Agilent U1840A Medalist
sj5000
Automated Optical
Inspection System
Operator Manual
Agilent Technologies
Notices
© Agilent Technologies, Inc. 2007
Manual Part Number
No part of this manual may be reproduced
in any form or by any means (including
electronic storage and retrieval or translation into a foreign language) without prior
agreement and written consent from
Agilent Technologies, Inc. as governed by
United States and international copyright
laws.
5186-5818
Revision
Revision B, March 2008
Printed in Malaysia
Agilent Technologies Microwave Products
(Malaysia) Sdn. Bhd.
Bayan Lepas Free Industrial Zone
11900 Penang, Malaysia
Phone: 60 (4) 680 5582
Fax: 60 (4) 680 8493
Warranty
The material contained in this document is provided “as is,” and is subject to being changed, without notice,
in future editions. Further, to the
maximum extent permitted by applicable law, Agilent disclaims all warranties, either express or implied,
with regard to this manual and any
information contained herein, including but not limited to the implied
warranties of merchantability and fitness for a particular purpose. Agilent
shall not be liable for errors or for
incidental or consequential damages
in connection with the furnishing,
use, or performance of this document
or of any information contained
herein. Should Agilent and the user
have a separate written agreement
with warranty terms covering the
material in this document that conflict with these terms, the warranty
terms in the separate agreement
shall control.
Technology Licenses
The hardware and/or software described
in this document are furnished under a
license and may be used or copied only in
accordance with the terms of such license.
Restricted Rights Legend
If software is for use in the performance of
a U.S. Government prime contract or sub-
contract, Software is delivered and
licensed as “Commercial computer software” as defined in DFAR 252.227-7014
(June 1995), or as a “commercial item” as
defined in FAR 2.101(a) or as “Restricted
computer software” as defined in FAR
52.227-19 (June 1987) or any equivalent
agency regulation or contract clause. Use,
duplication or disclosure of Software is
subject to Agilent Technologies’ standard
commercial license terms, and non-DOD
Departments and Agencies of the U.S.
Government will receive no greater than
Restricted Rights as defined in FAR
52.227-19(c)(1-2) (June 1987). U.S. Government users will receive no greater than
Limited Rights as defined in FAR 52.227-14
(June 1987) or DFAR 252.227-7015 (b)(2)
(November 1995), as applicable in any
technical data.
Safety Notices
CAUTION
A CAUTION notice denotes a hazard. It calls attention to an operating procedure, practice, or the like
that, if not correctly performed or
adhered to, could result in damage
to the product or loss of important
data. Do not proceed beyond a
CAUTION notice until the indicated
conditions are fully understood and
met.
WA RNING
A WARNING notice denotes a
hazard. It calls attention to an
operating procedure, practice, or
the like that, if not correctly performed or adhered to, could result
in personal injury or death. Do not
proceed beyond a WARNING
notice until the indicated conditions are fully understood and
met.
Agilent U1840A Medalist sj5000 Automated Optical Inspection System
Operator Manual <Revision B>
Revision History
Revision
Nature of Change
Author
Date
A
First Release
KA/KS
14 December
2007
B
Correct hyperlinks in manual.
YL Ng
24 March 2008
Change shortcut-key from ALT to
CTRL
Ayaru Alagesan
Added "Is moved until board stops"
to Machine Cycle.
Agilent Technologies
iii
1
Revision History
THIS PAGE IS INTENTIONALLY LEFT BLANK.
