Seica PILOT H4 User manual

PILOT H4
OPERATOR MANUAL

PUBLICATION ISSUED BY:
Via Kennedy, 24
10019 STRAMBINO (TO)
Phone No..: [phone]
Fax. No.: [phone]
e-mail: [email protected]
Web site: http://www.seica.com
Document Code: MA-VI-PIH40PEN-03
Software release: VIVA
Date of issue: 2014 - 07 - 28
The material in this manual is for informational purposes only, and is subject to change without notice.
Seica S.p.A. assumes no liability in case of error or consequential damages that may result from the use
or misinterpretation of any of the procedures provided in this publication.
Seica S.p.A. reserves the right to change the technical specifications without notice.
(*)Where ever Seica is noted in the present manual, it also implies Seica Inc., Seica Sarl, Seica China,
Seica subsidiaries, divisions, and/or affiliates.
(**) The cover image is for presentation purposes only

contents
i
CONTENTS
1 GENERAL...................................................................................................................................................................................... 1-1
1.1 AUDIENCE................................................................................................................................................................................... 1-2
1.2 ASSUMPTIONS............................................................................................................................................................................. 1-2
1.3 SYNTAX CONVENTIONS............................................................................................................................................................... 1-2
1.4 SEICA CUSTOMER CARE CENTER................................................................................................................................................. 1-4
1.5 COMMENTS ABOUT THE DOCUMENTATION ................................................................................................................................... 1-4
1.6 INTERNET WEBSITE...................................................................................................................................................................... 1-4
1.7 SAFETY RECOMMENDATIONS....................................................................................................................................................... 1-5
1.7.1 Project criteria ................................................................................................................................................................... 1-5
1.7.2 Safety devices...................................................................................................................................................................... 1-5
1.7.3 Safety devices location........................................................................................................................................................ 1-6
1.7.4 Warnings and recommended behavior ............................................................................................................................... 1-7
1.7.5 Intended use........................................................................................................................................................................ 1-8
1.7.6 Improper uses..................................................................................................................................................................... 1-8
1.7.7 Residual hazards................................................................................................................................................................. 1-8
1.7.8 WARNINGS FOR MAINTENANCE ACTIVITIES............................................................................................................... 1-8
1.8 TECHNICAL SPECIFICATIONS ....................................................................................................................................................... 1-9
1.8.1 Operating environment....................................................................................................................................................... 1-9
1.8.2 Electrical rating.................................................................................................................................................................. 1-9
1.8.3 Air specifications.............................................................................................................................................................. 1-10
1.8.4 Weight............................................................................................................................................................................... 1-10
1.8.5 Overall dimensions........................................................................................................................................................... 1-11
1.8.6 Work Area......................................................................................................................................................................... 1-12
2 SYSTEM OVERVIEW.................................................................................................................................................................. 2-1
2.1 GENERAL ARCHITECTURE.................................................................................................................................................. 2-2
2.1.1 AC group ............................................................................................................................................................................ 2-3
2.1.2 ATE rack............................................................................................................................................................................. 2-4
2.1.3 Axis drivers and filters........................................................................................................................................................ 2-4
2.1.4 Control panel and emergency button.................................................................................................................................. 2-4
2.1.5 Cover.................................................................................................................................................................................. 2-7
2.1.6 Power supplies.................................................................................................................................................................... 2-7
2.1.7 Motors ................................................................................................................................................................................ 2-7
2.1.8 Light indicator or semaphore ............................................................................................................................................. 2-7
2.1.9 PC-main.............................................................................................................................................................................. 2-7
2.1.10 Test area........................................................................................................................................................................... 2-8
2.1.11 Measuring heads............................................................................................................................................................... 2-8
2.2 FIXTURE CONTROL PANEL ................................................................................................................................................. 2-8
3 GETTING STARTED.................................................................................................................................................................... 3-1
3.1 SYSTEM STARTING.................................................................................................................................................................. 3-2
3.2 TRANSLATION............................................................................................................................................................................. 3-3
3.2.1 Translation ......................................................................................................................................................................... 3-3
3.3 TEST PROGRAM EXECUTION......................................................................................................................................................... 3-6
3.3.1 TEST ENVIRONMENT....................................................................................................................................................... 3-6
3.4 TEST RESULTS ............................................................................................................................................................................. 3-8
3.5 SYSTEM SHUTDOWN............................................................................................................................................................... 3-9
3.6 FIXED PROBES ........................................................................................................................................................................... 3-10
3.6.1 Fixed probe positioning.................................................................................................................................................... 3-10
3.7 SUPPORTS ................................................................................................................................................................................. 3-11
4 MAINTENANCE OPERATIONS ................................................................................................................................................ 4-1
4.1 GENERAL INSPECTION AND CLEANING ......................................................................................................................................... 4-2
4.2 CHECK OF THE FILTERS................................................................................................................................................................ 4-2
4.2.1 Replacing the filter ............................................................................................................................................................. 4-2
4.3 DIAGNOSTIC TOOLS..................................................................................................................................................................... 4-3
4.3.1 System diagnostic ............................................................................................................................................................... 4-3
4.3.2 Meaning of the error messages........................................................................................................................................... 4-4
SCAFP board layout ............................................................................................................................................................... 4-6
F32/P32 board layout.............................................................................................................................................................. 4-7
S64 board layout ..................................................................................................................................................................... 4-8
4.3.3OVP.................................................................................................................................................................................... 4-9
4.4 REPLACING THE PROBE NEEDLE ................................................................................................................................................. 4-10
4.5 REPLACING THE OPENFIX PROBE ................................................................................................................................................ 4-10

