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Polar Instruments PFL760 Service Manual

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Polar Instruments Ltd.
Garenne Park
St. Sampson
Guernsey
Channel Islands
http://www.polar.co.uk
Fax: +44 (0)1481 252476
Email: mail@polar.co.uk
MAN 164–9803
PFL760
SERVICE
MANUAL

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Summary of Contents for Polar Instruments PFL760

  • Page 1 PFL760 Polar Instruments Ltd. Garenne Park SERVICE St. Sampson Guernsey MANUAL Channel Islands http://www.polar.co.uk Fax: +44 (0)1481 252476 Email: mail@polar.co.uk MAN 164–9803...
  • Page 2 Copyright Polar Instruments Ltd. 1997 Microsoft and MS-DOS are registered trademarks of Microsoft Corporation IBM is the registered trademark of International Business Machines Corporation.
  • Page 3 PFL760 FAULT LOCATOR SERVICE MANUAL POLAR INSTRUMENTS LTD. HARDWARE WARRANTY Product Warranty. Product hardware is warranted to be free from defects in material and workmanship during the Warranty Period (as defined below). Product hardware is warranted to conform substantially to Polar’s then current (as of the date of Polar’s product shipment) published user documentation during the Warranty Period.

  • Page 5: Declarations

    DECLARATIONS European Community Directive Conformance Statement Refer to the Operator Manual to determine conformance with European Community Directives.

  • Page 6: Safety

    PFL760 SERVICE MANUAL SAFETY WARNING The service instructions contained in this manual are for use by qualified electronic service personnel only. WARNING The LIVE and NEUTRAL lines on later units are BOTH fused. When the unit is connected to its supply, the opening of covers or removal of panels is likely to expose dangerous voltages.

  • Page 7: Operation

    The unit is designed for use indoors in an electrical workshop environment at a stable work station comprising a bench or similar work surface. Use only the accessories (e.g. test probes and clips) provided by Polar Instruments. The instrument must be maintained and repaired by a skilled electronics technician in accordance with the manufacturer’s instructions.

  • Page 8: Specifications

    PFL760 SERVICE MANUAL SPECIFICATIONS Test Channels Test Ranges Junction 500µA Logic 150mA 1mA (to S/N 012392) High 1mA (S/N 012393 up) 90Hz Test Frequencies Low 500Hz Medium 2kHz High 0 – ±5V variable level Pulse Generator DC, Pulse mode 1,...

  • Page 9: Channel A And B Protection Fuses

    7.0kg (15.4 lb.) SYMBOLS REFER TO MANUAL These sockets are for connecting only Polar Instruments probes and connectors for use as described in the Operator Manual. To prevent damage to this product and to ensure its safe use observe the specifications given in this manual when connecting to terminals marked with this symbol.

  • Page 10: Table Of Contents

    Performance Check ........................... 1-1 Calibration Procedure......................... 1-1 Recommendations for Routine Maintenance ..................1-1 PERFORMANCE CHECK........................1-2 Procedure............................1-2 Testing the PFL760 clips, cables and relays..................1-3 SECTION 2 – CALIBRATION ........................2-1 CALIBRATION PROCEDURE ....................... 2-1 Equipment required ..........................2-1 Procedure............................2-1 SECTION 3 –...

  • Page 11: Contents

    CONTENTS WAVEFORM GENERATION AND DRIVE CIRCUITS ..............3-3 Waveform generators/buffers ......................3-3 Digital to analog converters ......................3-3 DRIVE CIRCUITS ..........................3-4 INPUT AMPLIFIER..........................3-4 System OK LED ..........................3-4 Footswitch input..........................3-4 A to D CONVERTER.......................... 3-5 Analog to digital conversion......................3-5 Signal input selection........................

  • Page 13: Section 1 - Performance Check

    SECTION 1 – PERFORMANCE CHECK MAINTENANCE AND CALIBRATION OF INSTRUMENTS For most of Polar Instruments’ products there are two maintenance procedures — the Performance Check and the Calibration. Some instruments may have a single (combined) procedure. Performance Check The Performance Check (or Checkout Procedure) is used to verify the basic functions of the instrument.

  • Page 14: Performance Check

    If communication fails check that the correct cable is in use and that it is connected to the selected serial port on the PC. If a fault in the PFL760 is detected such as a fuse failure this should be corrected and the diagnostic repeated until all tests pass before proceeding.

  • Page 15: Testing The Pfl760 Clips, Cables And Relays

    Note: a true RMS DVM may indicate a slightly different reading. Testing the PFL760 clips, cables and relays If it is desired to test clips and cables and the relays of the PFL760 it will be necessary to build a simple test fixture.

