Welding masks chameleon DIY repair

In detail: DIY repair chameleon welding masks from a real master for the site my.housecope.com.

Caught a hare while welding in a Chameleon mask?
Do not rush to throw it away, you can still fix it yourself.

If the light filter stops darkening, or darkens briefly during arc striking, and then - transparent glass, try to charge the mask battery by exposing it to the sun.

This procedure will help if the mask has been in a dark garage for a long time and the battery is discharged.

If this does not help, you need to disassemble the mask, get to the battery and replace it. To access the battery, you need to figure out how you will open the mask, because it can either be glued or assembled on internal latches.

Chameleon Batteries - CR2450 Tablet

The most convenient and simple option is, of course, when the light filter is attached to the mask body with screws.
Inside the case there is an electronic board, a light filter and a lithium power source, popularly a "pill".
It can be a CR2450 item or another item.

We measure the voltage across the element.

As a rule, the nominal voltage is 3V, although the mask can work at a lower voltage, but practice will already show this.
The power supply is usually soldered on both sides of the board. We carefully solder it and replace it with a new one.

If you cannot find exactly the same item on sale as a temporary solution to the problem, you can use the power supply installed on the computer motherboard.

Regardless of the quality level of any product, sooner or later it will still break or fail. This even applies to state-of-the-art chameleon welding helmets. There are many different factors that can affect the performance of the mask and render it unusable. For example, use in an unsuitable ambient temperature, mechanical stress, falling of the product, etc.

Video (click to play).

The most frequently broken components in a permanent assortment are available in shops selling welding helmets. In this regard, the selection and purchase of a new part will not cause difficulties.

It is worth taking a closer look at the details that make up the chameleon-type welding mask.
It is worth taking a closer look at the details that make up the chameleon-type welding mask.

Product body.
Knobs for changing settings (not available on all models).
Light-sensitive sensor.
Protective neck cover.
Arc sensor panel.
Battery, if there are several, then the following types are used:
lithium-ion battery;
solar battery.

Unfortunately, problems with the performance of chameleon-type welding masks occur quite often. The most affected area is batteries. If a solar battery is used as the main power source, then the problem may lie in a banal lack of charge. This problem is the easiest to solve, you just need to charge the battery. To do this, you need to put the product in the sun or under a bright light source. After a certain time, you need to check if the mask works. If the power source is a lithium-ion battery, charge them exactly following the instructions for use. If the problem is not solved by charging the batteries, then in this case a complete replacement of the batteries may be required, which is much more expensive.

Also, the glass in the welding mask can be damaged.This problem is easy enough to identify, it is enough just to carefully examine the glass for scratches, cracks, etc. Naturally, the automatic shade increase function will not work in this case. Replacing glass is quite an expensive procedure.

Also, the glass in the welding mask can be damaged. This problem is easy enough to identify, it is enough just to carefully examine the glass for scratches, cracks, etc. Naturally, the automatic shade increase function will not work in this case. Replacing glass is quite an expensive procedure.

Some welders are faced with the problem of fastening. Over time, it can loosen, which will not allow the mask to be firmly fixed on the head. They can be replaced without any problems, their cost is relatively inexpensive. This type of repair is one of the simplest.

The most difficult is the procedure for repairing the motherboard. It is very difficult to identify a specific failed contact. You will need to use a professional technical service to fix the motherboard. It is worth noting that this service is not cheap.

In the event of a defect or malfunction in the operation of the welding mask, the first step is to stop all work, with the obligatory shutdown of all equipment. Then you need to conduct a thorough examination to identify the defect. If no external faults were found, disassemble the mask and check the condition of the internal components.

To reduce the risk of a malfunction, a periodic technical inspection of all equipment is required. This will allow you to identify the defect at an early stage, therefore, eliminate the chance of complete breakage of the mask. We recommend that you complete this process at least once a month.

During the examination, you need to clean the mask from accumulated dirt, both outside and inside. You can use a plain cotton cloth to clean the cartridge. Under no circumstances should any solvents be used. The cables and the motherboard must be handled carefully.

Light sensors require special attention. To clean them, you need to dismantle the plates from the case and carefully clean it. When carrying out any of the above manipulations, you need to remove the power sources, regardless of the amount of battery charge.

During self-repair of a "chameleon" -type welding mask in a domestic environment, all manipulations must be performed very carefully. There is no risk of injury to the body, but it is quite easy to completely break the technique.

