How to repair a chameleon welding helmet - Metals and their processing

Do-it-yourself chameleon welding helmet repair

Every professional welder or DIYer who has to deal with this type of work knows how important it is to provide personal protection.

For example, using a high-quality and comfortable protective mask will greatly simplify the task.

It is worth noting that the use of a standard sample is not always possible, because the anthropometric data of each person is individual, so knowing how to make a welding mask with your own hands is worth it for everyone who is engaged in this difficult but important work.

General description and features

To begin with, it is necessary to say a few words regarding general definitions.

So, a welding mask is a special device designed to protect the eyesight and skin of the face from the harmful effects of ultraviolet radiation emitted during the welding process.

In addition, during work, the surfaces of the elements being welded are heated to high temperatures, which causes melting of part of the metal. This leads to the formation of harmful fumes, which should also be shielded by the mask.

The nuances of using this protective equipment determine some of the features of its manufacture. For example, the material from which the mask is assembled should not transmit ultraviolet radiation.

When making this element of equipment yourself, this point must be taken into account, since some materials, for example, linoleum, which can be considered as a material suitable for the task, transmit ultraviolet radiation.

Failure to comply with this condition may result in injury, so it must be taken into account.

Types of welding helmets

To fully consider the issue, it is necessary to determine possible options for manufacturing welding helmets. Based on the manufacturing features and materials used, several types of welding helmets can be distinguished.

Welding shield. This is the simplest type of protective device, which consists of a mask with an installed light filter and a handle for holding. This option is optimal for home use, as it allows you to quickly remove the shield from your face and put it back, which is quite convenient. However, this mask is not suitable for intensive use, because it limits movement and has insufficient functionality for professional use. The main advantage of such a mask is its affordable price and prevalence. Welding shield
Standard mask. It is also a fairly common option for manufacturing this protective device. The main difference between such a mask is the presence in the design of a special fastener, which is put on the head and serves to hold the mask in a certain position. Such masks are more expensive than shields and provide greater freedom of action, as they allow you to raise and lower the mask itself. This significantly improves the overall usability of the mask. The disadvantage of this type of design is that when the mask is raised, the face remains completely open, which is not very good from a safety point of view.

Mask with a folding light filter. This type of protective mask is a logical continuation of the previous manufacturing option. The main structural difference is the presence of a folding light filter, which allows you to begin carrying out tasks related to welding work. The point is that such a mask does not allow you to raise the entire mask, as in the standard version, but only the light filter. As a result, the face remains protected and you can immediately begin cleaning the slag from the weld seam.
Mask for specialized tasks. This type of welder protective equipment is the rarest and is used to solve highly specialized problems. The main difference between such a mask is that its design includes a special filtration or air supply system. This allows you to work with hazardous materials containing, for example, manganese or chromium. Here we can also mention helmets with an air supply system, which are used when working underwater. The structural complexity of such devices entails their significant increase in cost, although, based on the specifics of the application, their private use is inappropriate.

Chameleon mask

A separate category includes welding helmets with installed chameleon filters. Their main difference from other manufacturing options is the use of special light filters that can automatically change a number of their operational parameters from the degree of darkness to the interval for switching operating modes.

This filter consists of a protective film, LCD glass and a direct protective filter that screens ultraviolet and infrared radiation.

An automatic control element is supplied with it, with the help of which all necessary adjustments are made. This also includes an arc detection element and a solar panel needed to power the filter.

Such filters are more expensive than conventional ones, but provide good protection, while saving time, which means they have a positive effect on overall labor productivity.

The choice of a specific option for manufacturing a welding mask should be made based on the specifics of the intended tasks. Naturally, it is not advisable to purchase an expensive mask if you are going to use it only from time to time. As for making it yourself, it’s simply not possible to assemble the most complex types of masks with your own hands.