iv
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
Contents
1
Revision History
1
Legal Information
Legal Information 1-2
Warranty 1-2
Technology Licenses
1-2
Restricted Rights Legend 1-2
Service And Support
1-3
Agilent On The Web
1-3
Agilent By Phone
1-3
Table 1-1. Agilent Call Centers and Regional Headquarters
2
1-3
Safety and Regulatory Information
Safety Information
2-2
Safety Summary
2-2
Safety Notice
2-2
General 2-2
Environmental Conditions
2-3
Table 2-1. Environment Requirements
Before Applying Power
2-4
Ground The System 2-4
Fuses
2-4
Operator Safety Information 2-4
Safety Requirements
2-5
Machine's Intended Use
2-5
2-3
Electrical Safety
2-6
Electrical Enclosure
2-6
Emergency Stop Loop 2-6
Earth Bonding
2-8
PC Safety
2-9
Physical Safety 2-10
Protective Guards 2-10
Pinch Hazards
2-10
Machine Stability 2-11
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
v
Falling Objects
2-11
System Warning/Caution Labels 2-12
Table 2-2. Safety Symbols
2-12
Regulatory Markings 2-13
Table 2-3. Regulatory Markings 2-13
Electrostatic Discharge (ESD) Precautions 2-14
Table 2-4. Suggested Anti-Static Solutions for Site Planning
2-15
End of Life: Waste Electrical and Electronic Equipment (WEEE) Directive
2002/96/EC
2-16
3
Product Overview
Description
3-2
Machine Cycle
3-2
Operator Tasks - Summary
4
3-3
Starting and Stopping the Machine
Powering up the Machine from the 'Mains-Off' Position
Starting up the Software
4-3
Restarting After an E-Stop (Emergency Stop)
Shutting Down the Machine
5
Inspecting Boards
Overview of Operator Screen
5-2
Selecting Inspection Program
5-3
Inspecting Boards
Lighting Tower
5-5
5-7
Inspection Summary Information
5-8
5-9
Defect Review Process
AOF (Action On Fail) Toolbar
6-2
Operator AOF Shortcut Keys
6-3
Defect Review
Defect Types
vi
4-4
4-4
Manual Conveyor Width Adjustment
6
4-2
6-3
6-4
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
Automated Optical Inspection System
Operator Manual <Revision B>
1
Legal Information
Warranty 1-2
Technology Licenses 1-2
Restricted Rights Legend 1-2
Service And Support 1-3
Agilent On The Web 1-3
Agilent By Phone 1-3
Agilent Technologies
1-1
1
Legal Information
Legal Information
Warranty
The material contained in this document is provided “as is,” and
is subject to being changed, without notice, in future editions.
Further, to the maximum extent permitted by applicable law,
Agilent disclaims all warranties, either express or implied, with
regard to this manual and any information contained herein,
including but not limited to the implied warranties of
merchantability and fitness for a particular purpose. Agilent
shall not be liable for errors or for incidental or consequential
damages in connection with the furnishing, use, or performance
of this document or of any information contained herein.
Should Agilent and the user have a separate written agreement
with warranty terms covering the material in this document
that conflict with these terms, the warranty terms in the
separate agreement shall control.
Technology Licenses
The hardware and/or software described in this document are
furnished under a license and may be used or copied only in
accordance with the terms of such license.
Restricted Rights Legend
If software is for use in the performance of a U.S. Government
prime contract or subcontract, Software is delivered and
licensed as “Commercial computer software” as defined in
DFAR 252.227-7014 (June 1995), or as a “commercial item” as
defined in FAR 2.101(a) or as “Restricted computer software” as
defined in FAR 52.227-19 (June 1987) or any equivalent agency
regulation or contract clause. Use, duplication or disclosure of
Software is subject to Agilent Technologies’ standard
commercial license terms, and non-DOD Departments and
Agencies of the U.S. Government will receive no greater than
Restricted Rights as defined in FAR 52.227-19(c)(1-2)(June
1987). U.S. Government users will receive no greater than
Limited Rights as defined in FAR 52.227-14 (June 1987) or
DFAR 252.227-7015 (b)(2)(November 1995), as applicable in any
technical data.
1-2
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
Legal Information
1
Service And Support
Any adjustment, maintenance, or repair of this product must be
performed by qualified personnel. Contact your customer
engineer through your local Agilent Technologies Service
Center.
Agilent On The Web
For more information on Agilent Technologies’ products,
applications or services, please contact your local Agilent office.
The complete list is available at:
www.agilent.com/find/contactus
Agilent By Phone
If you do not have access to the Internet, call one of the
numbers in Table 1-1.
Table 1-1
Americas:
Asia-Pacific:
Agilent Call Centers and Regional Headquarters
Canada
(877) 894-4414
Latin America
305 269 7500
United States
(800) 829-4444
Australia
1 800 629 485
China
800 810 0189
Hong Kong
800 938 693
India
1 800 112 929
Japan
0120 (421) 345
Korea
080 769 0800
Malaysia
1 800 888 848
Singapore
1 800 375 8100
Taiwan
0800 047 866
Thailand
1 800 226 008
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
1-3
1
Legal Information
Europe and Middle East:
Austria
0820 87 44 11
Belgium
32 (0) 2 404 93 40
Denmark
45 70 13 15 15
Finland
358 (0) 10 855 2100
France
0825 010 700*
*0.125 ? fixed network rates
Germany
01805 24 6333**
**0.14 ?/minute
Ireland
1890 924 204
Israel
972-3-9288-504/544
Italy
39 02 92 60 8484
Netherlands
31 (0) 20 547 2111
Spain
34 (91) 631 3300
Sweden
0200-88 22 55
Switzerland
(French) 44 (21) 8113811 (Opt 2)
(German) 0800 80 53 53 (Opt 1)
United Kingdom
44 (0) 118 9276201
*Other European countries: www.agilent.com/find/contactus
Manufacturing Address
Agilent Technologies Microwave Products (Malaysia) Sdn. Bhd.