If the breakdown is serious enough, and you are not confident in your abilities, then it is better to contact a specialized service center. Since inept repairs will not solve your problem, but on the contrary will only aggravate it. It should be noted that self-parsing of the chameleon-type welding mask automatically excludes the possibility of further repairs under the warranty card.

Like all welding helmets, the Chameleon protects the welder's eyes from infrared radiation.An automatically adjustable light filter works in a convenient mode: the screen changes the degree of dimming from the illumination of the working field. It is dangerous to work when the Chameleon welding mask does not work for darkening.

It is necessary to figure out why the screen does not work. Sometimes it is enough to change the supply elements, to charge the battery. A dirty screen reacts worse to light, it may need to be wiped clean. If this does not help, it is better to turn to professionals.

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:

refractory glass that does not transmit ultraviolet and infrared radiation;
layers of polymer crystals that change the throughput;
to darken the filters, 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 sensors are triggered by radiation, the crystals are polarized, the screen darkens. The welder can see the junction of the metals within the eye-permissible range. After turning off the light source (electrode or arc), the sensors are triggered again. The screen brightens.

The tuning system regulates:

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

The adjustment is carried out at the preparatory stage, when the Chameleon mask is checked for serviceability before work.

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

a comfortable distance from the face to the protective screen is set, this is done when the latches are loosened;
the position of the filter is adjusted, the comfort of the view of the working area depends on it;
the intensity regulator is set: they determine in which mode the Chameleon welding mask is used, the operating manual must contain setting 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 masks of the Chameleon welder during work;
the holding time depends on the type of welding, for spot welding, the minimum interval is enough, with electrode welding, when a melt pool is formed, it is necessary for the screen to remain darkened longer.

The screen will not respond to light without being connected to a power supply. If the model is equipped with AAA alkaloid batteries or rechargeable batteries, the charging indicators are displayed in the area of the screen. If the red light is on, it's time to replace the batteries. Solar panels are charged when welding. If the mask does not turn on, point it towards a light source for a few minutes.
If the screen darkens unevenly, check the distance between the screen and both eyes. Perhaps, while adjusting the mask, adjusting it over the head, the filter shifted. It should be parallel to your face. Loosen the clips, align the cover.
If the screen flickers while welding, the cause may be in 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 fail, check the cleanliness of the surface of the sensors. For two modes of operation (welding and grinding), check which position the switch is in. The screen may flicker during low current welding at low sensitivity mode. The required level can be established experimentally in the course of work.
The filter does not darken immediately in the cold. Panoramic screens quickly change the degree of darkness in the temperature range from +50 to -10 ° С; Chameleons are not intended for harsh winters.
If the weld is poorly visible, there may be several reasons. Sometimes the film is forgotten on the protective glass. You can try to clean it, switch the dimming control.

If you hold the Test button for five seconds, the filter should darken. If there is no such tuning function, you need to check the 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 the exposure interval, because the flow is of constant intensity);
red spirals of incandescent lamps (darkening persists for the entire period of being near the emitter, it operates with an alternating current frequency);
a spark from a silicon lighter (the filter darkens occasionally when the wheel knocks out a spark);
a remote control for household appliances (sensors respond to infrared radiation in pulses, the light flux of the remote control is uniform);
smartphone screen during flash.

If the filter does not respond, check the power supply: change batteries or batteries, charge 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.

Welders should inspect the Chameleon at least once a month. Dirt is removed with a soft cloth or cotton cloth. Cleaning agents with aggressive, oily and abrasive glass bases are not suitable. 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 you turn off the power supply, just remove the batteries.

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

The cartridge latches are displaced towards the center of the filter and opened.

The damaged glass is removed together with the rubber gasket, it is rearranged to a new light filter of the Chameleon mask.

The assembled cartridge is placed in the working position. It should fit tightly.

