Shanghai stock

listed

Electric Control Maintenance Guideline

China No.1

JACK SEWING MACHINE CO; LTD

Company Address: No.15, Airport South Road, Jiaojiang
District, Taizhou, Zhejiang, PRC
JACK SEWING MACHINE CO; LTD
Electric Control
By long pressing and
WWW.chinajack.com
Maintenance Guideline
identifying above two-
dimensional code, enter
Jack Facebook
 Preface
Since Thomas Saint----an Englishman, created the first sewing machine in the mankind in 1790 until
Merritt Singer---an America industrialized the sewing machine in 1851, the duration only lasts for more
than 200-year history up to now. From the original hand-operated sewing machine to the present
electromechanical integration sewing machine, whether on machine appearance or on use performance
and sewing machine function, the qualitative change has occurred.

With continuous development of science and technology, the electromechanical integration sewing
machine enables that a large number of linkage-type mechanical actions are easy to be realized and
the operation is more convenient. The electromechanical integration sewing machine enters into the
downstream clothing enterprises. Consequently in the original sewing machine maintenance, the new
contents of electric control system maintenance are added so that higher requirements on sewing
machine maintenance are put forward. Numerous technical elites who know mechanical maintenance
are deeply aware of their own technology deficiency and urgently hope to be able to learn about the
maintenance technology on electric control system.

In view of this, the Technology Research Department in Jack Sewing Machine Co., Ltd. takes the lead
in creating a maintenance technology team integrated with electric control and machinery. Through
continuous technical research and teaching practices, we have cultivated the electromechanical
integration sewing machine maintenance specialty in batches.

In order to improve the industrial maintenance technology level and enable more people to learn the real
electric control system maintenance technology, this team sufficiently integrates the advantages and
many years of teaching experiences and maintenance attainment to compile a series of electric control
maintenance technology for sewing machine from zero basis to mastering for vast sewing machine
technology enthusiasts by serving energy-saving and directly-driven Electric control (ZOBOW Electric
Control), POWERMAX Electric Control (A4POWERMAX all-in-one machine) and QIXING Electric
Control (QIXINGA4 and 781E etc.) as blueprint.

The book takes a large number of real pictures as samples and starts from the angle of beginners,
through repeated analysis and explanation for several typical electric control structures and principles,
explaining the profound in simple terms and being popular and easy to understand, this book is
beneficial to fast learning for maintenance technology of electric control system. The book is divided into
such two sections as basic knowledge of Electric maintenance and series of electric control maintenance
guidance. Through learning for this book, the maintenance method for mainstream electric control on
current market can be mastered, and the reference functions for electric control of other brands can be
played.

It is believed that, through learning for this book, the maintenance level of electromechanical integration
sewing machine in sewing machinery industry will be greatly improved to make contribution to the
development of downstream industries such as clothing and so on.

Lin Jianlong-----Vice President of China Sewing Machinery Association

 Chapter IV ZOBOW A2S Maintenance Guide···························································092
Part I Basic Knowledge on Electric Maintenance Section I: Front of circuit board···········································································093
Section II: Main functional module division····························································094
I. Overview on Basic Knowledge of Electric Components···············································003 Section III: Circuit analysis················································································095
II. Introduction to Electric Components·······································································004 Section IV: Circuit analysis················································································105
III. Packaging Specification and Pin Identification of Chip Components·····························013
IV. Comparison Table for Special Electric Terms in English and Chinese···························016 Chapter V QIXING A2S Maintenance Guide·····························································121
Section I: Introduction to products·······································································122
Section II: Description to product barcode·····························································123
Section III: Introduction to parameters··································································124
Part II Electric Control Maintenance Guide
Section IV: Failure detection and maintenance······················································128

Chapter I E4 Electric Control Maintenance Guide····················································019

Chapter VI QIXING 781E Maintenance Guide···························································149
Section I: Front of circuit board···········································································020
Section I: Introduction to products·······································································150
Section II: Main functional module division····························································021
Section II: Description to product barcode·····························································151
Section III: Circuit analysis················································································022
Section III: Introduction to parameters··································································152
Section IV: Failure detection and maintenance······················································029
Section IV: Failure detection and maintenance······················································155

Chapter II F4 Maintenance Guide···········································································037

Chapter VII QIXINGA4 Maintenance Guide······························································184
Section I: Front of circuit board···········································································038
Section I: Introduction to products·······································································185
Section II: Main functional module division····························································039
Section II: Description to product barcode·····························································186
Section III: Circuit analysis················································································040
Section III: Introduction to parameters··································································188
Section IV: Failure detection and maintenance······················································047
Section IV: Failure detection and maintenance······················································191

Chapter III C4 Maintenance Guide··········································································056

Chapter VIII POWERMAX A4 Maintenance Guide·····················································213
Section I: Front of circuit board···········································································057
Section I: Introduction to products·······································································214
Section II: Main functional module division····························································060
Section II: Circuit analysis·················································································220
Section III: Circuit analysis················································································061
Section III: Failure detection and maintenance·······················································227
Section IV: Failure detection and maintenance······················································072
 Fundamentals of Electronic Service

Part I
Basic Knowledge on Electric Maintenance
 Fundamentals of Electronic Service

I. Overview on Basic Knowledge of Electric Components II. Introduction to Electric Components

1. Resistance
Letter on PCB Component Polarity or Unit of
Main Functions
board Name Direction Measurement

Ohm Limiting current, sharing General symbols of resistance

R Resistance None
Ω/ K Ω/ MΩ voltage (fixed resistance)
Storage for charge;
Farad
C Capacitance Yes partially resistance to DC;
F/ pF/ df/ uF
connection to AC
Storage for magnetic field Symbols of variable resistance
Henry
L Inductance None energy, resistance to AC;
uH/ mH
connection to DC
Quantity for turn Adjust the voltage and
T/ TR Transformer Yes Sliding contact potentiometer
ratio current of AC

D Diode Yes one-way conductivity

Thermistor
Triode/ Field
Effect Tube Used as an amplifier or
Q Yes Amplification times
switch
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Integrated circuit Realize its corresponding
U Yes Number of pin
chip functions
Generate the oscillation
frequency; provide
Y Crystal oscillator None Hertz (Hz)
the clock source to
microcontroller
Circuit overcurrent
F Fuse None Amps (A)
protection

K Relay Yes Conversion circuit Chip resistance Sampling resistance Varistor

S/SW Switch Yes Number of contact On-off circuit

Power supply or signal

J or JP Connection port Yes Number of pin
connection

During daily electric control maintenance learning, the combination marks on code and figure mentioned
in the table above may appear on our circuit board, for example: R12, C16, L1, T2, U2, etc. The code
with digit in the board for each component on the circuit board is called as “Bit Number” of components
on this board by us.
It’s worth noting that: 1. in the same board, two identical bit numbers do not appear.
Chromatic circleresistance Braking resistance Thermistor
 Fundamentals of Electronic Service

Definition: Resistance (Resistance, usually expressed by “R”), the inhibition function on current by ●● Identify the size of resistance element
conductor is generally referred to as the resistance of conductor itself.
Digital labeling method:
Function: The resistance generally plays the function of current limiting, voltage shunting and current
For example: how much is the resistance value of such resistances 101, 103, 1000, 1001, 4R7,
shunting in the circuit. For signals, both AC and DC signals can pass through the resistance. Main
4E12, and R025 respectively?
physical characteristic of resistance is that the electrical energy can be changed as thermal energy, that
is to say, the resistance is an energy dissipation element. Color ring labeling method:
Unit: the resistance is expressed generally by letter g, the unit of resistance is ohm, with ohm for short
andΩ for symbol, 1Ω = 1V/ A. Greater units cover kilohm (kΩ), megohm (M Ω) (mega = 1 million, i.e., 1 Table of Resistance Color Code
Temperature Coefficient PPM/ °C
million). Four strips Five strips Six strips

Error%

●● Common units and expression methods of resistance Multiplier (V)

Base unit: Ω
Important graph
Common unit: KΩ, kilohm (K: thousand)
Black, brown, orange, yellow, green, purple, gray, white, white, silvery white.
MΩ megohm (M: mega)
1 MΩ = 103 K Ω = 106 Ω Purple Grey
Brown Red Orange Yellow Green Blue White Black
rapurpureus
1KΩ = 1010Ω
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●● Labeling methods for chip resistance value
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of knowledge
●● Resistance value of resistance labeling method
The codes on the chip resistance are typically labeled as 3 digits or 4 digits, with a 3-digit accuracy of 5%
and a 4-digit precision of 1%.
I. Identification rule for 3-digit resistance value: firstly, first digit and second digit refer to the effective
Chromatic circle
digits for element value, and the third digit refers to the number of digit that should be multiplied behind labeling method
significant digits.

Example: 103 represents 10K, i.e. 10 x 1000 = 10000 = 10 K Ω Digitallabeling

method
II. Identification rule for4-digit resistance value: first three digits refer to the effective digits for element
value, and the fourth digit refers to the number of bit that should be multiplied behind significant digits.

Example: 1502 represents 15K, i.e. 150x100 = 15000 = 15K Ω

III. Labeling for resistance less than 10 ohm: R refers to resistance decimal point of ohm
●● Thermistor

Example: 2R0 represents 20Ω

Characteristics: The resistance value changes considerably with

Example: 1.47 represents 0.047Ω
temperature.
Division Positive Temperature Coefficient
accordingto Thermistor PTC (TR)
temperature,
characteristics Negative Temperature Coefficient
Thermistor NTC (TR)
 Fundamentals of Electronic Service

●● Varistor 2. Capacitance

Patch Electrolytic Safety Metal film Tantalum capacitance Ceramic patch

capacitance capacitance capacitance capacitance chip capacitance

The capacitor is composed by two mutually insulated and adjacent conductors and non-conducting
insulating medium in the middle layer, and two conductors form two poles of the capacitor to be led out
by lead wires respectively, which is a kind of energy storage element. The capacitance also is one of the
Property: The resistance value changes along with the voltage in non-linearity. When the voltage on most commonly used and most basic Electric components to be used for tuning, oscillating, blocking,
both ends is lower than the nominal rated value, the value of the varistor is close to infinity, and the filtering, coupling and bypassing in the circuit.
current flowing through it is extremely small; When the voltage on both sides is slightly higher than
the nominal rated value, its resistance decreases sharply to close the infinity, and the current flowing The capacitance is expressed by symbol C, unit: F, MF (10-6F), nF (10-9F) and pF(10-12F)
through it is extremely large so that it breaks down itself. Capacitance covers such two kinds as chip type and plug-in type.
Purpose: Over-voltage protection, lightning protection, suppression of surge voltage and protection of
follow-up circuits, etc. ●● Common unit and expression method of capacitance
Basic unit: F Farad Single conversion of capacitance:
Common unit: pF Picofarad
nFnanofarad
●● Use for 906B electric control: Varistor μF microfarad
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Marking number of
Component Name 550W/220V 750W/220V 550W/110V ●● Electrolytic Capacitor
circuit board
Varistor RV1 14D471 14D471 14D241 Purpose: Heteropolarity electrolytic capacitance usually plays
the functions of power supply filter, decoupling, signal coupling
Model of Varistor Varistor voltage (V) Voltage Limiting voltage (V) and time constant setting and DC separation in power supply
470 300 circuit or intermediate frequency and low frequency circuit.
14D471 385 775
Generally, it cannot be used for AC power circuit. When used as
14D241 240 150 200 m3/ h 395 filter capacitance in DC power supply circuit, its anode (positive
electrode) shall be connected with the positive pole terminal of
the power supply voltage, and the negative electrode (negative
electrode) shall be connected with the negative pole terminal
of the power supply voltage. The inverse connection can’t be
●● Use for 906B electrical control: Patch sampling resistance implemented; otherwise, the capacitor may be damaged.
The sampling resistance is also referred to as a current detection resistance, meaning the resistance Filter function: in the power circuit, the rectifier circuit will
with small resistance value, which is used to convert a current into a voltage signal in a circuit for turn AC into pulsating DC, however, an electrolytic capacitor with
measurement. The resistance value of sampling resistance is chosen to be less than 1 ohm, belonging greater capacity is connected behind rectifier circuit, and the
to milliohm resistance. charge-discharge characteristic is utilized so that the rectified
pulsating DC voltage becomes a relatively stable DC voltage. In
Marking number of practice, in order to prevent the power supply voltage on each
Component Name 550W/220V 750W/220V 550W/110V
circuit board section of circuit from changing due to the load change, 10 to
100microfaradof electrolytic capacitors are generally connected to the output end of power supply
Sampling resistance of and the input end of the load. Since the electrolytic capacitor with great capacity has certain electrical
R42, R43 R025 R020 R018 inductance so that the high-frequency and pulse interference signals cannot be effectively filtered out,
chip
therefore, a capacitor with a capacity of 0.001-0.1μF is connected in parallel on both ends so as to filter
out high-frequency and pulse interference.
 Fundamentals of Electronic Service

●● Polypropylene capacitor (CBB) 4. Diode

DC fixed capacitor of CBB22 metalized polypropylene film dielectric
Features: Non-polarity, very high insulation resistance, excellent frequency
characteristic and very small dielectric loss. The capacitance capacity
changes less with temperature and frequency.
Purpose: be applicable for the pulsating circuit at DC port of Electric
equipment.

●● Safety capacitance
Fast recovery diode Common diode Light emitting diode
Purpose: After failure of safety capacitor, electric shock will not be caused
so as not to endanger personal safety. The electrical discharge of safety Characteristics: unilateral conductivity. Namely, forward breakover, reverse cutoff (Current can only flow
capacitor is different from that of the common capacitor, and the charge from positive to negative)
will remain for a long time after the external power source is switched off. If Function: rectification, switching, voltage stabilization
touched by hand, the electric shock may be suffered; however, the safety
capacitance cannot produce this problem. For sake of safety and EMC, the
upper gauge capacitance is generally built on the power supply port. ●● Circuit symbol of diode

3. Inductance
Light emitting diode Common diode
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Voltage stabilizing diode
of knowledge

of knowledge
Light emitting diode

●● Volt-ampere characteristic of diode (V-I characteristic)

Chip inductance Common mode inductance I-inductance

●● Common mode inductance Forward

characteristic
Features: non-linear
Working current

Reverse breakdown
Interfering signal
voltage VBR Breakover
Power supply voltage drop

Function: play the function of EMI filter for suppressing EMI interference generated by high-frequency
signal lines radiating outward.
The reverse current
Principle: Common-mode inductor filter circuit, La and Lb are common-mode inductor coils. These two Voltage in dead
remains constant
coils are wound on the same iron core with the same number of turns and phase (reverse winding). zone
within voltage range.
Thus, when the normal current in the circuit flows through the common mode inductance, the current Reverse
generates a reverse magnetic field in the inductance coil wound in the same phase to offset mutually, characteristics
Only the impressed voltage is greater than
right now, the normal signal current is mainly affected by the coil resistance (and a small amount of
the voltage in dead zone, the diode break
damping due to leakage);When the common mode current flows through the coil, due to isotonicity of over can be realized.
common mode current, the inductive reactance of the coil is increased by generating a magnetic field in When the impressed voltage is greater than that of
the same direction in the coil so that the coil behaves as high impedance to generate stronger damping the reverse breakdown voltage, the diode is broken
down, and the unidirectional conductivity is lost.
effect so as to attenuate the common mode current and achieve the purpose of filtering.
 Fundamentals of Electronic Service

●● Function and working principle of voltage stabilizing diode 6. Relay

Function: The reverse breakdown characteristics of diode are utilized to play a role in stabilizing the
voltage. Function: the relay is usually applied in an automated control circuit and actually is a kind of “automatic
switch” that low current is utilized to control the operation of heavy current; there are such two sets of
Working principle: the characteristics of voltage stabilizing diode are utilized, after breakdown; the circuits as low-voltage control circuit and high-voltage working circuit. Therefore, the relay plays an
voltage on both ends remains unchanged basically. Thus, the output voltage on both ends of backward important role in automatic regulation, safety protection, and conversion circuit and so on.
remains constant basically if the supply voltage fluctuates due to fluctuations of power supply voltage or
other reasons.
7. Triode
●● 5 Rectifier bridge

Amplification (commonly used in power amplifier circuit for current

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of knowledge
amplification working under amplification status)
1. Function: AC is converted into DC.
Switching (commonly used in logic circuit, working in a saturation or
2. Pin definition: The maximum output of pin is output positive +, and the one on the other side is the
cutoff state)
output negative-,two ones in the middle are AC input.

8. IGBT (insulated gate bipolar transistor)

●● Working principle of rectifier bridge

IGBT (insulated gate bipolar transistor) is a kind of power semiconductor device composed of BJT
(bipolar transistor) and MOS (insulated gate field effect tube), concurrently having the advantages of
high input impedance of MOSFET and low breakover voltage drop of GTR.
Working principle: If the driving positive voltage is added between the gate electrode and the emitter
u negative half cycle, Va <Vb, diode 2 and 4 breakover, 1and 3 cutoff of the IGBT, the MOSFET is under breakover so that the low resistance state is formed between the
u positive half cycle, Va> Vb, diode 1 and 3 breakover, 2 and 4 cutoff collector and the base of the PNP transistor to give rise to transistor breakover; if the voltage between
the gate electrode and the emitter of the IGBT is 0V, the MOSFET cuts off the supply from PNP
transistor base current so that the transistor is cut off.
 Fundamentals of Electronic Service

Safety reliability: If the voltage between the IGBT gate electrode and the emitter, that is, driving voltage, Comparison Table of Common Chip Resistance, Packaging Size of Capacitance, Power and Withstand
is too low, the IGBT cannot work stably and normally. If the withstand voltage between the gate Voltage Value
electrode and the emitter is exceeded excessively, the IGBT may be permanently damaged; likewise,
If the allowable voltage added onto the collector and emitter of IGBT exceeds the withstand voltage
between the collector-emitter, and the current flowing through the collector-emitter of the IGBT exceeds Common
the maximum current allowed by the collector-emitter, the junction temperature of IGBT exceeds the Corresponding Maximum
Specifications Length (L) Width (W) High (t) Rated power
allowable value of junction temperature, IGBT may be permanently damaged. Specifications operating
(British (mm) (mm) (mm) (W)
(Metric) voltage (V)
System)

0201 0603 0.60 ± 0.05 0.30 ± 0.05 0.23 ± 0.05 1/20W 25

9. Three-terminal voltage stabilizer

0402 1005 1.00 ± 0.10 0.50 ± 0.10 0.30 ± 0.10 1/16W 50

0603 1608 1.60 ± 0.15 0.80 ± 0.15 0.40 ± 0.10 1/10W 50

0805 2012 2.00 ± 0.20 1.25 ± 0.15 0.50 ± 0.10 1/8W 150
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1206 3216 3.20 ± 0.20 1.60 ± 0.15 0.55 ± 0.10 1/4W 200 m3/ h

III. Packaging Specification and Pin Identification of Chip Components 1210 3225 3.20 ± 0.20 2.50 ± 0.20 0.55 ± 0.10 1/3W 200 m3/ h

1812 4832 4.50 ± 0.20 3.20 ± 0.20 0.55 ± 0.10 1/2W 200 m3/ h

2010 5025 5.00 ± 0.20 2.50 ± 0.20 0.55 ± 0.10 3/4W 200 m3/ h

2512 6432 6.40 ± 0.20 3.20 ± 0.20 0.55 ± 0.10 1W 200 m3/ h
 Fundamentals of Electronic Service

●● Identification on multi-pin element pin numbering IV. Comparison Table for Special Electric Terms in English and Chinese

Common mode
共模电感 逻辑芯片 Logic Chip
dots inductance

贴片电阻 Patch resistance 驱动芯片 Drive Chip

热敏电阻 Thermistor 保险丝 Fuse

压敏电阻 Varistor 变压器 Transformer

采样电阻 sampling resistance 整流桥 Bridge

电容 capacitance 模块 Modules

贴片电容 patch capacitance 晶振 Crystal

电解电容 Electrolytic Capacitor 单片机 Microcontrollers

Left lower principle 有极性电容 polar capacitor 电机 Motor

ampere-gauge
安规电容 继电器 Relays
capacitance
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担电容 load capacitance 电感 Inductor
●● Explanation for commonly used terms
二极管 diode 伺服电机 Servo.

Circuit: Closed circuit formed by lead wire components and parts

发光二极管 Light emitting diode 电流源 Current Source
Short circuit: short circuit is divided into such two kinds as power short circuit and local short circuit
1. The power short circuit means that the current flows directly from the positive pole to the 稳压二极管 voltage stabilizing diode 电压源 Voltage Source
negative pole under no-load.
快速恢复二极管 fast recovery diode 电压 Voltage
2. Local short circuit is caused by some components on the circuit
Open circuit: Open circuit refers to open circuit, and the resistance connected between two points is 交流电 alternating current 电流 Current
infinite.
Operational
Voltage: Potential difference between two points 直流电 DC voltage 运算放大器
Amplifier
Bit number: corresponding position number described for full circuit capacity.
短路 short circuit 程序 Program

Note: 开路 open circuit 电源芯片 Power supply chip

1. All multimeter measurements in this paper are obtained via measurement by adopting a VICTOR
VC890D multimeter. If the selected multimeter model is different, the measured data may be different; 电路图 Circuit diagram 设置器 Setting Device
everyone pays attention to distinction, please!
2. In this paper, the data measured by the multimeter is only for reference basis. 导线 lead wire 烙铁 Soldering Iron

焊锡丝 solder wire 速控器 Speed Control Device

 Fundamentals of Electronic Service

Part II
Electric Control Maintenance Guide
 Fundamentals of Electronic Service

Circuit Board Recognition

Section 1: Front of Circuit Board

Relay K1 Safety capacitor

Cx1, CX2

E4 Electric Control Maintenance Guide Varistor RV1

High-voltage electrolytic
capacitor, CD1, CD2 Fuse F1

Singlechip U6

Common mode
Circuit Board Recognition Operational
Amplifier U1
inductance L1

Rectifier
bridge B1
Yc capacitor CY1,
Drive chip U3 CY2, CY3
Thermistor TR1

Main Functional Module Division

IGBTQ3-Q8
photocoupler
Power Supply

Circuit Analysis Transformer T1

Chip U 2

High-voltage ceramic
chip capacitor C9

Section II Reverse side of circuit board

Failure Detection And Maintenance

Current-limiting
resistance

U-phase sampling
resistance

V-phase sampling
resistance
 Fundamentals of Electronic Service

Main functional module division Circuit Analysis

Section I Power Supply Section

Main functions of power supply section:

implement the filtering and rectification for
input 220V AC to form 300V DC. After filtering
and energy storage by a large capacitance,
output relatively stable 300V DC, while
supplying power to the motor through IGBT
while forming 15V supply and a 5V supply after
step-down by switching power supply section.
Power supply section 1 Here we divide the power supply section into
AC 220V, DC 300V, 15 and 5V.

power supply section 2

220Vsection: As shown in the left figure, 220V power is input via power plug, one circuit passes through
fuse F1, and then thevaristorRV1 is connected in parallel between two lines, the fuse (10A) and varistor
Power supply section 1 may play the function of overcurrent and overvoltage protection in the circuit. When the operating
current of the circuit is too high, the fuse will fuse. When the input voltage is too high, the varistor may
be punctured to play a role of protection. There is a filter circuit composed of two safety capacitors CX1
and CX2 and a common-mode inductor L1 behind. Its function is to filter the input 220V power supply
and suppress the interference of the Electric radiation in the grid to the circuit of the circuit board and
simultaneously prevent the circuit of circuit board from electromagnetic radiation to the power grid, and
then the relay K1 connected in parallel is connected to the thermistor. When the current flows through
Driving and signal for RT1 at the moment of electrification, the relay does not work. When 15v relay is electrified for
section working, the thermistor is short-circuited to quit the working state (this will be mentioned later).
Common failure s of 220V: 1. Fuse varistor explosion; 2. Common-mode inductance break-off;3. The
switch is non-conducting

Power supply section 2

Power supply section 1: convert 220V to 300V;

Power supply section 2: convert 300V to 5V, 15V, Vdr; Fast melting

Driving and signal section: the singlechip gathers the signals from motor, pedal plate and operation
panel and issues the driving signal to control the operation of motor and the brightness of handpiece
lamp. Circuit diagram of 220V Power Supply
 Fundamentals of Electronic Service

300V section: After the current passes through Section II Signal Section and Driving Section
the thermistor or relay, input from pin 1 and pin
2 of square bridge and form DC pulse with peak
value of 310 V after rectification by the square As shown in the figure, the signal and driving
bridge, the electricity here cannot be directly sections mainly comprise signal processing
supplied to the circuit behind, and the relatively section, driving section and current sampling
stable DC voltage is output after being filtered by and feedback section, completing signal
CD1 and CD2 filtering. We are used to calling it acquisition, processing, motor driving and
300V. Common failure s of 300V: current feedback actions. The detailed
1. Explosion of large capacitance C1 and C2, top introduction is implemented below.
heaving. Signal processing section:
2. The square bridge is damaged (the The signal processing section is the core of
Circuit diagram of 300V Power Supply measurement method will be mentioned later) whole circuit board, and the core element is
the singlechip, the Hall signal in the motor, the
Driving and signal parts Hall signal in the pedal plate and the current
sampling signal are finally transmitted into the
singlechip, the singlechip judges, analyzes
and processes the signals and then issues the
control signal.
Switching power supply section: as shown in the following figure, after 300V electricity output from
electrolytic capacitor passes through the switching power supply consisting of U2 power supply chip and
transformer, the three-way signal power supply is output from transformer in secondary level: Vdrv15V,
Vcu + 5V, L + 5V, and forms a feedback circuit through U5 and U4 as well asNo.1pin of power supply
chip. The switching power supply on this section is adopted with PWM switching power supply. When
the voltage fed back by sampling resistor divider connected by secondary MCU+5V of transformer
is compared with 2.5V reference voltage on same phase end of error amplifier, the error voltage is
generated so that the pulse width (i.e. the duty ratio) is adjusted. A modulation pulse is sent from pin When the motor is operating, six kinds of
2 to control the breakover and the turn-off frequency of the pin 4, and the charging and discharging change such as 101, 100, 110, 010, 001
process of transformer coil is continuously carried out, and each output voltage is stabilized. and 011 may appear for three sets of HALL
signals, which reflects the real-time position of
the motor rotor and outputs the control signal
to singlechip, controls the breakover of IGBT
through the driving chip U3 so as to drive the
motor rotor.
No.47 pin of singlechip is the signal input
pin of speed controller HALL; when the foot
pedal is treaded, the speed controller HALL
shall induce the change of magnetic field and
Pin position, Hallsignal of motor outputs the voltage signal which varies with
change of magnetic field to the singlechip;
Circuit ofmotor plug The singlechip shall adjust the motor speed by
judging the capacity of HALL signal.
There are eight paths of output signals
controlled by singlechip totally, wherein, six
paths of pins output PWM signal and directly
transmit to the drive chip through resistor, and
the rest two paths of signals are the signals
driven and controlled by the handpiece lamp
and the enable signals of chip driven by motor
Circuit Diagram of Plug for Speed Controller respectively.
 Fundamentals of Electronic Service

Section III Current Acquisition and Feedback Section As shown in the figure above for U3 pin figure, Pin 1 is a 15V power supply pin of U3. Six circuits of
signals output from the singlechip are MO _ HINU, MO _ HINW, MO _ HINW, MO _ UNU, MO _ UNV,
The current acquisition and feedback MO _ LINW, and input from six feet of U2 (HIN1), 3 (HIN2), 4 (HIN3), 5 (UN1), 6 (LIN2), 7 (LIN3) from
section mainly consists of an operational U3.
amplifier and a sampling resistance , the
circuit diagram is shown in the left figure, the Pin 8(VFO) is a failure output pin. When U3 detects that the signal transmitted by the singlechip or the
sampling resistance is connected in the motor current feedback signal is wrong or abnormal, the pin 8 outputs a low-level signal to the singlechip. The
current circuit, the current flowing through the singlechip stops driving after receiving the signal and reports the EA’s error code (this will be mentioned
motor flows back to the power supply section in the following failure analysis).
through the sampling resistance , and a 27 (H01), 23 (H02) and 19 (H03) are the drive signal output pins of IGBT upper bridge, 26 (VS1), 22
voltage signal UVW may be generated on the (VS2), and 18 (VS3) are the auxiliary output pins driven by the upper bridge, and the first three driving
sampling resistance to be served as an input signals act to drive the breakover of IGBT for upper bridge;16 (L01), 15 (L02), 14 (L03) are output pins
signal to the operational amplifier U1.Pin 8 of driven by the lower bridge to drive the breakover of the lower bridge IGBT.
operational amplifier is 5V power supply, and
Pin 3 is input pin of feedback signal for UVW Fan 73892 is used for driving chip U3 by us and can also be replaced by 2136. When using 2136, it is
current. The feedback signal is output to pin only necessary to mount a 1M resistance on R72.
43 CUR of the singlechip through pin 1after
being amplified for about 10 times by the
Breakdown Circuit Diagram of Operational Amplifier U 7 operational amplifier.

Section IV Driving Section

The driving section mainly includes a drive chip U3 and six IGBTs. The main function of the driving chip
U3 is to receive six circuits of PWM control signal from the singlechip to convert as a signal which can
drive the breakover and the shutdown of the IGBT and then output the signal to the IGBT.

The upper bridge is composed of Q4, Q6 and Q8, as shown in the left figure.
The lower bridge is composed of Q3, Q5 and Q7, pin 2 of the upper bridge IGBT is connected with the
positive pole of 300V power supply, the pin 2 is respectively connected with three sets of coils W, U
and V in the motor, which are the input ends of the motor current; The pin 2 of the lower bridge IGBT
is connected with motor coil W, U and V, which are the outflow ends of the motor current. At the same
time, the upper bridge and the lower bridge respectively conducts one IGBT to form a current circuit
together with the motor coil, but it is required to be noted that the IGBT in the same team of the upper
bridge and the lower bridge cannot be under breakover at the same time (e.g., Q8, Q3), otherwise the
short circuit may occur.
Pin Figure FAN73892 of Driving Chip U3
 Fundamentals of Electronic Service

Upper and Lower Bridge Circuit composed by IGBT Section V.Power Supply Section of LED Lamp

LED power supply section is as shown in Figure 1.

Since the LED lamp is mounted on the handpiece
and the personal safety is considered, therefore,
the power supply used by LED lamp is an
independent power supply and is not common-
ground with other circuits so that no personal
injury due to electric leakage can occur.
As shown in the left circuit diagram, when the
handpiece lamp is on, the singlechip supplies 5V
signal to U 7 coupler for breakover, and L + 5V is
under breakover, and the handpiece lamp is on.

Connection Mode of Motor Coil

One end of three groups of coils in the motor is connected with U, V and W, and the other end is
connected at the same point to form a star-shaped connection mode. Only there is current in two groups
of coils internally at the same time. There are three Halls in the motor, and when the rotor rotates, it
can induce the change of the rotor’s magnetic field and output the two variable values of 0 and 1. After
receiving the Hall signal by the singlechip, the angle position of the rotor can be judged, and then the
corresponding control signal is outputted to control the direction of the current in the motor coil through
the driving section to generate a magnetic field and rotate the rotor, and when the rotor rotates, the
direction of the current in the coil also changes so that the rotating magnetic field drives the rotor to
rotate all the time.

