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]
Warranty
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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
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shall not be liable for errors or for
incidental or consequential damages
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have a separate written agreement
with warranty terms covering the
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flict with these terms, the warranty
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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-
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(June 1995), or as a “commercial item” as
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ment users will receive no greater than
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(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.

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.)