(for internal use only)

Manual for Service Training

Beijing Sanding Optical & Electronic Instrument Co. Ltd.

1
 CONTENTS

1. ANGLE MEASUREMENT PART……………………………………………………1

1.1 Adjustments of Analogs (Photo-electric convertor)……………………………..1
1.2 Test Points on Main Board……………………………………………………………4
1.3 Adjustment of Zero-point Voltage……………………………………………….5
1.4 Adjustment of CCD sensor (Horizontal and Vertical)……………………….6
1.5 Solutions to Errors………………………………………………………………….10
2. DISPLAY & BOOTING-UP…………………………………………………...12
2.1 Booting Up Problems………………………………………………………………12
2.2 Repairing Display Board………………………………………………………….12
2.3 Volume is too low or no voice from buzzer…………………………………….12
2.4 Problems in Communication Port……………………………………………….12
3. EDM PART……………………………………………………………………….13
3.1 Entering the Test Mode……………………………………………………………..13
3.2 Adjustment of High Voltage…………................................................................14
3.3 Circuit Boards of the EDM…………………………………………………………..16
3.3.1 Emitting board…………………………………………………………………16
3.3.2 Intermediate Frequency Board…………………………………………………..17
3.3.3 Optical Coupler…………………………………………………………………….19
3.4 Beams Alignment ……………………………………………………………………20
3.5 Slip Ring……………………………………………………………………………….22
3.6 Error 31…………………………………………………………………………………23
3.7 EDM Faults Description…………………………………………………………….26
4. CALIBRATIONS..................................................................................................28
4.1 2C………………………………………………………………………………..28
4.2 High-low Difference………………..…………………………………………………29
4.3 Adjustment of Compensator…………….………………………………………….30
4.4 I Angle…………………………………………………………………………………34
4.5 Plate
Vial………………………………………………………………………………..35
4.6 Circular Vial……………………………………………………………………………35
4.7 Plumb Line……………………………………………………………………………36

2
4.8 Coarse Collimator…………………………………………………………………..36
4.9 Optical Plummet…………………………………………………………………….37
5. AXIS BLOCKING………………………………………………………………38
6. SOFTWARE DOWNLOADING………………………………………………39
7. TOOLS & CHEMICALS………………………………………………….....40

3
1. ANGLE MEASUREMENT PART

1.1 Adjustments of Analogs (Photo-electric convertor)

(ET and Series 300)
1. Connect probe CH1 of oscilloscope to CP1, CH2 to CP2. And place the
pliers of probes to GND of CSY-S. Make sure that the buttons on the probes
should be placed to “×10”.
2.Preparation: press CH1
MENU, and shift the
"Coupling" item to "ground",
then turn the "POSITION"
button above "CH1 MENU" to
make the "1→" on the left of
the screen to the bottom line
until it changes to "1↓". Then
we change the "Coupling"
item back to "DC". Do as the
same way with CH2.
3.Connect the CSY-2 and
analog with the white
connecting cable which is
attached to the CSY-2
machine.
4.Set on the oscilloscope:
Turn the button “VOLTS/DIV” below the “CH1 MENU” to make “CH1” under
the bottom line of screen to be 500mV;
Turn the button “VOLTS/DIV” below the “CH2 MENU” to make “CH2” under
the bottom line of screen to be 500mV.
5. Press “DISPLAY”, shift Format to “X~Y”, rotating the rasters, we can see
the circle. Adjust the adjusting screws on analog circuit board W2 and W3
with a screw driver:
W2: for adjusting the diameter of the figure
W3: for adjusting the roundness of the figure
Roundness: as round as possible
Diameter of the figure: 2.5~4 grids (1.3V~2.0V).
 W1 W2 W3 W4
P.S. on the oscilloscope, when CH1=500mV, CH2=500mV,
1 grid = 0.5V; 1 division =0.1V; 1 gird = 5 divisions
6. Shift the “Format” to “YT”, press “MEASURE” button and we can see the
tow sin waves. Adjust screw W2 to make the “Pk-Pk” value of both CH1 and
CH2 in the range of 1.3~2.0V. Adjust W3 to make the two sin waves
overlapped.(the difference between them should be less than 1 division).
7.Adjust the W1 and W4 to make the “Mean” value of CH1 and CH2 at about
2.5±0.2V.

Adjustment of the duel paths of the signal:

The Lisharing figure is actually
combined by the two sin waves of
each signal.
For each signal,
The peak-to-peak (Pk-Pk) value of each
sin-wave signal should be:
1.3V<p<2.0V (0.1V=1 division)
The peak value difference between two
sin waves should be less than 1 division.
Otherwise, E04 will appear.
Solution: adjust W3.

less than 1 division

less than 1 division

P.S

1 grid 1 division
If the signals are still not right, you may also try below method
(not recommended if the signal is not too serious):
First loosen the small group of screws, and adjust the big group of screws
on the horizontal axis
Loosened: decrease the signal value
Tightened: increase the signal value

The performance of the three groups of screws on the horizontal axis:

Big big: to adjust the tolerance between the two rasters
Medium group: to dismount the horizontal rasters
Small group: to fix the position of the two rasters
1.2 Test Points on Main Board
Main board is core of electronic system which almost musters all electrical signals
and plug-in devices and so on.
test points of the CH1、CH2 signals of H. analog

test points of the CH1、CH2 signals of V. analog

Check the signals of both

analogs, if the waves are
not good: check analogs;
If analogs are ok, replace
the main board.

F
zero-point voltage
D
E
zero-point signal
C
（Note：in theodolite,
we only test the 3rd and 4th
test points）

TR1: for adjusting the

upper analog’s zero-
point voltage

TR2: for adjusting the test points on the main board

lower analog’s zero-
point voltage
1.3 Adjustment of Zero-point Voltage
(only available for V. analogs)

1.Press “CH2 MENU” to switch off the CH2 signal. Just use CH1 probe.
2. Firstly, on the CSY-2 machine, put theCH1 probe to “Voset”, and its plier to
“GND”. And connect the white connecting cable of CSY-2 to the analog.
Rotating the telescope of instrument, we can see zero-point signal wave (see
the picture above).
Distance between the horizontal line and the peak point L
should be between 1 grid and 2 grids. If not,
L adjust adjusting screw on the analog W2
properly.
3. Put the probe at test point E on main board (see P4), while rotating the
EDM, and we get the wave of zero-point signal; then put the probe at point F,
we get the zero-point voltage line. So it is with point C and D.

Zero-point signal Zero-point voltage line

wave of zero-point signal

2 divisions (for theodolite) zero-point voltage line
3 divisions (for total station)

4. Adjust the TR1 or TR2 (see P4) to make the zero-point voltage line in the
position as described above. (for theodolite, 2 divisions above peak line; for
total station, 3 divisions above peak line).
5.Press “MEASURE” on oscilloscope, and check the test points on main
board (see picture on P5) just to see the “Pk-Pk” values and “Mean” values of
each channel of the four analogs (2 for Hr., 2 for V.), are all up to the
requirement. If not, readjust the analogs.
Note:
If the zero-voltage line is too high, E08 will appear;
If the zero-voltage line is too low, OSET will fail, “OSET” will appear on the
screen, or even it will sometimes cause incorrect reading.

1.4 Adjustment of CCD sensor (Horizontal and Vertical)

(400,500,600 Series)
Series 400,500,600 use angle measurement system of absolute encoder and CCD
sensor, which is different from Series 300 and theodolite that uses rasters.
With absolute encoding circle the machine can be turned on without initialization,
measuring results are more accurate.
Working principle: obtaining the code information from specific position on the circle
by photoelectric detector. Multiplexer will conclude if horizontal disk or vertical diskis
working, then all information will be transmitted to microprocessor CPU to calculate.
CPU will emit instructions to guide the operation then transmit the result to display.
 Absolute Encoder Circle code strip

Inspection
1. On the oscilloscope, shift to State “ X-Y, 1.00V, 25μs “(See picture below);
2. Put the probe at the test points C and D (for vertical disk), or A and B (for
horizontal disk);
(Caution: the test points’ locations vary on different series of main board, see
P8 );
3. Cover main board with a black cloth, to prevent light interfering to the
signal.
4. Rotate telescope gently at the meantime.

5. Check the arch wave on the oscilloscope. The wave standard:

a. the arches should be symmetrical;
b. the peaks of the wave should be more or less on the same horizontal line.
c. See the figure.

1V
2.8~3.2V

Peaks
Arch Symmetry
0

upper CCD,Vert. D

the 3rd leg

lower CCD,Vert. C
the 3rd leg

CCD with short wires, Hr. B

the 3rd leg

CCD with long wires, Hr. A

the 3rd leg

Series 400

D upper CCD, Vert.

rd
the 3 leg
.

C lower CCD, Vert.

the 3rd leg to the last

B CCD with short wires, Hr.

the 3rd leg
 A CCD with long wires, Hr.
the 3rd leg

Series 500/600

Adjustment
Fixing screw
Adapt the CCD to a proper position
until the arch wave is up to standard;
② If the arch wave is not good
enough, adjust the four fixing screws
or the two fixing screws on diode, to
make the diode at center of the
bracket.
③ Clean the glass surface of the
CCD and encoder disk with chemical Adjust the position of CCD
solution (alcohol : ether=3:7). Do it
carefully without any scratching.
④ Rotate disk and check the signal
to insure the waves from all part of
the disk should be in good condition.
⑤ Finally, restore those screws and
add some varnish on to fix them.
(Adjustments of both the horizontal
CCDs and vertical CCDs are the
same, except for the different
locations of test points , A,B for
horizontal and C,D for vertical ).

Clean the glass

surfaces of both
encoder circle and
CCD sensor.
1.5 Solutions to Errors
ET and 300 Series

Nut clearance (adjust clearance)

Mechanism
Discharging screw of vertical axis (tweak tightly)
Error 01

Horizontal analog (adjust again, if not ok, replace

it)
Circuit
Main board has problem (replace it)

Error 02： telescope is rotated too fast（protective error）

Error 03： telescope is rotated too fast （protective error）

Error 04: Vertical Analog 1（the upper analog）

Error 07: Vertical Analog 2（the lower analog）
Error 05: Horizontal Analog 1（the one with short wires）
Error 06: Horizontal Analog 2（the one with long wires）

A. The diameter of LISHARING figure is beyond 1.0~2.5V. Adjust the figure to

the normal range.
B. The tolerance between the two raster disks exceeds 0.02mm
Adjustment：
①On the vertical rasters, loosen the four big screws, and adjust the four small
screws to make the tolerance between two rasters within the range of 0.02mm
(using the 0.02mm tape to decide the tolerance). See P5
②or you may adjust the peak-to-peak value within 1.3~2.0V. (See P1~P2)
C. Signal is suddenly strong and suddenly weak obviously.
The rasters are unglued or the instrument gets crashed. Return the instrument
to factory.
D. The analog is damaged. Replace for a good one.
E. Main board has got problem. Replace for a good main board.

Error 08:
a. The diameter of the Lisharing figure is too big. See P1
b. Adjust the zero-point voltage.（zero-point voltage is too high）See P5 ~ P6
c. Main board is damaged, replace for a good one.
Additional Errors for Theodolite
E20—— I angle is not well set. Press “0SET”+“V%”+“0SET” to make a force
setting.
E21—— Check the compensator (See P32 ~ P33).

Series 400/ 500/ 600

Error 04：vertical CCD sensor（the upper CCD）

Error 07: vertical CCD sensor（the lower CCD）
Error 05: horizontal CCD sensor（the one with short wires）
Error 06: horizontal CCD sensor（the one with long wires）

A．Adjust the CCD signal；See P6 ~P9

B．Encoder disk is dirty, clean it.
C．The glass surface of CCD is dirty, clean it. Or CCD is damaged, replace it.
D．Light leaks through main board cover. Keep the CCD away from light.
E．The main board has got problem. Replace for a good one.

The signal of vertical disk or horizontal disk is unstable:

A． Clean the encoder disk.
B． Clean the CCD glass surface.

Error 31, please see P23 ~ P24.

2. DISPLAY & BOOTING-UP
2.1 Booting Up Problems
The voltage of battery is beyond 5.5~7.5V

Battery
Bad welding in the wires or joints on battery cover

no display Driving circuit is damaged

or booting-up
fails Display
The connecting cable of display is well connected

Main board: The program in charge of display is damaged,

replace the main board

2.2 Repairing Display Board

Two displays are connected to each other. Every time keep only one display
be connected with main board to see if it is ok. The solution is to replace the
broken display board.

2.3 Volume is too low or no voice from buzzer

Change buzzer on the left cover.

2.4 Problems in Communication Port

Examine cable pin of communication port and judge if the connection is cut;
See if connection between cable pin and data receptacle on main board is
correct; Inspect if baud rate is correct. If still not good, change main board.

3. EDM PART

3.1 Entering the Test Mode

Procedures:
1. Enter the test mode: for Series 300, POWER+F1 (5 times)+F4 (5 times).
for Series 400/500, Power→Config→“7”→”4”/”3”→press F1(5 times) and F4
(5 times); for Series 600, Power→Para→System→State.
2. By the implication on the screen, choose State 3, and go to Inside Path.
3. In such state, the signal values should be in accordance with the following
criterion:
TAPE 0
≈2.5V When rotating EDM, SIG value in the test mode should TAPE 1
be within 2.2—2.7V, otherwise, re-adjust the high voltage.

TAPE 3 1.6—2.5V
Inspections:
Inside path, no signal value:
Check emitting board, receiving board, and intermediate frequency board
Inside path, signals exist, but:
Tape 0,1,3 lower than required, problem with intermediate frequency board
Tape 0,1 signals ok, but signal of Tape 3 not good, check the receiving board
If signals of both inside and outside path are right, but hi-voltage is not
adjustable, it is problem with fibers.

After entering test mode, the path changes automatically between inside and
outside. Check the slip ring.
If there is big change in SIG under inside or outside path, the problem is with
slip ring or light reducing sheet.

3.2 Adjustment of High Voltage

On the back cov
er of every instrument, there is a sticker on which the recommended voltage
is written. And the actual working voltage attained with multimeter should be
10~15V less than this recommended voltage.
(For example, the recommended voltage
on the cover is 175V, then working
voltage should be within the range of test point of hi-voltage
160~165V)
There are two methods of adjusting the
high voltage.

Method 1: Adjusting high voltage through

high voltage holding screw.
1) Loosen the fixing screw of the holding
screw.
2) Use a screw driver, and adjust the
holding screw to make the high
voltage be up to the standard range.
(According to experience, when the
SIG value increases by 0.1V, the high
voltage would decrease 1V, vice versa.)
3) Power off to save the newly-adjusted
voltage data.
4) Turn on the instrument, and check
whether the high voltage is in the
range of 10~15V less than
recommended voltage. Otherwise,
repeat the steps above.
5) Tighten the fixing screw.
(This method is for fine adjustment of hi-voltage.)

Method 2: Adjusting high voltage through replacing light-reducing sheet

Replace or add a light-reducing sheet of suitable darkness on either side of
the inside path bar with varnish.
If the high voltage is higher than normal, replace for a lighter light-reducing
sheet;
If the high voltage is lower than normal, replace for a darker light-reducing
sheet.
(This method is for coarse adjustment of hi-voltage)

Notice:
When adjusting the holding screw, better not overturn it (no more than two
rounds), or else it will cause light leaking.
Two ways of diagnosing light leaking:
① Check through the EDM lenses in Inside Path state of the test mode to see
whether there is a red light point. If so, light leaking exists.
② Cover the EDM with a prism. Shake the prism and see whether the SIG
value in the Inside path of test mode changes or not. If it changes, light
leaking exists.
Solution to light leaking:
Readjust the holding screw back to a proper position. If the high voltage is not
within correct range, try to replace light-reducing sheet, see Method 2.

If the high voltage still fails after practice the above two methods, there is
probably something wrong with the intermediate frequency board. Replace for
a new one.
3.3 Circuit Boards of the EDM
3.3.1 Emitting board

Check the testing points under the test mode.

①the fourth leg，Power leg, Voltage ≈6.0V，it is connected with main board, slip ring,
and emitting board. If the voltage here is not around 6.0V, then we have to check
with multimeter to see whether it has problem with EDM main board or slip ring.

②Voltage supplied to
emitting tube ≈5V
EDM main board damaged

③ voltage of emitting tube:=3.3~3.5V,

if not in the range, emitting board
damaged or emitting tube damaged

⑤phase locking voltage =1~3V，

if not in the range，
replace emitting board.
 connected to power port from power power port of
slip ring main board to port of light reducing
frequency board light path motor
motor

3.3.2 Intermediate Frequency Board

Check the testing points under Test Mode Principle

① CZ10:input voltage of receiving board ≈3.9V;

(This port is connected to receiving board.)
if not, replace the receiving board.

② CZ9: voltage of frame oscillation

≈2.5V (300series)
≈1.6V (400,500,600series)
Note: If the volt is not right, we have to
unsolder the cable on back side
of the board, and test the volt again.
if it is ok, the problem is with emitting
board; if still not, problem is
with intermediate frequency board

③CZ4: high voltage test point

(10~15V less than recommended value,
see procedures in Hi-voltage Adjustment
P14)

⑤CZ5: bandpass amplification wave

(see P18 )
⑥CZ6: shaping amplification wave

⑦CZ8: distance measuring signal wave

④ CZ7:Hi-voltage controlling voltage=1~3V

CH1 500mV
M 500us

⑤ CZ5: bandpass amplification wave

CH1 2.00V
M 100us

⑥ CZ6: shaping amplification wave

 CH1 2.00V
M 100us

⑦ CZ8: distance measuring signal wave

3.3.3 Optical Coupler

fixing screws

test point
Check the signal wave while
rotating EDM
See Picture
optical coupler

Standard of wave:
The widths of each wave column CH12.00us M 1.00us
should be approximately the same
If not,
① Loosen the two fixing screws;
② Move the coupler board up or
down to a proper position, and
make the edge of the circle sheet
go across about 1/2 of the
coupler foot. (See Figure below).
③ Check the signal wave. If the
wave is not desirable, repeat the
Step ②.
 coupling signal wave

dimmer sheet

optical coupler foot 1/2

3.4 Beams Alignment

(Coaxiality of emitting signal, receiving signal and reticle center of EDM)
The three points: emitting signal point (red), receiving signal point (the color
depends on the outside light source you use) and the center point of reticle.
Three points deviation may cause error distance in distance measurement.
Sometimes when you aim at the center of prism you can not get measuring
result but it is ok when you aim the brink of prism.

Beams Alignment

1) Inspection
A. Put the total station in front of a collimator and adjust it to infinity distance
until you can see the reticle of collimator clearly; (note: there are two
 positions of distance in the collimator, the near distance point and the infinity
distance point. the scale of the infinity distance point is a bit smaller.)
B. Adjust an electronic theodolite to infinity distance, too;
C. Make the object lens of the two instruments be opposite, and we use the
telescope of the theodolite to observe the EDM. In order to make image clear,
we’d better put a white paper as background;
D. Turn the total station on, enter distance measurement mode, and focus it
until reticle of total station and red point can be clearly viewed.
E. Observe if the red point and center point of reticle of total station are
overlapped, if overlapped they are ok, otherwise it needs to be adjusted.
The checking procedures for receiving fiber is almost same with checking
emitting fiber, but you need to add an outside light source at the head of
receiving fiber.（See below）Remove screw A, take off the tube base, and add
an outside light source in the small hole.

Add an outside light source

Screw A (diode) to the receiving tube

receiving fiber (short) emitting fiber(long)

1
3

4 2

Adjustment:
A. Adjustment of Emitting Fiber
1）Make sure that the machine is in distance measurement mode.
2 ） Loosen the fixing screw 1 on emitting fiber (above figure), move the fiber
higher or lower, make the facula be clearest, then fix the screw 1.
3）Loosen the fixing screws 2 on emitting fiber board, adjust the position of the
bracket of emitting tube, make the center of facula be on the center of reticle
of total stations. Finally fix the screw and add some varnish on them.
B. Adjustment of Receiving Fiber.
1）Add an outside light source on receiving fiber.
2 ） Loosen screw 3, move the fiber to find facula in view field, adjust the
position of fiber, make the facula be clearest, then fix the screw.
3）Loosen screw 4, adjust the bracket of receiving tube, make the facula be in
the center of reticle, finally fix the screws and add some varnish on them.
4）Remove outside light source, install the original receiving board.

3.5 Slip Ring

electronic brush slip ring

GND

CLOCK

DATA

POWER
(Power Leg)
(on emitting board)
Volt.≈6.0V

legs connected to slip ring

Caution: Make sure that the legs are well

connected to the slip ring correspondingly,
neither open circuit nor short circuit.
Slip ring is the electric connection between EDM and main board of total
station. Faults of slip ring will mainly cause the failure of power supply to EDM
or failure of data communication.
Inspection：
⑴Take off the battery box. Use OHM of multimeter to check if the four leads of
slip ring get short circuit or open circuit. If so, restore them or replace for a
good slip ring.
⑵Under Test Mode/State 3/Inside, rotate the EDM, if the value of SIG
changes between normal value and 0 at times, then it indicates there is some
problem with the slip ring.

3.6 Error 31 Fault Inspection and Repairing Flow Chart:

Power on and Hear voice from motors

1. Voice not exist

Check the Power Leg on emitting board （≈ 6.0V ） See P22

good electricity no electricity

Check signals of Check if slip ring is short circuit or not
emitting board P16
short circuit good circuit
normal abnormal Replace it Check the electronic brush
Check see P22
motors replace the board
normal l damaged ok
Check electricity
Polarities of motors Replace for a good brush
of main board
get inversed
(seldom)
2. Voice exists

View facula under distance measuring mode

facula exists
no facula
Check intermediate frequency board
 Check high voltage Receiving

emitting
board volt. Check CZ9

tube

Emitti

board
≈3.9V P17

Bad
Fib

ken
bro
test point P17

er
abnormal

Bad

ng
no not good

Check frequency
Check board&Emitting
receiving board
board Method: Check
the voltages of
two leads of the
e for a
frequen

