ATG A3 User manual

User Manual for
Flying Probe Test System
V3.7

A-2
Test system A 3 V3.7
Thetestsystemmayonlybestarted,operatedandturnedoffbyatrainedoperator.A
trained supervisor may only carry out the password-protected operations.
Beforeturningonthesystem,theoperatormusthavereadthisquickreferencemanual
especially observing the documented safety precautions.
As far as no appropriate training on part of the company atg has taken place the
operator is not authorized to carry out the following activities:
- Transport
- Assembly
- Mounting
- Putting into operation
- Adjustment
- Repair
- Trouble shooting
- Putting out of operation
- Disassembly
The Reader should be familiar with the use of Windows.
This transcript only represents a draft. Therefore, it may not be accepted as faultless
and complete. We reserve the right for technical changes and errors.
Thishandbookisprotectedby copyright.Allrights reserved.Duplicationsof anykind,
storage and translations only by written permission of
atgtest systems GmbH
Zum Schlag 3
D-97877 Wertheim
Germany
Tel. [phone] / 2 91 - 0
Fax [phone] / 3 95 10
E-mail:[email protected]
Internet:www.atg-test-systems.de
This manual can be corrected and adapted to the technical progress at any time
without prior notice. 6/2001

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Test System A 3 V3.7
Table of Contents
Directions for avoiding personal injuries .............................................................A-6
atg test systems Software Certificate...................................................................A-9
Informationforusers ............................................................................................A-9
1. System Overview..........................................................................................A-10
1.1 Unloading and Transporting the Flying Probe Test System A3...................A-10
1.2 General View of the Test System................................................................A-12
1.3 General View of the Shuttle ........................................................................A-14
1.4 Assembly Rack...........................................................................................A-16
1.5 Test Requirement for Repaired Boards ......................................................A-18
1.6 The Operating Modes of the A3 Test System .............................................A-19
2. Turning on the Test System...........................................................................A-20
3. The User Mode...............................................................................................B-1
3.1 The User Interface of the User Mode .............................................................B-1
3.1.1 Status Field ................................................................................................B-2
3.1.2Buttons .......................................................................................................B-3
3.2 Load job ........................................................................................................B-4
4. Adjusting to a New Board................................................................................B-6
4.1 Ejecting the Shuttle .......................................................................................B-6
4.2 Adjusting the Product Holders.......................................................................B-7
4.2.1 Selecting the proper Terminal Bar Sizes ....................................................B-7
5. Starting a Test in User Mode .........................................................................B-10
5.1 Button Test Params (F5) in the User Mode..................................................B-12
5.1.1 Tab-box: Skip panels................................................................................B-12
5.1.2 Tab-Box: Misc...........................................................................................B-13
5.2 Scanning (Determining the board position with the camera) .......................B-15
5.2.1 Manual scanning ......................................................................................B-17
5.2.2 Automatic scanning ..................................................................................B-18
5.2.3 Wrong Board Position...............................................................................B-19
5.2.4 Canceling the scanning process ..............................................................B-19

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Test system A 3 V3.7
5.2.5 The Beginning of the Test ........................................................................B-20
5.2.6 Pausing and Resuming a Test .................................................................B-20
5.2.7 Canceling the test....................................................................................B-20
5.3 Test Result Output......................................................................................B-21
6. Removing the tested Board and inserting a new One...................................B-24
6.1 Turning off the Test System.........................................................................B-24
7. The Supervisor Mode ......................................................................................C-1
7.1Introduction....................................................................................................C-1
7.2 Switching to the Supervisor Mode .................................................................C-2
7.3 Changing the Password ................................................................................C-4
7.4 Generate Service Data ..................................................................................C-5
7.5 Test statistics.................................................................................................C-6
7.6 The operating window of the supervisor mode ..............................................C-7
7.7 The Functions of the new Supervisor Mode Buttons ....................................C-8
7.8 The Main Menus of the Supervisor Mode .....................................................C-9
7.8.1 The Main Menu Faults................................................................................C-9
7.8.2 The Menu Items of the Main Menu Faults.................................................C-10
7.8.3 Main Menu Debug ....................................................................................C-17
7.8.4 Main Menu Options...................................................................................C-23
7.8.5 Main Menu Item Show <boardname> .......................................................C-24
7.8.6 The Main Menu Tools...............................................................................C-33
7.8.7 Main Menu View.......................................................................................C-37
7.8.8 Main Menu Scanmarks .............................................................................C-37
7.8.9 Main Menu Antennae ...............................................................................C-41
7.8.10 Main Menu Faults ...................................................................................C-43
7.8.11 Main menu Markers ................................................................................C-46
7.8.11 The Main Menu Item Close.....................................................................C-46
7.9 Action Buttons of the Supervisor Mode........................................................C-47
7.9.1 Button Test Params (F5)...........................................................................C-49
8. Appendix ........................................................................................................D-1
8.1 Starting the Debugger ...................................................................................D-1
8.2 How to Calibrate the A 3 Test System ...........................................................D-2
8.3.1 Executing the C-Adjust ..............................................................................D-6
8.4 Exchanging a Test Needle ............................................................................D-8
8.4.1 Checklist for the Test Needle Exchange.....................................................D-8
8.4.2 Exchanging the Test Tip.............................................................................D-9

