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Fluke 45 Service Manual

Fluke 45
184 pages
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®
45
Dual Display Multimeter
Service Manual
For IEC 1010 Meters Only
PN 609203
March 1999 Rev.1, 1/04
© 1999-2004 Fluke Corporation, All rights reserved. Printed in U.S.A.
All product names are trademarks of their respective companies.
Advanced Test Equipment Rentals
www.atecorp.com 800-404-ATEC (2832)
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Table of Contents

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Fluke 45 Specifications

General IconGeneral
Diode TestYes
Display Digits5 digits
InterfaceRS-232
Frequency Range5Hz to 500kHz
Continuity< 25 Ω
Basic DC Accuracy0.05%
Power Supply115/230 V AC, 50/60 Hz

Summary

Chapter 1 Introduction and Specifications

1-1. Introduction

Overview of the Fluke 45 Dual Display Multimeter and its applications.

1-2. Operating Instructions

Guidance on operating the meter, referencing the User's Manual.

1-3. Options and Accessories

Details on available installation kits for battery and IEEE-488 interface.

1-4. Organization of the Service Manual

Explains the manual's structure, interdependence of chapters, and navigation.

1-5. Conventions

Defines notational conventions used throughout the manual for clarity.

1-6. Specifications

Comprehensive technical specifications for the Fluke 45 multimeter.

Chapter 2 Theory of Operation

2-1. Introduction

Introduces the chapter's layered description of Fluke 45 circuitry.

2-2. Functional Block Description

Describes the multimeter's main functional blocks and their roles.

2-3. Power Supply

Explains the power supply block's function in providing necessary voltages to the meter.

2-4. Analog Measurement Processor

Details the AMP's role in signal conditioning, A/D conversion, and measurement.

2-5. Input Protection Circuit

Describes circuits and fuses safeguarding the meter from over-voltage and over-current.

2-6. Input Signal Conditioning

Explains how input signals are scaled and conditioned for the A/D converter.

2-7. Analog-to-Digital (A/D) Converter

Details the process of converting analog voltage levels into digital data.

2-8. Serial Communication (Guard Crossing)

Describes the isolated communication path between the Digital Kernel and AMP.

2-9. Digital Kernel

Explains the function of the Digital Kernel in coordinating meter activities.

2-10. Display Assembly

Describes how the Display Assembly communicates with the Microprocessor.

2-11. IEEE-488 Interface Option (-05)

Refers to Chapter 8 for the theory of operation of the IEEE-488 option.

2-12. Battery Pack Option (-01)

Refers to Chapter 7 for the theory of operation of the Battery Pack option.

2-13. Detailed Circuit Description

General heading for detailed explanations of specific circuits.

2-14. Power Supply Circuit Description

Details the three functional sections of the power supply.

2-15. Raw DC Supply

Explains the function of the power transformer and DC supply conversion.

2-16. 5-Volt Switching Supply

Describes the pulse-width modulation technique for regulating the 5.1V DC output.

2-17. Inverter

Details the inverter circuit for generating display voltages and in-guard supplies.

2-18. Analog Measurement Processor

Explains the AMP chip's functions and its interaction with the Main Processor.

2-19. Input Protection

Details various input protection schemes including MOVs, fuses, and resistors.

2-20. Input Signal Conditioning

Explains signal scaling and filtering for A/D conversion across different rates.

2-21. Relays

Describes how latching relays route input signals based on selected functions.

2-22. DC Volts

Explains signal routing and attenuation for DC voltage measurements.

2-23. Ohms

Describes the ratio ohms technique used for resistance measurements.

2-24. 100 MΩ and 300 MΩ Ranges

Explains how these ranges perform conductance readings.

2-25. AC Volts

Details AC voltage scaling and conversion to DC via the true RMS converter.

2-26. DCmA

Explains voltage generation proportional to input current for DCmA.

