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351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
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SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover 3.a. The electrode and work (or ground) circuits plates to protect your eyes from sparks and are electrically “hot” when the welder is on. the rays of the arc when welding or observing Do not touch these “hot”...
Page 4
SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. explosion. 7.a. Use only compressed cylinders containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area. process used properly operating If this is not possible, cover them to prevent the regulators designed for the gas and welding sparks from starting a fire.
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SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé et les précautions de sûreté...
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TABLE OF CONTENTS-THEORY OF OPERATION Theory of Operation ..............E-1 General Description .
Page 10
THEORY OF OPERATION FIGURE E.2 - GENERAL DESCRIPTION ETHERNET AUDIO RECEPTACLE RECEPTACLE 5 VDC UNIGUN TO VGA SPLITTER INPUT RISER TO HELMET TERMINAL SWITCH (FUSED) RELAY 5 VDC BLOCK PATRIOT ENTRY MODULE STAND GREEN LED POLHEMUS SWITCH 115/230 VAC 5/12 VDC 50/60 Hz.
Page 11
THEORY OF OPERATION FIGURE E.3 - INPUT POWER AND DISTRIBUTION ETHERNET AUDIO RECEPTACLE RECEPTACLE 5 VDC UNIGUN TO VGA SPLITTER INPUT RISER TO HELMET TERMINAL SWITCH (FUSED) RELAY 5 VDC BLOCK PATRIOT ENTRY MODULE STAND GREEN LED POLHEMUS SWITCH 115/230 VAC 5/12 VDC 50/60 Hz.
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THEORY OF OPERATION FIGURE E.4 - VIDEO AND AUDIO OUTPUT, COMPUTER ASSEMBLY (CPU), TOUCHSCREEN MONITOR, USB HUB AND VGA SPLITTER ETHERNET AUDIO RECEPTACLE RECEPTACLE 5 VDC UNIGUN TO VGA SPLITTER INPUT RISER TO HELMET TERMINAL SWITCH (FUSED) RELAY 5 VDC BLOCK PATRIOT ENTRY MODULE...
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THEORY OF OPERATION FIGURE E.5 - USB HUB AND CONNECTIONS ETHERNET AUDIO RECEPTACLE RECEPTACLE 5 VDC UNIGUN TO VGA SPLITTER INPUT RISER TO HELMET TERMINAL SWITCH (FUSED) RELAY 5 VDC BLOCK PATRIOT ENTRY MODULE STAND GREEN LED POLHEMUS SWITCH 115/230 VAC 5/12 VDC 50/60 Hz.
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THEORY OF OPERATION FIGURE E.6 - MAGNETIC TRACKING, PATRIOT SEU/POLHEMUS, HELMET, RISER ARM ASSEMBLY, UNIGUN AND USB HUB ETHERNET AUDIO RECEPTACLE RECEPTACLE 5 VDC UNIGUN TO VGA SPLITTER INPUT TO HELMET RISER TERMINAL SWITCH (FUSED) RELAY 5 VDC BLOCK PATRIOT ENTRY MODULE STAND GREEN LED...
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TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. . F-1 How to Use Troubleshooting Guide .
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HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Page 17
• Always connect the VRTEX MOBILE to a power ® supply grounded according to the National - If you return a PC board to The Lincoln Electric Electrical Code and local codes. Company for credit, it must be in the static-shielding ------------------------------------------------------------ bag.
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Removal and Replacement Procedure. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Automation Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3878. VRTEX MOBILE...
Page 20
CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Automation Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3878. VRTEX MOBILE ®...
Page 21
CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Automation Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3878. VRTEX MOBILE...
Page 22
(instructor mode). CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Automation Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3878. VRTEX MOBILE...
Page 23
5. Perform the Uninstall NVIDIA Programs Procedure. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Automation Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3878. VRTEX MOBILE...
Page 24
Polhemus/Patriot SEU Module Test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Automation Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3878. VRTEX MOBILE...
Page 25
1-888-935-3878. tortion. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Automation Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3878. VRTEX MOBILE...
Page 26
Electric Automation Department at 1-888-935-3878. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Automation Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3878. VRTEX MOBILE...