Common failure s of signal and driving sections:

1, 5V and 15V short circuit;
LED Power Supply Section
2. ReportE1, EA and EJ errors;
3. Phase loss of motor
Common failure s of LED power supply section
(When the motor may walk and stop from time to time, after stopping, through turning the hand
wheel, the motor may walk again, and the sound is abnormal while rotating.) 1. Transformer damage (The lamp isn’t on)
4. Explosion of sampling resistance; 2. Damage of photocoupler U7;
5. Explosion of IGBT; 6. Pitch resistance and capacitor burnout. 3. Damage of transistor Q12.
 Fundamentals of Electronic Service

Failure Detection and Maintenance 2. Square bridge measurement

Section I Visual Detection

1. Check whether the large capacitance CD1 and Multimeter Diode Gear
CD1 are explosive and leak the liquid or whether
there is significant bump on the top; Black marking Red marking
Normal value
pen pen
2. Check whether the fuse and varistor are burnt out;
3. Check whether there is broken pin for common 1. 2. 0.500V
mode inductance;
4. Check whether the sampling resistance R102, 1. 3. 0.500V
R103, R105 and R106 are exploded or burned;
If above-said components are damaged, replace
2. 4 0.500V
the corresponding components and inspect
whether the routing on the circuit board are
burnout, and if there is a defect for routing, the 3. 4 0.500V
external lead wires can be connected.
Static test is required after visual inspection.
If any one of these values is about 0.002, it is
(Sampling resistance R102, R103, R105 and
shown that the interior of the rectifier bridge has
R106 are exploded to be black, the maintenance
been short-circuited, and the rectifier bridge
is difficult, it is recommended to return to factory
must be replaced and the measurement will be
for maintenance).
continued.

Section II. Static Measurement before Powering-on

3. Detection forcommon mode inductance

1. Measurement of IGBT

Multimeter Diode Gear

Black marking Red marking

Normal value
pen pen

2. 3. 0.450V

1. 3. 0.780V

If pin 2 and 3 feet are short-circuited, it is shown

that IGBT is damaged and is required to be
replaced itself. If the value of pin 1 and pin 3 is
abnormal, check whether the relevant resistance
of IGBT is normal. If the resistance value is
normal, replace the drive chip U3. (If the value is Measure pin 1, pin 2, pin 3 and pin 4 of common mode inductance with a multimeter. If the buzzer gear
close to 0, it is shown that the IGBT1 and pin 3 rings, ringing, the common mode inductance is normal, otherwise, replace the common mode inductance.
feet are punctured, IGBT is replaced.)
IGBT1, 3-foot measurement IGBT2, 3-foot
measurement
 Fundamentals of Electronic Service

4. Access detection 1. 300V is powered; the power supply can’t be powered.

As shown in the left figure:

Firstly, the multimeter is regulated up to the
buzzer gear, the switch of the circuit board is
opened, pin N of power plug and pin 2 of square
bridge are placed respectively, and the buzzer is
normal;
Then two probe are respectively placed on pin
L of power plug and pin 3 of square bridge to
display that the numerical value of about 100
Power
ohm is normal, and the positive and negative
electrodes are not distinguished for making pen. supply
chip
If above values is not normal, check whether the
circuit is complete, whether the switch is under
breakover, whether the fuse is normal, whether
the pin of common mode inductor is off and
whether the resistance value of the thermistor is
about 100 ohm.

Failure analysis: 300V is powered; the power supply can’t be powered, which may be the short circuit of
the power supply output, the damage of the power supply chip and the problem of the feedback circuit.
Methods of processing:
Section III Powering-on Detection and Maintenance 1. Measure Z4, C45and CD6 with a multimeter buzzer respectively, the buzzer rings, and then the short
circuit occurs.
2. If the buzzer does not work, check whether the power supply chip U2 and the fast recovery diode
If the static measurement is normal, powering-on detection can be started. Powering-on detection is a
(RS1M) D1 are burnt out;
very important step in maintenance. Unlike static detection, we can reduce the range of failure points
by observing the reflection after powering-on and reporting the error code and clarify the direction of 3. Check whether the resistance values of feedback circuit R58, R59 and R60 are normal and whether
maintenance. And by measuring the voltage for some key points under powering-on state, the problems EL817 is damaged;
can be solved more quickly by us.
 There is certain dangerousness for powering -on process, and attention should be paid to safety!
2. No actuation of relay
Firstly turn the switch onto OFF position before powering on and plug in the power line to make sure
Failure analysis: the relay is jointly controlled by Vdrr and singlechip, so the appearing problems can be
that there are not conductive objects on the circuit board and below so as to cause the short circuit,
started from power supply and the singlechip.
and then turn on the switch and observe the state of the circuit board. When the normal circuit board is
powered on, it can be heard that the green light is normally on and the relay sucks and closes. Methods of processing:
Measuring point of powering-on voltage: 1. Determine whether there is electricity for Vdrr power supply;
220V AC measuring point ——pin 2 and pin 3 of Rectifier Bridge 2. Whether the setter displays normally, the normal display indicates that the singlechip is
programmable. If the display can’t be realized, and the procedure can be fabricated newly;
300V DC measuring point——pin 1 and pin 4 of Rectifier Bridge,
3. Observe whether the transistor Q1 is damaged or the false welding exists;
Vdr DC measuring point——both ends of Z4
4. Check whether R57 and the pin 13 of singlechip are under breakover by utilizing the buzzer gear.
5 V DC measurement point _ both ends ofC46
5. Replace the singlechip.
 Fundamentals of Electronic Service

3. Messy code display 5. E2 code is warned (over-current)

Failure analysis: 5V power supply voltage is normal. After powering-on, the setter does not display or Failure analysis: Generally, when the driving section fails, such as IGBT short circuit, E2 code will be
the messy code displays or 8displays, belonging to the display failure. Since the setter is controlled by warned, not excluding the damage conditions of U6 and U3itself.
the singlechip signal, the signal error of the singlechip can lead to display failure.
Methods of processing:
Methods of processing:
1. Check whether the motor is burnt out;
1. Replace the display screen first;
2. Measure whether the value of IGBT and the resistance value of chip resistance around IGBT are
2. Check whether the resistance values of R95, R97 and R98 are normal, and check whether the normal;
voltage of pin 1 and pin 5 for J9 is 5V;
3. Replace 73892;
3. Replace the singlechip;
4. Finally replace the singlechip;
4. Replace the crystal oscillator;
6. E4 code is warned (error of motor Hall signal)
If the display abnormality is related to the drive, refer to E% for maintenance method
Failure analysis: in previous circuit analysis, it has been mentioned that the Hall signal of motor may
constantly detect the Hall signal of the motor in the course of operation of the motor, and the Hall signal
will be transformed according to certain rules. If the read Hall signal change is found not to change
4. Reporting E1 code (motor stalling)
in accordance with the given law or the detected value does not belong to the failure value, the SP
controller will warn the E4 error. In most cases of E4, the motor Hall is damaged; however, the failure of
Hall signal line may also cause the warning of E4.
Bootstrap
capacitance
C11, C12, C13

Failure analysis: If it is detected that the motor is unable to rotate after powering-on, report to E1.When
the handpiece is stuck or the signal section fails, it is possible to cause the motor stalling. The failure s
of signal section mainly covers the disconnection of signal line and the chip damage.
Methods of processing:
1. Firstly determine whether the IGBT is damaged;
Methods of processing:
2. Determine whether the resistance value of R75, R76, R77, R78, R79, and R80 is 200 ohm;
1. Check whether the motor socket and the electric control connection are normal (confirm whether the
3. Check whether the voltage drops of D11, D13 and D14 on diode gear is normal, and the voltage drop pin in the socket is normal);
is 0, 50 #generally.
2. Inspect whether the motor Hall is normal and whether the connecting wire of the motor is normal;
4. If E1 is still warned, measure whether C11, C12 and C13are short-circuited and replace the short-
3. Check whether the chip resistance ofR49, R50, R62, R64, R67, R68 and patch capacitor of C21, C28
circuit bootstrap capacitor.
and C31 are normal;
5. Check whether there is 15V voltage forC52, C41 and C36;
4. Replace the singlechip.
6. If normal above, replace U3;
 Fundamentals of Electronic Service

7. E5code is warned 10, Eb and EC failure (system overvoltage, system under-voltage)

Failure analysis: In addition to motor taking down, there are two needle positions Hall on the electric Failure analysis: When the singlechip detects that the 220V AC voltage input exceeds 280V, the
control. There are two magnetic steels on the hand wheel. When the motor is in operation, the Hall will singlechip will warn the Eb failure code; when the singlechip detects that the output of the 220V AC
induce the position change of the magnetic steel on the hand wheel, and then the position of the motor voltage is lower than 150V, the singlechip can vibrate out the EC failure code.
will be determined according to the setting value of the upper and lower needles. When the Hall signal
Methods of processing:
on needle position is abnormal, the needle position cannot be found and the E5 code is warned.
1. Check whether the external 220V AC voltage is stable;
2. Check whether the busbar detection circuit is failure.
Methods of processing:
1. Check whether the resistance values
of R85, R86, R87 and R88 are correct; 11. EJ failure (abnormal sampling circuit)

2. Replace the Hall of needle position on

Locating electric control; Operational Amplifier and Its Surrounding Failure analysis: After powering-on, the singlechip
Hall H145 3. If it is under urgent use, the function of Equipment detects whether the output of the operational
needle position can be closed; amplifier is 2.5V. If not, the system will warn EJ.
Methods of processing:
1. Determine whether the routing as shown in the
right figure is exploded off ;
2, Detect whether the resistance value of the
sampling resistance is normal, check the TVS1,
8. E6 code is warned (abnormal governor signal) TVS2 and TVS3 and measure by using a diode
gear, and replace the TVS tube if there is a
Failure analysis: The single chip can’t detect the signal conveyed by the speed regulating Hall to cause numerical value;
E6 failure.
3. Turn the multimeter to the resistance gear and
detect the resistance value of R6, R7, R23, R24,
R25, R31 around operational amplifier is normal
and the resistance value of R42 and R43 for filter
Methods of processing: circuit;
1. Determine if the governor is normal (how to 4. Replace the operational amplifier;
detect the governor will be explained in details
below). 5. Replace 73892.

2. Detect the resistance capacitance around

the governor socket in the electric control
motherboard.

9. EA failure (abnormal hardware overcurrent)

Failure analysis: Bus current sampling exceeds 0.45V and lasts for more than 200nS so as to cause EA
failure.
Methods of processing:
1. Check whether the value of IGBT is normal;
2. Check whether the sampling resistance and TVS tube are normal;
3. Replace 7289.
 Fundamentals of Electronic Service

Circuit board recognition

Section I Recognition that F4 circuit board is connected to PI

Locating the Hall Port
220V AC voltage port Motor port

F4 Electrical Maintenance Guide Motor Hall port

Circuit board recognition

Main functional module division

Speed controller, and Program burning port
external upgrading port

Port of pin and handpiece lamp signal Setter port

Circuit analysis
Section II Recognition on F4 Circuit Board Components

Failure detection and maintenance Safety capacitor CX2

High Voltage electrolytic
IGBTQ1-Q6

Common mode capacitor,CD1

inductor L1
Rectifier Bridge B1

Fuse F1

Operational
Varistor Rv 1 Amplifier U1

The drive chip U2

Safety capacitor
CX1

Thermistor RT1
MCU U6

Relay K1

Toppling switch S1
Transformer T1
Power supply chip U4
 Fundamentals of Electronic Service

Main functional module division Circuit analysis

Section I Power Supply Section

Circuit diagram of power supply

Power supply section 1 Power supply section 2 section (AC-DC)

Main functions of power supply section 1: implement the filtering and rectification for input 220V AC to
form 300V DC. After filtering and energy storage by a large capacitance, output relatively stable 300V
DC, while supplying power to the motor through IGBT while forming 15V power supply and 5V power
supply of chip and 5V electricity for handpiece lamp after step-down by switching power supply.
Detailed introduction is as follows:
220V section: As shown in the left figure, 220V electricity is input via power plug, one circuit passes
through fuse F1, and then the varistor RV1 is connected in parallel between two lines, the fuse (10A)
and varistor may play the function of overcurrent and overvoltage protection in the circuit. When the
operating current of the circuit is too high, the fuse will fuse. When the input voltage is too high, the
varistor may be punctured to play a role of protection for back-stage circuit. There is a filter circuit
composed of two safety capacitors CX1 and CX2 and a common-mode inductor L1 behind. Its
function is to filter the input 220V power supply and suppress the interference of the Electric radiation
in the grid to the circuit of the circuit board and simultaneously prevent the interference on circuit of
circuit board from electromagnetic radiation to the power grid, and then the relay K1 connected in
Power supply section 1 Power supply section 2 Driving and signal parallel is connected to the thermistor RT1. When the current flows through for RT1 at the moment of
section
electrification, the relay does not work. When 15v relay is electrified for working, the thermistor is short-
circuited to quit the working state (this will be mentioned later).
Common failure of 220V:
Power supply section 1: AC-DC power supply, converting 220V into 300V;
1. Fuse varistor explosion; 2.Common-mode inductance break-off; 3. The switch is non-conducting.4.
Power supply section 2: DC-DC power supply, converting 300V into 5V, L5V, Vdrv;
Damage of thermostat’s broken pin
Driving and signal section: the singlechip collects the signals from motor, pedal plate and operation
300V section: After the current passes through the thermistor or relay, input from pin 2 and pin 3 of
panel and issues the driving signal to control the operation of the motor.
rectifier bridge and form DC pulse with peak value of 310 V after rectification by the rectifier bridge, the
electricity here cannot be directly supplied to the circuit behind, and the relatively stable DC voltage is
output after being filtered by CD1 filtering. We are used to calling it 300V.
Common failure of 300V:
1. Explosion of large capacitance C1 and C2, top heaving.
2. The rectifier bridge is damaged (the measurement method will be mentioned later).
 Fundamentals of Electronic Service

Section II Driving and signal section

Signal and drive section:

Mainly comprises a signal processing section, a
driving section and a current sampling and feedback
section, completing signal acquisition, processing,
motor driving and current feedback actions.
Signal processing section:
The signal processing section is the core of whole
circuit board, and the core element is the singlechip,
the Hall signal in the motor, the Hall signal in the
motor and pedal plate and the current sampling
signal are finally transmitted into the singlechip,
the singlechip judges, analyzes and processes the
signals and then issues the control signal.
Common failures include:
Singlechip damage

Driving and signal section

Circuit diagram of Power Supply Section 2 (DC-DC)

It is mainly used for inputting the signals for motor
Switching power supply section: Hall and pin suspension Hall, which reflects the real-
time position of the motor rotor and the position of
As shown in the above figure, after the 300V power is filtered through CBB capacitor, a closed-loop pin suspension to provide the basis for the rotation
flyback switching power supply is composed by a power supply chip U4, a transformer T1, a 2.5V of single-chip drive motor (the principle of the driving
reference chip U8, an isolated optical coupler U7. section will be mentioned later).
The switching power supply adopts a PWM switching power supply, and the voltage of the sampling Common failures include: failures of E4 motor Hall
resistance (R86, R90) connected by the secondary MCU + 5V of the transformer is compared with a 2.5V and E5 pin suspension Hall (Hall failure, etc.).
reference voltage at the same phase end of the error amplifier in the U8 to generate an error voltage; Motor and pin suspension
and the pulse width (i.e., the duty ratio) of the power supply chip 4 is changed through the optical Hall signal Mainly comprise a speed controller Hall signal
coupler U7so that the charging and discharging process of the transformer coil is continuously carried and an external upgrade signal, wherein pin47 of
out, and each output voltage is stabilized. Motor Plug Circuit singlechip is a signal input pin of speed controller
Hall; when the foot pedal is treaded down, the speed
The secondary of the transformer is respectively rectified by a rectifying diode and a capacitor energy controller Hall induces the change of the magnetic
storage filtering circuit, and the three-circuit signal power supply is output: field and outputs a voltage signal changing with the
1. VDRV, used by relay K1 and drive chip U2, often referred to as 15 V; change of the magnetic field and outputs the voltage
signal to the singlechip; The singlechip adjusts
2. MCU + 5V, used by singlechip U6, operational amplifier U18, panel and all Hall (including motor Hall, the speed of the motor by judging the capacity
speed regulating Hall and positioning Hall); of the Hall signal. When the external upgrader
3. L + 5V is one circuit of isolation power supply to be used for LED handpiece lamp and pin switch. is connected, the program can be conveniently
upgraded for the singlechip.
Foot Pedal/ External Upgrade
Common failures include E6 governor failure (no
Circuit Diagram of Plug for Speed Controller connection of pedal or Hall deviation damage, etc.)
 Fundamentals of Electronic Service

Mainly comprise LED handpiece lamp power

supply and needle input signal, wherein, the
pin signal is isolated by a photocoupler U3
and is input to the singlechip.
Common failures include: failure of pin key

LED lamp/ pin-up signal

LED lamp plug circuit

Driving Circuit of Relay

In order to prevent handpiece being overturned
accidentally and the motor stops rotating
This circuit on this section is a driving circuit of relay. In order to prevent the high-voltage heavy current
so as to avoid the occurrence of accidental
damages the relay on the power-on instant, a single-chip delay circuit is added, and the pull-in of the
conditions, the toppling safety protection circuit
relay is controlled.
is designed. When the handpiece is tilted at
certain angle (usually greater than 35°), the Common circuit failure: no suction of relay (the sound of the relay can be heard when the relay is in
Dumping safety switch electric motor may stop rotating, and E7 failure normal condition) causes that the error warning OF occurs while treading the pedal.
is warned at the same time so as to achieve
Dumping safety switch circuit the purpose of protection.
Common failure: failure of S1 switch.

The port circuit of setter can be connected

with F3 idler wheel or F4 setter, mainly
covering 3 circuits of signals.

double-panel display panel Bus Current Detection

set-up interface circuit

Driving Circuit of Relay

The busbar voltage detection circuit is mainly

adopted with the principle of resistance The current acquisition and amplification feedback section mainly comprises an operational amplifier
voltage division, and the singlechip can detect and a sampling resistance, wherein, the sampling resistance is connected in the motor current circuit;
the bus voltage value in real time so as to set the current flowing through the motor flows back to the power supply section through the sampling
the high-low protection function. resistance and generates a voltage signal on the sampling resistance to input onto the pin 3 of
Common failures include: the failure of divider operational amplifier and output onto pin 45 MIAD-CUR through pin 7 after amplifying for about 10 times
resistance causes the misinformation of over- through the operational amplifier.
Bus Voltage Detection voltage or under-voltage. Common failures include: damage of sampling resistance R23 and R31 damage, error warning of E2, etc.

Bus Voltage Detection Circuit

 Fundamentals of Electronic Service

The driving section mainly comprises a driving chip U2 and six IGBTs. The main function of the driving
chip U2 is to receive 6 circuits of control signal of the singlechip and convert as a signal which can drive
the breakover and the shutdown of the IGBT and then output the signal to the IGBT.

I GBT Bridge-type Driver

As shown in the left figure, the upper bridge consists of Q1, Q3 and Q5.
The lower bridge is composed of Q2, Q4 and Q6, two pins of the upper bridge IGBT are connected
with the positive pole of the 300V power supply, three pins are respectively connected with such three
sets of coils as W, U and V in the motor which are the input ends of motor current; The 2pins of lower
bridge IGBT are connected with motor coil W, U, V which are outflow ends of the motor current. At the
same time, the upper bridge and the lower bridge conducts one IGBT to form a current circuit together
with the motor coil, but it is noted that the IGBT in same group of the upper bridge and the lower bridge
cannot be conducted on at the same time (e.g. Q1, Q2), otherwise, the short circuit is caused.
Driving circuit
One end of three sets of coils in the motor is connected with U, V and W, and the other end is connected
at the same point to form a star-shaped connection mode. When the current inflows from one set of
Pin Diagram of Driving Chip U2 (FAN73892) coil, the current may outflow from another set of coil through connecting points in the middle, therefore,
there is only current in two sets of coils at the same time. There are three Hall in the motor, and when
the rotor rotates, it can induce the change of the rotor magnetic field and output the two variables of 0
U2 pin (FAN73892)is as shown in above figure, pin 1 of U2 is a 15 V power supply pin, and six circuits and 1. After receiving the Hall signal by the singlechip, the angle position of the rotor can be judged,
of signals output from the singlechip are MO-HINU, MO-HINV, MO-HINW, MO-LINU, MO-UNV, MO- and then a corresponding control signal is output to control the direction of the current in the motor coil
LINW. After passing through R54, R55, R56, R57, R61 and R62, input from six pins of (HIN1), 3 (HIN2), through the driving section and generate a magnetic field to rotate the rotor, and when the rotor rotates,
4 (HIN3), 5 (LIN1), 6 (LIN2) and 7 (LIN3)of U2. the direction of the current in the coil also changes so that the rotating magnetic field drives the rotor to
Pin 8 (FO) is a failure output pin. When U2 detects that the signal transmitted by the singlechip or the rotate all along.
current feedback signal is wrong or abnormal, the pin 8 outputs 1 low-level signal to the singlechip. Common failures of signal and driving sections are as
After receiving the signal from the singlechip, stop driving and detect the error code of E2 (this will be follows:
mentioned in the failure analysis below).
1, 5V and 15V short circuit;
27 (H01), 23 (H02) and 19 (H03) are the drive signal output pins of IGBT upper bridge, 26 (VS1), 22
(VS2), 18 (VS3) are the auxiliary output pins driven by the upper bridge, the breakover16 (L01), 15 (L02), 2. Errors such as E1, E2 and E4;
14 (L03) of IGBT driving the upper bridge with the first three driving signals are the output pins driven 3. Phase loss of the motor (the motor stops and goes from
by the lower bridge, and the breakover of lower bridge IGBT is driven. time to time. After stopping, rotate the hand wheel motor
For driving chip U2, we use FAN73892 and can also replace by utilizing IR2136. While using IR2136, it and run again, and the sound is abnormal while rotating).
is necessary to install a 1M resistance on R97 and modify C19 capacitance as 2.2nF. 4. Sampling resistance explosion;
5.Explosion of IGBT;
6. Chip resistance and capacitor burnout.
 Fundamentals of Electronic Service

Failure Detection and Maintenance 2. Measurement of IGBT

Section I Visual Detection

Multimeter diode gear
1. Check whether the large capacitance CD 1
explodes, leaks the liquid or whether there is
Black probe Red probe Normal value
obvious heaving on the top.
2. Check whether the fuse and varistor are 2. 3. 0.450V
burnt out;
1. 3. 0.780V
3. Check whether there are broken pins for
common mode inductance and thermistor;
4. Check whether the sampling resistance R23 If pin 2 and pin 3 are short-circuited, show that
and R31 are exploded or burned. it is necessary to replace the IGBT itself. If the
value of pin 1 and 3 is abnormal, firstly check
whether the relevant resistance under the IGBT is
normal, and replace U2 if the resistance value is
If above-said components are damaged, firstly replace the corresponding components and inspect normal.
whether the traces on the circuit board are high and low, and if there is burnout for routing, the external
lead wires can be employed for connection. (If the value is close to 0, show that the IGBT1
and pin 3 are punctured, the IGBT is required
Static detection is required after visual detection. (Sampling resistance R23 and R31 are exploded to be replaced, and whether the peripheral
blackly, the maintenance is difficult, and it is recommended to return to the factory for maintenance) Measuring valueof Measuring valueof resistance value is normal is checked.)
IGBT1 and pin 3 IGBT2 and pin 3

Section II. Static Measurement before Powering-on

3. Measurement of Rectifier Bridge
1. Measurement of AC access
Black probe Red probe Normal value
As shown in the left figure:
Firstly, the multimeter is tuned onto the buzzer,
1. 2. 0.500V
the switch of the circuit board is on, two probe
respectively put the pin N of the power plug and
the two pins of the rectifier bridge, and the buzzer 3. 0.500V
rings normally;
Then two probe are respectively placed on the L 2. 4 0.500V
pin of the power plug and 3 pins of the rectifier
bridge, and the value around 140 (the value of
the diode file) is displayed to be normal, and the 3. 4 0.500V
probe don’t distinguish the positive and negative
poles.
If the above values are not normal, check whether If any of these values is around 0.002, show that
the circuit is complete, whether the switch is turned the interior of the rectifier bridge has been short-
on, whether the fuse is normal, and whether the circuited, and the measurement is implemented
common mode pin is off, and whether the resistance continuously after the rectifier bridge must be
value of the thermistor is about 100 ohms. replaced.
 Fundamentals of Electronic Service

Section III. Powering-on Detection and Maintenance 2. No suction of relay

Failure analysis: The relay is controlled by both the VDD and the singlechip jointly, so the problems can
be started from the power supply and the singlechip.
If static measurement is normal, powering-on detection can be started. Powering-on detection is a very
important step in maintenance. Unlike static detection, we can reduce the range of failure points by Methods of processing:
observing the reflection of power and error code and clarify the direction of maintenance. Measuring the 1. Determine whether the VDD power supply is powered;
voltage on critical points under powering-on state can help us solve the problem more quickly.
2. Whether the setter displays normally, the normal display indicates that the singlechip is a procedural.
 There is danger in powering-on process;attention should be paid to safety! If unable to be displayed, the burning procedure may be implemented newly;
Turn the switch to the OFF position before power is energized, plug in the power cord, make sure there 3. Replace the singlechip.
is no conductive object on the circuit board and under the circuit board so as not to cause a short circuit,
and then turn on the switch to observe the state of the circuit board. After the normal circuit board is
powered on, be able to hear the relay suction sound and the green light is always on meanwhile. 3. Messy code display
Measuring point of powering-on voltage: Failure analysis: The power supply voltage 5V is constant. After powering-on, the dynamometer does
220V AC measuring point ------pin 2 and pin 3 of Rectifier Bridge not show or the messy code displays or 8 displays, belonging to the display failure fully. Because the
setter is made of the singlechip, the singlechip signal shows that the SM fails.
300V DC measuring point ------pin 1 and pin 4of Rectifier Bridge
Methods of processing:
VDRV 15V DC measuring point---- both ends of Z1
1. Replace the display screen firstly;
5V DC measuring point _ both ends of Cd4
2. Check whether the resistance values of R70, R76 and R80 are normal, check whether the voltage of
pin 1 and pin 5 for J6 is 5V;
1. 300 V is powered; the power source can’t be powered. 3. Replace the singlechip;
Failure analysis: 300V power, power failure, which may be short circuit of power supply, damage of 4. Replace the crystal oscillator;
power supply chip and problem of feedback loop.
If the display abnormality is related to the drive, the maintenance method refers to E1.
Methods of processing:
1. Measure Z1, CD3, CD5 and buzzer respectively with multimeter buzzer for short circuit.
Section IV Failure Code Maintenance
2. If the buzzer does not work, check whether the power supply chip, TNY288PG and RS1M are burnt out;
3. Check whether the feedback photocoupler U7 (EL817) and U8 (AZ431) are damaged and carefully Table of Error Code
inspect the surrounding R85 (510Ω). R93 (1 kΩ), R95 (200 Ω), R86 (2 kΩ), R90 (2 kΩ);
Failure Code Failure Description

E1 Motor stalling

E2 Abnormal controller

E4 Abnormal motor Hall signal

E5 Abnormal positioning Hall signal

E6 Abnormal speed governor signal

Power supply E7 Protection of handpiece safety switch
chip
Eb System overvoltage
Resistance in
the periphery EC System under-voltage
No running for machine after standby for approx. 30s,enter
OF
into sleeping state, or too low voltage
 Fundamentals of Electronic Service

1. E1 failure (motor stalling) 3. E4 failure (abnormality of motor Hall signal)

Failure analysis: If it is detected that the motor
Bootstrap capacitors C3, C4, C5 is unable to rotate after powering on, E1 warns.
Failure analysis: damage of motor Hall and blocking
When the handpiece is stuck or the signal
of Hall signal line will cause the warning of E4.
section fails, it is possible to cause the motor
stalling. The failure of the signal section mainly Methods of processing:
appears on the signal line and the chip is 1. Check whether the motor socket and the electric
damaged. control connection are normal (check whether the
Methods of processing: pin in the socket is normal);
1. Firstly, it is determined whether the IGBT is 2. Inspect whether the motor Hall is normal and
damaged (the detection method of IGBT refers whether the connecting wire of the motor is normal;
to the static measurement); 3. Check whether the chip resistance and
2. Determine whether R54, R55, R56, R57, R61, capacitance are normal R34 = R35 = R36 = 10 kΩ,
R62 are 200 ohm; R24 = R25 = R26 = 4.7 kΩ, C11 = C12 = C13 = 1 nF;
3. Replace the driving chip U2 (73892); 4. Implement the welding repair or replace the
singlechip U6.
4. If E1 is still warned, measure C3, C4, C5,
replace the bootstrap capacitor with short circuit,
and the voltage drop is 0.620V.

4. E 5 Code warning

Failure analysis: in addition to motor handing

down, there is Hall of two needle positions on the
motor. There are two magnetic steels on the hand
2. E2 failure (overcurrent) wheel. When the motor is in operation, the Hall
will induce the position change of the magnetic
steel on the hand wheel, and then the position
of the motor will be determined according to the
setting value of the upper and lower needles. It
is similar to E4 failure, when the Hall signal is
abnormal, the needle position will not be found to
warn E5 code. Under this condition, the damage
Failure analysis: Generally, when the driving
possibility of Hall is greater, and this condition is
section fails, such as, IGBT short circuit, E2
also caused by no blocking of Hall signal circuit.
code will be warned, but the damage of U2 and
U6 itself is not excluded. Methods of processing:
Methods of processing: 1. Check whether the chip resistance and
capacitance are normal R27 = R28 = 4.7 kΩ, R37
1. Measure the resistance of the IGBT and the
= R38 = 10 kΩ, C14 = C15 = 1 nF;
surrounding chips;
2. Replace the positioning Hall;
2. Replace U2 (73892);
Positioning 3. If it is urgent for use, the function of needle
3.Finally replace the singlechip U 6;
Hall 4401 position can be closed (under warning failure
condition, long press “-” key and close the needle
position function);
4. Implement the welding repair or replace the
single chip U6.
 Fundamentals of Electronic Service

5. E6 failure (abnormal speed governor signal) 8. OF failure (sleeping function)

Failure analysis: The singlechip can’t detect the Failure analysis: system sleeping or too low system voltage
signal conveyed by the speed regulating Hall, E6 Methods of processing:
failure will be caused to be warned.
1. Press + or-key to awake the machine by one key
Methods of processing:
2. If the alarm cannot be eliminated, please check whether the power supply voltage or relay is under
1. Determine whether the speed governor is suction normally.
normal (how to detect the speed regulator will be
mentioned in detail below);
2. Detect whether the resistance capacitance
around the speed governor socket in the electric
control main board is normal;
Section V Maintenance of Motor and Speed Controller
3. Implement the welding repair or replace the
singlechip U6.
Common failures of ZOBOW Motor are divided into two types:

6. E7 failure (protection of handpiece safety switch) I. Coil burnout (E2 warning);

II. Damage of motor hall (E4warning).
Failure analysis: When the handpiece tips over,
the electric control will tip over and warn. If the coil is found to be burned, the coil is mailed directly to the manufacturer for maintenance. If the
electric control warns the code and the motor failure is determined, the connecting wire at the motor
Methods of processing:
plug should be determined to be connected normally. If the connecting wire of the motor is normal, it is
1. When the Electric control is placed normally, necessary to check whether the motor Hall is normal.
detect whether the handpiece tip-over switch
is short-circuited. If short-circuited, replace the
handpiece tip-over switch;
2. If there isn’t handpiece tip-over switch and the 1. Composition of motor
urgent use is required, the protection function can
be closed.(under the error warning status, close
the tilting protection function by pressing the key
long).