2-27. ACmA

Describes ACmA signal routing to the AC buffer and RMS converter.

2-28. Amps

Explains DC and AC amps signal routing via shunts and RMS converter.

2-29. Diode/Continuity Test

Describes front-end configuration for Diode/Continuity test.

2-30. Frequency

Explains how the frequency/continuity comparator uses AC buffer output.

2-31. Active Filter

Details the two-pole active filter for noise reduction in DC measurements.

2-32. A/D Converter

Explains the dual-slope A/D converter process and ranges.

2-33. Serial Communication (Guard Crossing)

Describes the isolated interface circuit for Microprocessor and AMP communication.

2-34. Digital Kernel

Outlines the six functional blocks of the Digital Kernel.

2-35. RS-232 Interface

Details the RS-232 interface components and signal transitions.

Chapter 3 General Maintenance

3-1. Introduction

Introduces handling, cleaning, fuse replacement, disassembly, and assembly instructions.

3-2. Warranty Repairs and Shipping Information

Provides instructions for warranty returns and contact information.

3-3. General Maintenance Information

General guidance for maintaining the instrument.

3-4. Required Equipment

Lists necessary equipment for calibration, troubleshooting, and repair.

3-5. Power Requirements

Details power input specifications and safety warnings for electrical shock.

3-6. Static Safe Handling

Crucial guidelines for preventing ESD damage to sensitive components.

3-7. Cleaning

Procedures for safely cleaning the meter’s exterior.

3-8. Fuse Test and Replacement

Outlines procedures for testing and replacing fuses.

3-9. Line Fuse

Specifies the location and replacement of the line fuse (F3).

3-10. Current Input Fuses

Identifies fuses protecting the 100 mA and 10 A inputs.

3-11. Testing Current Input Fuses

Provides a procedure to test the continuity of input fuses.

3-12. Replacing the 500 mA and 440 mA Input Fuses (F1 and F5)

Details the process for replacing the F1 and F5 input fuses.

3-13. Replacing the 10 A Input Jack Fuse (F2)

Explains how to access and replace the F2 input fuse.

3-14. Disassembly Procedures

Step-by-step guide for disassembling the meter from assembly to chassis level.

3-15. Remove the Meter Case

Procedure for removing the meter's outer case and rear bezel.

3-16. Remove Handle and Mounting Brackets

Instructions for detaching the meter's handle and brackets.

3-17. Remove the Front Panel Assembly

Steps to disconnect input terminals and remove the front panel assembly.

3-18. Remove the Display PCA

Instructions for releasing tabs and removing the Display PCA.

3-19. Remove the IEEE-488 Option

Procedure for detaching the IEEE-488 PCA and its cables.

3-20. Remove the Main PCA

Steps to disconnect connectors and remove the Main PCA.

3-21. Remove the Analog Measurement Processor Shields

Details removal of protective shields covering the AMP.

3-22. Remove the Rms PCA

Instructions for desoldering and removing the Rms PCA.

3-23. Remove the Battery Option

Procedure for disconnecting and removing the Battery Option.

3-24. Disconnect Miscellaneous Chassis Components

Steps for disconnecting various chassis-mounted hardware.

3-25. Assembly Procedures

General guide for reassembling the meter following disassembly steps.

3-26. Install Miscellaneous Chassis Components

Procedure for replacing removed chassis components.

3-27. Install the Battery Option

Steps for installing the Battery Kit Option into the meter.

3-28. Install the Rms PCA

Instructions for soldering the Rms PCA onto the Main PCA.

3-29. Install the Analog Measurement Processor Shields

Procedure for reinstalling protective shields for the AMP.

3-30. Install the Main PCA

Steps for installing the Main PCA, including insulator and standoff verification.

3-31. Install the IEEE-488 Option

Procedure for installing the IEEE-488 circuit board and cables.

3-32. Assemble the Front Panel Assembly

Steps for cleaning and connecting the display, keypad, and lens.

