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1. Ohms Function Performance Verification Diode Test Performance Verification sese Calibration Adjustment Calibration Preparation DC Voltage Connection e AC Voltage Calibration esee nennen Troubleshootiig eon eter Power UD Self eren teer iege Overall System Check DC Voltage Signal Fault Diagnosis 3 1 27 Service Manual 3 2 Maintenance 3 Introduction A A Warning To avoid electric shock or personal injury Do not perform any servicing other than operator maintenance unless you are qualified to do so These service instructions are for used by qualified personnel only e Do not allow water to get inside case e Remove any input signals prior to removing test leads and opening case e When servicing the meter use only specified replacement parts Make sure the battery door is closed and latched before you operate the meter prevent arc blast and resulting injury install only specified replacement fuses with the speed amperage interrupt rating and voltage rating listed in Fuse Replacement section 3 1 Introduction This chapter presents instructions for disassembly performance tests calibration adjustment and tr
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3. I ITI OI ETT ats v Dan T 9 NMOG 44O SWHO ovwo OWA 40 440 NOILISOd SNOILOSNNOO HOLIMS AHVILOMN 430GLS FLUKE 27 1001 MS 0 5120 MOOT LOOYNT LOOPNT a Ore NONWNOO A001 0 Tso 20 6a 62 940015 906 STO savar NOTAAL AOOLT 465 1 5270 vo AOOLT TZ 4 45 1 52 0 2 Cins s Okr aavog SANVOYO IN SANVITIIN sr Sr WNS 8 Oer WAS T AOE SAY TAN ZHAOT OWAOOOT aut MM 220 ot 3S 00 0Z UNS Oe LSHL SWHO SLIOA 101 Figure 5 1 1 Main cont 5 4 Schematic Diagrams 5 2 pi 20 E 2
4. 0805 942529 8 448 SOCKET 1 ROW PWB 0 100 CTR 18 POS 707026 1 LS 1 AF 5 7 24 602490 1 R 42 46 48 49 RES CERM 100K 1 063W 100PPM 643863 12 51 54 57 R 58 RES CERM 10K 1 063W 100PPM 605052 1 R 61 62 RES CERMET 3 32M 1 0 1W 400PPM 943639 2 02 16 MICROCOMPUTER 2095002 1 Y2 CRYSTAL 32 768KHZ 30 105PPM 7PF CLIP 1627036 1 An 5 column indicates a static sensitive part R58 52 1 C53 R490 R53 o R63 t R610 1 55 R62 R480 0 852 R470 C3 R51 R460 O R50 R59 R60 R57 Fluke 27 4004 aac13f eps Figure 4 4 A4 Digital PCA Chapter 5 Schematic Diagrams 5 1 27 Service Manual 5 2 Schematic Diagrams 5 Figure 5 1 A1 Main PCA Fluke 27 4001 08 27 Service Manual L S I II 0 L 9 S 5 0 ZT s dee
5. H1 H8 2PL MP4 MP7 1 2PL 1 TES MP5 MP2 E MP6 3PL 53 Button Up Subsection 04 Figure 3 2 Disassembly Most maintenance procedures require at least partial instrument disassembly The following procedure illustrated in Figure 3 2 provides complete step by step disassembly instructions to gain access to any assembly Complete disassembly 15 not required to gain access to most assemblies the following procedure contains notes that explain which maintenance procedures are possible at various levels of disassembly 1 Turn the function switch to the upper OFF position 2 Lift the tilt bail up about 1 inch up from the back of the instrument then gently pull out the ends of the tilt bail and remove it 3 Remove the four Pozidriv machine screws H6 that hold the battery cover MP14 to the bottom case then lift the battery cover and battery spacer out of the instrument Disconnect and remove the battery Unsnap the battery spacer from the battery cover 3 8 Maintenance 3 General Maintenance Information 10 11 12 13 14 15 16 Remove the old O ring MP15 Clean the O ring surfaces of the battery cover and the instrument case Install the battery holder on the battery cover then install the new O ring Remove the four Pozidriv screws H7 and rubber washers from the bottom case Lift the bottom case off the inst
6. by their connectors e Wear static ground straps e Use conductive foam to store components e Remove all plastic vinyl and Styrofoam from the work area e Use a grounded temperature regulated soldering iron Disassembly A A Warning To avoid the possibility of electric shock remove the test leads prior to disassembly A Caution Opening the instrument case in damp humid environments followed by moving the instrument to a cooler environment could cause condensation inside the case Instrument performance may be adversely affected by condensation A Caution To avoid contaminating the pcas with oil from the hands or O ring lubricant handle the pcas by the edges or wear gloves If does become contaminated refer to the cleaning instructions given later in this chapter Do not allow the LCD to come in contact with moisture Note Disassembly requires a number 2 Pozidriv screwdriver for all exterior screws and a number I Phillips head screwdriver for all interior screws Reassembly requires silicone lubricant Parker Super O Lube is recommended and new seals A Fluke seal kit Model 8025 A 7401 Fluke Part Number 738112 provides a complete set of seals and four replacement screws and washers for the bottom case A 2 oz tube of Parker Super O Lube can be obtained from the Fluke Corporation by ordering p n 812230 3 7 27 Service Manual Top Case Digital Main Board PCB Subsection Subsection MP17
7. 1 A2 A4 BT 1 Description MAIN PCA DIGITAL PCA SN below 8469001 DIGITAL PCA SN 8469001 and above BATTERY 9 V 0 15 MA FUSE F44 100A 1000 VAC DC FUSE 11 A 1000 VAC DC WASHER FLAT TEFLON 0 295 10 0 020 THK SCREW FIH P THD FORM STL 4 20 3 000 SCREW PH P SEMS STL 4 40 312 SCREW PH P THD FORM STL 4 14 375 SCREW PH P STL 4 40 250 SCREW PH PO STL 6 32 375 SCREW PH PO STL 6 20 1 256 SCREW PH P LOCK STL 4 40 1 000 WASHER FLAT STL 125 312 030 CASE TOP FLUKE 27 KNOB SWITCH YEL BOTTOM SHIELD ASSEMBLY O RING SYN RUBBER 114 ID 070 WIDE SPRING DETENT RING RET EXT FLAT STL 188 DIA DECAL TOP CASE FLUKE 27 SUPPORT TOP SHIELD SHIELD TOP CASE BOTTOM YEL FOOT CASE BAIL TILT YEL O RING SYN RUBBER 6 710 080 COVER BATTERY YEL O RING SYN RUBBER 1 612 1D 103 WIDE SPACER BATTERY YELLOW SHAFT SWITCH SUPPORT LCD INTERCONNECT MASK LCD FLUKE 27 CONN ELASTOMERIC LCD TO PWB 1 970 L DECAL MSHA APPROVAL FLUKE 27 TEST LEADS DECAL YEL WARNING ALLIGATOR CLIP BLACK ALLIGATOR CLIP RED COVER FUSE SWITCH MOMENTARY 27 USERS MANUAL 27 SERVICE MANUAL LCD 3 75 DIGIT BAR GRAPH MULTIPLEXED Fluke Stock Number 665007 665067 2096549 696534 943121 803293 696591 682310 721670 448456 129890 682070 733394 157008 739912 744508 2094238 654079 705947 654046 697078 2094094 654038 654384 203091 654335 744474 654392 670585 697185 665023 655894 683664 665034 682500 8098
8. 15 Verify that the UUT indicates between 2 696 and 2 704 V dc 16 Program the DMM Calibrator for an output of 27 V dc 17 Verify that the UUT indicates between 26 96 and 27 04 V dc 18 Program the DMM Calibrator output to 250 V dc 19 Verify that the UUT indicates between 249 6 and 250 4 V dc 20 Program the DMM Calibrator for an output of 1000 V dc 2 Verify that the UUT indicates between 998 and 1002 V dc 22 Switch off the DMM Calibrator Disconnect the Calibrator from the UUT AC and DC Current Performance Verification The following procedure may be used to test the ac and dc current functions and to verify current measurement accuracy 1 Turn the UUT function switch to the ac mA A position mA A 2 Connect the DMM Calibrator output to UUT mA HA input terminal 3 Switch on power to the DMM Calibrator and program the DMM Calibrator output for 27 mA at 50 Hz 4 Verify that the UUT indicates between 26 58 and 27 42 mA Program the DMM Calibrator output for 200 mA at 50 Hz 3 13 27 Service Manual 3 14 3 16 10 11 12 13 14 15 16 17 18 19 20 Program DMM Calibrator output for 2700 dc Set the UUT to the dc pA 21 22 23 Verify that the UUT indicates between 196 8 and 203 2 mA Program the DMM Calibrator output for zero amps Switch the UUT to the ac yA function uA then program the DMM Calibrator output for 2000 yA at 500 Hz Verify t
9. 20 50V Z5U 733386 4 C 34 CAP POLYES 1000 PF 20 1000V 668959 1 35 CAP POLYCA 1000 PF 20 100 V 721472 1 C 38 39 CAP POLYES O I UF 10 50 V 649913 2 C 41 42 CAP CER 10 PF 20 50V COG 721589 2 C 43 220 PF 20 50 740654 1 C 48 CAP POLYCA 0 033 UF 5 63 V 733451 1 C 49 CAP R05 CAP POLYES 0 022UF 10 50V 715268 1 C 51 0 01 UF 10 100 V X7R 557587 1 CR 1 4 DIODE 1N 4007 A52R DIODE SI 1KV 1A DO 41 707075 4 CR005 DIODE RL 1N4007R05A DIODE SI 1KV 1A DO 41 887203 1 CR6 DIODE SI BV 35 V LOW LEAKAGE 723817 1 CR 7 DIODE SI BV 75 0 V RADIAL INSERTED 659516 L 1 RF COIL ASSEMBLY 857792 1 MP 1 SHIELD FENCE 722280 1 MP 8 SUPPORT PCA 656108 1 P 1 CONNECTOR 18 707646 1 Q1 2 11 TRANSISTOR SI NPN SELECTED 92 685404 3 Q 12 TRANSISTOR SI N JFET TO 92 RAD T amp R 721936 1 Q 13 TRANSISTOR SI N JFET TO 92 723734 1 Q 15 TRANSISTOR SI PNP T092 698233 1 R 1 76 4 01 R NET CERM SIP HI V PROTECT 103454 1 R2 RES A52R RES WW 3 5K 596 5W 20PPM 107695 1 R3 RES MF 301 1 0 125 100 PPM 655274 1 R4 RES MF 332 K 1 0 125 W 100 PPM 655217 1 R 6 25 33 41 RES CF 100 K 5 0 25 658963 4 R7 RES VAR CERM 1K 20 0 3 W 706655 1 R9 RES A52R RES MF 402K 0 1 0 5W 100PPM 689638 1 R10 RES MF 44 8 K 0 1 0 125 W 100 PPM 714311 1 12 RES MF 14 3 K 1 0 125 W 100 PPM 721803 1 R 13 RES CF 1 5