7. Eb and EC failure (system overvoltage and system under-voltage)

Failure analysis: When the singlechip detects that
220V AC voltage input exceeds a certain value,
Motor coil Motor rotor Motor shell Hand wheel of motor
the singlechip will warn Eb failure code; When
the singlechip detects that the output of the 220V
AC voltage is lower than a certain value will warm
2. Composition of speed controller
Ec and the voltage value is set by the internal
parameters. Speed regulating Hall
Methods of processing:
1. Check whether the external 220VAC voltage is
stable;
2.Detect whether the bus detection circuit fails;
3. Implement the welding repair or replace the
singlechip U6.

Shell of speed controller T-shaped plate for speed controller Base of speed controller
 Fundamentals of Electronic Service

3. Detection of motor Hall

As shown in the left figure, properly insert
the motor to be tested, connect the electric
control onto power supply and turn on the
switch, adjust the multimeter onto DC 20v
gear, insert the black probe of the multimeter
into the jack socket in which the fine black
line is located, insert the red probe into one C4 Electric Control Maintenance Guide
of the jack sockets where the white, brown
and yellow fine wires are located, and
turn the hand wheel of the motor by hand
and observe the values displayed on the
multimeter. If 0 and 5 appear alternately, the
corresponding Hall of this wire is normal. If
the value is kept at 0 or 5 invariably, show
that the motor Hall (41F) corresponding to
the wire with this color has been damaged,
Circuit board recognition
and then the white, brown and blue wires
are tested in sequence completely, and
the color of the abnormal wires is recorded
down, and the motor is disassembled to find
out the Hall corresponding to this wire for
Main functional module division
replacement.

Circuit analysis

Failure detection and maintenance

No. 3
Hexagon
socket
If the speed controller does not run or the
electric control slowly moves under the
condition that the needle position is closed,
firstly loosen No.3hex screw and adjust
the magnet angle properly until the speed
Magnet controller can work normally. If the adjusting
position is invalid, firstly detect whether the
cable is normal. If normal, replace the speed
regulating Hall (50B) and then adjust the
position of the magnet.
 Fundamentals of Electronic Service

Circuit board recognition Section II Reverse Side of Circuit Board

Section I: Front of circuit board

Cement resistor plug-in J4

Safety capacitor Cx1

Bus current sampling resistance

R121/ R124 and TVS1
Common mode inductance L1

Safety capacitor Cx2

Thermistor.
Fuse F1

Relay K1

Bridge
rectifier B1 Power socket J1

Single-chip
processor U3
High-voltage Hall signal socket of
capacitance CD3, motor
CD4
USB upgrading socket

Hall signal socket

capable of stopping
needle
The drive chip U2

Electrical motor I-inductance

socket L3, L4

Three-end voltage regulator

7805 U22

Transformer T1 Panel interface Adapter plate interface Rectification diode D15

MOS tube
Power Chip U23 Q12-Q15

Functional socket Speed controller socket

 Fundamentals of Electronic Service

Section III Cognition on Pinboard Interface

Main Functional Module Division

Section I Function Introduction to Each C4 Electric Control Section

High voltage power

supply section

Motor drive section

Function section

Switching power
supply section
Section IV. Definition of Switchboard Interface

Safety switch of
sewing console
Launching modules
Front receiving

Rear receiving

Signal processing section

• 1. High-voltage circuit of main power supply: the input 220V AC is filtered and rectified to form
300VDC and then filtered by large capacitance, and the stable 300VDC is output after energy storage.
• 2. Switching power circuit: the stable 300V is via flyback power supply to get one circuit of isolated
power supply 30V. For two circuits of non-isolated power sources 15V and MCU 5V, of which 30V
supply power is fed to the electromagnet for power supply, and then the DC/ DC voltage drops to get
two circuits of power supply of L5V and U5V, and L5V supplies the power source to the panel and
the pinboard, and the U5V is used for charging the external USB interface; 15V supplies power to the
drive chip, and MCU5V supplies power to the singlechip.
• 3. Drive circuit: amplifying the drive signal of the singlechip to form six circuits of drive signal and
control the conduction and the turning-off of the IGBT so as to control the rotation of the motor.
• 4. Signal processing circuit: the singlechip is the core of the whole section, the motor Hall signal, the
stop pin signal, the speed controller signal, the setter signal and the current feedback signal are input
into the singlechip for processing, subsequently, the singlechip outputs a corresponding drive signal to
Pin safety switch drive the motor according to the acquired signal.
Pinboard communication line • 5. Function circuit: the signal output by the singlechip is processed to control the on-off of the
functional tube to control the action of the electromagnet.
Medium Receiving
• 6. Communication circuit: control the signal transmission of the singlechip and the panel.
 Fundamentals of Electronic Service

Circuit Analysis Section II Switching Power Supply Section

Switching power supply section: one circuit of bus voltage 300Vpasses through high-frequency filtering
Section I High Voltage Power Supply Section of CB2 ceramic chip capacitor; one circuit passes through IGBT to be supplied to motor for use; one
circuit is input to the three pins of the power supply chip U23 through R149 and R151 to provide an
initial current signal for the current detection; There is also one start voltage for the 7 pins of U23
Main function of high-voltage power supply section: filter and rectify the input 220VAC to form 300VDC (UC3842) after step-down of R153, R150, R147, and R148.U23 is a high-frequency switching power
and then output the stable 300VDC after large capacitance filters and energy storage, while supplying chip which outputs a PWM signal to one pin 1 of Q16 (STP9NK70ZFP/ T0-220FP) after operation.
power to the motor while obtaining 15V power supply, MCU5V power supply and 30V power supply When the PWM signal output by the 6 pins is at a high level, the Q16 is turned on and the bus voltage
through the switching power supply circuit. is charged to the inductance between the four and six pins of the primary side of the transformer. In
addition, R77, R78, R79, R80 in the circuit can convert the current signal into voltage signal. When the
voltage of 3 pins of input U23 through R157 exceeds 1V, the U23 chip reduces the pulse width to cause
the 7-pin power supply to be in an intermittent operation state to play the role of current detection and
regulation so as to achieve the purpose of overload protection; When the 6-pin output PWM signal is
low, Q16 is off, and the energy between the primary windings 4 and 6 of the transformer is consumed
by D17, C49, and R70.At the same time, the energy of the primary side is released to the secondary
winding, and the secondary winding generates inductor electricity. And the induced voltage between the
secondary windings forms a stable voltage through a subsequent diode, a capacitor rectification filter
and a three-terminal voltage stabilizer.

AC input interface

Detailed introduction is as follows:

220V power supply section: As shown in left figure, 220V power is input through the power plug, one
circuit passes through fuse F1, then the varistor RV1 and two Y capacitors are connected in parallel
between the two wires, the fuse (10A) and the varistor play the function of overcurrent and over-
voltage protection in the circuit, and when the operating current of the circuit is too high, the fuse will
fuse, and when the input voltage is too high, the varistor will be broken down to play the protection
function. The following is a filter circuit composed of two safety capacitors CX1, CX2 and a common-
mode inductance L1. Its function is to filter the input 220V power supply and suppress the conduction
of electronic radiation in the grid to the circuit of the circuit board so as to prevent the circuit board
circuit from interfering with the power grid. Then, the relay B1 connected in parallel is connected to the
thermistor, and when the current flows by, the relay does not work, and when the 15v relay is energized,
the thermistor is short-circuited, quitting the working state is (this will be mentioned later).

Common failures of 220V: 1. Blasting-off of fuse varistor

2. Pin breaking of common mode inductance
3. The switch is non-conducting

Switching Power Supply - Section in Front of Transformer

 Fundamentals of Electronic Service

Section in rear of the transformer for switching power supply: there are 3 circuits of output at the After the voltage of VDD (30V) is generated, it will pass through the AZ431 voltage stabilizing circuit,
transformer secondary side, and the first circuit is + 15V for 15V voltage of relay and drive chip; the and the voltage divided by the sampling resistance connected to the output end of VDD is compared
second circuit is MCU + 5V, which supplies 5V voltage to the singlechip, the operational amplifier and with the internal reference voltage of U14 to control the conduction of the U15 photocoupler 3
each Hall signal (including the motor hall, the speed regulating Hall and the positioning Hall);The third and 4. At this time, pin 8 of U23 output the voltage corresponding to the corresponding magnitude
circuit is VDD (30 V), which is mainly supplied to the functional section of the electromagnet or solenoid according to the current magnitude of the photo- coupler, after passing through R160, the voltage of
valve, and then depressurized by two circuits of AX3007 to obtain L + 5V and U + 5V, respectively, in the corresponding size is compared with the reference 2.5V voltage inside the U23, the voltage will
which L + 5V supplies power to the panel, the pinboard, the head lamp and the U + 5V to the external be compared with the reference 2.5V voltage inside the U23, the error voltage is generated, and the
USB charging interface. An RC absorption circuit is connected across the VDD output diode D15, which feedback voltage on the primary side of the pin is compared so that the pulse width is adjusted, and the
acts to suppress the reverse peak voltage (surge voltage) against the diode and act as a protective conduction and the turn-off of the switching tube are controlled by the pin 6 of U23 so as to achieve the
diode. The first, second, and third circuits are both rectified by diode and filtered to obtain stable DC purpose of real-time detection and regulation of the voltage.
voltage.

15 V power supply Power

supply
5V reference
Under-voltage
power supply
limit
Chengzhi electronic
production network Drive

Output
Oscillator
Latch

Error Current detection

amplifier comparator

Internal Schematic Diagram of UC3842

MCU + 5V power supply

30V power supply

Feedback Regulating Circuit

Switching Power Supply - Section in Front of Transformer
 Fundamentals of Electronic Service

Section III Signal Section and Drive Section The drive section mainly comprises a drive chip U2 and six IGBTs. The main function of the drive chip
U2 is to receive the 6-circuit control signal of the singlechip and convert to a signal which can drive the
conduction and the shutdown of the IGBT and then output the signal to the IGBT.
Signal and drive section: be mainly composed of signal processing section, drive section and current
sampling and feedback section; complete signal acquisition, processing, motor drive and current
feedback. The detailed introduction is as follows.

Pin Figure FAN73892 of Drive Chip U4

U2 pin (FAN73892) is shown in the above figure. No.1 pin is a 15 V power supply pin of U2. The six
circuits of signals output from the singlechip are MO-HINU, MO-HINV, MO-HINW, MO-UNU, MO _ UNV,
MO-LINW, after being filtered by R3, R4, R7, R8, R16, and DQS, and input from U2 (HIN1) 3 (HIN2), 4
(HIN3), 5 (LIN1), 6 (LIN2), 7 (LIN3).
Signal processing section: No. 8 pin (CS) is a failure output pin. When U2 detects that the signal transmitted by the singlechip or
the current feedback signal is wrong or abnormal, No. 8 pin outputs a low-level signal to the singlechip.
The signal processing section is the core of the whole circuit board, and the core element thereof is the
After receiving the signal from the singlechip, the singlechip stops drive and gives an E10 error code (this
singlechip, the Hall signal in the motor and the Hall signal in the pedal plate and the current sampling
will be mentioned in the following failure analysis).
signal are finally transmitted to the singlechip, the singlechip judges, analyzes and processes the
signals and then sends out a control signal. 27 (H01), 23 (H02), 19 (H03) are the drive signal output pins of IGBT upper bridge, 26 (VS1), 22 (VS2),
18 (VS3) are the auxiliary output pins driven by the upper bridge, and the first three drive signals act to
drive the conduction of IGBT of the upper bridge;16 (L01), 15 (L02), 14 (L03) are output pins driven by
Drive signal section: the lower bridge to drive the conduction of the lower bridge IGBT.
The drive signal section is a 6-circuit drive signal sent by the receiving processing singlechip, and the Drive chip U2 is FAN73892 used by us.
aim of controlling the rotation of the motor is achieved by controlling the working order of the IGBT.
 Fundamentals of Electronic Service

Common failures on signal and drive

sections:
1, 5V, 15V short circuit;
2. Report E1, E2 and E4 errors;
3. Phase loss of the motor (the motor walks
and stops occasionally, after stopping, turn
the hand wheel motor again, the sound is
abnormal at the time of rotation)
4. Blasting-off of sampling resistance;
5.IGBT blasts off;
6. Patch resistance and capacitor burn out.

Upper and Lower Bridge Circuit Composed of IGBT

As shown in the above figure, the upper bridge consists of Q11, Q9 and Q7, and the lower bridge is
composed of Q10, Q8 and Q5. The two pins of the upper bridge IGBT are connected with the positive Current sampling
pole of the 300 V power supply, and the three pins are respectively connected with the three groups of
coils W, U and V in the motor, which is the input end of the motor current; The 2-pin motor coil W, U, V Current Sampling Circuit
of the lower bridge IGBT is the outflow end # of the motor current. At the same time, the upper bridge
and the lower bridge conduct one IGBT to form a current circuit together with the motor wire. However, Current sampling section:
it is noted that the IGBT of the same group of the upper bridge and the lower bridge cannot be turned The current collecting and feeding back sections mainly consists of operational amplifier and the
on (e.g. Q1, Q2) at the same time; Otherwise, the short circuit will occur. sampling resistance, the circuit diagram is shown in the above figure, the sampling resistance is
One end of the three groups of coils in the motor is connected with U, V and W, the other end of the connected in the motor current circuit, the current flowing through the motor flows back to the power
three groups of coils is connected at the same point to form a star-shaped connection mode, there is supply section through the sampling resistance, and a voltage signal (U, V) is generated on the
only current in the two groups of coils at the same time. There are three Hall in the motor, and when the sampling resistance as an input signal to the operational amplifier U17, pin 8 of the operational amplifier
rotor rotates, induce the change of the rotor magnetic field and output the two change values of 0 and 1. is SV power supply, pin 2 is a U phase current feedback signal input pin, and pin 6 is a V phase current
After receiving the Hall signal by the singlechip, the angle position of the rotor can be judged to output feedback signal input pin. After the feedback signal is amplified by the operational amplifier, the V-phase
a corresponding control signal to control the direction of the current in the motor coil through the drive signal is output to the pin lv-mcu of the singlechip through the pin 7, and the U-phase is output to No. 43
section to generate a magnetic field to rotate the rotor. And when the rotor rotates, the direction of the pin lu-mtu of the singlechip through No.1 pin.
current in the coil also changes so that the rotating magnetic field drives the rotor to rotate all the time.
 Fundamentals of Electronic Service

C4 is also provided with an AC voltage and a bus voltage detection circuit in addition to the current Section IV. Brake Circuit and Function Section
sampling circuit.
Cement resistance interface

Bus voltage sampling

Busbar sampling circuit

Brake circuit
Sampling circuit for bus voltage: collect the voltage on both ends of R96 by series of resistance (R101,
R99, R98, and R96), filter out interference from signal via R97 and C16 filter circuits, and then give a
sampling signal to pin 3 of MCU (singlechip). Brake Circuit

When the sewing machine brake, a reverse electromotive force is generated in the motor coil, the
reverse electromotive force is superimposed on the bus voltage, when the bus voltage is higher than the
discharge voltage set by the software, the pin 39 MO-BRAKE of the MCU sends out an electric signal,
right now, Q2, Q3, Q6 are turned on, the reverse electromotive force will be released from the BUS +
via J4 cement resistance and Q3 to go back to PGND until the bus voltage is lower than the discharge
voltage value set by the software, the pin 39 MO-BRAKE of the MCU sends a low level signal, Q2 and
Q6 are turned off, and 15V feeds a high level to pin 1 of Q4 via R50 resistance and Z2 stabilizing tube ,
after Q4 breakover, pin 1 of Q3 is pulled down to turn off, and the brake circuit stops working.

Absorption circuit
AC voltage sampling

AC Sampling Circuit

The AC voltage sampling circuit is similar to the bus voltage sampling circuit; the narration isn’t
implemented any longer. Lift presser pin
 Fundamentals of Electronic Service

Failure Detection and Maintenance

Section I Visual Detection

Electromagnet interface
Electromagnet signal

Function Circuit of Electromagnet

Take the function of lifting presser as an example, the MCU’s pin 27 outputs a MO-TYJ signal to turn on
the pin 3 and pin 4 of photocoupler U10, VDD is supplied to the VDD (30 V) voltage of the Q15 via R91,
right now, pin 2 and pin 3 of Q15 (M0S tube) are turned on, the 30V voltage of the supply electromagnet
passes through the J9 electromagnet interface, the electromagnet and the Q15 return to the DGND.
the electromagnet suction of lifting presser starts working; In that operation mode of the other functional
electromagnet, when the electromagnetic release of the presser pin is different, a reverse electromotive
force is generated by the electromagnet, superposed on the VDD, right now, pin 13 of MCU sends out a
control signal to control the discharge of the U11, Q17 and U16 at a certain frequency so as to prevent
damage to the electromagnet and the VDD circuit device.

1. Check whether the high-voltage capacitance CD3 and CD4 blast away and leak the liquid or the top
is obviously convex.
2. Check whether the fuse and voltage-sensitive burn out
3. Check whether there is broken pin for common mode inductance
4. Check whether the sampling resistance R14/ R29/ R121/ R124 blast away or charring.
5. Whether the cement resistance is charring.
If the components are damaged, replace the corresponding components and inspect whether the traces
on the circuit board are high and low, and if there is a defect in the wiring, the external lead wires can be
used for connection.
Static test is required after visual inspection.
 Fundamentals of Electronic Service

Section II. Static Measurement before Powering-on 2. Fuse detection

Measure two ends of the fuse with the diode of the multimeter. If the buzzer sounds, it is normal;
Otherwise, replace the fuse.
1. The measurement of the AC circuit is as shown in left figure:
Two probes respectively discharge the pin L of the power plug and the pin 2 of the rectifier bridge. If
the buzzer sounds, it is normal;
And then the two probes are respectively placed on pin N of the power plug and pin 3 of the
rectifier bridge. If the buzzer sounds, it is normal, and the positive and negative electrodes are not
distinguished for probes.
If the above test is not normal, check whether the circuit is complete, whether the switch is turned
on, whether the fuse is normal, and whether the common mode inductive pin is off and whether the
resistance value of the thermistor is about 10 ohms.

Front measurement Reverse measurement

No powering-on for circuit board, gear of multimeter

diode
3. Detection for common mode inductance

Red probe Black probe Multimeter reading Measure the common mode inductance pin1, pin 2, pin3 and pin 4 with a multimeter diode. If the buzzer
sounds, the common mode inductance is normal; otherwise, replace common mode inductance.

Pin 2 N 0.01 -0.02

Pin 3 L 0.01 -0.02

Front of common mode

inductance Reverse of common
mode inductance
 Fundamentals of Electronic Service

4. Measurement of Rectifier Bridge 5. Measurement of IGBT

Gear of multimeter diode

Red probe Black probe Multimeter reading

Gear of multimeter diode

Pin 3 0.4-0.5
Black probe Red probe Normal value
Pin 4
Pin 2 0.4-0.5
2. 3. 0.4-0.5

Pin 4 0.4-0.5
1. 3. 0.7-0.8
Pin 1
Pin 4 0.4-0.5
If pin 2 and pin 3 are short-circuited, show that IGBT is required to be replaced itself. If the value of pin
1 and pin 3 is abnormal, firstly check whether the relevant resistance under the IGBT is normal. Replace
U2 if the resistance value is normal.(If the value is close to 0, show that the IGBT1 and pin 3 are broken
down, replace the IGBT.)
If any of these values is about 0.002, show that the interior of the rectifier bridge has been short-
circuited. The measurement can be continued after replacing the rectifier bridge.
 Fundamentals of Electronic Service

Section III Powering-on Detection and Maintenance 1. The power supply of controller is free of L + 5V/ U + 5V failure maintenance
If the static measurement is normal, the powering-on detection can be implemented. We can reduce
the range of failure points by observing the reflection and reported failure codes after powering-on. The
problems can be solved rapidly by measuring the voltage at some key points under powering-on state.
 There is certain danger for powering-on process, and the attention should be paid to safety!
Before powering-on, turn the switch to off position and plug in the power cord to make sure there is not
conductive object on the circuit board and below so as not to cause the short circuit, and then turn on
the switch, observing status of the circuit board. After the normal circuit board is powered on, the green
light is normally on, and the relay suction sound is heard.
Power-on voltage measuring points:
220V AC measuring points -----pin 2 and pin 3 of Rectifier Bridge
300V DC measuring points -----pin 1 and pin 4 of Rectifier Bridge
VDD (30 V) DC measurement points---- both ends of C74
+ 15 V DC measuring points-------both ends of C3
MCU + 5V DC measuring points _ both ends of C22
L + 5V DC measuring points_ both ends of C39
U + 5V DC measuring point _ both ends of C42

Common faults of the power supply section are as

follows:
1. Common faults of AC module:
1) Fuse and pressure-sensitive blasting away
2) The switch is non-conducting
3) Broken pin of common mode inductance
4) No suction of relay

2. Common faults of rectifying modules:

1) Large capacitance C1 and C2 blasting away, top
heaving
2) Damage of Rectifier Bridge
Failure Analysis: This is usually caused by no output of 30V or L + 5V/ U + 5V short circuit or damage of
power supply chip U20/ U21 and F2 for AX3007C.
Troubleshooting methods:
1. Check whether the 30V power supply is perfect.
2. Check whether the pin 1 and pin 2 of power supply chip U20 (U21) corresponding to the L + 5V (U +
5V) are short-circuited by adopting the gear of multimeter diode. If the short circuit occurs, U20 (or U20)
is damaged, the input resistance R13S/ R137 corresponding to the chip and the stabilovolt tube Z1 (or
the R138 and the stabilovolt tube Z6 are damaged), and detect whether the F2 resistance is abnormal.
 Fundamentals of Electronic Service

2. The power supply of the controller is continuously restarted (repeated actuation of relay) Section IV. Introduction to Failure Code

List of Error Code

Failure analysis:
Code Error Type Code Error Type
This is usually due to a 30V short circuit, 30V
feedback resistance breakage, and damage E1 Motor stalling E11 Overpressure during shutdown
of peripheral circuit of the switch MOS tube or
virtual welding or breakage of transformer pin. E2 Software over-current E12 System under-voltage

Troubleshooting: Abnormal communication between

E3 E13 Abnormal brake circuit
operation panel and control box
1. Check whether 30V is short-circuited.
E4 Motor Hall error E14 Abnormal parameter read-write
Fault 2. Check whether the switching MOS is normal
feedback and whether the sampling resistance R77-R80 E5 Abnormality of stop pin signal E19 Abnormal current detection circuit
is normal.
E6 Starting of presser protection function E20 Power off
3. Find out whether the feedback circuit of VDD
power supply is normal, especially whether the Starting on protection function for sewing
E7 E24 Abnormal speech chip
feedback circuit sampling resistance R71/ R76/ console
R74 is correct Abnormal communication between
E8 Protective function of pin bar guard is on E26
pinboard and controller
4. Check whether the transformer pins are Fullness upon counting with ascending
broken or welded virtually. E9 Abnormal pedal connection EA1
order for quantity of piece counting
Fullness upon counting with ascending
E10 Hardware over-current EA2
order for quantity of piece counting

Visual inspection for obvious damage

of elements and devices : 19-25 pin of Repair welding or
single chip U3/ R3/ R4/ R7/ R8/ R16/ replacement of
Rm is false welding defective devices

3. There is not reaction for controller powering-on, failure maintenance. After powering-up, measure whether
Replace the Test
C3 has 15 V voltage, if no/ low/ high defective device
replace U7

Measure whether the IGBT (Q5/ Q7/

Replace the
Q3/ Q9/ Q10/ CU1) is damaged with a defective devices
Test
diode gear
Failure analysis:
This is usually caused by open circuit on AC
Measure the test TVS1/ TVS2/ TVS3
with a diode file for a short circuit; the Replace the
resistor & measure the most R14/ R29/ Test

section or abnormal open source section of switch

defective device
R121/ R124 has a large resistance or
open circuit

Troubleshooting:
Whether IGBT grid resistance is
1. Check whether the switch is non-conducting, damaged by resistance gear R19/ FU3/ Replace the

Start-up
Test
R25/ R30/ R31/ R36/ R37/ R42/ R44/ defective devices

whether the fuse is fused and the common R45/ R47/ R55/ R5/ R22/ R26

resistor mode inductive pin is broken off.

Repair welding or

2. Check whether D28 is damaged or welded

Measure resistance with resistance replacement of Test
gear or damage R34/ R117/ R119 defective device

reversely
Replace U2 Test

Current 3. Check whether the starting resistance is

feedback damaged or broken.
Replace the motor Test

resistance 4. Check whether switch M0SQ16 is damaged

Return to the factory for
maintenance

5. Check whether the current feedback resistance

is damaged
 Fundamentals of Electronic Service

Failure analysis: If it is detected that the motor is unable to rotate after powering on, E1 will alarm. The solution is as shown in the following figure:
When the machine head is stuck or the signal section fails, it is possible to cause the motor to stall. The
Failure of the signal section mainly appears on the signal line. Check visually that the circuit board
has components which are obviously Repair welding or
damaged; if the 43/ 44 pin of the single replacement of Test
Primary Failure s: chip processor U3 is out of welding or
continuous welding
defective devices

1) Virtual welding or damage of IGBT (Q5/ Q7/ Q8/ Q9/ Q10/ Q11) and its peripheral resistance
2) Virtual welding or damage of FAN73892 (U2) and input resistance Measure U17 with a voltage of 20 V;
Pin 4 and pin 8 of U17 shall be SV;
Check R63/ R104
for virtual welding
Pin 1 and pin 4 shall be output at 2.5 V; or replace C23/ Test
3) Sampling resistance of busbar current and damage of TVS tube Pin 4 and pin 7 shall be output 2.5V: C25

4) The line of motor Hall is disconnected (mainly because the plug-in is loose or the motor Hall is
damaged) Test R38/ R40/ R51/ R56/ R59/
R102/ R103/ R105/ R105/ R1 06/
Replace the
5) The machine head is blocked tightly R107/ R108/ R109 with resistance
gear and check for damage or
defective devices Test

damage to C20/ C19

2. Failure maintenance of E02/ E19 (software overcurrent/ current detection circuit) Replace U17 Test

Failure analysis: E02 is mainly because the singlechip detects that the output voltage of the operational
Return to the factory
amplifier is more than 1.95V/3.95V; E19 is mainly due to the fact that the voltage value sampled by the for maintenance

singlechip on the 43 and 44 pin of the motor does not deviate 2.5 V. The main causes of this problem
are:
3. Failure maintenance of E03 (abnormal communication between operation panel and control box)
1) The sampling resistance of the two phases for U/ V or TVS tube is damaged.
Failure analysis and troubleshooting: It is usually caused by the lack of communication line between the
2) The operational amplifier and its peripheral components are damaged. main board and the panel. The main causes are:
1) The plug-in of panel communication line is loose.
2) The solution methods for solving virtual welding or damage for light coupling or peripheral devices
are as shown in the right figure:

Panel communication photocoupler

Check that the panel is faulty Replace the

Test
panel

Check whether the panel

Replace the
communication harness is loose Test
defective device
and the J8 plug-in is damaged

Check whether the vicinity of 5/ 7 pin

and U18/ U19 of the singlechip U3 is Repair
false or not and whether the welding Test
welding
and D32/ D31 are welded reversely

Use multimeter resistance to

Replace the defective
measure Rl/ Rl18/ R123/ R134/ devices
Test
R136/ R171 damage

Electricity Circuit board powering on, gear of DC voltage for multimeter

Use a diode to measure the U18/ Replace the defective
Test
Red probe Black probe Multimeter reading Q18/ U19/ D32/ D31 damage device

1 Pin 2.5V Return to the factory for

maintenance

7 pins 4 pins 2.5V

8 pins 5V
 Fundamentals of Electronic Service

4. Failure maintenance of E04 (motor Hall) 6. Failure maintenance of E06/ E07/ E08 (presser/ sewing console/ pin bar guard safety switch)

Inspect the insert for damage to Replace the

the plug-in defective device
Test Check whether the presser, sewing
table, needle bar shield are installed
and adjusted in place

Test R34/ R117/ R119/ R114/

Replace the
R11S/ RU6 for damage by Test
defective device
using resistance gear

Plug the loose plug-in on the adapter

plate properly
Test

Test motor Hall for damage Replace the

defective device Test
using diode gear

Replace the relevant sensor or

pinboard
Test
Return to the factory
for maintenance

Failure analysis: generally, because the singlechip does not detect the Hall signal error, the main
reasons are as follows: Return to the factory
for maintenance
1) The plug-in of motor Hall wire is loose. Inductor of presser safety switch
2) The filtering resistance capacitance around motor Hall plug-in produces the conditions of virtual
welding or continuous welding.
3) The solution methods for motor Hall signal damage are as shown in the following figure:

5. E05 (abnormal stop pin signal) failure maintenance

Check whether the plug-in Replace the Test

J10 is loose or not defective device

Is resistance test/ R110/ Replace the

R111/ R112/ R113 defective device
Test
damaged

Check whether the position

Adjust the magnetic
of the magnetic steel is Test
incorrect. steel

Locating Hall Test the needle hall for Replace the

damage using a diode file defective device Test
H1, H2 (H145)

Return to the factory

Safety switch inductor for sewing console Safety switch inductor for pin rod shield
for maintenance

Failure analysis: Generally, because the singlechip processor does not detect the error of stop pin Hall Failure analysis: typically caused by poor contact or sensor damage
signal, the main reasons are: Troubleshooting:
1) The plug-in of stop pin is loose 1) Check that the sensor plug-in is in good connection with the pinboard
2) The filter resistance capacitance around the plug-in of pin stop Hall occurs in the condition of false or 2) Replace the corresponding sensor or pinboard
continuous welding or Hall damage
3) The Failure source is eliminated, and the pinboard and sensor are returned to factory for
3) If the installation of nonmagnetic steel or magnetic steel is not in place, the motor hall on the cover of maintenance.
the motor is abnormal.
4) If it is urgent to use the closable pin stop function, the following figure is shown in the following figure:
 Fundamentals of Electronic Service