3-33. Install the Front Panel Assembly

Procedure for attaching the assembled front panel to the chassis.

3-34. Install the Handle and Mounting Brackets

Instructions for reattaching the handle and its mounting brackets.

3-35. Install the Meter Case

Final step to secure the meter case and rear bezel.

Chapter 4 Performance Testing and Calibration

4-1. Introduction

Introduces performance tests and calibration procedures for verifying meter operation.

4-2. Required Equipment

Lists recommended test equipment needed for performance tests and calibration.

4-3. Performance Tests

Provides tests to verify Fluke 45 operation against published specifications.

4-4. Front Panel Calibration

Details closed-case calibration using front panel controls and known reference sources.

4-5. Introduction

Introduces the basic calibration steps and their interdependence.

4-6. Entering Calibration Mode

Explains how to access the calibration mode and navigate the menu.

4-7. Exiting Calibration Mode

Describes how to safely exit calibration mode without losing data.

4-8. DC Volts Calibration (Front Panel)

Step-by-step procedure for calibrating DC Voltage functions via the front panel.

4-9. AC Volts Calibration (Front Panel)

Step-by-step procedure for calibrating AC Voltage functions via the front panel.

4-10. DC and AC Milliamp Calibration (Front Panel)

Procedure for calibrating DC and AC milliamp functions via the front panel.

4-11. DC and AC Amps Calibration (Front Panel)

Procedure for calibrating DC and AC amps functions using a boost amplifier.

4-12. Ohms Calibration (Front Panel)

Procedure for calibrating Ohms function via the front panel, including prompt editing.

4-13. Alternate Ohms Calibration (Front Panel)

Alternative procedure for Ohms calibration using discrete resistor values.

4-14. Continuity/Hysteresis Threshold Calibration (Front Panel)

Procedure for calibrating continuity and hysteresis threshold functions.

4-15. Frequency Calibration (Front Panel)

Procedure for calibrating frequency measurements via the front panel.

4-16. C2 Adjustment Procedure

Specific adjustment procedure for meters failing high frequency VAC performance tests.

4-17. Editing the Prompt for Different Calibration Points

Explains how to manually edit calibration prompts for non-standard points.

4-18. Calibration Using the Computer Interface

Details how to perform calibration using a computer interface.

4-19. Setup

Describes initial setup requirements for computer interface calibration.

4-20. RS-232 Interface

Procedure for connecting and configuring the meter for RS-232 calibration.

4-21. IEEE-488 Interface

Procedure for connecting and configuring the meter for IEEE-488 calibration.

4-22. The Calibration Procedure

Outlines the overall computer interface calibration process and considerations.

4-23. DC Volts Calibration (Computer Interface)

Step-by-step computer interface calibration for DC Volts.

4-24. AC Volts Calibration (Computer Interface)

Step-by-step computer interface calibration for AC Volts.

4-25. DC and AC Milliamps Calibration (Computer Interface)

Step-by-step computer interface calibration for DC/AC Milliamps.

4-26. DC and AC Amps Calibration (Computer Interface)

Step-by-step computer interface calibration for DC/AC Amps.

4-27. Ohms Calibration (Computer Interface)

Step-by-step computer interface calibration for Ohms.

4-28. Continuity/Hysteresis Threshold Calibration (Computer Interface)

Step-by-step computer interface calibration for continuity/hysteresis.

4-29. Frequency Calibration (Computer Interface)

Step-by-step computer interface calibration for frequency.

4-30. Concluding Calibration Using the Computer Interface

Final steps to exit calibration mode after computer interface use.

4-31. Alternate Ohms Calibration (Computer Interface)

Alternative computer interface calibration for Ohms using discrete resistors.

Chapter 5 Diagnostic Testing and Troubleshooting

5-1. Introduction

Introduces error codes and semi-modular design for troubleshooting.

5-2. Servicing Surface-Mount Assemblies

Provides an introduction to SMT and its specific servicing requirements.

