LKS 2017 TP16 XXV FFRM EN

FAULT FINDING, REPAIR

AND MEASUREMENT

Test Project Document

LKS_2017_TP16_FFRM_EN Submitted by:

Name : ASC WSC Team Member : Ina skills Electronics Type : Close Project Time : 4 Hours Point : 25 Points

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 2

1. INTRODUCTION TO TEST PROJECT DOCUMENTATION

1. Introduction To Test Project Documentation ... 2

2. Contents ... 3

3. Introduction ... 4

4. Description Of Project & Task... 5

5. Instruction To The Competitors ... 6

6. Equipment, Machinery, Installations And Materials Required ... 10

7. Marking Scheme ... 19

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 3

2. CONTENTS

This Test Project proposal consists of the following documentation/files: a. LKS_2017_XXI_TP16_FFRM_EN.docx

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 4

3. INTRODUCTION

This Test Project is a Stereo Multiplex (MPX) and FM Transmitter test, Instead of using special purpose ICs to produce the waveforms this design uses ordinary HCMOS logic. Audio Frequency (AF) signals are produced using binary counters and combinational logic and then filtered to obtain two very low distortion sine waves to serve as the test tones. These audio signals are then multiplexed by a 38 KHz Sub-Carrier to form a Left+Right and a Left-Right Double Side-Band Suppressed Carrier (DSBSC) signal to form the Stereo Multiplex (MPX). No fault and no measurement in the oscillator FM/ Modulation FM Block.

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 5

4. DESCRIPTION OF PROJECT & TASK

The block diagram of the Stereo Multiplex (MPX) and FM Transmitter is shown in Fig. 2.

Fig. 2 Block Diagram of Stereo Multiplex (MPX) and FM Transmitter test

Fig. 3: Audio Signals, Sub-Carrier and Multiplexed (MPX) Signals

The Signal Generator generates the 38 KHz sub-carrier and 19 KHz pilot tone. It uses an ingenious technique to generate 2 sine waves (audio) with very low distortion at around 300 Hz and 1.2 KHz.

The 38 KHz sub-carrier is used to multiplex the audio signals and then summed with the 19 KHz pilot tone by the Multiplexer & Summer to form 16 different waveforms

Manual Clock Control Logic Multiplexer & Summer MPX Output Signal Generator

Audio 19 KHz 38kHz

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 6

(Fig 4). The audio signals being encoded as Left or Right is based on the phase of the sub-carrier.

The 16 different waveforms

300 Hz right/ 1.2 KHz left MPX no 19 KHz pilot 300 Hz right/ 1.2 KHz left MPX with 19 KHz pilot 1.2 KHz left only MPX no 19 KHz pilot

1.2 KHz left only MPX with 19 KHz pilot 300 Hz left only MPX no 19 KHz pilot 300 Hz left only MPX with 19 KHz pilot 300 Hz left/1.2 KHZ right MPX no 19 KHz pilot 300 Hz left/1.2 KHZ right MPX with 19 KHz pilot 1.2 KHz right only MPX no 19 KHz pilot

1.2 KHz right only MPX with 19 KHz pilot 300 Hz right only MPX no 19 KHz pilot 300 Hz right only MPX with 19 KHz pilot 300 Hz + 1.2 KHz mono audio only 1.2 KHz mono audio only

300 Hz mono audio only 19 KHz pilot only

Fig. 4. The 16 different waveforms

The state of the Control Logic is advanced by the Manual Clock. In manual mode it is done by a Push Button with a de-bouncing circuit.

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 7

6. INSTRUCTION TO THE COMPETITORS

Fault Finding and Repair

1. Supply voltage of 12 + 0.1 volts to be applied to terminal P1, please take note of the polarity.

2. Adjust R5 to set the frequency 153 KHz + 0.5 KHz of the clock output at U7_3. If competitor board doesn’t match with the frequency, competitor can exchange the board to jury.

3. There are 3 faults which do not correspond to the demand specifications. Find and repair it.

4. Describe Defective Part and Fault Symbol.

5. When you request repair parts, both of the Competitor and the Jury have to sign to part list.

6. Describe the evidence of the repair.

FAULT

SYMBOL

DESCRIPTION FAULT

SYMBOL

DESCRIPTION

Open

(part, wire or PCB trace)

Stuck at high voltage (Pin, input, output, etc.) Short

(part, wire or PCB trace)

Stuck at low voltage (Pin, input, output, etc.) Part with larger value

(resistor, capacitor, etc.)

?

Incorrect part number or wiring connecting

Part with smaller value

(Resistor, capacitor, etc.)