Light filters for welding helmet

Depending on the specifics of the work performed, light filters for welding helmets can be divided into several categories. They will differ in the degree of filter throughput, and in the case of using a “chameleon” in the quality of workmanship. You can determine the degree of darkening of Russian-made filters by the markings applied. Thus, there are safety glasses on the market from C-3 to C-8 (or in DIN: from 8 to 13).

Darkness level of welding filters

You can clearly observe the differences in manufacturing options simply by looking at a regular light bulb. If the element is slightly darkened, the filament will be clearly visible, but the maximum level of protection will practically hide it from view.

If you have to carry out welding work on an ongoing basis, or if you want to be as safe as possible when using the device as an amateur, then you should turn to professional equipment. The modern market is able to offer many ready-made options. It is important to take into account that the price of such protective devices will be quite high. In this regard, the idea of making your own welding helmet comes to mind.

It is important to understand that the main problem in solving such a problem will be finding the necessary material. The bottom line is that ultraviolet and infrared radiation can penetrate even seemingly dense materials. In this regard, the best solution in such a situation would be to modernize the finished mask. The algorithm of actions will be as follows:

You need to purchase the simplest welding helmet. The price on the construction market here will fluctuate around several hundred rubles, and on foreign sites it may be even less. In this case, you should pay attention only to the overall quality of workmanship and the materials used.
Next, you need to dismantle the standard protective filter. As a rule, this means that a special latch is pulled out and the glass can be removed freely.
After this, a chameleon filter is installed. You can purchase it both in simple construction equipment stores and on foreign Internet sites. Installing the filter is simple - you just need to secure it with a few mounting bolts.

Checking the certification of a NAKS welder

Using the manipulations listed above, you can assemble a fully functional protective chameleon mask, which will not be inferior to the factory versions. At the same time, the cost savings will be quite significant, especially if you purchase components abroad, in any Chinese online store. This is exactly what most retailers on the market do, they simply put their logos on the assemblies.

DIY welding mask with air supply

During the welding process, not only ultraviolet and infrared radiation are released, but also harmful gases that rise upward, getting under the mask and then into the lungs. This phenomenon is not only unpleasant, but also dangerous to health.

The way out of this situation is to purchase a professional protective mask equipped with forced air supply. This type of protection can greatly simplify the task, but it is quite expensive.

You can save money if you make such a mask yourself.

You need to take a simple welding mask. If necessary, it can be upgraded according to the above scheme.
Next, the air supply system is mounted and secured. It can be made from simple polypropylene pipes with a diameter of about 2 cm. Pieces of pipes are soldered together through appropriate adapters. The result should be a structure resembling an oval.
A piece of tube is soldered into its upper part, the end of which is left uncovered. Next, air will be supplied through it.
A series of holes are drilled in the tubes along the perimeter, from which the pressure blower will subsequently blow out external gases.
The frame of the future air supply system is fixed to the inner surface of the mask.
Next, a pump is made to supply air. It can be made from the same polypropylene pipes, but with a larger diameter.
A plug is installed at one end of the pipe section into which a filter from any gas mask is screwed.
A fan (computer cooler) is mounted inside the pipe and blows air.
Next, the cooler can be connected to the battery.
The second end of the pipe is closed with a plug into which an adapter for a corrugated tube is screwed in (you can take a corrugated pipe for laying electrical wiring).
Wires inside a corrugated pipe
The tube is connected to the structure inside the mask and an improvised air supply is ready.

If you show due attention to detail and some ingenuity, you can end up with a pretty good version of a welding helmet with forced air supply.

You can watch a more complete and detailed video on how to make a welding helmet with air supply with your own hands.

DIY drawings on a welding helmet

The desire to decorate your working tool is inherent in all professionals. This will not only allow you to realize your creativity, but will also highlight an individual element of protection, which means no one will use it “by mistake.”

For example, you can apply some kind of colorful design to a welding mask. To do this, you just need to find a suitable picture and, after transferring it to paper, make a stencil. Next, the design is applied using a can of paint.

If it is possible to use a spray gun, then the task is greatly simplified. As you gain experience, you can try to apply more and more complex multi-layer designs.