Bayan Lepas Free Industrial Zone,
11900 Penang,
Malaysia.
Phone: 60 (4) 680 5582
Fax: 60 (4) 680 8493
1-4
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
Agilent U1840A Medalist sj5000 Automated Optical Inspection System
Operator Manual <Revision B>
2
Safety and Regulatory Information
Safety Information 2-2
Safety Summary 2-2
Safety Notice 2-2
General 2-2
Environmental Conditions 2-3
Before Applying Power 2-4
Ground The System 2-4
Fuses 2-4
Operator Safety Information 2-4
Safety Requirements 2-5
Machine's Intended Use 2-5
Electrical Enclosure 2-6
Emergency Stop Loop 2-6
Earth Bonding 2-8
PC Safety 2-9
Protective Guards 2-10
Pinch Hazards 2-10
Machine Stability 2-11
Falling Objects 2-11
System Warning/Caution Labels 2-12
Regulatory Markings 2-13
Electrostatic Discharge (ESD) Precautions 2-14
End of Life: Waste Electrical and Electronic Equipment (WEEE) Directive
2002/96/EC 2-16
Agilent Technologies
2-1
2
Safety and Regulatory Information
Safety Information
Safety Summary
The following general safety precautions must be observed
during all phases of operation of this instrument. Failure to
comply with these precautions or with specific warnings
elsewhere in this manual violates safety standards of design,
manufacture, and intended use of the instrument. Agilent
Technologies, Inc. assumes no liability for the customer's failure
to comply with these requirements.
Safety Notice
CAUTION
A CAUTION notice denotes a hazard. It calls attention to an
operating procedure, practice, or the like, that, if not correctly
performed or adhered to, could result in damage to the product or
loss of important data. Do not proceed beyond a CAUTION notice
until the indicated conditions are fully understood and met.
WA RNING
A WARNING notice denotes a hazard. It calls attention to an operating
procedure, practice, or the like that, if not correctly performed or
adhered to, could result in personal injury or death. Do not proceed
beyond a WARNING notice until the indicated conditions are fully
understood and met.
General
This product is provided with a protective earth terminal. The
protective features of this product may be impaired if it is used
in a manner not specified in the operation instructions.
WA RNING
2-2
DO NOT OPERATE IN AN EXPLOSIVE ATMOSPHERE. Do not operate the
product in the presence of flammable gases or flames.
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
2
Safety and Regulatory Information
WA RNING
DO NOT REMOVE RACK PANELS OR INSTRUMENT COVERS. Operating
personnel must not remove any rack panels or instrument covers.
Component replacement and internal adjustments must be made only
by qualified service personnel. Products that appear damaged or
defective should be made inoperative and secured against unintended
operation until they can be repaired by a qualified service personnel.
WA RNING
The protection provided by the Agilent U1840A Medalist sj5000
system may be impaired if the system is used in a manner not
specified by Agilent.
Environmental Conditions
The Agilent U1840A Medalist sj5000 Automated Optical Inspection System is designed for indoor use only. Table 2-1 shows
general environmental requirements.
Table 2-1
CAUTION
Environment Requirements
Environment Conditions
Requirements
Maximum Altitude
2000 meters
Temperature (Operation)
5 ° C to 40 ° C
Maximum Relative Humidity
The test system is designed to operate
in the range from 5% to 80% relative
humidity (non-condensing) with 80%
for temperature up to 31°C, decreasing
linearly to 50% relative humidity at
40°C
This product is designed for use in Installation Category II and
Pollution Degree 2, per IEC 61010-1 and 664 respectively. The
operating voltage should be in the range of 100-120 VAC/200-240
VAC, 50/60 Hz (8 A) with the Mains Supply Voltage fluctuations not
to exceed ±10% of the nominal voltage.
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
2-3
2
Safety and Regulatory Information
Before Applying Power
Verify that the product is set to match the available line voltage
and all safety precautions are taken. Note the external markings
of the instruments described in “Regulatory Markings”.
Ground The System
To minimize shock hazard, the instrument chassis and cover
must be connected to an electrical protective earth ground. The
instrument must be connected to the ac power mains through a
grounded power cable, with the ground wire firmly connected
to an electrical ground (safety ground) at the power outlet. Any
interruption of the protective (grounding) conductor or
disconnection of the protective earth terminal will cause a
potential shock hazard that could result in personal injury.
