Polar Instruments GRS550 User Manual
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Polar Instruments GRS550 User Manual

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Polar Instruments GmbH
GRS550 User Guide
Polar Instruments GmbH
Aichereben 16
A-4865 Nussdorf
Austria
Tel: +43 7666 20041 0
Fax: +43 7666 20041 20
http://www.polarinstruments.eu
e-mail: germany@polarinstruments.eu
MAN586–1120

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  • Page 1 Polar Instruments GmbH GRS550 User Guide Polar Instruments GmbH Aichereben 16 A-4865 Nussdorf Austria Tel: +43 7666 20041 0 Fax: +43 7666 20041 20 http://www.polarinstruments.eu e-mail: germany@polarinstruments.eu MAN586–1120...
  • Page 3 Registering your product ensures you can be kept up to date when upgrades or enhancements become available. Please register using the form below. Polar Instruments GmbH Aichereben 16 A-4865 Nussdorf Austria Fax: +43 7666 20041 20 Email: germany@polarinstruments.eu GRS550 serial number: Installed options: Name Company Job Title Address Post/ZIP Code Country Telephone...
  • Page 5 GRS550 with optional cart ACC225...
  • Page 7 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.

  • Page 9: European Community Directive Conformance Statement

    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 Declarations  i GRS550 User Manual...

  • Page 10: 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.

  • Page 11: Power Cord Colour Codes

    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. Safety  iii GRS550 User Manual...

  • Page 12: Grs550 Operation

    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.

  • Page 13: Specifications

    Z-axis travel (Rapid) 10mm (via solenoids) Max. flying height 100mm Max. board size 330 x 630mm Max. board weight Max. probing area 330 x 450mm Visual programming area 300 x 450mm Interface High-speed Ethernet Specifications  v GRS550 User Manual...

  • Page 14: Environmental Operating Conditions

    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). vi  Specifications GRS550 User Manual...

  • Page 15: Accessories

    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 Accessories  vii GRS550 User Manual...
  • Page 16  Accessories GRS550 User Manual...
  • Page 17 Creating and using board alignment points, excluding components from testing and controlling the GRS550 display. Locating board faults Using the GRS550 fault location modes to test with the GRS550 boards and locate board faults. Acquiring reference signatures and testing...

  • Page 18: Table Of Contents

    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  ...
  • Page 19 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 ...
  • Page 20 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 ...
  • Page 21 Removing Component Test Points ..........77  Saving the board information to a database .......... 77  Setting the Safe Fly Height ................77  Moving round the GRS550 display ............... 79  Changing the view magnification (zooming) ........79  Panning the display ................ 79 ...
  • Page 22 Status Light ....................107  Exiting the program ..................107  MAINTENANCE   GRS550 Basic Maintenance and Troubleshooting ........109  Periodic maintenance ................109  Replacing the test pin ................109  Replacing the test pin carrier ............... 109  Replacement of the probe head linear bearing ........110 ...
  • Page 23 34. GetActualAngle ................126  35. RFParkZ ..................126  36. RFMoveZ ..................126  37. SetLaserPointer ................126  38. RFTouchZ ..................127  39. SwitchLedRingsOnOff ..............127  40. Prober_ParkPosition ..............127  41. ImportCriticalNets ................127  42. TestCnt() ..................127  CONTENTS  xv GRS550 User Manual...

  • Page 25: Introduction To The Grs550

    GRS550 will accommodate surface mount components, BGA devices, through-hole legacy boards and boards using mixed technologies. The GRS550 Fault Locator is designed to run under the control of an IBM PC or compatible controller within the Windows 7 or Windows 10 operating system.

  • Page 26: Fault Finding

    Fault finding The GRS550 will prove a powerful fault finding tool — for example, the troubleshooting technician can use the software to highlight failed nets. With the net highlighted the operator can easily determine which devices are connected to a node.

  • Page 27: Cad Netlist Files

    — a file containing board layout information. The CAD data file defines all the pad and board trace information for the board. The GRS550 can import data from a wide variety of CAD Netlist formats. Rapid test file generation...

