The light filter on the chameleon welding helmet does not work

Greetings to car enthusiasts and simply visitors to my blog. Today I want to talk about which battery for the chameleon welding helmet is necessary when replacing it, and I will also make a small upgrade of the mask.

Not long ago it happened that it became necessary to weld one part to another.

I had at my disposal a Resanta MS 2 welding mask, which contained a chameleon filter.

Everything was ready for welding, but as soon as I started welding the part, the “Bunny” was caught.

I stopped working and decided to check the filter.

When I brought the lighter to the filter glass and lit it, the filter did not darken, but only some faint flickering appeared.

It became clear that the filter was faulty.

But they didn’t want to wait for the parts that needed to be welded to each other and had to be welded into the faulty mask.

The chameleon welding mask is not a cheap pleasure, and therefore it was certainly a shame, since the mask was only 1 year old.

The light filter on the chameleon welding helmet does not work

We are not talking about complex repairs, but just about replacing the batteries in the “Chameleon” welding helmet.
It is a faulty power supply that causes failure in most cases. The main element of protection in the chameleon mask is an automatic light filter. It changes automatically as soon as the arc appears, allowing you to control the start of welding without blinding your eyes. As a rule, a light filter has a multilayer structure. The use of several liquid crystal layers makes it possible to reduce the dependence of dimming on the angle of incidence of light. When the arc is ignited, the crystals are arranged in a certain order, due to which part of the light flux is blocked.

For proper operation of the filter, a power source is required. For some models, these are two AAA batteries located in a special compartment on the filter housing. For other models, the power source is hidden inside the case. As a rule, these are one or two lithium elements with a voltage of 3 volts, which have a very long resource. Although it is logical to assume that a cheap mask has a cheap battery installed.

I use a Resanta welding helmet, although the model doesn't really matter. Light filters of all models have the same operating principle and differ only in the design, the element base used and the presence or absence of adjustments. Like many, I do not use welding every day, but only when necessary. And once again, getting ready to weld something there, I was disappointed to discover that the Chameleon welding helmet did not work.

When pointing at a light source, the filter did not darken or only worked once in a while. Be it the sun, a bright lamp or a lighter.

Sometimes, when I lightly tapped the mask, the light filter would work. This suggested that there was a bad contact somewhere, a loose connection or something similar. But first of all, I thought that the problem was in the power supply of the light filter. My battery is almost done.

In such cases, it is sometimes advised to expose the mask to the sun for about two hours so that the battery is recharged from the built-in LED panel.

Perhaps this is true. But I didn’t want to wait two hours every time. Moreover, it is unknown what the final result will be. Maybe it will work, maybe not. In short, I decided to figure out what exactly was going on there and, if possible, restore the filter’s functionality.

The light filter is attached to the mask using two screws. After unscrewing the screws, remove it. There is a narrow gap along the perimeter of the case. Carefully pushing the halves of the body apart, we divide it into two parts. It doesn’t matter how you do it. Inside the case there is an electronic filling of the light filter and a lithium power source. The first thing you need to do is measure the voltage on it. The nominal voltage is 3 volts, but the light filter works properly when the voltage drops to 2.5 volts. However, this is just an assumption; there may be a spread in one direction or another. In my case, the voltage at the battery terminals was just over two volts, but nothing worked.

Having made sure that the battery is “dead”, we proceed to replacement. My filter used a CR2450 element. It is sealed into the board on both sides. We very carefully unsolder it and replace it with exactly the same new one.

If you don’t find the CR2450, you can replace it with the CR2032 element for a while; it is installed on computer motherboards. It is best to use the battery with a holder, this makes it easier to replace and you don’t have to overheat the “tablet” when soldering. As a last resort, you can solder two pins. Very quickly and with good flux, to perform the operation with one easy movement of the hand.

In this case, you can use double-sided adhesive tape to secure the battery.

Work order

As an example of self-repair, consider the process of restoring a professional device, which, after five years of operation, began to show signs of malfunctioning lithium-ion batteries. The cause of the breakdown was the operating mode - the mask was used several days a year.

The optimal operating mode for lithium-ion batteries is daily. If the work is seasonal, the battery requires periodic charging in the sun. It is recommended to store the mask at room temperature.

Description of the problem: at first the light filter did not work during evening work, while during the day it functioned flawlessly. After some time, the filter stopped working at any time of the day.

The following tools and materials are required for repairs:

• Screwdriver Set;
• Stationery knife;
• Glue gun;
• Lighter or matches;
• Battery holders (2 pcs.);
• Batteries (2 pcs.).

The algorithm of actions is as follows:

Dismantling the chameleon module

We carry out the work according to the scheme below:

General design of the welding helmet.

Scheme of dismantling the chameleon module.

Chameleon module. Inside view.

Let's open it

The front and back of the module are glued using heat sealant. Using a utility knife, make a continuous cut. Be careful not to damage important structural elements - shading glass, control module and connecting cable. In addition, the module contains glass solar cells. After modernization they will not be needed.

Internal structure of the module.

Removing solar panels and lithium battery

After dismantling the solar panels, access to lithium-ion batteries will open. All connecting wires must be removed

Remove the solar cell and lithium battery.

Installing battery holders

The type of holder depends on the specific model. In our case, the type of battery holders is CR-2025. Another area of ​​application for these power supplies is motherboards.

We connect the contacts with the holder by soldering to the terminals from the batteries, after which we attach them to glue.

The nature of the connection of the elements is serial, with connection to the positive terminal of the connection from the solar battery.

Battery holder type 2025/2032.

Batteries installed. Pay attention to the positive terminal.

Assembly and installation of the module

Place the module halves on glue. After assembly, you can check with matches - the filter should respond to a flash of light.

Module after repair.

Replacing batteries in the Chameleon mask

Unfortunately, the CR2032 battery did not last long.
Despite the fact that current consumption is measured in microamps, after some time the filter did not work again. Of course, a question like “What should I do?” didn't even arise. It was necessary to install a more powerful power source. The most suitable option is two 1.5V elements of size AA or AAA. They can be placed in a special battery compartment, which is commercially available. I didn’t have one, so I had to saw off the battery compartment from my favorite TV remote control.

I sawed off the part where the contacts for the batteries are located from the printed circuit board. I cleaned everything unnecessary (microcircuit and wiring) and soldered two stranded wires to the contacts. The end was lightly covered with what was at hand. It turned out to be a good battery compartment for two AA elements.

The battery compartment is attached to the mask with two M2.5 bolts. The holes are drilled in the center, so the mount does not interfere with the installation of batteries in the compartment. Can be mounted anywhere. The wires should be as short as possible. I secured the compartment at the top, above my head. In this case, the overall balancing is not disturbed, and there is free access to the compartment for replacing batteries. During idle periods, you can even remove one battery from the compartment. For the purpose of, so to speak, global economy.

Problems with the Chameleon mask

There is the following problem: when argon arc welding at 60...80A of steel strips, previously cleaned with an angle grinder, the Korund ASF 4/9-13 mask turns off for a tenth of a second. This happens rarely and most often when passing seams inside corners. Nevertheless, I manage to catch the “rabbits”, then, naturally, my eyes turn red and pain appears. Question: is the problem with the mask or is it my “crooked little hands” that are to blame?

Naturally, it is impossible to give a definite answer to this question. But there are several recommendations, because Chinese chameleon masks have been sold for several days and a lot of experience has been accumulated in their use. Take more interest from fellow welders.

Read the article on the website: Repairing a chameleon mask with your own hands

• Option number one: the optical sensor “does not see” the arc when welding in hard-to-reach places (or you cover the photocell with your hand). Adjust the sensitivity using the tuning knob. If it doesn't help, try using a regular filter. If you don’t want to burden yourself with selecting a light filter when welding at low/high currents, look for a mask with an electromagnetic arc sensor. Even such good PPE as Speedglas opens if you cook it “around the corner.”
• Option number two: the dimming is very slow, set the adjustment knob to maximum.
• The problem may also be this: simple cheap masks behave quite correctly when working with conventional inverters (without a set of “cool” welding functions). But as soon as you switch to professional equipment with the function of smooth ignition and arc extinction at a predetermined time, problems begin to appear. When ignited, the mask works normally, but after a while, when the arc flares up more strongly, subsecond shutdowns occur. This can be explained this way: the electronics adjust to the brightness of the light flux once, and then, when its intensity increases, it does not work a second time, because it is not adapted to such changes.