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4.6 CALIBRATIONS.................................................................................................................................................................... 4-12
4.6.1 JOYSTICK CALIBRATION............................................................................................................................................... 4-15
4.6.2 CAMERA CALIBRATION................................................................................................................................................. 4-15
4.6.3 ELECTRICAL PROBES CALIBRATION.......................................................................................................................... 4-15
4.6.4 MOBILE CAPACITIVE PROBE CALIBRATION............................................................................................................. 4-22
4.6.5 STAMPER CALIBRATION............................................................................................................................................... 4-25
4.7 LUBRICATING THE BALL SCREWS............................................................................................................................................... 4-28
4.8 LUBRICATING THE PROBE GUIDE (X DIRECTION)......................................................................................................................... 4-28
5 APPENDIX ..................................................................................................................................................................................... 5-1
5.1 USE THE HDU RECOVERY UTILITY ................................................................................................................................... 5-2
5.2 PC SETTINGS........................................................................................................................................................................... 5-2
5.3 RESTORING THE FACTORY CONFIGURATION................................................................................................................ 5-2
LIST OF FIGURES
Fig. 1-1 PILOT H4: “System configuration” dialog window..............................................................1-3
Fig. 1-2 PILOT H4: Example of VIVA Software GUI .......................................................................1-3
Fig. 1-3 PILOT H4: Safety device location....................................................................................1-6
Fig. 1-4 PILOT H4: System layout............................................................................................ 1-11
Fig. 1-5 PILOT H4: Side view and front view.............................................................................. 1-11
Fig. 1-6 PILOT H4: Work area ................................................................................................. 1-12
Fig. 2-1 PILOT H4: System overview ..........................................................................................2-1
Fig. 2-2 PILOT H4: System synoptics..........................................................................................2-2
Fig. 3-1 PILOT H4: Run Page of the VIVA software .......................................................................3-6
Fig. 3-2 PILOT H4: Program Report dialog window........................................................................3-8
Fig. 4-1 PILOT H4: SCAFP Module layout.....................................................................................4-6
Fig. 4-2 PILOT H4: F32/P32 Module layout ..................................................................................4-7
Fig. 4-3 PILOT H4: S64 Module layout ........................................................................................4-8
Fig. 4-3 PILOT H4: OVP board ...................................................................................................4-9
Fig. 4-5 PILOT H4: “System Maintenance” dialog window, tab “Calibration”.................................... 4-13
Fig. 4-6 PILOT H4: “System Configuration” dialog window, tab “Calibration”................................... 4-14
Fig. 4-7 PILOT H4 OVP Board .................................................................................................. 4-15
Fig. 4-8 PILOT H4 Setting the Electrical Probe Calibration............................................................ 4-16
Fig. 4-6 PILOT H4 “Set Camera X (TOP) dialog window ............................................................... 4-19
Fig. 4-7 PILOT H4 “Set Camera Y (TOP) dialog window” .............................................................. 4-20
Fig. 4-10 PILOT H4 Align top camera........................................................................................ 4-21
Fig. 4-12 PILOT H4 Setting the “Mobile Opens Probe” Calibration” ................................................ 4-22
Fig. 4-13 PILOT H4 “Calibration Mobile Open Probe” dialog window............................................... 4-23
Fig. 4-14 PILOT H4 Setting the “Stamper” Calibration”................................................................ 4-25
LIST OF TABLES
Tab. 4-1: PILOT H4: Maintenance schedule .................................................................................4-1
Tab. 4-2: Table of corrective actions ..........................................................................................4-5