You can watch the video on how to make a design on a welding helmet with your own hands.

In conclusion, it is worth noting that personal protective equipment should never be neglected, and especially when it concerns a risk to vision, as is the case with a welding helmet.

It is not always possible to purchase an expensive professional sample, but with the help of simple manipulations, you can significantly improve the simplest manufacturing option, which will allow you to achieve a significant improvement in performance characteristics, and therefore greater health protection.

By the way, assembly, modification and external tuning of welding helmets can also be considered as a business idea that can also generate income. How to use this idea is up to you.

tools Paint Material welding welding mask DIY

Source: https://respect-kovka.com/remont-svarochnoy-maski-chameleon-svoimi-rukami/

DIY chameleon mask repair (battery replacement)

If your chameleon welding helmet breaks, do not rush to buy a new one - you are quite capable of fixing the old one with your own hands.

We disassemble the “chameleon” welding helmet

This story began when I needed to do a little work related to welding - install an additional gate on the gate: weld and weld several parts to it and burn one hole. And, as they say, “nothing foreshadowed” until I checked the “chameleon” welding mask . She didn’t want to work: the most she could get out of her was a faint flicker of the screen.

In such cases, manufacturers sometimes advise keeping the mask in the sun to charge the internal batteries, but “recharging” did not help.

The amount of work was small, it did not require much responsibility, and I decided to cook “blind” for a while, covering my face with a mask, but without looking at the arc, since the “chameleon” filter itself is already quite dark. It was not possible to “pump up” the built-in batteries using the welding arc (there was a secret hope for this).

In general, one job was done, but a new task immediately arose: change the mask or try to fix it. Of course, to begin with, the second choice was chosen: throwing it away would always be possible.

The easiest part of the job is to remove the “chameleon” element from the mask. Since on this model the dimming control is located outside, we first remove it.

To do this, use a flat object (knife) to pry up the rotating handle of the regulator (1) and unscrew the plastic nut (2). There is nothing difficult in removing the filter element - it is installed on a latch (3).

We don’t need the mask body with the outer replaceable glass (more precisely, a sheet of transparent plastic) for now, let’s see how to disassemble the filter.

The preliminary task is to determine the size of the built-in batteries. Everything would be simple if the filter housing had some kind of compartment or slot for them, but such masks are quite rare. Our case is the most typical: the body is not dismountable. Using the same knife, pry up the dimming and sensitivity delay time regulators (4). In principle, you can remove the transparent plastic inserted into the body “from the eye side”, but this will not give us anything - we leave it as is.

“Non-separable case” in our case means that both halves of it are connected to each other, but there are no screws or at least stickers under which they can be hidden. The preliminary conclusion is that the halves are either glued together or secured with some kind of internal latches; this will become clear upon opening. To do this, we take the knife again and carefully try to separate the halves. The body should be held firmly during this operation.

The knife, by the way, is an ordinary table knife, with a rounded tip so as not to cut yourself if it accidentally slips. Having disconnected one of the corners, slowly, using the knife as a lever, we move along the perimeter (5).

If the connection were made using latches, they would break or come out of engagement (depending on your luck) with a characteristic crunch, and after the first such click, you could try to somehow press on them in order to save at least part of it.

Source: http://kak-svoimi-rukami.com/2013/12/remont-maski-xameleon-svoimi-rukami-zamena-akkumulyatora/

How to test a chameleon mask without welding

Simple and not very convenient glass filters have been replaced by new generation devices. The work is based on the principle of polarization of liquid crystals. When exposed to voltage, they change orientation and block light rays. In expensive analogues, several layers are used to ensure maximum uniformity of darkening. Another filter blocks ultraviolet and infrared radiation. Its action is constant.

Sensors that catch the arc and an electronic unit are built into the housing. All layers together form a block, which is protected on both sides by plastic filters. You can work with a grinder or hammer away scale without removing the mask. Plastic filters are consumables and require replacement over time.

The chameleon mask is currently one of the best means of protection when working with a welding machine.

The most important point is the response time. Professional models operate in one millisecond. However, the performance of this parameter decreases when working in cold weather. This is a disadvantage of the chameleon mask, since their limit is -10 degrees. Respectable manufacturers indicate in the product data sheet the response time based on the ambient temperature.

You need to store the chameleon mask in a heated room, otherwise its resource will quickly be exhausted.

Advice. The chameleon mask is designed in such a way that welding aerosols flow around the welder’s head as quickly as possible, and he does not ingest harmful gases.

Settings can be adjusted without interrupting the work process. The buttons are located inside the light filter or on top; they are convenient to adjust by touch.

Filter classification

The light filter is the main element of the mask. EN379 is a European standard regulating the parameters of light filters. Next comes the notation through the fraction 1/1/1/2. Let's take a look at what this marking means.

The first number is the optical class. It indicates how clearly and geometrically correctly objects will be visible through the filter. One is the best indicator. The higher the class, the faster your eyes will tire.
Light scattering essentially means transparency. An increase in this number indicates an increase in optical turbidity.
Shade is indicated in DIN or SHADE and characterizes the uniformity of the filter darkening. Which corresponds to the old marking C 4 -7 (4 - 9 DIN).
The angular dependence of the degree of darkness is within 15 degrees.

Please read the product datasheet before purchasing to ensure the quality of the product.

Secrets of choosing a mask

The mask is sold complete with or without filters. According to regulatory documentation, it must be made from materials that do not conduct current, are resistant to splashes and radiation into the space, that is, the welder’s face will be safe. Almost all modern masks meet these requirements.

Domestic manufacturers use plastic or fiber in production. Chameleons of European brands are distinguished by their exquisite design. Leather masks are produced for working in cramped conditions.

What parameters should you pay attention to besides the mask design itself? Professionals advise the following:

evaluate the weight, dimensions and configuration of the mask;
adjusting the headband strap;
check whether it is possible to install dioptric lenses.

The straps allow you to adjust the mask to fit your head. The ability to adjust the distance of the filter from the eyes allows you to set the viewing angle required for comfortable work.

It is better to buy a mask from a trusted manufacturer

If you need to use diopter lenses, you should think about purchasing filters with an extended viewing window, then you won’t need to lift the mask every time to look at the welding seam, this can be done over the lens.

Advice. Buy only certified chameleon masks with a warranty period and beware of fakes.

Light filter – selection criteria

When choosing a filter for a regular mask, there is no particular hassle; they differ only in the degree of darkening of the glass for different types of welding work. With a filter for a chameleon mask, everything is not so simple.

Not every manufacturer conscientiously cares about the safety of your vision. Therefore, be sure to check for a certificate that will confirm the quality of the product.
Possibility of changing the power supply. The built-in ones cannot be replaced; after their resource expires, you will have to buy new protection.
The higher the filter response speed, the better. For home use, one hundred microseconds is enough, for a professional, half as much.
If there are a large number of sensors responsible for the arc, the risk of spontaneous opening of the filter during the welding process is reduced.
The settings for the degree of darkness, trigger sensitivity and return to the starting position on a good mask are smoothly adjustable. This is especially worth noting. Step adjustment is considered a relic of the past.
The mode of operation with an angle grinder and some additional features make the welding process comfortable.

Advice. If the filter is designed to work with argon-arc welding, then it will cope perfectly with both electrodes and semi-automatic welding.

What does the market offer?

The leading positions in the production of masks and filters for them are occupied by China and Taiwan. However, the quality of the products leaves much to be desired: the filters do not operate on time or open spontaneously, which can have a very adverse effect on the health of the welder. But I'm pleased with the low cost.

Chameleons from a domestic manufacturer are reliable; their drawback is the possible spontaneous opening when working with argon welding.

OTOS is a Korean manufacturer. Sometimes these same masks go on sale under the French brand GYSMATIC. The weak point of this manufacturer is the filter; it can delaminate or become covered with stains and microcracks.