  • Page 28: Areas Of Application

    Gerber Plot files, allows the user to combine groups of pins into components to produce more efficient test files. Areas of application The GRS550 is an ideal instrument for a wide range of applications: Field Service –...

  • Page 29: Grs550 General Description

    GRS550 GENERAL DESCRIPTION GRS550 Controls and connectors The GRS550 Fixtureless Tester incorporates the following controls and connectors: Front Panel The Front Panel incorporates the following: GROUND Socket Use the ground/earth socket for connecting a wrist strap to prevent static damage when handling PCB assemblies.

  • Page 30: Rear Panel

    Important: changing the line voltage setting should only be performed by a skilled electronics technician. The GRS550 Flying Probe System uses wide input voltage range power supplies for 110V – 230V. Therefore, no line voltage selection is required on the GRS550.

  • Page 31: Usb3 Camera Connections

    Table and Probe Head. The 25-pin D-type JOYSTICK socket is connected to the Joystick via the supplied Joystick cable. LINK TO PC socket The LINK TO PC socket is used to connect the GRS550 Fixtureless Tester via the supplied GRS550 network cable to the controlling PC.

  • Page 32: Channel A Probe Output

    PFL A and COM sockets respectively. Connecting the test wires (PFL A and COM sockets) Connect the red wire between the PFL socket A of the GRS550 and Channel A of its measurement system, and the black wire between the PFL COM sockets of the GRS550 and Channel A COM of the measurement system.

  • Page 33: Installing The Grs550

    INSTALLING THE GRS550 Unpacking CAUTION: The GRS550 is extremely heavy (100 kg) — the GRS550 should not be moved or carried by fewer than four persons. CAUTION Four person handling required The system is shipped in sturdy transit packs. Open the packs carefully and remove the instruments and accessories.

  • Page 34: The Grs550 Environment

    Hint: The program may be started each time Windows is started — navigate to the GRS550 destination folder and create a short cut to the GRS550 in the Windows Startup group. The GRS550 For convenience create a short cut on the desktop. Note that the...

  • Page 35: Getting Started With The Grs550

    GETTING STARTED WITH THE GRS550 Starting the GRS550 To start the program, press Start|Programs|Polar GRS550 Software or double click the icon on the desktop with the mouse or highlight the icon and press <Enter>. The GRS550 program icon Configuring the GRS550 Specific system configurations are defined via the following tabs in the “Tools”...

  • Page 36: Prober/Bxd

    For every new test program generated, the GRS550 software creates a subfolder in the selected path, that contains the two reference images - AlignmentPoint1.bmp and AlignmentPoint2.bmp Delete Path: deletes the previously set folder for the Auto Alignment reference images.

  • Page 37: Setting Screen Colours

    This requires the motion control system to be fitted with the optional rotation axis. Do not tick this option when the system is in normal GRS550 mode. Bar Code Reader mounted – tick this option to enable the optional Bar Code Reader to read the serial number from the Board under test.

  • Page 38: Testing

    Testing tab. Choose the voltage range and frequency settings and which common will be connected to the measurement system common at test time. See Live Instrument Testing: Using the GRS550 COM sockets and Defining test conditions for details on these settings.

  • Page 39: Specifying Fault Entry

    Test List or any pin via the Component and Pins List. Specifying Fault Entry Users can choose between selecting nets by name, by number or by component and pin. Select the Fault Entry mode as required. See Highlighting Nets. GETTING STARTED WITH THE GRS550  15 GRS550 User Manual...

  • Page 40: Setting System Prompts

    Open circuit signatures may indicate a badly positioned test point, flux on a board or a missing ground connection, etc. The GRS550 can display a warning dialog to allow the operator to choose to save as reference or discard a signature that displays as open circuit (see Acquiring reference signatures).

  • Page 41: Print Report

    Enter print report details to be used as default for each test report printed. Adjustment Allows precise alignment of multiple GRS550 systems so that *.grs test files may be transferred between systems without realigning. Requires special alignment tools. Only to be used by authorized service personnel or when instructed.

  • Page 42: The Grs550 Screen

     The Board View Window, where the board layout is displayed and the GRS550 test points may be viewed and edited. The Board View Window can also be used to highlight nets during fault finding. The Board View...

