Troubleshooting/Solutions
A survey was taking during the 2009 season of typical types of problems DIY-er encounter and how they solved them. The graph below outlines the general survey topics and frequency of responses:
The problem is stated first; the solution is in bold
Soldering/Construction problem
- Ordered wrong part (H11A1) - Ordered proper part (H11AA1)
- Part soldered in backwards -Remove, resolder properly
- Confusion on ZC circuit -Helped by DIYC member
- Newly assembled board not working right - Reflowed connections with hotter iron
- Cracked resistors -Caused by torquing-down heatsink on SSRez too tightly.
- Channel not working on controller - Missed soldering a lead
Cabling problem (wrong pin-out, broken cable, etc.)
- Cable broke between testing and layout - Replaced cable
- Lights not coming on with controls - Plug in cat5 cable tighter
- Cheap 3-outlet extension cords, no contact - Replace
- Cheap cables with mismatched ends - Replace
- Cat5 control cable loose - Plug in until it "clicks"
- Cheap cable crimpers, poor connections - Get better quality crimper
- Channel not working on SSR - Replaced cat5 connector
- Poor cat5 connections - Wrong cat5 plug for the kind of wire. Solid vs. stranded makes a difference.
- Light string not working - Remember to plug it in.
- Broken cat5 internal cables (wires 6 and 8 out) - Rewired plugs with remaining 6 good wires
Circuit board manufacturing defect
- Two channels worked when only one should - Checked board traces, removed copper bridge on edge of board
Electrical/Electronic Component Failure/defective part/defective lights
- Light string bad - Replace string
- Lost 4 channels on Grinch - Switch to other working channels
- Led string not working - Shake/twist string to find bad LED, resoldered LED socket
- Channel had intermittent flicker - Replaced resistor and opto
- Channels coming on all by themselves with show not running - Bad batch of triacs; replaced.
- Dead light string - Replaced string
- Channel stuck on on SSR - Replaced SSR - borrowed from another DIYC member (it's nice to have a spare)