Microtest 6235 User manual

6235+7721+7605
S/W Ver
Firmware Ver
Date
1.0
APR 2020
User Manual
3 in 1 Transformer Comprehensive Tester

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+Safety Instructions
Please pay special attention to the safety instruction items described below when
operating and maintaining this machine. If these items and other warnings mentioned
inside this manual are not followed, it will be in serious violation of the safety
standards for the design, manufacture and operation of this instrument.
+Machine Maintenance Precautions
Operators must not remove the protective case of the instrument; only qualified
maintenance personnel are allowed to perform tasks including the replacing of
components inside the machine and internal adjustments etc. Do not change any
components when the power cable is already plugged into the socket. Under certain
special circumstances, there might still be dangerous voltage remaining even if the
power plug has already been unplugged from the power outlet. In order to avoid
causing injuries, disconnect the power and take the necessary discharge measures
before touching the inside of the instrument.
+Instrument Grounding
In order to prevent the danger of electric shock, please ground the power cable of the
instrument.
+Do not perform tasks such as maintenance or internal adjustments
alone
Do not perform tasks such as maintenance or internal adjustments alone.
+Do not change the components or modify the functions and
structures of the machine on your own
Without authorization from our company, do not install replacement components or
perform any modifications to this machine on your own in order to avoid increasing
the danger of the machine or causing damage to the machine. When the instrument
malfunctions, please send the instrument back to Microtest Corporation to have
professionals repair it for you in order to ensure its safety.
+Product Warranty Period
MICROTEST provides one-year warranty for this product starting from its shipping
date, but the warranty for some of the special components subject to the product
specifications and characteristics are not limited to this. Microtest Corporation will be
responsible for repairing or replacing products proven to be flawed (MICROTEST
will test whether the product was flawed or not) during the warranty period. Microtest
Corporation guarantees that the software and hardware used with the instrument can
execute their program instructions once they are properly installed on the instrument.
MICROTEST does not guarantee that no interruptions or errors will occur while
operating the software and hardware of the instrument.
+Product Warranty Restrictions
The warranty described above is not applicable to incorrect or improper use of this
product by the customer, modifications, maintenance or changing components of this
machine without authorization, or misuse of this product. In addition, warranty is not
provided for the storing and maintaining of this product in environments not within
the conditions specified.
Microtest Corporation all rights reserved.
Declaration: Microtest Corporation reserves the right to modify the contents of
this manual without further notice!

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Chapter 1. Precautions.............................................................................................3
1.1 Electrification and Electric Shock .............................................................3
1.2 Static electricity .........................................................................................3
1.3 Ground .......................................................................................................3
1.4 Power .........................................................................................................3
1.5 Connect the testing cable to the high voltage output terminal...................4
1.6 Warm up.....................................................................................................4
1.7 External control host ..................................................................................4
1.8 Machine malfunction .................................................................................4
1.9 Test End......................................................................................................4
1.10 Placement and Storage...............................................................................4
1.11 Emergency Handling..................................................................................4
Chapter 2. Start ........................................................................................................5
2.1 Setting process ...........................................................................................5
2.2 How to set the hardware architecture.........................................................6
2.3 Precautions before booting up .................................................................12
Chapter 3. Operation..............................................................................................12
3.1 6235 System Settings...............................................................................12
3.2 7605 System Settings...............................................................................14
3.3 6235 test item creation .............................................................................14
3.3.1 Entering the main menu of test items .................................................15
3.3.2 WINDING/FIXTURE editing description...................................16
3.3.3 SEQUENCE / BIN editing description........................................17
3.3.4 L/Lk/Q/Rac/Z/D/Ø/X/Y test item editing description .................22
3.3.5 Rdc test item edit description.......................................................25
3.3.6 Turn Ratio test item editing description.......................................26
3.3.7 C test item editing ........................................................................27
3.3.8 BALANCE test item editing description .....................................28
3.3.9 PIN SHORT test item editing description....................................29
3.3.10 CORRECTION fixture correction ...............................................30
3.3.11 DEVIATION error compensation setting description..................31
3.4 7721 and 7605 test item setting ...............................................................32
3.4.1 Layer short-circuit and high voltage tester setting.......................32
3.5 Test program data and statistical data storage management ....................37