  • Page 17: Section 2 - Calibration

    SECTION 2 – CALIBRATION CALIBRATION PROCEDURE WARNING: Hazardous voltages are exposed on the PCB when the cover is removed. This procedure should only be performed by a technically qualified person aware of the hazards and taking all reasonable care. Equipment required Accurate (0.5% or better at 10V DC) DVM Procedure 1.

  • Page 19: Section 3 - Circuit Description

    SECTION 3 – CIRCUIT DESCRIPTION THE MICROPROCESSOR KERNEL Refer to the PROCESSOR schematics System processor The system is based on an 8086 running in "min" mode at 8MHz. The clock oscillator is U21D and the frequency is set by X2 at 8MHz. The signal is buffered by U21E and U21C and then applied to the processor and the waveform generator.

  • Page 20: The I/O System

    PFL760 SERVICE MANUAL THE I/O SYSTEM Refer to the SYSTEM CONTROL schematics The input/output system All I/O in the system is memory-mapped; the processor’s I/O capabilities are not used. The control output signals are latched into 74HC374 ICs connected in pairs across the 16 bits of the data bus.

  • Page 21: Waveform Generation And Drive Circuits

    CIRCUIT DESCRIPTION WAVEFORM GENERATION AND DRIVE CIRCUITS Refer to the SINE GENERATOR schematic Waveform generators/buffers The waveforms required by the instrument are all generated from data stored in the two ROMs U38 and U39. 8MHz from the system clock oscillator is divided down by U50, a simple ripple counter, to provide a range of clock signals used throughout the instrument.

  • Page 22: Drive Circuits

    PFL760 SERVICE MANUAL DRIVE CIRCUITS Refer to the DRIVE CIRCUITS schematics The drive for the A (B) LOW voltage ranges is provided by power op-amp U52 (U53) whose output is protected by fuse F1 (F2) and voltage limiting zener diodes. The short circuit current is limited by the range resistors and the output is connected to the range selection relays.

  • Page 23: A To D Converter

    CIRCUIT DESCRIPTION A to D CONVERTER Refer to A to D CONVERTER schematic Analog to digital conversion U58 is a combined A to D and DAC sharing the 8-bit data bus interface. The DAC output from pin 2 is passed through demultiplexor U59 to one of the analogue stores, capacitors C36 – C44 and high input impedance op-amp buffers U47, U56 and U62.

  • Page 24: Power Supplies

    PFL760 SERVICE MANUAL POWER SUPPLIES Refer to the POWER schematics High voltage supply Power transformer T1 incorporates 3 secondaries providing one pre-regulation supply of about 210V, and two of 20V. The high voltage supply is regulated down to 180V by U69. R139 and D19 maintain the differential across the device to within safe limits.

  • Page 25: Section 4 - Dismantling Instructions

    SECTION 4 – DISMANTLING INSTRUCTIONS WARNING Service of this instrument should only be performed by skilled electronics service personnel. There are hazardous voltages inside the instrument when connected to its power supply. REMOVE THE POWER CORD before touching any part of the line input circuit. Note that high voltages may continue to be present for 2 minutes after power is removed until internal capacitors discharge.

  • Page 27: Section 5 - Line Voltage And Fuse Changing

    SECTION 5 – LINE VOLTAGE AND FUSE CHANGING WARNING: There are hazardous voltages inside the instrument when connected to its power supply. REMOVE THE POWER CORD before touching any part of the line input circuit. Note that high voltages may continue to be present for 2 minutes after power is removed until internal capacitors discharge.

  • Page 28: Input Protection Fuses

    PFL760 SERVICE MANUAL Input Protection Fuses Channels A and B are protected by fast blow fuses. If the probes are connected to a powered board, or to a large, charged capacitor, these fuses open to minimise damage to the instrument.

  • Page 29: Section 6 - Fault Diagnosis

    SECTION 6 – FAULT DIAGNOSIS WARNING: Hazardous voltages are exposed on the PCB when the cover is removed. These procedures should only be performed by a technically qualified person aware of the hazards and taking all reasonable care. SYSTEM DIAGNOSTICS If the “System OK”...

  • Page 31: Section 7 - Maintenance And Cleaning

    If it becomes necessary to repair the instrument, in the first instance contact the Polar Instruments distributor in your country. In case of difficulty contact Polar Instruments Ltd. at the address at the front of this manual. Do not send the instrument until shipping instructions have been received from the...