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Test System A 3 V3.7
8.4.3 Removal of the entire Needle Fixture .........................................................D-9
8.5 Z-Axis Removal...........................................................................................D-11
8.6 Z-Axis Installation........................................................................................D-13
8.6.1 Preparation...............................................................................................D-13
8.6.2 Assembly..................................................................................................D-14
8.6.3 Final Test..................................................................................................D-15
8.6.4 Error Messages after Z-axis Installation and their Probable Causes ........D-16
8.7 Avoiding Test Head Damages ....................................................................D-18
8.8 Testing Flexible PCBs.................................................................................D-19
8.8.1 The Simple frame .....................................................................................D-19
8.8.2 The Sandwich frame.................................................................................D-20
8.9 The Application of a Test tray for Testing Flexible Boards ..........................D-21
8.10 The A 3-Test Protocol................................................................................D-23
8.11 Brief Flow Chart of Data Preparation.........................................................D-26
8.12 Technical Specifications A 3 .....................................................................D-27
8.13 Maintenance Plan .....................................................................................D-29

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Test system A 3 V3.7
Directions for avoiding personal injuries
Inordertoavoid personalinjuries,the followingdirectionsshouldbepaid attentionto:
General Directions
Observe all safety and danger directions on the test system.
Onlyelectricalspecialistsortrainedpersonnelsupervisedand guidedbyanelectrical
specialist according to the electrical engineering regulations are authorized to carry
out work on the electrical equipment of the test system.
Take measures to only operate the machine in safe and functional condition!
Onlyoperate themachineif allsafetyprecautions andsafetyrequired equipmente.g.
detachable safety equipment, emergency off furnishings, etc. are installed and
functional!
In case of operational malfunctions immediately turn off and secure the machine!
Malfunctions must be eliminated promptly!
Electrical Energy
Use only original fuses with the proper current intensity! Turn off the machine
immediately in case of defects in the electrical power supply!
Onlyelectricalspecialistsortrainedpersonnelsupervisedand guidedbyanelectrical
specialist according to the electrical engineering regulations are authorized to carry
out work on the electrical equipment of the test system.
Machineandsystempartsneedinginspection,repairormaintenancemustbevoltage
free-ifrequired.First,checkthepowerlesspartsforresidualvoltagethengroundand
short-circuit them and isolate neighboring powered parts!
The electrical equipment is to be inspected/tested regularly. Defects as for example
loose connections or burnt cables must be eliminated immediately.
Ifitisnecessarytocarryoutworkonpoweredpartscallinasecondpersonthatincase
of an emergency can push the emergency-off button which turns off the voltage.
Securetheworkareawithared-whitesecuritychainandanappropriatewarningsign!
Use only insulated tools!

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Test System A 3 V3.7
In case of working on high voltage assembly racks connect the power cable to the
ground after switching the power off. Then short-circuit the assembly components
such as the capacitors with a grounding bus.
Safety Directions for Product Defects
In order to avoid product defects the following should be observed:
Do not carry out any program changes (software) to programmable control systems!
OrganizationalDirections
General Directions
This manual should be kept in reach of the test system at all times!
Inadditiontothe operator’smanual,universally validandotherobligatoryregulations
concerning the prevention of accidents and environmental protection should be
observed and instructed!
Safetyanddangerconsciousnessamongthepersonnelshouldbecontrolledregularly,
in consideration of the operator’s manual!
Allsafetyanddangerdirectionsaffixedto,atandonthetestsystemmustbevisibleand
clearly readable!
Without prior permission of the manufacturer, do not carry out any exchange, add-on
or reconstruction activities that could impair the machine’s safety!
Spare parts must meet the manufacturer set technical requirements. This is always
guaranteed with original spare parts!
Make sure to meet the deadlines stated in the operator’s manual for recurrent tests/
inspections!
Assignonlytrainedorinstructedpersonnel.Clearlydefine theresponsibilitiesofeach
staff member for either/and operation, preparation, maintenance or repair!
Make sure that only especially appointed personnel operate this machine!