Remember that in a high-quality mask you should not experience discomfort in your eyes

Chameleons from European brands are not cheap, but their quality is high. A filter from one manufacturer will not fit a mask from another.

Here is a list of brands that produce reliable and high-quality welding helmets and have international certificates:

OPTREL;
OTOS;
SPEEDGLAS;
TECHMEN.

Advice. If during welding work you feel discomfort: burning, tearing and rapid eye fatigue, immediately put this mask aside; it cannot be used. Symptoms indicate poor quality filters.

Now you know all the intricacies of choosing a chameleon mask. Not only your health, but also the quality of your work depends on the correct choice of mask.

How to choose a welding helmet: video

Source: https://steelfactoryrus.com/kak-proverit-masku-chameleon-bez-svarki/

DIY welding mask

Every professional welder or DIYer who has to deal with this type of work knows how important it is to provide personal protection.

For example, using a high-quality and comfortable protective mask will greatly simplify the task.

Customizing a chameleon welder mask

Welding work requires special personal protective equipment. The purpose of a welding helmet is to protect the retina from burns. A chameleon-type mask with an automatic darkening function allows visual control over the ignition of the arc.

Principle of operation

The appearance of the mask is not very different from classic models. The design is as follows:

A housing that protects the welder from splashes of molten metal and other harmful factors.
Liquid crystal multilayer light filter with the function of automatic adjustment of the darkening level, depending on the intensity of work.
Module for setting and controlling the light filter.
Removable power supply.

A light filter is installed in the viewing glass. It is a device with several liquid crystals. In an inactive state, they do not show themselves in any way - the glass only protects from glare. But when the light sensors signal, the filter comes into operation, rearranging the arrangement of the crystals, darkening the glass. The reaction to the flash is almost instantaneous - about 0.0005 seconds.

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The filter also reacts to the end of work with a delay, the level of which is set manually.

Please note that the design, thanks to built-in filters, provides protection from infrared and ultraviolet radiation even if it breaks.

How to configure correctly, what do you need to remember?

After purchasing a new device, you must study the operating instructions . This will help you figure out how to set up a chameleon mask for welding. Types of adjustments will be discussed later. Now we will give some useful tips to future users:

Do not use the chameleon for gas or plasma welding or cutting.
The mask has temperature protection against short-term exposures. If you leave the mask on a hot surface for a long time, it may become unusable.
The body of the shield is not designed for intense mechanical impact. A strong blow can break it.
Unauthorized changes to the design of the light filter are not allowed. Disassembling the cartridge yourself may cause damage. When replacing components, use spare parts recommended by the manufacturer.
Do not use surfactants or solvents to clean the mask. Water getting on the filter is strictly unacceptable.
Replace power supplies only in grinding mode. Salt batteries are used as removable batteries.
Immediately after purchase, adjust all available settings to your preferences. Even incorrect adjustment of the fastening straps will result in skin irritation.

Carrying out maintenance

If the chameleon welding helmet does not darken, as well as in the event of other malfunctions, you should stop working and turn off the power. To reduce the likelihood of failure, it is necessary to carry out regular maintenance of the device at least once a month.

During the work process, dust and dirt get on the filter. To remove dirt, use a cotton rag moistened with a neutral cleaning agent recommended by the manufacturer. The use of abrasives and products containing petroleum products is strictly prohibited . Cleaning is done with smooth wave movements without strong pressure on the surface. Do not bend the electronic cable - this may damage it.

Battery-powered masks require periodic replacement of the power source. The power compartment is located on the case. When changing batteries, do not forget to observe the polarity.

Types of adjustments

Regardless of the manufacturer, all models offer a limited selection of operating settings in order to increase comfort and productivity. The following parameters can be adjusted.

Preparation under the head

Reliable fixation is the main guarantee of convenience. A handle located at the level of the back of the head allows you to adjust the radius of the headband, and a special belt is responsible for the vertical position of the shield. Fitting is performed with the device worn on the head. If discomfort is felt before starting work, readjustment should be carried out.