+/-

Wrong Polarity

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 8

You may use the following Labels:

LOCATION CATEGORY SAMPLE

Power +5V/+12V/-5V/+5V/GND

Pin of IC IC2_8

Component of R/C/L R7_1㸦left/up:1 right/down:2㸧

Test Point TP1

Between Two Components R1-R2

Fig.6 Location Symbols Table

DEFECTIVE PART FAULT SYMBOL

Fault #1 IC2_8 - R7_1

BEFORE AFTER

Measurement #1

Node: _ R7_1______

Fig.7 Example of description of answer script (Condition: the frequency of the oscillator is too high.)

Voltage at R7_ 1 below than 1V

Voltage at R7_ 1 approximately 5V

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 9

DEFECTIVE PART FAULT SYMBOL

Fault #2 R1

BEFORE AFTER

Measurement #2

Node: _TP1______

1.00V/DIV 1.00ms/DIV

Fig.8 Example of description of answer script (Condition: the frequency of the oscillator is too high.)

GND GND

2ms 4ms

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 10

7. MEASUREMENT

Measure the following items:

1. Measure and record the frequency at U19_1

2. Press S1 button until signal out U10_12 = LOW, U10_9 = HIGH, U10_8 = HIGH, U10_11 = LOW, then measurement MPX OUT signal at P4.

3. ... 4. ...

For each measurement, sketch a schematic showing how to measure, using following equipment symbols.

