7

Mounting Screw (2)

Rear Bezel

Mounting Screw (2)

Rear Bezel

Figure 7-2. Removing the Case qb14f.eps

Figure 7-2. Removing the Case

4. Remove the two #6-32 x 1/4" panhead Phillips screws securing the Battery Pack Option (see Figure 7-4).

5. Carefully slide the Battery Pack Option out of the meter (as shown in Figure 7-4). Do not pinch the wires running from the circuit board to the battery terminals.

To prevent damage to the meter when servicing the Main PCA, unplug the battery pack ribbon cable at the Main PCA or disconnect the wires to the battery pack.

7-13. Installation

Use the following instructions to install the Battery Kit Option. Refer to the Instruction

Sheet (PN 856013 - supplied with the Battery Kit) for the more detailed instructions required with an initial installation of the Battery Kit Option.

1. Make sure the meter is turned off and disconnected from line power.

2. With the meter disconnected from line power, discharge the power supply capacitor by turning the meter on. After five seconds, turn the meter off.

3. Carefully slide the battery kit into the area reserved for it in the back of the meter (as shown in Figure 7-4). Make sure that both the retaining slots line up and the mounting holes mate. Do not pinch wires running from the circuit assembly to the battery pack terminals.

4. Secure the battery kit with two #6-32 x 1/4" panhead Phillips screws.

5. Attach the flat, white connecting cable at the Battery Pack Option circuit board (see Figure 7-3). The single blue line of the cable should be to the rear of the meter. Align the plastic socket on the cable end, then seat it securely in place.

6. Reinstall the meter case to seat properly in the front panel. Attach the rear bezel with the two panhead Phillips screws, and secure the case with the flathead Phillips screw in the bottom.

Caution

7. To ensure that the battery kit is properly installed, turn the meter ON before connecting the power cord. If the meter does not turn on, the battery pack may be in the discharged state. Charge the battery pack for 16 hours; then retest.

Fluke Battery

qb35c.eps

Figure 7-3. Installing the Battery Kit qb35c.eps

Figure 7-3. Installing the Battery Kit

Battery Pca 825885

qb34c.eps

Figure 7-4. Battery Pack Option Connecting Cable qb34c.eps

Figure 7-4. Battery Pack Option Connecting Cable

7-14. Performance Testing

7-15. General Operability

The following performance verification assumes the following initial setup configuration:

• The Battery Pack Option is physically installed in the meter.

• The red and black battery pack wires have been disconnected.

Refer to Table 7-1 for description of any equipment that is required during the performance tests.

1. Disconnect the meter from line power. Now turn meter power on (1 = on), then off (0 = off).

Note

Do not connect the battery pack until after the option assembly is turned on later in this procedure.

2. Connect the 1.8 kW resistor across the battery pack wires. Connect the voltmeter (Low to TP1 and High to TP2.)

3. Connect the meter to line voltage, but do not turn the meter on.

4. Check for a voltmeter reading of 9.35 V ±0.01V.

5. Now turn power on. Check for a voltmeter reading of 9.25 V ±0.01 V.

6. Remove the voltmeter and the 1.8 kW resistor.

7. Observing the polarity markings on the battery pack, connect the red wire to the positive (+) terminal. Then connect the black (or brown) wire to the negative (-) terminal. Reversal of these connections causes fuse F1 to open.

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

The following test is necessary only after repairs have been made to either the Low Battery Indicator Detector or the Low Battery Disconnect circuit.

1. Turn the meter OFF.

2. Unplug the two battery pack connectors from the battery pack terminals. Observing the correct polarity, connect the variable power supply to the two battery pack connectors.

3. Connect the voltmeter across the variable power supply.

4. Set the variable power supply to approximately 9 volts.

5. Now turn the meter ON, and check for correct operation of the Low Battery Indicator symbol.

• While watching the display, slowly lower the variable voltage power supply output. Check that the low battery indicator symbol comes on at 7.7 ±0.25 V dc.

• Now, slowly increase the variable voltage supply output. Check that the low battery indicator symbol goes out at about 8 V dc.

6. Check the Low Battery Disconnect point.

• With the meter still operating on the variable supply, slowly lower the voltage, and check that the meter goes OFF at about 7.0 V dc.

