SERVICE TRAINING

Presents to

Asianstar Technology Co. Ltd.

Avesco Marketing Corporation
Electronics Solution Co., Ltd.
Westek Electronics Pty Ltd

Presented by Alvin Quah // 17~19/04/2007

 Contents of Training

●Specifications
●Block & Wiring Diagrams
●Principles of Work    
●Structure of Equipments
●Guidance and Methodology of
Troubleshooting
●Calibration          
●Practical     
●Q & A   
63 Series AC Power Source
Specification
 I/P

I/P
Transformer
Triangle Isolated
MI
Keypad Rectifying Wave PWM Triggering
CR
Filter Generator
OP
LED
RO IGBT
CES
OFF SET
Block Diagram SO Voltage Setup Transformer &
R Filter
Synthesized Synthesized O/P
Frequencies Sine waves
Periodic Sampling
Frequency Feedback
ALARM
Voltage
EEPROM
Metering
Memory Module
A/D Signal
Processing
Protection Over Current
Control Measurement
Triggering
Protection
Circuit
FUSE Breaking IGBT Overload
Measurement Measurement
Over Temperature
Power Failure
Measurement
Measurement
INVERTER DC BUS
H / L Measurement
Wiring Diagram (63 Series)
Wiring Diagram (63 Series)
Wiring Diagram (64 Series)
 Principle of Work

1.A controller produces a triangle wave voltage of

20Vp-p with frequency 10KHz to ANLOG and the
ANLOG will generate and compare an alternating
triangle waveform with the ideal sine waveform. It
will then produce four SPWM before going through
a DRIVER. From the DRIVER, it passes through
photocouplers for isolation process, and to be used as
a triggering signal to the full-bridge IGBT.
1.Upon triggering the IGBT, the transformer T2
produces an ideal waveform of SPWM at the
secondary output. The Magnetic Contactor (MC)
may switch between high and low range of output
and eventually produces an output voltage with
feedback current and voltage regulation. At the
time, the LED displays will also indicate each
voltage, current and power from that.
 Structure of Equipment

PCB Function
2PCB-ANG63-A06 Analog Board

2PCB-CON63-A07 Main Control Board

2PCB-DRV63-A01 Driver Board

2PCB-DSP6612-A01 Display Board

2PCB-OPT63-A00

2PCB-SCR63-A01 Soft Start Board

2PCB-SNB63-A00 Snubber Board

 Important ICs on Mainboard
(CON63)
CPU: IC26 (P/N:IC89516AC25J)
–Programmed with firmware, BA XXX
EEPROM: IC16 & IC17 (P/N: IC93C66)
–Calibration required when using new ICs
 Guidance and Methodology of
Troubleshooting
●General Failure
Abnormal situation Possible causes and solutions

LCD does not have digital display
FAIL is displayed and buzzer beeps when
starting the machine
FUSE is displayed when starting the
machine
No response to pressing of any key on the
panel
1. Check if the input power is correct.
2. Check if FUSE is burnt.
3. Make sure if wire connection from SCN7 of 2PCB-CON63 PCB to SCN1 of
2PCB-DSP6612 PCB is correct.
1. Check if the input power is correct.
2. Test DC voltage at both ends of Capacitor, if it is about 270VDC.
1. Check if FUSE is burnt.
1. Check if LOCK is locked.
2. Check if CPU is normal.
Voltage display is 0.00V 1. Check if the power is correct.
2. Check if the working voltage is normal
3. Test TP8 of 2PCB-ANG63 PCB for sinusoidal wave.
a. Check IC5, 6, 9 of 2PCB-ANG63 PCB in case of NO,
b. Check IC16, 17 of 2PCB-CON63 PCB in case of YES.
3. Check if SCR is burnt.

The voltage showed is not the set value 1. Check if the power is correct.
2. Check if the working voltage is normal
3. Test TP8 of 2PCB ANG63 PCB if its sinusoidal wave is normal.
4. Check IC15 of 2PCB-ANG63 PCB.

Current display is incorrect 1. Check if P.F value is lower than that specified in specification.
2. If the calibrated value is correct.
3. Check IC14 of 2PCB-ANG63 PCB.
●Troubleshooting Methods

1.Remove
○ CN5 of SCR63 =>No supply to DC Bus
○ JP4 of CON63 =>No low DC signal
2.Put JP3 of CON63 to “REF”
3.Remove
○ CN5 of DRV63 (R, S & T phase for 3 phase output) =>No supply to
DRV63
4.Press
○ “SYSTEM” and power ON =>Pre-calibration mode
1.Measure waveform
○ Probe Hi to Tp 1 of CON63 and Probe Lo to IC27
(Heatsink) of CON63
Result of after “TEST” pressed:
■ Triangle waveform of Vp-p=20V, 10KHz
○ Probe Hi to Tp 8 of ANG63 and Probe Lo to Tp 23 of
ANG63
Result of after “TEST” pressed:
■ Tri-Square waveform of Vp-p=25V, 50Hz
1.Connect CN5 of DRV63
2.Repeat Step (4)
3.Measure waveform:
○ Probe Hi to Tp 8 of ANG63 and Probe Lo to Tp 23 of
ANG63
Result of before “TEST” pressed:
■ Sine waveform at below horizontal origin
Result of after “TEST” pressed:
■ Pure Sine waveform at middle of horizontal origin
○ Probe Hi to Tp 1 of DRV63 and Probe Lo to Tp 2 of
DRV63
Result of before and after “TEST” pressed:
■ DC line of 20V
○ Probe Hi to R36,R29, R26,R27 of DRV63 and Probe Lo to
Tp 2 of DRV63
Result of before “TEST” pressed:
■ No waveform
Result of after “TEST” pressed:
■ PWM of 20V, 10KHz
 1.Repeat (6) to (8) for S-phase and T-phase respectively (For
three phases output only)
2.Connect: CN5 of SCR63
3.Repeat (6), (7) and (8a)
4.Connect: JP4 of CON63
JP3 of CON63 to “ADJ” =>Original Setting
5.Repeat (6), (7) and (9) to output and verify the unit is fine.
○ In pre-calibration mode, recommended to test output at 10V, 50V,
100V, 150V, 200V, 250V & 300V.
6.Run in normal mode without pressing “SYSTEM” to
power on.
 Calibration
● Press and hold “LOCK/LOCAL” key while turn ON the AC Power Source.