EQUIPMENT SYMBOL

Power Supply Voltmeter Ammeter Oscilloscope Function Generator GND

Fig.9 Equipment Symbol Table

Fig.10 Example of Measurement Schematic V

A

FG

CH1 CH2

GND Vcc

TP1 TP2 5V

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

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Date: 20.10.2016 11

8. EQUIPMENT, MACHINERY, INSTALLATIONS AND MATERIALS REQUIRED ITEM QTY MATERIAL DESCRIPTION NOTES

1 1 FFRM PCB Material for the

project

12

9. PCB AND SCHEMATIC

13 Fig. 13. Schematics – Sheet 2

14 Fig. 14. Schematics – Sheet 3

15 Fig. 15. PCB Top Overlay

16 Fig. 16. PCB Bottom layer

17 Fig. 17. PCB Top layer

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 19

10. MARKING SCHEME

MAX MARK ASPECT OF CRITERION - DESCRIPTION

12 Finding faulty spots and evidence 3 Repairing (IPC-A-610-D)

8 Validity of measuring results

2 Documentation of measuring method Fig. 19. Marking

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

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Date: 20.10.2016 20

11. OTHERS

1. Part List for repairing

2. Fault Finding and Repair – Answer Script 3. Measurement – Answer Script

Part list for repairing

S/N DESCRIPTION VALUE DESIGNATOR QTY. COMPETITOR REQUEST COMPETITOR SIGNATURE JURY SIGNATUR E

1 Resistor ¼ W 1% 1,8 Ω R1 1

2 Resistor ¼ W 1% 390 KΩ R2 1

3 Resistor ¼ W 1% 150 KΩ R3 1

4 Resistor ¼ W 1% 10 KΩ R4, R11 2

5 Resistor ¼ W 1% 120 KΩ R6 1

6 Resistor ¼ W 1% 12 KΩ

R7, R9, R14, R15, R22, R26, R27

7

7 Resistor ¼ W 1% 47 KΩ R8 1

8 Resistor ¼ W 1% 82 KΩ R10 1

9 Resistor ¼ W 1% 39 KΩ R12 1

10 Resistor ¼ W 1% 1 KΩ R13, R17, R18,

R19, R20 5

11 Resistor ¼ W 1% 68 KΩ R16 1

12 Resistor ¼ W 1% 6,8 KΩ R21 1

13 Resistor ¼ W 1% 330 KΩ R23, R24 2

14 Resistor ¼ W 1% 4,7 KΩ R25, R30 2

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 21

S/N DESCRIPTION VALUE DESIGNATOR QTY. COMPETITOR REQUEST COMPETITOR SIGNATURE JURY SIGNATUR E

16 Resistor ¼ W 1% 1,5 KΩ R29 1

17 Multiturn /

Variabel Resistor 5 KΩ R5 1

18 Cap. MKM 100 nF

C1, C3, C4, C5, C6, C7, C8, C9, C10, C13, C15, C16, C17, C18, C19, C20, C21, C26, C28, C30

20

19 Cap. Ceramic 150 pF C2 1

20 Cap. MKM 330 nF C11 1

21 Cap. Ceramic 680 pF C12 1

22 Cap. Tantalum 2,2 uF C14 1

23 Cap. Ceramic 68 pF C22 1

24 Cap. MKM 1 nF C23, C32 2

25 Cap. Ceramic 220 pF C24 1

26 Cap. MKM 4,7 nF C25 1

27 Cap. Electrolit 47 uF C27, C29 2

28 Cap. MKM 22 nF C31 1

29 IC Regulator L 7805 U1, 1

30 IC Logic Gate HD

74HC86N U2, U6, U8 3 31 IC Logic Gate SN

74HC08N U3, U13 2

32 IC Logic Gate SN

74HC32N U4, 1

33 IC Binary

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 22

S/N DESCRIPTION VALUE DESIGNATOR QTY. COMPETITOR REQUEST COMPETITOR SIGNATURE JURY SIGNATUR E

34 IC Timer NE555 U7, U9 2

35 IC Counter SN

74LS93 U10 1

36 IC Logic Gate 74HC4075 U11, U14 2

37 IC Logic Gate SN

74HC04 U12 1

38 IC SMD 74HC4060 U15 1

39 IC Op Amp TLV2372 U16, U17 2

40 Led Red Led Red

3mm D1 1

41 Led Red Led Green

3mm D2, D3, D4, D5 4

42 Push Buttom PB 2 Pin S1 1

43 Terminal Block 3 Pin

T-Block 2

Pin P1 1

44 Header Molek 2 Pin

Header

Molek P2 1

45 Soket Molek 2 Pin

Soket

Molek P2` 2

46 Headsink Almunium

Headsink

L7805 U1` 1

47 Soket IC 14 Pin 14 Pin

U2`, U3`, U4`, U7`, U8`, U10`, U11`, U12`, U13`, U14`, U15`

11

48 Soket IC 16 Pin 16 Pin U5` 1

49 Soket IC 8 Pin 8 Pin U6`, U9`, U16`,

U17` 4

50 Spiser 1 Cm Spiser

Hexagonal 4

51 Wire 20 Cm Wire AWG22

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 23

S/N DESCRIPTION VALUE DESIGNATOR QTY. COMPETITOR REQUEST

COMPETITOR SIGNATURE

JURY SIGNATUR

E

52 Wire 20 Cm Wire AWG22

Black 1

53 Wire 20 Cm Wire 2 Layer 1

54 PCB Double Layer

16 x 10 CM

PCB Fault

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 24

Fault Finding & Repair – Answer Script

DEFECTIVE PART FAULT SYMBOL

Fault #1

BEFORE AFTER

Measurement #1

Node: _______

DEFECTIVE PART FAULT SYMBOL

Fault #2

BEFORE AFTER

Measurement #2

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 25

DEFECTIVE PART FAULT SYMBOL

Fault #3

BEFORE AFTER

Measurement #3

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 26

Measurement – Answer Script Measurement #1

Measurement SCHEMATIC

Measurement Output

Vertical Settings:

/div

Horizontal Settings:

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 27

Verification output graph

Calculation Volt peak to peak with formula Calculation frequency with formula

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 28

Measurement #2

Measurement SCHEMATIC

Measurement Output

Vertical Settings:

/div

Horizontal Settings:

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 29

Verification output graph

Calculation Volt peak to peak with formula

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 30

Measurement #3

Measurement SCHEMATIC

Measurement Output

Vertical Settings:

/div

Horizontal Settings:

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 31

Verification output graph

Calculation Volt peak to peak with formula

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 32

Measurement #4

Measurement SCHEMATIC

Measurement Output

Vertical Settings:

/div

Horizontal Settings:

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 33

Verification output graph

Calculation Volt peak to peak with formula Calculation frequency with formula

Test Project proposal for skills competition LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016 34

SELAMAT BERLATIH !!!

Akan dilakukan revisi soal:

Verification output graph

Calculation Volt peak to peak with formula

Test Project proposal for skills competition

LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016

30

Measurement #3

Measurement SCHEMATIC

Measurement Output

Vertical Settings:

/div

Horizontal Settings:

/div

Verification output graph

Calculation Volt peak to peak with formula

Test Project proposal for skills competition

LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016

32

Measurement #4

Measurement SCHEMATIC

Measurement Output

Vertical Settings:

/div

Horizontal Settings:

/div

Verification output graph

Calculation Volt peak to peak with formula

Calculation frequency with formula

Test Project proposal for skills competition

LKS_2017_XXV_TP16_FFRM_EN

Version: 1.0

Date: 20.10.2016

34

SELAMAT BERLATIH !!!

Akan dilakukan revisi soal: