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Agilent Technologies

Agilent U1840A Medalist sj5000 Automated Optical Inspection System

Operator Manual

Notices© Agilent Technologies, Inc. 2007

No part of this manual may be reproduced in any form or by any means (including electronic storage and retrieval or transla-tion into a foreign language) without prior agreement and written consent from Agilent Technologies, Inc. as governed by United States and international copyright laws.

Manual Part Number5186-5818

RevisionRevision 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

WarrantyThe material contained in this docu-ment is provided “as is,” and is sub-ject to being changed, without notice, in future editions. Further, to the maximum extent permitted by appli-cable law, Agilent disclaims all war-ranties, either express or implied, with regard to this manual and any information contained herein, includ-ing but not limited to the implied warranties of merchantability and fit-ness 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 con-flict 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 LegendIf 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 soft-ware” 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. Govern-ment 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 haz-ard. It calls attention to an operat-ing 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.

WARNING

A WARNING notice denotes a hazard. It calls attention to an operating procedure, practice, or the like that, if not correctly per-formed or adhered to, could result in personal injury or death. Do not proceed beyond a WARNING notice until the indicated condi-tions are fully understood and met.

iii

Agilent U1840A Medalist sj5000 Automated Optical Inspection SystemOperator Manual <Revision B>


Revision History

Revision Nature of Change Author Date

A First Release KA/KS 14 December 2007

B Correct hyperlinks in manual.

Change shortcut-key from ALT to CTRL

Added "Is moved until board stops" to Machine Cycle.

YL Ng

Ayaru Alagesan

24 March 2008

iv Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual

1 Revision History

THIS PAGE IS INTENTIONALLY LEFT BLANK.

Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual v

Contents1 Revision History

1 Legal InformationLegal Information 1-2

Warranty 1-2Technology Licenses 1-2Restricted Rights Legend 1-2Service And Support 1-3Agilent On The Web 1-3Agilent By Phone 1-3Table 1-1. Agilent Call Centers and Regional Headquarters 1-3

2 Safety and Regulatory InformationSafety Information 2-2Safety Summary 2-2Safety Notice 2-2General 2-2Environmental Conditions 2-3Table 2-1. Environment Requirements 2-3Before Applying Power 2-4Ground The System 2-4Fuses 2-4Operator Safety Information 2-4Safety Requirements 2-5Machine's Intended Use 2-5

Electrical Safety 2-6Electrical Enclosure 2-6Emergency Stop Loop 2-6Earth Bonding 2-8PC Safety 2-9

Physical Safety 2-10Protective Guards 2-10Pinch Hazards 2-10Machine Stability 2-11

vi Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual

Falling Objects 2-11

System Warning/Caution Labels 2-12Table 2-2. Safety Symbols 2-12Regulatory Markings 2-13Table 2-3. Regulatory Markings 2-13

Electrostatic Discharge (ESD) Precautions 2-14Table 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 OverviewDescription 3-2

Machine Cycle 3-2

Operator Tasks - Summary 3-3

4 Starting and Stopping the MachinePowering up the Machine from the 'Mains-Off' Position 4-2

Starting up the Software 4-3

Restarting After an E-Stop (Emergency Stop) 4-4

Shutting Down the Machine 4-4

5 Inspecting BoardsOverview 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

6 Defect Review ProcessAOF (Action On Fail) Toolbar 6-2

Operator AOF Shortcut Keys 6-3

Defect Review 6-3

Defect Types 6-4

1-1

Automated Optical Inspection SystemOperator Manual <Revision B>


1Legal InformationWarranty 1-2Technology Licenses 1-2Restricted Rights Legend 1-2Service And Support 1-3Agilent On The Web 1-3Agilent By Phone 1-3

1-2 Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual

1 Legal Information

Legal Information

WarrantyThe 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 LicensesThe 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 LegendIf 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.

Legal Information 1

Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator Manual 1-3

Service And SupportAny 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 WebFor 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 PhoneIf you do not have access to the Internet, call one of the numbers in Table 1-1.

Table 1-1 Agilent Call Centers and Regional Headquarters

Americas: Canada (877) 894-4414

Latin America 305 269 7500

United States (800) 829-4444

Asia-Pacific: 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


1 Legal Information

Manufacturing AddressAgilent Technologies Microwave Products (Malaysia) Sdn. Bhd.

Bayan Lepas Free Industrial Zone,

11900 Penang,

Malaysia.

Phone: 60 (4) 680 5582

Fax: 60 (4) 680 8493

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

2-1



2Safety and Regulatory Information

Safety Information 2-2Safety Summary 2-2Safety Notice 2-2General 2-2Environmental Conditions 2-3Before Applying Power 2-4Ground The System 2-4Fuses 2-4Operator Safety Information 2-4Safety Requirements 2-5Machine's Intended Use 2-5Electrical Enclosure 2-6Emergency Stop Loop 2-6Earth Bonding 2-8PC Safety 2-9Protective Guards 2-10Pinch Hazards 2-10Machine Stability 2-11Falling Objects 2-11System Warning/Caution Labels 2-12Regulatory Markings 2-13Electrostatic Discharge (ESD) Precautions 2-14End of Life: Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/EC 2-16


2 Safety and Regulatory Information

Safety Information

Safety SummaryThe 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

GeneralThis 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.