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Chapter 1. Precautions
This tester outputs voltage as high as 6000V DC for external testing; accidents will
happen if this tester is used incorrectly or improperly. Therefore, in consideration of
your own safety, please read the precautions described in this chapter carefully and
memorize them in order to prevent accidents from occurring.
1.1 Electrification and Electric Shock
In order to prevent electric shock, the wearing of insulating plastic gloves is
recommended before using this tester to perform testing related tasks.
1.2 Static electricity
This instrument uses components that are very sensitive to static
◼The desktop of the worktable must be grounded conductive
material.
◼The contact of the soldering iron and tools must be connected to
grounded conductors when not in use.
◼Maintenance personnel must wear static bracelets with leakage
resistance less than 1MΩ
◼Components or the assembling substrate must be placed in
protective cases with static protection.
1.3 Ground
This is a safety ground terminal on the rear panel case of this tester. Please
ground this terminal properly in order to prevent electric shock accidents from
occurring when touching the case.
1.4 Power
Power cables that comply with the local country specifications must be used, and
connectors applicable to IEC320 connectors must be used for the connection of
this instrument. Users must ensure that the ground cable is properly grounded. If
the power plug includes a fuse, 3 ampere fuses that meet the safety regulations
must be used; confirm that it’s AC power before use and adjust the 115V/230V
power selection switch on the rear panel to let the machine match local power
voltages.

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1.5 Connect the testing cable to the high voltage
output terminal
While the tester is powered off, insert the high voltage testing cables to the high
voltage output terminals on the tester respectively, and confirm that the exteriors
of the testing cables are not ruptured or shed.
1.6 Warm up
The tester can operate normally once the power is turned on; however, in order to
achieve the accuracy within specification, please turn on the machine in advance
and let it warm up for 30 minutes or more before use.
1.7 External control host
This tester can perform external control; make sure the operator is not touching
the high voltage output terminal and DUT when performing such controls in
order to avoid causing danger.
1.8 Machine malfunction
If it is discovered that this tester has malfunctioned, for example: the voltage
displayed on the voltmeter differs greatly from the voltage set, or there is no high
voltage output but the high voltage output warning indicator remains on etc.,
cease use immediately and contact our company or your dealer to perform
repairs.
1.9 Test End
Turn off the power switch when the tester is not being used.
1.10 Placement and Storage
The operating temperature and humidity range of this machine is 5oC - 40oC,
80% RH; the actions might be abnormal if this range is exceeded. The storage
temperature and humidity range of this machine is -20oC - 70oC, 80% RH. In
order to achieve accurate testing and for safety considerations, do not place this
machine in environments with direct sunlight exposure, high temperature, high
humidity, frequent vibrations or excessive dust.
1.11 Emergency Handling
When there is an electric shock or if the DUT or machine catches on fire, please
switch off the power and unplug the power cable.

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Chapter 2. Start
2.1 Setting process
Start
Machine Installation and
Wiring
7721 tester and fixture
connection
6235 corresponding settings
and test item creation
6235 tester and fixture
connection
7721 test item creation
Using fixtures to perform
component characteristics
test
Using fixtures to perform
high voltage and interlayer
short-circuit tests
End

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2.2 How to set the hardware architecture
⚫Main Architecture of the Three-in-one Transformer
Comprehensive Tester
The three-in-one transformer comprehensive tester mainly consists of the three
instruments 6235, 7721 and 7605, and the F7721 high/low voltage test fixture;
the following will describe how to connect the accessories in order.
Figure 2-2-1 Full front view of the 6235, 7721 and 7605 tester

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6235, 7721 and 7605 front wiring description: (Please refer to Figure 2-2-1)
1. This is the four-wire measuring connector of 6235; please connect the
four-wire measuring fixture connector at the end of the F7721 fixture
Test Line here.
2. 7721 high voltage output port; use the dedicated high voltage cable
from our company and connect it to the CH01~CH20 high voltage
ports of the F7721 fixture and the Core port on the fixture box
respectively using one-to-one connection. (The CH01~CH20 high
voltage ports on the F7721 fixture corresponds to the transformer slot
holes on the fixture)
⚫Full rear view of the Three-in-one Transformer
Comprehensive Tester
Figure 2-2-2 Full rear view of the 6235, 7721 and 7605 tester