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How to set up a Chameleon mask for welding

Like all other welding helmets, the Chameleon protects the welder's eyes from infrared radiation. The automatically adjustable light filter operates in a convenient mode: the screen changes the degree of darkness depending on the illumination of the working field. When the Chameleon welding helmet does not darken, it is dangerous to work.

You need to figure out why the screen is not working. Sometimes it is enough to change the power supply elements and charge the battery. A dirty screen reacts worse to light; it may need to be wiped. If this does not help, it is better to turn to professionals.

What should a welder pay attention to when selecting a Chameleon mask?

For welding helmet filters, there are four main parameters that are indicated on the product by the manufacturer and are standardized throughout the world:

• optical class;
• light scattering;
• homogeneity;
• angular dependence of the degree of darkening.

According to the European standard EN 379, they must be applied to the filter, indicating the class of each parameter through a slash and a mandatory link to the standard. For example, 1/1/1/2 EN 379.

Adjusting the Chameleon welding helmet

To understand how the Chameleon welding helmet works, you need to know the basic structural elements of the protective device. The overview screen has a layered structure:

• fireproof glass that does not transmit ultraviolet and infrared radiation;
• layers of polymer crystals that change transmission capacity;
• In order for the filters to darken, they are connected to a current source;
• light sensors (from 2 to 4, depending on the model);
• connection diagram to the power supply.

At the moment of welding, a spark appears, then a luminous flux. The radiation triggers the sensors, the crystals are polarized, and the screen darkens. The welder sees the junction of metals within the range acceptable to the eye. After turning off the light source (electrode or arc), the sensors are triggered again. The screen brightens.

The tuning system regulates:

• the degree of screen darkening, it is selected according to the instructions, depending on the type of welding;
• sensitivity to changes in light flux;
• shutter speed, that is, the time period for turning off the light protection.

The adjustment is made at the preparatory stage, when the serviceability of the Chameleon mask is checked before work.

How to properly prepare a welding helmet for work is written in the operating instructions. Setting up a chameleon mask includes several steps:

• a convenient distance from the face to the protective screen is set, this is done by loosening the clamps;
• The position of the filter is adjusted, the comfort of viewing the working area depends on this;
• the intensity regulator is installed: it is determined in what mode the Chameleon welding mask is used, the operating instructions must contain adjustment tables;
• depending on the current strength of the welding machine and the illumination of the workplace, the sensitivity mode is selected; high is indicated by the letter “H”, low – “L”, minimum – “L0”, it is selected experimentally, it is easy to adjust the Chameleon welder masks during work;
• the holding time depends on the type of welding; for spot welding, a minimum interval is enough; for electrode welding, when a melt pool is formed, it is necessary for the screen to remain darkened longer.

Main characteristics of chameleon filters

Optical class is the most important characteristic and determines how clearly and without geometric distortion an object is visible through an automatic light filter. This is an indicator of the diopter of the filter. It directly depends on both the quality of the glass used in manufacturing and the assembly quality of the optical “sandwich”.

The optical class designation may consist of three or four digits. The meaning of the numbers included in the designation of chameleon filters: for example, 1/1/1/2.

The first number—the optical class—determines how clearly and without geometric distortion an object is visible through an automatic light filter. The light filter has a multilayer structure. A large number of refractive surfaces blur the image if the glass has even the slightest curvature. The plates must be of ideal quality. The first class is characterized by the absence of distortion of geometric shapes and clear focusing. The second and third classes cause rapid fatigue and eye fatigue, similar to incorrectly selected glasses. Such filters are unsuitable even for short-term work.

The second number is the degree of light dispersion. The higher quality the crystals, the less dispersion and higher quality.

