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Troubleshooting gratification

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Posted by tstage on Tuesday, November 30, 2010 10:17 AM

rrinker

Unfortunately, Randy, I neglected to order enough because I still have other backburner projects needing to be completed, too.  Somehow, I don't think I'm alone though. Laugh

Tom

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Posted by tstage on Tuesday, November 30, 2010 10:12 AM

Don,

The wires coming off the Molex connector on the light board of my Niagara originally had a hard 180-degree turn to it.  I thought the flickering was either due to a bad connector or a bad socket connection (cold solder joint) on the board.  When touching up the four Molex pads on the board didn't make any difference, I removed the Molex connector/socket altogether and soldered the two light wires directly to the board.  When that still didn't solve the problem, I asked BLI for a new light board.

The new board, not surprisingly, came with the Molex socket.  All I did was trim off the top of the socket (so that I could have better access to the pins with my soldering iron) and soldered the light wires to the two left Molex pins.  Before doing that though I soldered ~2" long "extensions" of flexible 30ga wire to the existing front headlight wires to make the soldering connection easier.  I also covered the connections with small sections of shrink wrap so that there wouldn't be any possibility of a short happening.

Tom

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Posted by selector on Tuesday, November 30, 2010 10:04 AM

LOL! Smile

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Posted by DigitalGriffin on Tuesday, November 30, 2010 9:17 AM

Congrats Tom!

It does feel good to solve such problems.

I had a similar problem.  The molex connector on my Blueline T-1 failed after 2 weeks of use.  The molex connector board itself went bad.  I did some soldering directly to the pins bypassing the board.  I got the motor working, but then the light board failed.

BLI didn't have a replacement board.  So I sent it back to them for repair.  It's been six weeks and counting.  :-( 

Wish I had your perserverance.  I would have had it fixed myself by now.

 

Don - Specializing in layout DC->DCC conversions

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Posted by rrinker on Tuesday, November 30, 2010 7:57 AM

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Posted by tstage on Tuesday, November 30, 2010 12:56 AM

Greetings everyone!

I wanted to update everyone on the light board swap out on my Niagara.

Some of you may remember that the headlight on my Bluelline Niagara flickered intermittently and, through the process of elimination, I narrowed it down to what I thought was a faulty light board.  Mark from BLI was kind enough to send me a replacement light board in the mail a few weeks ago.

The upshot is that last night I finally got around to installing it in my Niagara.  I briefly tested the Niagara out on my layout and the headlight didn't flicker at all.  I also ran it at an open house this past evening for 10-15 minutes with nary a flicker.  (I love happy endings. Cool)

Anyway, so far, so good. Big Smile  Wanted to report back on how things fared with the replacement.

Tom

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Posted by Hamltnblue on Friday, October 8, 2010 3:17 PM

Looking at those pics I wouldn't rule out a cold solder joint.

If the self fabricated board is working I would stay with that and use the new board as a backup.

Springfield PA

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Posted by tstage on Wednesday, October 6, 2010 11:23 PM

tomikawaTT
The absolutely most maddening kind of electrical failure is an intermittent open circuit.

Gotta agree with you there, Chuck.

Tom

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Posted by tstage on Wednesday, October 6, 2010 11:20 PM

Randy and all,

Here's pics of the Blueline Niagara light board to give you an idea of what it looks like, as well as how big it is:

As you can see by the pictures above, the board is a bit beat up from all the soldering and unsoldering.  You can also see how each trace connects a through-hole on the Molex connector (removed) to its corresponding pin on the LED.  Although a 4-connection Molex connector is used on the board, only the left two pins are utilized.  The "GB" label (standing for "gray" and "black", for the wires) were added by me.

I did check the board for continuity with a multimeter and I found no problems.  However, I did NOT test it connected to the locomotive; nor did I try and flex the board to see if the traces were cracked internally.  Visually, I didn't see any problems with either of the traces, as seen in the last backlit picture.

So, Randy, at this point I really can't come up with anything definitive about the board.  What I do know is that the homemade look-a-like light board I installed last night is working fine.  And I'll be curious whether or not the replacement board coming from BLI performs the same.

After explaining my findings to BLI, I would hope that Mark would have said something if there had been a problem with the original light boards.  Even so, they aren't charging me for the replacement.  The only cost to me was the time typing up my findings to send to BLI and the stamp to send it.

I'll keep you all posted...

Tom

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Posted by tomikawaTT on Wednesday, October 6, 2010 10:19 PM

The absolutely most maddening kind of electrical failure is an intermittent open circuit.  Glad that your troubleshooting was so successful.

Chuck (Modeling Central Japan in September, 1964)

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Posted by simon1966 on Wednesday, October 6, 2010 7:14 PM

Now that is what I call "added value" look at the extra pleasure and hobby time you got out of the loco! 

I agree, I love fixing things and get great pleasure out of it as well.

Simon Modelling CB&Q and Wabash See my slowly evolving layout on my picturetrail site http://www.picturetrail.com/simontrains and our videos at http://www.youtube.com/user/MrCrispybake?feature=mhum

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Posted by tstage on Wednesday, October 6, 2010 7:05 PM

Randy,

I'll see what I can find out both visually and electrically (with my multimeter) and get back to you.