● Everytime after each calibration item, press “LOCK/LOCAL” key to

save the data stored and the calibration is completed.

● V-LO Calibration: Press “ ︿” or “ ﹀” key from the Frequency

display to select “V-LO". Connect a true RMS Voltmeter in output and
press TEST key and output a 150VAC voltage. Referring to the RMS
Voltmeter, press “ ︿ “ or “ ﹀“ key from the Current display to set
the voltage accordingly.
●V-HI Calibration: (As V-LO)
●A-LO Calibration: Press “ ︿” or “ ﹀” key
from the Frequency display to select “A-LO”.
Connect in series with a variable resistor as load and
a true RMS Ammeter in output and press TEST key
to a 100VAC voltage. Referring to the Ammeter,
press “ ︿ “ or “ ﹀“ key from the Current
display to set the current accordingly.
●A-HI Calibration: (As A-LO)
●P-LO Calibration: Press “ ︿” or “ ﹀” key
from the Frequency display to select “P-LO".
Connect a variable resistor as load and a true RMS
Power Meter in output and press TEST key to output
a 100VAC voltage. Referring to the Power Meter,
press “ ︿ “ or “ ﹀“ key from the Current
display to set the power accordingly.
●P-HI Calibration: (As P-LO)
●Press “ ︿” or “ ﹀” key from the Frequency
display to select the R, S or T phase (for 3-phase
output models).
●After the calibration is complete.
Q & A
 Preliminary Exam

1.Please explain briefly Over Current Fold Back

feature.
2.How to enter into Non-calibration mode for
troubleshooting process?
3.What does the AcLP and IgBT mean?
4.What is the button to press and store the calibration
data after each of the calibration item is done?
5.In what condition the OCP will appear?
6.What is PFC and the benefit of this PFC?
End of Series
62 Series AC Power Source
Specification
 62 Series ~

A. Selection of Input Voltage Range

Input voltage of 6210 is selectable as 115VAC or 230VAC. The
specific jumper setting is to determine the range of input
voltage.
 Block Diagram
MIC I/P
ROP Keyboard
RO Isolated
CES Transformer
Display
SOR

Rectifier &
Voltage Control
Filter

Sine Wave O/P

Frequency Control Power Output
Synthesizer
Amplifier Transformer

Frequency Sensor
Voltage & Current
Feedback
EEPROM Memory

A/D Voltage & Current

Sensor
 Principle of Work
●62 Series AC sources use linear isolated
transformer to rectify the AC main voltage for
the DC supply to the power amplifier. The
advantage of linear rectifier is that it produce a
very smooth and low noise DC level. This is a
major factor to have clean and low distortion
AC output voltage.
●The control circuit of the AC source is
microprocessor control and it is fully digital. The
CPU regulates the frequency and amplitude of the
sine wave via the digital synthesizer. When the CPU
receives a voltage setting, the CPU will generate a
sine wave and send a signal to the power amplifier
for amplification. Then the CPU will read back from
the digital feedback loop to fine tune the output
voltage to within the specification.
●Two feedback loops are used to regulate the stability
of the output voltage. One is Analog feedback for
quick response, typically within 100μs. The
regulation of ±0.5% of the set voltage is reached.
The other one is Digital feedback. The CPU reads the
output voltage and compares with the setting and
adjust the amplitude of the synthesized voltage
accordingly. The accuracy of the output voltage will
be within ±0.1 V of the setting.
●The output metering circuits reads True RMS
value of voltage and current. The
LED display shows True RMS readings. The
Power and Power Factor readings
are derived from the voltage and current
measurement.
 Structure of Equipment

PCB Function
2PCB-AMP-500-A02 Main Amp Board

2PCB-CFC-300-A03 Pre Amp Board

2PCB-CFW-318-A09 Main Control Board

2PCB-82147-A00 ROM Board

2PCB-CFW-OP7-A02 Female Control Board
2PCB-CSW-01-A00 Input Protection Board

2PCB-DSP-12-A00 Display Board

Structure of Equipment
 Important ICs on Mainboard
(CFW-318)
CPU: IC19 (P/N:IC89C52)
–Programmed with firmware, AB XXX
EEPROM: IC23 (P/N: IC93C46)
–Programmed with firmware, A XX
–Calibration required when using new ICs
Guidance and Methodology of Troubleshooting

● Alarm sounds when power on

Verify the unit without load and the detailed procedure is ：
A. Check if the resistor R/C-5-0.3 of 2PCB-AMP-500 is open,
short on TR5198, or damage on R6 、 R8 （ 39Ω ） and ZNR (ZP3)
of 2PCB-CFW-OP7.
 ● Alarm sounds with load
A. Verify the load current is within specification and
understand the actual inrush current of the load
B. Check 2PCB-CFW-318, 2PCB-CFC-300, 2PCB-CFW-OP7, 2PCB-
AMP-500 and sine wave output.
C. Check each of TR-5198 if it is damaged
D. Adjust VR3 of 2PCB-CFC-300 PCB (Be cautious on the
capacity limit when adjustment)
● Inaccurate Voltage
1.Power on in non-calibration mode (press “COARSE” and
power on) and set output voltage to be 240V. Compare
displayed voltage with actual voltage. Any difference is
within 25V could be solved by recalibration. Otherwise,
verify EEPROM (IC93C46) of 2PCB-CFW-318.
2.Should any difference is huge, check 2PCB-CFW-318, 2PCB-
CFC-300, 2PCB-CFW-OP7, output sine wave of 2PCB-AMP-500,
secondary voltage of T2, switching circuit of 2PCB-CFW-
OP07 and adjust VR2 of 2PCB-CFC-300.
3.Check secondary voltage of PT and TP11, TP12 and A/D
circuit of PCB-CFW-318.
 ● Inaccurate voltage with loads
A. Ensure output power does not exceed allowed capacity.
B. Check 2PCB-CFW-318, 2PCB-CFC-300, 2PCB-CFW-
OP7, output sine wave of 2PCB-AMP-500.
C. Check resistor R/C-5-0.3 of 2PCB-AMP-500 for any burn
signage or track broken .
D. Check the connection of each connectors.
E. Adjust VR1 and VR2 of 2PCB-CFC300 with specific test
procedure.
 ● Malfunction of all buttons after power on
A. Ensure front panel lock is not enabled.
B. Check connection between 2PCB-CFW-318 and 2PCB-DSP-12.
C. Verify the buttons are in good condition.
D. Replace 2PCB-CFW-318.
 Calibration
● To enter the calibration mode, hold down the Lock key and turn the power ON.
Continue to hold on the Lock Key for about 2 seconds until the LED displays are
stable.