Professional models have several additional fasteners for a more secure fit.

Distance from the eye to the filter

Special nuts are responsible for the distance between the eye and the glass. Please note that this indicator should be the same for each eye. Once the adjustment is complete, the nuts are secured.

Darkness level

Adjustable based on welding parameters. The user manual contains a table for selecting suitable indicators. There are two types:

The first type requires stopping welding to remove the mask and set new parameters. Found on amateur models.

The external location of the regulator allows you to adjust the dimming without interrupting production. Used by large enterprises with large volumes of work.

Sensitivity

Adjustment of the chameleon welder’s mask according to this parameter can be configured in two modes:

The first mode will protect vision not only from the arc, but also from all bright light sources, for example, molten metal. Low susceptibility reacts only to the arc.

Semi-automatic welding in an argon environment requires high sensitivity, since this technology has a low current level. There are technological schemes that allow you to select the necessary parameters, depending on the type of work.

Delay time

This function allows you to adjust the duration of the filter after welding is completed. It will be especially useful when using piece electrodes that can stick . If the adjustment is incorrect, the filter will open before the work is completed, which will result in burns to the retina.

Possible faults

Regardless of the manufacturer and quality of the unit, any mask can break. The reasons for failure may be the following:

Violation of operating temperature conditions.
Mechanical damage.
Use of low-quality components.
End of natural lifespan.

If the operating rules are violated, first of all, they lead to malfunctions of the automatic light filter for the welding helmet. Before contacting official representatives, try to determine the cause of the problem . Some breakdowns can be easily fixed on your own, without the involvement of qualified specialists. Spare parts for repairs can be purchased at points of sale of welding equipment.

The simplicity of the mask design ensures no maintenance problems. A technologically complex device is more difficult to repair.

The mask can be powered either by a solar panel or by batteries. Failure of batteries is the main cause of problems with the chameleon . In this case, the solar cells may simply be discharged. To localize the cause, just leave the device under natural light and then check the functionality. Removable batteries need to be replaced. Replacing the power supply assembly will cost much more.

Source: https://vi-pole.ru/nastrojka-maski-svarshhika-hameleon.html

Chameleon welding helmet, darkening does not work: do-it-yourself adjustment and repair | mk-soyuz.rf

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.

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 comfortable distance from the face to the protective screen is established, 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: they determine 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.

Possible malfunctions and methods for eliminating them

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.
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.
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.
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.
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.

Source: https://xn----ntbhhmr6g.xn--p1ai/metallyi/kak-nastroit-masku-chameleon-dlya-svarki

Do-it-yourself chameleon welding helmet repair - Metalworker's Guide

When welding, it is extremely important to provide yourself with protective equipment. During the process, a person is exposed to many dangers, such as the possibility of sparks and molten metal getting on the face and eyes, the harmful effects of gases and vapors of molten metals in the respiratory tract, the harmful effects of various types of radiation, and much more. In order to protect yourself from possible injuries, you must use a welding helmet.

Operating principle of the chameleon welding helmet

On the market you can find two types of shields, with a fixed degree of darkness and chameleon masks. Masks of the second type are distinguished by their higher cost and the presence of an automatic light filter that can respond 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-darkening filter, in turn, has a layered structure in which layers of liquid crystals alternate with special films.

At the moment the arc is ignited, the crystals are arranged in a certain order and do not allow part of the light to pass through.

chameleon welding helmet diagram

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

Existing faults. Do-it-yourself chameleon welding helmet repair

Let's look at the question of why the shield may not work. Let's look at typical welding helmet malfunctions. It often happens that a chameleon welding mask does not perform its main function, namely, it does not reduce the level of light radiation. The essence of the problem may lie in dead batteries.

The chameleon welding helmet can be powered by both regular AAA batteries and a solar panel located on the body. Simply put, replacing the battery can solve the problem. If we consider the first method of powering the shield with energy, then simply insert the batteries into it.