  • Page 43: Using The Grs550 Windows

    The Test List and Board View windows contain toolbar button shortcuts to commonly used commands. The main screen window will normally be maximised to full screen view — click the Maximise button (or double-click the GRS550 Title Bar or press Alt+Spacebar then X). Using the GRS550 windows...

  • Page 44: The Grs550 Menu System

    The GRS550 menu system All GRS550 commands are available from pull-down menus; commands can be accessed via the mouse or shortcut keys. GRS550 main menu bar The most frequently used commands are incorporated in the tool bar for each window.

  • Page 45: The File Menu

    The File menu provides the commands for saving and recalling a complete set of data for a board. The database facility allows the netlist and GRS550 files to be saved for subsequent review. Use the File menu commands to: Create a new set of board data Open and save a database —...

  • Page 46: Read Cad Netlist Command

    The Read CAD Netlist command contains the commands to load the conversion filters for the CAD data files. Choose the CAD file type, select the data file and press Open. 22  GETTING STARTED WITH THE GRS550 GRS550 User Manual...

  • Page 47: Prober Menu

    The resulting information — Gerber plot data, pad shapes and created components — can be stored as a GRS550 database for future use. Prober menu The Prober menu provides the commands and options to assign pads on the board as alignment points and align the board during the test process.

  • Page 48: The Display/Info Menu

    Display the highlighted nets on either the current layer only or on all layers. Activate the Fault Entry area on the Toolbar. The Net Information command displays a list of all nets on the board. 24  GETTING STARTED WITH THE GRS550 GRS550 User Manual...

  • Page 49: The Enhance Data Menu

    Data derived from CAD files may require some pre-processing prior to use in defining test points. For example, the entire board image must be located within the boundaries of the GRS550 table area. Use the Rotate, Mirror or Move Data commands to rotate, mirror and move the CAD Netlist layer as necessary.

  • Page 50: The Manual Programming Menu

    “Keep Out”. During the Test Point Allocation process, points marked as “Keep Out” will not be included in the list of points to be probed. 26  GETTING STARTED WITH THE GRS550 GRS550 User Manual...

  • Page 51: The Test Points Menu

    (moved to a new location). The Test List menu The Test List menu supplies the command and functions for working within the Test List window. GETTING STARTED WITH THE GRS550  27 GRS550 User Manual...

  • Page 52: The Window Menu

    Windows Layout and Toggle Camera Size buttons. Turn the video camera on or off and choose between Camera window sizes. Switch to the Test List view to edit the test list and test the board 28  GETTING STARTED WITH THE GRS550 GRS550 User Manual...

  • Page 53: The Configure Menu

    The Configure menu allows the user to alter camera settings, test default parameter settings, screen colors and the Fault Entry (net highlighting) method. The Help menu Select About for system information (firmware versions, etc.) GETTING STARTED WITH THE GRS550  29 GRS550 User Manual...

  • Page 54: Using The Grs550 Com Sockets

    GRS550 and measurement system COM sockets. Connect the COM test clip to the ground of the board under test and a COM socket on the GRS550 table. For boards with split ground planes ensure the COM is connected to the ground associated with the nets under test.

  • Page 55: Live Instrument Testing

    Component signatures are displayed in the Live Instrument window of the GRS550 screen. In Live Instrument the GRS550 may be driven to any location within the table area via the joystick. Ensure the GRS550 has been calibrated (see the Prober Calibration command from the Prober menu) and the board aligned (Align Board from the Prober menu).
  • Page 56 Channel B of the measurement system and probe the corresponding net and common (ground, Vcc, etc.) on the reference board. Click on Retract to withdraw the probe from the board surface. 32  GETTING STARTED WITH THE GRS550 GRS550 User Manual...

  • Page 57: Defining Test Conditions

    To specify test conditions manually, click the voltage and frequency buttons as appropriate (see Selecting the Voltage range). Selecting the Voltage range The GRS550 provides a range of current limited drive voltages. Only one drive voltage can be selected at a time. Setting Voltage Range...