The third number is the uniformity of the darkening of the filter. The filter contains several cavities with liquid crystals. The crystals are poured between the glasses, the distance between which is very small. Even with minimal glass non-flatness, this leads to spotty darkening.

The fourth number is the angular dependence. The smaller the angular dependence, the less distortion. To reduce the angular dependence, the amount of liquid crystals is increased, and this reduces other characteristics of the filters. Therefore, the number 2 is a normal indicator for most filters

Degree of initial darkening The lighter the initial state, the better it is visible. The degree of protection against harmful radiation must be at least 13DIN in any condition, regardless of whether the filter has worked or not.

Degree of darkening during weldingThe degree of darkening must correspond to the welding mode, i.e. the brightness of the welding arc, as well as the individual factors of the welder himself. Chameleon masks are made with darkening adjustments (9 – 13 DIN; 5 – 13 DIN).

Smooth manual adjustment of dimming, filter sensitivity and brightening delay

Professional filters come with three manual smooth adjustments:

• dimming (usually from 9 to 13 DIN, which corresponds to GOST filters C3-C9);
• sensitivity (can be set to protect against bright light radiation from a heated metal or electrode);
• opening delay time after welding is completed (so that the metal cools down and the afterglow does not “hit” the eyes, and also to prevent the filter from opening during short pauses).

Filter response time in temperature range

Almost all modern chameleon filters provide a response time of less than 0.001 seconds, which is enough to guarantee eye protection.

But it is necessary to take into account the temperature range of the filter and its condition:

1. The response time slows down as the temperature drops. For example, if at +55°C the response time can be 0.08-0.1 ms, then at a negative temperature of -5°C it is already 0.5-0.9 ms. Therefore, the lowest temperature for the operation of light filters is usually not lower than -10°C below zero. However, if the mask is not left in an unheated room or outdoors, it can operate normally at lower temperatures, being “warmed up” by heat from the welding arc and the welder during operation.
2. Dirt, dust, scratches on the protective glass, battery condition, etc. affect the correct operation of the filter. In these cases, everything will be determined by the sensitivity of the sensors and the quality of its manufacture.

Solar batteries or secondary power sources can be used as a power source. These can be AAA batteries, rechargeable batteries, lithium batteries.

Light filters with a built-in battery have a limited service life, which is why it is so important to have removable batteries. The duration of operation of the batteries depends on the geometric dimensions of the solar battery.

Field of view - the size of the working area of ​​the light filter. The larger the working area of ​​the light filter, the better the view and the more convenient it is to work.

The weight, shape, dimensions of the welder's mask, and the design of the headband are often no less important for convenience than the characteristics of the light filter. The more headband adjustments and degrees of freedom, the more convenient it is to adjust the mask to suit you and easily set up comfortable working conditions. If the mask does not allow you to move the filter closer or further away from your eyes, then you will not be able to adjust the optimal viewing angle.

Almost all modern welder's masks use transparent polycarbonate plastic as the outer protective glass - welding splashes practically do not damage its surface, unlike ordinary glasses.

The choice of a light filter must be made taking into account the optical class, which must necessarily correspond to the conditions and method of welding.

Dependence of the optical class on the type of welding:

TIG - welding with a non-consumable tungsten electrode in an argon environment. Welding of critical parts and structures made of stainless steel and aluminum is most often performed. As a result, there is a need to clearly distinguish the objects being welded, to see the smallest lack of fusion, pores, etc. The filter class should be maximum: 1/1/1/1; 1/1/1/2.

MIG - semi-automatic welding with a consumable electrode in an argon environment. Welding of non-ferrous metals. The speed of the welding process is higher compared to TIG welding, so the parts are not visible so clearly; the filter class can be used at a lower level: 1/2/1/2.

MAG - semi-automatic welding with a consumable electrode in a CO2 environment or a mixture. Welding ferrous metals at high speed, so it is permissible to use filters of a lower class: 1/2/2/2.

MMA - manual arc welding with a coated electrode: Amateur welding - 1/3/2/2. Professional welding - 1/1/1/2. The given data is not mandatory and depends on the specific welding conditions and the individual characteristics of the welder.

