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Pole Position Repair - 3 Namco PCB Sets

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  • Pole Position Repair - 3 Namco PCB Sets

    ==================================================
    Ok. Davefjedi's boards repairs.
    v 1.3
    ==================================================
    A marker for the beginning of this task, and plan of attack.
    These are my thooughts and plans. If i have left anything ou that you think may assist in the troubleshooting/repair of pole position boards, please let me know and i'll include it!

    Stage 1. Research & Communication.
    Status
    - Underway.
    Criteria
    - Find out all there is to find out. A challenge of limited scope, but infinite variety.
    - How many ways can a PPII Namco or Atari board set fail ?
    - Keep dave in the loop - issues, progress, at each stage.
    Commentary & Notes
    - See "Stage 1. Research & Communication" post below.

    Stage 2. Collect Boards and essential stuff.
    Status
    - Complete. Whoo Hoo! 5 August 2009.
    Criteria
    - Only the minimum required to fire up and see the Attract screen needed.
    Commentary & Notes
    - See "Stage 2. Collect Boards and essential stuff" post below.

    Stage 3. Initial Physical Inspection & test.
    Status
    - Done.
    Criteria
    - Get an idea of the problems experienced first hand.
    - inspect board sets, cab etc and have a go at game (dave is in the drivers seat!)
    Commentary & Notes
    See "Stage 3. Initial Physical Inspection & test" post below.

    Stage 4. Hook up on test bench and document.
    Status
    - started
    Criteria
    - establish benchmark configuration details and detailed description/documentation of issues
    Commentary & Notes
    See "Stage 4. Hook up on test bench and document." post below.

    Stage 5. Repair Approach to be taken
    Status
    - Done. Approach defined.
    - finish initial Arc Aid(tm) bench setup
    Criteria
    - use a clear methodology to ensure consistent results and best performance
    Commentary, Process and Notes
    See "Stage 5. Repair Approach to be taken " post below.


    Stage 6. Repairs - to dos
    Status
    - TBD
    Criteria
    - Repeat repair/test process until process no longer turns up faults
    - Survives hot/cold cyclic tests
    - Survives repeated on/off tests no longer turn up faults
    - Survives poke/prod/flex tests with no faults
    Iterations
    - Cyclic Process of test and repair
    - Repeat Stages 5/6 until all issues identified have been resolved.
    Commentary - Main repair process
    - see "Stage 6. Repairs - to dos" post below.


    Stage 7. Return boards to Dave for final acceptance test.

    Status
    - TBD

    Criteria
    - Must survive journey back to dave's place and installation into game/swapout with no probs
    - Must power up and play at least 10 games before i walk out the door - 20/20 warranty! =o)
    - Must work with a flogging every friday/sat with brown glass in hand, for at least one month

    Acceptance
    - Return boards to Dave for final acceptance test and celebration. is that what you call a "soak" test ?
    Last edited by andykmv; 6th August 2009, 09:19 PM. Reason: update/tidy up; final draft.
    HookedOnDefender,TimePilot,CrushRoller,1942,Pacman [original ghost in the machine!] VIDS: DefenceCmnd, Defender(2),Stargate(2),Joust,Joust2,MoonPatrol,Ph oenix,PolePositionII, Pacman, MsPacman, DKJr, MarioBros, LunarRescue,SegaTurbo,FujiSpeedRace PINS: Gottlieb Gladiators WANTED: Robotron, Sinistar, Maketrax, Timepilot & Defender Pinball! SOLD:Qix,Qbert TRADED:Gorf

  • #2
    Stage 1. Research & Communication

    Commentary
    As the owner Dave is in control, can call a halt & expect return of goods any time he wants.

    Notes
    Need more info, Looking for:
    - Repair logs, hints and tips on Internet and forums, Manuals, Schematics, Photos
    - Parts Sources (especially custom ICs)
    Query: Pole Position Manual Sp-219..Does it contain a Namco board set schematic ?
    Ans: No. Apparently namco did not release schematics. SP219 is an atari publication. Have not seen Sp219 content.

    Background Info
    - Switch mode supply 5v rail setting (unloaded - ie with game disconnected): TBA Dave to measure.
    - Switch mode supply 5v rail reading when game was connected: TBA Dave if he can recall what it was.
    Readings needed at: - Power Connectors, Test Points, some ICs on the board.