7. E09 (Pedal connection abnormal) failure maintenance 9. E11/ E12 (Over-voltage/ system under-voltage at the time of shutdown) failure maintenance

Failure analysis: usually due to poor contact

between the pedal and the control box, the failure
should be eliminated:
1) Check whether the connection between the pedal
and the control box is good Failure analysis: usually due to poor contact
2) The pedal sensor is damaged and the pedal is between the pedal and the control box, the failure
replaced. is eliminated:

3) Check whether R46/ R128 is damaged 1) Check whether the connection between the
pedal and the control box is good
2) The pedal sensor is damaged and the pedal is
replaced.
3) Check whether R46/ R128 is damaged
8. E10 (hardware overcurrent) failure maintenance

10. E13 (abnormal brake circuit) failure maintenance

Check visually whether the circuit board has Repair welding or
components which are obviously damaged; replacement of
whether the 38 pin/ R21 of the single chip
processor U3 is false or not defective device

After power-up, measure whether

Replace the
C3 has 15 V voltage, if no/ low/ Test
defective device Check whether the cement
high replace U7
resistance is inserted properly

Is the IGBT (Q5/ Q7/ Q8/ Q9/ Q10/ Replace the

Q11) damaged with a diode stop defective device Test
Measure the brake resistance with Replace the
a resistor for damage Test
defective device
Measure the measurement TVS1/
TVS2/ TVS3 with a diode range for
Replace the
a short circuit; the resistance file defective device
Test
measures R14/ R29/ R121/ R124
Measure the MOS transistor Q3 Replace the
whether the resistance is large or open Test
with a diode for damage defective device

Measure IGBT gate resistance with

resistance to R19/ R23/ R25/ R30/ Replace the defective Use resistance gear to measure
Test
R31/ R36/ R37/ R42/ R44/ R45/ device
MR6/ R39/ R48/ R49/ R50/ R52/
R47/ R55/ R5/ R22/ R26
R53/ R54; diode measurement Replace the
Test
Z2/ Z3/ D7/ Q2/ Q4/ Q6 is defective device
damaged
Replace U2 Test

Return to the factory for Return to the factory for

maintenance maintenance

Failure analysis: mainly due to IGBT, bus sampling resistance and FAN73892 damage, the main failure
is as follows:
1) Check whether the IGBT is damaged Failure analysis and troubleshooting: normally due to damage to cement resistance or no insertion of
2) Check whether the bus sampling resistance is damaged plug-in
3) Replace U2 FAN73892 1) Check whether the resistance value of cement resistance is normal and whether the plug-in is
connected.
2) Check whether Q3 is damage.
 Fundamentals of Electronic Service

11. E14 (abnormal parameter reading/ writing) failure maintenance 13. EA1—Causes for full occurrence on counting for ascending order upon counting for number of
pieces
The function on counting for number of pieces is opened, and the current sewing times reach the
The controller board downloads the
program newly
Test setting value for number of pieces;
Solution mode:
1) Press P key for cancelling;
Replace the singlechip Test 2) Enter the technician parameter area, set the parameter of P71 item as 5,

Return to the factory for

maintenance

Section V Other Common Problems

Failure analysis and troubleshooting: since the EC4 parameter is in Flash in the singlechip, the reasons 1. Trimming/ presser lifting/ no action of air suction/ failure maintenance
for this problem cover following three reasons: Failure analysis: usually caused by looseness of electromagnet plug-in, virtual welding of photocoupler,
1) Procedure error damage caused by heating of electromagnet, etc. The troubleshooting methods are as follows:
2) Singlechip damage 1) Check whether the plug-in is loose.
3) Unstable MCU + 5V power supply 2) Check whether the MOS tube corresponding to the electromagnet is damaged
3) Whether the electromagnet is damaged

12. Failure maintenance of E26 (abnormal communication between pinboard and controller)

Replace the
Whether the pinboard fails Test Visual inspection for obvious
adaptor plate
Replace the
damage to the device or loose Test
defective device
plug-in

Check whether the wiring harness

Replace the
of the adapter plate is loose and the
defective device Test
J7 plug-in is damaged

Test Q12/ Q13/ Q14/ Q15/ U16 Replace the Test

Visually inspect the pin 45/46 for damage using diode file; defective device
of the MCU U3 and the vicinity
of the Pin/ U5 for false or Repair welding Test
continuous welding and D23/
D24 reverse

Pinboard communication Replace the corresponding

Use a multimeter resistance photocoupler device Test
photocoupler
gear to measure the damage Replace the U9/U10/U11/U12/U13
to R27/ R32/ R33/ R170/ R175/ defective device Test
R174/ R28

Troubleshooting:
1) The wire harness is loose Using a diode to measure the Replace the
Test Replace the electromagnet Test
THD/ Q1/ U5/ D23/ D24 damage defective device

2) Damage or virtual welding of optical coupler

Pu/ U5 and its peripheral components
Return to the factory Return to the factory
The solution is as shown on the right figure: for maintenance for maintenance
 Fundamentals of Electronic Service

2. Manual trimming failure 4. Composition and maintenance of motor

Description on failure: press the manual trimming switch so that the trimming electromagnet is free of Common failures of ZOBOW motors are generally divided into three categories:
action.
I. Coil burnout (E2 alarm);
II. Damage of motor Hall (E4 alarm).
If the coil is found to be burned out, the coil shall be mailed directly to the manufacturer for maintenance.
If the electric control alarms E4 code and determines the motor failure, firstly determine whether the
connecting wire at the motor plug is connected normally. If the connection of the motor is normal, check
whether the motor Hall is normal or not, and the detection methods of the motor Hall are as follows.

Maintenance methods:
1. Confirm whether the manual trimming switch for software parameter P47 is closed.
(0: off, 1: on)
2. Observe the icon of middle and rear sensor on the panel. If the icon is on, show that the middle
Motor coil Motor rotor Motor housing Motor handwheel
and rear sensor is blocked, and the manual trimming cannot be performed. If the icon isn’t on, it is the
sensor failure. Refer to the failure of “Sensor Abnormality _ Icon On” for maintenance.
3. Universal detection resistance R37, R100 and capacitor C14 used for circuit overhauling, poor
replacement.
4. If the above problems cannot be solved, replace the sensor transmitting modules.

3. The machine head lamp does not work

Detection of Q4: gear of multimeter diode

Red probe Black probe Readings

Pin 2 Pin 1 0.66-0.68

Pin 3 Pin 1 0.67-035 Motor Hall detection:

Head lamp driving circuit
As shown in the left figure, properly insert the motor to be tested, electrically connect the power supply
Description of failure: repeatedly press the brightness adjustment button of the machine head lamp on and turn on the switch, adjust the multimeter to DC 20v gear, insert the black probe of the multimeter
the panel, and the machine head lamp remains off. Maintenance methods: into the socket in which the black line is located, insert the red probe into one of the sockets in white,
brown and yellow lines, and turn the hand wheel of the motor by hand, observe the values displayed
1. Check whether the connector J4 is loose by the multimeter. If 0 and 5 appear alternately, the corresponding Hall of this line will be normal. If the
2. Check resistance value of resistance R29, R31 and R32 with multimeter, and replace poor resistance. value is kept at 0 or 5, the motor Hall (41F) corresponding to the color line has been damaged, and then
white, brown and blue three lines are tested in sequence, write down the color of the abnormal line, and
3. Test Q4 with the gear of multimeter diode, and replace the poor resistance.
disassemble the motor and find out the Hall corresponding to this line for replacement.
 Fundamentals of Electronic Service

5. Composition and maintenance of speed controller

ZOBOW A2S Maintenance Guide

Circuit board of speed controller

Shell of speed controller

Circuit board recognition

Main functional module division

ZOBOW
Circuit analysis

A2S
Rear cover of speed controller Connecting wire of speed controller
Failure detection and maintenance

If the speed controller does not travel or the

electric control slowly travels under the request
of closing the pin stop, loosen the screw with
the cross screwdriver and adjust the position of
the circuit board properly. The speed controller
can work normally. If the adjustment position is
ineffective, check whether the detection cable is
normal. If normal, replace the speed regulating
Hall 50B and adjust the position of the circuit
board.

Speed regulating 50B

 Fundamentals of Electronic Service

Circuit board recognition Main functional module division

Section I Introduction to Main Board Circuit Board- Front of EA2S Circuit Board

Brake resistor
interface
Large capacitance
Fuse F1

Safety
capacitance

Thermistor

Relay

Driving chip
Large
capacitance

Functional
Transformer tube
ZOBOW

ZOBOW
A2S

A2S
817 Photocoupler Singlechip 7805

Section II Introduction to Board Circuit Board-Reverse of EA2S Circuit Board

1. AC module: implement the filtering processing for the input AC220V so as to reduce interference to
power supply system.
MOS tube Common failures: fuse burnout, varistor failure, no action of relay.
6 IGBTs of switching
power supply 2. Rectifier module: convert AC220V into BUS + (about 310 V) power supply.
Phase current 3. Drive and signal module: the singlechip collects the optical coder of motor, phase current detection,
detection Switching pedal, setter signal and sends the drive signal to control the motor operation or electromagnet action.
operational power supply
amplifier chip 4. Switch power module: output 5 circuits of VDD, + 15V, MCU + 5V, L+5V, MCU + 3.3V for 5-circuit
power supply.
Power source 5. Electromagnet module: the signal transmitted by the singlechip is subjected to photocoupler isolation
rectifier diode to control the action electromagnet.
 Fundamentals of Electronic Service

Circuit Analysis 300V section: After the current passes through the
temperature-sensitive or relay, input from pin 1 and
Section I. Power Supply Section pin 2 of the square bridge, and form a direct-current
pulse with a peak value of 311 V after rectification
by the square bridge, where the power cannot be
Main function of power supply section: directly supplied to the following circuit, and the
filter and rectify the input 220V AC to relatively stable DC voltage is output after being
form 300VDC. After filtering with large filtered by the CD1 and the high-frequency filter. We
capacitance and energy storing, output used to call it 300 V (BUS +),
more 300VDC, while supplying power to Common Failure s of 300V:
the motor, while reducing the voltage of the
switching power supply, afterwards, form 1. Large capacitance CD1
30V, 15V and 5V. The 5V supply power of Blasting off, top heaving.
panel forms MCU5V voltage drop as 3.3V
2. The square bridge is damaged (the detection
supply. Here we divide the power supply
method will be described later)
into AC 220V, DC 300V, 15V and 5V, single
chip 3.3 V, panel 5V, functional pipe 30V.
At first, 300V is input by the pin 7 of the power supply chip U3 (UC3842B) after being divided by R16,
220V section: As shown in the above R19,20, R21, U3-start voltage is given, because U3 is a high-frequency power switch, a PWM signal to
figure, 220V power is input through (Q5 (pqnk70ZFP1) is output at pin 6, and Q5 is turned on when the signal output by pin 6 is at a high
power plug and pass through fuse F1, level, A circuit is formed between the switch transformers 4 and 6.When the PWM wave output from pin
then the voltage dependent resistance 6 is at the low level, Q5 is turned off, discharged by 4 and 6 turn coil, and a discharge circuit is formed
RV1, fuse (1A) and voltage dependent by diode D8, C4, and R18.The switch forms a transformed magnetic field in the 4, 6 turn coil while the
resistance between the two wires act as over-current and over-voltage protection in the circuit. When other secondary coil is able to generate a corresponding induced electromotive force, i.e. a voltage,
the operating current of the circuit is too great, the fuse will fuse. When the input voltage is too large, to the other circuit. After the induced electromotive force is generated by the transformers 1 and 2,
ZOBOW

ZOBOW
A2S

A2S
the varistor is punctured to play a role of protection. The filter circuit consists of an angel capacitor the sampling current of Q5 is continuously fed to U3 power supply # and pin 3 of 1 ^; pin 2 input is the
CX1 and a common-mode inductor L1, which functions to filter the input 220V power supply so as to feedback voltage; when the feedback voltage is abnormal, the U3 chip may adjust the duty ratio of the
suppress the interference of the electronic radiation in the power grid to the circuit of the circuit board, PWM signal; The output voltage of the secondary coil is changed by adjusting the conduction length of
and simultaneously prevent the circuit board circuit from conducting electromagnetic conduction to the the switching tube in unit time.
power grid. And then, the relay K1 is connected in parallel to the thermistor. When the current flows
through, the relay does not work, and when the 15v relay is energized, the thermistor is short-circuited,
quit the working state (this will be mentioned below).
Feedback Input
Common failures of 220V: 1.Blasting-off of fuse pressure-sensitive; 2. Pin breaking for common mode
inductor; 3. The switch is non-conducting.

Output

Timing Current sampling

Feedback ground

Error amplification end

Circuit Diagram of 220V Power Supply
 Fundamentals of Electronic Service

The following figure is a circuit diagram of the switching power supply: Low-voltage power supply section: 15V, MCU5V, V2V, 30V, and the voltage of about 12.5V for the
continuous power supply to U3.STTH1602CFP is a 30V rectifying tube which outputs a rectified voltage
of 30V and supplies the power to the rear functional tube.U1 (78L15) outputs a DC voltage of 15 V to
drive chip U8 (IR2136S) and relay K1 to provide power. When relay is energized, pull-in for suction, the
thermistor is short-circuited, and power section is started.
112 (7805) outputs 5V DC voltage and supplies power to the operation panel and speed controller, and
the other section is converted by U7 (11173.3) to form 3.3 V voltage to MCU U10, EEPROM (24LC08D),
operational amplifier U9 (20072) to supply power, and the green light is always on (green light is a basis
for judging the presence or absence of 3.3 V power supply).
U7 (7805) outputs 5 V DC voltage to supply the power to the machine head lamp section because the
machine head lamp is mounted outside the machine head. In order to ensure the personal safety of the
user, an ALONE I STAND of 5V is used.
The following figure is a rectifier filter circuit consisting of low-voltage DC and peripheral circuits output
from the switching power supply:
ZOBOW

ZOBOW
A2S

A2S
MCU + 5V power supply

30V power supply

 Fundamentals of Electronic Service

Section II Signal Section and Drive Section

As shown in the figure, the signal and drive

section mainly comprises a signal processing
Drive section section , a drive section and a current
sampling and feedback section .Complete
signal acquisition, processing, motor drive
and current feedback. The following is a
detailed introduction.
Signal processing section:
15 V power supply
The signal processing section is the core
of the whole circuit board, and the core
element of the signal processing section is
the singlechip, the optical coder signal in the
motor, the Hall signal in the pedal, the current
sampling signal is finally transmitted to the
singlechip, the singlechip judges, analyzes
and processes the signals and then issues a
Signal processing section control signal.
ZOBOW

ZOBOW
A2S

A2S
Left figure is the measuring point of the output voltage
on each A2S circuit:
5V voltage MCU5V which represents the machine head
lamp section is the other 5 V output from the switching
power supply circuit to be mainly used for supplying
power to the pedal (and panel), secondly, used for
outputting a 3.3 V voltage to the 11173.3 power supply
which is supplied to power supply of each chip. VDD is
test point a 30V voltage that supplies power to the functional tube.
Program burning

U10 Singlechip Pin Diagram

 Fundamentals of Electronic Service

The singlechip (deleted by F28034) is shown in the figure above, with 64 pins totally, of which pin 16, Section III Current Collection and Feedback Section
29, and 57 are connected with a 3.3 V voltage at the power supply pin. Pin 41 and 60 are grounded.
The three-phase signals ENCA, ENCB and ENCZ of the motor are respectively input from 62, 63 and
4 of the singlechip, and 50, 51, 53, 54, 55 and 56 are respectively MO-LINW, MO-HINW, MO-UNV, The current acquisition and feedback section mainly consists of the calculation amplifier and the
MO-HSUP, MO-LINU, MO-HINU, which are output pins of a 6-circuit signal driven by a motor, Three sampling resistance. The circuit diagram is shown in the following figure. The sampling resistance is
sets of drive signals will exhibit six variations of 101, 100, 110, 010,011, 001, which are transmitted connected to the motor current circuit, and the current flowing through the motor flows back to the power
directly to drive chip U8 (IR21365) to control the turn-off of 168.31, 52, 36, and 64 pins are the output supply section through the sampling resistance. And a voltage signal is generated on the sampling
end of the presser pin, the reverse sewing, the clamping wire and the presser pin lifting function resistance as an input signal to the operational amplifier U9, The feedback signal is output to pin 15 and
signal, respectively, and the normal work of the functional pipe is controlled. The pin 12 is the output pin 18 of the singlechip after the operational amplifier is output to the singlechip through pin 1 and pin 7.
pin of the control speed. The pin 22 is the control pin that the machine head turns to the switch. Pin
45,46,47,48 are the input pins for the program burning. The pin 39 is the discharge circuit signal output
pin which outputs PWM pulses to control the operation of the discharge circuit. Pin 37 and 38 are the
communication port of the singlechip and the panel. Pin 33 and 34 are the upgrade port of the external
program of the speed regulator interface. Pin 2 and 3 are the read-write pins of the singlechip and the
EEPROM, the EEPROM is a charged erasable programmable memory, and can be used for erasing
and reprogramming the function of the common voltage.

IGBT bridge-type drive

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A2S

A2S
Current sampling

Pedal & Upgrade Current Collection and Feedback Section

Section IV Drive Section

Above figure is the circuit diagram of speed controller plug

The drive section mainly comprises a drive chip U8 and six IGBT. The main function of the drive chip U8
Pin 1of pedal is the power supply pin of MCU5V, pin 2 is the control pin of the pedal, pin is empty pin, is to receive the control signal of the singlechip to convert into a signal which can drive the conduction
pin 4 is a signal pin that NO.33 pin transmits to updater, pin 5 is grounded, The 4 and 6 pins are external and the shutdown of the IGBT and then output the signal to the IGBT.
program upgrade pins that can be selected on the upgrade or upgraded to the setter.
 Fundamentals of Electronic Service

The upper bridge is composed of Q6, Q7 and Q8,

as shown in the left figure.
The lower bridge is composed of Q9, Q10 and
Q11, pin 2 of upper bridge IGBT are connected
with the positive pole of the 300V power supply,
and the three pins are respectively connected with
the three groups of coils W, U and V in the motor,
and the input end of the motor current; pin 2 of
the lower bridge IGBT connects motor coil W, U, V,
which is the outflow end of the motor current. At
the same time, each upper bridge and the lower
bridge conducts one IGBT to form a current circuit
together with the motor coil, but it is noted that
the IGBT of the same group of the upper bridge
and the lower bridge cannot be turned on (e.g.
IGBT bridge drive Q6, Q9) at the same time, otherwise the short
circuit is caused.

circuit of upper and lower bridge composed of IGBT

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A2S

A2S
Drive circuit One end of the three groups of coils in the motor
is connected with u, v and w, and the other end is
Pin Figure IR2136S of Drive Chip U8 connected at the same point to form a star-shaped
connection mode, (Therefore, only current in the
two groups of coils is current) deleted at the same
time. A photoelectric encoder is arranged in the
As shown in the above figure, NO.1 pin is the 15V power supply pin of U8. The six signals output from motor, the grating sheet is driven to rotate when
the singlechip are MO-LINW, MO-HINW, MO-LINV, MO-HIN2, MO-LINU, MO-HINU, and then input from the rotor rotates, two light couplers on the motor
the six pins of U8 (HIN1) 3 (HIN1) 3 (HIN1) 3 (HIN2), 4 (HIN3), 5 (UN1), 6 (LIN2), 7 (LIN3). can output three signals of A/ B and Z, the position
signals are converted into two change values of
No. 8 (VFO) pin is a failure output pin. When U8 detects that the signal transmitted by the singlechip
0 and 1 and then output a corresponding control
or the current feedback signal is wrong or abnormal, No. 8 sends a signal to the singlechip. After
signal to control the direction of the current in the
receiving the signal from the singlechip, the driver stops drive and gives an E01 error code (which will
motor coil through the drive section to generate
be explained in the following failure analysis).
a magnetic field to rotate the rotor, and when the
27 (H01), 23 (H02), 19 (H03) are the drive signal output pins of IGBT upper bridge, 26 (VS1), 18 (VS3) rotor rotates, the direction of the current in the coil
are the auxiliary output pins driven by the upper bridge, and the first three drive signals act to control the also changes so that the rotating magnetic field
conduction of the IGBT of the upper bridge, the C23, C25 and C26 between the upper bridge and the drives the rotor to rotate all the time.
VS are referred to as the bootstrap capacitance, and the power supply is provided for the upper bridge Connection mode of motor coil
drive;16 (L01), 1 5 (LOS), 14 (Lo3) are output pins driven by the lower bridge to drive the lower bridge
Common Failures of signal and drive sections: 1. 5V, 15V short circuit; 2. E01 and E08 alarms; 3. When
IGBT.
the motor is open phase (the motor runs and stops occasionally. While rotating the handwheel motor
For drive chip U8, we use IR2136S. runs again, and the sound is abnormal at the time of rotation. 4) Sampling resistance blasting-off; 5.
IGBT is blasts off; 6. Patch resistance and capacitor are burn out.
 Fundamentals of Electronic Service

Failure Detection and Maintenance 2. Square bridge measurement

Section I Visual Detection Multimeter diode gear

Check whether the CD1 and CD2 blast off and Black probe Red probe Normal value
whether there is a significant heave on the top of
the high-pressure capacitor. 1. 2. 0.500V
1. Check whether the fuse and pressure-sensitive
are burn-out 1. 3. 0.500V
2. Check whether the common mode inductance is
broken pin.
2. 4 0.500V
3. Check whether IGBT and sampling resistance
R79/ R81/ R82/ R83 are blasted off or burned.
3. 4 0.500V
4. Whether the cement resistance is blacking.

If above-said components are damaged, replace

the corresponding components and inspect
whether the traces on the circuit board are high If any one of these values is 0.002, show that
and low, and if there is a defect in the wiring, the the inside of the rectifier bridge has been short-
external leads can be connected. circuited and the rectifier bridge is required to
be replaced.
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Static detection is required after visual inspection.
A2S

A2S
(Sampling resistance R79/ R81/ R82/ R83 blast
off in black, the maintenance is difficult, it is
recommended to return to factory maintenance)

Section II. Detection before Powering-on

1. Measurement of IGBT

Black probe Red probe Normal value

2. 3. 0.450V
3. Detection for working mode inductance

1. 3. 0.780V

If pin 2 and pin 3 are short-circuited, the damage

Measure the common mode inductance pin
to the IGBT itself is required be replaced. If
1, pin 2, pin 3, and pin 4 with a multimeter. If
the value of pin 1 and pin 3 is abnormal, check
the buzzer gear sounds, the common mode
whether the relevant resistance under the IGBT
inductance is normal, otherwise, replace the
is normal, and replace it if the resistance value
common mode inductance.
is normal. (If the value is close to 0, show that
the IGBT1 and pin 3 are punctured, the IGBT is
Measurement value of IGBT1 and pin 3; measurement
value of IGBT2 and pin replaced just.)
 Fundamentals of Electronic Service

Common failures on power supply section are

as follows:
As shown in the left figure:
1. Fuse, pressure-sensitive blasting off
Two probes respectively discharge pin L of
power plug and pin 2 of the rectifier bridge. If 2. The switch is non-conducting
the buzzer sounds, it is normal;
3. Broken pin of common mode inductance
And then two probes are respectively placed
2) Common failures of rectifier module:
on pin N of the power plug and pin 3 of the
rectifier bridge, the buzzer is normal, and 1.Large capacitance CD1 and CD1 blast off,
the positive and negative electrodes are not and top heaves.
distinguished between the table pens. 2. Damage of rectifier bridge
If the above test is not normal, check whether
the circuit is complete, whether the switch is
turned on, whether the fuse is normal, and
whether the common mode inductive pin is
off, and whether the resistance value of the
thermistor is about 10 ohm.

Repeated actuation of relay

Failure analysis: This is usually caused by 30V
Section III. Powering-on Detection and Maintenance short circuit, 30V feedback resistance damage,
and damage to the peripheral circuit of the
switching MOS tube due to virtual welding or
If static measurement is normal, power-on detection can be started. Powering-on detection is a very breakage of the transformer pin.
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important step in maintenance. Unlike static detection, we can narrow down the range of failure points
A2S

A2S
by observing the reflection of power and error code and clearly maintain the direction of maintenance.
And by measuring the voltage of some of the key points in the energized state, we can be helped to
solve the problem more quickly.
 There is certain danger for powering-on process, and the attention should be paid to safety!
sampling resistance
Turn the switch to the OFF position before power is energized, plug in the power cord to make sure
there is no conductive object on the circuit board and under the circuit board so as not to cause a short
circuit and then turn on the switch to observe the state of the circuit board. When the normal circuit
board is powered on, it can be heard that the green light is normally on and the relay sucks. Troubleshooting
1. Check whether 30V is short-circuited.
2. Check whether the switching MOS is normal
220V AC measuring point o-----pin 2 and pin 3 of rectifier bridge and the sampling resistance R45-R48 is normal.
BUS + (310V) DC measuring point -----pin 1 and pin 4 of rectifier bridge 3. Find out whether the feedback circuit of the
VDD power supply is normal, especially the
VDD(30V) DC measurement point ----- D21 side
feedback resistances R50, R54, R55, R29, and
+ 15 V MCU + 5V 1) Common Failure ----- C16 side EL817 are normal;

L + 5V DC measurement point------ C5 side 4. Check whether the transformer pins are

broken or broken.
MCU + 3.3 V DC measuring point ------ C17 side
5. Inspect whether the other components around
DC measuring point-----both ends of C46
the switching power supply are deficient-welded.
 Fundamentals of Electronic Service

Brief Introduction to Failure Code

Code Error type Code Remarks

Err-01 Hardware over-current Err-10 Setter communication failure

Err-02 Software over-current Err-11 Upper thread detection failure

Detection failure of motor’s initial
Err-03 System under-voltage Err-12
angle
Failure for loss of optical encoder
Err-04 Overpressure during shutdown Err-13
signal for motor
Failure of mainboard read-write
Err-05 Over-pressure during operation Err-14
EEPROM
Err-06 Failure of electromagnet circuit Err-15 Motor over-speed protection

Err-07 Failure of current detection circuit Err-16 Motor reverse

Err-08 Motor stalling Err-18 Motor overload

Err-09 Brake circuit failure A-UP Alarm of turning and lifting switch:
The controller power supply is free of L + 5V/ U + 5V failure maintenance
Failure analysis: 1. E01 (hardware over-current) failure maintenance)
This is usually due to no output of 30 V, or an L + 5V/ U + 5V short circuit, MCU3. 3V short circuit. Failure analysis: normally due to IGBT, bus sampling resistance and IR2136S damage. The hardware
overcurrent and control voltage are low, and the driver chip IR2136S issues P-FAULT signal. No.8 pin
Troubleshooting methods:
of 2136 is an error pin, and No. 9 pin is a pin that enables No.8 to alarm error. The circuit that led to
1. Check whether the 30V power supply is intact, if it is normal, enter the next step; the abnormality of No. 9 pin is the channel of E01 error. If the first 15V circuit is abnormal, E01 will be
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A2S

A2S
2. Check whether the L + 5V/ U + 5V/ MCU3. 3V is intact, and whether the reverse-parallel IN4148 has caused, therefore, it is required to check U10 and peripheral circuits.
normal pipe pressure drop; Troubleshooting:
3. Check whether the DSP/ operational amplifier/ EEPROM is normal, including whether the section s 1. Check whether the IGBT Q6-Q11 and its peripheral devices are deficient or damaged
around the DSP/ Operational Amplifier/ EEPROM are damaged or invalid. 2. Check whether the busbar sampling resistance, drive chip U8 and peripheral devices are virtual
welding or are damaged.
3. Check whether pin 32 and R98 resistance of singlechip U10 are virtual welding or the resistance
Controller powering-on is free of reaction Failure
value is abnormal.
maintenance
MOS 4. Measure whether TVS tube is damaged
Failure Analysis: This is usually caused by an open
circuit in the AC section or an abnormal open 5. Measure whether the bootstrap diode and the capacitor resistance are damaged by utilizing the
source section of the switch diode gear.
6. Whether the photoelectric encoder 3.3 V is short-circuited over ground;
Troubleshooting:
1. Check whether the switch is non-conducting,
Start-up whether the fuse is fused, and the common mode
resistor inductive pin is broken.
2. Check whether the start-up resistance of damaged
or broken check valve is damaged or broken.
3. Check whether the switching MOS Q5 is damaged
or broken
rectifier tube 4. Check whether the other components around the
switching power supply are deficient or damaged
 Fundamentals of Electronic Service

The following figure is the drive and IGBT circuit

The circuit board is powered on, DC voltage gear
of multimeter
Multimeter
Red probe Black probe
reading

Pin 1 1.65V

Pin7 4 1.65V

Pin 8 3.3V

Drive circuit
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A2S

A2S
IGBT bridge-type drive

2. Failure maintenance of E02/ E07 (software over-current/ current detection circuit)

Failure analysis: In order to ensure the normal operation of the motor, the motor needs to be monitored IGBT bridge drive
in real time. If the circuit is over-current, the motor can be avoided as much as possible. Therefore, the
current detection circuit is designed, and the current is collected from the source stage of Q9 and Q10.
After AD conversion is carried out by MCP602/ 20072 chip, it is sent to DSP for judgement.E02 is mainly
because the singlechip detects that the output voltage of the operational amplifier exceeds 2.4 V; E07
is mainly due to the fact that the singlechip detects that the voltage value of the operational amplifier
output deviates from 1.65 V due to the fact that the singlechip is not driven by the motor.
The main causes of this problem are:
1. Sample resistance of the U/ V two phases or damage of TVS tube
2. Damage of operational amplifier (mcp602/ 20072) and peripheral components
Current sampling
 Fundamentals of Electronic Service

3, E03/ E04/ E05 (system under-voltage/ shutdown time over-voltage/ run-over voltage) failure 4. E08 (motor stall) failure maintenance
maintenance Failure analysis: E08 indicates that the motor is stalling. During the operation of the motor, the
singlechip collects the real-time signal of the motor Hall. If the motor operates normally, the Hall signal
of the motor constantly changes. If the detected motor Hall signal remains a constant value during the
Failure analysis: operation of the motor, the motor does not rotate, so it will be alarmed to E08.When the machine head
E03/ E04 troubleshooting is usually caused due to is stuck or the signal section fails, it is possible to cause the motor to stall. The failure of the signal
bus sampling resistance damage: section mainly refers to breakage of the signal line and the chip damage.
1. Check whether the input voltage is AC220V
2. Replace busbar sampling resistance and filter
resistance capacitance R1/ R2/ R3/ R4/ R6/ D1
3. Check whether the singlechip and peripheral
equipment are virtual welding or damaged
E05 Troubleshooting:
1. Check whether the brake resistance is not
inserted;
2. Check whether the brake resistance and the
circuit are damaged.

Visually inspect for obvious damage to Repair welding or

components; whether the 50-56 pin of the replacement of
defective device
The following figure is a bus sampling circuit MCU U10 is solder-welded
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A2S

A2S
After power-up, measure whether C2 has 15 Replace the defective
devices
Test
V voltage, if no/ low/ high replace U1.