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6235, 7721 and 7605 rear wiring description: (Please refer to Figure 2-2-2)
1. Handle: 6235 control cable port; please use the included RJ-45 cable
from our company and connect this port to the Remote Control port
on the F7721 fixture.
2. RS-232: 7721 communication port; please connect the RS-232 cable
included from our company to this port, and connect the other end to
the RS-232 communication port of 7605.
3. Remote: 7721 control cable port; please connect the dedicated cable
included from our company from this port to the Remote port on the
F7721 fixture.
4. H.V.: 7721 high voltage input port and 7605 high voltage output port;
please use the dedicated high voltage cable to connect these two so
that high voltage can be output from CH1~CH20 on the front panel of
7721 during the withstand voltage test and insulation test.
5. RETURN: 7721 high voltage return port and 7605 high voltage
return output port; please use the dedicated high voltage cable to
connect these two so that high voltage can be returned from
CH1~CH20 on the front panel of 7721 during the withstand voltage
test and insulation test.
6. INTER LOCK: High voltage output safety socket; dedicated INTER
LOCK connector must be inserted in order for 7605 to output high
voltage successfully.
7. RS-232: 7605 communication port; please connect the RS-232 cable
included from our company to this port, and connect the other end to
the RS-232 communication port of 7721.

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Full view of the Dedicated Fixture Box for the Three-in-one
Transformer Comprehensive Tester
⚫F7721: Transformer fixture.
Figure 2-2-3 Top view of the F7721 transformer test fixture

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Figure 2-2-4 Full side view of the F7721 transformer test fixture
F7721 wiring description: (Please refer to Figure 2-2-3 and Figure 2-2-4)
1. Transformer test slot; the slot pins start from the bottom-left, which is
PIN 1, and then slowly increase towards the right to PIN10. The
top-right to the top-left is PIN11~PIN20.
2. PASS and FAIL: Good product (PASS) and defective product (FAIL)
test indicators.
3. START and STOP: Start test (START) and stop test (STOP) buttons.
4. Test Line: This is where the four-wire measuring fixture connector of
the F7721 fixture is connected; please connect this connector to the
four-wire measuring port of 6235.
5. Foot Switch: Foot switch connector. (This can only be used by
purchasing the dedicated foot switch from our company)
6. Remote Control: 6235 control cable port; please use the included
RJ-45 cable from our company and connect this port to the Handler
port on the rear panel of 6235.
7. Core: High voltage input port that supplies high voltage to the core
probe; use the dedicated high voltage cable to connect this port with
the CORE port on 7721.
8. Remote: 7721 control cable port; please connect the dedicated cable
included from our company from this port to the Remote port on the
rear panel of 7721.

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9. DC24V: Please connect the dedicated adapter connector included
from our company here.

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2.3 Precautions before booting up
Before operating the three-in-one transformer comprehensive tester, you must
confirm that the voltage range currently used for the machine has sufficient and
stable AC voltage to supply every one of the devices of the automatic testing
system.
Chapter 3. Operation
3.1 6235 System Settings
Press the Menu control key and the main menu will be displayed on the screen.
Press System to enter system settings; the up and down keys can be used to select
the item to change, as shown in Figure 3-1-1.
Figure 3-1-1
1. Lock edit key: Function key On/Off setting; set password allows
setting the password for the keyboard lock.
2. Inverse LCD: LCD backlight setting; select Yes to highlight the screen.
3. Beep: Test completed prompt setting; it can be selected using the Prog
key.
a. Pass: Prompt when test was successful.
b. Fail: Prompt when test has failed.
c. All: Prompt no matter what the test result was.
d. OFF: Disables the prompt.
4. Trigger mode: Test mode setting.
a. Single: Single test.
b. Repeat: Continuous test.
c. Auto: Automatic test.

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5. Trigger delay: Trigger delay time setting.
6. Display test data: Test result display setting.
a. All Steps: Display all test data.
b. Fail Steps: Only display test failed data.
7. Display font: Display font size setting.
a. Small: Set small font size.
b. Large: Set large font size.
8. Print test data: Print test data; allows selecting whether to print the test
results, or print via key output.
a. No: Do not print.
b. Yes: Execute printing.
c. By Key: Print via key output.
9. Break test: Whether to stop testing if there was a Fail during the test.
Options include On 1 NG, On 3 NG and On 5 NG, which will stop
testing when there is 1, 3 and 5 Fails respectively during testing.
Selecting No will not stop testing.
10. Fail lock: When this function is enabled, if the test result is FAIL, the
fixture will not detach automatically; the STOP button needs to be
pressed to detach the fixture. This reminds the operator that the DUT is
defective.
11. Upload test data: Transmit the test result to the computer through
RS-232; RS-232 must be set.