    Last edited by andykmv; 23rd July 2009, 11:11 PM.
    HookedOnDefender,TimePilot,CrushRoller,1942,Pacman [original ghost in the machine!] VIDS: DefenceCmnd, Defender(2),Stargate(2),Joust,Joust2,MoonPatrol,Ph oenix,PolePositionII, Pacman, MsPacman, DKJr, MarioBros, LunarRescue,SegaTurbo,FujiSpeedRace PINS: Gottlieb Gladiators WANTED: Robotron, Sinistar, Maketrax, Timepilot & Defender Pinball! SOLD:Qix,Qbert TRADED:Gorf

    Comment


    • #3
      This should be an interesting repair log, good luck!
      "Beer, it does a belly good!"

      Wanted: Pacman Cab Next Project: Skinny MAME Cab for Samfoot, thread soon, no really. I might even do one on my Pole Position cab!

      Comment


      • #4
        Stage 2. Collect Boards and essential stuff.

        Originally posted by Foot View Post
        This should be an interesting repair log, good luck!
        The more i read pole position repair logs, the more i feel i am getting into a bizarre form of masochism!

        Commentary
        - http://www.aussiearcade.com/showthread.php?t=23723
        - Boards only - DONE!- 3x namco boardsets received [1 very good (but issues), 2x bad].

        - Connectors - DONE - 1x 18x2 card edge received from dave,
        - Connectors - DONE - other 1x 18x2, and 2x 18x2 card edge connectors ordered. (Arrived today 28July09)
        - Connectors - DONE - will have to buy 4x MateNLock 3 pin Power connectors, pins. Found some cheap on ebay. (arrived 5/8/09! Whoo Hoo!)


        Notes
        - Namco (Japanese) boardsets, Not Atari.
        - Have PPI manuals and schematics
        - Have PPII Namco manual
        - PPII Namco Schematic/Board Layouts apparently not available. 28Jul09.
        Last edited by andykmv; 5th August 2009, 01:47 PM. Reason: Updated status 28 july 09
        HookedOnDefender,TimePilot,CrushRoller,1942,Pacman [original ghost in the machine!] VIDS: DefenceCmnd, Defender(2),Stargate(2),Joust,Joust2,MoonPatrol,Ph oenix,PolePositionII, Pacman, MsPacman, DKJr, MarioBros, LunarRescue,SegaTurbo,FujiSpeedRace PINS: Gottlieb Gladiators WANTED: Robotron, Sinistar, Maketrax, Timepilot & Defender Pinball! SOLD:Qix,Qbert TRADED:Gorf

        Comment


        • #5
          Stage 3. Initial Physical Inspection & test

          Commentary
          - While at Daves we fired up the game, the inspected and swapped out each
          - of the three board sets to show the fault as described by dave.
          - Not quite the same as the fault in summer (not nearly as bad) butr there regardless.
          - jan 2010 - we're in summer and first 38 hrs doesnt show up the same fault. hmm. need to leave on soak longer.

          Notes
          1. Initial inspection
          1a. showed a number of socketed ics pulled and legs cleaned.
          1b. No sockets or soldered components removed or replaced.
          1c. Possible heat related problem - was worse in Summer vs minot issues in Winter.
          1d. Will post some pics of current condition.
          2. Test
          all 3 boards installed one after the other into cab at davefjedi's place. noted issues:
          2a.Board 1 (Good Board)
          - unusual changing artifacts near cars. Looks like a roadside post (white) varying in size, just to left of car.
          - jan 2010 - could have been the rear left wheel hub image too. hmm.
          2b. Board 2 (Ram 22 Error) - found a loose bit of ic leg stuck between two pins
          - we removed it but issue didnt improve
          2c. Board 3 (i forget what the issue was with that - might have been
          - a dotty screen, no picture as such, will have
          - to wait until plugged in for bench test.
          2d. Dumb pup underfoot with pink collar. (where did that come from ?)
          - Might have been daves imagination - possible symptom of PPII withdrawal, except it kept getting underfoot and I almost ran it over so guess it was real!