• After the meter goes OFF, slowly increase the voltage, and check that the meter does not come ON before approximately 8.0 V dc.

Note

The meter may not come on, above 8 volts until the power is cycled.

7. There are no adjustments to set the Low Battery Indicator point or the Low Battery Disconnect point.

7-17. Cycle/Float Charge Rate Switch Test

Use the following procedure to verify operation of the meter's Cycle/Float Charge Rate Switch. Note that this test is required only after repairs have been performed on the Cycle/Float Rate Switch Test circuits.

1. Turn the meter OFF.

2. For this procedure, use a battery simulator as a substitute for the regular battery pack. Connect this simulator (shown in Figure 7-5) as follows:

• Connect a 33W, 5W load resistor in parallel across the output of a variable voltage power supply.

• Disconnect the battery charger wires from the battery.

• Connect the simulator to the battery charger wires. Install a 0.1W shunt resistor in series with the red wire.

• Connect a voltmeter across the shunt resistor to measure the voltage drop across and the charging current through the resistor.

3. With no ac line power applied to the meter, adjust the variable voltage power supply for 8.5 V dc output.

4. Now apply ac line power, and check that the charging current is greater than 250 mA.

5. Slowly increase the variable voltage supply output. Check for the following:

• The charging current decreases as the supply voltage approaches 10 V dc.

• The current should continue to decrease as the voltage increases, until the current is between 60 and 80 mA.

• With any additional decrease in current (increase of the supply voltage), the current should suddenly jump to a low value (less than 0.5 mA.)

• When the variable voltage supply output is reduced to 9.35 V dc, the current should be between 5 and 15 mA.

OPTIONAL VOLTMETER TO MONITOR A BATTERY VOLTAGE

METER TO MEASURE CHARGING CURRENT

OPTIONAL VOLTMETER TO MONITOR A BATTERY VOLTAGE

□ □ □ □ 1=11=11=1 kp

1-J

1-J

+ (Tj

V

I

-c^

O

o

POWER SUPPLY 0 TO 15V

POWER SUPPLY 0 TO 15V

METER TO MEASURE CHARGING CURRENT

■© o

p) o

r

□ □□ □ = = =

Figure 7-5. Cycle/Float Charge Rate Switch Test qb36f.eps

7-18. Calibration

The Battery Pack Option is adjusted at the factory for optimum performance and should not require adjustment when installed. However, if either of the two adjustment pots on the top of the Battery Pack Option circuit assembly have been turned inadvertently, or if the unit has been repaired, the following procedure can be used to reset the controls for optimum battery life and proper power supply system performance.

The following equipment is needed to perform these adjustments:

The following steps describe how to adjust the Battery Pack Option:

1. With the Battery Pack Option installed in the meter and with the meter disconnected from line power, unplug the battery connectors from the battery + and - terminals (Figure 7-6).

2. Install the 1800 W resistor across the battery pack connectors.

3. Connect the meter to line power and turn the meter ON.

4. Connect the test leads from another voltmeter across test points TP1 and TP2 on the Battery Pack Option circuit assembly (as shown in Figure 7-7). Adjust the front potentiometer (R39) (top of the Battery Pack Option circuit assembly) until the voltmeter across the test points reads 9.25 V.

5. Turn the meter OFF.

6. Connect the test leads from another voltmeter across TP1 and TP2 on the battery pack option circuit assembly. Adjust rear potentiometer R20 (top of the battery pack option circuit assembly) until the voltmeter across the test points reads 9.35 volts. (With the meter connected to line power and turned off, the charging voltage reads approximately 9.35 volts.)

7. Disconnect the line cord from the meter.

8. Remove the 1800 W resistor, and plug the battery pack connector wires back into the battery pack (the red wire to + and the black wire to -.)

9. To ensure the battery pack connector wires are properly connected and the battery kit is properly installed, turn the meter ON without plugging in the power cord.

Fluke Battery Pack

Figure 7-6. Unplugging the Battery Pack Connectors

7-19. Troubleshooting

Troubleshooting can be facilitated by removing the Battery Pack Option and connecting the Battery PCA with an extender cable (Fluke Part Number 854245). Refer to the removal instructions provided earlier in this chapter.