When replacing the filter, remove the regulator knob, 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 the "bunnies".Before putting on, check the settings, mode switches, battery power. Always check if the filter darkens. 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 right away. It is dangerous to use a defective mask. If a defect is found or the filter does not respond, the malfunction is serious, welding cannot be continued.It must be remembered during work that the powerful radiation of the arc and molten electrodes is destructive. In addition to discomfort, this threatens damage to the retina. In order not to lose sight, it is necessary to correctly adjust the degree of filter darkening.For the safety of the mask, it is important to observe the storage regime: inoperative filters and solar panels are protected from exposure to light.Additional options make repairs more difficult and increase the risk of mask failure. If the degree of shading has decreased significantly, it is necessary to examine the structure.Some of the component parts cannot be repaired and must be replaced. If you cannot do it yourself, you need to contact the service center. The warranty is only valid for complete masks. If you have time to dig into it, you will have to pay for the services of the service.It is not worth taking on the repair of the motherboard: this is the business of professionals. It is better to immediately contact the service center. Unsuccessful DIY repairs can result in additional costs.There are two types of visors on the market, with a fixed degree of shade and a chameleon mask.Masks of the second type are distinguished by a higher cost and the presence of an automatic light filter, which is able to react to the intensity of light radiation, thereby protecting vision. The principle of operation of the chameleon welding mask is based on the fact that the light filter instantly reacts to light radiation and, depending on the intensity of the latter, automatically darkens the light radiation. The auto-dimming filter, in turn, has a layered structure in which layers of liquid crystals alternate with special films. At the moment the arc is struck, the crystals are ordered in a certain order and do not transmit part of the light. Image - Welding masks chameleon DIY repair

chameleon welding mask diagram

Based on this principle, you can effectively protect your eyesight from the influence of bright vision.

Let's figure out why the shield may not work. Let us consider the malfunctions characteristic of a welding mask. Often, a chameleon welding mask does not fulfill its main function, namely, it does not lower the level of light radiation. The essence of the problem may lie in dead batteries. The chameleon welding mask can be powered by both conventional AAA batteries and a solar panel located on the body. Simply put, replacing the battery can solve the problem. If we consider the first way to power the shield with energy, then simply insert the batteries into it. In the case of battery power, you need to hold the shield under a bright light, thereby charging it.

But even after the performed procedure, you can find that the shield still does not work. The reason may be in the protective glass. Usually, with this type of malfunction, cracks, chips and other mechanical damage are visible on the glass. In this case, it is necessary to replace the liquid crystal glass, which is the most expensive component in the mask. It is important to remember that the new glass must fully comply with the previous one in all respects.

The light filter may blink. Here, the protective glass can be either simply dirty or damaged. In this case, it is better to immediately change the light filter with a protective glass.

It is better not to repair the light filter of the welding mask yourself. It would be more correct to contact the specialists at the service center. It will cost money, but the service center can accurately identify the cause of the breakdown and specialists will easily eliminate it.

Poor visibility does not favorably affect vision, therefore it is important to properly fix the headband, install a good source of illumination in the workplace, remove the film from the protective glass, and adjust the degree of dimming. At low temperatures, there may be a delay in dimming. Do not use the mask at temperatures below -10 degrees Celsius.

In order to know how to set up the mask and how to check its performance, it is better to refer to the instruction manual. Important to remember:

the chameleon mask is not suitable for plasma and gas welding and cutting;
do not leave the shield on a hot surface;
it is better not to disassemble the filter cartridge;
the shield will not withstand strong blows;
the filter cannot be changed. It is allowed to use spare parts that are indicated in the instructions;
if the chameleon welding mask does not darken the image, it is required to stop working and identify the possible cause of the malfunction;
it is necessary to prevent moisture from entering the light filter;
when cleaning the shield, it is not recommended to use detergents and solvents;
the wearing headband may cause an allergic reaction, the straps must be adjusted correctly to prevent skin irritation;
in order to change the batteries, put the shield in the grinding mode. When the red light on the filter comes on, the batteries must be replaced;
before starting work, you must adjust the mask for yourself to achieve maximum comfort.You can select the amount of shade, delay time and sensitivity level.

In order to reduce the likelihood of breakage to zero, it is necessary to carry out maintenance from time to time. The minimum interval between repairs should be one month. To remove dirt and dust, you can use a cotton cloth that has been pre-moistened with a non-corrosive liquid. Do not use oil-based cleaning agents or abrasive materials as this can damage the shield. All cleaning operations must be done with care, do not press hard on the material.

There are several types of adjustments in the welding helmet. Before starting work, it is extremely important to configure all the characteristics. This is necessary for the most effective use of the mask during work. The following are the following types of adjustments.