10. 5 0 25 649962 1 14 RES MF 500 0 25 0 25 W 100 PPM 697557 1 15 RES MF 107 1 0 125 W 50 PPM 1 An indicates a static sensitive part 714295 4 8 Reference Designator R 16 28 29 R 18 R 19 20 R 23 R 26 R 27 R 30 31 32 R35 R 36 R 37 R 38 R 39 Table 4 2 A1 Main PCA cont Description RES CF 1 M 5 0 25 W RES MF 412 K 1 0 125 W 50 PPM RES VAR CERM 100 K 20 0 3 RES WW 4 995 25 4 RES WW 005 5 5 RES MF 499 K 1 0 125 W 100 PPM RES MF I 5 M 1 0 125 W 100 PPM RES MF 20 K 0 25 0 125 W 50 PPM RES MF 22 6 K 0 25 0 125 W 50PPM RES CF 4 7 K 5 0 25 W RES CF 47 K 5 0 25 W RES MF 5 49 K 1 0 125 W 100 PPM RES CF 1 5 5 0 25 W RES CF 300 K 5 0 25 W RES CF 200 K 5 0 25 W VARISTOR 430 V 10 1 MA THERMISTOR RECT POS 1K 40 25 C SWITCH ROTARY UPPER SWITCH ROTARY LOWER 52 4015 8025 AP25 CHIP ASSEMBLY TESTED DIODE SI RECT BRIDGE BV 50 V 10 1A C 1 23 V 60 PPM TC BAND GAP REFERENCE FLUKE 27 4501 WIRE MILLIAMP JUMPER1 600 VOLT FUSE CONTACT CONTACT 600 V FUSE FLUKE 27 4401 CONNECTOR BATTERY ASSY CRYSTAL 32 768 KHZ 1 3 X 8 MM OHMS INPUT RES NET ASSY TESTED JF25 An indicates a static sensitive part List of Replaceable Parts Fluke Stock Number 649970 714287 658989 658948 655423 714980 714998 715029 715011 721571 721787 721795 732800 732818 681841 706 amp 38
11. 6 0 O This tests Fl 44 100 A 1000 V If either of the above display indications is OL overload replace the appropriate fuse 3 6 Fuse Replacement Referring to Figure 3 1 use the following procedure to check or replace the Fluke 27 fuses l 2 3 Item HA Perform steps 1 through 4 of the battery replacement procedure Pull the fuse cover down then out of the meter Remove the defective fuse or check continuity through the suspected fuse and if necessary install a new fuse of the same size and rating Snap the fuse cover back into place Reinstall the battery cover as instructed in step 6 of the battery spacer replacement procedure Table 3 2 Replacement Fuses Description Fluke Part Number Quantity Fuse 44 100 1000 VAC DC 943121 1 FA Fuse 11 A 1000 VAC DC 803293 1 ATo ensure safety use exact replacement only Maintenance 3 General Maintenance Information 3 7 General Maintenance Information 3 8 Handling Precautions for Static Sensitive Devices Caution This unit contains CMOS components which can be damaged by static discharge Static sensitive components include U1 the custom analog U2 microcomputer and op amp To prevent static discharge damage take the following precautions when servicing the instrument Perform all work at a static free work station e Do not handle components or pca printed circuit assembly
12. BG26 038 50 BG27 BG28 J8 7 36 25 048 51 BG29 BG30 R3 59 MAX J8 gt 8 35 015 MIN 15 ie RA 60 A 78 ACH 2 VDD 12 50V 8 GND 22 54 J8 GND e H3 53 13 50 0 22 J8 gt 16 e 55 J8 gt 11 FLUKE 27 1002 aaci2f eps 5 6 Figure 5 2 A2 Digital PCA Schematic Diagrams 5 C5300 R58 E3 6527 R490 c3 R53 R63 Yl ES R61 1 55 86207 R60 R480 C3 R52 R470 C R51 R460 C1 R50 TP TPI 857 Figure 5 3 A4 Digital Fluke 27 4004 Aac13eps 5 7 27 Service Manual en SISVL NOISIASH N 1 aavoa 44S 1 st 19 bt 1 3001 3001 MOOT er gt 20 ocu iL 22 avoron awoton 2 2 d5Hd 9 6 8 Ss BERNER e aaa 9 932988 t oaaa yy 1 5 zu TH 888 8800 04980 Y os t sa 95260024
13. HON NT ge 11995 22585 261225 E 9 8 ATO oton 9 ex 3 al 91DaS zoas 56 25 i5 en az 9E SIUS VZONS 9725 08 moor 95 88 ES Ta zada EH qe troas 22945 Lt 192 0794 z z z z THdHd 054 toas 92645 88 725 92 DE 21995 LZ98S 6t 525 zanz gal aE Ta9ga BD umn t de 2 TIDAS 82948 0v 622 ls 8n ae de 01945 62939 IY 055 5t o 68945 9 8 29 1122 tasaa oe Fez 8945 IED3S Ev 225 casad oocad 82 as ZEDHS v 265 ener oa LE uv 49 LZ 9945 EDHS SP PEG 9 A 92 Sous VEDHS 95 cesyg ra ST poas S 9HS Ly 4 PZ T549 Sy 9ES MTON S 06 MET SN EZ 538 zasad al RE cada y oc hz SnI elf 4 06 locs 1als z va MOL ZV 16 6 MOL 3001 aud yeg 9 3 1axin ATOL LNOX 91 TST 9 Ir va 1axun zn NIX j A IV 29 8 A 28894 ze A cou 899406 45 2 521 L 95 1 4 64 88 1 ari
14. LCD segments are functioning Maintenance 3 Performance Tests 3 14 3 15 Voltage Functions Performance Verification The following procedure may be used to verify proper operation and calibration of the ac and voltage measurement functions Required test equipment is listed in Table 3 1 Caution Connect the common terminal of the Digital Multimeter Calibrator to the COM terminal on the UUT 1 Verify that both the Digital Multimeter Calibrator hereafter referred to as the DMM Calibrator and the UUT are off 2 Connect the UUT using the volts ohms diode test input terminal to the ac output connections of the DMM Calibrator 3 Turn the function switch on the UUT to the ac voltage position V Switch on power to the DMM Calibrator and program it for an output of 2 7 V ac at 100 Hz 5 Verify that the UUT indicates between 2 684 and 2 716 V ac 6 Program the DMM Calibrator for an output of 27 V ac at 10 kHz 7 Verify that the UUT indicates between 26 43 and 27 57 V ac 8 Program the DMM Calibrator output for 250 V ac at 10 kHz 9 Verify that the UUT indicates between 244 7 and 255 3 V ac 10 Program the DMM Calibrator for an output of 1000 V ac at 10 kHz 11 Verify that the UUT indicates between 967 and 1033 V ac 12 Program the DMM Calibrator for an output of zero volts 13 Turn the UUT function switch to the dc voltage position V 14 Program the DMM Calibrator output for 2 7 V dc
15. of each part and its reference designator The parts lists give the following information e Reference designator e An indication if the part is subject to damage by static e Description e Fluke stock number e Total quantity e special notes 1 factory selected part Caution A symbol indicates a device that may be damaged by static discharge How to Obtain Parts Electrical components may be ordered directly from the manufacturer by using the manufacturers part number or from the Fluke Corporation and its authorized representatives by using the part number under the heading FLUKE STOCK NO In the U S order directly from the Fluke Parts Dept by calling 1 800 526 4731 Parts price information is available from the Fluke Corporation or its representatives Prices are also available in a Fluke Replacement Parts Catalog which is available on request In the event that the part ordered has been replaced by a new or improved part the replacement will be accompanied by an explanatory note and installation instructions 1f necessary To ensure prompt delivery of the correct part include the following information when you place an order e Instrument model and serial number number and revision level of the pca containing the part e Reference designator e Fluke stock number e Description as given under the DESCRIPTION heading e Quantity Manual Status Information The Manual Status Information tabl
16. output for 2 700 V dc 4 Adjust potentiometer R19 on UUT for a display indication of 2 700 V on the 3 V range 5 Program the DMM Calibrator for zero output and disconnect the Calibrator from UUT 8 C4 320 V AC Range ibi Volts C10 1000 V AC Range 2 Range 6 3 2 Range at 10 kHz 2v AC Range 06 Figure 3 3 Calibration Adjustment Locations 3 21 AC Voltage Calibration There is a single ac to dc converter adjustment for basic ac voltage accuracy However each ac voltage range must be calibrated independently for high frequency accuracy Variable capacitors provide these high frequency adjustments There should be no interaction between the various ranges when adjustments are made in the specified order Use the following procedure to calibrate the ac voltage ranges Maintenance 3 Troubleshooting A AWarning The following procedure requires that high voltages be supplied to the UUT for calibration Read the safety precautions in the Fluke 27 Users Manual be
17. position it at the beginning of the tapered area Place the bottom case on the top case then start four new thread forming screws H7 with rubber washers The new screws and washers are provided in the seal kit Press the case halves firmly together and using a number 2 Pozidriv screwdriver tighten the screws in a diagonal pattern lower right upper left upper right lower left to ensure a proper seal 27 Service Manual 3 11 18 If the battery compartment O ring MP15 was not replaced during disassembly it should be replaced before reassembly Use the procedure given in step 5 of the disassembly procedure 19 Connect the battery to the battery terminal connector then slide the battery into the battery compartment 20 Slide the battery spacer cover assembly into the back of the instrument 21 Start the four screws H6 that secure the battery cover Press firmly on the battery cover while tightening the screws in a diagonal pattern using a number 2 Pozidriv screwdriver 22 Move the rotary switch knob from OFF to any function All segments of the LCD should illuminate briefly if the instrument has been properly assembled Cleaning Caution Do not use aromatic hydrocarbons or chlorinated solvents for cleaning These solutions will react with the plastic materials used in the instrument Caution Do not allow the LCD to come in contact with moisture Clean the exterior plastic parts using a mild solu