If powered by a battery, you need to hold the shield under a bright light to charge it.

But even after this procedure, you may find that the shield still does not work. The reason may be the protective glass. Typically, 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.

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

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

Poor visibility does not have a beneficial effect on vision, so it is important to properly secure the headband, install a good lighting source in the workplace, remove the film from the protective glass, and adjust the degree of darkness. At low temperatures, there may be a delay in dimming. Do not use the mask at temperatures below - 10 degrees Celsius.

How to properly set up a chameleon mask for welding? What do you need to remember when working?

In order to know how to set up the mask and how to check its performance, it is better to refer to the operating instructions. 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 impacts;
Changes cannot be made to the filter. It is allowed to use spare parts specified in the instructions;
if the chameleon welding helmet does not darken the image, you need 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 headband for putting on can cause an allergic reaction, the straps must be adjusted correctly to prevent skin irritation;
In order to change the batteries, switch the shield to grinding mode. When the red light on the filter lights up, you need to replace the batteries;
Before starting work, you need to adjust the mask to suit yourself to achieve maximum comfort. You can select the darkness level, delay time and sensitivity level.

Types of adjustments for chameleon welding helmets

There are several types of adjustments in a 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 when working. The following are the types of adjustments.

Adjusting the distance from the eyes to the filter

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 should be equal. If everything is done correctly, the locking nuts should be tightened.

Adjusting the darkness level

Depending on the type of welding and the current value, you can select the required degree of darkening from the table. This can also be done during operation using the regulator, which is located on the outside of the shield.

Adjusting sensitivity

There are two types of sensitivity: high and low. For most cases, you can set the control knob to the middle position. When working in TIG mode at low current values, maximum sensitivity is required.

For optimal settings, it is better to set the sensitivity to maximum, and then reduce it until the filter begins to perceive light radiation only from the welding arc, and not from external light sources (the sun, lighting lamps, etc.).

What documentation is drawn up when carrying out welding work?

The required degree of sensitivity can also be selected according to a scheme where each type of welding has its own level of sensitivity.

Adjusting the delay time

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 welding with high amperage.

Finally

The auto-darkening shield perfectly neutralizes the negative effects of light radiation. There is a huge selection of such shields on the market, such as: welding mask Resanta MS 2, Bars MS-207, Centaur MS-30R and many others.

The shield must be checked upon purchase, otherwise you may purchase a defective or faulty shield. Repairing a chameleon welding helmet with your own hands is worth doing if the damage is not serious. For example, anyone can replace batteries or protective glass.

But if the malfunction is related to the light filter, then it is better to contact a service center, where the breakdown will be quickly identified and corrected.

[Total: 7 Average: 3.4/5]

Source: https://ssk2121.com/remont-svarochnoy-maski-chameleon-svoimi-rukami/

Solving the problem of non-darkening of the chameleon welding helmet

How to choose the right chameleon welding helmet

Professional welders take safety issues seriously, since not only the results of their work, but also their own health depend on it. Traditional types of welding helmets, as a rule, do not provide sufficient protection for the eyes and the entire face as a whole.

There are a number of design flaws, the consequences of which can be seen in the video or read about them in reviews. However, there is a technological development - a welding helmet, which allows you to minimize all kinds of risks.

In this article we will analyze in detail how to choose the right means of protection - a chameleon, and what its features are.

The design and operating principle of the best mask

The key element in this mask, which experts pay attention to, is the automatic light filter. Its response speed to changes in the frequency of the glow is so high that it allows you to start welding without the slightest risk to the eyes. In specific figures, this is no more than one fraction of a millisecond, but with some consideration for temperature. Because when the thermometer is negative, the filter’s response deteriorates significantly.

Advice. At 10 degrees below zero, it is no longer recommended to work with it.

