Agilent Technologies U1840A Medalist sj5000 User manual

Agilent Technologies
Agilent U1840A
Medalist sj5000
Automated Optical
Inspection System
Hardware 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 Number
5186-5789
Revision
Revision A, December 2007
Agilent Technologies Microwave Products
(Malaysia) Sdn. Bhd.
Bayan Lepas Free Industrial Zone
11900 Penang, Malaysia
Phone: [phone]
Fax: [phone]
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ject to being changed, without notice,
in future editions. Further, to the
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The hardware and/or software described
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If software is for use in the performance of
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(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.

Agilent U1840A Medalist sj5000 Hardware Manual iii
Contents
1 Safety and Regulatory Information
Safety Information 1-2
Electrical Safety 1-6
Physical Safety 1-10
System Warning/Caution Labels 1-12
Electrostatic Discharge (ESD) Precautions 1-14
End of Life: Waste Electrical and Electronic Equipment (WEEE) Directive
2002/96/EC 1-16
2 Introduction to the Medalist sj5000
Advantages of the Medalist sj5000 2-2
Post-Reflow Inspection 2-3
Camera Navigation 2-4
Parts of the Medalist sj5000 2-5
System Overview 2-5
Front View 2-6
Rear View 2-9
Conveyor 2-11
Power and Communications 2-13
Electrical Power 2-13
Communications 2-14
3 Installation
Checking the Facilities and Tools 3-2
Unpacking the sj5000 3-2
Moving the sj5000 3-4
Adjusting the Height and Leveling the sj5000 3-6
Mounting the Lighting Tower 3-7
Installing the Keyboard and Monitor 3-8
Connecting the Mains Cable 3-10

iv Agilent U1840A Medalist sj5000 Hardware Manual
Earth Cable Connection 3-11
4 Starting Up the Medalist sj5000
Before Powering Up 4-2
Powering Up the sj5000 for the First Time 4-3
Powering Up From the Mains Off Position 4-4
Powering Up to Restore From an Emergency Stop 4-5
Machine Cycle 4-5
5 Changing the Conveyor Rail Width
Sensors and Flags 5-2
Manual Width Adjust 5-3
Auto Width Adjust 5-4
The Auto Width Adjust Window 5-4
6 Auto Width Adjust Conveyor Setup
Linear Mechanical Setup 6-2
Conveyor Edge Clearance Adjustment 6-3
AWA Mechanical Setup 6-6
AWA Setup and Calibration 6-7
Auto Width Adjust Calibration 6-7
Conveyor Width Adjustment 6-10
Testing the Move, Stop, and Jog Functions 6-11
General Conveyor Checks 6-12
Board Sensor Checks 6-13
AWA Conveyor Component Alignment 6-15
Clamp Home Sensor Adjustment 6-16
Conveyor Speed Adjustment 6-18
Changing Conveyor Direction 6-19
7 Camera and Lighting Calibration
Camera Calibration 7-2
Focusing the Camera 7-2
Auto-Scaling 7-6
Lighting Calibration 7-9
Lighting Calibration (Manual) 7-10
Auto Calibration 7-12
Calibration on Location 7-13

Agilent U1840A Medalist sj5000 Hardware Manual v
The Lighting Controller Window 7-14
Lighting Calibration Files 7-16
Lens Foreign Body Check 7-17
8 Camera and Lighting Controller Testing
Camera Testing 8-2
Lighting Controller Testing 8-5
9 Downloading PLC Programs
Downloading Using a USB Cable 9-2
Downloading Using the Serial Cable 9-4
Selecting Dual or Single Lane Operation 9-6
10 Setting Up Barcode Readers
Microscan MS-4 USB Barcode Reader 10-2
Install Microscan ESP Software 10-2
Install USB-to-Serial Virtual Com Port Driver 10-2
Download Barcode Reader Setup File 10-3
Set Up Multiple Barcode Readers 10-5
Align Barcode Reader 10-7
Test Barcode Reader Using HyperTerminal 10-8
Configure sj5000 Software 10-8
Microscan MS-820 Serial Barcode Reader 10-10
Set Up Single Barcode Reader 10-10
Set Up Dual Barcode Reader 10-12
Handheld Barcode Reader 10-15
Install the Barcode Reader 10-15
Program the Barcode Reader 10-17
11 Troubleshooting
Error Messages 11-2
Troubleshooting the Software 11-3
Troubleshooting the System Power 11-6
Troubleshooting the 24 V Supply 11-6
Troubleshooting the Conveyor 11-7
Troubleshooting the Camera 11-12
Troubleshooting the Lighting Controller 11-15
Troubleshooting the Lighting Tower 11-16