general
1-1
1GENERAL
The PILOTH4 system belongs to the new generation of flying probers, created to solve the problem of
testing electronic boards without the aid of fixtures or specialized mechanical devices.
PILOTH4 is particularly suitable for testing prototypes, samples, small series, SMD boards with specific
accessibility problems: in general, when the costs and time of constructing a fixture are not justifiable.
The technology and materials used for measuring head motion provides extremely high levels of
acceleration and speed. The system requires little maintenance and offers a high level of system uptime
for critical time-to-market” situations.
The brushless motors used for the horizontal movements of the heads also require little maintenance and
the integrated encoders keep the position of the heads constantly under control so no realignment or
calibration is necessary after a stop.
This manual contains all of the required information to use the test system safely and correctly. The
procedures used to test electronic boards together with inspection and maintenance on the system are
considered in detail.
The operator is recommended to read this manual thoroughly and familiarize with test procedures and
system operation.
A knowledge on testing, electronics and use of Personal Computer is required.

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1.1 AUDIENCE
This manual contains useful information for:
•Operators in charge of testing mounted boards
•Developers of test programs
•Technicians in charge of maintenance operations on the system
1.2 ASSUMPTIONS
Technical knowledge on testing, electronics and use of Personal Computer is required.
1.3 SYNTAX CONVENTIONS
To facilitate the understanding of the sentences used to describe the software, we have used the
following symbols:
WARNING Indicates a potential hazard for the operator or the system that could result from
the action described in the warning.
NOTE: Indicates a note, a recommendation or a point on which readers should focus more carefully.
The syntax to select a software menu or menu item is as follows:
MENU\item 1 = Select the menu indicated, then choose item 1.
Example: BOARD\Select
MENU 1\MENU 2\MENU n \item 1 = Select menu 1, submenu 2, ..., submenu n, and then item 1.
Example: TOOLS\HARDWARE\Autolearn\Debug
The keyboard selection is indicated as follows:
Button 1+ Button 2 = Press button 1 and button 2 simultaneously.
Button 1, Button 2 = Press button 1, release it and press button 2.
The files are indicated using the following syntax:
File.nod
File.srg ... etc,
where "File" is the filename and “.nod” and ".srg" are the file extensions.

general
1-3
The dialog windows and their components are described by means of the terms described in Fig. 1-1
Fig. 1-1 PILOT H4: “System configuration” dialog window
he Graphical User Interface of the VIVA software provides a set of commands and buttons, arranged in
horizontal and vertical toolbars. Fig. 1-2 is an example of the VIVA software GUI.
Fig. 1-2 PILOT H4: Example of VIVA Software GUI
Text box
A
B
C
Name of the
dialog window Tab
Radio
button
Section
Checkbox
Button

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1-4
1.4 SEICA CUSTOMER CARE CENTER
SEICA “CUSTOMER CARE CENTER” (SCCC) is the support to the customers. It is always possible to call
the SCCC if you can’t solve your problem through the product help on line or technical documentation.
Before calling the SCCC please be sure to have the following info:
¾System type
¾System serial number
¾Software release
Phone [phone]
Fax [phone]
E-mail [email protected]
Mail SEICA S.p.A.
Via Kennedy, 24
10019 Strambino (TO) – ITALY
World Wide Web www.seica.com
1.5 COMMENTS ABOUT THE DOCUMENTATION
You can email to: [e-mail] if you have comments or suggestions about the documentation.
1.6 INTERNET WEBSITE
You can find update info about products, technologies and events on: http://www.seica.com