18. to Table 3 4 and to the schematics in Chapter 5 of this manual as necessary during the following troubleshooting procedures Power Up Self Test When the function switch is moved to any position from the OFF position the instrument performs a power on self test All LCD segments are switched on while the test is being performed about 1 second then the unit commences normal operation Overall System Check If the LCD display segments do not light or if other malfunction indications occur during power up or operation perform the following overall system check All measurements are taken with respect to common The overall system check is helpful in 3 17 27 Service Manual 3 25 isolating malfunction to the component area and Table 3 4 provides further fault Isolation within the component area Refer to the disassembly and reassembly procedures as necessary paragraphs 3 9 and 3 10 1 Set up the instrument as follows a Perform steps 1 through 10 of the disassembly procedure to remove the battery cover bottom case and main pca shield assembly from the instrument b Perform steps 21 through 23 of the disassembly procedure to remove the top and bottom shields from the main pca Perform step 14 of the reassembly procedure to install the main in the top case d Perform step 15 of the reassembly procedure to secure the main pca to the input terminals 2 Select the de voltage function V Use a
19. 5 3 5 AOS ZHOOT 202 XL v DWAL Z A i 2 adozz SEN on AOS QE ag 265 179 o la sta AE9 01 5202 9 Feo 120 263 a 2s 610 y at 280 518 46 S bee m Pom om Lea 5 aga 0 5565 L ES sott sort 4 4 290 ufo Bee 02 L Sp ozo era 919 x x la NE vt 3 Ek 3 gt ou gt gt o gt A OH o o o bs von NO a z gt Safer lt a INM 2 A HOLVHOSINI HELUZANOD lt a SAIIOV ov GA e sz amp r 89 Isal ss o yoor HQ aux DA ZE 79 ama 37 x15 e SH TA E 3 o 5 t 55545 lt tuaa 8888 B S o B N 5556 n 2242725 ls mum SRESS Ae 1 108 2 Aos 5 4466 I19L101 d 052 e A6 1 ES LOOPNT sad FLUKE 27 1001 111 Figu
20. 602995 654301 654319 700112 418582 654707 665049 707190 659524 670577 643031 616938 Parts Lists Total 22XNNNAaa a 424 9 ld aa yd dl oa dd 4 4 4 9 27 Service Manual Fluke 27 4001 08 Figure 4 2 1 Main Table 4 3 A2 Digital PCA List of Replaceable Parts Parts Lists Reference Description Fluke Stock Number Total Designator Qty 12 13 44 47 CAP CER 0 22 UF 80 20 50 V Z5U 733386 6 J8 SOCKET 1 ROW PWB 0 100 CTR 18 POS 707026 1 LS 1 TRANSD PIEZO 24 602490 1 02 E 5 4 685628 1 5 column indicates static sensitive part Figure 4 3 A2 Digital PCA Fluke 27 4002 aacO9f eps 4 27 Service Manual Table 4 4 A4 Digital PCA Reference Description Fluke Stock Number Total Designator Qty C 52 59 0 1 UF 10 25 7
21. 71 855742 744607 738047 738120 665031 2094100 690203 690206 654293 Total Qty dl dd Y dl dl 10385830 534110 dl Ba Top Case Digital PCA Subsection MP2 2PL NS Button Up Subsection Figure 4 1 Final Assembly Main Board Subsection List of Replaceable Parts Parts Lists FLUKE 27 T amp B aac07f eps 4 4 7 27 Service Manual Table 4 2 A1 Main PCA Reference Description Fluke Stock Total Designator Number Qty A3 FUSE PCA 665015 1 1 1 LOW POWER 721928 1 C3 CAP POLYES 0 022 UF 10 1000 V 448183 1 C 4 10 CAP VAR 0 25 1 5 PF 1700 TEFLON 721480 2 6 2 7 100 V CER 714600 1 7 430 PF 5 50 V COG 732644 1 CAP VAR 6 50PF 50 V CER 714618 1 9 5100 PF 2 50 V COG 732651 1 C11 CAP POLYCA 0 027 UF 5 63 V 733444 1 C14 CAP 714550 1 C15 CAP 740654 1 C 16 CAP TA IOUF 20 10 V 714766 1 C 17 50 CAP CER 33 PF 5 50 V COG 714543 2 C 18 19 0 027 UF 10 63 720979 2 C 20 CAP POLYES 0 47 UF 10 50 V 697409 1 C 21 CAP POLYPR 0 033 UF 10 63 V 721050 1 C 22 36 CAP POLYES 0 01 UF 10 50 V 715037 2 C 23 37 CAP TA 22 UF 20 10 V 658971 2 C 30 CAP CER 4 0 PF 0 25 PF 1500 V COJ 714535 1 31 33 40 0 22 UF 80
22. Digital Voltmeter DVM to check the battery voltage at the battery connector battery voltage must be above 6 3 V If battery voltage 15 less than 7 5 V battery replacement is advised Normal current drain is less than 600 uA 4 Connect either an oscilloscope or frequency counter using low capacitance probe to pin 54 of Ul or to the junction of C17 and 1 the crystal A 32 768 kHz sine wave with an amplitude of approximately 600 mV peak to peak should be present at the junction of C17 and 1 3 peak to peak at 01 pin 54 Note that U2 and the display will not operate 1f the clock signal 15 not present If the clock signal 1s not present the most likely causes are Ul or C17 5 Use a DVM to check for a reference voltage of 1 00V dc adjustable through 1 9 at pin 13 of Ul or at the junction of R15 and R18 If the reference voltage is not present the most likely causes are VR1 R12 R15 R18 R19 R37 or U1 6 Use a DVM to check for Vm voltage middle at pin 55 of U2 pin 16 of 18 or at the junction of R3 and R4 Vm should be 1 6 V de 0 1 V If Vm is not present the most likely causes are R3 R4 or C13 DC Voltage Signal Tracing The following procedure is a step by step method of tracing a dc voltage input through the instrument s circuits to the output of the active filter Faulty components in the input signal path can be identified using this procedure All measurements are taken with respect to common 1 Se
23. FLUKE 27 Multimeter Service Manual For IEC 61010 CAT Meters Only PN 690206 November 1998 Rev 1 9 03 1998 2003 Fluke Corporation All rights reserved Printed in U S A All product names are trademarks of their respective companies Table of Contents Chapter Title 1 Introduction and 1 1 Using the Meter 1 2 Operating Instructions 1 3 Specifications LE 2 Theory of Operation 2 n 2 1 Introducir P 2 2 Functional Description 2 3 Block Diagram Description 2 4 Input Overload Protection eere 2 5 Function Switching Circuits eere 2 6 Signal Conditioning 2 1 Custom Analog IC 01 2 8 Perrpherals to U b edi rentre 2 9 Microcomputer Control 2 10 Display M 3 Malntenande cra o 3 1 Introduction o neret EP aan 3 2 Service Information een 3 3 Operator Maintenance 3 4 Battery Replacement 3 5 A O 3 6 Fuse Replacement dd 3 7 General Maintenance Information esee 3 8 Handling Precautions for Static Sensitive Devices 3 0 115 AER 3 10 Reass mbly M oiiaaie 3 11 EE 3 12 Performance ee e
24. Operating Temperature Storage Temperature 15 to 55 C to 40 C for 20 minutes when taken from 20 55 C to 85 C without battery to 60 C with battery Electromagnetic Compatibility In an RF field of 2 V m on all ranges and functions except mVac total accuracy specified accuracy 1 0 or range For mVac total accuracy specified accuracy 1 5 or range EN 61326 1 1997 Temperature Coefficient Relative Humidity Altitude 0 1 x specified accuracy C 18 C or gt 28 C 0 to 95 0 C to 35 C 0 to 70 35 C to 55 C 2000 meters Battery Type Battery Life 9 V NEDA 1604 or 6F22 or 006P 1000 hrs typical Shock Vibration and Water Resistance Per MIL T 28800 for a Style A Class 2 Instrument Size HxWxL 2 2 in x 3 75 in x 8 in 5 6 cm x 9 5 cm x 20 3 cm Weight 1 6 pounds 0 75 kg Waterproof 1 meter Safety Complies with ANSI ISA S82 01 1994 CAN CSA 22 2 NO 1010 1 1992 to 1000 Overvoltage Category UL License pending to UL3111 1 License pending to EN61010 1 2 1 2 2 2 3 2 5 2 6 2 7 2 9 2 10 Chapter 2 Theory of Operation os m Functional Description eee eis Block Diagram Description Input Overload Protection Function Switching Circuits Signal Conditioning Circuits Custom Analog U1 Peripherals to eer t
25. United States Department of Labor Mine Safety and Health Administration MSHA for use in mines approval 2G 3665 0 To maintain MSHA permissibility repairs to these instruments must be made using parts exactly like those furnished by Fluke Corporation Any changes in the intrinsically safe circuitry or components may result in an unsafe condition The Fluke 27 multimeter was tested by the MSHA for intrinsic safety in methane air mixtures only The Fluke 27 multimeter 15 approved with a 9 V NEDA 1604 carbon zinc battery only Do not use to check electrical blasting circuits Do not connect to an electrically energized circuit in a hazardous area Maintenance 3 Operator Maintenance Battery Replacement A AWarning To avoid false readings which could lead to possible electric shock or personal injury replace the battery as soon as the battery indicator EM appears The Fluke 27 is powered by a single 9 V battery NEDA 1604 6F22 or 006P Referring to Figure 3 1 use the following procedure to replace the battery 1 2 Battery connector Turn the rotary switch to OFF and remove the test leads Lift the instrument stand on the back of the instrument then remove the four 6 X 32 Pozidriv screws from the battery cover Pull the battery cover straight out from the back of the instrument A coin slot in the side of the battery cover facilitates removal A A Warning To avoid electrical shock or personal injur