5-3. Error Codes

Explains power-up self-tests and how failures are reported via error codes.

5-4. General Troubleshooting Procedures

Outlines the overall approach to troubleshooting the Fluke 45.

5-5. Power Supply Troubleshooting

Guides users through troubleshooting the meter's power supplies.

5-6. Raw DC Supply

Details troubleshooting steps for the Raw DC Supply section.

5-7. 5-Volt Switching Supply

Explains how to troubleshoot the 5V switching supply using an oscilloscope.

5-8. Inverter

Provides guidance on troubleshooting the inverter circuit.

5-9. Analog Troubleshooting

Addresses problems indicated by Error 8 or 9, focusing on analog circuits.

5-10. Uart Test

Describes a test for the optoisolators and UART circuitry.

5-11. DC Volts Troubleshooting

Troubleshooting procedures for DC Voltage measurements.

5-12. AC Volts Troubleshooting

Troubleshooting procedures for AC Voltage measurements.

5-13. Ohms Troubleshooting

Troubleshooting procedures for Ohms measurements.

5-14. Digital Troubleshooting

Procedures for diagnosing issues related to the display and digital components.

5-15. Display Assembly Troubleshooting

Specific steps to troubleshoot problems with the display assembly.

5-16. Calibration Failures

Discusses common calibration failure indications and causes.

5-17. Introduction

Introduces calibration failure troubleshooting and error indications.

5-18. Calibration-Related Components

Identifies key components involved in measurement function calibration.

5-19. Calibration Interrelationships

Explains how calibration of one function can affect others.

5-20. Retrieving Calibration Constants

Describes how to retrieve and verify calibration constants via the computer interface.

5-21. Replacing the EEROM A1U5

Outlines the procedure for programming a new EEROM with the meter's serial number.

Chapter 6 List of Replaceable Parts

6-1. Introduction

Introduces the chapter containing illustrated lists of replaceable parts.

6-2. How to Obtain Parts

Provides detailed instructions on ordering replacement parts from Fluke.

6-3. How to Contact Fluke

Lists contact information for Fluke customer support and web resources.

6-4. Manual Status Information

Defines assembly revision levels documented in the manual.

6-5. Newer Instruments

Explains how changes and improvements are identified and documented.

6-6. Parts

Directs users to detailed listings of Fluke 45 parts.

Chapter 7 Option -01 Battery Pack

7-1. Introduction

Introduces the Battery Kit as a field-installable option for portable operation.

7-2. Specifications

Lists specifications for the Battery Kit, including cell type and charge time.

7-3. Theory of Operation

Explains the fundamental principles behind the Battery Pack Option's functionality.

7-4. Functional Block Description

Describes the five functional blocks of the Battery Pack Option PCA.

7-5. Switching Power Supply

Details the switching power supply's regulation and temperature compensation.

7-6. Cycle/Float Charge Rate Switch

Explains how the switch monitors and adjusts charging voltage based on battery current.

7-7. Low Battery Indicator Detector

Describes the comparator circuit that monitors battery voltage for the indicator.

7-8. Low Battery Disconnect

Explains the FET switch circuit that prevents deep battery discharge.

7-9. Constant Voltage Trickle Charger

Details the trickle charger circuit that maintains battery charge on line power.

7-10. Other Circuits

Describes other circuits within the battery pack option, like diodes and fuse.

7-11. General Maintenance

Guidance for maintaining the Battery Pack Option.

7-12. Removal

Step-by-step procedure for removing the Battery Pack Option from the meter.

7-13. Installation

Step-by-step procedure for installing the Battery Kit Option into the meter.

7-14. Performance Testing

Outlines procedures to verify the proper performance of the Battery Pack Option.

7-15. General Operability

Basic tests to verify the general functionality of the Battery Pack Option.