general
1-5
WARNING!!!
DISCONNECTPOWER SUPPLY
BEFORESERVICING OPERATION
P3
P2
P1
1.7 SAFETY RECOMMENDATIONS
1.7.1 Project criteria
The system PILOT H4 has been designed and manufactured in accordance with the essential safety
requirements contained in the Machine Directive 2006/42/CE; in the EMC DIRECTIVE 2004/108/EC
(and subsequent amendments) on electromagnetic compatibility; in the Low Voltage Directive
2006/95/CE (and subsequent amendments) on electric safety.
The compliance with the aforementioned directives has eliminated or reduced hazards to the minimum,
both during ordinary operation and servicing.
1.7.2 Safety devices
The system is manufactured with premium quality components. All components used are thoroughly
tested in accordance with the quality standards set forth in the laws in force.
The system is equipped with several safety devices to reduce operators' hazards to a minimum. The
section that follows lists the devices installed on the system.
(P1,P2,P3) Warning labels
They warn the operator of possible hazards or preventive actions that must be followed.
(P4) Protection panels: Protect the system from environmental hazards and prevent users from
coming into contact with internal components that can be powered during operation. These panels can
only be removed with the help of a socket wrench.
(P5) Protective cover: It prevents the operator from putting his/her arms inside the working area
where there can be mechanical parts in motion. In fact, the system halts if the operator opens the cover
while the system is working.
It powers off the measurement electronics. It doesn’t switch off the Personal Computer.
(P6) Lock on the cover: There is a button on the protective cover that must be pressed to open it. This
button prevents the operator from accidentally opening the cover.
(P7) Emergency button: When pressed, it switches the system off (not the Personal Computer).
(P8) Automatic switches: They automatically switches off the system when there is extra current
absorption.
(P9) Fuses: In the system there are 10 fuses that protect electrical parts of the test system when there
may be current ranges in excess of system operational requirements.
(P10) Ground protection circuit: It refers to the ground potential of all parts in the system that can be
touched by the operator to avoid electrical shocks.

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1.7.3 Safety devices location
Fig. 1-3 PILOT H4: Safety device location

general
1-7
1.7.4 Warnings and recommended behavior
In order to avoid all risks of injury to persons or damage to the machines installed, it is recommended to
follow the warnings and rules of behavior:
Note: Seica declines all liability for any damage to things and/or injury to persons deriving from failure to
follow these warnings.
WARNING Do not perform on the mechanical and/or electronic parts of the system other
operations than those listed in the maintenance section of this manual
WARNING If the test system is used in a manner not specified by the manufacturer (see
paragraph INTENDED USE), the protection provided by the equipment may be
impaired. See paragraph 1.7.5 Intended use
WARNING Seica does not assume any liability in case of damages caused by incorrect
operations, not compliant with the instructions provided.
WARNING Operation of the PILOTH4 system is very easy; however, these simple rules
should be followed: Equipments in motion can be dangerous. Despite the safety
devices are installed to prevent or reduce to a minimum the operator errors, do
not perform any actions if not in compliance with the instructions provided.
WARNING Do not mount any tool on the flying probes that is different from the needle used
to test electronic boards (drill, cutter, miller, etc).
WARNING When the system is testing, do not introduce into it any object different from the
board to be tested.
WARNING Do not introduce any liquid in the system.
WARNING Refer to MAINTENANCE SECTION of this manual for complete instructions
concerning cleaning, inspection and ordinary maintenance.
WARNING If the system needs to be moved from the installation site, make sure that this
operation is carried out by qualified and authorized personnel only.
WARNING USER PLUGS: Max current: 8A. Max leakage current: 30mA (to be intended as
the sum of the currents for the two user plugs)

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1.7.5 Intended use
The PILOTH4 system is to be used exclusively to test different types of electronic boards (specifically,
prototypes, samples, small series and SMD boards with particular accessibility problems). The use of the
system for different purposes, for example to test electronic boards whose dimensions exceed the set
limits, or boards containing liquid or inflammable parts) may cause injury to persons or damage to the
system, and are therefore considered as improper uses for which Seica declines any liability.
Note: For other uses, consult the Seica Technical Department beforehand.
1.7.6 Improper uses
The system is not designed to support any tool on the probe that is different from the test needle. Do not
mount any drill, cutter or miller on the test probe. See also the warning in the Safety notes.
1.7.7 Residual hazards
In order to avoid risks of injury to persons or damage to equipment caused by residual risks, that is, risks
that remain despite all the measures adopted, or non-evident potential risks, we recommend that the
operator always respects what is listed in the Warnings and rules of behavior paragraph and follow
the instructions here below:
•The working staff must wear suitable clothing, do not wear baggy clothes, loose sleeves that can
be entangled inside the system during operation.
•Do not wear dangling ties or scarves, necklaces, bracelets and rings
•Long hair (wear a cap, if necessary)
•Moreover, if the operator rashly inserts his/her limbs inside the lateral openings, there is the risk
to crush the limbs.
•There is the risk of pricking the finger if a careless work is done when replacing the test needle.
1.7.8 WARNINGS FOR MAINTENANCE ACTIVITIES
The complexity and the high technological level of the PILOT H4 test system, require a detailed
description and classification of the maintenance schedule, as well as the requirements for the personnel
authorized to perform these activities.
The customer is authorized to carry out the ordinary maintenance operations described in the
MAINTENANCE section of this manual. For other operations, customers should contact the Customer
Service of Seica S.p.A., which will determine whether to provide specific instructions or to arrange an on-
site inspection.
WARNING Customers must always contact the technical personnel of Seica S.p.A. before
carrying out any operation.