● Voltage Calibration
Connect a calibrated AC voltage meter to the AC source output as shown above. Press
the “PF” key. The AC source will output a voltage about 240V. Look at the Voltmeter
reading, use “∧” and “∨” key to adjust the reading on the voltmeter to 240 V. Press
the “LOCK” key to confirm.
 ● Low Range Ammeter Calibration
Connect a Calibrated True RMS Ammeter and a variable resistor to the output of the
AC source as shown above. Make sure that the “COARSE” LED is OFF. If it is
lighted, press the “COARSE” key to turn it OFF. Press the “A” key. The AC source
will output 110 V immediately. Adjust the variable resistor until the reading on the
Ammeter reads 1.800A. Press the “LOCK” key to confirm.

● High Range Ammeter Calibration

Connect a Calibrated True RMS Ammeter and a variable resistor to the output of the
AC source as shown above. Make sure that the “COARSE” LED is ON. If it is not,
press the “COARSE” key to turn it ON. Press the “A” key. The AC source will output
110 V immediately. Adjust the variable resistor until the reading on the Ammeter has
right reading (500VA=4A,1KVA=8A,2KVA=16A). Press the “LOCK” key to
confirm.
 ● Low Range Power Calibration
Connect a Standard Wattmeter and a variable resistor to the output of the AC source as
shown above. Make sure that the voltage sensing points are as close to the AC source
output as possible to achieve good result. Make sure that the “COARSE” LED is OFF.
If it is lighted, press the “COARSE” key to turn it OFF.
Press the “W” key. The AC source will output 240 V immediately. Adjust the output
voltage or the variable resistor until the reading on the Wattmeter reads 300 W. Press
the “LOCK” key to confirm.
● High Range Power Calibration
Connect a Standard Wattmeter and a variable resistor to the output of the AC source as
shown above. Make sure that the voltage sensing points are as close to the AC source
output as possible to achieve good result. Make sure that the “COARSE” LED is ON.
If it is not lighted, press the “COARSE” key to turn it ON. Press the “W” key. The
AC source will output 110 V immediately. Adjust the output voltage or the variable
resistor until the reading on Wattmeter has right reading
(500VA=450W,1KVA=900W,2KVA=1800W). Press the “LOCK” key to confirm.
Q & A
 Preliminary Exam
1.What is the difference between 61, 62, 63, 64, and 65 in terms of function
and type? Please state the number of output phases of each series?
2.For 62 series, what is the V and I specification for? If the output is 125V
at 1.8A, what is the tolerance range allowed? And, what does the
following spec mean:-
Voltage (V), Accuracy +/-(1% of reading + 1 count), Resolution: 0.1V
Current (I), Accuracy +/-(1% of reading + 5 count), Resolution: 0.001A.
3.If the LED of 0-150V is lit, what is the maximum current for 6205 can be
loaded?
4.How to calibrate Voltage and if the output shows 237V, how to make the
adjustment?
5.At no-load condition, the fuse of 6205 is blown upon power up, how to
troubleshoot and what is the possible cause?
End of Series
74 Series Electrical Safety Analyzer
Specification
 7400 Series ~

A. Table of Model
MODEL MODEL ACW DCW IR GND CONT. Analog
Classification:
NUMBER CHECK Meter
0 7430 V V V X X V
1 7440 V V V V X V
2 7550DT V V V X V X

3 7564SA V V V V X X

4 7410 V V V X X X
5 7410 V V V X X X
6 7420 V V V X X X
7 7420 V V V X X X
8 7530DT V V V X V X

9 7520DT V V V X V X

10 7412 V V V X X V
11 7540DT V V V X V X

12 7422 V V V X X X
Block Diagram
 Principle of Work
● 4 test capabilities (ACW, DCW, IR and GND) shares a
AMPLIFIER of 8V/35A specification.

● ACW
CONTROLLER sends 50/60Hz sine wave signal to AMP for signal
amplification. T2 will step up the output voltage to 5000V.

● DCW
CONTROLLER sends 600Hz sine wave signal to AMP for signal
amplification. T2 will step up the output voltage to 6000V
and pass through rectifier to obtain DC high voltage
output.

● IR
 ● GND
CONTROLLER sends 50/60Hz sine wave signal to AMP. After
amplification, the signal is directed to current output.
 Structure of Equipment

PCB Function
2PCB-7440-A17 Main Control Board
2PCB-AMP-270-A03 Main Amp Board

2PCB-CHV-06-A06 High Voltage Board

2PCB-CKB-03-A00 Keypad Board

2PCB-CSW-04-A01 Input Protection Board

2PCB-CVM-03-A01 CVM Board

2PCB-REC-17-A01 Main Rectifier Board

2PCB-DSP-06-A00 Display Board

2PCB-RS232-A02 RS232 Interface Board

 Important ICs on Mainboard (7440)

CPU: IC12 (P/N:IC89516AC25P)

–Programmed with firmware, AB XXX

EEPROM: IC40 (P/N: IC28C256)

–Programmed with EEPROM Data, D02
Smart GFI: IC66 & IC67 (Both P/N:ICLM311)
Guidance and Methodology of Troubleshooting

● No LCD display after power on

A. Check input voltage 115V/230VAC.
B. Verify FUSE is good and installed properly.

● No LCD display if above step is verified

A. Check 7.372MHz from crystal of PCB 7440
a. If no output signal, check IC20 or Crystal.
b. If yes, check IC12.
B. Check TP27 of PCB 7440 as at +5VDC.
a. If no +5VDC ， check IC46, D22 and D23.
C. Check connection from CN8 of PCB 7440 to CN1 of LCD.
D. LCD failure
 ● Malfunction of keyboard and cannot proceed test
operation A. Observe if LED of LOCK is lit. If yes, the
keyboard is locked. Press “LOCK” to disable the LOCK.
B. Check connection from CN9 of PCB 7440 to CN1 of PCB CKB-
03.
C. Check IC13 and IC24 of PCB 7440.