Light filter: the key element of the chameleon welding helmet

The principle of operation of such a filter is based on changing the spatial orientation of the liquid crystal layer under the influence of voltage. The polarization process of the LCD layer (which is provided by the corresponding films around it) partially blocks the transmitted light, eliminating uneven dimming. The layered structure of the automatic light filter can also protect against infrared/ultraviolet rays, thanks to the constant action of the special filter and the electronic control unit.

In addition, the filter includes recognition sensors for instant identification of the welding arc and a charger. Together with the housing, the modern technological device weighs a maximum of 100g, which allows it to be installed in almost any type of welding helmet. The technical safety of the unit itself is guaranteed by the installation of additional light filters on the mask.

Key indicators of a chameleon that should guide your purchase

Filter response speed. It should not exceed 1 millisecond, since instant response is the main characteristic of this type of mask. The only point at which deviations from this indicator are allowed are low temperature conditions.

The response speed of the light filter is one of the important indicators for the chameleon mask

Quantity and quality of adjustment types. Often, their range is quite wide and includes the following:

dimming adjustment;
sensitivity;
opening delay.

Different types of adjustments can also be located differently on the mask device: both outside, on one of the sides, and inside, on the filter itself. Here we should also note such an important point as the smoothness of switching: there are masks with a traditional stepped type and a smooth one (featured by an optimal degree of darkening).

Extent of visible area.

Attention! It should be remembered here that the higher this indicator, the more fragile the filter becomes.

Type of welding. The main point here will be the ability of the filter to work with argon-arc (tig) welding. Because if he has it, he can also easily cope with other types of welding, be it manual (mma) or automatic (mag).

Design features of the mask design, dimensions of the device. The efficiency of a welder’s work directly depends on the level of comfort that a welding mask provides him. The design of the head and the optimal weight of the unit, accordingly, must be in balance.

The welding helmet must provide the welder with the necessary level of comfort

Mask certification. Depending on the frequency and testing method, designations such as DIN, DIN plus, CE are distinguished. So, often the darkening of the filter occurs within 10 DIN.

Optical parameters. Here the following indicators are taken into account:

transparency coefficient;
radiation scattering;
uniformity of shading.

The level of such characteristics is determined by the corresponding numbers on the body of the mask.

Charger for turning the light filter on/off.

Characteristics of countries producing welding devices

Masks originally from China or Taiwan are distinguished by their budget cost and low quality products.
That is, they do not guarantee the required safety and may fail during operation;
Masks of Russian origin have slightly lower performance characteristics, but provide more reliable operation of the devices than previous models;
Masks from Korea are characterized by their fragility and inability to withstand frequent temperature changes.

In particular, cracks or stains are considered a typical phenomenon for them;
Masks, as well as chameleon light filters of European origin, compensate for their high price and the lack of the ability to change filters - with a guarantee of product quality. As a rule, they have a multilayer liquid crystal structure (from 3 and above).

Chameleon welding helmet: an example of a model from one of the popular companies on the market

Useful tips when choosing a chameleon, based on reviews from welders

The typical dimensions and weight of the device should not cause discomfort;
To choose the most comfortable welding helmet, you should pay attention to the possibility of additional adjustments. In addition to the standard options, there is an adjustment of the permissible distances of the filters from the face;
The technical data of the welding helmet must correspond to the level of certification declared by the manufacturer.
To do this, you need to check the class indicators, guarantees and place of origin of the product in the papers. Thus, the chameleon has the first diopter class of light filters, which allows you to see the object without any distortion, and the first class of light scattering, which determines the optical purity of the filter;
The ratio of the level of darkness, according to the manufacturer, to the welding current.

These recommendations allow you to individually select a chameleon welding helmet based on the optimal parameters of the devices for comfortable work. Also, during the purchase, you should ask the manufacturer about the availability of additional light filters and standard equipment of the unit.

And, of course, it doesn’t hurt to make sure that there is no access for light between the automatic light filter and the declared mask.

How to choose a chameleon welding helmet

Source: https://remodelo.ru/remont/instrumenty/kak_vybrat_masku_xameleon.html