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5/12 VDC POWER SUPPLY TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 28
TROUBLESHOOTING AND REPAIR F-14 F-14 5/12 VDC POWER SUPPLY TEST (continued) FIGURE F.3 – 5/12 VDC POWER SUPPLY LOCATION CASE BACK 5/12 VDC ASSEMBLY POWER SUPPLY CIRCUIT BREAKER PROCEDURE 1. Perform the Case Cover Removal Procedure. WARNING 2. Locate the 5/12 VDC power supply. See Figure F.3.
Page 29
TROUBLESHOOTING AND REPAIR F-15 F-15 5/12 VDC POWER SUPPLY TEST (continued) FIGURE F.4 – POWER SUPPLY TEST POINTS 5/12 VDC POWER SUPPLY 502D 601C 801(+) GROUND 701(–) 900(+) 10. Perform the Case Cover Replacement 6. Check for 12 VDC from leads 701(-) to lead Procedure.
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(EARLIER MODELS) WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 32
TROUBLESHOOTING AND REPAIR F-18 F-18 INPUT FILTER TEST (EARLIER MODELS) (continued) FIGURE F.5 – INPUT FILTER ASSEMBLY LOCATION CASE BACK ASSEMBLY INPUT FILTER ASSEMBLY PROCEDURE 1. Remove input power to the machine. WARNING 2. Make certain that the switched fused entry mod- ule (on/off switch) on the back of the machine is ELECTRIC SHOCK can kill.
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TROUBLESHOOTING AND REPAIR F-19 F-19 INPUT FILTER TEST (EARLIER MODELS) (continued) FIGURE F.6 – INPUT FILTER TEST POINTS 501A 601A 10. Perform the Case Cover Replacement 5. Check the resistance from leads 501 to 601 at Procedure. the input filter. Resistance should be 4.5 meg ohms.
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INPUT FILTER TEST (LATER MODELS) WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 36
TROUBLESHOOTING AND REPAIR F-22 F-22 INPUT FILTER TEST (LATER MODELS) (continued) FIGURE F.7 – INPUT FILTER BOARD LOCATION INPUT FLITER BOARD PROCEDURE 4. Locate the Input Filter board. See Figure F.7. WARNING NOTE: Make certain that the PC board mounting screws are tight.
Page 37
TROUBLESHOOTING AND REPAIR F-23 F-23 INPUT FILTER TEST (LATER MODELS) (continued) FIGURE F.8 – INPUT FILTER BOARD XXXX XXXX XXXXXXXXXXXXXXXXXX 8. Use a capacitance meter that meets the follow- ing requirements: Full scale accuracy: Less than 1% ±1 digit Resolution: Minimum 3 digits nF range display: Minimum of 3 significant...
Page 38
TROUBLESHOOTING AND REPAIR F-24 F-24 INPUT FILTER TEST (LATER MODELS) (continued) TABLE F.1 – CAPACITANCE AND RESISTANCE TESTS DESCRIPTION TEST POINT TEST POINT EXPECTED READING Resistance Measurement B1 or B4 B2 or B3 530,000 ohms Resistance Measurement 0 ohms Resistance Measurement 0 ohms Capacitance Measurement B1 or B4 Ground pad at mounting...
Page 39
MAIN CABLE ASSEMBLY TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 40
TROUBLESHOOTING AND REPAIR F-26 F-26 MAIN CABLE ASSEMBLY TEST (continued) FIGURE F.9 – MAIN CABLE ASSEMBLY HEAT CABLE 3/4” WOVEN SPLIT SHRINK CABLE SHEATH AUDIO CABLE EXTENSION 15’ USB USB 2 A-B CABLE 15’ USB USB 4 M-F CABLE 15’ VGA VGA 2 M-M CABLE LEAD...
Page 41
TROUBLESHOOTING AND REPAIR F-27 F-27 MAIN CABLE ASSEMBLY TEST (continued) FIGURE F.10 – MONITOR CABLE CONNECTIONS 12VDC USB 2 VGA IN USB 2 AUDIO Speaker 12VDC USB 4 Speaker VGA M-M CABLE TEST PROCEDURE USB M-F CABLE TEST PROCEDURE 1. Remove input power to the machine. 1.
Page 42
TROUBLESHOOTING AND REPAIR F-28 F-28 MAIN CABLE ASSEMBLY TEST (continued) FIGURE F.11 – MONITOR POWER CABLE END MONITOR POWER CABLE 901B (RED) CABLE END TEST POINT 701D (BLACK) TEST POINT USB A-B CABLE TEST PROCEDURE AUDIO CABLE EXTENSION TEST PROCEDURE 1.