● Inaccurate Ammeter
A. Recalibrate ammeter.
B. IC36 of PCB 7440 is faulty.
 ● LCD displays 0.00 KVAC
A. Verify TP12 of PCB 7440 has sine wave signal ：
a. If no, check IC21, IC41, IC36 and IC33.
b. Otherwise, PCB AMP-270 is possibly down.

B. Check voltage of “+” and “-” from PCB AMP-270 ：

a. If no, check BR1 and BR2 of REC-17.
b. Otherwise, check TP1 of AMP-270 if it has output ：
i. No output at TP1 – Check Q1-Q18, R1-R26 and IC1.
ii. Output at TP1 – T2 failure
iii. If T2 has output, check RY1, R2 and R1 of PCB CHV-06.

C. Verify Pin 9 (IC18) of PCB 7440if it has output. If no

output, check IC18 、 IC21 、 IC2 、 IC17 。
D. If PCB CSU-105 has no HV output, check RY of PCB CSU-
105.
● Error shows HI FAIL
A. Check IC34 、 IC35 、 IC38 、 IC39 、 IC48 、 IC49 and
TP18 of PCB 7440.

● Voltage does not match as per setting

A. Recalibrate voltage.
B. Check IC36 of PCB 7440 IC36 。

● No buzzer sound when alarm

A. If TP3 of PCB 7440 is LO, BZ1 might be faulty.
 Calibration
● ENTER THE CALIBRATION MODE
○ Press the “0”and “1” keys simultaneously and then turn the input power switch
on. The program will automatically enter to the calibration mode. Use the “”
(Forward) and “” (Backward) keys to move through the calibration menu. The
following instructions follow the sequential forward scrolling through the
menu.

● PASSWORD SETTING
○ Press the “” key, the program will advance to the Password setting mode. The
Password can be any four (4) digit number. If the Password is set to “0”, the
keyboard lock out will be selected by the LOCK key on the front panel without
a Password. The Password default is preset to “0” at the factory.
● MEMORY LOCK SELECTION
○ Press the “” key, the program will advance to the Memory Lock selection mode. If
the MR-Lock is selected “ON”, the Memory selection Menu will be disabled when in
Lock Mode. If the MR-Lock is selected “OFF”, the Memory selection Menu will be
enabled when in Lock Mode. Different memories can be recalled but the test parameters
or steps can not be changed. The MR-Lock default is preset to “ON” at the factory.

● ACW VOLTAGE CALIBRATION

○ Press the “” key, the program will advance to the AC Voltage calibration of the
ACW test. Connect an AC standard voltage meter which can measure up to 5000V to the
output connectors and then press the “TEST” button, the program will automatically
generate an output of about 5000VAC. Use the Numeric keys to enter the standard value
of voltage, unit “V”, and then press the “ENTER” key to store the standard value
of AC hipot voltage for calibration.
● DCW VOLTAGE CALIBRATION
○ Press the “” key, the program will advance to the DC Voltage calibration of the
DCW test. Connect a DC standard voltage meter which can measure up to 6000V to the
output connectors and then press the “TEST” button, the program will automatically
generate an output of about 6000VDC. Use the Numeric keys to enter the standard value
of voltage, unit “V”, and then press the “ENTER” key to store the standard value
of DC hipot voltage for calibration.

● IR VOLTAGE CALIBRATION
○ Press the “” key, the program will advance to the DC Voltage calibration of the IR
test. Connect a DC standard voltage meter which can measure up to 1000V to the output
connectors and then press the “TEST” button, the program will automatically
generate an output of about 1000VDC. Use the Numeric keys to enter the standard value
of DC voltage, unit “V”, and then press the “ENTER” key to store the standard
value of IR test voltage for calibration.
● AC CURRENT, 40mA RANGE, CALIBRATION
○ Press the “” key, the program will advance to the AC 40mA range calibration of the
ACW test. Connect a resistor about 100K/10W in series with a AC standard Ammeter
which can measure up to 10mA to the output leads. The Ammeter should be connected
to the return lead, then press the “TEST” button, the program will automatically
generate an output of about 1000V/10mA. Use the Numeric keys to enter the standard
value of current, unit “mA”, and then press the “ENTER” key to store the standard
value of AC 40mA range for calibration.

● AC CURRENT, 3.5mA RANGE, CALIBRATION

○ Press the “” key, the program will advance to the AC 3.5mA range calibration of the
ACW test. Connect a resistor about 100K/10W in series with a AC standard Ammeter
which can measure up to 3mA to the output leads. The Ammeter should be connected to
the return lead, then press the “TEST” button, the program will automatically
generate an output on the output connectors about 300V/3mA. Use the Numeric keys to
enter the standard value of current, unit “mA”, and then press the “ENTER” key to
store the standard value of AC 3.5mA range of the hipot test.
● DC CURRENT, 10 mA RANGE, CALIBRATION
○ Press the “” key, the program will advance to the DC 10mA range calibration of the
DCW test. Connect a resistor about 100K/10W in series with a DC standard Ammeter
which can measure up to 10mA. The Ammeter should be connected to the return lead,
then press the “TEST” button, the program will automatically generate an output of
about 1000V/10mA. Use the Numeric keys to enter the standard value of current, unit
“mA”, and then press the “ENTER” key to store the standard value of DC 10mA
range.

● DC CURRENT, 3500A RANGE, CALIBRATION

○ Press the “” key, the program will advance to the DC 3500A range calibration of
DCW test. Connect a resistor about 100K/10W in series with a DC standard Ammeter
which can measure up to 3000A. The Ammeter should be connected to the return lead,
then press the “TEST” button, the program will automatically generate an output of
about 300V/3000A. Use the Numeric keys to enter the standard value of current, unit
“A”, and then press the “ENTER” key to store the standard value of DC 3500A
range.
● 11 DC CURRENT, 350A RANGE, CALIBRATION
○ Press the “” key, the program will advance to the setting and reading of DC 320A
range calibration of the DCW test. Connect a resistor about 1M/0.25W in series with a
DC standard Ammeter which can measure up to 300A. Connect the Ammeter to the
return leads, then press the “TEST” button, the program will automatically generate
an output of about 300V/300A. Use the Numeric keys to enter the standard value of
current, unit “A”, and then press the “ENTER” key to store the standard value of
DC 350A range.