suitable

reducin
signals
Adjust

g sheet
Replac
holding
Check

voltage

Method: take off the fixing screw of emitting tube

board

light-
screw

the emitting tube to check if there is P16

the

P14
on

cy

emitting light:
Yes: fiber broken
No: emitting tube broken
or Emitting board bad

Inspection Procedures:
At the moment of powering on instrument, listen if there is voice from motor in
EDM (and voice from motor of light-path transition system).
1. If no voice, add a DC 3V to motor to see if it has been broken. If motors are
good, test followings:
1) Inspect the Power leg on emitting board to connect with slip ring part (see
P22,) （under distance measuring state）to see if it is about 6.0V.
2) Check if slip ring is in shorted circuit, or weak welded.
3) Check the connection with main board and relevant ports.
4) If above is ok, go to next step. Turn the instrument on, under distance
measurement state, look into objective lens, to see if there is red facula, if
not, try to rotate motor of light-path transition system. If still no facula, it
needs to check emitting fiber or emitting board.
5) Inspect whether emitting fiber is broken.
6) Test voltage of the ports on emitting board.
If above are ok, we need to inspect intermediate frequency board to find
error points. See below:
a) Use a multimeter to test the voltage of CZ9 point, the voltage is the
output voltage of emitting board. The value should be ≈2.5V (300series)
or ≈1.6V (400,500,600series), if not, there is problem with emitting board.
b) Use a multimeter to test the voltage of CZ10 point, the point is the testing
point of receiving board. The value should be around 3.9v, if not, inspect small
board and receiving fiber.
c) If above points are ok please inspect the hi-voltage of CZ4 point. The value
should be lower than the recommended voltage for 10~15V
(please find the recommended voltage on the back of EDM cover). If the hi-
voltage is out of the normal range, we need to adjust it as below:
①If there is no big difference between testing voltage and recommended
voltage, we can adjust hi-voltage controlling screw.
Turn on the instrument, enter adjustment state, enter state 3.
（for 300, to change light path, press F1. To change measuring tape, press F4.
0, 1 are low frequency, 3 is high frequency, for 400/500/600, see manuals）.
②In adjustment state 3, under inside light path, low frequency state, loosen the
fixing screw, then adjust hi-voltage control screw.:
When inside light path signal become lesser, restart the total station, enter test
mode again. Now high-voltage controlling value and high voltage value will be
larger.
When inside light path signal become larger, restart the total station, enter test
mode again. Now high-control value and high voltage value will be lower.
(High-voltage control screw can be turned in 2 rounds, if hi-voltage can not be
well adjusted by this screw, it needs to change light-reducing piece in inside
light path).
To change light-reducing piece:
a. Take zero-fixing board down, turn inside light path out, take off its light-
reducing piece；
b. Change for a suitable light-reducing piece, paste on with varnish, fix zero-
fixing board on the bracket. Turn on the total station, check the high-voltage. If
still not ok, repeat the adjustment steps of high-voltage.
(When high-voltage is lower than recommended voltage, use a darker light-
reducing piece; When high-voltage is higher than suggested voltage, use a
lighter light-reducing piece.)
7) After fixing above, if the problem still appears, the middle-frequency board
should be changed.
8) If above are ok, we enter Adjustment State 2 to check Optical Coupling
board.
.9) Checking Optical Coupling Wave.
Set oscilloscope to be 0.1V state, place probe on the middle point on the
optical coupling board to watch signal of this point (meanwhile rotating the light
reducing motor gear). (See P19)
Gear value Checking: Under adjustment state 2, put a prism onto Objective
lens, the correct gear value should be about 11.
If there is big error, adjust it as below:
Loosen 2 fixing screws, move the optical coupling board upward or downward,
make the Gear value be correct.
10) When above is ok, enter adjustment state 3.
a) Check the CZ5 point on intermediate frequency board. In inside light path,
set oscilloscope to be 0.1V state, 10db attenuation, put probe on CZ5.
Observe the signal. Under low frequency, the signal should be 2.2~2.7V.
Under high frequency, the signal should be 1.6~2.5V. Middle-frequency
signals should be sine wave（See P17）.
11) Optical and electronic crosstalk: Under outside light path, set oscilloscope
to be 5mV, 10db attenuation, and place probe on the CZ6 point. Under low
frequency, Vp-p<100mV; under high frequency Vp-p is a little higher.;
12) Use a multimeter to test CZ7 point on middle-frequency board. The point is
 High Voltage controlling point, normal value should be 1—3V.
13) Check the stability of inside light path（State 3, inside light path）.
①Under inside light path, low-frequency signal is about 2.5v, turn EDM a round,
the signal should change between 2.2—2.7V, if it is not in this range, adjust
high-voltage controlling screw.
②Under inside light path, hi frequency signal is about 1.7v, turn EDM a round,
the signal should change between 1.6—2.5V.
If it is not stable, adjust it as above.
③Under inside light path, high frequency, put a prism onto objective lens,
shake the prism. If signals voltage change, it needs to adjust high-voltage
controlling screw. If no changes, it is good.
④After fixing all of screws, then check again high-voltage, high-voltage control,
intermediate frequency signals.

3.7 EDM Faults Description

1. Failures of Distance Measuring

a. long distance measuring failure:
Solution: Adjust the beam alignment, see P20.
b.short distance measuring failure;
Solution: Adjust the optical coupler, see P19.
c.both of long distance and short distance measuring failure
Solution: check slip ring (whether get short circuit or open circuit); optical
fibers (whether get broken); intermediate frequency board (signals); emitting
board (check signals); inside path (check whether it gets stuck).

2. Exaggerated reading
①Without rotating EDM (telescope), reading is correct; while EDM
(telescope) being rotated, exaggerated reading occurs, it is the problem with
slip ring;
②Without rotating EDM, exaggerated reading appears, then something
wrong with intermediate frequency board, receiving board or EDM main
board.
③Prism system gets dirty or moldy, clean it or change it. After being re-
assembled, we have to readjust all the calibrations.

3. Repairing on Faulty Reading of Distance Measuring

① If the faulty reading is a fixed value, then readjust the instrument constant;
② If the faulty reading is flexible, then check the three boards on EDM
(emitting board, intermediate frequency board, receiving board); ③
In coordinate measurement, if there is error reading in Z coordinate, the
problem is probably with the software, rewrite or update the software.

4. High-voltage Broken down (hi-volt. much higher than recommended value)

a. Receiving fiber is broken
Solution: Replace for a good one;
b. Inside light path doesn’t move, it is locked tightly, or the inside path is dirty
Solution: check the inside path and clear the resistance
c. Motor driving circuit problem, or bad welding on the emitting board
Solution: Replace emitting board

5．Inside path signal changes

a. Receiving optical fiber is broken:
Solution: replace receiving fiber
b. High-voltage controlling transformer is broken
Solution: replace intermediate-frequency board
c. something wrong with capacitance receiving board
Solution: Replace the receiving board

6. There is obvious difference between high frequency and low frequency of

light path signal
a. phase-locking fails
Solution: replace the emitting board
b. Frequency-mixing circuit problem
Solution: replace emitting board

7. Inside light path signal is zero, hi-voltage is higher than normal,

a. There is problem with 2.2N capacitance on receiving board
Solution: replace receiving board
b. Receiving board opens circuit to ground

8．Instrument measures automatically (without prism)

There is problem with measurement stopping system
Solution: change intermediate frequency board

9. Unstable reading of distance measuring results

a. High-voltage is too high:
Solution: adjust high-voltage over again.
b. Voltage of CZ9 port on intermediate frequency board is wrong
Solution: change intermediate frequency board
c. The frequency of main oscillation is wrong
Solution: replace the emitting board

10. Inside path signal is zero, and the voltage of high-voltage controlling is 0
Communication between EDM and main board is bad.
Slip ring fault: short circuit or open circuit
Solution: replace slip ring
11. High-voltage too high, and inside path signal 4.9V, distance measuring
fails
Initiative response of high-voltage is too slow, and high-voltage controlling
transformer is bad.
Solution: replace intermediate-frequency board

4. CALIBRATIONS

4.1 2C (Perpendicularity between Sight Line and Horizontal Axis)

Inspection:
1. Level the instrument.
2. Sight the crosshair of telescope at a point A (+10 for example) of the
vertical scale in the horizontal collimator. And press (0set), and then press
(Enter).
3. Reverse the telescope and sight at the same point A, and note down the
horizontal angle value “a”, which should be ±8″ difference from 180°.

