Polar Instruments GRS550 User manual

Polar Instruments GmbH
GRS550 User Guide
Polar Instruments GmbH
Aichereben 16
A-4865 Nussdorf
Austria
Tel: [phone]
Fax: [phone]
http://www.polarinstruments.eu
e-mail: [email protected]
MAN586–1120

PRODUCT REGISTRATION
Registering your product ensures you can be kept up to date when upgrades or enhancements
become available.
Please register using the form below.
To: Polar Instruments GmbH
Aichereben 16
A-4865 Nussdorf
Austria
Fax: [phone]
Email: [email protected]
GRS550 serial number:
Installed options:
Name
Company
Job Title
Address
Post/ZIP Code
Country
Telephone
Fax
E-mail

GRS550 with optional cart ACC225

GRS550 USER MANUAL
POLAR INSTRUMENTS GmbH
COPYRIGHT
Copyright 2020 (c) by Polar Instruments GmbH. All rights reserved. This software and
accompanying documentation is the property of Polar Instruments GmbH and is licensed to the
end user by Polar Instruments GmbH or its authorized agents. The use, copying, and
distribution of this software is restricted by the terms of the license agreement.
Due care was exercised in the preparation of this document and accompanying software. Polar
Instruments GmbH shall not be liable for errors contained herein or for incidental or
consequential damages in connection with furnishing, performance, or use of this material.
Polar Instruments GmbH makes no warranties, either expressed or implied, with respect to the
software described in this manual, its quality, performance, merchantability, or fitness for any
particular purpose. DISCLAIMER
1. Disclaimer of Warranties. POLAR MAKES NO OTHER WARRANTIES, EXPRESS, IMPLIED
OR STATUTORY, REGARDING PRODUCTS. ALL OTHER WARRANTIES AS TO THE QUALITY,
CONDITION, MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR NON-
INFRINGEMENT ARE EXPRESSLY DISCLAIMED.
2. Limitation of Liability. POLAR SHALL NOT BE RESPONSIBLE FOR DIRECT DAMAGES IN
EXCESS OF THE PURCHASE PRICE PAID BY THE END USER OR FOR ANY SPECIAL,
CONSEQUENTIAL, INCIDENTAL, OR PUNITIVE DAMAGE, INCLUDING, BUT NOT LIMITED TO,
LOSS OF PROFITS OR DAMAGES TO BUSINESS OR BUSINESS RELATIONS, WHETHER OR
NOT ADVISED IN ADVANCE OF THE POSSIBILITY OF SUCH DAMAGES, THE FOREGOING
LIMITATIONS SHALL APPLY, NOTWITHSTANDING THE FAILURE OF ANY EXCLUSIVE
REMEDIES.
TRADEMARKS
Copyright Polar Instruments GmbH. ©2020
Microsoft, Windows, Windows XP, Windows 7, Windows 10 are registered trademarks of
Microsoft Corporation.
IBM is the registered trademark of International Business Machines Corporation.
Adobe®, Adobe® Reader®, Adobe Acrobat® Reader, Adobe Portable Document Format (PDF)
Copyright 2020 Adobe Systems Incorporated
All other trademarks acknowledged.

GRS550 User Manual Declarations i
Declarations
European Community Directive Conformance Statement
This product conforms to all applicable EC Council Directives, including:
EC Council Directive 89/336/EEC on the approximation of the laws of the Member States
relating to electromagnetic compatibility.
EC Council Directive 73/23/EEC on the harmonisation of the laws of the Member States
relating to electrical equipment designed for use within certain voltage limits.
A declaration of conformity with the requirements of these Directives has been signed by:
Polar Instruments GmbH
Aichereben 16
A-4865 Nussdorf
Austria
Harmonised standards applied in order to verify compliance with these Directives:
EN 50081-1:1992
EN 50082-1:1992
EN 61010-1:1993