26. ach input value Maintenance Calibration Adjustment Table 3 3 Ohm Function Performance Test 3 17 Step Resistance Indication 1 1000 99 5 to 100 5 2 1 000 997 to 1 003 k 3 10 00 9 97 to 10 03 k 4 100 0 99 7 to 100 3 k 5 1MO 997 to 1 003 6 10MO 9 89 to 10 11 M 37 open circuit 00 10 to 0010 nS Note Conductance nS range must be entered using manual range selection Diode Test Performance Verification The following procedure may be used to verify proper operation of the diode test function This test can not be performed unless the source can sink 0 6 mA at 0 9 V 1 Turn the UUT function selection switch to the diode test function 2 The UUT should display OL 3 Connect the DMM Calibrator to the UUT volt ohms diode test input terminal and common and switch on Calibrator power 4 Program the DMM Calibrator output for 1 00 then push the Range Lock button on the Calibrator to place the Calibrator in the 3 3V range 5 Program the DMM Calibrator output for 0 090 V and verify that the UUT indicates approximately 0 090 V and the beeper is sounding continuous tone Increase the DMM Calibrator output to 0 11 V The beeper should turn off Increase the Calibrator output to 1 0V then slowly decrease the Calibrator output to 0 6 V Note that the UUT beeper produces a short beep as the voltage descends through 0 7 V typical silicon diode threshold 8 Push the DMM Cali
27. brator Range Lock button to return to Autorange operation 3 18 Calibration Adjustment 3 19 Under normal operating conditions the Fluke 27 should maintain its specifications for a period of one year after calibration If the instrument has been repaired or if it has failed any of the performance tests the following calibration adjustment procedures must be performed Use a non conductive tool for adjustments Note In the following procedures the Fluke 27 is referred to as the unit under test or UUT Calibration Preparation Allow the UUT to stabilize at an ambient temperature of 21 to 25 degrees Celsius 70 to 77 degrees Fahrenheit and at a relative humidity of less than 80 with the power off for at least 30 minutes before beginning calibration Calibration adjustments require removal of the bottom cover Complete steps 1 through 7 of the disassembly procedure given earlier in this chapter and then reconnect the battery to UUT s battery connector 3 15 27 Service Manual 3 20 DC Voltage Connection The voltage function must be calibrated before calibrating the other functions Use the following procedure to calibrate the de voltage function 1 Connect the DMM Calibrator to the UUT volts ohms diode test input terminal and common Refer to Figure 3 4 for calibration component locations 2 Select the de voltage function on UUT Switch on power to the DMM Calibrator and program the Calibrator
28. cations Instrument specifications are presented in Table 1 1 Table 1 1 Specifications Function Range Resolution Accuracy V 3 200 V 0 001 V 0 1 1 32 00 V 0 01 V 0 1 1 320 0 V 0 1V 0 1 1 1000 V 1V 0 1 1 mV 320 0 mV 0 1 0 196 1 320 00 010 0 3 3 3 200 0 001 0 2 1 0 32 00 0 01 0 2 1 nS 320 0 0 1 0 2 1 3 200 MO 0 001 MO 0 2 1 32 00 MO 0 01 MO 1 1 32 00 nS 0 01 nS 0 2 10 N 2 080 V 0 001 V 1 1 typical 40 Hz 2 kHz 2 kHz 10 kHz 10 kHz 30 kHz 3 200 V 0 001 V 0 5 3 2 3 496 10 32 00 0 01 V 0 5 3 2 3 4 10 320 0 V 0 1V 0 5 3 2 3 4 10 1000 V 1 196 3 3 3 Not Specified mv 320 0 mV 0 1 0 5 3 2 3 4 10 When using the REL A function to compensate for offsets Function Range Resolution Accuracy Typical Burden Voltage mark 32 00 mA 0 01 mA 0 75 2 5 6 mV mA 320 0 mA 0 1 mA 0 75 2 5 6 mV mA 10 00 A 0 01 A 0 75 2 50 mV A ee 320 0 uA 0 1 uA 0 75 2 0 5 mV uA 3200 A 1 0 75 2 0 5 mV uA 32 00 mA 0 01 mA 1 5 2 5 6 mV mA mA A 320 0 mA 0 1 mA 1 5 2 5 6 mV mA 40 1000 Hz 10 00 A 0 01 A 1 50 mV A 320 0 uA 0 1 uA 1 5 2 0 5 mV uA 40 1000 Hz 3200 yA 1 1 5 2 0 5 mV uA 1 5 27 Service Manual 1 6 Table 1 1 Specifications cont F
29. ce the pointer toward the center of the display while the rotary switch knob is in the upper OFF position To reassemble the main pca shield assembly fit the top shield MP9 over the component side of the pca taking care not to bend the connector pins Make sure the shield posts fit through the holes in the pca and verify that the rotary switch is in the upper OFF position Position the bottom shield MP3 on the back of the pca with the stand offs fitted through the pca then position the top shield on the top of the pca with the molded stand offs fitted through the pca Install the two Phillips head machine screws 8 and flat washers through the top shield into the bottom shield Install the three thread forming Phillips head screws H4 through the bottom shield into the top shield Carefully fit the main pca shield assembly into the top case taking care to ensure that the connector pins on the main pca are lined up properly with the connector on the digital pca and the switch shaft extension aligns with the two rotary switch wafers in the OFF position do not use force Engage the connector by pressing lightly on the bottom shield at the case screw holes Install the four Phillips head machine screws H3 with lock washers that secure the main pca shield assembly to the back of the input terminals again using a diagonal pattern Install a new O ring MP13 on the bottom case MP10 if it was not replaced during disassembly and
30. cost to the purchaser For in warranty service ship the instrument post paid to the Fluke Service Center nearest you A list of service centers 15 included at the back of this manual Fluke Service Centers are also available for calibration or repair Upon request a cost estimate will be provided before work is performed on instruments If reshipment is necessary please use the original shipping container If the original container is not available be sure that adequate protection is provided to prevent damage during shipment It 15 recommended that the instrument be surrounded by at least 3 inches of shock absorbing material in the shipping container To contact Fluke call one of the following telephone numbers USA 1 888 99 FLUKE 1 888 993 5853 Canada 1 800 36 FLUKE 1 800 363 5853 Europe 31 402 675 200 Japan 81 3 3434 0181 Singapore 65 738 5655 Anywhere in the world 1 425 356 5500 Or visit Fluke s Web site at www fluke com Register your product at register fluke com 3 3 Operator Maintenance 3 4 Note The Fluke 27 Multimeter has been designed to meet the requirements of the United States Department of Labor Mine Safety and Health Administration for use mines If your instrument has MSHA approval a decal stating so will be present on the bottom of your instrument The following Warning applies only if the decal is present A A Warning The Fluke 27 multimeter is approved permissible by the
31. d rtc bene 3 13 Display Rm 3 14 Voltage Functions Performance 3 15 AC and DC Current Performance Verification 3 16 Ohms Function Performance Verification esee i 27 Service Manual 3 17 Diode Test Performance Verification 3 18 Calibration 3 19 Calibration Preparation 3 20 DC Voltage Connection eere eret cess ette regen 3 21 AC Voltage Calibration 3 22 Trouble shootmg 2 erret eet tr o eene teer n e 3 23 Power Up Self Tetuan canalla 3 24 Overall System CHECK su ld 3 25 DC Voltage Signal Tracing 3 26 Fault Diagnosis Guide 4 List of Replaceable Parts coccion 4 1 o To iP 4 2 How to Obtain Parts ie ln 4 3 Manual Status 4 4 Newer Instruments ent 4 5 Service ci TO 4 6 Parts iii dni nilo pa 5 Schematic DisgraMS ici tai 5 1 Specifications List of Tables Recommended Test Equipment Replacement USES Ohm Function Performance Test Fault Diagnosis Final Assembly 1 Main PCA anh ree AZ Distal ue qr Digital POA iii 27 Service Manual Li
32. d two resistors in Z1 Several components external to U1 provide for ac to dc conversion they are C41 C42 C43 R35 R7 C16 R30 R31 and R32 The system clock with a frequency of 32 768 kHz controls all timing synchronization for the instrument Y1 is a quartz crystal which determines the frequency of the clock oscillator circuit Microcomputer Control A CMOS 4 bit microcomputer U2 controls the various instrument functions and drives the LCD display The microcomputer reads and processes data samples from the A D converter sends a code to U1 which represents the operator selected function performs the Touch Hold algorithm selects the correct A D mode for the function in used controls range sets the autozero flag and disables the analog filter during autoranging In reading and processing A D samples the computer accepts raw sample data applies necessary corrections as described in the preceding discussion of U1 and accumulates 10 samples which then become the full resolution conversion for digital display Each minor conversion is also processed for the bar graph display For the diode test and continuity function the microcomputer evaluates the data and determines whether or not the beeper should be switched on Touch Hold operation requires the microcomputer to perform a different algorithm The microcomputer does not allow a full resolution conversion to be completed unless the input signal is stable When a stable reading