Whether IGBT (Q6/ Q7/ Q8/ Q9/ Q10/ Q11) Replace the defective
devices Test
is damaged by diode shift

Measure the measurement TVS1/ TVS2/

TVS3 with a diode shift; resistance + if Replace the defective
Test
R79/ R81/ R82/ R83 is measured to have a devices
greater resistance or open circuit

Measure the IGBT gate resistance with a

Replace the defective
resistor for damage devices
Test
R57/R58/R59/R70/R71/R72

Repair welding or
Measure resistance with resistance gear for replacement of defective Test
misleading or damage/ R64/ R65/ R66 device

Replace the drive chip U8 Test

Bus voltage detection

Replace the motor Test

Return to the factory for

maintenance

Replace the motor

 Fundamentals of Electronic Service

5. E09 (brake circuit abnormal) failure maintenance

Failure analysis and troubleshooting: normally due to damage of cement resistance or no insertion of
plug-ins
1. Check whether the resistance value of cement resistance is normal and whether the plug-ins is
IGBT bridge drive connected properly.
2. Whether the inspection machine Q2 is damaged
3. Measure whether the triodes of Q1, Q3 and Q4 are normal and whether the peripheral resistance is
damaged.
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A2S

A2S
The following figure is the brake circuit

Current sampling

Brake circuit
Drive circuit
 Fundamentals of Electronic Service

6. E10 (abnormal communication between the setter and the controller) failure maintenance 7. E13 (motor photo) failure maintenance

Troubleshooting: Failure analysis: generally, because the single-

chip processor does not detect the optical-
1. The wire harness is loose
coded signal error, the main reasons are as
2. Photocoupler U1/ U2 and its peripheral follows:
components are damaged or dashed.
1. The motor’s optical cable plug-in is loose
3. Check whether the power supply voltage 3.3V,
2. The filter resistance capacitance around the
of the singlechip is normal and whether the output
optical encoder plug-in of the motor occurs in
voltage of the 11173.3 three-terminal voltage
the condition of false or continuous welding
regulator is normal.
3. Damage to light in motor
4. Whether the MCU (U3) on the setter fails.
4. Deformation of grating piece in motor

communication
optical coupler
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A2S

A2S
Communication of A2 and A2S Setters

Optical- coded signal

 Fundamentals of Electronic Service

8. E14 (parameter read/ write abnormal) failure maintenance 9. Other failures

Failure analysis: It is usually caused by the loosening
of the electromagnet plug-in, the virtual welding of
Failure analysis and troubleshooting: Since
the light coupling, the damage or the heating of the
the A2S parameter is in the EEPROM external
electromagnet, the damage and the like.
to the singlechip, the reason for this problem is
mainly three of the following: Troubleshooting:
1. MCU + 3.3V power supply is unstable 1. Check whether the plug-in is loose

2. EPP3M dummy weld or damage 2. Check whether the MOS tube corresponding to
the electromagnet is damaged.
3.Singlechip welding or damage of single chip
3. Whether the electromagnet is damaged
microcomputer
4. Check whether the section of the resistance
capacitance or the like is damaged.
5. Isolation and optical coupling corresponding to
the replacement function tube
The following figure is a functional circuit
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A2S

A2S
The following figure is an EPROPROM circuit
 Fundamentals of Electronic Service

Product Introduction

Electric Control Maintenance Guide of QIXING A2S

Product Introduction

Product Barcode Description

Speed Controller Motor

QIXING

QIXING
Introduction to Parameters
A2S

A2S
Failure Detection and Maintenance

Electric Control Box QIXING 450 wire Optical Coder

 Fundamentals of Electronic Service

Product Barcode Description Introduction to Parameters

Section I Barcode Description of Electric Control Mainboard User Parameters (Long press for P3 second after startup)
Parameter Initial Description for Content Value and
Chinese Description Scope
Items Value Remarks

P01 Maximum rotation speed (rpm) 200-5000 4000 Maximum speed setting at sewing machine

the higher the slope value of the climbing

slope of the controller, the steeper the
P02 Acceleration curve adjustment (%) 10-100 80
speed; the smaller the slope value, the
slower the speed
Same to quick function key on key panel
P03 Pin stop position selection DN/UP DN (s) UP: upper stop needle DN: lower stop
needle
Speed setting at the backstitch on front
P04 Initial backstitch speed (rpm) 200-3200 1800
section (initial backstitch)
Speed setting at the backstitch on rear
P05 Terminated backstitch speed (rpm) 200-3200 1800
section (terminated backstitch)

P06 Continuous return speed (rpm) 200-3200 1800 Speed setting when continuous backstitch

P07 Slow start-up speed (rpm) 200-1500 400 Speed setting at slow start

Needle number setting at slow start-up,

P08 Slow number of stitches (needle) 0-99 2
each unit represents half stitching
Fixed needle sewing [P34. SMP] is set
Automatic needle sewing fixing at the speed setting in the A state (or
P09 200-4000 3500
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QIXING
speed (rpm) the speed setting when the AUTO key of
A2S

A2S
Production date of selection for needle box is pressed)
A2S mainboard On: After the last section of the sewing
needle is finished, the stop backstitch
operation will be automatically performed.
After the suture is fixed, the Note: in any sewing mode, it is not possible
function of stopping the suture is to perform the needle-filling function.
P10 ON/OFF ON
automatically performed (the setting OFF: After the last section of the suture
of no needle-filling function) is finished, it will not be possible to
automatically perform the function of
stopping the back-stitch, and it is necessary
to implement the front or action.

When pressing the headstock back-stitch

Function mode selection when switch by hand: J: JUKI method (action
P11 J/B J
backstitch pressing by hand when in the stitching or midway) B: ROTHE
mode (starting from the sewing machine)

Inital backstitch section, reverse

electromagnetic coil operation opportunity:
Inital backstitch motion mode
P12 A/M A A: gently touch the pedal, i.e. automatically
selection
perform the inital backstitch ; M: controlled
by the pedal, stopped at any time

CON: After completion of the initial

Note: as shown in the figure, the upper right corner of above mainboard is labeled with 1632, 16
backstitch section, the next section of
refers to production in 2016, 32 represents this mainboard is produced on the 32nd week, namely, the P13
Start backstitch end point operation
CON/ STP CON function STP is automatically continued:
mainboard is produced in the fourth week in August, 2016. mode selection
After completion of the initial stitch length,
the automatic stop is automatically stopped
 Fundamentals of Electronic Service

0: half needle, 1: stitch, 2: continuous Table of Parameter Content for Technicians (Start up and enter by pressing P key)
P15 Needle-filling mode 0-2 0
replenishment
Parameter Initial Description for Content Value and
Chinese Description Scope
P18 Initial backstitch compensation 1 0-200 131 0200 step lagging of action Items Value Remarks
Force selection when the machine
P19 Initial backstitch compensation 2 0-200 158 0200 step lagging of action P44 Brake force 1-50 16
stops
A: The pedal is fully treaded after stitching, Period signal of sewing When backstitching is performed, the
Terminated backstitch motion
P45 10-40 20
P20 A A
i.e. automatically perform the backstitching. output (%) output is periodically saved
mode selection M: Controlled by the pedal, be able to be
stopped at any time The function selection
ON: After the line is cut, the self-action
of the angle of the lifting
P24 Pedal counter-pedal voltage 30-500 110 P46 ON/OFF OFF reversal function (angle is determined
needle after the rotation of
by [P47. TR8]) OFF: No action
Terminating backstitch the needle is reversed.
P25 0-200 131 0200 step lagging of action
compensation 3 After the completion of the incision,
Terminating backstitch Adjust the angle of lifting
P26 0-200 158 0200 step lagging of action P47 50-200 160 the angle of the needle is adjusted in
compensation 4 needle after cutting.
the reverse direction from the needle.
Continuous backstitch, reverse the
electromagnetic coil action time: A: gently P48 Low speed (speed) (rpm) 100-500 210. Positioning speed setting
Continuous backstitch motion
P28 A-M A touch pedal, i.e. automatically perform
mode selection continuous backstitch M: Controlled by the Adjust the speed of the motor at the
pedal, be able to be stopped at any time P49 Rated speed (rpm) 100-500 250
start-up cycle
P29 Rear brake force after cutting 1-50 20 Allowable operating time
P54 10-990 200 m3/ h Required Action Time for SFC Timing
(ms)
Force application for thick
P30 0-100 0 Action time of dialing/ scanning timing
materials P55 Dial/ scanning action time/ 10-990 380
Thread shearing force sequence
P31 0-100 40 ON: After the power supply is turned
application
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QIXING
Auto-locate and locate on, automatically find the upper
A2S

A2S
Continuous backstitch P56 ON/OFF ON
P32 0-200 131 0200 step-by-step lagging of action
compensation 5 after power-on positioning signal and then stop
Continuous backstitch OFF: No action
P33 0-200 158 0200 step-by-step lagging of action
compensation 6 Upper positioning adjustment. When
A: Gently touch the pedal, namely, Upper positioning the value decreases, stop the needle
automatically performs the sewing action of P58 0-1799 40
Selection of sewing mode of adjustment in advance. When the value is
P34 A-M A the fixed needle. increased, stop the needle.
fixed needle M: controlled by pedal, can be stopped and
started at any time Lower positioning adjustment. When
Stitching number mode 0: Manual piece number 1: number of Lower positioning the value decreases, stop the needle
P35 0 0-1 P59 0-1799 750
selection automatic pieces adjustment in advance. When the value is
0: no action; 1: For the pull-out action increased, stop the needle.
Setting of line output function 100-
P37 0-11 8. 2-11, the operation force is gradually P60 Test speed (r/ s) 2000 Set test speed
(wire clip force track setting) 4000
increased.
ON: Trimming action OFF: no trimming Item A test options, after setting,
P38 Setting of output function ON/OFF ON
action P61 Item A test ON/OFF OFF continuously operate according to the
View items for number of Quantity of pieces or number of speed set by [P60. TV]
P41 0-9999 0
stitching and number of stitches stitching to be completed automatically

N01 electric control version number Item B test options, after setting, cycle
N02 selection box version number P62 Test B test ON/OFF OFF according to the cycle set by [P60. TV]
P42 Information display N01-N07 N01 N03 speed N04 pedal ADN05 upper of startup-stitching-shutdown-trimming
positioning angle N06 lower fixed angle
N07 bus voltage AD Item C test options, after setting,
execute the cycle of startup-stitching-
Motor rotation direction setting P63 Test C test ON/OFF OFF
P43 CCW/ CW CCW CW: clockwise CCW: counter clockwise shutdown free of positioning function
(positive inversion) according to the speed set by [P60. TV]
 Fundamentals of Electronic Service

P64
Test B and C conduction
1-250 20 Set conduction time in B and C tests
Failure Detection and Maintenance
time
Section I Composition of Electric Control

P65 Test B and C stop time 1-250 20 B. Set the parking time in the C test

Handpiece protection 0: No detection; 1: zero signal 2: positive

P66 0-2 1.
switch detection signal detecting

Upper stop needle position

P72 0
correction

Lower-stop needle position

P73 0
correction

Full output time of The action time of full output when the
P76 10-990 150
backstitch (ms) backstitch begins to operate

Dwelling time of free-

P77 stitching termination 20-200 75
backstitching (ms)
Mainboard Panel
Clamping angle of wire
P78 10-150 100 Starting locating angle of wire clip
clamp
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A2S

A2S
P79 Ending angle of wire clip 160-359 270 Location angle upon ending of wire clip

Setting for feed angle of trimming (0 °

P80 Cut-in angle of trimming 5-359 18
calculation for bottom positioning)

Setting for angle of knife-adding for

Angle of knife-adding for
P81 5-359 140 trimming (0 ° calculation for bottom
trimming
positioning))

Angle setting of knife back knife (0 °

P82 Angle of knife back knife 5-359 172
calculation for bottom positioning))

Angle of force application

P84 for thick materials upon 0-359 9
startup
Angle of force application
P85 for thick materials upon 0-359 57.
ending

The Starting angle of encoder is read

by pressing wire clamping key, and the
P92 Starting angle of encoder 0-479 445 ex-factory has been set, not changing
freely (change at will will produce the Base Shell
malfunction.).
 Fundamentals of Electronic Service

Section II Cognition of Mainboard

1. Interface Definition

Three-phase interface of motor

220VAC interface

Encoder interface Definition of AC power Definition of panel interface Definition of brake resistance
interface J1 220V interface J4
1, L5V, TX
Power line interface Brake resistance interface
2, RX 4, GND

1. + 5 V
voltage
2. Empty
3. Empty
4. Empty
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Speed Control Interface
A2S

A2S
Definition J 7 5. UP needle stop
position
1. Empty
6. Empty
2、+5V
7, A 8, B 9, GND
3. Speed control signal
grounding
4. Grounding

Interface of speed
controller
4.2.2 Trimming electromagnet: 1, 8
Burn-in interface
Clamping wire (wire-sweeping)
electromagnet: 2, 9
Functional Car, etc.: 4 signal, 11 (+ 5V)
1.U phase
interface
Manual backstitch: 5 signal, 12 signal
2. V phase
ground
3.W phase
Backstitch Electromagnet: 6,13
4. GND grounding
Manual needle refilling: 7,14
 Fundamentals of Electronic Service

Section III. Cognition on of Circuit Board Components 1. Distribution of A2S circuit board area (front of main board)

Varistor

FUSE Large capacitor Functional

drive circuit

Functional
tube 540

common mode
inductance

relay
Transformer

Thermistor

High voltage power Front of switching

supply section power supply circuit
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A2S

A2S
2. Distribution of A2S circuit board area (negative side of mainboard)

Voltage conversion chip

Low -voltage power supply circuit

Functional Encoder signal

drive circuit circuit
Functional
photocoupler

Signal
6 IGBTs Drive circuit
processing
Singlechip
circuit

Rectifier
tube Panel power
circuit

Switch tube
IF8N80

3843B 21369 E dynamic chip Switching power supply circuit

 Fundamentals of Electronic Service

3. Function description for each A2S electric control section Section IV. Circuit Analysis
High-voltage circuit of main power supply: filter and rectify the input 220VAC to form 300VDC, then filter 1. Analysis on high voltage power supply circuit
the capacitor, and output the stable 300\/ DC power after energy storage.
Switch power circuit: step down the stabilized 300V to form a more stable 32V voltage, supply the
functional tube, and supply the voltage source to the panel.
Low voltage power circuit: step down the voltage of 300V to form a relatively stable voltage of 15V, 5V
and 3.3V.
Panel power circuit: step down the 32V voltage to form a stable 5V voltage to the panel.
And the drive circuit is used for amplifying the drive signal of the singlechip to form a six-way drive signal
and controlling the conduction and the turning-off of the IGBT so as to control the rotation of the motor.
DSP signal circuit: Single chip processor is the core of whole section, motor Hall signal, stop pin
signal, speed controller signal, panel signal and current feedback signal are all input into the singlechip
for processing. Subsequently, the singlechip outputs a corresponding drive signal to drive the motor
according to the acquired signal.
Function signal circuit: the signal output by the singlechip is processed to control the on-off of the Analysis on high voltage power supply circuit:
function tube to control the action of the electromagnet.
The main purpose of the power section is to rectify filter and the 220V AC voltage to form a stable 300 V
Encoder signal circuit: Control the motor encoder signal. DC voltage and cover the protection function.
The detailed analysis is as follows: 220 V AC voltage in which one circuit passes through J1, through
the fuse, the common mode inductance enters the rectifier bridge pile; The other circuit flows through
the common mode inductance, the thermistor enters the rectifier bridge pile, the rectifier bridge pile
rectifier forms the AC voltage of 220V to form a DC voltage of 300V, enters into a large capacitor to
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filter and form a stable 300/ DC voltage, and then forms a DC voltage of 1 5V through the switching
A2S

A2S
power supply circuit, Power is supplied to the relay to cause the electromagnet in the relay to generate
magnetism and cause the switch in the relay to close, the thermistor enters the working state, and the
4. Introduction to A2S electric control power distribution DC high voltage of 300V is transmitted from the relay to other places of electric control.

2. Circuit analysis on low voltage power supply

analysis on power supply for drive section:
C58, C59 Functional
Large capacitor tube DC voltage of 300V is input from Q6 (SC11170G)
300V pin 4.When the Q6 internal switch is on, pin 5-8
U6 power Panel
32V supply chip 5V output current, charge the inductor through the
(XL1509) inductor L2, and then forms a circuit through
Switching 32V to 5V
power
the back load. When the switch tube is off, it is
JP1 socket DB1 Rectifier
Bridge supply discharged by the L2 inductance. After the D2 and
220V AC
access 220V AC to L2 inductors, the load forms a discharge circuit.
330V DC U13 Drive Chip The Q6 internal switch tube is constantly switched
voltage
(IR2136S)
Q6 Power Chip to form a stable 15 V voltage, and 15V voltage can
(SC11170G) be measured from C4. 15V voltage is divided into
300V to 15V U3 power U14 three-terminal
two circuits, one circuit is supplied to U13 (IR2136S)
supply chip stabilivolt
(1117L-33) and the other supplies power to U3 (EUP3482A).
(3482A)
1 5V conversion 5V conversion to 3.3V And the pin 2 is a feedback pin which receives the
IGBT feedback voltage at the output end to control the
to 5V
300V switching frequency of the chip so as to achieve the
purpose of stabilizing the voltage.
DSP
 Fundamentals of Electronic Service

3. Analysis on DSP Signal Processing Circuit

15 V voltage is input from pin 2 of U3 (EUP3482A), and a 5V DC voltage is output from pin 1 and 3
through the surrounding base circuit. The measuring point of 5V voltage is ZND7. 5VDC voltage is
supplied to U14 (1117L-33). The U14 drops the 5V voltage to 3.3 V to the DSP power supply. Measuring
point of 3.3V is C92, LED3 is a light emitting diode and detects whether the 3.3V voltage is normal.
Analysis on power supply for functional section:
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A2S

A2S
The 300V high-voltage DC voltage is accessed into the transformer, a 32 V low voltage DC is formed
through the switching power supply circuit, and 32V voltage has two functions. On the one hand, the
functional pipe (540) is provided with an operating voltage, and on the other hand, as shown in the There are 64 pins for A2S DSP chip. The definition of each pin is analyzed below:
following figure, input from pin 1 of U6 (1509), U1 is supplied with an operating voltage to drop to 5V Therein, pin 10, 26, 38, 57 is a 3.3 V voltage connected to VDD, and the pin 19 is AVDD, which is the
from U1 to the front panel. 3.3V voltage on analog section, but the four pins in this circuit are connected to the same 3.3 V voltage.
The 9, 25, 41 pin is grounded and the pin 20 is the grounding for AVSS analog section. 2, 3, 60, 61,
62, and 63 pins are pulse width modulation PWM1 _ IPM, PWM4 _ IPM, PWM5 _ IPM, PWM2 _ IPM,
PWM3 _ IPM, PWM6 _ IPM six circuits of signals drive the chip U13 (IR2136S).Pin 4, 5, 49, 50, 51,
52, and 55 are the encoder signal pins, where pin 4 and 5 are upper and lower positioning signals
respectively. Pin 47, 45, 44 and 48 are scanning lines, presser pin lifting, backstitch, and signal output
ends of these functions. The pin 7 is the reset signal pin, and the low level is valid. When the input is
low, the reset function is started. The pin 1 is the signal pin for detecting 220VAC voltage. If 220VAC
voltage cannot be input to U11 or U11 photocoupler damage, the error code of PSR-OFF will be
alarmed. Pin 12 is the signal control line of pin pedal. Pin 42 is the signal terminal of the head instead of
the switch. The pin 6 is the relay signal output pin, which provides a low level for the relay to enable the
relay to operate normally.
 Fundamentals of Electronic Service

5. Function drive circuit analysis

As shown above, the drive circuit includes a drive chip U13 (IR2136S), a separating device IGBT and a
surrounding resistive capacitor.
Pin 2, 3, 4, 5, 6, and 7 are connected with 6 PWM signals, PWM signals are sent by DSP. The pin
8 is the error pin and is low effectively. The pin 1 is a + 15 V voltage and the pin 13 is the grounding
terminal.
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A2S

A2S
27 (H01), 23 (H02), 19 (H03) are drive signal output pins of IGBT upper bridge, 26 (VS1), 22 (VS2)
and18 (VS3) are auxiliary output pins driven by an upper bridge, drive the IGBT breakover of an upper
bridge with the first three drive signals;16 (L01), 15 (L02), 14 (L03) are output pins driven by the lower
bridge to drive the conduction of the lower bridge IGBT. The pin 2 of the upper bridge IGBT is connected
to a DC high voltage of 300 V.

4. Analysis on encoder signal circuit

Function circuit: The circuit mainly consists of functional pipe (540), Schottky diode, photocoupler and
surrounding resistance capacitor.
1. The function of the functional pipe is to drive the normal operation of the electromagnet after receiving
Motor encoder signal circuit: The circuit is the control signal from the DSP.
mainly composed of anode and cathode butt
2. The function of Schottky diode is follow-up. In the circuit, it is generally used to protect the elements
diode and surrounding resistor capacitor.
from being broken or burned by induced voltage, and is connected in parallel to both ends of the
The CN1 interface is connected with a element which generates induced electromotive force to form a circuit therewith so that the resulting
socket of the motor encoder, and the rotary high electromotive force is consumed in a continuous current mode in the circuit. so as to play a role in
displacement is converted into a serial digital protecting the components in the circuit from being damaged.
pulse signal through a motor encoder and
3. The photocoupler is the isolation signal and is transmitted after the signal is isolated.
then input to pin 4, 5, 49, 50, 51, 52, and 55 of
the DSP, wherein the pin 4 and 5 are UP and The working principle of the functional section is that the control signal is output by the DSP, and the
DOWN, namely, upper positioning and lower control signal is isolated by the optical coupler and transmitted to the functional tube to drive the work of
positioning pin. the electromagnet.
 Fundamentals of Electronic Service

Section V Maintenance of Electric Control 2. Static detection

1. Visual detection

1. AC circuit measurement
As shown in the left figure, put the two probes into the pin L of the power plug and pin 2 of the rectifier
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bridge respectively, and the value around 10 is normal.
A2S

A2S
Then adjust the multimeter to the buzzer gear, and two probes are respectively on both pin N of the
power plug and the pin 3 of the bridge rectifier. If the buzzer sounds, it is normal.
If the above values are not normal, check whether the circuit is complete, whether the fuse is normal
1. Check whether the large capacitors C58 4. Check whether the sampling resistance of R38 and whether the common mode inductor pin is broken, and whether the resistance value of the
and C59 are open or closed; and R3 is burned and blasting off; thermistor is about 10 ohm, and if not, replace it.
2. Check common mode inductance L0 are 5. Check whether the switching power circuit is
free of broken pins; burned or not;
2. Measuring method of
3. Check whether the fuse F2 and the 6. Inspect whether there is any trace on the rectifier bridge and diode
varistor ZNR5 burn out; surface of the circuit board; gear

Black probe Red probe Normal value

Methods of processing:
1. The large capacitor of C58 and C59 blasts off and leaks the liquid, replace the large capacitor, and 1. 2. 0.500V
check whether the rectifier bridge and IGBT value are normal;
1. 3. 0.500V
2. If the common mode inductance L0 is broken, the common mode inductance is replaced;
2. 4 0.500V
3. The varistor blasts off and the fuse is burnt out: replace the Varistor and the fuse, and measure
whether the bridge rectifier and IGBT value are normal; 3. 4 0.500V
4. R38 and R39 sampling resistance blasting-off: return to factory for maintenance.
5. If the switch power circuit is burnt out severely, replace the electric control. If any one of these values is about 0.002, show
that the inside of the rectifier bridge has been
6. If the surface is broken, it is necessary to connect with wires and check whether the value of the short-circuited, and the rectifier bridge needs to
rectifier bridge and IGBT is normal. be replaced.
 Fundamentals of Electronic Service

3. Diode gear of IGBT measuring multimeter Error Code Contents

No display No display on the panel

Black probe Red probe Normal value
Display OFF Start up and display OFF

E01 System overvoltage

2. 3. 0.400V
E02 System under-voltage

E03 Abnormal transmission communication between operation panel and CPU

1. 3. 0.650V
E05 The touch of the speed controller is abnormal

E07 Motor stalling

E08 Continuous manual backstitch for more than 15s

E10 Overcurrent protection of electromagnet

E11 Abnormal location signal

If the pin 2 and pin 3 are short-circuited, the
damage to the IGBT itself is required to be E13 Electric power module overheat protection
replaced. If the value of pin 1 and pin 3 is
abnormal, check whether the relevant resistance E14 Abnormal encoder signal
under the IGBT is normal, and replace it if the
E15 abnormal over-current protection of electric power module
resistance value is normal.(If the value is close to
0, show that the IGBT1 and pin 3 are punctured, E17 Failure of machine head protection switch
and the IGBT is replaced just.)
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A2S

A2S
1. No display: No display on the panel

IGBT1, 3-pin measurement IGBT2, 3-pin

D17 Diode
measurement

Section VI. Powering-on Detection and Maintenance

If static measurement is normal, powering-on detection can be started. Powering-on detection is a very
important step in maintenance. Unlike static detection, we can narrow down the range of failure points
by observing the reflection of power and error code and clearly maintain the direction of maintenance.
Measuring the voltage of some of the key points in the energized state can help us solve the problem
C19 capacitor
more quickly.
 There is certain danger for powering-on process, and the attention should be paid to safety!
Turn the switch to the OFF position before power is energized and plug in the power line to make sure
there isn’t conductive object on the circuit board and under the circuit board so as not to cause a short
circuit and then turn on the switch to observe the state of the circuit board.
 Fundamentals of Electronic Service

Failure analysis: 3. E01 system overvoltage\ E02 system under-voltage

The voltage on the panel is 5 V power supply, so it is firstly determined whether the voltage source is
normal. The switching power supplies the 300 VDC voltage to a 32V voltage, and the 32V voltage can
be measured from the C19 capacitor, and the power chip U6 (XL1509) and the peripheral circuit reduce Failure analysis:
the 32V voltage to 5 V supply to the panel. The system overvoltage and system under-
Methods of processing: voltage are mainly caused by the electric control
singlechip, detecting that the input 220V AC
1. Check whether C19 capacitor is provided with 32V.voltage. If there is not 32V voltage, the circuit voltage is higher than 264V or lower than 176V.
failure of the switching power supply will be described. Please replace the components of the switch
power supply, including PSR (IF8N80), PH9 (817), U5 (431) and PSR (3843B). Method of processing:

2. If it is 32 V, check whether the D17 is provided with 5V voltage, then replace U6 (XL1 509) and then, 1. Check whether the external AC voltage is about
if there is not display on the panel, show that the panel chip has been burnt out, replace the panel 220V, if the voltage is high or low, troubleshoot
directly. the external power supply and retest after
troubleshooting.
2. Detect the resistance and the capacitor of the
bus voltage detection section on the mainboard,
wherein the resistances Rm, R16, R5, R8 are
2. Start up and display OFF
120kΩ, R11 is 6.7kΩ, R194 is 3.kΩ, and the
Failure analysis: capacitor C88 is 100 pF. Please remove the
Start up and display OFF is due to the fact that detection resistor and capacitor.
the singlechip in the electric control does not 3. If the resistance capacitor is normal, the single
detect the 220V voltage supply. 220V voltage of chip processor is damaged, and the single chip
high voltage passes through R126, R127, R128, processor can be replaced.
R129 resistance and reaches U11 (354T), and U11
transmits 3.3V voltage signal through the resistor
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A2S

A2S
divider to the singlechip. Methods of processing:
Firstly, the resistance of R126, R127, R128 and 4. E03 Operating panel and abnormal CPU transmission communication
R129 on the power board is tested to be 120KΩ,
because both of them are connected in parallel, so Failure analysis:
the measured resistance value should be 60 KΩ. E03 is mainly caused by the abnormal
If the resistance is normal, replace the U11 (354T) communication between the single chip and the
light coupling. panel, among which there are two main factors, I.
Abnormal voltage; II. Abnormal signal.
Methods of processing:
1. Re-burn the program, check whether the
electronic control is still reported to E03, and most
E03 is the problem that the program is lost, and
the charging procedure can solve a part of the
problem.
2. Measure C40 whether there is 15V voltage.
Measure whether C82 is provided with 5V voltage.
Measure whether C92 capacitor is provided with
3.3V voltage. If the voltage is abnormal, replace
Q6 (1 1 1 70G), U3 (3482A) and ZND7 (5V
voltage stabilization).
3. When the voltage is normal, E03 is still
alarmed. If the singlechip is damaged, please
return to the factory for maintenance.
 Fundamentals of Electronic Service

5. Abnormal E05 Speed Controller Contact a. Check whether the motor socket and encoder socket are
burnt or bent, the motor socket and encoder socket are all
signal transmission ports, and if there is any damage, give
an error alarm.
In case of broken needle in the motor socket, replace the
socket. Poor contact of the encoder plug can also lead to
abnormal signal transmission. Therefore, after the socket is
damaged, the encoder socket needs to be replaced.
Motor socket Encoder socket

b. Abnormal drive signal

1) Check whether the IGBT is in the normal
multimeter diode range.

Black probe Red probe Normal value

Failure analysis:
2. 3. 0.400V
The speed controller signal cannot be detected by electric control, so E05 failure is alarmed.
Methods of processing: 1. 3. 0.650V
Firstly, the replacement method is used to confirm whether it is a quick-control problem, and if the test
is normal after replacement, the replaced speed controller is opened with the Screwdriver to check If the IGBT is short-circuited for pin 2 and pin 3, it
whether the connecting wire in the speed controller is in the circuit and detect whether the inductance, is necessary to replace the IGBT itself. If the value
speed regulating Hall and the resistance capacitor around the speed controller are normal. If it is of pin 1 and pin 3 is abnormal, check whether the
abnormal, replace it. relevant resistance under the IGBT is normal, and
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replace the IGBT if the resistance value is normal
A2S

A2S
(IR2136S).(If the value is close to 0, show that the
6. E07 Motor Stalling
IGBT1 and pin 3 are punctured, and the IGBT can
Failure analysis: be replaced.)
a. Poor contact of motor plug wiring results in no rotating;
b. The signal of the positioner is abnormal;
c. The headstock mechanism is locked deadly, or foreign matters in the motor belt are involved for Measuring value of IGBT1 and pin 3; Measuring
jamming; value of IGBT 2 and pin 3
d. The processed objects are too thick, and the torque of the motor cannot run through;
e. Abnormal drive output.
The main reason for electronic control alarming E-07 error is that there is a problem with the motor
drive. The motor drive section mainly consists of separating device IGBT, U13 (IR2136S) and the
surrounding resistance capacitor. Except that above components will alarm while being damaged, E-07
error will also be alarmed for sockets and encoder sockets.
Method of processing:
The phenomenon of E-07 error alarm is generally divided into three situations:
2) Detect the capacitor of C42, C43, C44
a. Failure of motor socket and encoder socket; capacitor 22uF above drive chip U13 (IR2136S),
b. Abnormal drive signal; and the voltage drop shall be 0.600V.

c. Low-speed motor shaking of motor. 3) Detect whether D100, D101, D102 fast
Sometimes, b and c are interspersed each other, for example, some signal elements are abnormal in recovery diode is 0.500V, R34, R35, R36 are 10Ω.
voltage anomalies. If the value is abnormal, replace it.
 Fundamentals of Electronic Service

7. E-08 manual reverse-sewing failure 10. E14 Encoder Signal Exception

Failure analysis: Failure analysis:
If the continuous “manual backstitch” exceeds for The encoder detects that the anomaly of the positioning signal will be fed back to the singlechip, and
15 seconds, the motor will cut off all the work and then the singlechip alarms the E11 failure .Method of processing:
alarm E-08 failure, when the motor is unable to Maintenance method is similar to E11, and there isn’t interpretation any longer.
rotate. Methods of processing:
If the manual backstitch switch is damaged, the
short circuit of the backstitch solenoid can be
alarmed to E-08 failure. Therefore, it is necessary 11.Abnormal over-current of E15 power module
to detect whether the manual backstitch switch
and the backstitch solenoid are failure. 1) Check whether the IGBT is in the normal
multimeter diode gear.