Page 43
TROUBLESHOOTING AND REPAIR F-29 F-29 MAIN CABLE ASSEMBLY TEST (continued) FIGURE F.12 – TERMINAL BLOCK LOCATION CASE BACK ASSEMBLY TERMINAL BLOCKS FIGURE F.13 – TERMINAL BLOCK LEAD LOCATIONS POWER CABLE MONITOR ORANGE 2 901B (RED) ORANGE 1 701D (BLACK) WHITE 3 WHITE 2 WHITE 1 BLUE 2...
Page 44
TROUBLESHOOTING AND REPAIR F-30 F-30 MAIN CABLE ASSEMBLY TEST (continued) FIGURE F.14 – VGA M-M CABLE 15 FT. FIGURE F.15 – AUDIO CABLE EXTENSION VRTEX MOBILE ®...
Page 45
INPUT RELAY TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 46
TROUBLESHOOTING AND REPAIR F-32 F-32 INPUT RELAY TEST (continued) FIGURE F.16 – INPUT RELAY ASSEMBLY LOCATION CASE BACK ASSEMBLY INPUT RELAY PROCEDURE 3. Press and hold the green “ON” button on the WARNING front of the machine. Hold for five seconds to start system.
Page 47
TROUBLESHOOTING AND REPAIR F-33 F-33 INPUT RELAY TEST (continued) FIGURE F.17 – INPUT RELAY TEST POINTS 701F(–) 801D(+) VRTEX MOBILE ®...
Page 49
VGA SPLITTER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 50
TROUBLESHOOTING AND REPAIR F-36 F-36 VGA SPLITTER TEST (continued) FIGURE F.18 – VGA SPLITTER LOCATION VGA SPLITTER PROCEDURE 5. Check for the presence of 12 VDC at leads WARNING 901A(+) to 701E(–) at the terminal block. See Figure F.19 and Figure F.20. See Wiring ELECTRIC SHOCK can kill.
Page 51
TROUBLESHOOTING AND REPAIR F-37 F-37 VGA SPLITTER TEST (continued) FIGURE F.19 – TERMINAL BLOCK LOCATION CASE BACK ASSEMBLY TERMINAL BLOCKS FIGURE F.20 – TERMINAL BLOCK LEAD LOCATIONS ORANGE 2 901A(+) ORANGE 1 701E(–) WHITE 3 WHITE 2 WHITE 1 BLUE 2 BLUE 1 GRN/YLW 2 GRN/YLW 1...
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USB HUB TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 54
TROUBLESHOOTING AND REPAIR F-40 F-40 USB HUB TEST (continued) FIGURE F.21 – USB HUB LOCATION USB HUB PROCEDURE 4. Check for loose or faulty connections at the WARNING USB hub and components attached to the hub. 5. One port at a time, plug a USB mouse with a ELECTRIC SHOCK can kill.
Page 55
TROUBLESHOOTING AND REPAIR F-41 F-41 USB HUB TEST (continued) FIGURE F.22 – TERMINAL BLOCK LOCATION CASE BACK ASSEMBLY TERMINAL BLOCKS FIGURE F.23 – TERMINAL BLOCK LEAD LOCATIONS ORANGE 2 ORANGE 1 WHITE 3 WHITE 2 701A(–) WHITE 1 BLUE 2 801A(+) BLUE 1 GRN/YLW 2...
Page 57
CPU TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 58
TROUBLESHOOTING AND REPAIR F-44 F-44 CPU TEST (continued) FIGURE F.24 – CPU LOCATION BRACKET PROCEDURE NOTE: If Green “ON” button does not remain ON, WARNING it must be held in when testing voltages. 5. Check for blue CPU light on front of CPU. See ELECTRIC SHOCK can kill.
Page 59
TROUBLESHOOTING AND REPAIR F-45 F-45 CPU TEST (continued) FIGURE F.25 – CPU LIGHT LOCATION LIGHT FIGURE F.26 – INPUT POWER RECEPTACLE LOCATION INPUT POWER RECEPTACLE VRTEX MOBILE ®...