33. e that precedes the parts list defines the assembly revision levels that are documented in the manual Revision levels are printed on the component side of each pca 4 3 27 Service Manual 4 4 4 4 4 5 Newer Instruments Changes and improvements made to the instrument are identified by incrementing the revision letter marked on the affected pca These changes are documented on a manual supplement which when applicable is included with the manual Service Centers To contact Fluke call one of the following telephone numbers USA 1 888 99 FLUKE 1 888 993 5853 Canada 1 800 36 FLUKE 1 800 363 5853 Europe 31 402 675 200 Japan 81 3 3434 0181 Singapore 65 738 5655 Anywhere in the world 1 425 356 5500 Or visit Fluke s Web site at www fluke com Note The Fluke 27 Multimeter has been designed to meet the requirements of the United States Department of Labor Mine Safety and Health Administration for use in mines If your instrument has MSHA approval a decal stating so will be present on the bottom of your instrument The following Warning applies only if the decal is present A AWarning The Fluke 27 multimeters are approved permissible by the United States Department of Labor Mine Safety and Health Administration MSHA for use in mines approval 2G 3665 0 To maintain MSHA permissibility repairs to this instrument must be made using parts exactly like those furnished by the Fluke Corporation A
34. easuring current check the meter s fuses see How to Test the Fuse Never touch the probe to a voltage source when the test leads are plugged into the 10 A or 40 mA input jacks To avoid false readings which could lead to possible electric shock or personal injury replace the meter s battery as soon as the low battery indicator EM appears Avoid working alone Remove all surface water from the product including water around within and under the rotary knob input receptacles and buttons prior to connecting to any voltages A Caution To avoid possible damage to the meter or to equipment under test e Disconnect the power to the circuit under test and discharge all high voltage capacitors before testing resistance continuity or diodes e Use the proper function and range for your measurement applications e When measuring current turn off circuit power before connecting the meter in the circuit Remember to place the meter in series with the current This manual presents service information for the Fluke 27 Multimeters Included are a theory of operation general maintenance procedures performance tests calibration procedures troubleshooting information a list of replaceable parts and a schematic diagram Operating Instructions For operating instructions refer to the Users Manual provided with the instrument at time of purchase Introduction and Specifications Specifications 1 1 3 Specifi
35. ete erbe Microcomputer essere 2 1 27 Service Manual 2 2 Theory of Operation 2 Introduction 2 1 Introduction This chapter describes how the Fluke 27 works First a functional description presents an overview of operation This is followed by a block diagram description which describes the major circuit functions in more detail For reference a detailed schematic diagram is included in Chapter 5 2 2 Functional Description A block diagram of the Fluke 27 circuitry 15 shown in Figure 2 1 As this figure shows the instrument is composed of two major functional sections the analog section and the digital section Each section contains one major active component and one or more peripheral circuits Most analog functions are performed by a custom analog IC U 1 and analog peripherals to Ul Digital functions are performed by a CMOS 4 bit microcomputer U2 The custom analog IC contains the A D converter signal conditioning circuits and the digital control circuitry required for communication with the microcomputer Although the custom IC 15 primarily analog digital circuits provide state machine control for the A D converter a read counter for A D samples decoding ROMs for analog switch drive and bus control for communication with the microcomputer The microcomputer controls the A D converter initiates the range and function sw
36. fore performing the following procedure 1 Select the ac voltage function on the UUT Connect the DMM Calibrator to the volts ohms diode test input terminal on the UUT 3 Program the DMM Calibrator output for 2 7 V ac at 100 Hz 4 Adjust R7 to obtain a display of 2 700 V 0 001 V 5 Program the DMM Calibrator output for 270 V at 10 kHz 6 Adjust C4 to obtain a display of 270 0V 40 1 V ac 7 Program the DMM Calibrator output for 1000 ac at 10 kHz 8 Adjust C10 to obtain a display of 1000 V ac 1 V ac 9 Program the DMM Calibrator output for 27 00 V ac at 10 kHz 10 Adjust C8 to obtain a display of 27 00 V 0 01 11 Program the DMM Calibrator output for 2 700 V ac at 10 kHz 12 Adjust to obtain a display of 2 700 ac 0 001 13 Program the DMM Calibrator output for 2 700 ac at 100 Hz 14 Verify that the UUT display indicates 2 700 V ac 0 017 V ac 15 Switch off both the DMM Calibrator and Disconnect the DMM Calibrator from the UUT 16 Refer to the instructions in paragraph 30 10 to reassemble the UUT after calibration 3 22 Troubleshooting 3 23 3 24 Caution Static discharge can damage CMOS components U1 and U2 Follow the handling precautions for static sensitive components given previously Never remove or install components without first disconnecting all inputs to the instrument and turning the function selector switch to OFF Refer
37. hat the indicates between 1968 and 2032 uA Program the DMM Calibrator to standby Connect the DMM Calibrator output to the UUT amp A and common COM input terminals Switch the UUT to the AC mA A function then program the DMM Calibrator output for 5 A at 1 kHz Verify that the UUT indicates between 4 91 and 5 09 A Program the DMM Calibrator to standby Set the UUT to the de function mA A Program the DMM Calibrator output for an output of 5 0 A dc Verify that the UUT indicates between 4 94 and 5 06 A Program the DMM Calibrator to standby Turn the function switch on the UUT to the de mA A position Connect the DMM Calibrator output to the UUT mA uA input terminal then program the DMM Calibrator for an output of 27 mA dc Verify that the UUT indicates between 26 78 and 27 22 mA function Program the DMM Calibrator for 2 7 mA Verify that the UUT indicates between 2678 and 2722 Ohms Function Performance Verification The following test may be used to verify correct ohms function operation and to verify UUT accuracy in the various ohms ranges 1 Connect the DMM Calibrator to the UUT using the volts ohms diode test input terminal and common Turn the function switch to the position Switch on power to the DMM Calibrator Program the DMM Calibrator to the resistance values indicated in Table 3 2 and verify that the UUT indication is within the tolerances given for e
38. iodes CR1 CR2 CR4 ensure that the fuses instead of shunts open in very high current overload conditions Transistors Q1 Q2 and Q1 provide additional overload protection for the millivolt and ohms functions If sufficient overload voltage is present the transistors turn on and connect that input to common through limiting resistors R2 and RT1 thereby protecting the circuitry in U1 A clamp circuit CR6 and Q15 connected to the volt ohms diode test input through Z1 and C3 provides similar protection for the volts ohms diode test input Function Switching Circuits Input signals are routed from the overload protection circuits to the function switch The function switch is a rotary switch with two double sided wafers which provide the necessary switching to select each of the various functions In addition battery voltage is routed through the function switch from the battery voltage regulator to U1 and from U1 to U2 Signal Conditioning Circuits Each input signal is routed through signal conditioning circuitry before reaching U1 Input signals received through the volts ohms diode test input J1 are routed through 71 a precision resistor network The resistor network provides precise input scaling for the various voltage ranges and it provides precision reference resistors for the ohms function The capacitors in parallel with the various resistors in Z1 are used in the ac voltage functions the variable capacitors pro