Adjustment:
Take off reticle cover, and adjust the left and right screw properly.
(Note: Don’t adjust the screws beyond 1′; otherwise it will affect the beam
alignment)
For example, the “a” value on the reversed position is 180º00'40" (in which
40" is just the difference). Adjust the horizontal clamp and tangent screw to
make the horizontal angle value to half of the difference as 180º00'20". Then
sight at the horizontal collimator, and see how much the deviation is from
Point 10. Next we take off the reticle cover on the eyepiece and adjust the left
and right adjusting screws to make the vertical reticle line back to the Point
10. Finish.

4.2 High-low Difference

(Perpendicularity between Horizontal Axis and Vertical Axis)

Inspection:
First Position Second Position
1. On first position (main board
side is on your left when
sighting), sight at the center of
crosshair in horizontal
collimator.
2. Sight in the lower collimator,
note down the corresponding
grid value A on the horizontal
reticle crosshair.
3. On second position (main Hor. collimator Hor. collimator
board is on your right when
sighting), do as the same with A B
above two procedures, and
note down the other
corresponding grid value B.
4. The difference between A and
B, |A-B|, is just the high-low
difference value, which should
be less than 9″ (0.3 grid on
 the scale).
(Note: on the scale of reticle,
1 grid=30″) Lower collimator Lower collimator

Adjustment:
Take off the center cover below EDM.
Tighten the left or right screw under center cover as per which side is higher.
If the above procedure is not satisfactory, we have to disassemble the main
body and scratch the side which is higher than the other.

4.3 Adjustment of Compensators

Collimator

B C

Leveling Screws A, B, C

Caution: Go to the compensator mode (F2+Power, F1 five times, F4 five

times), if ①the F value showed on the screen is fluctuating or ②it exceeds
±10000, and can’t be adjusted, that means the compensator is broken. We
have to replace for a good one.

Vertical Compensator of Series300/400/500/600

Adjustment of Vertical Compensator (Tilt Sensor):

a. Level the instrument.
b. Enter the compensator mode. For Series 300, press F2+POWER to turn
on, then press F1 five times and F4 five times to enter the compensator
mode; For Series 400/500, Power→Esc→Config →“2” →“1”; For Series 600,
Power→Para→System→F2.
c. Frequency value of compensator is showed on the first row, and this F
value should be within the range of ±30.

Rectifying the F value:

a. Take the battery back cover off the instrument;
b. Tap two side of compensator with a small hammer to make F value
within±30.
If the above value can not be rectified, we have to calculate and input
coefficient of compensator.
Coefficient of the Vertical Compensator

1. Enter the compensator mode.

2. Aim the instrument at the reticle
center of the collimator.
3. Adjust the leveling hand wheel A
which is close to the collimator to make
the instrument go up 5 grids on the
reticle. At this moment, note down the F
value (F1). Up 5 grids
4. In the same way, we adjust the
instrument 5 grids down from the reticle
center, and note down the F value F2.
5.Then we can calculate out the
coefficient as: K=（|F1|+|F2|）/300.
6. Press”ENTER” and “INPUT”, and
input the K value. After that, press
"ENTER" three times and escape. The
coefficient of compensator is well set.
Down 5 grids
Checking the accuracy of the coefficient
1. Go the angle measurement mode.
2. Aim the instrument at reticle center of the collimator, note down the Vertical
angle value A0.
3. By adjusting the leveling hand wheel, we make the instrument up 4 grids,
note down the Vertical angle value A1.
4. In the same way, we adjust the instrument 4 grids down from the reticle
center and note down the angle value this time A2.
5.Compare the value A1 and A0, in the second unit( ＂), the difference should
be less than about 6 ＂. So it is with A2 (in the second( ＂) unit, the difference
between A0 and A2 should be less than about 6＂).
6. If A1 and A2 are not up to requirement, repeat the steps above.

500 Series
Setting Coefficient of Horizontal Compensator
1. Level the instrument precisely. Do the Vertical Index adjustment (high-low
difference, see P31).Then go to compensator mode (press “Esc”, “CONFIG”,
“7”, “1”) and adjust the compensator value within the range of ±30 (take the
battery back cover off the instrument and tap two sides of the compensator).
2. Initially, in compensator mode (electronic bubble mode) we input the
coefficient as 4.00, and remain the temperature as 0.20 (temperature
coefficient). Press [ENT] twice, then [SFT] + [.], take a look at "Y" on the
display, note down the value θ (0).
3. Quit to Angle Measuring. Sight the instrument at a certain point E(point 10
for example) in the horizontal collimator, then 0set the horizontal angle. After
that, sight the instrument in the lower collimator, and note down the point F on
the vertical cross hair. Press [SFT] + [.].
4. Enter the compensator mode (electronic bubble mode) again, and turn the
leveling hand wheel B and C to make instrument tilt left-side until the number
in Y of electronic bubble reach +1'40". (For right-side it should be -1'40")
5. Rotate the telescope and turn the horizontal tangent screw. Sight the EDM
at the point E on the vertical cross hair in the horizontal collimator. Then press
[ESC]. Fix the horizontal tangent screw. And sight the telescope vertical cross
hair in the lower collimator. 0set the horizontal angle. Next, sight the
instrument at point F on the vertical cross hair in the lower collimator. Here,
note down the horizontal angle θ(h) and vertical angle θ(v).
6. Finally, we are able to calculate the Compensator's coefficient with the
formula:
K1= 4×(1'40"-θ0)×0.577/θH 0< θH <90º
or
K1=4× (1'40"-θ0)×0.577/(360º-θH ) 270º<θH<360º
Note: θ(v) is the angle between horizontal collimator and the lower collimator.
Usually, we take tgθ(v)=0.577, for the angle of the two collimator scopes we
used is always 30°. So this angle value depends on the collimators you used.
7. Level the instrument again. And follow the steps above. Tilt the instrument
right-side to -1'40", so that we attain the other coefficient K2.
8. Lastly, the coefficient of horizontal compensator is calculated as:
K= (K1+K2)/2
9. At the end, we go to the compensator mode, press “OK” and input the K
value in place of the initial coefficient 4.00.