          Last edited by andykmv; 27th January 2010, 05:59 AM.
          HookedOnDefender,TimePilot,CrushRoller,1942,Pacman [original ghost in the machine!] VIDS: DefenceCmnd, Defender(2),Stargate(2),Joust,Joust2,MoonPatrol,Ph oenix,PolePositionII, Pacman, MsPacman, DKJr, MarioBros, LunarRescue,SegaTurbo,FujiSpeedRace PINS: Gottlieb Gladiators WANTED: Robotron, Sinistar, Maketrax, Timepilot & Defender Pinball! SOLD:Qix,Qbert TRADED:Gorf

          Comment


          • #6
            Stage 4. Hook up on test bench and document.

            Commentary

            DONE:
            -----
            Basic workbench structure (top and bottom) completed. Ready to move it to the Garage. (The Arc Aid (tm) station =O) )
            The Bench (all 3.6m x 0.9m of it!)
            http://picasaweb.google.com/andykmv/Gamerooms?authkey=Gv1sRgCPLPue22jfPiIg#53673636928 48041490
            The bench with namco ppii getting ready for hooking to power
            http://picasaweb.google.com/andykmv/...63675013593346
            Card edge connectors arrived.
            MateNLoks arrived.
            Currently checking namco circuit diagram to hookup power to boards using the matenloks. Existing power connections may have been done via Molex 0.062 3x2 connector. Left that lead installed, Dave confirmed MateNLoks used so MateNLoks used for Test Power Harness!
            started setting up a basic wiring loom to suit using spare stuff. Good Boardset hooked up. No sound or controls in this revision of the test harness.
            harness rev 2 - added sound, controls and test buttons to harness. added steering hack (quadrature encoder from an old serial mouse - tore my hair out for about an hour until i realised inputs were pulled up not down).


            Next:
            -----
            - still need to add brake pot to test harness then mount switches and pots to a small panel - test driving involves chasing the steering encoder around the desk, and tryin' to find a button in the harness bundle so a bit maddening.
            - photograph all boards

            - need to draft up board layouts diagrams and identify all ics , especially those associated with video display and video memory. this will give me some layouts to work with, as check lists and to focus on the components relevant to the symptoms described. the atari layouts look to be significantly different from the atari layouts - chip coordinate nos and resistor designations(r127-129 for ex. for steering input pull ups/pull downs) are different for same part on schematics.

            Notes
            - Link to Optical Encoder - Quadrature Encoding (the steering wheel circuit)
            [ame="http://en.wikipedia.org/wiki/Rotary_encoder"]Rotary encoder - Wikipedia, the free encyclopedia@@AMEPARAM@@/wiki/File:Gray_code_rotary_encoder_13-track_opened.jpg" class="image">
            This will enable me to hack a makeshift steering circuit. makeshift hack done. looks like the namcos are pull u[ps in the steering inputs vs pull downs for the atari schematic.
            - Check the system clock and clock chain that all clocks are within spec. This should be one of the first tests!

            Last edited by andykmv; 3rd February 2010, 11:34 AM. Reason: Auto Merged Double Post.
            HookedOnDefender,TimePilot,CrushRoller,1942,Pacman [original ghost in the machine!] VIDS: DefenceCmnd, Defender(2),Stargate(2),Joust,Joust2,MoonPatrol,Ph oenix,PolePositionII, Pacman, MsPacman, DKJr, MarioBros, LunarRescue,SegaTurbo,FujiSpeedRace PINS: Gottlieb Gladiators WANTED: Robotron, Sinistar, Maketrax, Timepilot & Defender Pinball! SOLD:Qix,Qbert TRADED:Gorf

            Comment


            • #7
              Stage 5. Repair Approach to be taken

              Commentary

              TO DO:
              DONE - Define approach to be taken.
              TBA - build minimal test loom - connections to power supply, test switches, monitor.
              TESTING - will rely on demo mode initially for game operation.