general
1-9
1.8 TECHNICAL SPECIFICATIONS
To ensure a correct operation of the system, it is necessary to verify that the requirements described
here below are met.
1.8.1 Operating environment
The system should be installed in a relatively dry, clean environment, preferably with an air conditioning
system, which maintains a constant temperature and humidity.
1.8.2 Electrical rating
Input rating: 230 Vac +15% -10% 50-60 Hz 14A
120 Vac +15% -10% 50-60 Hz 24A
Power cord
230
Vac
PVC 600V 90°C 3xAWG12 for 230VAC
To be fitted with plug 60 IEC 309 2P+ 50-60Hz ±15% IP44
230VAC
120
Vac TYPE SO, 3Xawg12 CONDUCTORS-NEOPRENE JACKET UNSHIELDED 90°C 600 Volt. Cable length :not more than 5 meters.
Socket outlet:
230
Vac Series 62 IEC 309 2P+ 50-60Hz ±15% IP44 230VAC
120
Vac NEMA L5-30R for 110VAC 50-60 Hz ±15%.
•The power supply source must be located not more than 5 meters (approx. 15 feet) from the
PILOTH4 and must be accessible by an operator.
•The power supply source must be provided with a switch located near the power source plug.
•The power supply source must be provided with the ground reference.
•The sound pressure level, with system working in worst conditions is not to exceed 70dB.
Temperature: 23±5 ° C
Humidity: Min. 20% Max. 80%
Floor surface
planarity:5mm/m
Altitude: < 4000m
Pollution degree: 2
Installation category: II
Class: I

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1.8.3 Air specifications
Air supply: Filtered at 3 μm
99.9% of the oil must be filtered from air
The air must be dried with a dew point of 10 °Celsius
Compressed air supply: Typical: 4 Atm Max: 6 Atm
Air supply setting: Min. 4.5 Atm Typ. 5.5 Atm Max. 6 Atm
Air flow: Min. 1N/l
Air compressor
capacity: Min. 10 l/min
Air input: 3/8” Female with GAS thread
Air hose to system: 3/8” ID Minimum
1.8.4 Weight
System weight:
1577 Kg (3469 lb)
System weight with
packing:
1800 Kg (3960 lb)

general
1-11
1.8.5 Overall dimensions
The figure shows the system dimensions. It is necessary to reserve a certain clear space around the
system to ensure good air circulation for the electronics and to have enough space for easy access to the
inspection and maintenance points. The following is a scale drawing of the required work area and the
place usually occupied by the operator.
Fig. 1-4 PILOT H4: System layout
Fig. 1-5 PILOT H4: Side view and front view

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1.8.6 Work Area
It is recommended to leave a clearance area between the system and possible external instrumentation,
in order to guarantee a good air circulation for the electronics onboard and to have sufficient space to
access the inspection/maintenance points of the system
The figures 1-4- and 1-5 respectively, show the system layout and the work area with overall dimensions
Fig. 1-6 PILOT H4: Work area
Height 1480mm (58.27”)
Length 1740mm (68.50”)
Width 1330mm (52.36”)

system overview
2-1
2SYSTEM OVERVIEW
Fig. 2-1 PILOT H4: System overview
B1 - Front doors for easy access to all the systems electronic racks and components
B2 - Side panel
B3 - Protective cover (tiltable), protecting the work area
B4 - PC compartment door
B5 - Tiltable keyboard/mouse support
B6 - Control Panel
B7 - Work area
B8 - LCD Monitor

PILOT H4 - Operator Manual
2-2
2.1 GENERAL ARCHITECTURE
The system can be considered as a whole with functional blocks interacting together. The picture below
illustrates the system general architecture. What follows is a technical description for every block.
Fig. 2-2 PILOT H4: System synoptics
1)Light indicator
2) SMEMA connection
3) Air filter and tap
4) Main ON/OFF Switch
5) System power plug
4
1
2
3 5
CONS22