● IR RESISTANCE, XXX.XM RANGE, CALIBRAITON

○ Press the “” key, the program will advance to the XXX.XM range calibration of
the IR test. Connect a 50M/0.25W/1000VDC standard resistor to the output connectors,
then press the “TEST” button, the program will automatically calibrate the XXX.X
M range of IR test.
● IR RESISTANCE, XXXXM RANGE, CALIBRATION
○ Press the “” key, the program will advance to the XXXXM range calibration of the
IR test. Connect a 50M/0.25W/1000VDC standard resistor to the output connectors,
then press the “TEST” button, the program will automatically calibrate the XXXX
M range of IR test.

● GROUND CONTINUITY, AC VOLTAGE CALIBRAITON (Model 7440 only)

○ Press the “” key, the program will advance to the AC Voltage calibration of the
Ground continuity test. Connect a AC standard voltage meter which can measure up to
10VAC to the High current and Return output leads, then press the “TEST” button,
the program will automatically generate an output of about 7VAC. Use the Numeric
keys to enter the standard value of voltage, unit “V”, and then press the “ENTER”
key to store the standard value of AC Ground Continuity voltage.
● GROUND CONTINUITY, AC CURRENT CALIBRATION (Model 7440 Only)
○ Press the “” key, the program will advance to the AC Current calibration
of the Ground continuity test. Connect a AC standard Ammeter which can
measure up to 30AAC to the High current and Return output leads, then press
the “TEST” button, the program will automatically generate an output on
the output leads of about 30AAC. Use the Numeric keys to enter the standard
value of current, unit “A”, and then press the “ENTER” key to store the
standard value of AC Ground Continuity current.
 Preliminary Exam
1.Please state what are the measurement units for
ACW, IR and GB.
2. How to verify if a 7440 is working properly?
3. What are the important ICs in the mainboard 7440?
4. How to enter into calibration mode for 7440.
5. What are those resistor values required to calibrate a
7440?
6. When LCD shows 0.00KV after each test, what are
those possible PCBs might be faulty?
Q & A
End of Series
71 Series Hipot (III) Tester
 71 Series ~

A. Table of Model
Classification:
MODEL ACW DCW IR CONT.
CHECK

7130 √ X X X

7132 √ X √ X

7140 √ √ X X

7142 √ √ √ X
Specification
 Block Diagram
INPUT OUTPUT
TRANSFORMER AMPLIFIER
TRANSFORMER
AC INPUT 115/230V 115V T1

+
V+ T2

Selec H.V
0V -
115/230V tSoft 115V +
+

Start 0V
V-

DC
AC
Controller
Power
HIGH
VOLTAGE
OUTPUT
DISPLAY
VOLTAGE &
KEYBOARD CURRENT
CONTROLLER SENSOR

Remote
Input/Outp
ut
RS485
Wiring Diagram
 Operating Principle
ACW:
● CON3670 sends a sine wave signal of 50/60Hz to AMP3670.
● AMP3670 amplifies the signal and passes T2 for step up of
voltage (Max voltage: 5KVac) and to be delivered as output
voltage.
● At the same time, there will be a feedback loop of voltage and
current.
● This feedback voltage and current are used as load regulation
and measurements of voltage and current.
DCW:
● CON3670 sends a sinewave signal of 600Hz to AMP3670.
● AMP3670 amplifies the signal and passes T2 for step up of
voltage.
● It will be rectified and sent as output voltage (Max voltage:
6KVdc).
● At the same time, there will be a feedback loop of voltage and
current.
● This feedback voltage and current are used as load regulation
and measurements of voltage and current.
IR:
● Same as DCW
● Max voltage: 1KVdc
● At the same time, there will be a feedback loop of voltage and
current.
● This feedback voltage and current are used as load regulation
and measurements of voltage and current.

● Measurement of Resistance is the conversion of V/I

 Structure of Equipment

PCB Function
2PCB-AMP3670-A07 Main Amp Board

2PCB-CON3670-A06 Main Control Board

2PCB-HRY3670-A02 High Voltage AC/DC SWITCH Board

2PCB-HV3670-B02 High Voltage Board

2PCB-KEY3670-A00 Keypad Board

2PCB-PWR3670-A02 Input Power Select Board

Structure of Equipment
 Important ICs on Mainboard
(CON3670)
CPU: IC19 (P/N:ICW78E516BP-40JC)
–Programmed with firmware, BA XXX
EEPROM: IC15 & 20 (P/N: IC93C66)
–Calibration required when using new ICs
Guidance and Methodology of Troubleshooting

●SHORT
○ SHUNT Failure (R3, R4 of HV3670)
○ SHORT detection circuit (CON3670)
○ Current Feedback circuit (CON3670)
●Arc-Fail
○ Relay faulty
○ ARC detection circuit (CON3670)
○ ARC detection circuit (HV3670)
●BREAKDOWN
○ Relay faulty (ACW: RY1 of HRY3670)
(DCW: RY2 of HRY3670)
○ SHORT detection circuit (CON3670)
○ ARC detection circuit (CON3670)
●Fuse Burned
○ Relay faulty (RY2 of HRY3670)
○ Amplifying circuit (Transistor, Resistors/Bridge Diode of
AMP3670)
●Unable to power on
○Soft Start circuit (R1 & R2 of PWR3670)
○Fuse burned
○Fuse holder loosen
●No display
○LCD failure
○Improper connection of LCD flat cable
●Malfunctioned TEST Or INTERLOCK OPEN