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12. Set RS-232: Data transmission setting of RS-232 is as shown in Figure
3-1-2.
a. Tester ID number: Set tester number.
b. Baud rate: Baud rate setting.
c. Character length: Data length.
d. Stop bits: Stop bit.
e. Parity: No parity check.
f. Terminator: End character.
Figure 3-1-2
3.2 7605 System Settings
7605 test items do not need to be edited in the 7721 three-in-one system; all test items
are edited from 7721 and then sent to 7605 through RS-232. When operating the
machine individually, please refer to the 7605 manual.
3.3 6235 test item creation
After setting the system settings of each machine, you can start editing all test items to
test; the following is the introduction on how to set each test item.

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3.3.1 Entering the main menu of test items
First press the Set key on 7721, and then select comprehensive test to enter the
comprehensive test programming
Next, press the Set key on the front panel of 6235, and the screen will display the
function setting menu, as shown in Figure 3-2-2.
Figure 3-2-2

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3.3.2 WINDING/FIXTURE editing description
WINDING/FIXTURE: Sets the corresponding positions of the transformer pins and
fixtures, as shown in Figure 3-3-2-1.
Figure 3-2-2-1
Transformer Fixture / Winding Setting Description:
1. Transformer Fixture Setting: Sets the corresponding positions of the
transformer pins and fixtures.
TF Pin: Transformer pin; does not need to be set.
Fixture Channel: The transformer is inserted at the fixture end; use the number
keys to set it. If the DUT pin has less than 20 PINs, the Clear option can be used
to clear it as an empty pin.
2. Mapping: Automatically sets the corresponding pins; simply enter the two
parameters below and then press the ENTER key.
Transformer total pins: Enter the total number of transformer pins.
Fixture start channel: Enter the position where pin 1 of the transformer is
inserted on the fixture.
3. Clear: Clear individual settings.
4. Clear all: Clears all fixture pin settings that corresponded to the previous
transformer.
5. EXIT: Exits and returns to the function setting menu.
6. WINDING: Transformer coil setting; after selecting, it will enter the
Transformer Winding Setting screen as shown in Figure 3-2-2-2.
Wind: Transformer coil group name (N1~N20); does not need to be set.
Pin+: Positive pin of the transformer coil; set using the number keys.
Pin-: Negative pin of the transformer coil; set using the number keys.
Swap: Swap Pin+ and Pin- pins.

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Figure 3-2-2-2
3.3.3 SEQUENCE / BIN editing description
Teat Sequence Setting: Sets the test order and whether to test that test item, as shown
in Figure 3-3-3-1.
Figure 3-3-3-1
Teat Sequence Setting Description:
1. : Moves the test item highlighted by the cursor one item up.
2. : Moves the test item highlighted by the cursor one item down.
3. : Whether to test this test item.
4. RESET: Resets all settings to their default values.
5. SET BIN: Enters the component classification determination function setting.
6. EXIT: Exits and returns to the function setting menu.

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BIN Sort Setting: Component classification determination function setting; select
SET BIN to enter the BIN Sort Setting screen, as shown in Figure 3-3-3-1 below.
There are four classification settings: Equal, Sequential, Tolerance and Random. The
quality of the components is determined based on the conditions you set.
Figure 3-3-3-1
BIN Sort Setting Description:
1. BIN function: Component classification test item setting; there are five test
items available for selection, which are Ls, Lk, Q, Rs and Rdc. If you do not
want to use any component classification functions, select OFF to disable this
function.
2. BIN number: Component classification level setting; the greater the value, the
more classifications there can be. The maximum number of classifications varies
according to the different settings (classification methods); Equal can have a
maximum of 32 classification levels and the remaining Sequential, Tolerance and
Random can only have a maximum of 15 classification levels.
3. BIN method: Classification method setting; there are four classification methods
available for selection: Equal, Sequential, Tolerance and Random.

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⚫Equal: Equal distribution of levels. As shown in Figure 3-3-3-2 below, four
classification levels are used for explanation; users only need to set the
maximum and minimum limits (BIN 1 and BIN 4 Limit), and the system will
automatically distribute the levels BIN 1 - BIN 4 equally based on your
settings.
Figure 3-3-3-2
⚫Sequential: Manually set levels in continuous sequence. As shown in Figure
3-3-3-3 below, four classification levels are used for explanation; not only do
users need to set the maximum and minimum limits (BIN 1 and BIN 4 Limit),
they also need to click Prog to enter and manually set levels BIN 1 - BIN 4 for
each segment, as shown in Figure 3-3-3-4.
Figure 3-3-3-3
Figure 3-3-3-4