After choosing a filter, you need to try on a welding helmet. It should be adjustable to fit your head. The mask is attached to the head by pulling up a special wheel or strap, while making sure that it does not leave the head when it moves and to do this, adjust the depth of the mask using an additional upper strap. The adjustment elements must be reliable. Inexpensive masks often have soft and fragile rims, unreliable and poorly adjustable tightening nuts, and an inconveniently located axis for attaching the rim. The size of the filter's working area should be acceptable for most jobs.

Possible malfunctions and methods for eliminating them

1. The screen will not respond to light unless connected to a power supply. If the model is equipped with AAA alkaloid batteries or rechargeable batteries, charging indicators are displayed in the screen area. If the red light is on, it's time to replace the batteries. Solar panels are charged while welding. If the mask does not turn on, point it towards a light source for a few minutes.
2. If the screen darkens unevenly, check the distance from it to both eyes. Perhaps while they were adjusting the mask and adjusting it to the head, the filter shifted. It should be parallel to the face. Loosen the clamps and align the casing.
3. If the screen flickers during welding, it may be due to the outer glass. Sometimes it is enough to wash it. In case of mechanical damage (scratches, surface chips) it must be replaced. If the filter continues to act up, check the cleanliness of the sensor surface. When there are two operating modes (welding and grinding), check which position the switch is in. The screen may flicker when low-current welding in low sensitivity mode. The desired level can be established experimentally during operation.
4. The filter does not darken immediately in the cold. Viewing screens quickly change the degree of darkness in the temperature range from +50 to -10°C; Chameleons are not intended for harsh winters.
5. If the weld seam is difficult to see, there may be several reasons. Sometimes the film is forgotten on the protective glass. You can try cleaning it, switching the dimming control.

How to fix it yourself

The main question is what is the problem with dimming. Let's see what goes wrong most often. A common defect is that a chameleon mask does not darken light radiation, and this is its main task.

One of the root causes may be batteries that have zero charge.

The mask has two batteries: standard AA batteries and solar energy, which is powered through a panel in the body. Usually just replacing the battery is enough.

But if replacing the batteries does not help, then you can try charging from solar energy, leaving the mask for a short period in the sun or bright light.

But this is not the main reason and the way to solve it. This is not one of the possible sources of the dimming problem. There may also be a problem with the protective glass. Usually this damage is visible to the naked eye: chips, cracks, abrasions.

The solution to this problem is usually to replace the mesomorphic glass, which is one of the most expensive elements of the mask. But only glass that is completely similar to the previous one will do, watch this carefully.

“If the light filter blinks, check whether the protective glass is dirty. In the worst case, it may be damaged. If it is damaged, the light filter with protective glass must be replaced.”

With such a problem, it is better to contact a specialist rather than deal with it yourself. The service center is here to help you. Of course, this is not the most economical option, but this way you will know that the root cause of the defect has been accurately identified and they know how to eliminate it.

When working with a welding machine, many factors affect vision impairment, which the Chamaleon mask helps prevent, therefore, when using the mask, make sure that the headband is properly secured, make sure there is good lighting, check that there is no protective film on the glass, and monitor the level of darkness.

High and low temperatures often affect the degree of darkening and may be the reason for its delay. The manufacturer warns that at -10C the Chameleon mask may not work correctly.

How to test a Chameleon mask without welding

When you hold down the Test button for five seconds, the filter should darken. If there is no such configuration function, you need to check Chameleon in other ways. The sensors are triggered by a powerful light beam. The filter is turned towards the light source at least three times, the screen should darken in all cases. Light protection reacts to:

• radiation from the sun (the filter should darken and open after an exposure interval, because the flow is of constant intensity);
• red spirals of incandescent lamps (darkening persists throughout the entire period of being near the emitter; it operates at an alternating current frequency);
• a spark from a silicon lighter (the filter darkens sporadically when the wheel knocks out a spark);
• remote control for household appliances (sensors react to infrared radiation pulses, the light output of the remote control is uniform);
• smartphone screen during flash.

If the filter does not respond, check the power supply: change the batteries or batteries, charge the solar panels. The sensitivity of the filter is checked with an incandescent lamp. If the spiral is equally visible at different settings, the regulator does not work.