Black probe Red probe Normal value

2. 3. 0.400V
8. Abnormal E11 Positioning signal
1. 3. 0.650V
Failure analysis:
The encoder detects that the positioning signal
anomaly will be fed back to the singlechip, and
then the singlechip alarms E11
If the IGBT is short-circuited for pin 2 and pin 3
Failure processing methods:
pin, it is necessary to replace the IGBT itself. If
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A2S

A2S
Check whether the encoder and grating piece are the value of pin 1 and pin 3 is abnormal, check
abnormal. Replace test encoder and grating slice whether the relevant resistance under the IGBT
for the problem. If the encoder is failure, replace is normal, and replace the IGBT if the resistance
U1 (74HC164D), U2, U3. value is normal (IR2136S).(If the value is close to
Measuring value of IGBT1 and pin 3; Measuring 0, it indicates that the IGBT1, 3 pin are punctured,
value of IGBT 2 and pin 3 and the IGBT can be replaced.)
2) Detect the capacitor of C42, C43, C44
capacitor 22uF above drive chip U13 (IR2136S),
and the voltage drop shall be 0.600V.
3) Detect whether D100, D101, D102 fast recover
the diode is 0.500V, R34, R35, R36 are 10Ω. If
the value is abnormal, replace it.
IGBT heat-
radiating
adhesive
9. E13 power module overheat protection
Failure analysis:
The electric control detects that the IGBT of the power
device is too hot, which leads to the failure of the E1 3. 12. E17 handpiece switch protection failure

Method of processing: Firstly, check whether the handpiece protection

IGBT switch is in the correct position. If the handpiece
Check whether IGBT is in good contact with the protection switch is correct, press and hold the P
heat dissipation glue of the base, and then detect key to turn on, adjust the parameter to P-66, and
whether the IGBT is short circuit. If the IGBT is adjust the parameter in P-66 from 1 to 0.
short circuit, replace the corresponding IGBT.
 Fundamentals of Electronic Service

Product Introduction

Electronic Control Maintenance Guide of

QIXING 781E

Product Introduction

Product Barcode Description Speed controller Motor

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Introduction to Parameters
781E

781E
Failure Detection and Maintenance

Electric control box

 Fundamentals of Electronic Service

Product Barcode Description Introduction to Parameters

1. Key Description

View and save the contents of the selected parameter number: select
Parameter View the parameter number and press Enter to view and modify the operation.
Save Key After modifying the parameter value, press it, then exit and save the
parameters.
1. Press the key in the normal startup mode and enter the user’s

Enter function key parameter mode

in parameter area 2. In the shutdown state, press and hold the key to turn on and enter
the technician parameter mode

1. When parameter increment key is selected in parameter selection

Up-adjustment key area.
2. When the value increment key is set in the parameter content area.

Down -adjustment 1. When parameter is decremented in parameter selection area.

key 2. When the value decrement key is set in the parameter content area.

2. Factory data resetting

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781E

781E
Press and hold the up
Press ENTER for Press F key for
and down keys and
confirmation Shut
start the display at the confirmation
same time P11 down and restart

Production Date of 781E

Mainboard

3. Enter user parameters as well as modify and save

Note: As shown in the figure, the upper right corner of the upper board is marked with 1518, 15
represents that this mainboard is produced in 2015, and 32 represents that this mainboard is produced
on the 32nd week.

Modify arameter Press and hold Press ENTER

Press F key to enter Press ENTER to down the up and Press F to
user parameter items by pressing to confirm the
confirm the down keys to modify confirm the exit
under normal mode down and down modification
keys Parameters the parameters
 Fundamentals of Electronic Service

4. Enter technician modeas well as modify and save 6. User parameters

Chinese Name Description on Content Value and
Parameters Scope Initial value
Description Remarks
Maximum speed Maximum rotation speed setting while stitching
P01 10-360 300
(spm) (actual speed = number of display * 10)
Sewing starting Speed setting for front stitching(sewing starting)
P02 10-360 130.
speed (spm) (actual speed = number of display * 0)
Rotation speed of cutter timing head (actual
P03 Cutter action speed 10-100 55
Press and hold the Modify a Press and hold
Press ENTER
speed = number of display * 10)
Press ENTER down the up and
Press F to
F key to turn on to parameter item
to confirm the down keys to modify to confirm the First needle speed
enter the technician by holding down
Parameters the parameters
modification confirm the exit P04 10-360 80 (actual speed = number of display * 10)
parameters
and down keys parameters limit
Second needle
P05 10-360 80 (actual speed = number of display * 10)
speed limit
Third needle speed
P06 10-360 200 m3/ h (actual speed = number of display ”0)
limit
5. Comparison table for Display Font and Actual Font Fourth needle
P07 10-360 250 (actual speed = number of display * 10)
speed limit
Fifth needle speed
P08 10-360 200 m3/ h (actual speed = number of display * 10)
Digital font section: limit
Number of knife The number of needle required while cutting, the
P10 0-010 3
operation needles speed of cooperating with the cutters.

7. Technician parameters
Actual value
Chinese Name Description on Content Value and
Parameters Scope Initial value
Description Remarks
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Pin step discharge Delay startup time while treading down to fit the
781E

781E
Liquid crystal P13 10-990 560
time (ms) confirmation of the presser pin laying down
display
Under the condition that the large disc is not
Number of
P16 1-990 400 detected, how much needle is to be operated by
protective needle
the needle for protection
Automatic
1: After starting the power supply, automatically
P17 searching for upper 0-1 1.
find the carrier signal and stop 0: no action
positioning
English font section: When the upper position is adjusted, the needle
Upper positioning can be stopped in advance when the value is
P18 40-180 65
English adjustment reduced, and the stop needle will be delayed
letter when the value increases.
P19 Test working time 1-250 20 Setting for breakover time during Item C test
Liquid
P20 Test Stop Time 1-250 20 Setting for breakover time during Item C test
crystal
display Item A test option, which will run continuously at
P21 Item A Test 0-1 0
P01 speed after setting
English Item B test option, set after setting will be fully
letter P22 Item B Test 0-1 0
functional as per P01 test speed
Liquid Item C test option. After setting, no positioning
crystal P23 Item C Test 0-1 0 operation will be carried out according to the
display speed of P01
Handpiece 0: Turn off the handpiece protection function 1:
English P24 0-1 1.
protection switch Open the handpiece protection function
letter
Anti-lifting height of
Liquid P30 0-400 50
presser pin
crystal Selection on
display 0: Reverse-pedal stop in the midway. 1: Unable
P31 reverse-pedal stop 0-1 0
reverse-pedal stop in the midway
in the midway
 Fundamentals of Electronic Service

Failure Detection and Maintenance 2. Cognition on main board

Interface Definition

1. Composition of electric control 220VAC interface

DC32V power plug

Step motor
interface

Mainboard Panel
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Plug of speed
controller

Motor interface

Functional socket Motor encoder interface

Step Drive Board
 Fundamentals of Electronic Service

3. Cognition on circuit board elements

Step motor interface
F2 (15A fuse)

Step drive board

and mainboard DC32V input
communication interface
interface T2 high-frequency
NTR55 thermistor transformer
Db1 rectifier bridge
32V electrolytic
capacitor

SFC (TOP271EG
switch tube)

C48, C59.

Front of Main Control Board

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Rectifier tube

PH1, PH2, PH3

4D10S photocoupler

Singlechip

ACS1, ACS2
current sensor
Step drive board burning
interface
Reverse side of mainboard
 Fundamentals of Electronic Service

Switching power
High voltage
supply circuit
power circuit

U9, U11 Current

Sensor

Q7-Q14
IRF540N
Field effect tube

U7, U8, U10,

U12 (IR2184S)
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D12-D15
(US1M)

D9 U6
MB56 diode (EUP3453WIR1)

Switching power
supply circuit

DSP signal
U1 circuit
Singlechip

Drive circuit

Encoder
signal circuit

Front of Step Drive Board

Distribution of Circuit Board Area (Main Control Board)

 Fundamentals of Electronic Service

Introduction to the functions for each part of the main control board
High-voltage circuit of power supply: rectify the input 220V AC to form 300V DC, then filter the large
capacitor, and then output the stable 300V DC after energy storage.
Switch power circuit: step down the stabilized 300V to form a more stable 32 V voltage, supply the
functional tube, and supply the voltage source to the panel.
Low voltage power circuit: step down the voltage of 300V to form a relatively stable voltage of 15V, 5V
and 3.3V.
Panel power circuit: step down the 32V voltage to form a stable 5V voltage to the panel.
And the drive circuit is used for amplifying the drive signal of the singlechip to form a six-way drive Current detection
circuit
signal, and controlling the conduction and the turning-off of the IGBT so as to control the rotation of the
motor.
DSP signal circuit: singlechip is the core of whole section, motor Hall signal, stop pin signal, speed
controller signal, panel signal and current feedback signal are input into the singlechip for processing,
and subsequently the singlechip outputs a corresponding drive signal to drive the motor according to Functional tube
the acquired signal. signal circuit

Encoder signal circuit: Control the motor encoder signal.

Functional drive
signal circuit
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Introduction of Main Control Board Power Distribution

5V chip
C57, C58
Acoustic large Functional tube
capacitor
Panel
300V U2 power chip
5V
(XL1509)
32V conversion U14 three-terminal
Switched- to 5V stabilovolt tube
mode power (1117L-33)
5V 转 3.3V Step CPU signal
JP1 socket DB1 Rectifier supply
U13 Driving Chip circuit
220V AC Bridge
entering 220VAC (IR2136S)
voltage 300 V1 flow DSP
U1 power chip
(XL1509)
15V conversion to 5V

IGBT Photocoupler PH1, PH2, PH3

300V
Distribution of Circuit Board Area (Step Drive Board)
 Fundamentals of Electronic Service

Function description for each part of step drive board 4. Circuit analysis
Power circuit: 32V voltage on the main board forms 14.6 V S5V and 3.3V through the power supply I. Analysis on high voltage power supply circuit
circuit to supply the power to drive chip, the current sensor and the singlechip respectively.
Current detection circuit: detect whether the current in the circuit is too high.
Function signal circuit: process the signal output by the singlechip and transmit the signal to the
drive chip, and the drive chip controls the on-off of functional pipe so as to control the action of the
electromagnet.
CPU Signal Circuit of Step Drive Board: Mainly control the drive signal in the step drive panel.

Analysis on high voltage power supply circuit:

The main purpose of the power supply section is to rectify the 220V AC voltage, filter and then form a
stable 300 V DC voltage and cover the protection function. The detailed analysis is as follows:
220VAC voltage goes through the fuse and the common mode inductance to enter the rectifier bridge
pile; The other circuit flows through the common mode inductance, the thermistor enters the rectifier
bridge; the rectifier bridge forms the AC voltage of 220V to form a DC voltage of 300V, enters into a
large capacitor to filter and form a stable 300V DC voltage and then forms a DC voltage of 15 V through
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the switching power supply circuit, Power is supplied to the relay, causing the electromagnet in the relay
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to generate magnetism, causing the switch in the relay to close, so that the short-circuit thermistor and
the DC high voltage of 300V are transferred from the relay to other places of electric control.

Introduction to Power Supply Distribution of Step Drive Board

U7, U8, U10, U12

(IR2184S) II. Analysis of low voltage power supply circuit

U6 (EUP3453) Drive part power analysis:

J3 socket U2 (XL1509)
32 V conversion to
32 V DC 14.6 V conversion U9、U11 The DC voltage of 300V is input from pin 4.
voltage input 14.6 V to 55 V Current sensor (SC1117).When Q6 internal switch is on, pin
5-8 output current, charge the inductor through
the inductor L2, and then form a circuit through
the back load. When the switch tube is off, it is
discharged by the L2 inductance. After the D2 and
U14 (1117L-33) L2 inductors, the load forms a discharge circuit.
55V conversion to The Q6 internal switch tube is constantly switched
3.3V
to form a stable 15V voltage, and 15V voltage
can be measured from C4. 15V voltage is divided
into two circuits, the circuit supplies power to U13
(IR2136S), and the other supplies the power to
DSP U3 (EUP3842A).
 Fundamentals of Electronic Service

III. Analysis on DSP Signal Processing Circuit

15V voltage is input from pin 2 input of U3 (EUP3482A), and a 5VDC voltage is output from pin 1 and
3 through the surrounding base circuit. The measuring point of 5V voltage is ZND 7. 5V DC voltage is
supplied to U14 (1117L-33). U14 drops 5V voltage to 3.3 V to U2 (SI8421), the DSP supplies the power,
the measuring point of 3.3 V is C93, LED3 is a diode to detect whether 3.3 V voltage is normal.

Analysis on Power Supply for Functional Section:

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300V high-voltage DC voltage is accessed into the transformer, a 32V low-voltage DC is formed through
the switching power supply circuit, and 32V voltage has two functions. On the one hand, the functional
There are 64 pins on the A4 ‘s DSP chip. The definition of each pin is analyzed below:
pipe (540) is provided with an operating voltage, and the other hand, as shown in the following figure,
input from pin 1 of U6 (XL1509) to U1, supply the operating voltage, step down U1 to 5V voltage, give Pin 10, 26, 38 and 57 are 3.3 V voltage connected to VDD, and pin 19 is 3.3 V voltage connected by
U2 (SI8421A), U9 (MCP6541/ TP1941), U7 (QG04), front panel. AVDD on analog section, which is the, but the four pins in this circuit are connected to the same 3.3V
voltage. Pin 9, 25 and 41 are grounded. Pin 20 is the grounding on AVSS analog section. Pin 2, 3, 60,
61, 62, and 63 are pulse width modulation PWM1 _ IPM, PWM4 _ IPM, PWM5 _ IPM, PWM2 _ IPM,
PWM3 _ IPM, PWM6 _ IPM six-way signals to drive chip U13 (IR2136S). Pin 4, 5, 49, 50, 51, 52, and
55 are the encoder signal pins, where pin 4 and 5 are respectively upper and lower positioning signals
Pin 47, 45, 44 and 48 are scanning lines, presser pin lifting, backstitch, and signal output ends of these
functions. Pin 7 is a reset signal pin, and the low level is valid. When the low level is input, the resetting
function is started. The pin 1 is the signal pin for detecting 220VAC voltage. If 220VAC voltage cannot
be input to U11 or U11 photocoupler damage, the error code of PSR-OFF will be alarmed. Pin 12 is the
control line of pedal signal. Pin 42 is the signal terminal of reverse switch for handpiece. Pin 6 is the
relay signal output pin to provide a low level for the relay so as to enable the relay to operate normally.
 Fundamentals of Electronic Service

IV. Analysis on DSP Signal Processing Circuit VI. Functional drive circuit analysis

As shown above, the drive circuit includes a drive chip U13 (IR2136S), a separating device IGBT, and a
surrounding resistive capacitor.
Pin 2, 3, 4, 5, 6, and 7 are connected with 6 circuits of PWM signal, and PWM signals are sent by
DSP. The pin 8 is the error pin and is active low level. The pin - is a + 15 V voltage and pin 12 is the
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grounding terminal.
Pin 27 (H01), 23 (H02), 19 (H03) are the drive signal output pins of IGBT upper bridge, 26 (VS1), 22
(VS2), 18 (VS3) are the auxiliary output pins driven by the upper bridge, and the first three drive signals
act to drive the conduction of IGBT of the upper bridge;16 (L01), 15 (L02), 14 (L03) are the output pins
driven by the lower bridge and drive the conduction of the lower bridge IGBT. Pin2 of the upper bridge
IGBT is connected to a DC high voltage of 300 V.

V. Encoder signal circuit analysis

Function circuit: The circuit mainly consists of functional pipe (540), Schottky diode, photocoupler and
Motor encoder signal circuit: The circuit is surrounding resistance capacitor.
mainly composed of anode and cathode 1. The function of the functional pipe is to drive the normal operation of the electromagnet after receiving
butt diode and surrounding resistor the control signal from the DSP.
capacitor.
2. The function of Schottky diode is following current. In the circuit, it is generally used to protect the
CN1 interface is connected with a socket elements from being broken or burned by induced voltage, connected in parallel to both ends of the
of the motor encoder, and the rotary element which generates induced electromotive force and forms a circuit therewith so that the resulting
displacement is converted into a serial high electromotive force is consumed in a continuous current mode in the circuit so as to play a role in
digital pulse signal through a motor protecting the components in the circuit from being damaged.
encoder, and then input to 4, 5, 49, 50, 51,
3. The photocoupler is the isolation signal and is transmitted after the signal is isolated.
52, and 55 pins of the DSP, wherein pin 4
and 5 are UP and DOWN, namely, upper The working principle of the functional section is that the control signal is output by the DSP, and the
positioning and lower positioning pin. control signal is isolated by the optical coupler and transmitted to the functional tube to drive the work of the
electromagnet.
 Fundamentals of Electronic Service

5. Electric control maintenance II. Static test

I. Visual detection
1. AC circuit measurement
As shown in the left figure, put the two probes into
the L pin of the power plug and pin 2 of the rectifier
bridge respectively, and the value of the left and
right is normal.
And then transfer the multimeter to the buzzer,
both N pin of the power plug and pin 3 of the bridge
rectifier respectively. If the buzz sounds, show that
it is normal.
If the above values are not normal, check whether
the circuit is complete, whether the fuse is normal,
and whether the common mode inductive pin is
off, the resistance value of the thermistor is about
10ohm, and if not, replace it.
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1. Check whether the large capacitor C48 and C59 blast off or leaks the liquid;
2. Check whether there are broken pins for common mode inductance L0; 2. Measuring method of rectifier bridge

3. Check whether the fuse F2 and the varistor ZNR1 are burnt out; Multimeter diode gear

4. Check whether the switching power circuit is burnout;

5. Inspect whether there is any trace on the surface of the circuit board;

Methods of processing:
1. The large capacitor of C48 and C59 blasts off, i.e., replace the large capacitor and check whether the
rectifier bridge and IGBT value are normal; Black probe Red probe Normal value

2. If the common mode inductance L0 is broken, the common mode inductance is replaced; 1. 2. 0.500V
3. The varistor blasts off and the fuse is burnout: replace the varistor and fuse and measure whether the
bridge rectifier and IGBT value are normal; 1. 3. 0.500V
4. If the switch power circuit is burnt out severely, replace the electric control.
2. 4 0.500V
5. If the surface is broken, it is necessary to connect with guide lines; check whether the value of the
Rectifier Bridge and IGBT are normal. 3. 4 0.500V
 Fundamentals of Electronic Service

3. Measurement of IGBT III. Powering-on detection and maintenance

If static measurement is normal, powering-on detection can be started. Powering-on detection is a very
important step in maintenance. Unlike static detection, we can narrow down the range of failure points
by observing the reflection of power and error code and clearly maintain the direction of maintenance.
And by measuring the voltage of some key points under powering-on state, we can be helped to solve
the problem more quickly.
 There is certain danger, for powering-on process, and the attention should be paid to safety!
Turn the switch to the OFF position before power is energized, plug in the power line to make sure that
there are not conductive objects on the circuit board and under the circuit board so as not to cause a
short circuit and then turn on the switch to observe the state of the circuit board.

Error Code Content

Failure of high-voltage power

Abnormal high-voltage power supply
supply
Failure for power supply of side
Abnormal power supply of line
board
Failure for power supply of step
Abnormal power supply for step drive board
drive board

E01 The main voltage shed is too high

Abnormal communication between main control board CPU and

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E03
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step drive board CPU

E05 Abnormal governor signal

E06 The presser pin step motor is not in the correct position

E07 Motor stalling

E09、E11 Abnormal positioning signal

E14 Abnormal encoder signal

Measuring value of IGBT 1 and pin 3 Measuring value of IGBT 2 and pin 3

E15 Abnormal over-current protection for power supply

If pin 2 and 3 are short-circuited, the damage Multimeter diode gear
to the IGBT itself needs to be replaced. If E17 The handpiece protection switch is not in the correct position
the value of pin 1 and 3 is abnormal, check
whether the relevant resistance under Black probe Red probe Normal value
the IGBT is normal, and replace it if the E18 The mechanical lock sensor is not in the correct position
resistance value is normal. (If the value is 2. 3. 0.400V
close to 0, show that the IGBT1 and pin 3 are E19 The large-board sensor is not in the correct position
punctured, and the IGBT can be replaced.)
1. 3. 0.650V
 Fundamentals of Electronic Service

1. High voltage power supply failure: abnormal high voltage power supply c. Detection of IGBT
Multimeter diode gear
Failure analysis:
The failure of high-voltage power supply is Black probe Red probe Normal value
generally divided into two kinds: open circuit
and short circuit; The open circuit is because
the 220V AC circuit is abnormal, and the short
2. 3. 0.400V
circuit is caused by short circuit of high voltage
components, such as rectifier bridge, IGBT,
etc.
1. 3. 0.650V
Methods of processing:
1. The open circuit processing method shall
be measured according to the measurement
method of AC circuit (refer to Step I of the
measurement of Hh). If pin 2 and pin 3 are short-circuited, show
2. Short-circuit failure shall be measured that the damage of IGBT ^ body is required
according to the following steps to be replaced. If the values of pin 1 and 3
are abnormal, check whether the relevant
a. Firstly detect whether the fuse is burned or resistance of the IGBTF surface is normal. If
not; if the fuse is burnt out, replace the fuse, the resistance value is normal, replace it. (If
and if the fuse is replaced, be sure to not be the value is close to 0, show that the IGBT1
electrified, and the next step is required to be Measuring value of IGBT1 Measuring value of and pin 3 are punctured, and the IGBT can be
tested; and pin 3 IGBT 2 and pin 3 replaced.)
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b. Detect the rectifier bridge
Multimeter diode gear

2. Low-voltage power supply failure of main control board: analysis on abnormal failure of low-voltage
power supply:
Low-voltage power supply failure of main control board: is mainly caused by the short circuit of the
low-voltage chip and the surrounding components.
Methods of processing:
If the short circuit occurs, replace the components corresponding to the voltage, and the
Black probe Red probe Normal value corresponding components of each voltage are as follows:
Main control board 300v short circuit: DB1I, IGBT, C48, C59
1. 2. 0.500V
Main control board 32v short circuit: Rm, U2, C19
1. 3. 0.500V
Main control board 15v short circuit: U1, C5, U13
2. 4 0.500V Main control board 5v _ IPM short circuit: U2, D6, C200, PH1-PH3 (drive 6 signal), C198, C83
5v short circuit of main control board: U1, D5, C199, PH1-PH3 (drive 6 signal), U17 (drive 6 signal),
3. 4 0.500V
ACS1-ACS2, D24-D30 (encoder signal), U8 (encoder signal) main control board 3.3 v short circuit:
U14, U1 (506), D33 (control signal)
If any one of these values is about 0.002,
D4 (signal of handpiece protection switch),
show that the inside of the rectifier bridge has
been short-circuited, and the rectifier bridge is DO, D7 (large-disc inductor signal)
required to be replaced.
 Fundamentals of Electronic Service

Switch tube Q7
(TOP271EG)

C201 Start
capacitor

Startup resistance
Power-on test is 5.8V

There isn’t 15V voltage on main control board:

1. Remove pin 1 of U1 and U13, if warp up, firstly eliminate it and measure whether C5 (470 uF) is
normal or not. If abnormal, replace it.
2. Start up and measure C2_1 to observe whether the voltage of C2 _ 1 is 5.8v.
If start up and measure, C2 _ 1 voltage is free of 5.8v:
1): Measure whether C39 (10 uF), R15 (12k) and R6 (1.5k) are normal. If abnormal, replace it.
2): Measure whether D2 (US1M) and D3 (M7) are abnormal. If abnormal, replace it. There isn’t voltage of 32 V on main control board
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3): Replace 01. 1. Measure whether the starting capacitor C201 is provided with voltage of 5.85V through powering-
4): Replace L4 (2.2mH). on measurement. If provided, show works. If not, measure the resistance value of startup resistor R61,
R63 and R64 (1.5M) are normal, if abnormal, replace the startup resistance. If normal, replace Q7.
3. Replace U1 (1509) and U13 (2136).
2. If powering-on measurement C19 voltage is less than 32 V, replace U5.
3. If Q7 blasts off, replace Q7, PH9, and U5.

S t a r t u p
resistance

No 5V and 3.3V on main control board

1. Replace U2 (XL1509) directly
There is 15V and isn’t 5V _ IPM on main control board 2. If 5v voltage doesn’t reach less than 5v: Replace
1. Directly replace U1 (XL1509). C198.3. 3. If 5v voltage is too high, replace L2 (2.2
mH).
2. 5v_IPM voltage is less than 5v: replace C200.
3. 5v_IPM voltage is too high: replace L4 (2.2mH).
Too high voltage of 5v _ IPM may cause burn PH1, PH2, and PH3. Therefore, it is necessary to detect
PH1, PH2 and PH3. If there is short- circuit breakdown or burnout, please replace it.
 Fundamentals of Electronic Service

3. Failure of high -voltage power supply: abnormal high voltage power supply
Failure analysis:
The low-voltage power supply failure of step drive board is mainly caused by the short circuit of the
low-voltage chip and the surrounding components.
Methods of processing:
Components of corresponding voltage shall be replaced, and the components for corresponding
voltage shall be as follows:
Step drive board 32v short circuit: U6
Step drive board 14.6 v short circuit: U2, D9, and U7 U8 U10 U12
Step drive board 5v_1 short circuit: U2, ZND7, U9 U11 (current sensor)
Step drive board 3.3 v_1 short circuit: U14, U1 (506)

DC32V voltage input interface

Abnormal low-voltage power supply of step

drive board 4. E01 main voltage is detected to be too high
1. There isn’t 32v for step drive board; check Check that the supply power voltage is correct. (Or whether to exceed the specified rated voltage)
whether the red and black lines are inserted
5. Abnormal transmit communication between E03 main control board CPU and step drive board CPU
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2. There is 32v but isn’t 14.6 v for step drive
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board, replace U6.
3. There are 32v and 14.6 v but isn’t 5V for
step drive board, replace U2. Failure analysis:
4. There are 32v and 14.6 v but isn’t 5V for E03 is mainly caused by the abnormal
step drive board, replace U14. communication between the singlechip and the
Relay panel, including two main factors, I. abnormal
measurement voltage; 2. Normal voltage and abnormal signal.
point Methods of processing:
1. Firstly, troubleshoot the failure of power supply,
DC 14.6 V voltage measuring point D9 start up and observe whether the LED3 of the
main board and step drive board is on.
If it is not on, show that the voltage is abnormal,
and the processing method shall be implemented
according to the failure of the low-voltage power
supply of the main control board.
2. Whether the startup shows version 911 (main
control board program version): After startup, 911
display, and then display E03:
Start up and measure whether the relay voltage
Board reset circuit of the main control board has a voltage of about
4.3 V (relay pull-in), if not, burn the main board
ZND7 (5V stabilivolt) DC5V_1 program, such as E03, the resetting circuit of the
Measuring Point main control board is measured whether to be
normal, if abnormal, the crystal oscillator of the
resistance capacitor shall be replaced.
 Fundamentals of Electronic Service

7. E07 Motor stalling

Failure analysis:
a. Poor contact of motor plug wiring results in non-rotating;

Communication Resetting circuit b. The signal of the positioner is abnormal;

interface between of the step drive C. The head mechanism or foreign substances on the motor belt are involved for dead clamping;
step drive board board
and main control d. The processed objects are too thick, and the torque of the motor is insufficient, unable to run through;
board
E. Abnormal drive output.
After the start-up display 911, display E03 (Communication failure between step drive board and main The main reason for the electronic control alarm E-07 is that there is a problem with the motor drive.
control board): The motor drive section is mainly composed of separating device IGBT, U13 (IR2136S), light coupling,
logic chip U17 and surrounding resistance capacitor. Except that the E-07 error may be alarmed by
1) Measure whether the reset circuit of step drive board is normal, if abnormal, replace the crystal
damage of above components, there are motor sockets and encoder sockets.
oscillator of resistance capacitor normally.
2) Check whether the wires are plugged in and the wires are measured.
Methods of processing:

6. E06 presser in step motor doesn’t reach the correct position 1. Measure whether the main board is provided
with 15V and 5V voltage. Refer to maintenance
mode for low-voltage power supply of main
board for measurement method.