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TROUBLESHOOTING AND REPAIR F-46 F-46 CPU TEST (continued) FIGURE F.27 – INPUT RELAY TEST POINTS 701F(–) 801D(+) VRTEX MOBILE ®...
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POLHEMUS / PATRIOT SEU MODULE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 62
TROUBLESHOOTING AND REPAIR F-48 F-48 POLHEMUS / PATRIOT SEU MODULE TEST (continued) FIGURE F.28 – POLHEMUS / PATRIOT SEU MODULE LOCATION POLHEMUS / PATRIOT SEU MODULE BASE PROCEDURE 3. Carefully apply input power to the machine, WARNING make sure switch is “ON” and check for LED light.
Page 63
TROUBLESHOOTING AND REPAIR F-49 F-49 POLHEMUS / PATRIOT SEU MODULE TEST (continued) FIGURE F.29 – POLHEMUS / PATRIOT SEU MODULE FRONT SENSOR 1 SENSOR 2 SOURCE CONFIG RS 232 BACK FIGURE F.30 – TERMINAL BLOCK LOCATION CASE BACK ASSEMBLY TERMINAL BLOCKS VRTEX MOBILE...
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TROUBLESHOOTING AND REPAIR F-50 F-50 POLHEMUS / PATRIOT SEU MODULE TEST (continued) FIGURE F.31 – TERMINAL BLOCK LEAD LOCATIONS ORANGE 2 ORANGE 1 WHITE 3 701B(–) WHITE 2 WHITE 1 801B(+) BLUE 2 BLUE 1 GRN/YLW 2 GRN/YLW 1 GREY 2 GREY 1 RED 5 RED 4...
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UNIGUN TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 66
TROUBLESHOOTING AND REPAIR F-52 F-52 UNIGUN TEST (continued) FIGURE F.32 – UNIGUN LOCATION UNIGUN ASSEMBLY DIVIDER PANEL PROCEDURE 4. Check for loose or faulty connections on the WARNING cable. 5. Locate the in-line RCA type plug at the ELECTRIC SHOCK can kill. See Figure F.33.
Page 67
TROUBLESHOOTING AND REPAIR F-53 F-53 UNIGUN TEST (continued) FIGURE F.33 – “Y” ADAPTER AND RCA PLUG LOCATION “Y” ADAPTER RCA PLUG FIGURE F.34 – RCA PLUG TEST POINTS RCA PLUG VRTEX MOBILE ®...
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HELMET TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 70
TROUBLESHOOTING AND REPAIR F-56 F-56 HELMET TEST (continued) FIGURE F.35 – HELMET LOCATION HELMET PROCEDURE NOTE: Do not remove DVI connections prior to WARNING removing and USB connections. 5. Move the USB plug from USB 6 to an open port ELECTRIC SHOCK can kill.
Page 71
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 72
TROUBLESHOOTING AND REPAIR F-58 F-58 CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.36 – CASE COVER MOUNTING SCREWS TOP SCREWS (4) RIGHT SIDE SCREWS (6) REMOVAL PROCEDURE 1. Remove input power to the machine. WARNING 2. Using a 3/8” nutdriver, remove the four screws securing the case top.
Page 73
TROUBLESHOOTING AND REPAIR F-59 F-59 CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Using a 3/8” nutdriver, replace the eleven screws securing the left side case cover. 2. Using a 3/8” nutdriver, replace the six screws securing the right case side cover. See Figure F.36.
Page 75
REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 76
TROUBLESHOOTING AND REPAIR F-62 F-62 5/12 VDC POWER SUPPLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.37 – 5/12 VDC POWER SUPPLY LOCATION CASE BACK 5/12 VDC ASSEMBLY POWER SUPPLY CIRCUIT BREAKER REMOVAL PROCEDURE 1. Remove input power to the machine. WARNING 2.
Page 77
TROUBLESHOOTING AND REPAIR F-63 F-63 5/12 VDC POWER SUPPLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.38 – 5/12 VDC POWER SUPPLY LEADS 5/12 VDC POWER SUPPLY 502D 601C 801(+) GROUND 701(–) 900(+) FIGURE F.39 – 5/12 VDC POWER SUPPLY MOUNTING SCREW LOCATION CASE BACK ASSEMBLY MOUNTING...
