2011 PERTANDINGAN KEMAHIRAN MALAYSIA

(ELEKTRONIK)

SOALAN
PERINGKAT AKHIR
NAMA: ______________________________________ NO. KP: ______________________________________

JABATAN PEMBANGUNAN KEMAHIRAN KEMENTERIAN SUMBER MANUSIA

Project: Fault Finding And Repair Time Limit: 2 hours

1.0

REQUIREMENTS

1.1 1.2

You have to find and repair 4 faults in the given circuit. A basic Waveform Generator. In order to carry out the required tasks, you may need to refer to the following documentations: Circuit Schematic Diagram PCB Layout Diagram Component List

1.3 .
2.0

Unless otherwise stated, all waveforms and voltages are measured with reference to ground (0V).
BACKGROUND INFORMATION

The board consists of several basic circuits which connected together produces PWM waveforms. The test pins TP11 and TP12 show the PWM outputs. P3 header output provides the product of the two waveforms.

3.0

CIRCUIT DESCRIPTION

3.1 3.2 3.3

The overall circuit diagram in shown Figure 1. The DC Power supply can be varied up to 60V by adjusting the VR1. The waveform generated by the sine wave generator is inverted by the IC U7A and appears at the output OUT1/1 (TP8). The frequency of the waveform can be adjusted by changing the variable resistor, VR4. The variable resistor, VR5, is used to vary its amplitude and VR6 for adjusting the offset level. The frequency and the amplitude of the square wave output at TP2 can be varied by adjusting VR3 and VR4 respectively. The frequency and the amplitude of the triangle waveform can be varied by adjusting VR7 and VR9 respectively. TEST EQUIPMENT REQUIRMENTS Dual DC Power Supply Digital Oscilloscope Desktop link to Oscilloscope Assortment of connecting cables 1 set 1 set 1 set 1 set

3.4 3.5

4.0

INSTRUCTIONS TO THE COMPETITOR Please carry out this project as per the following steps: (1) Competitors must carry out the fault finding and repair work. Also, on the fault finding and repair answer sheet you must record the location of the fault, the detail of the fault and the fault symbol. Use the Fault Symbol Table as a reference for fault symbol. (2) After finding the fault, if you need a component in order to repair it, you will be permitted to order the new component from the expert. You are only allowed to request for components on the component list. (3) Make sure that you request the least supply of necessary components for this project. Make note that a wrong request will lead to a reduction of 0,75 marks in your overall score of this project. (4) Repair the located faults. And, check that it operates correctly after repairing.

THE SYMBOLS LIST OF THE FAILED STATE

Fault symbol Description Open (Part or wire) Incorrect wiring (Part to part wire) Short (Part or wire) Incorrect polarity part (Including incorrect pin location due to misplacing) Part with a large value (Resistor, Capacitor, Frequency, etc) Part with a small value (Resistor, Capacitor, Frequency, etc) Incorrect part number or incorrect wiring connection Defected (Including partly broken) Remark

Examples for filling in the answer table

If the value of R1 was too large or small,

Defective part Fault 1 R1

Failed state symbol

or

If the polarity of diode D1 was opposite,

Defective part Fault 1 D1 Defective part Fault 1 IC1(pin-1) IC2(pin-2) Defective part Fault 1 IC1(pin-1) IC2(pin-2)

Failed state symbol

If the line between Pin-1 of IC1 and Pin-2 of IC2 was open,

Failed state symbol

If the line between Pin-1 of IC1 and Pin-2 of IC2 was incorrect wiring,

Failed state symbol

If IC1 dose not operate(Broken),

Defective part Fault 1 IC1

Failed state symbol

THE ANSWER TABLE OF THE REPAIR STATE Defective part Failed state symbol

Fault 1

Fault 2

Fault 3

Fault 4

PARTS LIST
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Timer 7-segment decoder 4-bit comparator BCD counter One short M/V BCD Up/Down counter Phase Locked Loop 7-Segment Diode Diode Light Emitting Diode Diode Capacitor for Ceramic Capacitor for Ceramic Capacitor for Ceramic Capacitor for Electric Capacitor for Electric Capacitor for Electric Capacitor for Electric Capacitor for Electric Capacitor for Electric Capacitor for Ceramic Resistor Parts name Parts value(Model) NE555 74LS47 74LS85 74LS90 74LS123 74LS192 MC14046 FND-507(A-com) 1N4148 Zener 3V EL204RD, D_BRIGDE 1A 10nF 100pF 100nF 1000uF 1uF 100uF 0.47uF 10uF 4.7uF 1000pF 39K, 0.25W, 1% Qty 1 2 2 2 1 2 1 2 1 1 1 1 1 1 16 1 1 1 1 1 1 3 1 U8 U3 ,U5 U6, U7 U10, U11 U2 U1, U4 U9 LED1, LED2 D1 D3 D2 DB1 C18 C3 C1, C2, C4, C6, C7, C8, C9, C10, C12, C13, C14, C16, C17, C19, C21 C23 C20 C22 C26 C25 C24 C5,C11,C15 R21 Reference number