39. itching formats data for display and drives the display The mode push buttons supply input to the microcomputer to initiate various modes Output from the microcomputer is displayed on the liquid crystal display LCD ANALOG SECTION DIGITAL SECTION nos mes IA FUNCTION SWITCHING 02 DATA ADDRESS INPUT OVERLOAD PROTECTION LCD DISPLAY SIGNAL CONDITIONING J3 COM BATTERY VOLTAGE BATTERY VOLTAGE REGULATOR BATTERY VOLTAGE aac01s tif Figure 2 1 Overall Functional Block Diagram 2 3 Block Diagram Description Each of the blocks in the Figure 2 1 is discussed in the following paragraphs In many cases Circuit sections are described in greater detail than is shown in the Figure 2 1 27 Service Manual 2 4 therefore it may be helpful to refer to the schematic located near the back of this manual Input Overload Protection Overload protection for the volts ohms diode test input J1 is provided by a network of five metal oxide varistors RV1 through RV5 a current limiting resistor R2 and a thermistor A 44 1004 1000 V fuse provides protection for the mA uA input 12 current shunts An 1000 V fuse provides protection for the 10 A input 13 current shunt In addition for the and mA ranges a bridge rectifier U7 and four d
40. lect the dc voltage function V then apply 2 V de input through the volts ohms diode test input terminal 2 Using a DVM measure the 2 V input at the input terminal Check pin of the input divider Z 1 for 2 V dc If 2 V dc is not present R2 SI RV1 RV2 RV3 RVA or RV5 may be defective 4 Check pin 3 of Z1 for approximately 200 mV dc If 200 mV is not present either Z1 Ul may be defective Measurement may be approximately 10 low if a 10 input impedance DVM is being used for signal tracing 5 Check the active filter input pin 28 of U1 for approximately 200 mV dc If 200 mV is not present U1 may be defective Measurement may be affected by loading Maintenance Troubleshooting 3 6 Check the active filter output pin 29 of U1 for approximately 200 mV dc If 200 mV 15 not present R13 R16 C18 or C19 may defective Measurement may be affected by loading 3 26 Fault Diagnosis Guide Table 3 3 presents a fault diagnosis guide for the Fluke 27 The left column lists various malfunction The left column lists various malfunction symptoms The center column recommends actions to determine the exact problem The right column lists the components most likely to be defective Table 3 4 Fault Diagnosis Guide Symptom Recommended Action Possible Component Blank display Do system check given in paragraph 3 24 BT1 U1 U2 Y1 C13 Display reads zero in v
41. nce 3 General Maintenance Information 10 11 12 13 14 15 16 17 Note the small bump at the center of tone edge of the momentary switch 53 56 Place the momentary switch in the case with the bump toward the LCD display Place the digital pca in the top case with the connector toward the back of the instrument and at the top of the case Install the four lower Phillips head screws H5 that secure the digital pca over the momentary switch Note that the momentary switch provides a seal between the case and the digital pca Install the screws using a diagonal sequence 1 upper right then lower left then upper left then lower right Install the two thread forming Phillips head screws H2 above the connector that hold the top of the digital pca Install a new O ring MP4 on the rotary switch shaft if not previously installed then place the Teflon washer H1 on the rotary switch shaft then install the rotary switch knob in the front of the top case Lubricate the outer edges of the detent spring MP5 with a very thin layer of silicon lubricant then install the detent spring over the rotary switch shaft Detent spring orientation is not critical Install the E ring retainer MP6 on the rotary switch shaft Rotate the rotary switch to the upper OFF position Place the rotary switch extension shaft MP17 on the rotary switch shaft Note the small pointer on the base of the extension shaft Pla
42. nt all main components are accessible Reassembly Note Reassembly requires a number 2 Pozidriv screwdriver for all external screws a number 1 Phillips head screwdriver for all internal screws silicone lubricant Parker Super O Lube is recommended and new seals A Fluke seal kit Model 8025A 7401 Fluke Part Number 738112 provides a complete set of seals and four replacement screw and washers for the bottom case 2 oz tub of Parker Super O Lube can be obtained from the Fluke Corporation by ordering p n 812230 Reassembling the instrument is primarily a reversal of the disassembly procedure However some precautions are necessary to ensure proper sealing and to maintain water tight integrity Use the following procedure to reassemble the instrument Caution Do not touch the elastomeric LCD contact strips MP20 or contacts of the momentary switch S3 S6 with bare hands Wear gloves or remove the contact strips using clean pliers or tweezers Avoid contaminating the contact strips Position the LCD mask MP19 in the top case MP1 then place the LCD U3 in the LCD mask with the Fluke part number toward the top of the instrument pressing the LCD lightly to engage the spring action of the LCD mask Place the LCD interconnect support MP18 over the LCD then place the elastomeric connector strips MP20 at the top and bottom of the LCD interconnect support with the black connection strip against the LCD Maintena
43. ny changes in the intrinsically safe circuitry or components may result in an unsafe condition The Fluke 27 multimeter was tested by MSHA for intrinsic safety in methane air mixtures only The Fluke 27 multimeter is MSHA approved with a 9 V NEDA 1604 carbonzinc battery only Do not use to check electrical blasting circuits Do not connect to an electrically energized circuit in a hazardous area A AWarning To ensure safety when servicing use only specified parts Use exact repleacement parts where specified List of Replaceable Parts 4 Parts Lists 4 6 Parts Lists The following tables list the replaceable parts for the 27 Multimeter Parts are listed by assembly alphabetized by reference designator Each assembly is accompanied by an illustration showing the location of each part and its reference designator The parts lists give the following information e Reference designator e An indication if the part is subject to damage by static discharge e Description e Fluke stock number e Total quantity e Any special notes i e factory selected part A Caution A symbol indicates a device that may be damaged by static discharge Manual Status Information Ref Des Assembly Name Fluke Part No Revision Level Al Main PCA 665007 A A2 Digital PCA 665067 E SN and below A4 Digital PCA 2096549 003 above SN 4 5 27 Service Manual 4 6 Table 4 1 Final Assembly Reference Designator
44. o Zar 15 lezu orsa 88 55 Zso Sava OWL 88 554 1 lt Zimm 1se c6 65 i ad v6 1ISY TE lt WZE E N ZOU 30 01 I 1 fe j 58 854 e 070 970 u 2 VHSH SNIHSHNISNS ALHAVS tations AH ISAW SSONVHO M e e odo Zso T WHSW V NI 50 SI ATENASSVW IAWA SIHI v SIvHuV4 OHOIN NI SI WHONVLIIOVdVO TIY 72 SI HONVISISHS lt 5 55 1 2 aaci4f eps Figure 5 4 A4 Digital PCA cont 5 8
45. occurs the conversion is completed and the microcomputer generates the corresponding display and freezes it the microcomputer then waits for a change in the signal to exceed a certain threshold and then begins watching for a stable reading again There are two exceptions to this simple algorithm First open test lead indication does not allow a full resolution conversion to be completed either the microcomputer continues to wait for a stable signal which is outside the open test lead region Open test leads in voltage or current function result in low readings open test leads in resistance or diode test functions result in off scale Theory of Operation 2 Block Diagram Description 2 10 readings Second if the Touch Hold button is momentarily pressed at any time then the full resolution conversion is forced to complete in spite of input or test lead conditions The microcomputer also sets the required A D converter mode single mode is used in all voltage and current conversions but there are three ohms function A D converter modes a diode test mode and two power up test modes battery test and self test The microcomputer sends the proper code to Ul to select the required A D converter mode Following each group of 10 samples in normal operation the microcomputer sets the autozero flag Both manual and autoranging are controlled by the microcomputer The microcomputer loads a range register in Ul in conjunction with a mode de