Page 78
TROUBLESHOOTING AND REPAIR F-64 F-64 5/12 VDC POWER SUPPLY REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Place new 5/12 VDC power supply into position in the machine. See Figure F.37. NOTE: Note placement of insulator if applicable. 2. Using a small phillips screwdriver, replace the four previously removed mounting screws and associated washers securing the 5/12 VDC power supply to the case back assembly.
Page 79
REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 80
TROUBLESHOOTING AND REPAIR F-66 F-66 MAIN CABLE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.40 – MONITOR POWER CABLE END 12VDC USB 2 VGA IN USB 2 AUDIO Speaker 12VDC USB 4 Speaker REMOVAL PROCEDURE NOTE: For reassembly be sure to take note of how WARNING many turns of wire pass through the toroid and also the direction and location.
Page 81
TROUBLESHOOTING AND REPAIR F-67 F-67 MAIN CABLE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.41 – MAIN CABLE ASSEMBLY HEAT CABLE 3/4” WOVEN SPLIT SHRINK CABLE SHEATH AUDIO CABLE EXTENSION 15’ USB USB 2 A-B CABLE 15’ USB USB 4 M-F CABLE 15’...
Page 82
TROUBLESHOOTING AND REPAIR F-68 F-68 MAIN CABLE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.43 – AUDIO PORT LOCATION GREEN AUDIO PORT FIGURE F.44 – RETAINING GROMMET LOCATION RETAINING GROMMET PLUG BUTTON CASE BACK ASSEMBLY VRTEX MOBILE ®...
Page 83
TROUBLESHOOTING AND REPAIR F-69 F-69 MAIN CABLE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.45 – TERMINAL BLOCK LOCATION CASE BACK ASSEMBLY TERMINAL BLOCKS FIGURE F.46 – TERMINAL BLOCK LEAD LOCATIONS POWER CABLE MONITOR ORANGE 2 901B (RED) ORANGE 1 701D (BLACK) WHITE 3 WHITE 2...
Page 84
TROUBLESHOOTING AND REPAIR F-70 F-70 MAIN CABLE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully install the new main cable assembly. 7. Carefully replace any previously removed cable ties to wires running from the machine to mon- 2. Using a small slot head screwdriver, connect itor.
Page 85
INPUT RELAY REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 86
TROUBLESHOOTING AND REPAIR F-72 F-72 INPUT RELAY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.47 – INPUT RELAY LOCATION CASE BACK ASSEMBLY INPUT RELAY REMOVAL PROCEDURE 3. Locate the Input Relay. See Figure F.47. WARNING 4. Label leads 801D, 701F, 501B and 502B and their appropriate terminals.
Page 87
TROUBLESHOOTING AND REPAIR F-73 F-73 INPUT RELAY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.48 – INPUT RELAY LEAD LOCATIONS 501B 502B 701F(–) 801D(+) MOUNTING SCREWS (2 PLACES) REPLACEMENT PROCEDURE 1. Carefully place new input relay into position. Take note to replace plastic insulator previously removed (if present during disassembly).
Page 89
USB HUB REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 90
TROUBLESHOOTING AND REPAIR F-76 F-76 USB HUB REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.49 – USB HUB LOCATION USB HUB REMOVAL PROCEDURE 3. Locate the USB hub. See Figure F.49. WARNING 4. Label and remove all leads from hub terminals. See Figure F.50.
Page 91
TROUBLESHOOTING AND REPAIR F-77 F-77 USB HUB REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.50 – USB HUB LEAD LOCATIONS USB HUB CABLE TIE USB 5 USB 4 USB 6 USB 3 USB 7 USB 2 REPLACEMENT PROCEDURE 1. Carefully place the new USB hub into position in the machine.
Page 93
VGA SPLITTER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 94
TROUBLESHOOTING AND REPAIR F-80 F-80 VGA SPLITTER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.51 – VGA SPLITTER LOCATION VGA SPLITTER REMOVAL PROCEDURE 3. Locate the VGA splitter. See Figure F.51. WARNING 4. Perform the USB Hub Removal Procedure. ELECTRIC SHOCK can kill. 5.
Page 95
TROUBLESHOOTING AND REPAIR F-81 F-81 VGA SPLITTER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.52 – VGA SPLITTER LEAD LOCATIONS FRONT VGA SPLITTER INPUT OUTPUT HUB 1 VGA 1 VGA 6 VGA 2 BACK REPLACEMENT PROCEDURE 1. Place the new VGA splitter into position in the machine.