Fuses
Use only fuses with the required rated current, voltage, and
specified type (normal blow, time delay). Do not use repaired
fuses or short-circuited fuse holders. To do so could cause a
shock or fire hazard.
In order to avoid electrical hazards, all system internal fuses must
be replaced by trained and qualified personnel.
WA RNING
Operator Safety Information
Module connectors and Test Signal cables connected to them
cannot be operator accessible.
WA RNING
M
Cables and connectors are considered inaccessible if a tool (e.g.
screwdriver, wrench, socket, etc.) or a key (equipment in a
locked cabinet) is required to gain access to a conductive
surface connected to any cable conductor (High, Low or Guard).
WA RNING
2-4
Assure the equipment under test has adequate insulation
between the cable connections and any operator-accessible parts
(doors, covers, panels shields, cases, cabinets, etc.)
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
2
Safety and Regulatory Information
Verify there are multiple and sufficient protective means (rated
for the voltages you are applying) to assure the operator will
NOT come into contact with any energized conductor even if
one of the protective means fails to work as intended. For
example, the inner side of a case, cabinet, door cover or panel
can be covered with an insulating material as well as routing the
test cables to the front panel connectors of the module through
non-conductive, flexible conduit such as that used in electrical
power distribution.
Safety Requirements
The following is a list of the safety requirements for electrical
equipment for measurement control and laboratory use:
• IEC 61010-1:2001 / EN 61010-1:2001
• Canada: CSA- C22.2 No.1010.1:1992
• USA: UL 61010A-1 :2002
See certificate for list of relevant standards.
Machine's Intended Use
In addition with the above environmental conditions, the
machine is designed to be used solely in a Surface Mount
Technologies (SMT) production line.
CAUTION
This machine must only be used with conveyors on both sides
either in-line or in off-line operation. This is to prevent users from
accessing pinch points inside the machine.
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
2-5
2
Safety and Regulatory Information
Electrical Safety
Electrical Enclosure
Live power and control circuits are situated in various parts of
the machine.
• The Main Control Panel is accessed through the rear access
panel, which is mechanically locked.
• During the Off position, the machine only has main voltage on
the primary side of the Main Isolator.
WA RNING
LETHAL VOLTAGE
DANGEROUS VOLTAGES EXIST IN THIS EQUIPMENT. ENSURE
THAT ALL ELECTRICAL ENCLOSURE COVERS ARE FITTED AND
INTACT BEFORE OPERATING THE EQUIPMENT.
Emergency Stop Loop
The Emergency Stop (E-Stop) is designed according to the
relevant safety standard. It is controlled using a Carlo Gavazzi
Class IV safety relay.
NOTE
The sj5000 has four clearly visible and identifiable emergency stop
buttons, two on the front of the machine and two on the back. To activate
these buttons, push in once on the red pushbutton.
Refer to the hardware manual for E-stop locations on the
sj5000. The E-stop system is also activated by opening the
system's front access door.
2-6
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
2
Safety and Regulatory Information
The Emergency stop circuit has the following attributes
associated with it:
• During an E-Stop, power is removed from all motors
including conveyors and XY Table. The only exception is that
turning the maintenance key switch to the "on" position
re-enables power to the clamping motors. This allows the
clamping motors to be operated for engineering tests,
troubleshooting or calibration.
• E-Stop overrides all modes of operation within the SJ5000
machine.
• When power is removed from the system, the E-Stop is
activated automatically and must be reset on powering the
machine back up.
There are two ways to reset the E-stop. If the system
software is running, click Okay to remove the E-stop
condition. If the system software is not running, press the
blue ES RESET button on the switch plate. In either case, you
must first fix the condition that caused the E-stop by either
closing the front door or pulling the E-stop button out.
Front Switch Panel - sj5000
• On startup, NO uncontrolled motion can occur.
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
2-7
2
Safety and Regulatory Information
• The E-stop circuit has two channels, both of which go
through all four E-stop switches and the front door switch. If
either channel of the E-stop circuit is activated, an E-stop
condition will result, and no motive power to the gantry or
conveyor will be applied.
• Resetting the E-stop circuit can only happen when both
safety channels are closed.
• In maintenance mode the user is permitted to operate the
clamping mechanism, as described above.
Earth Bonding
All external metal surfaces are mechanically and electrically
bonded to the machine earth point.
The bonding wire used is identified by its green and yellow
insulation.
2-8
CAUTION
Never remove or cut these wires. If you find a cut or damaged
connection, do not operate the machine and inform a suitable
qualified person as soon as possible.
WA RNING
THIS MACHINE MUST ALWAYS BE EARTHED WHILE IN USE.