Checking the Accuracy of the Coefficient

1. Level the instrument beforehand.
2. Sight the EDM at a reference point N (point 10 for example) in the lower
collimator. Then, turn the EDM and sight at the horizontal collimator
telescope. Here, press [F1] twice to 0set the horizontal angle value. Note
down point M (the point in horizontal telescope).
3. Press [SFT]+[.] to open the compensator mode. Turn the leveling hand
wheel B and C to make the instrument tilt left-side around 2'(see "V" value on
the display). Press [ESC], and then sight the EDM at point M again. 0set the
horizontal angle value. Turn the EDM and sight at point N in the lower
collimator, and look at the horizontal value "HAR", which is just the
compensating Error of horizontal compensator.
4. Level the instrument; tilt it on the other side (right-side) by turning leveling
hand wheel B and C following the steps above. Then we attain Compensating
Error of the horizontal compensator on the right-side.
5. Both these two Errors should be within range of ±6".

600 Series
Setting Coefficient of Horizontal Compensator
1. Level the instrument precisely in all directions. Do the Vertical Index
adjustment. Then go to the compensator mode (PARA→System→HADJ) and
adjust the compensator value within the range of ±30(take the battery back
cover off the instrument and tap two sides of the compensator). Initially, we
input the coefficient as 4.00(press OK and input 4.00), and keep the
temperature coefficient as 0.20(the lower row). Note down the value θ0 at Y of
the horizontal angle in the electronic bubble mode(F2→F6→F5). Quit to Angle
Measuring.
2. Sight the instrument at a certain point E (10, for example) on horizontal line
of the scale line in the upper collimator, then 0set the horizontal angle. After
that, sight the instrument in the lower collimator and remember the
corresponding point F on the horizontal scale line.
3.Enter the electronic bubble mode (F2→F6→F5), turn the screw B and C to
make instrument tilt left-side until the value at Y of the electronic bubble
screen reaches +1'40".
4. Rotate the telescope and turn the horizontal tangent screw, and sight at the
point E on the horizontal scale line in the upper collimator. Fix the horizontal
tangent screw. Then sight the telescope at the horizontal scale line in the
lower collimator. 0set the horizontal angle. Next sight the instrument at point F
on the scale line in the lower collimator. Here, note down the horizontal angle
θH in the screen.
Then, we can calculate the compensator's coefficient as follows:
K1= 4×(1'40"-θ0)×0.577/θH 0< θH <90º or
K1=4× (1'40"-θ0)×0.577/(360º-θH ) 270º<θH<360º
5. Level the instrument again and follow the steps above. Tilt the instrument
right side to -1'40" in the same way. We can get the other coefficient K2.
Lastly, the coefficient of horizontal compensator is calculated as:
K= (K1+K2)/2.
6. At the end, we go to the compensator mode (PARA->System->HADJ),
press “OK” and input the K value in place of the initial coefficient 4.00.
Checking the Accuracy of the Coefficient
1. Level the instrument precisely in all directions.
2. Sight the instrument at a reference point N (10 for example)on the
horizontal scale line of the lower collimator. Lock the horizontal fixing
screw(e.g. point 10). Turn the EDM and sight at the upper collimator. Here,
0set the horizontal angle value, remember the corresponding position point M.

2. Enter the compensator mode. Turn the hand wheel B and C to make the
instrument tilt left around +2' (see "Y" value on the display), then sight the
EDM at point M again. 0set the horizontal angle value. Turn the EDM and
sight at point N in the lower collimator, and then look at the horizontal value
"HAR", which is just the compensating error of compensator. This error should
be within

3. Level the instrument; tilt it on the other side (right side), by turning the
leveling hand wheels B and C as the steps above. And the compensating
error of the horizontal compensator on the right side can be attained. And we
should make sure that both errors should be within the range of 6". Otherwise,
repeat the steps of calculating of the compensator coefficient and re-input the
coefficient until the compensating errors are within the range of 6".

4.4 I Angle
(Vertical Angle Index)

Adjustment:
1. Go to the item “V ANGLE 0 POIN”
(for Series 300, Press F1 +
Power, and then F1; for Series
400/500,
Power→Esc→Config→“2” → “1”
for 600 Series, Power→ADJ→V
ANGLE 0 POINT). Then 0set;
2. On first position (main board side
is on your left when sighting), aim at
a point (10, for example) on the
vertical crosshair of the scale in
horizontal collimator, and press
“Enter”;
3. Reverse the instrument to second position (main board side is on your right
when sighting), and sight at the same point, and press ENTER;
At this moment, if the I Angle error is too much deviation, “ERROR” will be
displayed. At this time press keys as follows for force alignment:
Series 300, press F3→F2→F2;
Series 400, press F1→F2→F2;
Series 500, press F1→F2→F2;
Series 600, press F1→F2→F2.
Theodolite, press “0SET”+“V%”+“0SET”
4. Power off to save the force setting.

Checking the Accuracy of I Angle

1. Sight the instrument at a point (10, for example) on vertical crosshair in
horizontal collimator, and note down the vertical angle value A1;
2. Reverse the instrument and sight it at the same point, note down the angle
value A2;
3. |A1+A2-360°| is just the I angle error, which should be less than 6″. If not,
repeat the adjustment.
4.5 Plate Vial
Inspection method:
a. Rotate instrument, make plate level parallel with line between any two
leveling screws, and then adjust leveling screw to make plate bubble
centered.
b. Turn the instrument for 90 degrees, adjust the third leveling screw, and
make the plate bubble be centered.
c. Repeat the a, b steps, make the plate bubble be centered in above
two positions.
a. Rotate instrument around vertical axis with a 180°.
b. If the plate bubble still be centered (or its offset is less than 1/4 of a grid),
plate bubble is upright to vertical axis.
Adjusting method:
a. Adjust leveling screws, make plate bubble be centered;
b. Rotate instrument with a 180°, watch the offset of plate level;
c. Tweak adjustment screws with correction pin, make plate bubble to move
half of the offset back;
d. Rotate the instrument with a 180°, check adjustment result;
e. Repeat the steps above until the plate level is centered.

