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New Optrel Satellite Problems

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  • New Optrel Satellite Problems

    Anyone here using an Optrel Satellite and had the ADF (Auto Darkening Filter) overheat and stop working for short periods of time? The filter wont hold the proper shade and eventually quits working alltogether within seconds when it gets warm. After a few minutes of cooling off, it works fine.

    I have just started using one in the past few weeks, and the digital filter craps out once in a while when I am doing prolonged welding over 150 amps. Mind you, I am 5'6" so my arms are short, and I keep my hood about 12 to 20 inches from the work, depending on the process and joint configuration.

    I'm just wondering if I should warranty it or if it's my welding stlye causing the problem.
    Last edited by JonnyTIG; 03-12-2007, 10:09 PM.
    Jonny

    Dynasty 300DX
    Esab PCM 1000

  • #2
    Disclaimer: I'm no expert and am not familiar with the helmet or it's design specifications. That said, your description of technique and environment doesn't sound like anything that even approachs the edges of the envelope of normal practices.

    Sounds to me like you have a defective unit and should be knocking on the vendor's door with warranty papers in hand.
    Tom Veatch
    Wichita, KS

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    • #3
      Youve got a defective allright. The Satellite is one of the finest hoods on the market today. Ive got one and it has NO problems whatsoever. Probably the best $ Ive spent welding.

      Comment


      • #4
        I have had my Optrel going on 4 years and never had any problem, I sometimes tig aluminum at 190-200 amps about 16-18" from the workpeice and have never had a failure. Sounds like a defective AD lens to me.
        Regards, George

        Hobart Handler 210 w/DP3035 - Great 240V small Mig
        Hobart Handler 140 - Great 120V Mig
        Hobart Handler EZ125 - IMO the best 120V Flux Core only machine

        Miller Dynasty 200DX with cooler of my design, works for me
        Miller Spectrum 375 - Nice Cutter

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        • #5
          Two other welders I work with have the sattelite helmets, one is a little over a year old and is the older green shade, and one is a month old, identicle to mine, with the newer clearer blueish shade. A am going to try using those helmets and see if They get hot and shut down, just to rule out my welding practices.

          I do appreciate your input and tend to lean towards a defective ADF, however I would like to try out another lid to proove it before I call the vendor and raise the roof.

          Thanks,
          Jonny

          Dynasty 300DX
          Esab PCM 1000

          Comment


          • #6
            Well to heck with that testing idea. I ordered a replacement lid today, however the wrong model showed up this afternoon, so I will be waiting until sometime tomorrow.

            What I like about my local supplier is the fact there were no questions asked, they just send out a new unit. Good service when you don't have to explain or bicker.
            Jonny

            Dynasty 300DX
            Esab PCM 1000

            Comment


            • #7
              Originally posted by JonnyTIG View Post
              Well to heck with that testing idea. I ordered a replacement lid today, however the wrong model showed up this afternoon, so I will be waiting until sometime tomorrow.

              What I like about my local supplier is the fact there were no questions asked, they just send out a new unit. Good service when you don't have to explain or bicker.
              Good service is worth every $.
              Makes me think of Miller for an example...

              Comment


              • #8
                The right helmet showed up today around lunch time. Not bad service on warranty considering it was coming from 3.5 hours away.
                Jonny

                Dynasty 300DX
                Esab PCM 1000

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                • #9
                  Unfortunetly the new helmet does the same thing. After 20 minutes of AAC @ 400 amps the ADF started to not hold the proper shade. After a minute I had it cranked to #13 filter and I was left seeing green and purple spots when done.
                  Jonny

                  Dynasty 300DX
                  Esab PCM 1000

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                  • #10
                    I have a jackson NEX-GEN and I'm about you'r size. The only time I ever have problems is doing long flux core runs (30 minute weld passes) at super high heat. Like you I'm small and need to be kind of close to the arc. I've run it well beyond it's limits and it works fine. I even had a cover plate warp so badly while welding that it poped right out of my helmet and the filter was fine. The optrel satilight is the only direct competitor to the NEX-GEN so it should be able to take the same kind of beating I put mine through. All the testamony out their says that both of them are a draw in all catagories and thats my opinion as well since I have used both, so I'd say it's defective.
                    Thats my 2 cents.

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                    • #11
                      I'm pretty sure the helmets aren't defective, they both worked well in normal welding situations, however they both overheated when I was doing continous high amperage work. Almost like they have a duty cycle that the manufacturer doesn't mention. None of the literature talks about a thermal shut down feature, so I have drawn the conclusion that the electronics get too hot and malfuction or simply shut off. I will be trying two other helmets, one just like mine, and one that is the same model from over a year ago, and seeing how they respond. I've never liked auto darkening helmets up until I tried the new generation of Optrels, now that the filter isn't just a green shade like the older ones, I found the true color ADF to be a lot better for my eyes. I'll see if the other lids do the same thing as the two I've tired, and determind the fault from there.
                      Jonny

                      Dynasty 300DX
                      Esab PCM 1000

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