Tom

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Posted by rrinker on Wednesday, October 6, 2010 6:22 PM

 Not sure I would have gone to the trouble of getting a repalcement, once it worked with the wires and LED soldered on. Direct hard wired connection beats an extra mechanical connector int he chain any day. Next step, once the new board is in place, check continuity of the traces ont he old one. Seems odd that anything could actually fail on a board that is two traces from one set of holes to another. Even if a trace delaminated during the sodlering of either the molex connector or the LED, unless the copper is torn it would be a stable connection. If it flips sides via a through-hole, it's possible the internal plating wasn't done properly, causing a poor connection. It's also posisble there is a microsocopic crack across one of the traces, so if the board flexes it stops making contact. That's somethign you might feel with a fingernail or see with a magnifier.

 Now that you narrowed it down to the board, I'm curious to knwo what's wrong with it. ANd if the replacement has been changed at all to maybe address a flaw they found out after the fact.

                                --Randy

 


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Posted by tstage on Wednesday, October 6, 2010 6:17 PM

I find with situations of this sort, it's best - for me - to describe the problems in written form rather than trying to relay it over the phone verbally.  Inevitably I'll end up leaving some important point out.  If I write it out, I can read and re-read everything before sending it off.  And the tech department then has the e-mail to refer back to, if needed.

I do the same them when bringing in my car for servicing.  The top half of the 8-1/2 x 11 sheet of paper includes both car and personal contact information.  The other "half" includes the problem, when the problem occurs, my observations, etc.  I've had service departments tell me on several occasions after reading through my "fact sheet", "This is GREAT!!  I wish all our customers did this."

I always admire those who are able to verbally express themselves well.

Tom

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Posted by richhotrain on Wednesday, October 6, 2010 5:53 PM

tstage

 richhotrain:

Call BLI.

They are awful at answering emais but wonderful to deal with by phone.

Rich

Rich,

I've never had a problem with the BLI Tech department getting back to me within 12-24 hours.

Tom

Tom,

I have had nothing but good experiences with the BLI Tech Department (aka Customer Service).  However, I always had quicker response times via the phone versus email.  Good to hear that email is just as effective nowadays.

Rich

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Posted by tstage on Wednesday, October 6, 2010 5:25 PM

richhotrain

Call BLI.

They are awful at answering emais but wonderful to deal with by phone.

Rich

Rich,

I've never had a problem with the BLI Tech department getting back to me within 12-24 hours.

Tom

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Posted by richhotrain on Wednesday, October 6, 2010 5:24 PM

Wow, I stand corrected.  Apparently, they do answer their emails.

Glad to hear the good news, Tom, and nice detective work on the troubleshooting.

Rich

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Posted by tstage on Wednesday, October 6, 2010 5:22 PM

Thanks, Crandell.  Thanks, Rich.  At least the Niagara ran properly.  Now the engineer can see rather than guess what's coming up the line. Laugh

Also, I got word from Mark Rice @ BLI this morning that my light board is on its way. Yes So, I'm guessing that they had no discrepancies with the findings that I relayed to them.   I'm sure they're glad to have one less locomotive in the queue, too.

Tom

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Posted by richhotrain on Wednesday, October 6, 2010 5:20 PM

Call BLI.

They are awful at answering emais but wonderful to deal with by phone.

Rich

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Posted by richg1998 on Wednesday, October 6, 2010 3:30 PM

Nice troubleshooting. I have been down that path a few times.

Rich

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Posted by selector on Wednesday, October 6, 2010 1:31 PM

Excellent, Tom.  I am full of admiration for you.  YesSmile  And you get to enjoy your nice Niagara....'cuz a NYC guy's gotta have one.  Yuh just gotta..... Laugh

-Crandell

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Troubleshooting gratification
Posted by tstage on Wednesday, October 6, 2010 7:43 AM

Greetings all,

I just wanted to share a story of an experience I just had troubleshooting an electrical issue with a BLI Blueline Niagara.

I bought my Blueline Niagara earlier in the year.  It's been a very good runner (especially with the Lenz Silver-MP decoder installed into it) and I really like the sound.  However, I had a consistent inconsistent front headlight that would randomly flicker on and off.

When I initially investigated the problem a while back I thought the issue might stem from the Molex connector on the small light board, because the wires seemed to be pinched as they made the 180 degree turn from the left side to connect to the light board.  With the front cover off, whenever I wiggled the connection the light would "sometimes" cut in and out.

After procrastinating contacting BLI, a couple of nights ago I finally decided to knuckle down and tackle the issue myself.  I unsoldered the Molex socket and pins from the board and wires and hardwired the wires directly to the light board to see if that made a difference.  No change.

I next tried replacing the LED.  However, instead of attaching it to the light board, I just soldered the gray and black wire to their appropriate pins on the LED.  No matter how I moved the LED and wires around, the light would NOT flicker.  Aha!  We are making progress.

I then soldered the LED and the gray and black wires back on the light board. BINGO! - the light flickered.  So, that says to me that the light board is the culprit.

FYI: The postage stamp-size light board is nothing special electrically.  It neatly holds the Molex connector and LED, with a trace running up from each pin on the Molex connector to the appropriate pin on the LED. There are also two additional holes near the center of the board so that the board can be fastened to a plate inside the boiler. This positions the LED so that its beam shines through the front headlight port.

Last night I took my experiments and observations a step further.  Although it took me a little time, I fabricated a similar light board out of some perf board I had and installed it into my Niagara.  Even as I ran the Niagara around the layout several times, there was nary a flicker of the LED.  I've contacted BLI via e-mail, relayed to them the findings that I've explained here, and asked them if they could just send me a replacement light board instead of me sending the entire locomotive in for repair.

As maddening as these sorts of things can be sometimes, it is especially gratifying to figure them out.  Hope you don't mind me sharing my longwinded story.  I'll let you know what I find out from BLI.

Tom

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