46. olt dc Do do signal tracing in paragraph 3 25 1 21 01 51 Display hangs up in self test mode Do system check given in paragraph 3 24 R15 R18 R19 R12 R37 VR1 21 Ut C20 21 Display reads OL or 0 in 320 mA R9 R10 01 range Display reads 0 in 320 mA or 10A F1 F2 R9 R20 R14 ranges AC volts is inaccurate Check calibration R31 R32 R29 R30 320 mV range reads OL 011 01 AC volts measurement noisy at 1 R16 C18 C19 50 60 Hz Wrong annunciator displayed S1R U1 Volts inaccurate t Check calibration RV2 RV5 Ohms inaccurate 21 U1 Intermittent display Clean connectors and connector strips on Display Assembly LCD and pca Display reads constant offset in C18 C19 C20 shorted volts Ohms reads low or will not read OL 01 02 shorted or leaky Ohms reads random or alternates R2 RT1 between 3 19 27 Service Manual 3 20 Chapter 4 List of Replaceable Parts Title Introd HOD energie How to Obtain Parts Manual Status Information Newer Instruments Service CENTET S TT RE Parts Lists 4 1 27 Service Manual 4 2 4 1 List of Replaceable Parts 4 Introduction Introduction This chapter contains an illustrated list of replaceable parts for the Fluke 27 Multimeters Parts are listed by assembly alphabetized by reference designator Each assembly is ac companied by an illustration showing the location
47. oubleshooting The performance tests may be used as an acceptance test when the instrument is first received and can be used later as a preventive maintenance tool A l year calibration cycle is recommended to maintain the instrument s specifications In addition the seals should be replaced during servicing to maintain the environmental specifications stated in that manual A seal kit is available from the factory The seal kit Model 8025A 740 1 part number 738112 contains a complete set of seals and four replacement screws and washers for the bottom case The test equipment required for the performance tests and calibration adjustments is listed in Table 3 1 Test equipment with equivalent specifications may be used if the recommended models are unavailable Table 3 1 Recommended Test Equipment Instrument Type Required Characteristics Recommended Model Voltage Range 0 1000 V ac 05 Frequency Range 40 10 000 Hz 1 DMM Calibrator Voltage Range 0 1000 V dc Fluke Model 5500A Accuracy 05 Current Range 2 mA 5 Accuracy 2 Values 100 ohm 1 kilohm 10 kilohm 100 kilohm 1 megohm 10 megohm Accuracy 06 3 3 27 Service Manual 3 2 Service Information The Fluke 27 has a lifetime warranty upon shipment of the instrument to the original purchaser Conditions of the warranty are described on the registration card Malfunctions that occur within the limits the warranty will be corrected at no
48. pendent map In autorange the analog filter 15 disabled to increase the autoranging speed Peripheral components Q13 and C12 force the microcomputer to reset when the function switch is moved to OFF A voltage divider network R3 R4 and C13 supplies a mid level voltage to drive the multiplexed display Display The liquid crystal display LCD operates under direct control of the microcomputer Characters are generated by the computer and displayed on the LCD Both digital readings and an analog bar graph display are presented in conjunction with annunciators and decimal points Refer to the Fluke 27 Users Manual for a more detailed description of the display 2 7 27 Service Manual 2 8 ON Me E 02 UY UY UY UY UY UY UY UY WW 02 W UY UY UY 02 W C9 3 19 Chapter 3 Maintenance 5 554 1 2444 Service Information Operator Battery Replacement nennen A Fuse Replacement ad General Maintenance Information esee Handling Precautions for Static Sensitive Devices Disassembly INS Cni nassen einn Performance Tests kn Display Test E Voltage Functions Performance AC and DC Current Performance Verification
49. re 5 1 1 Main cont 5 5 27 Service Manual REFERENCE DESIGNATON NOT USED 1 11 14 43 11 7 51 2 01 Ly 9 2 7 yy FLUKE 27 4002 e d 53 54 55 56 92 U3 9 9 RANGE REL MIN MAX HOLD 11 SMAA 17 ws 27LCD osi 18 M K e 10 011 19 4C 4B 021 20 4A 4G 5 9 x2 21 4 4 22 DP300 5 012 23 44 45 46 47 022 24 J8 gt 3 1 0 22 0 22 0 22 0 22 2 25 50V 50V 50V 50V 042 26 3D DP30 151 6 ALPHA 013 27 2 2 4KHZ TN 023 28 2A 26 J8 13_loscour 033 29 2F 2E 5 043 30 2D DP3 J8 gt 10 12 osc n 014 31 1B 1c 024 32 1AGD 1E J8 gt 1 58 R2 034 33 ES 044 34 78 2 57 R1 015 35 BG J8 9 sl BETA 025 36 BG1 BG2 035 37 BG3 J8 gt 12 4 045 39 BG5 BG6 16 40 BG7 BG8 J8 gt 13 3 DIO2 026 41 BG9 BG10 036 42 BG11 BG12 J8 gt 14 2 046 43 BG13 BG14 17 44 BG15 BG16 J8 gt 15 1 027 45 17 BG18 037 46 BG19 BG20 J8 5 41 026 047 47 BG21 BG22 o18 48 BG23 BG24 78 6 40 016 028 49 BG25
50. rument and remove the O ring MP13 between the top and bottom cases Always install a new O ring prior to reassembly At this point all calibration adjustments are accessible through the openings in the side of the pca shield Refer to the calibration adjustment procedure later in this chapter to calibrate the instrument Remove the four Phillips head screws H3 at the bottom of the pca that connect the pca to the input terminals molded into the top case Carefully lift the upper end of the main pca and shield assembly to disconnect the assembly from the digital pca then lift the main pca and shield assembly clear of the case TO TOP OF INSTRUMENT ROTARY SWITCH EXTENSION SHAFT 055 1 Figure 3 3 Switch Extension Shaft Installation Note the position of the rotary switch extension shaft MP17 With the rotary switch in the OFF position the single small pointer on the base of the extension shaft 15 pointed toward the top of the instrument Refer to Figure 3 3 Lift the rotary switch extension shaft MP17 off the rotary switch shaft the shaft on MP2 Remove the E ring retainer MP6 and the detent spring MP5 from the rotary switch shaft Pull the rotary switch knob MP2 out from the front of the top case MP1 Take care not to loose the Teflon bearing washer H1 under the knob To replace the O ring MP4 on the rotary switch shaft cut off the existing O ring without scratching the metal shaf
51. st of Figures Figure 3 1 Battery and Fuse Replacement 9 22 Disassembly arinaa S Dri tes 3 8 3 3 Calibration Adjustment Locations 3 16 4 1 Assembly rar ore LE EE 43 A2 Digital PCA 4 4 Aa Disital PCA A 5 1 AL PCA E 222 AZ Digital PCA unse nee anne et 3 3 Digital PC ice oen ee pei en o 27 Service Manual vi 1 1 1 2 1 3 Chapter 1 Introduction and Specifications Title Page Using the Meter Specifications 27 Service Manual 1 2 Introduction and Specifications 1 Using the Meter Safely 1 1 Using the Meter Safely Use the meter as described in this manual Otherwise the safety features provided by the meter might be impaired A Warning identifies conditions and actions that pose hazards to the user a Caution identifies conditions and actions that might damage the meter Read First Safety Information Read First Safety Information This meter complies with EN 61010 1 1993 ANSI ISA S82 01 1994 and CAN CSA C22 2 No 1010 1 92 Overvoltage Category Use the meter only as specified in the Users Manual otherwise the protection provided by the meter ma
52. t Clean the shaft thoroughly and slide a new O ring over the shaft into the groove on the shaft 3 9 27 Service Manual 3 10 17 18 19 20 21 22 23 24 Remove the four lower Phillips head screws 5 that secure the digital to the top case using a diagonal pattern 1 e remove the upper right screw then the lower left then the upper left and last the lower right Then remove the two Phillips head screws H2 at the top of the digital pca above the connector Carefully lift the digital straight up from the top case and remove it Caution Do not touch the elastomeric LCD contact strips MP20 or contacts of the momentary switch S3 S6 with bare hands Wear gloves or remove the contact strips using clean pliers or tweezers Avoid contaminating the contact strips Lift the momentary switch S3 S6 from the top case Remove the elastomeric LCD contact strips MP20 and LCD interconnect support MP18 located on the back of the LCD Remove the LCD U3 and the LCD mask 19 from the case To disassemble the main pca shield assembly first remove the two Philllips head screws H8 from the top shield MP9 Take care not to lose the flat washers under the screw heads Turn the assembly over and remove the three thread forming Phillips head screws H4 that secure the bottom shield MP3 Lay the bottom shield aside and separate the top shield from the pca At this poi
53. tion of detergent and water on a soft cloth Clean dust from the pcas using clean dry air at low pressure less than 20 psi Clean contaminates from the pcas using isopropyl alcohol and a soft brush followed by demineralized water and a soft brush remove the LCD before washing Dry the pca at 50 to 60 degrees Celsius for 24 hours after washing and before reassembly to assure that no moisture is sealed in the instrument 3 12 Performance Tests 3 13 The following procedures allow you to check the performance of the Fluke 27 against the specifications given in the Fluke 27 Users Manual The procedures are recommended for incoming inspections periodic calibration verification and as an aid in troubleshooting If the instrument fails any test calibration adjustment or repair is needed Prior to performing any of the sting procedures allow the instrument to stabilize to room temperature 18 to 28 degrees Celsius Also check the fuses and if the battery annunciator is displayed change the battery Note In the following procedures the Fluke 27 is referred to as the unit under test or UUT Display Test When the function switch is moved from the OFF position to any other position the instrument performs a power up self test All LCD segments in the display are switched on while the test is in progress then the instrument commences normal operation This automatic self test verifies that the instrument is functional and that all