Additional selection criteria

In addition to the above parameters, the buyer may also be interested in other characteristics:

1. The degree of darkening depends on the angle of incidence of the radiation. Good masks should have several layers of quality filters.
2. The opening and closing time of the filter should not exceed 2 milliseconds. As a rule, all masks on the market meet this requirement. But during operation, malfunctions may sometimes occur. So, in cold weather, the response time of the filter slows down a little. This feature must be taken into account when working in cold weather.
3. The presence of a battery - it is designed to turn the filter on or off.
4. Certification – very often welding helmets are designated with the CE symbol. It means that one sample was tested before sales. The DIN marking provides information that the product is tested every two years in the amount of 10 samples. And DIN plus means that the same number of samples pass the test, but every year.
5. Arc detection method - in most cases, the optical method is used for Chameleon type welding helmets. To do this, special infrared sensors are installed in the mask.

Carrying out maintenance

Welders should inspect the Chameleon at least once a month. Dirt is removed with a soft rag or cotton cloth. Cleaning products with aggressive, oily and abrasive bases are not suitable for glass. It is important to remember that filters are fragile and cannot withstand shock loads. To get to the light sensors, the casing is dismantled. This is done when the power supply is turned off, just remove the batteries.

Step-by-step instructions for replacing the protective screen:

1. The cartridge latches are moved to the center of the filter and opened.
2. The damaged glass is removed along with the rubber gasket, and it is replaced with a new light filter of the Chameleon mask.
3. The assembled cartridge is installed in its working position. It should fit tightly.

When replacing the filter, remove the regulator knob and potentiometer. Then the elements are assembled in the reverse order. Be sure to check the sensitivity lever; the delay time adjustment should work perfectly so as not to catch “bunnies”.

How to use a welding mask

Be sure to read the user manual before use, which can make it easier for you to adjust the mask for welding tasks and avoid any obscuring problems.

But remember:

• the Chameleon mask should fit tightly to your head and not create voids - this will give you confidence when working that the mask will not fall off and you will not be injured;
• To replace the power supply elements, it is necessary to transfer the shield to grinding. If the red light comes on, you need to change the batteries;
• if you are prone to allergies, then make sure that the belt for putting on does not rub the areas of contact, otherwise it is more likely that you may experience skin irritation;
• Do not use detergents or aggressive cleaning agents to clean the damper;
• the light filter does not handle moisture and may fail;
• if you notice that the quality of the darkening has deteriorated or is absent, then stop welding until the cause of the malfunction is determined;
• It is better not to change the specified settings for the light filter. Only the spare parts specified in the instructions are suitable for its adjustment;
• do not use physical force on the shield;
• It’s logical to take the filter cartridge to a specialist to find out what’s broken in it;
• a surface with elevated temperatures can damage the shield and cause dimming problems;
• The Chameleon mask is not used for plasma or gas welding.

Safety precautions

Before putting it on, check the settings, operating mode switches, and battery charge. Always check to see if the filter is getting dark. If it turns off during welding, the protective glass protects the eye to a small extent from IR and UV rays. But it’s safer to stop working immediately. It is dangerous to use a faulty mask. If a defect is found or the filter does not respond, the malfunction is serious and welding cannot be continued.

It must be remembered when working that the powerful radiation of the arc and molten electrodes is destructive. In addition to discomfort, this threatens to damage the retina. To prevent loss of vision, it is necessary to correctly adjust the degree of darkening of the filter.

To preserve the mask, it is important to follow the storage regime: non-functioning filters and solar panels protect from exposure to light.

Conclusion

Auto-dimming controls exposure to harmful radiation. There is a large selection of shields in this direction: Forte MC-1000, Centaur SM-152, Vitals Professional Thor 2500 LCD...

Don’t forget to check the shield when purchasing so as not to purchase a faulty or defective one. Only in case of minor damage and dimming problems can you carry out repairs yourself.

Such breakdowns include replacing power supplies or protective glass. If the filter breaks down, you should contact a service center, where they will replace it efficiently and quickly.