With the meter off (but plugged into line power), check for approximately 16 V dc (at 120 V ac line) raw dc supply between the ground test point and the cathode of either A1CR2 or A1CR3. If necessary, check for transformer secondary voltage of approximately 24 V ac.

Use an oscilloscope to trace the waveforms associated with the switching power supply.

• With the line voltage at 120 V ac, check the waveform at the drain of FET Q5. This signal should be a 25 V p-p square wave, with the negative part at zero volts, a period of 20 to 25 ^s, and an ON duty ratio of .20 to .50. This square wave may exhibit a damped sine wave (two to ten cycles) ringing on the trailing half of the positive portion. The sine wave amplitude should be from 10 to 20 V p-p.

• Check for a 15 V p-p square wave at the gate of Q5.

• Check for a 0.5 V p-p sawtooth waveform (with a period of 20 to 25 ^s) at U4-3. Make sure that the oscilloscope is ac-coupled for this measurement.

Troubleshoot other sections of the Battery Pack Option assembly by making dc voltage measurements. For circuit common, use the GND test point on the main circuit board or the common end of R30 on the Battery Pack PCA. Note that the battery pack negative terminal is not connected to common when the low battery disconnect circuit turns off Q2.

Vpl Es2 Off

qb38c.eps

Figure 7-7. Test Points and Adjustments qb38c.eps

Figure 7-7. Test Points and Adjustments

7-20. Additional Tests

The Low Battery Indicator Detector/Low Battery Disconnect Test and the Cycle/Float Charge Switch Test described earlier under Performance Testing can also be used as fault isolation aids in troubleshooting the Battery Pack Option.

7-21. Schematic Diagram

The schematic diagram for the Battery Pack Option is included in Chapter 9 of this manual.

7-22. List of Replaceable Parts

Figures 7-8 and 7-9 provide illustration for parts list in Tables 7-2 and 7-3, respectively. Refer to Chapter 6 for parts ordering information.

Table 7-1. Option -01 Battery Pack Final Assembly

Reference

Description

Fluke

Total

Note

Designator

Stock

Qty.

No.

A

4

* BATTERY PCA

825885

1

BT

1

BATTERY,LEAD-ACID,8.0V,2.5AH

822262

1

H

1-4

SCREW,PH,P,LOCK,STL,6-32,.250

152140

4

MP

1

RETAINER,BATTERY

828814

1

MP

34

TAPE,FOAM,URETHANE,ADHES,.063,.500

854539

1

TM

1

FLUKE 45 BATTERY KIT INST SHEET

856013

1

W

1

CABLE ASSY,FLAT,10 COND,MICROMOD,3 IN

831552

1

qb39c.eps

Figure 7-8. Option-O1 Battery Pack Final Assembly

Table 7-2. A4 Battery Pack PCA

Reference Designator

Description

Fluke Stock No.

Total Qty.