              Procurement:
              - have sets of test switches already in hand
              - have one card edge connector, other card edge connectors arrived 28Jul09 .
              DONE- Need 4 x mate n lock connectors, pins and crimper for power connection to board sets (2x 3 pin mate n lock per board set). Will have to buy 4x MateNLock 3 pin Power connectors, pins. Found some cheap on ebay.
              DONE (Provisional) - make larger 60 pin idc cable so boards can be laid flat. have to source idc 60 pin plugs x 2, plus some ribbon cable. may not need these as boards are back to back anyway - just fold out! Process

              1. do iterations of test, repair, test on Board 2, comparing with Board 1 as repairs are being undertaken.
              2. Identify Boards as folllows
              2a. Board 1 - good board hooked up as a comparison test, and second repair subject
              2b. Board 2 - 1st repair subject
              2c. Board 3 - spare parts in case required then third repair subject
              3. if a particular repair solves an aspect of the reported faults, undertake that repair or rework that section of both
              boards 2 & 1. use board 3 for parts if necessary. fix last.
              4. once obvious faults have been fixed as per reported symptoms, repair/rework both Boards 1 & 2, then re-run
              comparisons/tests.
              5. once boards 2,1 are repaired satisfactorily, repair board 3
              6. when issues are resolved a larger test set will be made incl brake, accel, test buttons, volume, spkrs so a more detailed
              test/fault-repair cycle can be undertaken . do longer term tests - running 24x7.

              Notes
              Risk: If 60 way idc cables are not reliable, then - need to obtain 2 x 60 in IDC connectors and i've got plenty of cable (i think) at least now i know where to get them!
              Last edited by andykmv; 5th August 2009, 02:29 PM. Reason: update statsus 28 july 09
              HookedOnDefender,TimePilot,CrushRoller,1942,Pacman [original ghost in the machine!] VIDS: DefenceCmnd, Defender(2),Stargate(2),Joust,Joust2,MoonPatrol,Ph oenix,PolePositionII, Pacman, MsPacman, DKJr, MarioBros, LunarRescue,SegaTurbo,FujiSpeedRace PINS: Gottlieb Gladiators WANTED: Robotron, Sinistar, Maketrax, Timepilot & Defender Pinball! SOLD:Qix,Qbert TRADED:Gorf

              Comment


              • #8
                Stage 6. Repairs - to dos

                Commentary - Main repair process
                - Begin detailed board inspection and clean (Boards 2&3 only) - will do compressed air clean first, and clean with a toothbrush and electrolube spray cleaner
                - Check board support strip on each board - boards are sagging in the middle!
                - Poke/prod/flex test
                - check for dry solder joints and resolder any suspect joints
                - check for shorts/loose swarf that may cause shorts
                - cleanup socketed chips first and check for missing/broken/folded legs and bad sockets; replace bad/suspect sockets.
                - remove and check ics with darkened legs (some of the customs have blackened legs up top. not sure if they have been removed/cleaned yet.)
                - Hot/cold cycling test on video section chips.
                - run comparison tests on various board components.
                1. Check system clocks!
                - tag sus chips with amber spot, bad chips with red spot.
                - fix bad chips first
                HookedOnDefender,TimePilot,CrushRoller,1942,Pacman [original ghost in the machine!] VIDS: DefenceCmnd, Defender(2),Stargate(2),Joust,Joust2,MoonPatrol,Ph oenix,PolePositionII, Pacman, MsPacman, DKJr, MarioBros, LunarRescue,SegaTurbo,FujiSpeedRace PINS: Gottlieb Gladiators WANTED: Robotron, Sinistar, Maketrax, Timepilot & Defender Pinball! SOLD:Qix,Qbert TRADED:Gorf

                Comment


                • #9
                  Updated 28th july 09

                  Update:
                  harness connectors either arrived or not far away.
                  bench completed ready to move to workshop.
                  HookedOnDefender,TimePilot,CrushRoller,1942,Pacman [original ghost in the machine!] VIDS: DefenceCmnd, Defender(2),Stargate(2),Joust,Joust2,MoonPatrol,Ph oenix,PolePositionII, Pacman, MsPacman, DKJr, MarioBros, LunarRescue,SegaTurbo,FujiSpeedRace PINS: Gottlieb Gladiators WANTED: Robotron, Sinistar, Maketrax, Timepilot & Defender Pinball! SOLD:Qix,Qbert TRADED:Gorf

                  Comment


                  • #10
                    As big Kev used to say "Im EXCITED"
                    The best action is wrist action!!!!!!