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
2
Safety and Regulatory Information
PC Safety
The PC's motherboard contains a lithium battery: CR2032 3V.
See explanation of warning labels.
CAUTION
Dangerous voltages may exist in the PC after the electrical
supply has been disconnected.
There is a danger of explosion if the battery is incorrectly
replaced. Replace only with the same or equivalent type
recommended by the manufacturer.
Dispose of used batteries according to manufacturer
instructions.
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
2-9
2
Safety and Regulatory Information
Physical Safety
Protective Guards
This machine is fitted with a set of protective guards that fully
enclose any moving and electrical mechanisms that may harm
you during normal use. Under no circumstances should these
guards be removed.
WA RNING
DO NOT OPERATE THE MACHINE WHILE ANY OF THE SAFETY
GUARDS ARE OPEN, LOOSE, DAMAGED OR MISSING. THIS
INCLUDES ACCESS PANELS TO THE PC. THE PROTECTION
PROVIDED MAY BE IMPAIRED IF IT IS NOT USED IN THE
CORRECT MANNER.
Pinch Hazards
The machine is fitted with safety side panels on the left and
right hand sides of the platform. These panels protect the user
from electrical and mechanical hazards within the work area.
The user is to be aware of potential pinch hazards situated at
the conveyor entry and exit openings.
To prevent pinch hazards, it is recommended to add additional
guards or covers preventing access to the conveyor entry and
exit openings. These guards could be preventive guards or
conveyors.
2-10
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
2
Safety and Regulatory Information
WA RNING
Moving parts at the conveyor Entry and Exit openings situated at
the sides of the machine. These can cause finger and hand
damage. No attempt should be made to operate the machine
while personnel are working in these areas. E-stop the machine
before placing fingers or hands in these areas. It should be
additionally noted that Agilent recommends that boards should
only enter or exit the sj5000 on a conveyor - not via hand loading.
Machine Stability
CAUTION
This machine weighs approximately 750 kg, and has a low
center of gravity.
Do not attempt to lift or tip the machine at either end or side, as
you could damage both the machine and injured yourself. Do
not even attempt this with the help of others.
Falling Objects
CAUTION
Do not store boards, equipment, stencils, or other material on
top of the machine.
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
2-11
2
Safety and Regulatory Information
System Warning/Caution Labels
The following are a list of warnings and their associated
explanation.
Table 2-2
Safety Symbols
Safety symbols
Explanation
Warning electrical danger.
Label located on both left and right side panels also on right rear door to indicate High Voltage
within.
General warning label.
Located inside PC at the lithium battery.
This indicates you must read the manual before operating the machine.
Label located on front right side of the hood.
Moving parts at the conveyor Entry and Exit openings (for the Board) at the sides of the machine,
which could cause finger and hand damage.
230 Volts warning labels
Location:
•
•
•
•
•
•
PC
Motor Controller
Transformer Cover
Top of front Electrical Box
Main Terminal Trunking Cover
Main filter
Warning that hands could be crushed from below. Location
• Top center of rear panel
2-12
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
2
Safety and Regulatory Information
Table 2-2
Safety Symbols (continued)
Safety symbols
Explanation
Warning to mind your head.
Label located on the front left and right sides of hood.
Warning that maintenance switch is in ON position.
The pneumatic air pressure is actuated.
Using the maintenance GUI, the stops and clamps can be operated; therefore, be caution as pinch
points around clamps can cause injury.
Warning of high voltage.
Location:
• Main Filter
• Main Terminal Trunking
Regulatory Markings
Markings on the system, in manuals and on instruments provide
information about compliance with international regulations.
Table 2-3 defines the markings you may find in a manual or on
an instrument.
Table 2-3
Regulatory Markings
Regulatory markings
The CE mark is a registered trademark of the European Community. This CE mark shows that the
product complies with all the relevant European Legal Directives.
The TUV mark is a registered trademark of the Technischer Uberwachungs-Verein. A TUV mark with
the indicators "C" and "US" means that the product is certified for both the U.S. and Canadian
markets, to the applicable American and Canadian standards.
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
2-13
2
Safety and Regulatory Information
The C-tick mark is a registered trademark of the Spectrum Management Agency of Australia. This
signifies compliance with the Australia EMC Framework regulations under the terms of the Radio
Communication Act of 1992.
This text indicates that the ISM device complies with Canadian ICES-001.
Cet appareil ISM est conforme à la norme NMB-001 du Canada.
This instrument complies with the WEEE Directive (2002/96/EC) marking requirement. This affixed
product label indicates that you must not discard this electrical/electronic product in domestic
householdwaste.
