not sure what the solar panels are even for because when the batteries die, the auto-darkening doesn't work. My old HF one still works, and I don't think there is even battery to replace.

 

[mark-NJ]

^^^^

I have to say: When my "good" helmet died yesterday, my old Home Depot "Lincoln" worked flawlessly.

I think I spent something like $70 bucks or such, it has no batteries to go bad. Viewing is limited, color is atrocious, headgear is a compromise (at best!) and SS looks a very odd orange color while welding.

But it has never once flashed me, never once failed me, never once let me down (caveats notwithstanding). I'm very glad I never got rid of it when I upgraded.

 

[u3b3rg33k]

They do die. I was teaching my son to weld. I put an auto dark helmet on him and proceeded to show him how to strike and run a bead. I did not realize that his helmet had gone bad. Fortunately, no long term harm, but I learned a lesson. He didn’t know enough to say anything, and I trusted the helmet. Student gets vintage helmet now.

the UV protection (and a chunk of the light filtering) is permanent in the glass. just the "i wanna see while i weld" bit is electronic. no listed helmet should put your eyes at risk of damage from a bad sensor.

 

[yhprum]

If it doesn’t have replaceable batteries, there could be some smaller coin shaped batteries inside that can be changed out with a little care.

 

[mark-NJ]

Here's another update from Lincoln about this:

I was told that darkness will kill the sensors. I asked how the darkness in the box the helmet was shipped in might cause damage.

A while back, I had heard this, too. Since I had a conversation going with Lincoln, I decided to use the opportunity to ask this:

"While I've got you, can I ask another question? I've heard & read (and it may be myth / lore) that these auto-darkening helmets can "go bad" if they're not allowed to "charge" with exposure to light. I keep my helmet in the black bag that was provided, so I can't figure doing so could be detrimental to the life of the helmet. Do these helmets need to be kept "out" so that they can be exposed to light?

Here's the answer I received from Lincoln:

Mark, The older model lens did need to charge in the sunlight. The new lens such as your runs on a CR2450 battery. We recommend you storing in the black bag provided. Exposing it to the light can cause your lens to auto darken thus wearing out the battery.


Hope that helps

 

[Steve_P]

^^^^

I have to say: When my "good" helmet died yesterday, my old Home Depot "Lincoln" worked flawlessly.

I think I spent something like $70 bucks or such, it has no batteries to go bad. Viewing is limited, color is atrocious, headgear is a compromise (at best!) and SS looks a very odd orange color while welding.

But it has never once flashed me, never once failed me, never once let me down (caveats notwithstanding). I'm very glad I never got rid of it when I upgraded.

I'm kinda like you as I have an old HF, probably 20+ years, the first, or maybe second, generation of auto-darkening helmets. I have no idea if it has batteries; but if it does, they are tiny. I'm sure it's not the best, but I like it, and it's been 100% reliable. If it has batteries, this has to be a record for battery life. I store it in a plastic bag (not clear) to keep it clean. It has a dial to select the shade and I keep it at the minimum. If it dies, then I will buy something "nicer".

 

[no704]

This is why I love my fixed lens hoods! Had an IT guy come ask me the other day why his HF auto dark wasn’t working while tring to look at the sun.
I lent him a couple fixed shade big windows so he could watch the eclipse with his son.

 

[Raineman]

As a long-suffering Browns fan, let me say: "see ya next week!"

I'm sure Sunday was a boost to your spirit. Certainly wasn't to mine.

 

[f121]

My old mask went bad, got flashed a few times. Lost my sh** because my head hurt and spent $300 on a speedglas. No regret.

 

[mark-NJ]

First of all, @dnschmidt

As a long-suffering Browns fan, let me say: "see ya next week!"

Sorry brother, but I was doing backflips!

~~~~

As for the helmet, Lincoln has...again...amazed. The sensor units are out of stock, so rather than make me wait, they sent a complete, new-in-the-box helmet.

Outstanding customer service is alive & well in Ohio!

 

[Beerhippie]

I had to replace my 3M Speedglas last year for the same reason--but mine was old enough I didn't even bother asking about warranty. I got another Speedglas, but that is probably my last one.

Good to hear about Lincoln being a stand-up company! That's far too rare in the days of stockholder satisfaction....

 

[MBfreak]

ESAB is top quality in everything they do.
And they only employ top grade people, from the store clerks to the metal scientists.
And everybody in between.
Look for the NASA movie ( New Orleans factory??) where they stir weld together large "pipe" parts to create a
tall rocket outer tube. Diameter well over 3 m.
The stir weld contraption says ESAB.
As good as it gets.
Richard Feynman would have given them thumbs up.

Ola

 

[gungatim]

You didn't get flashed. Auto darkening lenses filter the UV whether they darken or not.

Anything electronic can suddenly fail.