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Variable Resistor Variable Resistor Variable Resistor Test Point Pin Push button switch DIP Soket DIP Soket DIP Soket Connector Transistor Transistor

10K, 0.25W, 1% 330, 0.25W, 1% 6.8K, 0.25W, 1% 1M, 0.25W, 1% 100K, 0.25W, 1% 15K, 0.25W, 1% 470, 0.25W, 1% 1K, 0.25W, 1% 4.7K, 0.25W, 1% 0.47, 1W, 1% 100K, 5K, 2K, LC-2-G Tact PB 4-P RIC-DIP-8 RIC-DIP-14 RIC-DIP-16 Header 2 H1061 C1815

8 17 1 1 1 1 2 1 1 1 1 1 1 4 2 1 2 7 1 1 3

R1, R2, R3, R11, R12, R13, R30, R31 R4, R5, R6, R7, R8, R9, R10, R14, R15, R16, R17, R18, R19, R20, R27,R33,R35 R22 R23 R24 R25 R28,R29 R32 R34 R26 VR2 VR3 VR1 TP1, TP2, TP3, TP4 SW1, SW2 U8 U10, U11 U1, U2, U3, U4, U5, U6, U7, J1 Q1 Q2, Q3,Q4

COMPONENT LIST WHICH COMPETITORS ORDER FOR REPAIRING

Item
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Parts name

Parts value

Qty

Experts Signature

Competitors Signature

SCHEMATIC DIAGRAM: FIGURE 1

Schematic: DC Power Supply

TP1 L1 220mH R1 0R1/1W R2 0R1/1W 8 5 7 4 GND U1 DRVC VCC -VIN IPK SWC SWE GND TCAP MC34063U 6 1 2 3 C2 222 GND Q1 TIP122 R4 1K GND D1 UF4007 VR1 50K VCC1 C3 100uF/100V

R3 1K

GND GND GND +12V P2 1 2 3 -VCC Header 3

DC +12V INPUT
P1 2 1 Header 2 GND +12V C1 100uF/25V GND VR2 5K R7 1K GND R5 0R1/1W 8 5 7 4 U2 DRVC VCC -VIN IPK SWC SWE GND TCAP MC34063U GND 6 1 2 3 C4 472 Q2 TIP122 R6 1K D2 UF4002 -VCC C5 100uF/50V GND

L2 120mH

GND

10

TP13 +12V 1 C17 100uF/25V C18 104 2 GND GND

11

U3 IN

LM7805CT OUT GND 3 C19 104

VCC C20 100uF/25V

TP14

Schematic: Sine Wave Output

TP3

+12V VR6 100K +12V R17 10K -VCC U5A TL082ACJG R15 1 10K +12V

TP4 R24 10K +12V U5B TL082ACJG 7 OUT1 SINE WAVE TP8 U7A TL082ACJG 1 OUT1/1 +12V C13 104 -VCC 8

R8 +12V VR3 4K7 5K R9 4K7 +12V

1 2 3 4 5 6 7

U4 SIN ADJ NC SIN OUT NC TRI. OUT SIN ADJ (DUTY VADJ) TIMING V+ SQU. OUT FM BIAS FM SWEEP XR8038 R11 0R1
R10 +12V

14 13 12 11 -VCC 10 9 8 TP2 R12 15K

2 3 C10 474 R13 240K -VCC GND 4

6 5 4

+12V C9 104 -VCC -VCC

-VCC SQUARE +12V WAVE

-VCC R14 10K

VR5 R16 100K 4K7

8 GND

R23 10K

2 3 GND 4

-VCC

-VCC

VR4 50K R10 51K

R11

12

Schematic: Triangle output

+12V C12 104 +12V U6B TL084CN 7 TP5 SQUARE WAVE VR7 2 3 11 100K R18 100K GND 11 1 4 +12V 4 U6A TL084CN 1 VR9 100K R20 10K -VCC TP6 R19 10K TRIANGLE WAVE 9 10 R21 4K7 3 R22 10K 1K +12V 4 TP7 U6C TL084CN 8 OUT2

GND

6 5 2

+12V C11 104 -VCC

-VCC

-VCC GND

VR8

100K

13

11 -VCC

Schematic: PWM Output

VCC +12V 4 U8A LM324AN 1 R27 470R CMP1 R25 10K Q4 9013 ,., GND VCC R28 470R CMP2 U8B LM324AN 7 R26 10K +12V C15 104 GND GND Q3 9013 +12V C116 104 GND ., CMP2 ,. ; CMP1