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Test system A 3 V3.7
Maintenance Directions
Makesuretomeetthedeadlinesforadjustment,maintenanceandinspectionactivities
andappointmentssetintheoperator’smanualincludingtheinformationforexchanging
parts/partialequipment!Trainedandqualifiedpersonnelmayonlydotheseactivities.
Before carrying out extraordinary or reparation activities always make sure to inform
the operator! Appoint a responsible supervisor!
Carry out all activities concerning operation, production adaptations, changes or
adjustmentstothetestsystemanditssafetyrequiredequipment,aswellasinspection,
maintenance,repair,andturning-on/offproceduresaccordingtothedocumentationin
the operator’s manual and in the repair directions!
Secure the repair area if required as spaciously as possible!
If the machine is completely turned off for maintenance and repair work it must be
secured against unexpected reactivation:
- Lock up the main control equipment and withdraw the key and/or
- Set up a warning sign next to the main power switch.
If a disassembly of safety equipment is required for set-up, maintenance and repair
activities, the reassembly and inspection of the safety equipment must immediately
take place after the maintenance and repair work is completed.
Directions concerning Material and Environmental Damage
Ensure a safe and environmentally harmless disposal of all substances and material
used for operation as well as of all exchanged parts.

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Test System A 3 V3.7
atg test systems Software Certificate
Youhavepurchasedorleasedatestsystemfromatgtestsystems,Inc.(atg).Thistest
system includes different software programs. All of these software programs are
ownedeitherbyatg or its licensors. atg guarantees that these software programsare
legally licensed from atg or its licensors.
You have the non-exclusive right to use the software in the course of operating the
purchasedorleasedatgtestsystem.Youalsohavetherighttomakeonecopyofeach
program as backup and safety copy.
However, you do not have the right to use the software programs in applications
exceeding the operation of the atg test system or to make copies thereof beyond the
herein-definedscope.Youfurtherdonothavetherighttoprovidethirdpartieswiththis
software unless you sell or lease it together with the rest of the atg test system or to
modify the software programs in any way.
If you sell or lease the atg test system, you are obligated to make sure that the buyer
or lessee is aware of the above-described scope of his right to use the software
programs. Your own right of using the software programs ceases when you sell or
lease the test system.
Information for users
Thetest system meets the requirementsofISO9001only,if once a year ameasu-
rementcalibrationiscarriedoutbythecompanyatgtestsystemsGmbH&Co.KG.
This measurement calibration confirms the national standards of the German
CalibrationService (DKD), the physical technicalfederalinstitution(PTB)or other
national standards of representation of physical units in accordance with the
international unit system (SI).
The test system gets a test badge and a confirmation certificate will be issued.
Please ask for a quotation from your atg-representation.

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Test system A 3 V3.7
1. System Overview
1.1 Unloading and Transporting the Flying
Probe Test System A3
The user is responsible for the company internal transport of the test system
even in the presence of atg personnel. Furthermore, he must pay attention
that all safety and accident prevention precautions are observed.
The appropriate safety gear is to be worn during these activities. The applied
transport devices (crane and lifting devices, forklift, hand forklift etc.) must be
sufficiently dimensioned for the load to be transported!
The transported object including its loose parts must be secured against
moving, turning, tipping, tilting (consider center of gravity!).
Do not walk underneath lifted objects! Sufficiently secure the transported
object! When turning/arranging the transported object in narrow areas pay
attention towards keeping a sufficient safety distance (risk of bruising!)
Inspect the test system for transport damages!
Unloading and Transport:
With a forklift (min. fork length 1.80 m, lifting capacity of at least 1600 kg) drive
underneath the thinner side of the palette and carefully lift the test system off the
transport truck. Move the test system as close as possible to its final operating
destination.
Attention! Wear the appropriate safety gear for these
activities! Pay attention to the generally applicable
safety precautions!
Attention! The accident precaution instructions for
transporting the test system must be compellingly
observed!