● Remote supply (9Vac) of input transformer (T1) is faulty and

no voltage.
●Inaccurate current measurement for below 3.500mA

● A. Lost data of calibration

● B. Improper connection of HV3670 RY2(RY-842-1C-C-
24)NC.
●Fluctuated output voltage or flickering on LCD
○Output transformer (T2) faulty
 Concept of Operation
●Setup and Features
1.Memory: Location to save our parameter for the
products need to test.
○ 71 Series Hipot III has 10 memories.
2.Step: Use for multiple test such as different voltage
setting, function setting or specification. Example;
You need to perform ACW, Insulation and Ground
Continuity test so you need to has step feature.
○ 71 Series Hipot III has 3 steps feature for each memory.
●Lock: With this feature it wouldn’t allow anyone to
change your specification you have saved in.
○ 71 Series Hipot III has Lock and Memory Lock features.
○ Press “F1” and power on ， it will temporarily
disable LOCK & Memory Lock of SYSTEM
parameters. Meanwhile, this allows to enter
SYSTEM and turn off LOCK as needed.
●Change of Model
○ Press “F1”+“F4” and power on
○ Key in Password=6666 and select desired
model.
○ Press “ENTER” to confirm before exit.
○ For special customized model, key in
Password-=7777 ， and select select desired
model. Press “F2” to switch from Normal to
Special.
● Initialization of EEPROM
○ Press “RESET” and power on, CPU will verify EEPROM data. If
the EEPROM has been initialized before ， there is no
necessary to perform this step. Otherwise, new EEPROM is
required for this initialization step.
 Calibration
Press “CAL” button at rear panel and power on to
enter Calibratin Mode (as figure below).  
 Calibration
● ACW Voltage Calibration
 
Press “v” KEY, select “AC 5000V ” and press ”Select” KEY.
Connect HV and RETURN channels to a High Voltage meter in
parallel. Press “TEST” KEY to output a 5KVac voltage. By
referring to the HV meter, set the voltage accordingly and press ENTER.

● DCW Voltage Calibration

Press “v” KEY, select “DC 6000V ” and press ”Select” KEY.
Connect HV and RETURN channels to a High Voltage meter in
parallel. Press “TEST” KEY to output a 6KVdc voltage. By
referring to the HV meter, set the voltage accordingly and press ENTER.
 Calibration
● IR Voltage Calibration
 
Press “v” KEY, select “IR 1000V ” and press ”Select” KEY.
Connect HV and RETURN channels to a High Voltage meter in
parallel. Press “TEST” KEY to output a 1KVdc voltage. By
referring to the HV meter, set the voltage accordingly and press ENTER.
● ACW High Range Current Calibration
Press “v” KEY, select “AC 20.00mA ” and press ”Select” KEY.
Connect a 100K resistor and true RMS Ammeter in series
with HV and Return. Press “TEST” KEY to output a 1KVac
voltage. By referring to the Ammeter, set the current accordingly and
press ENTER.
 Calibration
● ACW Low Range Current Calibration
 
Press “v” KEY, select “AC 3.500mA ” and press ”Select” KEY.
Connect a 100K resistor and true RMS Ammeter in series
with HV and Return. Press “TEST” KEY to output a 300Vac
voltage. By referring to the Ammeter, set the current accordingly and
press ENTER.
● DCW High Range Current Calibration
Press “v” KEY, select “DC 7.50mA ” and press ”Select” KEY.
Connect a 100K resistor and true RMS Ammeter in series
with HV and Return. Press “TEST” KEY to output a 700Vdc
voltage. By referring to the Ammeter, set the current accordingly and
press ENTER.
 Calibration
● DCW Low Range Current Calibration
 
Press “v” KEY, select “DC 3.500mA ” and press ”Select” KEY.
Connect a 100K resistor and true RMS Ammeter in series
with HV and Return. Press “TEST” KEY to output a 300Vdc
voltage. By referring to the Ammeter, set the current accordingly and
press ENTER.
● DCW Low Range Current Calibration (2)
Press “v” KEY, select “DC 350.0 A ” and press ”Select” KEY.
Connect a 1M resistor and true RMS Ammeter in series with
HV and Return. Press “TEST” KEY to output a 300Vdc voltage.
By referring to the Ammeter, set the current accordingly and press ENTER.
 Calibration
● IR Low Range Resistance Calibration
Press “v” KEY, select “IR 999.9MΩ” and press
”Select” KEY. Connect HV and RETURN channels to a
50M resistor in parallel. Press “TEST” KEY to
store the resistance value automatically.

● IR High Range Resistance Calibration

Press “v” KEY, select “IR 9999MΩ” and press
”Select” KEY. Connect HV and RETURN channels to a
50M resistor in parallel. Press “TEST” KEY to
store the resistance value automatically.
Q & A
 Preliminary Exam
1.What is the measurement units for following tests:-
1.ACW
2.DCW
3.IR
4.GB
2.Why we have to set the high limit for ACW and DCW?
3.What are the 3 resistance values required to calibrate the 71 series?
4.Please brief explain Lock and Memory Lock and its functions.
5.What is Smart GFI and how it judges the failure?
6.When display is showing Interlock Open, please state the possible causes.
7.If we experience the unit is unable to power on, what are the possible
causes?
End of Series
7700 Series Electrical Safety
Compliance Analzyer
 7700 Series ~

Table of Model Classification:

MODEL ACW DCW IR Ground Bond

7742 √ √ √ √

7740 √ √ √ √

7730 √ √ √ X
 Description of the block diagram

Description of 7740 block diagram

● It will be determined firstly whether there is any overload condition when testing,
and when CONTROLLER sends signal of the Relay to the SWITCH BOARD. If
there is overloaded, the protection circuit will send a LOW signal to
CONTROLLER, to stop the test at this time. Otherwise, it will be determined
whether the leakage is high. If so, the protection circuit will send a LOW signal to
CONTROLLER and stop the test.

● The SWITCH BOARD will feed back the signal of voltage, current and leakage at
this time, which is processed in the feed back circuit, generating voltage, current,
power and leakage feed back signal to the CONTROLLER for processing, and
then sending to DISPLAY for display.