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.

WARNING 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.

WARNING DO NOT OPERATE IN AN EXPLOSIVE ATMOSPHERE. Do not operate the product in the presence of flammable gases or flames.

Safety and Regulatory Information 2


Environmental ConditionsThe Agilent U1840A Medalist sj5000 Automated Optical Inspec-tion System is designed for indoor use only. Table 2-1 shows general environmental requirements.

WARNING 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.

WARNING 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.

Table 2-1 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

° °

CAUTION 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.



Before Applying PowerVerify 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 SystemTo 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.

FusesUse 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.

Operator Safety Information

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).

WARNING In order to avoid electrical hazards, all system internal fuses must be replaced by trained and qualified personnel.

WARNINGM

Module connectors and Test Signal cables connected to them cannot be operator accessible.

WARNING Assure the equipment under test has adequate insulation between the cable connections and any operator-accessible parts (doors, covers, panels shields, cases, cabinets, etc.)



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 RequirementsThe 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 UseIn 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.



Electrical Safety

Electrical EnclosureLive 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.

Emergency Stop LoopThe Emergency Stop (E-Stop) is designed according to the relevant safety standard. It is controlled using a Carlo Gavazzi Class IV safety relay.

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.

WARNING LETHAL VOLTAGEDANGEROUS VOLTAGES EXIST IN THIS EQUIPMENT. ENSURE THAT ALL ELECTRICAL ENCLOSURE COVERS ARE FITTED AND INTACT BEFORE OPERATING THE EQUIPMENT.

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.



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.



• 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 BondingAll 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.

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.

WARNING THIS MACHINE MUST ALWAYS BE EARTHED WHILE IN USE.



PC SafetyThe 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.



Physical Safety

Protective GuardsThis 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.

Pinch HazardsThe 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.

WARNING 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.



Machine Stability

Falling Objects

WARNING 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.

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.

CAUTION Do not store boards, equipment, stencils, or other material on top of the machine.



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



Regulatory MarkingsMarkings 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

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

Table 2-2 Safety Symbols (continued)

Safety symbols Explanation

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.



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.

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.

ESD SymbolCaution: Static Sensitive. Electrostatic discharge in this area may cause equipment damage or test disruption.



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 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.

CAUTION 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.



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.

3-1



3Product Overview

Description 3-2Machine Cycle 3-2Operator Tasks - Summary 3-3

This chapter provides an overview of the sj5000.


3 Product OverviewP

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The sj5000 is a machine vision system that inspects surface mount technology (SMT) components and solder joints on printed-circuit assemblies (PCAs).

The sj5000 performs the following tasks:

• Checks the boards to ensure that the components are present and placed properly on the board.

• Checks component polarity if clear orientation indicators are present on the component body.

• Checks component markings to identify wrong parts.

• Inspects post-reflow component solder joints and bridging regions.

• 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.

• Is clamped to prevent movement.

• 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.

• Is retained in the system if the defect review is to be done on the monitor.

Product Overview 3


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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4-1



4Starting and Stopping the Machine

Powering up the Machine from the 'Mains-Off' Position 4-2Starting up the Software 4-3Restarting After an E-Stop (Emergency Stop) 4-4Shutting Down the Machine 4-4

This chapter describes how to start and shut down the sj5000.


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.

Starting and Stopping the Machine 4


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.



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.

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.




5-1



5Inspecting Boards

Overview of Operator Screen 5-2Selecting Inspection Program 5-3Manual Conveyor Width Adjustment 5-5Inspecting Boards 5-7Inspection Summary Information 5-8Lighting Tower 5-9

This section describes the sj5000 startup and the typical functions involving program preparation.


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.

Inspecting Boards 5


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.


5 Inspecting Boards

5 The software displays a graphic showing the location of components on the board.

Inspecting Boards 5


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.

1 Ensure no boards are present in the inspection machine.

NOTE The rail width cannot be changed if there are any boards inside the 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.


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.

Front Switch Panel of sj5000

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.

Inspecting Boards 5


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.


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

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


5 Inspecting Boards


6-1



6Defect Review Process

AOF (Action On Fail) Toolbar 6-2Operator AOF Shortcut Keys 6-3Defect Review 6-3Defect 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.


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.

Defect Review Process 6


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:

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.

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


6 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.

Documents

Agilent U1840A Medalist sj5000 Automated Optical ...literature.cdn.keysight.com/litweb/pdf/5186-5818.pdf · Agilent U1840A Medalist sj5000 Automated Optical Inspection System Operator