Electrostatic Discharge (ESD) Precautions
Static electricity is destructive to your production process and
the Agilent U1840A Medalist sj5000. Careless handling and poor
site planning can cause system reliability problems and reduce
your product yield. The system may not be as easily damaged as
the modules you will be testing, but good anti-static planning
will help ensure high reliability.
The ESD symbol below indicates areas where ESD caution must
be exercised. This is to prevent damage to instruments and/or
test disruption.
ESD Symbol
Caution: Static Sensitive.
Electrostatic discharge in this area may cause equipment damage or test
disruption.
2-14
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
Safety and Regulatory Information
2
While not an exhaustive list of anti-static precautions, Table 2-4
shows suggestions to consider as you plan your system area:
Table 2-4
CAUTION
Suggested Anti-Static Solutions for Site Planning
Precaution
Suggested Solution
Anti-static flooring
Plan to use an anti-static floor
covering or mats.
Grounding straps
Plan for foot straps in conjunction
with anti-static flooring and wrist
straps for system operators.
The system test rack is secured to the pallet of the shipping crate
and wrapped with a plastic wrap. Do not move the crate or the test
rack and pallet to a static sensitive area until you have removed the
plastic wrap from the test rack.
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
2-15
2
Safety and Regulatory Information
End of Life: Waste Electrical and Electronic Equipment (WEEE) Directive
2002/96/EC
This product complies with the WEEE Directive (2002/96/EC)
marking requirement. The affixed product label (see below)
indicates that you must not discard this electrical/electronic
product in domestic household waste.
Product Category:
With reference to the equipment types in the WEEE directive
Annex 1, this product is classified as a “Monitoring and Control
Instrumentation” product.
Do not dispose in domestic household waste
To return unwanted products, contact your local Agilent office,
or see:
http://www.agilent.com/environment/product
for more information.
2-16
Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
Agilent U1840A Medalist sj5000 Automated Optical Inspection System
Operator Manual <Revision B>
3
Product Overview
Description 3-2
Machine Cycle 3-2
Operator Tasks - Summary 3-3
This chapter provides an overview of the sj5000.
Agilent Technologies
3-1
Product Overview
Description
The sj5000 is a machine vision system that inspects surface
mount technology (SMT) components and solder joints on
printed-circuit assemblies (PCAs).
O N L Y .
R E V
X 0 1
3
The sj5000 performs the following tasks:
• Checks the boards to ensure that the components are present
and placed properly on the board.
U S E
• Checks component polarity if clear orientation indicators are
present on the component body.
• Checks component markings to identify wrong parts.
• Reports defects for repair purposes.
• Displays graphics to represent component placement X and
Y offset distributions at the end of each board inspection.
Machine Cycle
In an inspection cycle, a PCB:
• Enters the system from the upstream machine.
• Is moved until the board stops.
F O R
A G I L E N T
I N T E R N A L
• Inspects post-reflow component solder joints and bridging
regions.
• Is clamped to prevent movement.
C O P Y .
• Is inspected for errors.
• Is released if there are no board defects or if the defect
review is to be done at a separate repair station.
P R E L I M I N A R Y
• Is retained in the system if the defect review is to be done on
the monitor.
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3
Product Overview
Operator Tasks - Summary
An sj5000 operator performs several important tasks. These are
summarized below and described in detail in subsequent
chapters.
1 Select a new board program.
When a new board type is to be inspected, select the board
program.
2 Review all errors on the board and pass or fail the board.
If the sj5000 detects defects, view each failure on the monitor
to verify whether the failures are real. Based on this review,
pass or fail the board. The system then ejects the board.
3 Notify an engineer if the sj5000 cannot inspect a board.
If you encounter problems inspecting a board, or if the
fiducial inspection fails to be carried out successfully, notify
an engineer.
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Product Overview
I N T E R N A L
U S E
O N L Y .
R E V
X 0 1
3
P R E L I M I N A R Y
C O P Y .
F O R
A G I L E N T
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Operator Manual <Revision B>
4
Starting and Stopping the Machine
Powering up the Machine from the 'Mains-Off' Position
Starting up the Software 4-3
Restarting After an E-Stop (Emergency Stop) 4-4
Shutting Down the Machine 4-4
4-2
This chapter describes how to start and shut down the sj5000.
Agilent Technologies
4-1
4
Starting and Stopping the Machine
Powering up the Machine from the 'Mains-Off' Position
To power up the machine from the 'Mains Off' position:
1 Ensure that the X-Y Table is free to move over its entire
envelope before continuing. Remove any tools or equipment
that may hinder the table as it moves inside the enclosure.
2 Ensure that the power key switch at the front of the system is
off.