Current Failure analysis: 2. Measure whether pin 1 and 3 (normal pressure

sensor The main problem of E06 is whether the step motor is drop 0.630V) pin 2 and 3 voltage drop (normal
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abnormal. Firstly, it is determined whether the power pressure drop 0.400 V) of each IGBT are normal,
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supply of the step drive board is normal, and secondly, and the straight-through breakdown can be
Functional whether the step-drive signal is detected to be normal. replaced. If the voltage drop of 1 and 3 is infinite,
tube Methods of processing: the resistance value of R218-R223 is 100 Ω, and
it is still not normal. Replace U13 (IR2136S).
IR21845 1. Firstly, troubleshoot the power supply and switch on
to observe whether the LED3 of the step drive board is 3. Measure the voltage drop of C42-C44 (22uF)
on. capacitor (normal pressure drop 0.630 V) for
If it is not on, show that the voltage is abnormal, and normal and abnormal replacement.
the processing method shall be implemented according 4. Measure whether the resistance value of
to the failure of the low-voltage power supply of the R34-R36 is 1000 and is not replaced normally.
step drive board.
5. Measure whether the resistance value of
2. Measure whether Q14-Q14 (IRRF540N field effect IGBT1, 3-pin IGBT2, 3-pin R203-R208 is up-pull 10k (the motor drives
tube) is normal: measure pin 1-3 pressure drop (0.620) measurement measurement six signals). If it is abnormal, replace the
and pin 2-3 pressure drop (0.570) are abnormal and corresponding PH1, PH2 and PH3.
abnormal. If two or more are broken, be sure to replace
U7, U8, U10, and U12 (IR2184S). 6. Whether the resistance value of R196-R201
is 3000 (6 signals of photocoupler are isolated).
3. Measure whether the resistance of R46, R61, R74
If abnormal, replace it
and R83 is 10Q, if abnormal, replace it.
4. Measure whether the D12, D13, D14 and D15 diodes 7. Measure whether the pull-down 10k resistance
are normal, the voltage drop is about 0.48V, and the of U7 (74HC04D): R116-R121 is normal. If
D13, D14 and D15, if abnormal, replace it. abnormal, replace it.
5. Measure whether U9 and U11 are normal: start up
and measure whether C84 and C86 voltage is about
1.25V, if abnormal, replace the corresponding U9 and
U11 current sensors.
 Fundamentals of Electronic Service

8. Abnormal upper positioning signal under E09/ E11 9. Abnormal over-current protection of E15 power module
Failure analysis:
The motor cannot find the positioning signal, the
positioning signal on the motor encoder is abnormal
or the electric control positioning signal transmission
is abnormal.
Method of processing:
1. Measure whether the pressure drop of D29 (upper)
and D30 (lower) is normal (0.600V) and replace it
normally. If it is not normal, replace U8 (74HC14D).
2. If it is still not normal, measure the resistance value
R108 (10kΩ) of the pull-up resistor of the needle
position signal, whether the resistance value of R110
(10 kΩ) is normal. Measure the pull-up resistance
value R109 (10kΩ) of the pin position signal of the
lower stop pin, whether the resistance value of R111 (10
kΩ) is normal. If abnormal, replace it.
9. Abnormal E14 Encoder Signal
Abnormal encoder signal, encoder failure or encoder
signal transmission abnormality in electric control may
cause E14.
Methods of processing:
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1. Measure whether D26 (X), D25 (Y), D24 (Z)
pressure drop (0.600V) or resistance value (23K)
are normal, if abnormal, replace U8 (74HC14D). If
abnormal, replace D26, D25 and D24.
2. If it is still not normal:
Measure whether the X-signal pull-up resistor R85
(1k), R90 (22k), R95 (22k), C67 (100 pF) and C 9 (1
ohm) are normal. If abnormal, replace them.
Measure whether the Y signal pull-up resistor R84
(1k), R89 (22k), R94 (22k), C66 (100 pF) and C10 (1
ohm) are normal. If abnormal, replace them.
Measure whether the Z-signal pull-up resistor R83 1. Measure pin 1 and 3 of each IGBT (normal pressure drop 0.630V), pin 2, 3 pressure drop. Whether
(1k), R88 (22k), R93 (22k), C65 (100 pF) and C11 (1 normal pressure drop 0.400V is normal, in case of short circuit breakdown, replace it. Pin 1 and 3
ohm) are normal. If abnormal, replace them. pressure drop is up to infinity; measure whether R218-R223 resistance is 1000. If still abnormal, replace
3. Measure whether D27 (A), D28 (B) pressure drop U13. (IGBT measurement is as described above, no more description here)
(0.600V) or resistance value (32k) are normal if still 2. Start up and respectively measure whether the voltage of C84 and C86 is 1.25v. If abnormal, replace
abnormal, replace D27 (A) and D28 (B). ACS1 and ACS1.
Measure whether the pull-up resistors R86 (10k), R91 3. Measure the peripheral resistance capacitor.
(22k), R96 (22k), C68 (100 pF), C12 (1H) on A signal
are abnormal, If abnormal, replace them. ACS1: C28 (100K), C35 (1k), R157 (10k), R159 (10k), C84 (2.2,) ACS2: C8 (100), C36 (1k), R163 (10k),
R165 (10k), C86 (2.2. 2)
Measure the pull-up resistors R87 (10k), R92 (22k),
R9 7 (22k), C69 (100 pF), C13 (1 ohm) on B signal, 4. Measure the U13FAILURE line:
and If abnormal, replace them. R41 (10k), R68 (5.1k), R151 (1k), C81 (100 pF) Replace PH10 (LTV-357T-C)
 Fundamentals of Electronic Service

Electric Control Maintenance Guide of QIXING A4

Product Introduction

Product Code Description

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Introduction to Parameters
781E

781E
A4
Failure Detection and Maintenance

10. E17: The handpiece protection switch is not in the correct position
1. Measure whether the D4 voltage drop or the resistance value is normal. If abnormal, replace it. If still
abnormal, measure whether the pull-up resistor R3 (10k) the pull-down resistor R47 (10k), R49 (22k),
and C26 (100ohm) are normal. If abnormal, replace them.
2. P24 parameter (handpiece protection switch) is changed as 0: off.
11. E18 sensor is not in correct position (sensor on handpiece step motor). There is not 4P socket
detection sensor failure for 4P socket.
12. E19 large-disc inductor is not in correct position
Sensor failure detection
 Fundamentals of Electronic Service

Product Introduction Product Barcode Description

Section I Barcode Description of Electric Control Mainboard
QIXING

QIXING
A4

A4
Speed controller Electric control box

Production date of A4
mainboard

Note: as shown in the figure, the upper right corner of above mainboard is labeled with 1632, 16
refers to production in 2016, 32 represents this mainboard is produced on the 32nd week, namely, the
Motor mainboard is produced in the fourth week in August, 2016.
 Fundamentals of Electronic Service

Section II Description of Motor Barcode

Introduction to Parameters
Parameter Chinese Setting
Scope Initial Value Description for Content Value and Remarks
Items Description Key
Maximum rotation
P01 200-5000 4000 Maximum speed setting at sewing machine
speed (rpm)
the higher the slope value of the climbing
Acceleration curve slope of the controller, the steeper the speed;
P02 10-100 80
adjustment (%) the smaller the slope value, the slower the
speed
Pin stop position Same to quick function key on key panel UP:
P03 DN/UP DN
selection upper stop needle DN: lower stop needle
Initial backstitch Speed setting at the backstitch on front
P04 200-3200 1800
speed (r/s) section (initial backstitch)
Terminated
Speed setting at the backstitch on rear section
P05 backstitch speed 200-3200 1800
(terminated backstitch)
(r/s)
Continuous
P06 backstitch speed 200-3200 1800 Speed setting when continuous backstitch
(r/s)
Slow start-up
P07 200-1500 400 Speed setting at slow start
speed (r/s)
Slow number of Needle number setting at slow start-up, each
P08 0-99 2
stitches (needle) unit represents half stitching
Fixed needle sewing [P34. SMP] is set at
Automatic needle
the speed setting in the A state (or the speed
P09 sewing fixing 200-4000 3500
setting when the AUTO key of selection for
speed (r/s)
needle box is pressed)
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ON: After the last section of the sewing needle
After the suture is
A4

A4
is finished, the stop backstitch operation will
fixed, the function
be automatically performed. Note: in any
of stopping
sewing mode, it is not possible to perform
the suture is
the needle-filling function. OFF: After the last
P10 automatically ON/OFF ON
section of the suture is finished, it will not be
performed (the
possible to automatically perform the function
setting of no
of stopping the back-stitch, and it is necessary
needle-filling
to implement the front treading action or rear
function)
treading action.
Function mode When pressing the headstock back-stitch
selection when switch by hand: J: JUKI method (action when
P11 J/B J
backstitch in the stitching or mid-circuit ) B: ROTHE
pressing by hand mode (starting from the sewing machine)
Initial backstitch section, reverse
Initial backstitch electromagnetic coil operation opportunity:
P12 motion mode A/M A A: gently touch the pedal, i.e. automatically
selection perform the initial backstitch; M: controlled by
the pedal, stopped at any time
CON: After completion of the initial backstitch
Start backstitching
section, the next section of function STP is
end point
P13 CON/ STP CON automatically continued: After completion of
operation mode
the initial stitch length, the automatic stop is
selection
automatically stopped
Slow-speed ON : Startup of slow startup
P14 ON-OFF OFF
startup OFF : Shutdown of slow startup
Needle-filling 0: half needle, 1: stitch, 2: continuous
P15 0-2 0
mode replenishment
550W 220V 7.1. 1-A4 29th
Internal code
(Power) (Voltage) (Model) (Flow No.)
 Fundamentals of Electronic Service

Termianted A: The pedal is fully treaded after stitching, i.e. P44 Brake force 1-50 16 Force selection when the machine is stopped
backstitching automatically perform the backstitching.
P20 A A Adjust the motor speed when the trmming
motion mode M: Controlled by the pedal, be able to be P49 Trimming Speed (r/ s) 100-500 250
selection stopped at any time period is adjusted
Termination Effective ON when there is not applied needle Lifting time of
P50 10-990 250 Adjustment item when lifting action of presser
P21 of Backstitch ON-OFF ON box: Terminating backstitch function opening lifting presser (ms)
Function Selection OFF: The backstitch function is closed Presser lowering
P52 10-990 120 Presser delay-lowering adjustment item
Effective ON when there is no applied needle time (ms)
P27 Induction switch 0-9 1. selection box: stop the back-stitch function to turn ON: After half rear pedal, no presser output is
Half-pedal lifting
on OFF: the back-stitch function is turned off applied.
P53 presser lifting ON/OFF OFF
Continuous backstitch, reverse the OFF: When the half-pedal pedal is treaded,
function
Continuous electromagnetic coil action time: A: gently the presser shall be lifted.
P28 backstitch motion A-M A touch pedal, i.e. automatically perform Automatic find the On: Turn on the electric motor, automatically
mode selection continuous backstitch M: Controlled by the P56 upper positioning ON/OFF ON find the upper positioning signal and stop the
pedal, be able to be stopped at any time after powering-on OFF: no action
Rear brake force Lifting presser
P29 1-50 20 P57 1-120 10 Forced closing after holding time of Presser
protection time (s)
after cutting
Position adjustment. When the value
Force P58
Upper positioning
0-1799 40 decreases, stop the needle in advance. When
P30 application for 0-100 0 adjustment
the value increases, stop the needle.
thick materials Lower positioning adjustment. When the value
Thread shearing Lower positioning
P31 0-100 40 P59 0-1799 750 decreases stop the needle in advance. When
adjustment
force application the value increases, stop the needle.
Continuous P60 Test speed (r/ s) 100-4000 2000 Set test speed
P32 backstitch 0-200 131 0200 step-by-step lagging of action Handpiece
0: not detection, 1: detecting for zero signal, 2:
compensation 5 P66 protection switch 0-2 1.
detecting for positive signal;
Continuous detection
P33 backstitch 0-200 158 Trimming
OFF: no detection
compensation 6 P67 protection switch ON/OFF OFF
ON: detection
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A: Gently touch the pedal, namely, detection
A4

A4
Selection of automatically performs the sewing action of When the backstitch operation is performed,
P34 sewing mode of A-M A the fixed needle. Backstitch release the output of the backstitch machine is
P69 0-40 2.
fixed needle M: controlled by pedal, can be stopped and buffer (ms) periodically saved, and the heating of the
started at any time backstitch electromagnet is avoided.
Fixed needle Lifting presser
P71 0-40 2. Relieve the force released by the presser
P35 sewing function OFF Reserved; Invalid setup here release buffer (ms)
setting Upper stop pin
P72 0
Selection of the position correction
P36 number of stitches 0-1 0 Reserved;Invalid setup here Lower stop needle
P73 0
of fixed needle position correction
Setting of line Press and take the encoder angle, and the
0: no action;1. The pull-out action is 2-11 Encoder starting ex-factory has been set. Do not make any
output function P92 0-479 445
P37 0-11 8. clamp wire action, and the operation force angle change at will (change at will may produce
(wire clip force
gradually increases the failure)
track setting)
Output function ON: Trimming action OFF: no trimming
P38 ON/OFF ON
setting action
The Presser Same to fast feature on the key panel
output is selected UP: When stitching stops, the Presser is
P39 when the stitching DN/UP DN (s) automatically lifted.
stops in the DN: When stitching stops,, the Presser is not
midcircuit lifted automatically (controlled by rear pedal)
Motor rotation
direction CW: clockwise
P43 CCW/ CW CCW
setting (positive CCW: Counter-clockwise
inversion)
 Fundamentals of Electronic Service

Failure Detection and Maintenance Section II. Cognition to Mainboard

Section I Composition of Electric Control

220V AC interface

OFF alarm interface

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A4

A4
Mainboard Power panel

Functional interface

Presser lifting interface

Interface of speed
controller

Burning sequence
interface

Motor encoder
interface
Base Shell
 Fundamentals of Electronic Service

Section III. Cognition on of Circuit Board Components

1. Power board

AC power interface DC high-voltage interface

definition J1 definition J4
Safety capacitor Thermistor
220 V power line 1. GND is grounded
Relay
interface 2. + 300V power supply

Presser interface Lightning

definition J5 Brake resistance interface protection tube
definition J6
1. Presser signal
Brake resistance interface
2. Grounding

F2 fuse
Speed controller
interface definition J7 Common mode Rectifier Bridge
1. Empty inductor

2. +5V
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A4

A4
3. Speed controller
signal
2. Main board (front)
4. Grounding

electromagnet interface
Encoder Interface Definition Transformer
definition HEAD1
HEAD5
4 Electromagnet: 1, 9
1. + 5 V voltage C19 electrolytic
Clamping wire (wire-sweeping) capacitor
2. U phase signal
electromagnet: 2, 10
3. V-phase signal
Presser inductor: signal 3
signal grounding signal 11 4. W phase signal
Stitching lamp: 4 signal 5. UP upper needle stop Large capacitor
grounding, 12 (+ 5V) position
Manual backstitching: signal 6. Empty
5, signal 1 and 3 grounding
7、A
Backstitch Electromagnet:
8、B
6,14
9. GND grounding Functional tube 540
Manual stitching-refilling: 7
10. GND grounding
AD Detection: 15
 Fundamentals of Electronic Service

3. Main board (reverse side) 5. Distribution of A4 circuit board area (mainboard)

Switching power
Rectifier tube MUR2040 supply circuit
Switch tube IF8N80
Panel power circuit

Power Chip XL1509

Power Chip 3843B

Driving signal circuit

IGBT
Low voltage
power supply
circuit
Power Chip 11170G
Driving chip IR2136S

Communication chip
SI8421
Functional signal
Singlechip
circuit

Encoder signal circuit DSP signal loop

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6. Function description for each part of electric control of A4
A4

A4
High-voltage circuit of main power supply: filter and rectify the input 220VAC to form 300VDC, then filter
4. Distribution of A4 circuit board area (power board) the capacitor, and output the stable 300\/ DC power after energy storage.
Switch power circuit: step down the stabilized 300V to form a more stable 32V voltage, supply the
functional tube, and supply the voltage source to the panel.
Low voltage power circuit: step down the voltage of 300V to form a relatively stable voltage of 15V, 5V
and 3.3V.
Panel power circuit: step down the 32V voltage to form a stable 5V voltage to the panel.
And the drive circuit is used for amplifying the drive signal of the singlechip to form a six-circuit drive
signal and controlling the conduction and the turning-off of the IGBT so as to control the rotation of the
motor.
DSP signal circuit: Single chip processor is the core of whole section, motor Hall signal, stop pin
signal, speed controller signal, panel signal and current feedback signal are input into the singlechip
for processing, and subsequently the singlechip outputs a corresponding drive signal to drive the motor
according to the acquired signal.
Function signal circuit: the signal output by the singlechip is processed to control the on-off of the
function tube to control the action of the electromagnet.
Encoder signal circuit: Control the motor encoder signal.
 Fundamentals of Electronic Service

7. Introduction to the distribution of electric control power supply of A4 2. Circuit analysis on low voltage power supply
C58, C59 Functional tube
Large capacitor
300V Power supply analysis for drive section:
U6 Power Chip Panel
(XL1509) 5V DC voltages of 300V is input from Q6 (SC1117)
3V to 5V
pin 4.When the Q6 internal switch is on, pin
Switching 5-8 output current, charge the inductor through
JP1 socket DB1 Rectifier power supply
220V AC
U2 the inductor L2, and then form a circuit through
Bridge (S18421)
accessing 220V AC to 5V, 3.3V
the back load. When the switch tube is off, it is
U13 Driving Chip
voltage 330V DC (IR2136S) discharged by L2 inductor. After passing through
Q6 Power Chip D2 and L2 inductors, the load forms a discharge
(SC11170G) circuit. The Q6 internal switch tube is constantly
300V to 15V U 3 Power Chip switched to form a stable 15 V voltage, and 15V
(3482A) U14 triacs (1117L-33)
15V conversion 5V conversion to 3.3V voltage can be measured from C4. 15V voltage is
to 5V divided into two circuits; one circuit is supplied to
IGBT U13 (IR2136S) and the other supplies power to
300V
U3 (EUP3482A).
DSP

Section IV. Circuit Analysis

1. Analysis on high-voltage power supply circuit

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A4

A4
relay

Analysis on high voltage power supply circuit:

The main purpose of the power section is to rectify the 220V AC voltage, filter and then form a stable
300V1: current voltage and cover the protection function. The following is a detailed analysis:
220VAC voltage, one circuit passes through and the fuse, the common mode inductor enters the
rectifier bridge pile; The other circuit flows through the common mode inductor, the thermistor enters into
a rectifier bridge pile, the rectifier bridge pile rectifying 220VAC voltage to form a DC voltage of 300V, 15V voltage is input from pin 2 of U3 (EUP3482A), and a 5V1 is output from pin 1 and 3 through the
filtering to form a stable 300VDC voltage in a large capacitor, forming a DC voltage of 15V through the surrounding base circuit. The measuring point of 5V voltage is ZND7. 5VDC voltage is supplied to
switching power supply circuit and supplying power to the relay, causing the electromagnet in the relay U14 (1117L-33). The U14 drops the 5V voltage to 3.3 V to U2 (SI8421) and DSP for power supply.
to produce magnetism which causes the switch in the relay to close so that the 300VDC high voltage Measuring point of 3,3V is C92, LED3 is a light emitting diode and detects whether the 3.3V voltage is
of short-circuit thermistor is transferred from the relay to other places where the electrical control is normal.
electrically controlled.
 Fundamentals of Electronic Service

Power Analysis on Functional Section: 3. Analysis on DSP Signal Processing Circuit

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The 300V high-voltage DC voltage is accessed into the transformer, a 32V low voltage DC is formed
A4

A4
through the switching power supply circuit, and 32V voltage has two functions. On the one hand, the
functional pipe (540) is provided with an operating voltage, and on the other hand, as shown in the
following figure, input from pin 1 of U6 (1509) and provide the service voltage to U6, and then U6 drop
the voltage as 5V voltage to U2(SI8421A), U9(MCP6541/TP1941), U7(QG04) and front panel.

There are 64 pins on the A4’s DSP chip. The definition of each pin is analyzed below:
Therein, pin 10, 26, 38, 57 are 3.3V voltage connected to VDD, and the pin 19 is AVDD, which is the 3.3V
voltage on analog section, but the four pins in this circuit are connected to the same 3.3 V voltage. The
9, 25, 41 pins are grounded and the pin 20 is the grounding for AVSS analog section. 2, 3, 60, 61, 62,
and 63 pins are pulse width modulation PWM1_IPM, PWM4_IPM, PWM5_IPM, PWM2_IPM, PWM3_
IPM, PWM6_IPM six circuits of signals drive the chip U13 (IR21365).Pin 4, 5, 49, 50, 51, 52, and 55 are
the encoder signal pins, where pin 4 and 5 are upper and lower positioning signals respectively. Pin 47,
45, 44 and 48 are scanning lines, lifting presser, backstitch and signal output ends of these functions.
The pin 7 is the reset signal pin, and the low level is valid. When the input is low, the reset function is
started. The pin 1 is the signal pin for detecting 220VAC voltage. If 220VAC voltage cannot be input
to U11 or U11 photocoupler damage, the error code of PSR-OFF will be alarmed. Pin 12 is the signal
control line of pin pedal. The pin 42 is the signal terminal of the head instead of the switch. The pin 6 is
the relay signal output pin to provide a low level for the relay to enable the relay to operate normally.
 Fundamentals of Electronic Service

Functional Partial Power Analysis: 5. Analysis on function drive circuit

As shown above, the drive circuit includes a drive chip U13 (IR2136S), a separating device IGBT and a
surrounding resistance capacitor.
Pin 2, 3, 4, 5, 6, and 7 are connected with 6 PWM signals, PWM signals are sent by DSP. The pin 8 is
the error pin and is low effectively. The pin 1 is a +15 V voltage and the pin 13 is the grounding terminal.
27 (H01), 23 (H02), 19 (H03) are drive signal output pins of IGBT upper bridge, 26 (VS1), 22 (VS2)
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A4

A4
and18 (VS3) are auxiliary output pins driven by an upper bridge, drive the IGBT breakover of an upper
bridge with the first three drive signals;16 (L01), 15 (L02), 14 (L03) are output pins driven by the lower
bridge to drive the conduction of the lower bridge IGBT. The pin 2 of the upper bridge IGBT is connected
to a DC high voltage of 300 V.

4. Analysis of encoder signal circuit Function circuit: The circuit mainly consists of functional pipe (540), Schottky diode, photocoupler and
surrounding resistance capacitor.
Motor encoder signal circuit: The circuit is mainly
composed of anode and cathode butt diode and 1. The function of the functional pipe is to drive the normal operation of the electromagnet after receiving
surrounding resistor capacitor. the control signal from the DSP.

Motor encoder signal circuit: The circuit is mainly 2. The function of Schottky diode is follow-up. In the circuit, it is generally used to protect the elements
composed of anode and cathode butt diode and from being broken or burned by induced voltage, and is connected in parallel to both ends of the
surrounding resistor capacitor. element which generates induced electromotive force to form a circuit therewith so that the resulting
high electromotive force is consumed in a continuous current mode in the circuit. so as to play a role in
The CN1 interface is connected with a socket of protecting the components in the circuit from being damaged.
the motor encoder, and the rotary displacement is
converted into a serial digital pulse signal through 3. The photocoupler is the isolation signal and is transmitted after the signal is isolated.
a motor encoder and then input to pin 4, 5, 49, 50, The working principle of the functional section is that the control signal is output by the DSP, and the
51, 52, and 55 of the DSP, wherein, the pin 4 and control signal is isolated by the optical coupler and transmitted to the functional tube to drive the work of
5 are UP and DOWN, namely, upper positioning the electromagnet.
and lower positioning pin.
 Fundamentals of Electronic Service

Section V Maintenance of Electric Control 2. Static test

1. Visual detection

1. AC circuit measurement
As shown in the left figure, put two probes into the L
1. Check whether the large capacitors C58 and pin of the power plug and pin 2 of the rectifier bridge
C59 are open or closed; respectively, and the value around 10 is displayed, it is
normal.
2. Check whether the common mode inductor L0
produces broken pins; Then transfer the multimeter to the buzzer gear firstly,
and place two probes both pin N of the power plug and
3. Check whether the fuse F2 and the varistor pin 3 of the bridge rectifier respectively, if the buzzer
ZNR5 burn out; sound, it is normal.
4. Check whether the sampling resistor of R38 If the above values are abnormal, check whether the
and R39 is burned and blasts off; circuit is complete, whether the fuse is normal, and
5. Check whether the switching power circuit is whether the pin of common mode inductor is off, and
burned or not; whether the resistance value of the thermistor is about
10 ohm, and if not, replace it.
6. Inspect whether there is any trace on the
surface of the circuit board;
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2. Measuring method of rectifier bridge
A4

A4
Multimeter diode gear

Blackprobe Red probe Normal value

1. 2. 0.500V
Method of processing:
1. 3. 0.500V
1. The large capacitor of C58 and C59 is exploded, i.e. replace the large capacitor, and check whether
the rectifier bridge and IGBT value are normal; 2. 4 0.500V
2. If the common mode inductor L0 is broken, the common mode inductor is replaced;
3. 4 0.500V
3. The varistor is cracked and the fuse is burnt out: replace the voltage-sensitive resistor and the fuse,
and measure whether the bridge rectifier and IGBT value are normal;
4. R38, R39 sampling resistance explosion: return to factory maintenance.
5. If the switch power circuit is burnt out, replace the electric control. If any one of these values is about 0.002, show that the
inside of the rectifier bridge has been short-circuited,
6. If the surface is broken, it is necessary to connect with wires; check whether the value of the Rectifier
After the rectifier bridge needs to be replaced, the
Bridge and IGBT is normal.
measurement can be implemented.
 Fundamentals of Electronic Service

Error Code Contents

No display No display on the panel

Display OFF Start-up display OFF

E01 System overvoltage

Measuring value of IGBT1 and E02 System under-voltage

pin 3
E03 Abnormal transmission communication between operation panel and CPU

E05 Abnormal contact of speed controller

E07 Motor stalling

E08 Continuous manual backstitch exceeds for more than 15 seconds

E10 Overcurrent protection of electromagnet

Measuring value of IGBT2 and E11 Abnormal positioning signal

pin 3
E13 Power module overheating protection

E14 Abnormal encoder signal

3. Measurement of IGBT
E15 Abnormal over-current protection of electric power module
Blackprobe Red probe Normal value Multimeter diode gear
If the pin 2 and 3 are short-circuited, the damage to E17 Failure of handpiece protection switch
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the IGBT itself needs to be replaced. If the value of
A4

A4
1. 2. 0.500V pin 1 and 3 is abnormal, check whether the relevant
resistance under the IGBT is normal, and replace
it if the resistance value is normal.(If the value is
1. 3. 0.500V close to 0, show that the IGBT1, pin 3 is punctured,
and the IGBT can be replaced.)
1. No display: No display of panel

3. Powering-on detection and maintenance

If static measurement is normal, powering-on detection can be started. Powering-on detection is a very
important step in maintenance. Unlike static detection, we can narrow down the range of failure points
by observing the reflection of power and error code, and clearly maintain the direction of maintenance.
And by measuring the voltage of some key points in the energized state, we can be helped to solve the
problem more quickly.
 There is certain danger for powering-on process; the attention should be paid to safety!
Turn the switch to the OFF position before power is energized and plug in the power line to make sure
there are not conductive objects on the circuit board and under the circuit board so as not to cause a C 1 9
short circuit, and then turn on the switch to observe the state of the circuit board. capacitor D17 Diode

C19 capacitor D17 Diode

 Fundamentals of Electronic Service

Failure analysis: 3. Failure analysis on overvoltage of E01 system\

The voltage on the panel is 5V power supply, so it is firstly determined whether the voltage source E02 system under-voltage:
is normal. The switching power supplies 300VDC voltage to a 32V voltage, and 32V voltage can be The system overvoltage and system under-voltage
measured from C19 capacitor, and the power chip U6 (XL1509) and the peripheral circuit reduce 32 V are mainly caused by the electric control singlechip
voltage to 5V power supply to the panel. detecting that the input 220V AC voltage is higher
Methods of processing: than 264V or lower than 176V.