  • Page 33: Section 8 - Replacement Parts

    Note: Parts marked with an asterisk (*) have been subject to modification in later instruments. Safety critical parts (listed in bold type) must be replaced with parts obtained from Polar Instruments Ltd or your Polar Instruments distributor to ensure continued safe operation.

  • Page 34: Main Board Components

    PFL760 SERVICE MANUAL MAIN BOARD COMPONENTS Part Nº Description Circuit Reference CEA103 10uF Electrolytic C13, C35, C47, C49, C50, C52, C105, C106, C114 CEA105 220uF C25, C28, C30, C902, C903 CEA113 22uF C1, C2, C3, C4, C5, C6, C7, C10 CEA118 3.3uF 250V...
  • Page 35 REPLACEMENT PARTS ICA192 74HC374 U1, U2, U3, U4, U9, U16, U40, U44, U45, U66, U107, U902, U913 ICA194 6264 U34, U35 ICA214 LM7812 U108 ICA227 8253 / 71054 ICA236 ULN2003 ICA240 4053 U51, U909 ICA241 4052 ICA243 4051 U59, U60, U63 ICA244 74HC153 U48, U912...
  • Page 36 PFL760 SERVICE MANUAL MQX260P34 Pin Header MQX313 9-pin Filtered D Serial Nº. to 10911 MQX293 25-pin D Serial Nº. 10912 up *MQX337 ¼" Stereo Jack Late instruments MSH104 M3 Solder Tag MSH108 Resistor Bracket R49, R82 MWPD919 Volts Warning Label...
  • Page 37 REPLACEMENT PARTS RCT2K0 1/4W R61, R75 RCT2K2 1/4W R89, R94 RCT2K49 2K49 1/4W R41, R42, R125 *RCT31K6 31K6 1/4W R53, R67 RCT33K 1/4W R123 RCT390K 390K 1/4W R131 RCT47K 1/4W R100, R101, R102, R104, R105, R106, R107, R108, R902, R903 RCT49K9 49K9 1/4W...

  • Page 38: Scanner Components

    PFL760 SERVICE MANUAL SCANNER COMPONENTS Part Nº Description Circuit Reference CEA103 10uF Electrolytic CEA105 220uF Electrolytic CVD109 0.1uF Ceramic C2, C4 DSP101 IN4148 D1 TO D128 ICA209 74HC238 U3,U4 ICA236 ULN2003 ICA285 ULN2803 U1, U2 MPCD901 MQX207 40 Way Ejector Header...

  • Page 39: Mechanical Components

    M4 Solder Tag MWP155 Ground Label MWP156 Serial Number *MWPD906 Machined Rear Panel MWPD917 Power Label MWPD918 Footswitch Label MWPD1114 PFL760 Front Label WMA102 0.15m Blue Wire WMA103 Green/Yellow Wire WMA104 Brown Wire WMA221 Cover Ground Cable Assy WMA245 Input Socket Harness LED PCB COMPONENTS Part Nº...
  • Page 40 PFL760 SERVICE MANUAL LED117 Green LED *LED115 Red LED *LED120 Bi-Color LED MPCD941 LED PCB MPP201 Spacer WMA108 Link 0.5" WMA268 LED Cable...