ii Safety GRS550 User Manual
Safety
CAUTION — HANDLING
CAUTION: Four person handling required
Exercise caution when carrying or moving the GRS550. The
GRS550 is extremely heavy (100 kg) — the GRS550 should not
be moved or carried by fewer than four persons.
WARNING The LIVE and NEUTRAL lines on this unit are BOTH fused.
This unit contains no user-serviceable parts.
When the unit is connected to its supply, the opening of covers or
removal of panels is likely to expose dangerous voltages. To maintain
operator safety, do not operate the unit unless the enclosure is
complete and securely assembled.
The unit is designed to be used with the OPERATE/ INTERLOCK
OVERRIDE switch in the OPERATE position and the Perspex
hood in the down position. The INTERLOCK OVERRIDE position
is for qualified service personnel only.
DO NOT OVERRIDE THE SAFETY INTERLOCK.
The probe tip is extremely sharp — take care when fitting or
removing boards.
GROUNDING This unit must be earthed (grounded); DO NOT operate the
instrument with the safety earth disconnected.
Ensure the instrument is connected to an outlet with an effective
protective conductor terminal (earth).
DO NOT negate this protective action by using an extension cord
without a protective conductor.
Note: This instrument is fitted with 3-wire grounding type plug
designed to fit only into a grounding type power outlet.
If a special local plug must be fitted to the power cord ensure this
operation is performed by a skilled electronics technician and that
the protective ground connection is maintained. The plug that is
cut off from the power cord must be safely disposed of.

GRS550 User Manual Safety iii
POWER CORD COLOUR CODES
Power cord colour codes are as follows:
Europe
brown live
blue neutral
green/yellow earth (ground)
United States
black live
white neutral
green ground
POWER SUPPLY
Line voltage setting
Check that the indicated line voltage setting corresponds with the
local mains power supply. See the rear panel for line voltage
settings.
To change the line voltage settings refer the instrument to a skilled
electronics technician.
Instructions for changing the line voltage settings are contained in
the Service Manual published by Polar Instruments.

iv Safety GRS550 User Manual
GRS550 OPERATION
This document contains instructions and warnings that must be
observed by the user to ensure safe operation. Operating this
instrument in ways other than detailed in this manual may impair
the protection provided by the instrument and may result in the
instrument becoming unsafe. Retain these instructions for later
use.
The unit is designed for use indoors in an electrical workshop or
factory floor environment at a stable workstation comprising a
bench or similar work surface. The optional custom cart ACC225 is
available as accessory. ACC225 consists of a 19“ Rack for the
GRS550 controller and optional system components, Monitor,
Keyboard arm. Contact Polar Instruments GmbH for details.
Use only the accessories (e.g. test probes and clips) provided by
Polar Instruments.
The instrument must be maintained and repaired by a skilled
electronics technician in accordance with the manufacturer’s
instructions.
If it is likely that the protection has been impaired the instrument
must be made inoperative, secured against unintended operation
and referred to qualified service personnel.
Protection may be impaired if, for example, the instrument:
Shows signs of physical damage
Fails to operate normally when the operating instructions
are followed
Has been stored for prolonged periods under unfavourable
conditions
Has been subjected to excessive transport stresses
Has been exposed to rain or water or been subject to liquid
spills
CAUTION
Electrical Isolation
Always disconnect the board under test from the local mains
supply (including ground) before using this instrument.

GRS550 User Manual Specifications v
Specifications
Electrical
Nodal Impedance Test Facilities
Test Ranges
Junction
Logic
Low
Med
High
Vpk Ipk
1V 500µA
10V 5mA
10V 150mA
20V 1mA
40V 1mA
Test Frequencies
Low
Medium
High
90Hz
500Hz
2kHz
Tolerance adjustment 1 – 99%
For electrical test specifications refer to the measurement system
Operator Manual
Mechanical Probe Head Connected to Channel A output on rear
panel
Table COM connections 4
Linear speed 190mm/second
X-Y Positioning System
Accuracy ± 0.04mm over 300mm (± 0.0016” over 12”)
Resolution 0.016mm (0.0006”)
Repeatability ± 0.008mm (estimate)
Minimum pad size 0.3mm
Probing rate 5 tests/second (depending on test time
& distance moved)
Probing force 6oz/170g (maximum)
Z-axis travel (Main) 100mm
Z-axis travel (Rapid) 10mm (via solenoids)
Max. flying height 100mm
Max. board size 330 x 630mm
Max. board weight 2kg
Max. probing area 330 x 450mm
Visual programming area 300 x 450mm
Interface High-speed Ethernet

vi Specifications GRS550 User Manual
Environmental operating conditions
The instrument is designed for indoor use only under the following
environmental conditions:
Altitude Up to 2000m
Temperature +5°C to +40°C ambient
Relative humidity RH 80% maximum at 31°C — derate
linearly to 50% at 40°C
Mains borne transients As defined by Installation Category II
(Overvoltage Category II) in IEC664
Pollution Degree 2 (IEC664)
Power Requirements
230V ± 10%, 115V ± 10% or 100V ± 10% at 50/60Hz, 250VA.
Line Fuses Refer to the fuse values marked on the rear panel of the
instrument.
Physical characteristics (excluding accessories)
Dimensions:
Width 650 mm (25.6 in.)
Depth 800 mm (31.5 in.)
Height (closed) 524 mm (20.6 in.)
Height (open) 524 mm (38 in.)
Weight 100kg (222 lb.)
Symbols The following symbols are used in this instrument.
CAUTION To prevent damage to this product and to ensure
its safe use observe the specifications given in this manual when
connecting to terminals marked with this symbol.
COM This terminal is internally connected to earth (ground).