7-16. Low Battery Indicator Detector and Low Battery Disconnect Test

Specific tests for the low battery indicator and disconnect circuits.

7-17. Cycle/Float Charge Rate Switch Test

Procedure to verify the operation of the Cycle/Float Charge Rate Switch.

7-18. Calibration

Describes how to adjust the Battery Pack Option's controls for optimal performance.

7-19. Troubleshooting

Provides guidance and procedures for troubleshooting the Battery Pack Option.

7-20. Additional Tests

Mentions that performance tests can also be used for fault isolation.

7-21. Schematic Diagram

Refers to Chapter 9 for the schematic diagram of the Battery Pack Option.

7-22. List of Replaceable Parts

Directs users to illustrations and tables for replaceable parts of the option.

Chapter 8 Option -05 IEEE-488 Interface

8-1. Introduction

Introduces the IEEE-488 Interface Option for programmable instrument use.

8-2. Theory of Operation

Explains the fundamental principles of the IEEE-488 interface standard.

8-3. Functional Block Description

Describes the functional blocks implementing the IEEE-488 standard.

8-4. Detailed Circuit Description

Details the circuits comprising the IEEE-488 Assembly.

8-5. Main Assembly Connectors

Explains the interface via ribbon cables to the Main Assembly.

8-6. Address Decoding Circuit

Describes how the circuit decodes memory cycles for the IEEE-488 Controller.

8-7. Isolation Circuits

Details circuits that allow the Microprocessor to turn off power to the IEEE-488 components.

8-8. IEEE-488 Controller

Explains the integrated circuit that manages IEEE-488 bus transactions.

8-9. IEEE-488 Transceivers/Connector

Describes the transceivers and connector for proper electrical characteristics.

8-10. General Maintenance

Guidance for maintaining the IEEE-488 Interface Option.

8-11. Removing the IEEE-488 Interface Option

Step-by-step procedure for removing the IEEE-488 Interface Option.

8-12. Installing the IEEE-488 Interface Option

Step-by-step procedure for installing the IEEE-488 Interface Option.

8-13. Performance Testing

Outlines performance tests to verify IEEE-488 Interface operation.

8-14. Troubleshooting

Provides guidance for troubleshooting common problems with the IEEE-488 Interface.

8-15. Power-up Problems

Identifies probable fault areas causing power-up failure when the option is installed.

8-16. Communication Problems

Addresses issues related to communication between the meter and IEEE-488 controller.

8-17. Failure to Select IEEE-488 Interface Option

Discusses reasons why the option might not be selectable.

8-18. Failure to Handshake on IEEE-488 Bus

Details troubleshooting steps for handshake failures on the IEEE-488 bus.

8-19. Failure to Enter Remote

Steps to check the remote/local control circuit operation.

8-20. Failure to Receive Multiple Character Commands

Troubleshooting guide for issues receiving commands from the bus.

8-21. Failure to Transmit Query Responses

Troubleshooting guide for issues transmitting query responses.

8-22. Failure to Generate an End or Identify (EOI)

Checks for correct EOI signal generation during message termination.

8-23. Failure to Generate a Service Request (SRQ)

Troubleshooting for SRQ generation issues.

8-24. Schematic Diagram

Refers to Chapter 9 for the schematic diagram of the IEEE-488 Interface Option.

8-25. List of Replaceable Parts

Directs users to illustrations and tables for replaceable parts of the option.

Chapter 9 Schematic Diagrams

9-1 A1 Main PCA

Provides the schematic diagram for the A1 Main PCA.

9-2 A2 Display PCA

Provides the schematic diagram for the A2 Display PCA.

9-3 A1A1 True Rms PCA

Provides the schematic diagram for the A1A1 True Rms PCA.

9-4 A4 Battery PCA

Provides the schematic diagram for the A4 Battery PCA.

9-5 A5 IEEE-488 Interface PCA

Provides the schematic diagram for the A5 IEEE-488 Interface PCA.

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