1. Check whether the capacitor of C1 9 has a voltage of 32 V. If there is not voltage of 32 V, the circuit Methods of processing:
failure of the switching power supply will be described. Please replace the components of the switch 1. Check whether the external AC voltage is about
power supply, including PSR (IF8N80), PH9 (817), U5 (431), and PSR (3843B). 220V, if the voltage is high or low, troubleshoot
2. If there is 32V, check whether D17 has a voltage of 5V, then replace the U6 (XL1 509) and then, if the external power supply and retest after
there is not display on the panel, if the panel chip has been burnt out, replace the panel directly. troubleshooting.
2. Detect the resistance and the capacitor of the bus
voltage detection section on the main board, wherein
the resistances Rm, R16, R5, R8 are 120kΩ, R11 is
6.7kΩ, R194 is 3.kΩ, and the capacitor C88 is 100
pF. Please dismantle the resistor and capacitor for
detection.
3. If the resistance capacitor is normal, the singlechip
2. Switch on and display OFF is damaged, and the single chip processor can be
Failure analysis: replaced.
The startup display OFF is because the singlechip
in the electric control does not detect the 220V high-
voltage power supply. The voltage of high-voltage
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220V passes through R126, R127, R128, R129
A4

A4
resistor reaches U11 (354T), and U11 transmits the
voltage signal of 3.3V through the resistor divider to 4. Failure analysis on abnormal malfunction for E03
the singlechip. operating panel and CPU transmission communication:
Methods of processing: E03 is mainly caused by the abnormal communication
Firstly, the resistance of R126, R127, R128 and between the singlechip and the panel, including two
R129 on the power board is tested to be 120KΩ, main factors, I. Abnormal voltage; 2. Normal voltage,
because both of them are connected in parallel, so abnormal signal
the measured resistance value should be 60KΩ. If Methods of processing:
the resistance is normal, replace the U11 (354T)
photocoupler. 1. Charge the program and re-examine whether the
electronic control alarms E03. Most E03 produces
the problem that the program is lost, and a part of the
problem can be solved by charging program.
2. Measure C40 whether there is a voltage of 15V by
powering on. Measure whether C82 has a voltage of
5V. Measure whether C92 capacitor has a voltage of
3.3 V. If the voltage is abnormal, replace Q6 (11170G),
U3 (3482A) and ZND7 (5V supply pipe).
3. When the voltage is normal, E03 still alarms, show
that the singlechip is damaged; please return to the
factory for maintenance.
 Fundamentals of Electronic Service

a. Check whether the motor socket and encoder

socket are burnt or bent for pin, the motor socket
and encoder socket are all signal transmission
Motor socket ports. If there is any damage, alarm the error.
In case of broken needle for motor socket, replace
the socket. Poor contact of the encoder plug
can also lead to abnormal signal transmission.
5. Failure analysis on abnormal E05 speed controller contact: Therefore, after the socket is damaged, the
encoder socket needs to be replaced.
The speed controller signal cannot be detected by electric control, so E05 failure is alarmed.
Methods of processing:
Encoder socket
Firstly, the replacement method is used to confirm whether it is problem of speed controller, and if
the test is normal after replacement, the speed controller that has been replaced is opened with a
screwdriver. Check whether the connecting wire in the speed controller is in the circuit, and detect
whether the inductor, speed regulating Hall and the resistance capacitor around the speed controller are
normal. If it is abnormal, replace it.

b. Abnormal drive signal

1) Check whether the IGBT is normal or not
Multimeter diode gear
6. Failure Analysis on E07 motor stalling:
a. Poor contact of motor plug wiring results in no rotating; Black probe Red probe Normal value
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A4

A4
b. The signal of the positioner is abnormal;
2. 3. 0.400V
C. The handpiece mechanism or foreign matters on the motor belt are involved for jamming;
d. The processed objects are too thick, and the torque of the motor is insufficient and cannot run 1. 3. 0.650V
through;
E. Abnormal drive output. If the IGBT is short-circuited for 2 and 3 pin, it is
The main reason for electric controller alarming E-07 is that there is a problem for motor drive. The necessary to replace the IGBT itself. If the value
motor drive section mainly consists of separation device IGBT, U13 (IR2136S) and the surrounding of pin 1 and pin 3 is abnormal, check whether the
resistance capacitor. Except that E-07 may be alarmed due to damage of above components, there are relevant resistance under the IGBT is normal, and
motor sockets and encoder sockets. replace the IGBT if the resistance value is normal
(IR2136S).(If the value is close to 0, show that the
Methods of processing: Measuring value of Measuring value of
IGBT1 and pin 3 are punctured, and the IGBT can
IGBT1 and pin 3 IGBT2 and pin 3
The phenomenon of E-07 error alarming is generally divided into three kinds of conditions: be replaced.)
a. Failure of motor socket and encoder socket;
b. Abnormal drive signal;
C. Low-speed shaking of motor.
2) Detect the capacitor of C42, C43, C44
Sometimes b and c are interspersed each other, for example, some signal elements are abnormal to
capacitor 22uF above drive chip U13 (IR2136S),
cause anomalvoltage.
and the voltage drop shall be 0.600V.
3) Detect whether D100, D101 and D102 fast
recovery the diode is 0.500V and whether R34, R35
and R36 are 10Ω. If the value is abnormal, replace it.
 Fundamentals of Electronic Service

7. E-08 manual backstitch failure 11. Abnormal E14 Encoder Signal

Failure analysis: Failure analysis:
If the continuous “manual backstitch” exceeds for 15s, the motor The encoder detects that the anomality of the positioning signal and feeds back to the singlechip, and
will cut off all the work and alarm E-08 failure when the motor is then the singlechip alarms the E11 failure.
unable to rotate. Methods of processing:
Methods of processing: The Maintenance method is same to E11, the explanation isn’t implemented any more.
If the manual backstitch switch is damaged, the short circuit of the
12. Abnormal over-current of E15 electric power
backstitch solenoid can be alarmed to E-08 Failure. Therefore, it
module
is necessary to detect whether the manual backstitch switch and
the backstitch solenoid fail. 1) Detect whether the IGBT is normal or not
Multimeter diode gear
8. E10 electromagnet overcurrent protection
Failure analysis: Black probe Red probe Normal value

The current protection of the electromagnet is mainly because that 2. 3. 0.400V

U2 (Si8421AB) detects that the current in the electromagnet is too
large to be fed back into the singlechip, and then the E10 failure is 1. 3. 0.650V
alarmed.
Method of processing:
Detect U2 (Si8421 AB), U9 (C4TG8) and U7 pins. E10 failure
code is generally presented. Replace the above components with
the replacement method. If the E10 failure code is also present, If the IGBT is short-circuited for pin 2 and 3, it is
return to the factory for maintenance. necessary to replace the IGBT itself. If the value
QIXING

QIXING
of pin 1 and 3 is abnormal, check whether the
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relevant resistance under the IGBT is normal, and
9. Abnormal E11 positioning signal IGBT1, 3-pin IGBT2, 3-pin replace the IGBT if the resistance value is normal
Failure analysis: measurement measurement (IR2136S).(If the value is close to 0, show that the
IGBT1 and pin 3 are punctured, and the IGBT can
The encoder detects that the anomaly of the positioning signal be replaced.)
will be fed back to the singlechip, and then the singlechip
alarms the E11 Failure. 2) Detect the capacitor of C42, C43, C44 capacitor
22uF above drive chip U13 (IR2136S), and the
Methods of processing: voltage drop shall be 0.600V.
Detect U2 (Si8421 AB), U9 (C4TG8) and U7 pins. The E10 Failure 3) Detect whether D100, D101, D102 fast recovery
code is generally present. Replace the above components with diode is 0.500V, R34, R35, R36 are 10Ω. If the value
the replacement method. If the E10 Failure code is also present, is abnormal, replace it.
return to the factory for maintenance.
13. E17 head switch protection failure
Firstly, detect whether the handpiece protection
switch is in the correct position. If the handpiece
10. Failure analysis on overheating protection of E13 power protection switch is correct, press and hold the P key
module: to turn on, adjust the parameter to P-66, and adjust
IGBT heat-
radiating The electric control detects that the IGBT of the power device the parameter in P-66 from 1 to 0.
adhesive is too hot to lead to the failure of E13. 14、E20
Methods of processing: Service refer to E07
Check whether IGBT is in good contact with the heat
dissipation glue on the base, and then detect whether the IGBT
is short-circuited. If the IGBT is short-circuited, replace the
corresponding IGBT.
 Fundamentals of Electronic Service

Product Introduction

Section I Main Components

Electric Control Maintenance Guide of

POWERMAX A4 Motor

Product Introduction Operation

screen
Clamping wire
electromagnet
Electric
control box
Circuit Analysis Handpiece
operation button
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Failure Detection and Maintenance
A4

A4
Backstitch electromagnet

Lifting presser Trimming electromagnet

electromagnet
 Fundamentals of Electronic Service

1. Composition of motor Section II Introduction to Electric Control System of A4 Flat-Seam All-in-One Machine

Motor encoder
Motor stator Motor encoder Hood Product specifications are shown in the following table:
Motor rotor Product Model of POWERMAX
Grating sheet
AHE59-55 Power Supply Voltage AC220 ± 20% V
Company

Power Supply Frequency 50Hz/60Hz Maximum Output Power 550W

Related safety matters related to electric control:

• Please read the Product Manual and assorted Mechanical Manual of Sewing Machine before using
the product.
• This product must be installed or operated by trained professionals.
• Please keeps a circuit from the arc welding equipment as far as possible so as not to interfere with the
electromagnetic wave generated by the controller.
Grating sheet Circuit board of motor encoder
• Please do not use at room temperature above 45° or below 0.
• Do not use in any place where the humidity is below 30% or over 95% or in the place where there is
dew and acid mist.
• Turn off the power supply and unplug the power plug when installing the control box and other
components.
• In order to prevent an interference or leakage accident, please properly implement the grounding
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engineering, and the grounding wire of the power line must be connected with the earth in a secure
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manner.
• All components for maintenance must be provided or approved by the Company before use.
• Turn off the power supply and unplug the power plug before any maintenance service is performed. In
case of high-pressure hazard in the control box, it is necessary to turn off the power off for five minutes
before opening the control box.
2. Composition of electric control box

Definition on external electrical control interface and interface:

Baseplate circuit board of electric Shell
controller Note: When normal force is used but can’t be
inserted, check whether the plug is matched with
the socket, whether the direction of the insertion Interface
or the direction of the needle is correct! The of speed
grounding project of the system must be done, and controller
the qualified electrical engineering personnel shall
be required to carry out the construction. Before Lifting presser
the product is powered on and put into use, it is electromagnet
necessary to ensure that the grounding wire of the interface
grounding # system with the AC input of the power
outlet has been safely and reliably grounded is the Handpiece
yellow-green line. The grounding line should be electromagnet
reliably connected to the safety protection grounding interface
of grid so as to ensure safe use and prevent
abnormal conditions. Do not press or excessively
distort all power lines, signal lines and grounding
lines so as to ensure safe use!
 Fundamentals of Electronic Service

(Back)
Handpiece electromagnet

Lifting presser electromagnet Rectifier tube

300 V switch tube

Output signal 3 electromagnet output
Sensor Input Negative

5V 地
Pedal Interface Definition
Pedal analog signal

5V Digital Grounding Trimming electromagnet Voltage stabilization

Potentiometer input
IGBT module 7805
Sensor input positive

Needle-filling switch

Backstitch switch

Backstitch electromagnet

Pinch-stitch electromagnet

current sampling
resistance

Lifting presser function

interface

Section III Cognition to A4 Circuit Board

(Front)
Functional output
Common interface
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interface of speed
Mode controller
Safety capacitor Rectifier Bridge Functional Tube
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Inductance

Section IV Circuit Distribution of A4 Circuit Board

AC-to-DC circuit of main power supply: the input 220VAC is filtered and rectified to form 300V DC and
then filtered by large capacitor, and the stable 300V1: current is output after energy storage.
Switch power supply circuit: step down the stabilized 300V and then form 30V, 15V, 5V, HMI5V and 3.3V
220V AC
interface
voltage through the three-terminal tube to supply power to each circuit.
photocoupler And the drive circuit is used for amplifying and processing the drive signals of the DSP chip to form
Thermistor
each drive signal and controlling the conduction and the turning-off of each IGBT so as to control the
Electrolytic capacitor burning program rotation of the motor.
interface
The singlechip is the core of the whole section, the motor Hall signal, the stop pin signal, the speed
Encoder interface control signal, the setter signal and the current feedback signal are input into the singlechip for
processing, Subsequently, the singlechip outputs a corresponding drive signal to drive the motor
Driving chip 2136S 5 V conversion 3.3 v chip according to the acquired signal.
The function circuit is controlled on the control signal from the DSP chip to control the on-off of the
Motor interface
functional tube so as to control the action of the electromagnet #
Communication circuit: It is responsible for signal transmission of DSP chip and operation panel.

Transformer
Power Chip 3842B
 Fundamentals of Electronic Service

AC-to-DC circuit of main power supply Circuit Analysis

Section I Analysis for Power Supply Circuit
The schematic diagram of A4 electric control power supply is as follows:

J6 socket FUS1 D1 rectifier C1, C2 Large

Thermistor capacitor 300VDC
220V AC access fuse tube bridge

Signal circuit of motor drive and

current detecting circuit encoder
filter capacitor U10(78L15) U17(2136S)

All 3.3 V power

filter capacitor U27(7805) U26 (pin 2 output 3.3 V) supply chips and
Switched-
mode photocoupler inside
power
supply Panel, speed controller,
filter capacitor U24(7805) external circuit of optical
coupler

filter capacitor Electromagnet drive circuit

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Figure 1-A4

AC-to-DC circuit analysis of main power supply:

The main purpose of this power supply section is to rectify the 220V AC voltage and form a stable
300VDC voltage through the energy storage filtering of large capacitor. In order to improve the circuit
performance, overvoltage protection, over-current protection and anti-interference related components
are added in the circuit, referring to Figure 2-A4 for details:

Figure 2-A4

As shown in Figure 2-A4 and 220V, the AC voltage enters from J6 through fuse FUS1, common mode
interference suppression capacitor CY1, CY2, serial mode interference suppression capacitor CX1,
voltage dependent resistor VR2, and negative temperature coefficient thermistor L1, and then enters pin
Signal processing Communication circuit Functional circuit 2 and 3 of the rectifier bridge through common mode choke inductor coil L1.After rectifying the rectifier
circuit bridge, output from 1 and 4 pin and connect to two ends of the large capacitors CD1 and CD2, and the
Switching power supply stable 300VDC voltage is formed through capacitor filtering.
circuit
 Fundamentals of Electronic Service

Circuit analysis on switching power supply: As shown in Figure 3-A4, D5, R55, and C27 form a release circuit for releasing the electric energy
caused by the induced electromotive force generated during the cut-off of the Q20 field effect tube in the
The circuit functions to DC-DC voltage drop for 300 V DC voltage, generating the supply voltage
primary coil so that the switching power supply circuit element is prevented from being broken down.
required for each circuit, 15 V, MCU5V, 3.3 V (3.3 V from + 5V via U26 voltage conversion), 5 V HMI,
VDD (29 V). As shown in Figure 3-A4, the following section is a voltage feedback circuit composed of components
such as Z13, Z14 and U5 feedback photocoupler.The transformer secondarily generated VDD voltage
is connected with a feedback circuit , and the fed back voltage and the 2.5V reference voltage are
compared to generate an error signal; the signal is sent to pin 2 of U1 through the feedback circuit; the
U1 chip adjusts the pulse width (i.e. the duty ratio) according to the strength of the feedback signal;
The output of the stabilized pulse signal to Q20 is finally output to the pin 6 of U1 (UC3842BD) so as to
result in stable voltage output. The above is the basic working principle of this voltage feedback circuit.
Common damage elements for this circuit:
U1 power chip, U5 feedback light coupling, Z14TL431, Z13, Q20 switch tube, R27, R28, R29, R235,
C12, fast recovery diode, T1.

Section II Analysis on Signal Processing Circuit

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DSP (Digital Signal Processor) is a kind of
microprocessor for digital signal processing,
which is mainly applied to the real-time and
fast realization of various digital and analog
signals. The main function of the electronic
control DSP digital signal processor is
to receive signals recognizable by DSP
Figure 3-A4 (including operation panel command signal,
As shown in Figure 3-A4, the 300 V (+ UZK) output from the circuit board is reduced by the voltage encoder signal, speed controller Hall signal,
divider circuit composed of R90, R94, R93, R91 to supply the start voltage to the pin of U1 (UC3842BD) motor current detection signal, circuit error
power supply chip 7, and the PWM pulse width modulation signal with high frequency is output from signal, each sensor signal), Then, the DSP
the sixth pin after the start of the operation, This signal is connected to the first pin (grid electrode) of judges, analyzes, processes and outputs
the MOSFET Q20 switching tube through the R48 resistor, and when the PWM signal is high, the Q20 the corresponding control signals according
is turned on, and when the PWM signal is low, the Q20 is turned off, so that the on and off of the Q20 to the advance burning program, and each
can be controlled, An intermittent charge/ discharge operation with a frequency of 100 KHz is performed executing circuit completes the respective
on the primary line of the transformer by 300V, and because the other secondary coil and the primary operation when the control signals are
coil of the transformer are wound on the same magnetic core, an induced electromotive force (voltage) received.
is generated at each secondary line. The output voltage of each secondary line of the transformer is
respectively rectified, and the working voltage required by each circuit is formed by the filter circuit: 15V,
MCU5V, 3.3V (3.3 V is obtained by converting the MCU 5V through the U26 voltage), 5V HMI, VDD
Figure 4-A4
(29V).
 Fundamentals of Electronic Service

As shown in Figure 4-A4, the DSP chip model for electric control of A4 is TMS320LF28034PAGT, with Section III Analysis on Motor Drive Circuit and Current Detection Circuit
64 pin totally, pin 16, 29, 57 and 61 are connected to + 3.3 V supply voltage, pin 6, 17, 28, 41, 42, 58,
60 are connected with grounding (GND), and pin 12 is the signal input pin of V _ PEDAA4I control.4, 13, The main function of the drive section for motor is to receive the 6-circuit drive control signal output by
20, 62, 63, and 64 are respectively HALL _ A _ DSP, HALL _ B _ DSP, HALL _ C _ DSP, ENC _ A-DSP, the DSP chip to process, amplify the drive control signal and finally drive the six IGBIs in correct order.
ENC _ B _ DSP ‘UP-DSPI Vocoder Signal Input Pin. The HALL _ A _ DSP, HALL _ B _ DSP and HALL
_ C _ DSP are three- phase signal input pins. The ENC _ A _ DSP and ENC _ B _ DSP are motor angle
signal input pins, where UP _ DSP is the upper stop pin signal input, and the input pin. The 22-pin is the
on-switch signal input pin.15. The 18-pin is the current detection signal detection input pin.19 and 21 pin
are respectively V _ DB and V _ AC voltage detection signal input pin. The pin 11 is the input pin of the
DIN1 _ DSP head backstitch button signal. The pin 22 are the input pin of the DIN2 _ DSP handpiece
turning-over switch signal. The pin 44 are the DIN _ MJX _ DSP complement button signal input pin.
The pin 32 is the input pin of the failure signal of the PB _ FLT _ DSP motor drive circuit.
The pin are PWMEN _ DSP motors-drive the k-signal output pins.50, 51, 53, 54, 55, 56 are PWMC _
DOWN _ DSP, PWMC _ UP _ DSP, PWMB _ DOWN _ DSP, PWMB _ UP _ DSP, PWMA _ DOWN _
DSP, PWMA _ UP _ DSP six-circuit PWM (pulse width modulation) motor drive signal output pin, PWM
signal firstly passes through coupling resistance, passes to drive chip U17 (IR2136S) for processing and
then is connected to one pin of each IGBT (explained more later) after coupling resistance. The pins
35, 10, 52, and 49 are the presser pins, the clamp wire, the backstitch and the presser lifting function
signals respectively, and the action of the electromagnet is controlled. The pins 23, 37, and 38 are D/ R
_ CTRL, SCITXD, and SCIRXD three-circuit communication signal pins. Pin 2 and pin 3 are SDA, SCL
two and EEPROM chip U25 communication signal pins respectively.
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Figure 5-A4

As shown in Figure 5-A4, the motor drive circuit section is composed of a drive chip U17 (2136), six
IGBTs (GF20H60DF) as well as a peripheral resistor, a capacitor, a fast recovery diode and the like.
 Fundamentals of Electronic Service

The main function of the drive chip U17 is to receive the control signal from singlechip to convert to a Section V Functional Circuit Analysis
signal which can drive the conduction and the shutdown of the IGBT, and then output the signal to the
IGBT. The first 15V supply input pin of the U17 chip is the GND and COM _ GND terminals, 28, 26, The function of functional circuit is to receive the control signal from the DSP chip, and through the
24, 22, and 20, 18, respectively, of GND and COM _ GND, and the pins are three ALONE I STAND resistor, the photocoupler isolation circuit transfers the signal to the control field effect tube of field effect
bootstrap boost power input pins. The six-circuit PWM (pulse width adjustment) signal output by DSP tube grid to control the conduction and the turn-off of the field effect tube to control the operation of the
chip is PWMA _ UP _ DSP, PWMB _ UP _ DSP, PWMC _ UP _ DSP, PWMA _ DOWN _ DSP, PWMB electromagnet.
_ DOWN _ DSP, PWMC _ DOWN _ DSP six-circuit drive signal respectively input from the 2nd, 3rd, high-speed electromagnet
4th, 5th, 6th, and 7th pin, and the processed signals are GA _ UP, GB _ UP, GC _ UP, respectively. GA_
DN, GB_DN, GC_DN. This six-circuit signal controls Q17, Q19, Q23, Q18, Q21 and Q24 to turn on and
off in a certain order. Because the stator coil of the motor is connected with the circuit through the J4
interface, the stator coil of each group of motors is also energized in a certain order so that the rotating
Backstitch electromagnet
magnetic field with the center of the motor as the center of the motor is generated on the stator coil, This
rotating magnetic field drives the motor rotor equipped with permanent magnets to rotate together. The
six-circuit PWM signal will be alarmed to the E-01 or 08 error code any circuit during transmission. The
eighth pin of the U17 drive chip is provided with the error signal output pin of the chip; when the chip
Discharge circuit
detects that the drive circuit current is too large. No. 8 pin will output the error signal of the low level;
after the signal passes through the filter circuit, the signal is transmitted to the DSP; The DSP displays
the error code after receiving the signal and the panel communication.
presser foot lifting
As shown in Figure 5-A4, R150, TVS2, R151, TVS3, R4, R40, TVS1, U20 (operational amplifier chip) electromagnet
and peripheral resistor constitute the current detection circuit. The pin 8 power supply of U20 + 3.3 V,
4-pin GND terminal, There are two discharge circuits inside the chip, pin 2 and 3 are the input pins of
the first operational amplifier, and one is the output pin. Pin 5, 6 are the input pin of another operational
amplifier, and the pin 7 is the output pin.The two operational amplifiers respectively detect two phases
of the U and V, detect the current sampling signal formed by the sampling resistor in R1 50 and R151, Clamp-wire electromagnet

and transfer the amplified signal after the operational amplifier to the DSP JS so as to realize the over-
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current protection during the operation of the motor.The current detection circuit has a problem reporting
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E-07 or E-01 error codes.

Figure 7-A4
Section IV. Signal Circuit Analysis on Motor Encoder
As shown in Figure 7-A4, when sewing is finished, the DSP outputs the DQS signal through the wire,
R63 resistor, U7 optical coupler and R74 resistor to the grid of the Q6 field effect transistor (MOSFET).
The motor encoder signal circuit has the function of receiving an angle pulse signal and a phase pulse The drive voltage after the inversion amplification is obtained at the gate of Q6 so that Q6 can meet the
signal generated by the motor encoder circuit board and then reliably transmitting the pulse signal to the conduction condition. At this time, the current flows out through the coil of the electromagnet through
high-speed counting input pin corresponding to the DSP through the pull-up resistor and the filter circuit. the first pin of the J12 interface, then flows through pin 8 of 2 interface, and then the current flows from
the 2 pin (drain) of Q6, and flows out from the third pin to the DGND ground wire. Because the coil of
the electromagnet generates a magnetic field through the current, the iron core of the electromagnet
attracts the iron core of the electromagnet, at the same time, the linkage is driven by the connecting rod
to engage with the static knife to form an anti-slide action. The above is the process of the formation of
the above-mentioned action. The implementation of other functions is similar to that of other functions.
In order to eliminate the induced electromotive force which can damage the component of the circuit, a
release circuit is added into the functional circuit, as shown in Figure 7-A4, the coil of the electromagnet
is taken as an example, and the D13 is connected at two ends of the electromagnet coil to play a
Figure 6-A4
role of releasing the high-voltage anti-phase induced electromotive force. Since the lifting presser
As shown in Figure 6-A4, the J2 interface is a motor encoder and an electrically controlled circuit board electromagnet and the backstitch electromagnet coil can generate larger induced electromotive force,
connection port, and + 3.3V power supply of the circuit board is supplied to the encoder circuit board the controllable release circuit is specially set for them, and the related components are shown in
through GND terminal of pin 8 and pin 5 at the interface. When the motor is driven, the grating moves Figure 7-A4: the working principle is slightly more complicated than the release circuit of the reversible
in the encoder photoelectric sensor, and the sensor outputs three correct encoder pulse signals: ENC _ functional circuit, The main purpose is to release and consume an inverted induced electromotive force.
A, ENC _ B, HALL _ A, which are passed to the DSP chip through the encoder transmission circuit as
Components that are frequently damaged in circuits are field-effect tubes and optocouplers.
shown in the figure. Encoder damage or related circuit damage may cause E-13, E-08, and the failure
rate of components of this circuit is very low.
 Fundamentals of Electronic Service

Failure Detection and Maintenance Section II Static Test of A4 Circuit Board

Section I Visual Detection of A4 Circuit Board

1. Measurement on AC circuit of power supply
As shown in the figure, adjust the multimeter to
the buzzer, respectively put the ACL pin of the
power plug and pin 2 of the rectifier bridge. If the
buzzer sounds, it is normal;
Then put two probes into the pin 3 of the pin of
the power plug and pin 3 of the rectifier bridge
and the value of the left and right of the display 13
is normal.
If the above values are not normal, check that the
circuit is complete, whether the fuse is normal,
and whether the common mode inductor pin is off,
the resistance value of the thermistor is about 13
ohms, and if not, replace it.
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Figure 8-A4
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2. Measurement of Rectifier Bridge
The value of the multimeter diode range is as follows

Figure 9-A4
Black probe Red probe Normal value
1. Check whether the surfaces of FUS1 fuse, Rectifier Bridge and thermistor on the high-voltage circuit
section of the main power supply are burnt out or blast off, and check whether the large capacitor blasts 1. 2. 0.5V
off and leaks the liquid as well as heaves on the top. 1. 3. 0.5V
2. Check whether the components of the switching power supply circuit are obviously damaged.
2. 4 0.5V
3. Check whether the IGBT and the surrounding resistor in the motor drive and current detection circuit
are obviously burned and blast off. 3. 4 0.5V
4. Check whether the contact pins of the socket are broken off and bent.
If any one of these values
Above contents are the main scopes of visual inspection. If damage components are found, please is about 0.002, show that
replace it. the inside of the rectifier
Note: The bad elements found during visual detection may be the “a tip of iceberg” of the actual bridge has been short-
damaged components. Therefore, after the components with obvious damage are replaced, the other circuited, and the rectifier
relevant components need to be statically tested by a multimeter (explained in detail later), and other bridge needs to be
damages are eliminated on the circuit board. After the components are short-circuited, the test can be replaced.
conducted to prevent the electric control system from being damaged again.
 Fundamentals of Electronic Service

3. Measurement of IGBT Section III Circuit Board Maintenance

Maintenance of Err-01 (hardware overcurrent
failure)
1. Check visually whether there are obvious
damage elements on the circuit board; if
any, replace the bad original firstly, and then
The value of the multimeter diode range is as measure whether the IGBT Q17, Q18, Q19,
follows Q21, Q23, Q24, and the surrounding resistance
are damaged by using the diode gear; if there is
any damaged IGBT, replace it, and then conduct
Blackprobe Red probe Normal value the test.
2. 3. 0.450V If it is not found that the IGBT is damaged or
the bad IGBT is still reported correctly after
1. 3. 0.780V replacing the IGBT, the next maintenance step
Figure 9-A4 is entered.(The troubleshooting step is carried
out after the motor fails)

Figure 11-A4
As shown in the figure, adjust the multimeter to the buzzer, respectively put the ACL pin of the power
plug and pin 2 of the rectifier bridge. If the buzzer sounds, it is normal;
Then put the two probes into the three pin of the pin of the power plug and pin 3 of the rectifier bridge,
and the value of the left and right of the display 13 is normal.
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If the above values are not normal, check that the circuit is complete, whether the fuse is normal and
whether the common mode inductor pin is off, the resistance value of the thermistor is about 13 ohms,
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and if not, replace it.

4. Measurement of functional pipe

Detection of functional tubes:

Use a multimeter diode gear:
The black probe is connected with one pin, the red probe is Figure 12-A4
connected with pin 3, and the voltage drop of about 1.6 V
can be measured;
The black probe is connected with pin 2, the red probe is
connected with pin 3, and the voltage drop of about 0.5 V
can be measured;
Detection of presser discharge tube:
Adopt a multimeter diode gear:
Voltage values between Voltage values between pin
The red probe is connected with pin 2, and the black probe pin 2 and pin 3 of U10 1 and pin 2 of U10 or C40
measures pin 1 and 3 respectively, and the voltage drop of
about 1.2 V can be measured; 2. When the circuit board is energized, the multimeter DC voltage is used to detect whether the input
voltage (pin 2, 3) of U10 (78L15) has 22V. If yes, check whether the output voltage (pin 2, 1 or both
The above measurement is normal. If the measured value
ends of C40) of 78 L15 has 15 V. If not, replace U10 (78 L15).And then carry out the test, and if the
is about 0.002V, check whether the corresponding diode
failure is reported correctly, the next maintenance step is carried out.
beside the functional pipe is normal. If it is abnormal, replace
it; If it is normal, replace the corresponding functional pipe.
 Fundamentals of Electronic Service

3. Measure whether the resistance of TVS3

R151, TVS2, TVS1, and R150 is damaged
by using resistance gear. Note that TVS1,
TVS2 and TVS3 need to be removed and Voltage values between Voltage values between
tested. If the resistance value is less than pin 2 and pin 3 of U10 pin 1 and pin 2 of U10
1 MΩ, replace (no leakage pipe on the new or on both ends of C40
version circuit board is omitted)
4. Replace U17
3. Measure whether the resistance of TVS3
R151, TVS2, TVS1, R150, R124, R125,
R126, R127, R129, and R130 is damaged
Figure 13-A4 by using resistance gear. Note that TVS1,
TVS2 and TVS3 need to be removed and
tested. If the resistance value is less than
1 MΩ, replace (If there isn’t TVS pipe on
the new version of circuit board, this item is
Section III. Circuit Board Maintenance of Alarm Failure Code omitted.)
4. Replace U17

Figure 16-A4
Maintenance of Err-08 (Rotor Stalling Failure)
Maintenance of Err-10 (Communication Failure)
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3. Measure whether the resistance of TVS3 R151,
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TVS2, TVS1, and R150 is damaged by using
resistance gear. Note that TVS1, TVS2 and TVS3
need to be removed and tested. If the resistance
value is less than 1 MΩ, replace (If there isn’t TVS
pipe on the new version of circuit board, this item
is omitted.)
4. Replace U17

Figure 14-A4
2. When the circuit board is energized, the
multimeter DC voltage is used to detect whether
the input voltage (pin 2, 3) of U10 (78L15) is 22V.
If yes, check whether the output voltage (pin 2, 1
or both ends C40) of 78 L15 is 15V. If not, replace Figure 17-A4
U10 (78 L15), and then perform the test, and the 1. Visually check whether there is obvious damage to the control board. If it is necessary to replace
error alarm still exists, enter the next maintenance the damaged element firstly, and then use the voltage shift to measure if there is a 5V voltage output
step. between the pin 2 and the pin 3 of U24. If not, replace the U24, and then test, if the error alarm still
occurs, enter the next maintenance step.
2. Measure whether the control board D16 (in new version, this diode is not easy to be damaged) with
Figure 15-A4 the diode gear is damaged. If the D16 is normal or damaged D16 is replaced, if the error alarm still
occurs, enter the next step for maintenance.
 Fundamentals of Electronic Service

Old Version No trimming, no backstitch, no lifting presser operation failure maintenance

Figure 20-A4
1. Check whether the functional output interface of the front of the maintenance circuit board is in
contact with the electromagnet interface. If the contact pin falls off or the contact is not good, contact
Figure 18-A4
with the pin. In addition, it is necessary to check whether the electromagnet is damaged. If the
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POWER MAX
electromagnet is damaged, replace the electromagnet first. If there is no problem, the problem is on the
electric control main circuit board.
A4

3. Measure that the resistance value of R1 (there isn’t such resistance in the new version), R57, and

A4
R82 is normal. After the resistance is replaced, if the error alarm still occurs, replace U3, U11 and U12. 2. Visually inspect the power board for obvious damage to components.
3. Measure Q6, Q5, Q2, Q3 with diode gear.
4. Replace the corresponding optical coupler U7, U23, U29, U7.
New Version There is no display failure maintenance on the panel caused by the circuit board

1. If it is determined that there is not power failure

caused by the circuit board, it is possible to
firstly detect whether the AC access of the power
supply has a problem according to the static
detection method described in 3.7. Replace the
bad element if necessary. If there is no or replace
the broken element, the following steps shall be
carried out for maintenance.

Figure 19-A4 Figure 21-A4

 Figure 22-A4
2. Check whether the components of the power supply section in Figure 18-A4 and 18-A4 are damage,
and replace them if necessary. If there is no obvious damage, replace the power supply chips U1, U5,
Z14, Z13 and U24 in sequence. If the problem still exists, please return to the factory for maintenance.
POWER MAX

Maintenance for speed controller failure

A4

This kind of failure is normally caused by a

speed controller when the rotation speed
of treaded speed controller motor speed
doesn’t reach the highest speed or there is not
reaction.
The method comprises the following steps:
firstly, unscrew the metal cover plate on the
speed controller, then unscrew the fixing screws
of the Hall circuit board, adjust the mounting
Fixing position of the circuit board, fix the circuit board
screw slightly, and then insert the speed controller
to turn on the power supply for testing; Press
Speed
the + key to enter the monitoring
control parameter set at the interface to be set, adjust
Hall up to the 025 parameter, observe the value of
the parameter (the normal value is 405-430
Hall when the speed controller is not treaded on the
speed controller), if the deviation of the value
JACK SEWING MACHINE CO., LTD.
circuit
board displayed behind the 025 parameter is too Editor-in-chief in Technical Support Department
large, the position of the circuit board needs to
Editors in Charge: Zhao Shangwei; Zhu Haixin;
be adjusted until the panel displays a normal
Wang Rong; Pan Yunhui; Cai Huxin
pedal voltage sampling value.If the correct
pedal sampling voltage cannot be reached by Reviewed by: Du Ruiminɡ
adjusting the position of the Hall circuit board, Checked by: Ouyang Liangjing
replace the speed control Hall.
Figure 23-A4 First Edition in July, 2018