Page 97
REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 98
TROUBLESHOOTING AND REPAIR F-84 F-84 POLHEMUS / PATRIOT SEU MODULE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.53 – POLHEMUS / PATRIOT SEU MODULE LOCATION POLHEMUS / PATRIOT SEU MODULE BASE REMOVAL PROCEDURE 3. Locate the Polhemus / Patriot SEU Module. WARNING See Figure F.53.
Page 99
TROUBLESHOOTING AND REPAIR F-85 F-85 POLHEMUS / PATRIOT SEU MODULE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.54 – POLHEMUS / PATRIOT SEU MODULE LEAD LOCATIONS FRONT SENSOR 1 SENSOR 2 SOURCE CONFIG RS 232 BACK REPLACEMENT PROCEDURE 6. Perform the Case Cover Replacement 1.
Page 101
CPU REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Page 102
TROUBLESHOOTING AND REPAIR F-88 F-88 CPU REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.55 – CPU LOCATION BRACKET REMOVAL PROCEDURE 5. Using a phillips screwdriver, label and discon- WARNING nect leads 701F and 801D from terminals A1 and A2 on the input relay. See Figures F.56 ELECTRIC SHOCK can kill.
Page 103
TROUBLESHOOTING AND REPAIR F-89 F-89 CPU REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.56 – INPUT RELAY LOCATION CASE BACK ASSEMBLY INPUT RELAY 11. The CPU bracket can now be carefully moved toward the back of the machine to make way for CPU removal out of the left side of the machine.
Page 104
TROUBLESHOOTING AND REPAIR F-90 F-90 CPU REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.57 – INPUT RELAY LEAD LOCATIONS 701F(–) 801D(+) FIGURE F.58 – CPU LEAD LOCATIONS INPUT POWER DVI 1 AND DVI 2 RECEPTACLE USB 7 GREEN ENET AUDIO PORT VRTEX MOBILE ®...
Page 105
TROUBLESHOOTING AND REPAIR F-91 F-91 CPU REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.59 – CPU MOUNTING BOLTS MOUNTING NUTS (2) BRACKET SMALL CPU FOAM PAD LARGE CPU FOAM PAD REPLACEMENT PROCEDURE 1. Carefully position CPU through the left side of 8.
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CMOS BATTERY REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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TROUBLESHOOTING AND REPAIR F-94 F-94 CMOS BATTERY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.60 – CPU LOCATION BRACKET REMOVAL PROCEDURE 1. Remove input power to the machine. WARNING 2. Perform the Case Cover Removal Procedure. ELECTRIC SHOCK can kill. 3. Locate the CPU. See Figure F.60. •...
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TROUBLESHOOTING AND REPAIR F-95 F-95 CMOS BATTERY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.61 – CMOS BATTERY REMOVAL MOUNTING NUTS (2) BRACKET CPU COVER THUMB SCREWS LARGE CPU FOAM PAD 7. Using a phillips screwdriver (if necessary), remove the three thumb screws from the back of the CPU securing the CPU cover.
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(Login screen) on monitor. See Figure 6. Connect the USB mouse and keyboard to the F.63. USB ports located on the rear of the CPU. NOTE: Initial Lincoln Electric Green Initiative splash screen may not appear. VRTEX MOBILE ®...
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FMD. 20. The machine will now proceed to load the 12. On the touchscreen monitor press MENU and VRTEX Mobile software. then select shutdown and then YES to shut 21. At the login screen, verify the correct image down the machine.
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TROUBLESHOOTING AND REPAIR F-98 F-98 CMOS BATTERY REMOVAL AND REPLACEMENT PROCEDURE (continued) 25. Using the touchscreen monitor, press MENU, select shutdown and then Yes to shut down the machine. 26. Remove input power to the machine. 27. Disconnect the USB keyboard and mouse from the USB ports.
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BIOS SETUP PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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TROUBLESHOOTING AND REPAIR F-100 F-100 BIOS SETUP PROCEDURE (continued) FIGURE F.64 – BIOS screen PROCEDURE 2. If the boot screen appears, it will read “Press <F1> to continue.”. WARNING 3. Using the USB keyboard, Press the F1 key, then immediately press the F2 key until the BIOS setup must be performed when replacing BIOS setup utility appears.