4.6 Circular Vial

After examining the plate bubble, circular bubble should be centered, too (or
not beyond the reticle circularity), what indicates the circular bubble is vertical
to vertical axis.
Adjusting method:
a. Adjust circular level after plate bubble being centered.
b. Loosen the screw (one or two) opposite with bubble deflective direction;
c. Tweak tightly the screw on the direction accordant deflective until circular
level is centered;
d. Adjust three adjustment screws for several times until circular level is
centered;
e. The force power fixing three adjustment screws must be consistent when
circular level is centered at last.

4.7 Plumb Line

Perpendicularity of vertical axis, it means Perpendicularity of vertical line of
reticle to horizontal axis. It requests no visible error.
a. Make horizontal line of reticle aiming at one arbitrary value on vertical line
of graduation of collimator;
b. Tighten and fix the vertical tangent screw.
c. Rotate horizontal tangent screw to move the reticle horizontally.
d. If the offset from horizontal line on reticle to graduation line is within 3 ＂, the
reticle is not declining.
Adjusting method:
a. Loosen two screws among three ones which fixes the base of reticle board;
b. Knock the base of reticle board with a tool to make plumb line accord with
standard;
c. Tighten screws then drop varnish on them.

4.8 Coarse Collimator

Inspecting method：
a. Make vertical line on reticle board aim at plummet (can be replaced with
arbitrary plumb line).
b. Rotate focusing hand wheel to see the plummet.
c. If perpendicular bisector of “△” in the coarse collimator is superposited with
plumb line of plumb, there is no offset on coarse collimator.
Adjusting method：
a. Adjust two screws on coarse collimator.
b. If offset is big, loosen two screws, wrest coarse collimator.
c. If offset is not big, loosen a screw, knob coarse collimator with relevant tool.

4.9 Optical Plummet

·Inspection
1. Set the instrument on the tripod and place a piece of white paper with two
perpendicular lines, then intersect drawn on it directly under the instrument.
2. Adjust the focus of the optical plummet and move the paper so that the
intersection point of the lines on the paper comes to the center of the field of
view.
3. Adjust the leveling screws so that the center mark of the optical plummet
coincides with the intersection point of the cross on the paper.
4. Rotate the instrument around the vertical axis and at every 90°observe
whether the center mark position coincides with the intersection point of the
cross.
5. If the center mark always coincides with intersection point, no adjustment is
necessary.
Otherwise, the following adjustment is necessary.
a. Aim at the mark in the floor center through optical plummet;
b. Rotate alidade with a 180°, check the offset;
c. Take optical plummet eyepiece cover off, adjust the four screws upper and
above, left-and-right with 1/2 offset (adjust two screws upper and above if
leaning up and down, while adjust other two screws left-and-right if leaning left
and right );
d. Rotate alidade with a 180°to return the primary position; adjust excess 1/2
offset with leveling screws
If offset is big, adjust with screw 1,2 which is shown in figure 2.20.

5. AXIS BLOCKING
Adjustment
Note: Once the blocking occurs, do not force turning the instrument.
Otherwise it will cause a greater damage to the axis.
1.Vertical Axis Blocking:
axis sheath
1). Disassemble the instrument.
2). Keep the axis vertical, and separate
the axis shaft and the axis sheath, then axis shaft
remove those balls bearing carefully.
3). Clean the oil on the surface of both
axis shafting and axis sheath.
4). Add some green grease (Cr2O5) on the grinding stick. And then grind the
axis sheath with the stick uniformly. Be aware that you should grind in one
direction, clockwise or counter-clockwise avoiding damage to the axis.
5). Grinding finished, clean the grease on the surface with a clean cloth.
6). Add some oil to the place grinded.
7). Clean the surface of the encoder disk with chemical solution (ethanol :
aether=3:7).
8). Mount the balls bearing back. And reassemble the vertical axis.
If the tolerance between axis shafting and axis sheath still feel tight, repeat
the procedures above.

2. Horizontal Axis Blocking

Causes: the axis gets dusty, rusted, moldy, or mal-posed (frequently
happens).
Adjustment
There are three groups of screws on the axis (See P3).
① Take off the analogs. Loosen the small group of screws;
② Tighten the big group of screws to increase the tolerance between two
rasters, preventing from getting stuck while dismounting the axis.
③Loosen the medium group of screws, and take out the horizontal rasters.
④ Loosen the fixing ring and grind the axis the same way as vertical axis.
Clean the encoder disk with chemical solution (ethanol : aether=3:7).
⑤ Restore the fixing ring.
⑥ Assemble the rasters back. There is one tiny triangle point at the edge of
each raster. While assembling, make sure that direction of the two triangle
points are placed downside.
⑦ Assemble the upper analog at this time.
⑧ Mount the rasters back in the first position (the main board side of the
instrument should be on your left hand when sighting the telescope/EDM).

6. SOFTWARE DOWNLOADING
Series 300 jumper

1. Connect the total station and PC

with data communication cable;

2. Take off the right cover (the side

with main board);

3. Plug off the jumper on the main

board and insert it on the upper
two-pin socket;
4. Double click the software, and
choose a corresponding com port plug off the jumper
according to your computer;

5. Power on the instrument and the

screen will appear ”Please wait…”;

6. Press ＂ PROGRAM ＂ on the

software, and programming starts;

7. Programming finished power off.

8. Restore the jumper to its initial

place. (notice: just insert the jumper
back into one foot of the pin socket,
do not get short circuit.) Insert the jumper

Series 400/ 500/ 600

1. Connect total station to computer with data communication cable.
2. Double click the software, and choose a corresponding com port according
to your computer.
3. Press F1 while powering on the instrument.
4. Press F4 in time. The display will show “Please wait…”
5. Press “PROGRAM” on the software, and programming starts.
6. Programming finished, plug off the battery.

7. TOOLS & CHEMICALS

CSY-2 Box
Oscilloscop
e
 Multimeter

Grinding Sticks (H.&V.) Collimator

Light reducing sheets

Bats Tape of 0.02mm

Allen
key

Tweezer
Extender
Screwdrivers

Varnish Green Grease (Cr2O5) Lubricant

Cleaning Solution (alcohol: aether=3:7)