Note

C

6, 7

CAP,CER,1800PF,+-10%,50V,C0G,1206

769786

2

C

8

CAP,CER,33PF,+-10%,50V,C0G,1206

769240

1

C

9

CAP,AL,47UF,+-20%,50V,S0LV PROOF

822403

1

C

11

CAP,AL,10UF,+-20%,63V,S0LV PROOF

816843

1

C

12

CAP,AL,47UF,+-20%,100V,S0LV PROOF

837492

1

C

13

CAP,AL,1000UF,+-20%,16V,SOLV PROOF

837468

1

C

14

CAP,CER,0.22UF,+80-20%,50V,Y5V,1206

740597

1

C

15

CAP,AL,2.2UF,+-20%,50V,SOLV PROOF

769687

1

CR

3, 5, 9

* DIODE,SI,SCHOTTKY BARRIER,40V,1A

837732

3

CR

4, 7, 8

* DIODE,SI,BV=75V,IO=250MA,SOT23

830489

3

CR

10

DIODE,SI,100 PIV,1.0 AMP

698555

1

CR

11

DIODE,SI,100 PIV,3.3 amp,schottky

837740

1

F

1

FUSE,.095X.28,5A,125V,FAST,AXIAL

696427

1

J

1

HEADER,1 R0W,.050CTR,10 PIN

831503

1

Q

2, 5

* TRANSIST0R,SI,NM0S,1W,D-PAK

822106

2

Q

3, 7

* TRANSIST0R,SI,PNP,SMALL SIGNAL,S0T-23

742684

2

Q

4, 6, 12, 13

* TRANSIST0R,SI,NPN,SMALL SIGNAL,S0T-23

742676

4

R

2

RES,M0X,1.5K,+-5%,1W

603685

1

R

3, 42

* RES,CERM,47K,+-5%,.125W,200PPM,1206

746685

2

R

11

* RES,CERM,130K,+-5%,.125W,200PPM,1206

851761

1

R

13

* RES,CERM,523K,+-1%,.125W,100PPM,1206

844956

1

R

14

* RES,CERM,100K,+-1%,.125W,100PPM,1206

769802

1

R

15

* RES,CERM,10.5K,+-1%,.125W,100PPM,1206

851852

1

R

16, 43

* RES,CERM,10M,+-5%,.125W,300PPM,1206

783274

R

17

* RES,CERM,470K,+-5%,.125W,200PPM,1206

746792

1

R

18

* RES,CERM,330K,+-5%,.125W,200PPM,1206

746776

1

R

19

* RES,CERM,51K,+-5%,.125W,200PPM,1206

746693

1

R

20

RES,VAR,CERM,10K,+-20%,0.3W

837559

1

R

21

* RES,CERM,59K,+-1%,.125W,100PPM,1206

851803

1

R

22

* RES,CERM,301K,+-1%,.125W,100PPM,1206

821652

1

R

23

* RES,CERM,470,+-5%,.125W,200PPM,1206

740506

1

R

24

* RES,CERM,3.3K,+-5%,.125W,200PPM,1206

746529

1

R

25

RES,METAL FILM,2.26k,+-1%,0.5W

603693

1

R

26, 44

* RES,CERM,10,+-5%,.125W,200PPM,1206

746214

R

27

* RES,CERM,100K,+-5%,.125W,200PPM,1206

740548

1

R

28

* RES,CERM,12,+-5%,.125W,200PPM,1206

845458

1

R

29, 34- 37

RES,CF,0.50,+-5%,0.25W

830646

R

30

RES,CF,560,+-5%,0.25W

810440

1

R

31

* RES,CERM,100,+-5%,.125W,200PPM,1206

746297

1

R

32, 41

* RES,CERM,1K,+-5%,.125W,200PPM,1206

745992

R

33

* RES,CERM,120,+-5%,.125W,200PPM,1206

746305

1

R

38

* RES,CERM,910,+-5%,.125W,200PPM,1206

769257

1

R

39

RES,VAR,CERM,200,+-20%,0.3W

837567

1

R

40

* RES,CERM,6.8K,+-5%,.125W,200PPM,1206

746024

1

R

45

* RES,CERM,2.2K,+-5%,.125W,200PPM,1206

746479

1

Table 7-2. A4 Battery Pack PCA (cont)

Reference Designator

Description

Fluke Stock No.

Total Qty.

Note

T

1

INDUCTOR,FXD,DUAL,EE24-25,0.4MH,1.2A

817379

1

U

1

* IC,VOLT REG,ADJ,1.2 TO 37 V,1.5 AMPS

460410

1

U

2

* IC,COMPARATOR,DUAL,LOW PWR,SOIC

837211

1

U

3

* IC,CMOS,HEX BUFFERS,SOIC

837229

1

U

4

* IC,VOLT REG,ADJ,SWITCHING REGULATOR

821215

1

VR

2

* IC, 1.23V,150 PPM T.C.,BANDGAP V. REF

634451

1

VR

3

* ZENER,UNCOMP,15V,5%,8.5MA,0.2W,SOT-23

83787

1

VR

4

* ZENER,UNCOMP,6.8V,5%,20MA,0.2W,SOT-23

83795

1

W

1

WIRE ASSY,BATTERY,BLACK

834960

1

W

2

WIRE ASSY,BATTERY,RED

844332

1

Figure 7-9. A4 Battery Pack PCA

Chapter 8

DIY Battery Repair

DIY Battery Repair

You can now recondition your old batteries at home and bring them back to 100 percent of their working condition. This guide will enable you to revive All NiCd batteries regardless of brand and battery volt. It will give you the required information on how to re-energize and revive your NiCd batteries through the RVD process, charging method and charging guidelines.

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