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TROUBLESHOOTING AND REPAIR F-101 F-101 BIOS SETUP PROCEDURE (continued) FIGURE F.65 – BIOS setup navigation keys 8. Set the ‘EuP Function’ to ‘Disabled’. Also set the ‘Power-On after Power-Fail’ to ‘Power On’ or ‘Enabled’. See Figure F.69. 9. Using the USB keyboard, navigate to the “Boot” tab.
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TROUBLESHOOTING AND REPAIR F-102 F-102 BIOS SETUP PROCEDURE (continued) FIGURE F.66 – Load previous values FIGURE F.67 – Set system date and time VRTEX MOBILE ®...
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TROUBLESHOOTING AND REPAIR F-103 F-103 BIOS SETUP PROCEDURE (continued) FIGURE F.68 – Advanced tab FIGURE F.69 – Power management configuration VRTEX MOBILE ®...
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TROUBLESHOOTING AND REPAIR F-104 F-104 BIOS SETUP PROCEDURE (continued) FIGURE F.70 – Boot tab FIGURE F.71 – Save configuration VRTEX MOBILE ®...
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NVIDIA CONTROL PANEL SETUP PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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TROUBLESHOOTING AND REPAIR F-106 F-106 NVIDIA CONTROL PANEL SETUP PROCEDURE (continued) FIGURE F.72 – Desktop PROCEDURE 6. Using the USB mouse, right click on the desk- top and select NVIDIA Control Panel from the NOTE: Icons, programs and message boxes may menu.
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TROUBLESHOOTING AND REPAIR F-107 F-107 NVIDIA CONTROL PANEL SETUP PROCEDURE (continued) FIGURE F.73 – Taskbar 11. Using the USB keyboard and mouse, press start and then press shutdown to shut the machine down. 12. Turn machine on by depressing the green cir- cular button on case front.
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TROUBLESHOOTING AND REPAIR F-108 F-108 NVIDIA CONTROL PANEL SETUP PROCEDURE (continued) FIGURE F.74 – Crosstrainer.exe FIGURE F.75 – Host application VRTEX MOBILE ®...
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TROUBLESHOOTING AND REPAIR F-109 F-109 NVIDIA CONTROL PANEL SETUP PROCEDURE (continued) FIGURE F.76 – NVIDIA control panel FIGURE F.77 – Setup multiple displays VRTEX MOBILE ®...
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TROUBLESHOOTING AND REPAIR F-110 F-110 NVIDIA CONTROL PANEL SETUP PROCEDURE (continued) FIGURE F.78 – Make primary VRTEX MOBILE ®...
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UNINSTALL NVIDIA PROGRAMS PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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TROUBLESHOOTING AND REPAIR F-112 F-112 UNINSTALL NVIDIA PROGRAMS PROCEDURE (continued) FIGURE F.79 – USB hub location USB HUB PROCEDURE 6. Turn machine on by depressing the green cir- cular button on case front. If the green button NOTE: Icons, programs and message boxes may does not stay on, press and hold the green appear both in the helmet’s FMD (face button and then press up and release the CPU...
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TROUBLESHOOTING AND REPAIR F-113 F-113 UNINSTALL NVIDIA PROGRAMS PROCEDURE (continued) FIGURE F.80 – DVI1 connection location DVI 1 AND DVI 2 10. Using the USB mouse, move the cursor 15. Uninstall all NVIDIA programs from top to towards the bottom of the monitor until the bottom by right clicking the program, select taskbar appears.
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TROUBLESHOOTING AND REPAIR F-114 F-114 UNINSTALL NVIDIA PROGRAMS PROCEDURE (continued) FIGURE F.81 – Desktop 20. Connect the FMD’s (face mounted display) 23. Place StartUpSim.bat shortcut into startup by USB6 to the 7 port USB hub located inside of left clicking the start icon, select all programs the machine.
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UNIGUN REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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TROUBLESHOOTING AND REPAIR F-120 F-120 UNIGUN REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.90 – UNIGUN LOCATION UNIGUN ASSEMBLY DIVIDER PANEL REMOVAL PROCEDURE 4. Remove any and all attachment(s) (tips) on WARNING Unigun. 5. Remove toroid and follow Unigun leads to the ELECTRIC SHOCK can kill.