GRS550 User Manual Accessories vii
Accessories
Standard Accessories
Joystick lead ACC591
Camera lead ACC592
Test pin carrier ACC594
Common lead ACC198 x 2
Spring pin COM lead ACC585 x 4
GRS550 lead (black) ACC316
GRS550 lead (red) ACC317
GRS550 to PC cable ACC502
Test pin (pack of 25) ACC505
Calibration compound MPA192
Joystick + interface cable ACC593
Grease for lead screw (syringe) MPA197
Light Oil for linear bearings MPA198
GRS550 Operator Manual MAN586
GRS550 Software FSW178
Options
Custom cart incl. Monitor + keyboard arm ACC225
QR/Bar Code Reader ACC349
Status light indicator (pole mounted) ACC348
Active Test Option ACC996
Tooling pins, 3.5mm for mounting of PCB´s ET01140-02
Tooling pins, 4.5mm for mounting of PCB´s ET01141-02
M3 support for mounting of PCB´s ET02393-02
M4 support for mounting of PCB´s ET02393-04
Spare aluminum mounting plate ET00678-07
Contact Polar Instruments GmbH for details on system options

viii Accessories GRS550 User Manual

GRS550 User Manual Accessories ix
GUIDE TO THE MANUAL
Introduction Introduces the Polar Instruments GRS550.
GRS550 general description GRS550 controls and connectors, using COM lines
and probes.
Installation/set up Hardware and software requirements and
instructions for installing and uninstalling the
software.
Using the GRS550 software Getting to know the GRS550, the GRS550
environment and menu system. Using the Live
Instrument facility to examine nodal impedance
signatures.
Creating test lists Creating Test Lists from CAD data and manually
progamming components. Creating and using board
alignment points, excluding components from testing
and controlling the GRS550 display.
Locating board faults
with the GRS550 Using the GRS550 fault location modes to test
boards and locate board faults.
Acquiring reference signatures and testing
components, using alternative signatures and Video
Sectioning for visual board comparison
Maintenance System maintenance and troubleshooting
Reference Keyboard and display colour reference tables,
ActiveX remote control command set

x CONTENTS GRS550 User Manual
CONTENTS
Declarations i
European Community Directive Conformance Statement................................i
Safety ii
CAUTION — HANDLING................................................................................ii
WARNING.......................................................................................................ii
GROUNDING..................................................................................................ii
POWER CORD COLOUR CODES................................................................iii
POWER SUPPLY...........................................................................................iii
Line voltage setting.................................................................................iii
GRS550 OPERATION ...................................................................................iv
CAUTION.......................................................................................................iv
Electrical Isolation...................................................................................iv
Specifications v
Electrical..........................................................................................................v
Nodal Impedance Test Facilities.....................................................................v
Mechanical......................................................................................................v
Environmental operating conditions...............................................................vi
Power Requirements......................................................................................vi
Line Fuses......................................................................................................vi
Physical characteristics (excluding accessories) ...........................................vi
Symbols .........................................................................................................vi
Accessories vii
Standard Accessories ...................................................................................vii
Options..........................................................................................................vii
CONTENTS x
INTRODUCTION TO THE GRS550 1
The GRS550 Fixtureless Tester...............................................................1
Nodal impedance fault finding..................................................................1
Rapid program creation............................................................................1
Fault finding..............................................................................................2
External instrument control ......................................................................2
Schematic display....................................................................................2
Nodal Impedance.....................................................................................2
CAD Netlist files.......................................................................................3
Rapid test file generation .........................................................................3
GRS550 features .....................................................................................3
GRS550 integrated programming and test environment..........................3
Areas of application..................................................................................4
PC Control................................................................................................4
GRS550 GENERAL DESCRIPTION 5