● The reading may be used to determine the upper and lower limit of the voltage,
current, power, leakage and power factor and it is required to stop the test
immediately and display its information if it is found out that the limit is exceeded
or is under at the DELAY TIME.
Description of 7730 block diagram
● The description of 7730 is same as 7740, but it differs in that
the AMP amplifier of this model utilizes switching type
power sine wave amplifier. The sine wave input is cut into
frequency-modulated wave, and is used to control the width of
waveform according to the LEVEL high or low, and then the
LC filter is used to reduce it to the original sine wave.
 Operating Principle

1. ACW: CONTROLLER sends the sine wave of 50/60Hz to AMP7500, AMP

where the signal is amplified and sent to T2 for stepping up the voltage, with
the maximum output up to 5000VAC. The voltage and current feedback is
taken from the output terminal in the meantime, achieving a stabilized output
voltage, and voltmeter and ammeter indication.

2. DCW: The CONTROLLER sends 600Hz sine wave to AMP7500, AMP

where the signal is amplified and sent to T2 for stepping up the voltage, and
after half wave rectification and filtering for the maximum output up to
5000VDC. The voltage and current feedback is taken from the output terminal
in the meantime, achieving a stabilized output voltage, and voltmeter and
ammeter indication.
3. IR: Same as DCW, but the maximum output voltage is up to 1000VDC and the
voltage and current feedback is taken from the output terminal in the meantime,
achieving a stabilized output voltage and voltmeter, MΩ meter indication.
Note: The MΩ meter indication is obtained after converting with R= V/I.

4. GND: CONTROLLER sends the sine wave of 50/60Hz to AMP7500, AMP where
the signal is amplified and sent out directly, with the maximum output up to 8VAC/30
A. The voltage and current feedback is taken from the output terminal and in the
meantime, achieving a constant output current, and the current and mΩ meter
indication.

5. CONT.CHECK: ANG7500 BOARD generates a 0.1 ADC constant-current source

output, taking the voltage across LOAD, with the ground impedance obtained after
converting with R= V/I.
 Important ICs on Mainboard
(CON7500)
CPU: IC36 (P/N:IC27512) and
IC40 (P/N:IC78E516B)
–Programmed with firmware, BA XXX

EEPROM: IC26 (P/N: IC29C020)

–Programmed with EEPROM Data, F06
 Guidance and Methodology of Troubleshooting
Symptoms
No LCD indication and without
other power indication when power
on.
Analyzer is normal, but LCD no
display.
The keypad of front panel can not
operate.
Possible reasons and elimination
1. Check the input voltage setting, 115 V/230VAC.
2. Check and confirm whether fuse properly mounted or not.
3. Check for failed I/P mains switch.
4. Check R2, R3 at 2 PCB-PWR7500 for normal operation (10 Ω)
1. Check the connecting line from 2 PCB-KEY7500 to LCD.
2. Check the connecting line from 2 PCB-CON7500 to 2 PCB-
KEY7500.
3. Check LCD FOR failure.
4. Check LCD backlight for correct setting.
5. Check 2 PCB-KEY7500 IC1~ IC5 for normal operation.
6.
1. Check
Check 2thePCB-CON7500
machine and see if it is set to "LOCK" mode
2. Check connecting line from 2 PCB-CON7500 to 2 PCB-KEY7500.
3. Check the buttons for failure.
4. Check if the machine is set to " PLC Remote Control ON" mode or
not.
 Symptoms
LCD displays 0.00 KVAC
The ammeter display not correct
The display of voltage setting is
wrong.
Without alarm sound from the
buzzer
The indicators of PASS and FAIL
not bright
Possible reasons and elimination
1. Check 2 PCB-CON7500 TP21 for sine wave output:
a. If no, check IC47, IC41, IC48 and IC43 on the board.
b. If there is sine wave, may be 2 PCB-AMP7500 fails.
2. Check "V+" and "V-" voltage of 2 PCB-AMP7500:
a. If no, check MD1 and MD2
b. If there is voltage, check O/P for output:
i. Check Q1-Q10, R1-R25, IC1 if no 0/P output.
ii. If O/P has an output, may be transformer T2 fails.
iii. If transformer T2 has an output, check 2 PCB-HV7500 RY2, R3 and
R4.
1. Re-calibrate ammeter.
3. Check feedback attenuation resistor for open circuit.
2. Maybe EEPROM fails.
1. Re-calibrate voltmeter.
2. Maybe EEPROM fails.
1. If CON7500 TP7 is a H, maybe the buzzer BZ1 fails, if TP7 is a L,
check IC6.
1. Check the bulb for burnout.
 Symptoms Possible reasons and elimination

Abnormal display & output Error 1. EEPROM is faulty.

2. IC 43 in CON-7500 is faulty.

Screen picture appears after power 1. Press RESET to power on.

on (9002.,9003) 2. IC36 and IC40 (CPU), or IC26 (EEPROM) is faulty.
3. Re-calibrate
 Calibration
● The calibration step of OMNIA SERIRS: Press the rear panel "CAL" key to start,
enter the calibration mode: (as shown in the following diagram.)
Calibration
1. AC Hipot voltage ok Connect the
2. DC Hipot voltage ok 100KΩ load in
3. IR DC Voltage ok series with the
4. AC 40.00mA range 40mAAC standard
5. AC 3.500mA range current meter.
6. DC 20.00mA range --------------------------
7. DC 3.500mA range When the load is
8. DC 350.0uA range connected ， press
9. IR 999.9MΩ range TEST to start the
10. IR 9999.9MΩ range calibration
11. IR 50000MΩ range process.
12. GND Bond Voltage
13. GND Bond Current
14. AC Real 200W ， 40mA
15. AC Real 20W ， 40mA
16. AC Real 20W ， 3.5mA
17. AC Real 2W ， 3.5mA
18. DC Continuity 10Ω

▲Move up ▼Move down

● The ACW voltage calibration: With" ︿ ", " ﹀” key, select “AC
Hipot Voltage". A standard HV meter is connected at output HV,
RETURN terminals in parallel, press "TEST" key, the HV, RETURN
terminals will output a voltage about 5 KVAC at this time, enter the
reading of standard HV voltmeter, press "ENTER" key.

● The DCW voltage calibration: With" ︿ ", " ﹀” key, select "the DC
Hipot Voltage". A standard HV meter is connected at output HV,
RETURN terminals in parallel, press "TEST" key, the HV, RETURN
terminals will output a voltage about 5KVDC at this time, enter the
reading of standard HV voltmeter, press "ENTER" key.