TP9

VCC U9 TLP250 R29 330R ,,

+12V

OUT1 2 3 +12V C14 104 -VCC 1

TP11

11

-VCC OUT2

+12V OUT1/1 4 6 5 2

TP10 VCC R30 330R GND +12V

P3 1 2 Header 2

OUTPUT

U9 TLP250

11

'

TP12

-VCC

GND

14

PCB COMPONENT LAYOUT

15

PCB LAYOUT

16

Pertandingan Kemahiran Malaysia (PKM)

PARTS LIST

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Parts name
DC-to-DC Converter Control Circuit Three-Terminal Medium Current Positive Voltage Regulator Precision Waveform Generator JFET-Input Operational Amplifier JFET-Input Operational Amplifier Transistor Inverter For Air Conditionor IGBT Gate Drive Power Mos Fet Gate Drive Quad Low-Power Operational Amplifier

Parts value(Model) MC34063U MC78M05BT XR8038 TL082ACJG TL084CN TLP250 LM324AN UF4007 UF4002 222 472 474 104 100uF/25V 100uF/100V 100uF/100V 100uF/25V 0R1/1W 1K, 0.25W, 1% 4K7, 0.25W, 1% 51K, 0.25W, 1% 0R1, 0.25W,0.5%

Qty 2 1 1 2 1 2 1 1 1 1 1 1 10 1 1 1 1 1 4 4 1 1 U1,U2 U3 U4 U5,U7 U6

Reference number

U9,U10 U8 D1 D2 C2 C4 C10 C9, C11, C12,C13,C14,C15, C16,C18, C19 C1 C3 C5 C17.C20 R1,R2,R5 R3, R4, R6, R7 R8, R9,R16.R21 R11 R10

Diode Diode Capacitor for Ceramic Capacitor for Ceramic Capacitor for Ceramic Capacitor for Ceramic Capacitor for Electric Capacitor for Electric Capacitor for Electric Capacitor for Ceramic Resistor Resistor Resistor Resistor Resistor

17

Pertandingan Kemahiran Malaysia (PKM)

23 24 25 26 27 28 29 30 31 32 33

Resistor Resistor Resistor Resistor Resistor Resistor Potentiometer Potentiometer Potentiometer Potentiometer Potentiometer

15K, 0.25W, 1% 240K, 0.25W, 1% 10K, 0.25W, 1% 100K, 0.25W, 1% 330, 0.25W, 1% 470, 0.25W, 1% 50K 5K 5K 50K 100K

1 1 10 1 2 2 1 1 1 1 5

R12 R13 R14,R15,R17,R19, R20,R22,R23,R24,R25, R26 R18 R29,R30 R27,R28 VR1 VR2 VR3 VR4 VR5,VR6, VR7, VR8 ,VR9 TP1, TP2, TP3, TP4, TP5, TP6, TP7, TP8, TP9, TP10, TP11, TP12, TP13, TP14,

34

Test Point Pin

LC-2-G

16

35 36 37 38 39 40 41 42

Inductor Inductor DIP Socket DIP Socket Connector Connector Transistor Transistor

220mH 120mH RIC-DIP-8 RIC-DIP-14 Header 2 PIN Header 3 PIN TIP122 9013

1 1 6 3 2 1 1 2

L1 L2 U1, U2,U5,U7,U9,10 U4,U6,U8 P1, P3 P2 Q1,Q2 Q3,Q4

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Pertandingan Kemahiran Malaysia (PKM)

EQUIPMENT, MACHINERY, INSTALLATIONS AND MATERIALS REQUIRED

Host country prepares the following equipments, machinery, installations and materials for each competitor Item 1 2 3 4 5 Qty 1 1 1 1 1 Material Worktable with ESD protection Office chair Workstation Lamp Oscilloscope Universal Digital Multi-meter 2CH, BW=100[MHz], 1GS/s V, , A, etc Description W=1800 , D=900, H=750 [mm] Notes

Proposal the Hot country prepares the following equipments, machinery, installations and materials. Item 1 Qty 10set Material All parts Description Notes

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Pertandingan Kemahiran Malaysia (PKM)

The competitor needs to prepare the following equipments, machinery, installations and materials. Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Qty Material Soldering Iron Soldering Iron Stand Solder wick or Solder Remover Lead Bender Pincer Nipper Wire Stripper Scissors Tweezers IC pick PCB stand Parts box Precise screwdriver Screw driver Screw driver Scale Template Safety Glasses Cotton Glove Brush Industrial wiper For trimmer resistor + type - type 300mm Electric Symbol Description Notes

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