  • Page 41: Section 9 - Schematic Diagrams

    SECTION 9 – SCHEMATIC DIAGRAMS...
  • Page 42 This page is intentionally blank.
  • Page 43 CONSEL 2 CONSEL 3 R125 REF2 2K49 1% 74HC151 MUX2INH R130 130K 1% 4051 MUXC MUX C MUXB MUX B MUXA MUX A Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 A to D converter...
  • Page 44 47K 1% R206 R106 74HC14 REF2 47K 1% 1N4148 IP GAIN 3 R204 ISO1 100K U55B U106E ULN2003 74HC14 C115 2N3904 0.1uF R205 Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 AMPLIFIER S/No10912 to 12483...
  • Page 45 47K 1% R206 R106 74HC14 REF2 47K 1% 1N4148 IP GAIN 3 R204 ISO1 100K U55B U106E ULN2003 74HC14 C115 0.1uF 2N3904 R205 Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 AMPLIFIER to S/No 10911...
  • Page 46 22R 1W 22R 1W B LO 12V 5W LM759 16K 1% 220uF B JUNC 820R 12V 5W R85 20K 1% .22uF 2K2 1% Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 Drive circuits to S/No12483...
  • Page 47 1N4148 +UREG R924 270R ISO1A CNY74 R922 D910 270R 1N4148 U925B 74HC74 R921 270R D913 R920 1N4148 10uF 270R D911 C911 1N4148 10uF Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 Footswitch S/No 12484 up...
  • Page 48 SIG MATRIX SLSA0 SLSA1 SLSA2 SHSA0 SHSA1 SHSA2 SSPARE U67A +15V A RELAYS B RELAYS 74HC374 SCANNER D[0..15] +12V 74AC32 SENS1 SENS2 SENS3 COM MATRIX SCANNER Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 Interface...
  • Page 49 100K U920A C112 U106E 270pF R106 R105 74HC14 Q20base 47K 1% 47K 1% C115 0.1uF 2N3904 REF 2 U55B IP GAIN 3 ULN2003 Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 AMPLIFIER S/No 12484 up...
  • Page 50 22R 1W 22R 1W B LO LM759 12V 5W 16K 1% 220uF B JUNC 820R R85 20K 1% 12V 5W .22uF 2K2 1% Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 Sine Drive S/No 12484 up...
  • Page 51 SENS2 270R SENS3 270R CLK1 270R TOUT2 270R OUT1 LAMP CLK2 OUT2 AUX_IN 74HC374 74HC373 TIMER INPT INPT 8253 25 pin "D" Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 System Control Ports S/No12484 up...
  • Page 52 SEC3 0.1uF 10uF 79L05 C105 C104 10uF 1N4007 0.1uF C103 -15V 2,200uF 1N4007 10uF SEC4 .1uF 1N4007 Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Polar Instruments Ltd PFL760 POWER S/No 12484 up Inst. Title Title Rev Code...
  • Page 53 1N4007 SEC3 0.1uF 10uF 79L05 C105 C104 1N4007 10uF -15V R141 0.1uF C103 R142 -15V 2,200uF 1N4007 10uF SEC4 .1uF 1N4007 0.1uF 10uF Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 POWER to S/No 10911...
  • Page 54 1N4007 0.1uF 10uF 79L05 C105 C104 10uF 1N4007 -15V R141 0.1uF C103 R142 -15V 2,200uF 1N4007 10uF SEC4 .1uF 1N4007 0.1uF 10uF Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 POWER S/No 10912 to 12483...
  • Page 55 74AC32 ENABLE HI RAM (STACK) 10uH 0.1uF U31B 74HC74 74AC32 U14D U31A 74AC32 RESET R-IN U31D 74AC32 74AC32 RESET 7705 10uF .1uF 62256 Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 PROCESSOR S/No 10912 up...
  • Page 56 (STACK) 10uH 0.1uF U31B 74HC74 74AC32 U14D U31A 74AC32 RESET R-IN U31D 74AC32 RESET 74AC32 U33F 7705 10uF .1uF 74HC04 62256 JP12 WATCHDOG Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 PROCESSOR to S/No 10911...
  • Page 57 SENS1 270R OUT0 SENS2 270R SENS3 270R CLK1 270R TOUT2 270R OUT1 LAMP CLK2 OUT2 AUX_IN 74HC374 74HC373 TIMER INPT INPT 8253 Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 System control S/No to 12483...
  • Page 58 R908 R909 R902 PULSE_4 R905 47K 1% 10K 1% C110 0.1uF D901 C904 C903 .1uF 220uF 4053 R903 47K 1% 74HC374 U54H D[0..15] D[0..15] ULN2803 D[0..15] Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 Pulser...
  • Page 59 U47B REF2 4K99 1% 1MHz TL084 10V REF 1MHz REF2 ADJ 10K 1% U33A LOAD 27512 2KHz 74HC161 74HC374 4040 74HC04 2MHz 2MHz U33C 74HC04 Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 Sine Generator...
  • Page 60 ROW5 D112 D109 D111 D110 D113 ROW6 D127 D122 D120 D118 D116 D114 D125 ROW7 D124 D117 D119 D128 D126 D123 D115 D121 ROW8 Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 128 channel relays...
  • Page 61 ULN2803 ULN2803 +15V ROW1 ULN2803 ROW2 ULN2803 ROW3 SLSA0 ULN2803 SLSA1 SLSA2 ROW4 ULN2803 ROW5 ULN2803 74HC238 ROW6 ULN2803 ROW7 ULN2803 ROW8 ULN2803 Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 128 channel relay drive...
  • Page 62 SLSA1 K130 SLSA2 220uF .1uF SHSA0 SHSA1 SHSA2 ULN2003 +15V A 26WAY A 40WAY BSIG K129 10uF .1uF +15V ULN2003 B 26WAY B 40WAY Polar Intruments Ltd Garenne Park, St. Sampsons Guernsey, Channel Islands Inst. Title PFL760 128 channel connectors...

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