It is imperative that the visor is securely attached to the head. The diameter of the headband can be adjusted using a knob located at the back of the head. The procedure must be carried out with a shield on the head, which will allow you to obtain the necessary tension. In the event that the headgear sits high or low, you should fix it with a strap passing over the top of the head. Before starting work, it is necessary to check the fit of the shield. If it does not sit securely, you need to re-adjust.

The mask can be moved away from the eyes and brought closer to the eyes by loosening the locking nuts. The distance from both eyes and the filter must be equal. If everything is done correctly, the lock nuts must be tightened.

Depending on the type of welding and the current value, the required degree of shading can be selected from the table. This can be done during operation with the help of the regulator, which is located on the outer side of the shield.

There are two types of sensitivity: high and low. For most applications, you can set the knob to the middle position. When operating in TIG mode at low amperage, maximum sensitivity is required. For optimal settings, it is better to set the sensitivity to maximum, and then turn it down until the light filter begins to perceive light radiation only from the welding arc, and not from external light sources (sun, lighting lamps, etc.). The required degree of sensitivity can also be selected according to the scheme, where each type of welding has its own level of sensitivity.

The adjustment is made using the regulator knob, which is located on the inside of the cartridge. A short delay is suitable for spot welding, and a long delay is suitable for high amperage welding.

The auto-dimming shield perfectly neutralizes the negative effects of light radiation. There is a huge selection of such shields on the market, such as: Resanta ms 2 welding mask, Bars MS-207, Centaur MS-30R and many others. The shield must be checked upon purchase, otherwise you can purchase a defective or faulty shield. Do-it-yourself repair of a chameleon welding mask should be done if the breakdown is not serious. For example, everyone can replace batteries or protective glass. But if the malfunction is related to the light filter, then it is better to contact the service center, where the breakdown will be quickly identified and corrected.

Despite the high quality of many products, there are still no eternal things and any technique breaks down sooner or later. Malfunctioning welding helmets can occur for many reasons. This can be incorrect adherence to the temperature regime, mechanical damage, substandard or defective components, and so on. Do-it-yourself repair of a chameleon welding mask can be both quite simple and very difficult, depending on what is broken.The job description of a welder of any category prohibits the use of damaged equipment, be it a welding mask or a welding transformer, so if a breakdown is found, you should not continue to use the product, but it is better to postpone everything for repair.The more complex the model of the mask, the more convenient it is to work with and at the same time, the more problems with it can arise. Before repairing, you should study the design and other features of the existing mask. Indeed, sometimes it is necessary to replace any parts or elements, therefore, you should know exactly what the work is to be done with.Spare parts for chameleon welding masks can be purchased in the same places where the masks themselves, since many people encounter breakdown problems in working conditions.Very often there is such a situation when the chameleon welding mask does not work. In this case, most likely, the problem lies in the batteries. If everything is solar powered, then the mask can simply be fully seated and needs to be recharged. To do this, you need to put it in a sunny place and then check it for performance. If the work is on lithium batteries, then they also need to be replaced or recharged, depending on the design. The strangest moment here will be damage to the power supply unit itself, since then it will need to be replaced, and this is already more expensive and more difficult.There may also be a problem with glass breakage. In this case, it is quite easy to identify a breakdown, since, as a rule, cracks or other mechanical damage are observed on the glass. Naturally, the welding mask does not darken in this case. It also requires replacement of liquid crystal glass, and its parameters must exactly correspond to the previous one. This is one of the most expensive items.Fasteners often fail, which are replaced with similar ones, or simply reattached in a more reliable way. This is one of the simplest types of repairs.It is very difficult to repair the control board. Here it is not difficult to notice any problems, except for the most obvious ones. It is also not always possible to carry out repairs on your own, therefore, you often have to use the services of a professional service. If this element breaks down, the parameters may not be adjusted or the darkening or lightening of the filter may not work.If you find malfunctions on the chameleon welding mask, then first of all you should stop all welding work that was carried out and you need to turn off the equipment. Then it is advisable to conduct an external examination to identify possible malfunctions and their causes. Further, if all else fails, then you need to disassemble the product in order to inspect from the inside.Periodic maintenance should be carried out to reduce the likelihood of breakdown. It should be held at least once a month. This helps remove dirt and dust that builds up in the cartridge on the light filter. To clean the cartridge, use a clean cotton cloth that is moistened with a non-corrosive liquid. Do not use abrasive materials, solvents or substances that contain oil. During cleaning, you do not need to bend the electronic cable and you do not need to press hard on the material in order not to damage it.