54. unction Overload Input Impedance Common Mode Rejection Normal Mode Ratio canti Protection nomina Rejection 1 unbalance J 1000 rms 10 with lt 100pF 120 dB at 50 Hz 60 Hz gt 60 dB at 50 Hz 60 Hz mV 1000 V rms 10 in with lt 100pF gt 120 dB at 50 Hz or 60 2 gt 60 at 50 Hz or 60 Hz 1000 Vrms 10 in with lt 100PF de to 60 Hz coupled 1000 Vrms 0 in with lt 100PF de to 60 Hz coupled 0 1000 V rms Open Circuit Test Full Scale Voltage Voltage Up to 3 2 32 or nS 2 8 V de 420 mV dc 1 38 V dc 107 V Hz Basic electrical accuracy is specified from 18 to 28 C with relative humidity up to 95 for a period of one year after calibration All ac conversions are ac coupled average responding and calibrated to read the true rms value of a sine wave input Accuracy is specified as of reading number of least significant digits Ranging is either automatic or manual in all functions with more than one range Test resistance below approximately 270 Maximum voltage between any terminal and earth ground Fuse protection in the gt Ffunction produces a continuous audible tone 1000 V Analog Display mA or yA 44 100 A 1000 V Fast 11 A 1000 V Fast Digital Display 3200 counts updates 2 sec 31 segments updates 25 sec
55. used to provided the fast response bar graph display and fast autoranging New samples are taken every 40 ms Ten samples are summed to produce a full resolution digital display with full scale greater than 3200 counts A 100 ms autozero phase occurs every 10 sample sequence Basic A D conversion elements and waveforms are illustrated in Figure 2 2 As this figure shows a residual charge is retained by the integrator capacitor due to the overshoot past the true zero base line In the absence of an autozero phase the residual charge would normally produce a significant error in the sample next taken However a digital algorithm eliminates the error and accounts for the residue as it propagates through all 10 samples HIGH Z BUFFER INTEGRATOR COMPARATOR Se REFER TO WAVEFORM INPUT UNKNOWN INTEGRATE COMPARE 32 768 kHz 1 XTAL STATE MACHINE CLOCK PRESET PULSES E TO BAR GRAPH 10 MINOR CONVERSIONS 400 ms A TO DIGITAL 1 FULL RESOLUTION CONVERSION DISPLAY AS SEEN AT COMPARATOR INPUT INTEGRATE READ ZERO RAMP RAMP BASELINE RESIDUE E AUTO E EAT ZERO 1 2 aac02s tif Figure 2 2 A D Conversion Elements and Waveform Digital circuitry in U1 provides state machine control for the A D converter a read counter for A D samples decoding ROMs for analog switch drive and for read counter 2 5 27 Service Manual 2 6 preset and bi directional bus control for storing control outp
56. uts from the microcomputer and for transferring data to the microcomputer Basic timing for the A D converter is defined as a series of 10 integrate read cycles samples followed by a 100 ms autozero phase However the diode test and continuity function the 32 range the battery test the power up self test overload recovery autoranging and the Touch Hold mode all required variations from the basic timing The state machine in combination with the ROM and preset read counter plus an autozero flag under computer control establishes the timing variances necessary for the various functions Peripherals to 01 Circuitry peripheral to 01 provides regulated battery voltage to power Ul a regulated reference voltage for the A D converter a system clock signal conditioning and amplifier stabilization The battery voltage regulator consists of AR1 Q12 and associated components the regulator circuit supplies consistent operating power to Ul and through a second regulator circuit in Ul to the microcomputer U2 Voltage regulator VR1 and associated components supplies a regulated 1 000 V reference voltage for the A D converter Potentiometer R19 provides for calibration adjustment of the reference voltage Additional circuits are necessary for the active filter integrator and buffer in Ul the active filter response is determined by R13 R16 C18 and C19 Integrator and buffer signal characteristics are determined by C20 C21 an
57. vide calibration adjustment for the high frequency ac ranges Current inputs received through the mA uA input J2 and the A input 13 develop a voltage across shunt resistors R14 R20 and R23 320 uA 32 mA and 10 respectively Resistors R9 and R10 comprise a 10 1 divider for the 3200 and 320 mA current ranges Custom Analog IC U1 The analog to digital converter autorange switching and most of the remaining active analog circuitry including additional signal conditioning are contained in U1 a custom LSI package Peripherals to U1 include the system clock the reference voltage regulator for the A D converter and some filtering and amplifier stabilization components U1 also contains digital circuitry for state machine control over the A D decoding ROMs for analog switch drive and read counter preset and registers to store control outputs from the microcomputer Analog to digital conversion is accomplished within U1 using a modified dual slope A D converter circuit as shown in Figure 2 2 The conversion method in the Fluke 27 can be described as a charge coupled multiple slope technique A series of 10 minor Theory of Operation 2 Block Diagram Description conversions occur every 40 ms each at 1 10th the desired resolution without taking time for an autozero phase between the conversions These minor conversions or samples as they are called in the following discussion occur at a rate of 25 per second and are
58. y remove the test leads and any input signals before replacing the battery or fuses Make sure the battery door is closed and latched before you operate the meter Disconnect and remove the battery Snap the battery connector to the terminals on the new battery then slide the battery into the battery compartment Insert the battery spacer cover into the instrument then start the four screws removed in step 2 Press firmly on the battery cover while tightening the screws in a diagonal pattern 4 3 Battery cover Fuse cover yetf eps Figure 3 1 Battery and Fuse Replacement 3 5 27 Service Manual 3 6 3 5 Fuse Test A AWarning To avoid electrical shock or personal injury remove the test leads and any input signals before replacing the battery or fuses Make sure the battery door is closed and latched before you operate the meter To prevent equipment damage or injury install ONLY specified replacement fuses with the amperage voltage interrupt and speed ratings listed in the Fuse Replacement Maintenance section Turn the function selector switch to the position Connect a test lead from the volts ohms diode test input terminal to the A input terminal The display should indicate between 0 1 and 0 3 This tests F2 11 A 1000 fast Move one end of the test lead from the A input terminal to the mA uA input terminal The display should indicate between 5 3 Q and
59. y be impaired A A Warning To avoid possible electric shock or personal injury e not use the meter it is damaged Before use inspect the case for cracks or missing plastic Pay particular attention to the insulation surrounding the connectors e Inspect the test leads for damaged insulation or exposed metal Check test lead continuity Replace damaged leads e Donot use the meter if it operates abnormally Protection may be impaired When in doubt have the meter serviced e Do not operate the meter around explosive gas vapor or dust e Do not apply more than the rated voltage as marked on the meter between terminals or between any terminal and earth ground e Before each use verify the meter s operation by measuring a known voltage e When servicing the meter use only specified replacement parts e Use caution when working above 30 V ac rms 42 V ac peak or 60 V dc Such voltages pose a shock hazard e Keep your fingers behind the finger guards on the probe when making measurements e Connect the common test lead before connecting the live test lead Disconnect the live test lead first e Remove test leads from the meter before opening the battery door e Make sure the battery door is closed and latched before operating the meter e Use only a single 9 V battery properly installed in the meter case to power the meter 27 Service Manual Follow all equipment safety procedures Before m

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