Digital Elite Helmet repair

[xryan]

I'm currently on my third Digital Elite helmet, using the current version with the front release mounted cover lens. My first one lasted just over the warranty period and the lens started acting weird not darkening completely in areas. Fortunately it was replaced by Miller. My second one lasted about a year after the warranty period and started eating batteries, it seems that the solar cell or charging circuit decided to stop doing it's job. I ended up getting another one for "free" when buying some equipment and using the $500 rebate. I also have an Optrel 684 that I bounce between with the current version Digital Elite usually for overhead welding because all the flat front helmets are useless for that.

ANYWAY... has anyone opened up the lens unit before? It works fine, just doesn't charge and CR2450 batteries ain't cheap. Any pointers on getting the unit split open? It doesn't look like it's snapped together, I'm thinking the halves are ultrasonically welded? I figure I could test out the charging circuit to see if it's the solar cell or maybe cold solder joints, etc.

Ryan

[ryanjones2150]

Hammer?

[xryan]

75 views, no one has any suggestions besides a hammer?

[ryanjones2150]

Sorry man, wish I could help more.

[mx842]

I wish I could help also because I have the same problem with mine. The one digital Elite I own has always eat batteries like crazy. It seems like everytime I pick the dang thing up the the low battery light is flashing. I have a couple older Jackson helmets that I put new batteries in once a year weather they need them or not. I'm lucky to get by a month with this Elite before having to put two new ones in. I took it back to the place I bought it a couple times and all they said was everything looked okay, no problems. The second time I took it in they said the batteries I were using were no good......HUH!! I said well that's why I have brought it back twice because the thing keeps eating them. They gave me two new ones and even put them in for me because they said I could be installing them wrong. I went to use it a couple days later and the light was flashing again.....go figure, I gave up on it after that. It does look nice hanging on the wall though.

[tommy2069]

i keep mine in the light .i found that if i store it in my tool box on my truck for a extended period of time it will act up.but sisne i have been leaving it out it does just fine.if for some reason i do put it in my box i try to set it out in the sunlight for a while before i use it.i have two of them so i really don't have to rely on one .the problem i have with mine is the cheap head bans they seem to strip out very easily and the lws says they don't sell replacements for them. guess ill try to make one fit it one day.

['Stang]

i keep mine in the light .i found that if i store it in my tool box on my truck for a extended period of time it will act up.but sisne i have been leaving it out it does just fine.if for some reason i do put it in my box i try to set it out in the sunlight for a while before i use it.i have two of them so i really don't have to rely on one .the problem i have with mine is the cheap head bans they seem to strip out very easily and the lws says they don't sell replacements for them. guess ill try to make one fit it one day.

I don't know what LWS you have in your area. My LWS has replacement headgear for Miller hoods. I have an old Miller Performance a/d hood that I used when I was in school. I didn't like the head band in it. I went to my LWS and bought the newer style gear. They have an online store. Scott-Gross.com. I have ordered several things from them and they are always on time and the price is competitive. Hope this helps.

[xryan]

i keep mine in the light ... the lws says they don't sell replacements for them. guess ill try to make one fit it one day.

Dude your LWS is blowing you off. Find a new one. Headgear is a wearable item and replacements are a standard shelf item in every LWS I have ever been to. The newer style Miller headgear with the double straps on top are WAY better than any other style. As far as batteries in wrong, BS. As far as only using Panasonic batteries (Miller replacement) or any other brand, they all work, or don't work all the same. This is #3 of my electronic helmets so not big deal but I'd like to fix it. It's not a dark non solar storage problem either, it eats batteries in +- 15 minutes of arc time.

No one has split one open before that had a cracked lens?

[ryanjones2150]

You might be a pioneer in this field.

[tommy2069]

yea the guy who works there is cool but the manager well she isn't so nice. the guy said they don't sell them but i guess it's my bad for not asking if he could order me one.might have to look online for a head ban replacement with the hours i work i rarely have time to make it to the store when they are open.i go every 90 days just to pay up on my account and back off to work i go.

[xryan]

The new Gen II headgear is #256174 which I have on my helmets that has the dual top band.

There is now an even NICER Gen III version that has a bigger ratchet pad that is spherical. #271325

[mx842]

Cool what do these newer headgear cost? They do look nice, I never did have too much of a problem with the older headgear it's just the battery thing that get's to me.

[xryan]

$25 ish. I don't remember why I replaced my headgear, but the double head strap with the rotating rear strap fits so much nicer. I was at my LWS for some 316 tig wire, I was standing there for about 5 minutes thinking there was something I wanted to ask but didn't remember to tell them if they have or see any damaged lenses to save it so I can practice trying to open it up without destroying my "good" one.

As a side note, I saw a rechargable button cell yesterday on Amazon, I might order 4 2450's and charger. At least that way I can use the helmet for my little helper. $5-10 worth of CR2450 batteries for 15 minutes of arc time is $0.50 minute. That's why the helmet just hangs on the wall....