"HELPFUL TROUBLESHOOTING HINTS."
- When preforming any tests or repairs on an SCR or MOSFET system, always discharge
the capacitors using a resistor or a VOM set to a high voltage scale.
A 220 ohm resistor will work well if placed across the capacitor leads; hold it
for a couple of seconds to insure it is fully discharged. To make sure the capacitor is discharged, measure the
voltage with your VOM. Be sure to keep your fingers off the resistor leads themselves by holding the body of the
resistor or insulating the resistor leads. Using a VOM will discharge the capacitors very slowly due to the high
internal resistance, but at least you will be sure the capacitor is fully discharged when the meter reads zero
volts. Don't forget to disconnect the battery first!!
- An additional test to make on any power SCR is to measure the GATE to CATHODE
resistance.
A typical measurement should be between 20 and 50 ohms. If a measurement of less
than 10 ohms exists, the SCR is concidered insensitive and will require a stronger pulse to gate on. If the measurement
is more than 125 ohms, then the SCR is concidered too sensitive and may fire erratically on noise pulses. In either
case, I would recommend replacing the SCR.
- When working with circuit boards that have flat contacts, never use a wire brush
to clean the contacts.
The best way is to use a pencil eraser; I generally carry a full size artist or
drafting eraser. A standard pencil eraser will work but will not last very long. For best results clean the contacts
of oil or grease with plain alcohol then use your eraser to put a final shine on the contacts. Abrasives will only
damage the surface.
- Most panel assemblies have large power components mounted on heat sinks for proper
heat dissipation.
Between the heat sink and panel baseplate you will find an insulator to electrically
isolate the two. By using an ohmeter, check to make sure that the insulator has not broken down. Use the highest
resistance scale and measure between heatsink and baseplate; you should show infinite resistance (a total open
conection).
- Keep in mind that when you're working with the main control cards that there
may be terminal strips attached to the card that are not part of the card.
As an example, a General Electric EV-1 control card has left and right terminal
strips that connect to the control card itself. If you are taking measurements to the terminal strips, remember
that there is also a connection from the terminal strip to the control card which may be defective. The EV-1 terminal
strip has two small finger connections that connect to the control card. It is always a good idea to remove these
strips, and using a small pair of needle nose pliers, pinch these fingers together to make sure your connections
are secure.
- Never replace fuses with other than the proper value fuse.
If a fuse continues to blow that means there is a short or partially shorted circuit
in the system. Even though a #8 screw will fit most fuse holders, I don't recommend using them to replace fuses.
- Never disable the 1A or Bypass circuit to reduce the overall speed of the vehicle.
This will only lead to overheating of the panel and cause thermal problems and
premature SCR failures. Typically the bypass is used not only to increase speed but also to give the SCRs a chance
to rest and cool-off.
- When taking voltage measurements in any electronic system, it is very important to understand
where to reference your meter. When taking voltage measurements, 99.9% of the time you should reference your meter
to battery negative. That means connect your battery negative lead, or black lead to vehicle battery negative.
This way you will always read a positive voltage and you will also be reading voltages like every other electronics
technician.
|