GRS550 User Manual CONTENTS xi
GRS550 Controls and connectors........................................................... 5
Front Panel.............................................................................................. 5
Main Table............................................................................................... 5
Probe Head............................................................................................. 5
Camera Head + Laser Pointer ................................................................ 5
Optional Bar Code/Matrix Code Reader.................................................. 5
Table Outlet Panel................................................................................... 6
Rear Panel .............................................................................................. 6
Line voltage selection.............................................................................. 6
USB3 Camera connections..................................................................... 7
JOYSTICK connector.............................................................................. 7
LINK TO PC socket................................................................................. 7
EXT. CONNECTIONS TO TABLE socket............................................... 7
Channel A probe output .......................................................................... 8
Channel A COM (common return) connector.......................................... 8
PROBE output......................................................................................... 8
PROBE COM (common return) connector.............................................. 8
Using the manual GRS550 probes.......................................................... 8
Connecting the test wires (PFL A and COM sockets)............................. 8
Switchable COM sockets ........................................................................ 8
INSTALLING THE GRS550 9
Unpacking ............................................................................................... 9
The GRS550 operating software............................................................. 9
Software Remote Support....................................................................... 9
The GRS550 environment..................................................................... 10
GETTING STARTED WITH THE GRS550 11
Starting the GRS550............................................................................. 11
Configuring the GRS550....................................................................... 11
Cam/Video............................................................................................. 11
Prober/BxD............................................................................................ 12
Setting screen colours........................................................................... 13
Testing................................................................................................... 14
Specifying Fault Entry ........................................................................... 15
Setting system prompts......................................................................... 16
Print report............................................................................................. 17
Adjustment ............................................................................................ 17
The GRS550 screen.............................................................................. 18
Using the GRS550 windows.................................................................. 19
The GRS550 menu system................................................................... 20
Selecting commands............................................................................. 20
The File menu ....................................................................................... 21
Read CAD Netlist command ................................................................. 22
Prober menu.......................................................................................... 23
The Display/Info menu .......................................................................... 24
The Enhance Data menu ...................................................................... 25
Remove Data ........................................................................................ 25
Rename Vias......................................................................................... 25
The Manual Programming menu........................................................... 26
The Keep Out Areas menu.................................................................... 26
The Test Points menu........................................................................... 27
The Test List menu................................................................................ 27
The Window menu ................................................................................ 28

xii CONTENTS GRS550 User Manual
The Configure menu ..............................................................................29
The Help menu.......................................................................................29
Using the GRS550 COM sockets...........................................................30
Connecting the test cables..............................................................30
Live Instrument testing..................................................................................31
Live Instrument screen...........................................................................31
Defining test conditions.................................................................................33
Test Range selection .............................................................................33
Selecting the Voltage range...................................................................33
Selecting the Frequency range..............................................................34
Resistive signatures........................................................................34
Reactive signatures.........................................................................34
Semiconductor signatures......................................................................36
Diode signatures.............................................................................36
Bus signatures ................................................................................37
Locating faults on bus-connected nets...................................................37
Signature stability...................................................................................39
Cycle...............................................................................................41
CREATING THE TEST LIST 42
Mounting the board .......................................................................................42
Homing the GRS550..............................................................................43
Calibrating the Probe .............................................................................43
Creating the Test List (programming test points)..........................................45
Creating the test list ...............................................................................45
Creating test points from CAD data...............................................................45
Loading the CAD Netlist file...................................................................45
Removing superfluous data ...................................................................47
Loading Gerber Plot Data ......................................................................47
Creating Components............................................................................48
Creating the component..................................................................49
Creating test points manually........................................................................51
Creating a new board.............................................................................51
Manual Programming tool bar.......................................................................52
Creating alignment points..............................................................................52
Choosing alignment points.....................................................................53
Creating components manually.....................................................................55
Creating Single Point components.........................................................55
Creating single in-line packages............................................................56
Creating small outline IC (SOIC) devices...............................................57
Creating dual in-line package devices ...................................................58
Determining device pin pitch and count.................................................59
Creating quad flat-pack devices.............................................................60
Copying devices.....................................................................................61
Adding a QR/Bar Code Position.............................................................62
Linking schematics to the board type............................................................64
Searching for components.....................................................................64
Setting alignment points................................................................................65
Choosing alignment points from CAD data............................................65
Excluding areas of the board from testing.....................................................66
Advanced Keep Out Options..................................................................67
Excluding single test points and components ........................................67
Excluding test points and components by window.................................69
Allocating Test Points....................................................................................69