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Test System A 3 V3.7
Loosen all 4 screws on the palette bottom side.
Insert the forklift fork (min. fork length 1.20 m, lifting capacity of at least 1600 kg)
from the front side (shuttle side) underneath the test system and carefully lift it off
the palette. The packing foil can be taken off in secured areas.
Store the accessory parts (monitor, spare parts) at the test system.
Size Test SystemA3 Space requirements Test System A3
Width 2.60 m Width 4.10 m
Depth 1.15 m Depth 3.00 m excluding operator’s working
Height 1.90 m (opened) area
Set-up, installation and putting into operation only by atg test
systems service personnel!

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Test system A 3 V3.7
1.2 General View of the Test System
Fig. 1: General view of the A3 test system
1
34
5
6
7
8
89
10
12
2
11
2
2

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Test System A 3 V3.7
Position Description/Function
1 Main Power Switch (gray rotary switch)
MachineOn/Off
2 Emergency Off
Machine Stop
3 Release of shuttle clamp (yellow button)
Release fine adjust for turning knob no. 10
4 Illuminationcontroller top camera
5 Illuminationcontroller bottomcamera (option)
6 Control on (green button)
Machine control on
7 Control off (red button)
Machine control off
8 Flying probes with test needles
9 Shuttle
Ejectable board holding device
10 Signal Light
Indicates the machine status
11 Control Computer
The control PC is located behind this flap.

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Test system A 3 V3.7
1.3 General View of the Shuttle
Fig. 2: General view of the A 3 shuttle
2
2
4
4
5
3
77
99
8
8
88
8
10
6
1

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Test System A 3 V3.7
Position Description/Function
1 Handle for shuttle
2 Fixing screws for left holder
3 Limit stop of shuttle
4 Fixing screws right Holder
5 Tension lever for lateral pressure
6 Spring loaded tense for head on pressure
7 Fixing screws for front holder
8 Clamp pieces
9 Fixing screws for rear holder
10 C-Adjust-Board

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Test system A 3 V3.7
1.4 Assembly Rack
Fig. 3: Assembly racks
1 3 4 5 6 7 8 9a 9b 9c 9d
2

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Test System A 3 V3.7
Position Description/Function
1 Netcard for measure power supply ±15 V / 5 V
2 Extender-I/O-card
3 Head Controller / Motor Driver, Camera(s)
4 Measurement Controller
5 A_MUX(analog-multiplexer)
6 High voltage measuring card (HV 500), option
7 I/O-Controller(controlcard)
8Crate Controller (main control card)
9a Head Unit / Motor Driver, Rail 0 (top, front)
9b Head Unit / Motor Driver, Rail 1 (top, rear)
9c Head Unit / Motor Driver, Rail 2 (bottom, front)
9d Head Unit / Motor Driver, Rail 3 (bottom, rear)

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Test system A 3 V3.7
1.5 Test Requirement for Repaired Boards
Boardstestedfaultyareoftenrepairedandreused.Repairedboardsmustberetested
in a complete test.
Onlyacompletenewtestcangiveacorrectgood-resultbecausetherecanbecertain
fault constellations which can prevent the finding of all other faults (see figure).
Besides this, not all faults can be fixed with the repair or new faults may have
developed.
This does not depend on the applied test system or test method.

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Test System A 3 V3.7
1.6 The Operating Modes of the A3 Test
System
TheTestPlayer,thecontrolsoftwareofthetestsystem,offerstwodifferentoperating
modes:
1. The User Mode
is active directly after starting the Test Player. The user mode provides all basic test
functions, most parameters, however, cannot be modified in the user-mode.
The test runs are normally carried out in the user mode. During this, the possibilities
oftheuserarereducedsofarthatthetestsoftwaremaybelearnedquicklyandapplied
without having to experience great difficulties. The test parameters do not have to be
changed for the user mode, provided that the test parameters were appropriately
preset in the supervisor mode.
2. The Supervisor Mode
canbeactivated fromthe usermodebyenteringapassword.Inthesupervisormode,
you can adjust the basic settings, interrupt the test in progress or carry out controls.
Specially trained personnel must only activate the supervisor mode.
In this handbook, the user-mode and the supervisor-mode are extensively explained
and described.

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Test system A 3 V3.7
2. Turning on the Test System
1. Turn the Main Power Switch (Fig.1, No.1) to the On-position
The Control Off lamp (red key) is illuminated
The control PC boots
The fan of the control unit starts to run
2. Push the Control On-Key (green key)
The Control starts
The signal light shines red
The test probes carry out a short movement
3. Start the TestPlayer- program
On the desktop, start the TestPlayer program by double-clicking its icon.
The operator program TestPlayer starts.
The icons on the desktop of the control PC