● The IR voltage calibration: With" ︿ ", " ﹀” key, select "the IR DC

Voltage". A standard HV meter is connected at output HV, RETURN
terminals in parallel, press "TEST" key, a voltage about 1 KVDC at this
time will be delivered, enter the reading of standard HV voltmeter, press
● ACW high range current calibration: With" ︿ ", " ﹀” key, select "the
AC 40.00 mA range". The output terminals HV, RETURN are connected
with a load about 100 KΩ, and then connect a standard ammeter in serial,
press "TEST" key, a voltage about 1 KVAC at this time will be delivered,
enter the reading of standard HV voltmeter, press "ENTER" key.

● ACW low range current calibration: With" ︿ ", " ﹀” key, select "the
AC 3.500 mA range". The output terminals HV, RETURN are connected
with a load about 100 KΩ , and then connect a standard ammeter in serial,
press "TEST" key, a voltage about 300VAC at this time will be delivered,
enter the reading of standard HV voltmeter, press "ENTER" key.
● DCW high range current calibration: With" ︿ ", " ﹀” key, select "the DC
20.00 mA range". The output terminals HV, RETURN are connected with a load
about 100 KΩ, and then connect a standard ammeter in serial, press "TEST" key, a
voltage about 1KVDC at this time will be delivered, enter the reading of standard
HV voltmeter, press "ENTER" key.

● DCW low range current calibration: With" ︿ ", " ﹀” key, select "the DC 3.500
mA range". The output terminals HV, RETURN are connected with a load about
100 KΩ, and then connect a standard ammeter in serial, press "TEST" key, a
voltage about 300VDC at this time will be delivered, enter the reading of standard
HV voltmeter, press "ENTER" key.

● DCW low range current calibration: With" ︿ ", " ﹀” key, select "DC 350.0 μ
A range". The output terminals HV, RETURN are connected with a load about
1KΩ, and then connect a standard ammeter in serial, press "TEST" key, a voltage
about 300VDC at this time will be delivered, enter the reading of standard HV
voltmeter, press "ENTER" key.
● IR low resistance calibration: With" ︿ ", " ﹀” key, select "the IR
999.9 M range". The output terminals HV, RETURN are connected with a
standard resistor 50MΩ. Press "TEST" key, it will enter automatically at
this time the reading of the standard resistance, completing the low
resistance calibration.

● IR high resistance calibration: With" ︿ ", " ﹀ " key, select "the IR 9.999
G range". The output terminals HV, RETURN are connected with a
standard resistor 50MΩ. Press "TEST" key, it will enter automatically at
this time the reading of the standard resistance, completing the high
resistance calibration.

● IR high resistance calibration: With" ︿ ", " ﹀ " key, select "the IR 50.00
G range". The output terminals HV, RETURN are connected with a
standard resistor 500MΩ. Press "TEST" key, it will enter automatically at
this time the reading of the standard resistance, completing the high
● GND voltage calibration: With" ︿ ", " ﹀” key, select "the
GND Bond Voltage". The output terminals HV, RETURN are
connected with a standard voltmeter, press "TEST" key, the
CURRENT, RETURN terminal will output a voltage about
7VAC at this time, enter the input reading of standard
voltmeter, press "ENTER" key.

● GND current calibration: With" ︿ ", " ﹀” key, select "the

GND Bond Current". The output terminals HV, RETURN are
connected with a standard ammeter, press "TEST" key, the
CURRENT, RETURN terminal will output a voltage about
100MΩ at this time, enter the input reading of standard
ammeter, press "ENTER" key. "TEST" key, read standard
● Real Current HV high current calibration: With" ︿ ", " ﹀”
key, select "the 200 Ws of AC Real, 40mA". The output
terminals HV, RETURN are connected with a 100kΩ resistor
and then a standard ammeter, press "TEST" key, a voltage
about 3000VAC at this time will be delivered, enter the input
reading of standard voltmeter, press "ENTER" key.

● Real Current LV high current calibration: With" ︿ ", " ﹀”

key, select “AC Real 200W, 40mA". The output terminals
HV, RETURN are connected with a 100kΩ resistor and then a
standard ammeter, press "TEST" key, a voltage about
1200VAC at this time will be delivered, enter the input
reading of standard voltmeter, press "ENTER" key.
● Real Current HV low current calibration: With" ︿ ", " ﹀”
key, select " AC Real 20 W, 3.5mA" The output terminals
HV, RETURN are connected with a 1MΩ resistor and then a
standard ammeter, press "TEST" key, a voltage about
2800VAC at this time will be delivered, enter the input
reading of standard voltmeter, press "ENTER" key.

● Real Current LV low current calibration: With" ︿ ", " ﹀”

key, select “AC Real 2W, 3.5mA". The output terminals
HV, RETURN are connected with a 1MΩ resistor and then a
standard ammeter, press "TEST" key, a voltage about
1000VAC at this time will be delivered, enter the input
reading of standard voltmeter, press "ENTER" key.
 ● DC Continuity calibration: With" ︿ ", " ﹀” key,
select "the DC Continuity 10Ω ".
Step 1: Firstly short outputs between CURRENT and
RETURN terminals, press "TEST" key, at this time it will
automatically do offset for the testing line.
Step 2: The output CURRENT and RETURN terminals are
connected with a standard resistor of 10Ω. Press "TEST"
key, it will read out automatically at this time the reading
input of the standard resistance, then the DC Continuity
calibration is over, power off.
Q & A
 Preliminary Exam
1.Please explain in what condition Probe-Hi is used.
2.How many line configuration that LLT is able to set? Please state 4 types.
3.What is MD?
4.If a 1M ohm resistor is connected from G to L as a DUT and the DUT I/P power is
supplied at 230V, what is the expected result (uA) to be shown by 7742 when LLT
is tested as the following configuration:
-Neutral [Closed]
-Reverse [Off]
-Ground [Open]
5.Please differentiate Total Current and Real Current.
6.What is the troubleshooting method on AMP PCB when it is suspected to be
defective in a 7742/7740?
7.Please state the process on how to notify Extech a service case and get the right
part from them.
End of Series
Congratulation!
THE END