vi Agilent U1840A Medalist sj5000 Hardware Manual
Troubleshooting the PC and Monitor 11-17
Troubleshooting the Safety Relay 11-18
Troubleshooting the XY Table 11-19
Checking the System 11-20
Troubleshooting 11-38
12 Maintenance
Overview 12-2
Weekly Maintenance 12-3
Monthly Maintenance 12-6
Quarterly Maintenance 12-8
Yearly Maintenance 12-9
A System Specifications
B Reference Documents

1-1
Agilent U1840A Medalist sj5000 Automated Optical Inspection System
Hardware Manual
Agilent Technologies
1
Safety and Regulatory Information
Safety Information 1-2
Electrical Safety 1-6
Physical Safety 1-10
System Warning/Caution Labels 1-12
Electrostatic Discharge (ESD) Precautions 1-14
End of Life: Waste Electrical and Electronic Equipment (WEEE) Directive
2002/96/EC 1-16

1-2 Agilent U1840A Medalist sj5000 Hardware Manual
1Safety 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
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.
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 1
Agilent U1840A Medalist sj5000 Hardware Manual 1-3
Environmental Conditions
The Agilent U1840A Medalist sj5000 Automated Optical Inspec-
tion System is designed for indoor use only. Table 1-1 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 1-1 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.

1-4 Agilent U1840A Medalist sj5000 Hardware Manual
1Safety 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.
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.
WARNING
M
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.)

Safety and Regulatory Information 1
Agilent U1840A Medalist sj5000 Hardware Manual 1-5
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.

1-6 Agilent U1840A Medalist sj5000 Hardware Manual
1Safety 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.
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.
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 VOLTAGE
DANGEROUS 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.

Safety and Regulatory Information 1
Agilent U1840A Medalist sj5000 Hardware Manual 1-7
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.

1-8 Agilent U1840A Medalist sj5000 Hardware Manual
1Safety 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.
PC Safety
The PC's motherboard contains a lithium battery: CR2032 3V.
See explanation of warning labels.
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.
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.

Safety and Regulatory Information 1
Agilent U1840A Medalist sj5000 Hardware Manual 1-9

1-10 Agilent U1840A Medalist sj5000 Hardware Manual
1Safety 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.
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.
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.

Safety and Regulatory Information 1
Agilent U1840A Medalist sj5000 Hardware Manual 1-11
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.

1-12 Agilent U1840A Medalist sj5000 Hardware Manual
1Safety and Regulatory Information
System Warning/Caution Labels
The following are a list of warnings and their associated
explanation.
Table 1-2 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
•Transform er C over
•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

Safety and Regulatory Information 1
Agilent U1840A Medalist sj5000 Hardware Manual 1-13
Regulatory Markings
Markings on the system, in manuals and on instruments provide
information about compliance with international regulations.
Table 1-3 defines the markings you may find in a manual or on
an instrument.
Table 1-3 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 1-2 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.

1-14 Agilent U1840A Medalist sj5000 Hardware Manual
1Safety and Regulatory Information
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 household waste.
ESD Symbol
Caution: Static Sensitive.
Electrostatic discharge in this area may cause equipment damage or test
disruption.