3 Ensure the rear access doors are locked and turn the Mains
Isolator to the ON position.
4 Ensure the Maintenance Switch is in the O position.
5 Ensure that the front door is fully closed.
6 Turn the key switch at the front of the machine to the ON
position if not already in this position. The green indicator
should light.
7 If the system has an uninterruptible power supply (UPS),
turn the unit on.
8 Turn on the Monitor.
9 Ensure all E-Stops are released and push in the E-Stop Reset
button (ES RESET), which is the blue button located to the
left of the AWA IN/OUT buttons on the switch plate.
10 Power on the PC at its ON switch and wait the log-on prompt.
This can take a few minutes.
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4
Starting and Stopping the Machine
Starting up the Software
Follow the steps below to start the sj5000 GUI:
1 Click on the SJ Series icon on the desktop, as shown below:
Or alternatively click: Start → All Programs → Agilent
Technologies → SJ Series
2 When the TaskChooser (shown below) appears click on the
Inspect Boards? icon.
You are now in Operator mode.
3 Ensure the correct program for the current PCA is selected,
The PCA will automatically be inspected once the PCA enters
the system.
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4
Starting and Stopping the Machine
Restarting After an E-Stop (Emergency Stop)
Follow the steps below to restore normal operation after an
Emergency stop:
1 Ensure that the X-Y Table is free to move over its entire
envelope before continuing. Ensure no equipment or tools
are left inside the machine.
2 Ensure the Maintenance Switch is in the O position
3 Ensure that the front door is fully closed.
4 Pull out the four E-Stop buttons until they stay up.
5 If the GUI software is running, click Okay on the Emergency
stop message to reset the software.
Shutting Down the Machine
When you have finished inspecting boards, eject the final board
and shut down the machine using the following steps:
1 Close the GUI interface by shutting the window using the X
in the upper right corner.
2 The following message is displayed:
Click the Yes button to close the software or No to cancel the
shut down.
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Starting and Stopping the Machine
4
3 Shut down the PC by clicking Start → Shut Down. Make sure
the Shut down option is selected; then click OK.
4 Turn off the UPS if one is installed. Turn off the main system
power key. Side view of UPS installed in sj5000[Beside PC] is
shown below.
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Starting and Stopping the Machine
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Operator Manual <Revision B>
5
Inspecting Boards
Overview of Operator Screen 5-2
Selecting Inspection Program 5-3
Manual Conveyor Width Adjustment 5-5
Inspecting Boards 5-7
Inspection Summary Information 5-8
Lighting Tower 5-9
This section describes the sj5000 startup and the typical
functions involving program preparation.
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5-1
5
Inspecting Boards
Overview of Operator Screen
Below is an image of the screen when the operator logs into the
GUI software under Operator level.
The Inspect Boards? option takes you into Operator mode, which
does not require a password
1 Board Select - when this button is clicked, another window
opens for the user to choose which board to run (see
Selecting Inspection Program).
2 Run Summary - Displays statistics of recent board runs
3 Main Display Area - This displays the camera view, board
graphic or inspection summary.
4 Status Bar - This indicates the current status of the machine.
A summary for the last board is shown between inspections.
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5
Inspecting Boards
Selecting Inspection Program
Follow the steps below to select an inspection program:
1 Ensure no boards are present in the inspection machine.
2 Click the Board Select button.
3 In the window that appears, select the name of the board to
test and click Load.
4 If Auto Width Adjust is enabled, the conveyor will
automatically adjust conveyor width for the loaded board
program. If the conveyor does not adjust to the correct
width, change the conveyor width as described in Manual
Conveyor Width Adjustment.
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5
Inspecting Boards
5 The software displays a graphic showing the location of
components on the board.
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5
Inspecting Boards
Manual Conveyor Width Adjustment
You may have to adjust the conveyor rail width to accommodate
a new board through the sj5000. Follow the steps below to
manually adjust the conveyor rail width.
NOTE
The rail width cannot be changed if there are any boards inside the
machine.
1 Ensure no boards are present in the inspection machine.
NOTE
When you press and hold the AWA IN/OUT button for few seconds, the
conveyor switches on. Wait until the conveyor switches off again before
continuing. This usually takes a few seconds.
If you see the error message below, remove any board or foreign material
from the conveyor.
Press "PLC RESET" button at front switch Panel sj5000 to manually
adjust the conveyor.
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5
Inspecting Boards
2 Press the In or Out buttons to adjust conveyor rail width. The
white button moves the adjustable rail in, and the black
button moves it out.