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TROUBLESHOOTING AND REPAIR F-121 F-121 UNIGUN REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.91 – “Y” ADAPTER AND RCA PLUG LOCATION “Y” ADAPTER SEN 1 RCA PLUG FIGURE F.92 – INPUT CABLE GROMMET LOCATION CASE FRONT ASSEMBLY INPUT CABLE GROMMET VRTEX MOBILE ®...
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TROUBLESHOOTING AND REPAIR F-122 F-122 UNIGUN REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 5. Perform the Case Cover Replacement 1. Carefully place Unigun cables through input Procedure. cable grommet on machine case front. See Figure F.92. 6. Perform the Hardware Initialization (PIMAN. EXE) Procedure, located in the Polhemus/ 2.
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HELMET REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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TROUBLESHOOTING AND REPAIR F-124 F-124 HELMET REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.93 – HELMET LOCATION TOP SCREWS (4) RIGHT SIDE SCREWS (6) REMOVAL PROCEDURE 4. Disconnect USB 6 cable from the USB Hub. WARNING See Figure F.95. See Wiring Diagram. 5.
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TROUBLESHOOTING AND REPAIR F-125 F-125 HELMET REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.94 – HELMET LOCATION HELMET FIGURE F.95 – USB 6 AND SEN2 LEAD CONNECTION LOCATIONS USB 3 HUB 2 VGA 2 USB 5 VGA 6 USB 4 USB 6 USB 6 USB 3 VGA 1...
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TROUBLESHOOTING AND REPAIR F-126 F-126 HELMET REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.96 – DVI 1 CONNECTION LOCATION DVI 1 AND DVI 2 REPLACEMENT PROCEDURE 7. Install any previously removed cable ties. 1. Replace Helmet. 8. Install right side panel previously removed. 2.
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TOUCHSCREEN MONITOR CALIBRATION PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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TROUBLESHOOTING AND REPAIR F-128 F-128 TOUCHSCREEN MONITOR CALIBRATION PROCEDURE (continued) FIGURE F.97 – TOUCHSCREEN MONITOR CONNECTIONS 12VDC USB 2 VGA IN USB 2 AUDIO Speaker 12VDC USB 4 Speaker PROCEDURE 3. Connect a USB mouse and USB keyboard to WARNING the two USB ports on the front of the machine.
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TROUBLESHOOTING AND REPAIR F-129 F-129 TOUCHSCREEN MONITOR CALIBRATION PROCEDURE (continued) FIGURE F.98 – MONITOR CALIBRATION SCREENSHOT ELO ICON TASK BAR ARROW 8. Left click the arrow icon on the right side of the task bar. Double-click the “ELO” icon and select “Align.”...
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REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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TROUBLESHOOTING AND REPAIR F-132 F-132 GREEN ON BUTTON REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.99 – GREEN START BUTTON LOCATION CASE FRONT BEZEL ASSEMBLY LAMP HOLDER GREEN ON BUTTON ASSEMBLY REMOVAL PROCEDURE 4. Take hold of the lamp holder assembly and gen- WARNING tly rotate (counter-clockwise) and remove from the bezel assembly.
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TROUBLESHOOTING AND REPAIR F-133 F-133 GREEN ON BUTTON REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.100 – GREEN START BUTTON LEAD LOCATIONS 701C(–) (INNER LEAD) 502A 801C(+) (OUTER LEAD) PROTECTIVE 501C TERMINAL REPLACEMENT PROCEDURE 1. Secure the bezel assembly to the case front. 2.
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TROUBLESHOOTING AND REPAIR F-134 F-134 RETEST AFTER REPAIR DESCRIPTION This procedure will aid the technician in testing the basic operations of the VRTEX MOBILE ® after any repair or replacement procedure has been completed. 1. Make sure the stand, the monitor, the VR 8.
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MANUFACTURING TOLERANCE PER E2056 SCALE: CONTROL: CLEVELAND EQUIPMENT TYPE: VRTEX MOBILE UNLESS OTHERWISE SPECIFIED TOLERANCE: PAGE ___ OF ___ ON 2 PLACE DECIMALS IS ± .02 in. ( ± 0.5 mm) NONE ON 3 PLACE DECIMALS IS ± .002 in. ( ± 0.05 mm) DRAWN BY: A.Koshar...
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