                    Comment


                    • #11
                      Update 29th july 09

                      Originally posted by andykmv View Post
                      Update:
                      harness connectors either arrived or not far away.
                      bench completed ready to move to workshop.
                      Power supply adapter plus/sockets for ATX power supply arrived today. This means i can make up half of the power supply connections. come on mate-n-loks!
                      HookedOnDefender,TimePilot,CrushRoller,1942,Pacman [original ghost in the machine!] VIDS: DefenceCmnd, Defender(2),Stargate(2),Joust,Joust2,MoonPatrol,Ph oenix,PolePositionII, Pacman, MsPacman, DKJr, MarioBros, LunarRescue,SegaTurbo,FujiSpeedRace PINS: Gottlieb Gladiators WANTED: Robotron, Sinistar, Maketrax, Timepilot & Defender Pinball! SOLD:Qix,Qbert TRADED:Gorf

                      Comment


                      • #12
                        Stage 2 complete.

                        Originally posted by andykmv View Post
                        Power supply adapter plus/sockets for ATX power supply arrived today. This means i can make up half of the power supply connections. come on mate-n-loks!
                        Matenloks arrived today - woo hoo!

                        Must get out in the shed tonite ,
                        I/m in for a big surprise.
                        a package arrived in the mail today,
                        whos picking it up the wife ?
                        she'll say "whats this"!
                        & im sure she'll dis;
                        when horses could be snug
                        in a nice new rug..
                        da da da da da
                        this chriiiiiiiiistmas.

                        made space for the new bench in the garage, and started shifting parts and tools out to the garage. Whoo Hoo!
                        bench getting setup now. finding tools and parts.
                        setup VGA monito ready for testing CGA to vga scan converter for use with araced boards, until i can get cga crt fixed.
                        Last edited by andykmv; 6th August 2009, 09:28 PM.
                        HookedOnDefender,TimePilot,CrushRoller,1942,Pacman [original ghost in the machine!] VIDS: DefenceCmnd, Defender(2),Stargate(2),Joust,Joust2,MoonPatrol,Ph oenix,PolePositionII, Pacman, MsPacman, DKJr, MarioBros, LunarRescue,SegaTurbo,FujiSpeedRace PINS: Gottlieb Gladiators WANTED: Robotron, Sinistar, Maketrax, Timepilot & Defender Pinball! SOLD:Qix,Qbert TRADED:Gorf

                        Comment


                        • #13
                          RFI: power supply voltage output in cabinet

                          Originally posted by Davefjedi View Post
                          As big Kev used to say "Im EXCITED"
                          Dave,

                          could you please tell me:
                          1. do the boards connect up to power using
                          (a) the pcb mounted 3 pin matenlok connectors (2), or
                          (b) the added on 0.062 molex 6 pin connector ? if this is the case were the matenloks faulty or did the game come to you that way ?
                          ANS: The Mate N loks are there, in the harness, no sign of the molex 6 pin connector. Good.

                          2. could you please measure the voltage output of
                          (a) the switcher at each pin of each connector per 1(a) above (Connectors are in the harness!)
                          (b) connector per 1(b) above - THIS CONNECTOR DOESNT EXIST IN CAB HARNESS - Do you want me to remove this connector from the good PCB ?)

                          and post the result back here ? i expect they will be +5v and +12v (per the namco wiring diagram), but before i hook up the good board to power i want to confirm the voltages to make sure my test rig power wiring is correct.

                          3. could you also confirm the current rating of your switcher output for the 5v supply and the 12v(?) supply. so i can ensure i use a suitably rated psu. nothing worse than an underated over loaded psu!
                          Last edited by andykmv; 21st August 2009, 07:59 PM. Reason: updated.
                          HookedOnDefender,TimePilot,CrushRoller,1942,Pacman [original ghost in the machine!] VIDS: DefenceCmnd, Defender(2),Stargate(2),Joust,Joust2,MoonPatrol,Ph oenix,PolePositionII, Pacman, MsPacman, DKJr, MarioBros, LunarRescue,SegaTurbo,FujiSpeedRace PINS: Gottlieb Gladiators WANTED: Robotron, Sinistar, Maketrax, Timepilot & Defender Pinball! SOLD:Qix,Qbert TRADED:Gorf

                          Comment


                          • #14
                            I will get you pics and measurements tonight
                            The best action is wrist action!!!!!!

                            Comment


                            • #15
                              here are the pics of the edge connectors
                              Attached Files
                              The best action is wrist action!!!!!!

                              Comment

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