NOTE
When initializing width adjust, the conveyor will switch on briefly to
check if there are any boards in the machine. The machine will not accept
a board from an upstream machine whilst AWA functionality is on.
Front Switch Panel of sj5000
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5
Inspecting Boards
Inspecting Boards
Inspect a board using the following steps:
1 Confirm that the correct inspection program is loaded by
verifying the program name in the upper left portion of the
main operator interface.
2 Load a board into the machine.
3 The machine automatically starts inspecting the board.
4 When inspection is completed;
• If defects were found, the operator may be asked to review
the defects on the inspection machine - see Defect Review
The need for the operator to do this depends upon how
site engineering has configured the machine.
• If no defects were found, the board passes inspection and
will be automatically ejected from the machine.
5 The machine is ready to accept the next board after the
current board leaves the machine.
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5
Inspecting Boards
Inspection Summary Information
A summary of the last board inspection is shown on screen
whilst waiting for the next board to inspect.
1 Mean and Standard Deviation (Sigma) for last inspection
2 Bullseye Chart - Shows offsets measured during last
inspection.
3 X and Y Offset - Histograms chart for last inspection
4 Run Summary - Displays statistics for boards recently
inspected
5 Defects Map - A board graphic colour coded by defect type
6 Defect Counts - Statistics from the last inspection
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Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual
Inspecting Boards
5
Lighting Tower
The lighting tower shows machine status.
• RED - Machine Stopped - Defects found requiring review. An
alarm may also be sounded
• AMBER - Machine not busy - No boards available or
downstream machine busy
• GREEN - Machine Inspecting
• RED + AMBER + GREEN - Machine error - Example:
Emergency Stop
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Inspecting Boards
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Operator Manual <Revision B>
6
Defect Review Process
AOF (Action On Fail) Toolbar 6-2
Operator AOF Shortcut Keys 6-3
Defect Review 6-3
Defect Types 6-4
This chapter is only applicable when the sj5000 system is
configured for operators to review defects on the machine.
NOTE
For defect review using a separate repair station please consult the
relevant manual relevant for repair solution.
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6
Defect Review Process
AOF (Action On Fail) Toolbar
The AOF toolbar will be displayed at the end of inspection when
defects are found on the board.
The table below shows all possible buttons available on the AOF
toolbar menu.
Button
Function
This brings the user to the next failed component
detected during inspection.
This returns the user to the previously inspected
component.
This option releases the board from the SJ to the
downstream system.
This command allows the user to reinspect the current
failed component.
Colored boxes used by the inspection algorithm will be
displayed over the defective component.
This allows the user to mark False Fail if the sj5000
incorrectly reports a component or joint as being
defective.
If you click this button, the following window will
appear:
The Operator must enter a reason for marking this
component as a false fail. Click OK when finished.
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6
Defect Review Process
Operator AOF Shortcut Keys
The AOF mode in Operator level has keyboard shortcut keys
associated with various action.
These are listed in the table below:
Shortcut Key
Command
CTRL + P
Move to the previous error
CTRL + N
Move to the next error
CTRL + R
Release the board
CTRL + G
Toggle the graphics on the board
CTRL + S
Open the Load Board dialog
Defect Review
Follow the steps below to review defects:
1 Examine each defect by clicking the Next button.
2 Click the Reinspect button to show the inspection graphics.
3 If a False Fail (incorrect defect report) is encountered,
Notify an engineer
OR
Click the False Fail button if this option is enabled.
4 After inspecting each of the errors on the board, click Release
Board to release the PCA to the downstream machine.
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Defect Review Process
Defect Types
The following table lists and describes the defect types reported
by the sj5000.
Error
Description
Missing
The component has not been placed on the PCB or has fallen off, or a component that was not
supposed to be loaded is on the board.
Hor Off
The component has failed inspection because it has a horizontal offset that is greater than the offset
threshold.
Left/Right Off
The component has failed inspection because it has a vertical offset greater than the offset threshold.
Skew
The component has failed inspection because it is rotated more than permitted by the skew threshold.
Polarity
The component, although present, has failed inspection because it has been placed at the wrong
orientation.
Bad Joint
A solder joint has failed inspection due to insufficient or excess solder, a lifted lead or many other
possible reasons.
Bridging
Solder bridging is found in between leads or adjacent to the component.
Tweeze
A lead on an SOIC, QFP, TSSOP or similar component is bent.
Billboard
The component is present, but is sitting on its edge rather than flat on the board.
Flipped
The component is present but has been placed face-down.
Extra Part
A component has been placed at a location which should be left empty.
Barcode
The barcode was missing or not readable by the system camera.
OCV/OCR
The component failed inspection because an expected marking or symbol could not be found.
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