  • Page 58: Selecting The Frequency Range

    This is displayed as a circular or elliptical signature. For a pure reactance the major and minor axes of the ellipse align with the display axes. 34  GETTING STARTED WITH THE GRS550 GRS550 User Manual...
  • Page 59 The following table is included as a guide to frequency selection. Only one frequency can be selected at a time. GETTING STARTED WITH THE GRS550  35 GRS550 User Manual...

  • Page 60: Semiconductor Signatures

    High frequency is selected. Semiconductor signatures Diode signatures The Nodal Impedance technique use in the GRS550 is especially useful for locating defective active devices that may be inserted correctly, and therefore measure correctly when tested for simple forward and reverse resistance, but exhibit, for example, a “soft...

  • Page 61: Bus Signatures

    During normal testing the GRS550 allows the measurement system COM line to be connected under program control to one or more of four COM lines on the GRS550 table. In Live Instrument it will be necessary to move the COM manually to a ground plane associated with the net under test.
  • Page 62 Good and damaged protection diodes signatures Look for vertical lines (shorts). Short circuit signature Look for horizontal lines (opens). Try looking at signatures using several voltage ranges; some faults only show up on certain ranges. 38  GETTING STARTED WITH THE GRS550 GRS550 User Manual...

  • Page 63: Signature Stability

    A and B. Unstable digital IC signature Instability or oscillation in signatures are often the result of capacitive circuits and can be reduced by using the GRS550’s facility to insert a delay prior to each test using the Pre Charge function.
  • Page 64 Vcc may rise enough to turn on portions of the IC; the current drawn will immediately discharge the decoupling capacitor. This sequence of events represents a rapidly changing impedance at the node under test and causes the 40  GETTING STARTED WITH THE GRS550 GRS550 User Manual...

  • Page 65: Cycle

    Cycle Select Cycle to continuously cycle through each voltage range, displaying the signatures. To stop cycling, select a drive range, or select Auto. GETTING STARTED WITH THE GRS550  41 GRS550 User Manual...

  • Page 66: Creating The Test List

    Mounting the board The GRS550 is able to accommodate a wide range of PCB sizes and layouts. When mounting a PCB for testing the user will need to consider the size and shape of the board. A number of mounting...

  • Page 67: Homing The Grs550

    Homing the GRS550 Before using the GRS550 it will be necessary to “home” the table and probe to their reference locations. From the Prober menu choose the Prober Home command; the probe and table will be returned to their reference positions.
  • Page 68 The Calibrate Probe dialog box Use the joystick to centre the camera on the Calibration Block and click the Save button — the GRS550 will record the crosshair position and produce a probe pin indentation close to the same point on the Calibration Block.

  • Page 69: Creating The Test List (Programming Test Points)

    CAD data if available (see Creating test points from CAD data) or created using the manual programming interface (see Creating test points manually). The GRS550 includes a full range of file import formats as shown in this list: Creating test points from CAD data...
  • Page 70 Click on the File|Read CAD Netlist menu item and choose the netlist format from the dropdown list, e.g. Select the file from the dialog box and press Open. The GRS550 displays the pad and trace data for the board. If necessary, use the Enhance Data|Rotate Data command to rotate to a suitable orientation.

  • Page 71: Removing Superfluous Data

    Names, Package Descriptions or Net Information. If the Gerber file format is chosen for import (File|Read Cad Netlist|Read Gerber|Gerber Plot Data) the Gerber Plot Data command displays the Read Gerber Plot Data dialog box. CREATING THE TEST LIST  47 GRS550 User Manual...

  • Page 72: Creating Components

    The Create Component function allows the user to specify individual pads on the plot as belonging to actual components. Grouping pads to form components can greatly reduce board test times. Components can consist of a wide range of device 48  CREATING THE TEST LIST GRS550 User Manual...

  • Page 73: Creating The Component

    For components with high pin counts, dual in-line package ICs, quad flat-pack devices, etc. use the Add Series of Pins command. Name the component, e.g. U123, supply the package description and press OK. CREATING THE TEST LIST  49 GRS550 User Manual...
  • Page 74 Locate the crosshair on the first pad in the next series and repeat the process for each series of pins. All the marked pins will be regarded as a single component. Repeat the process for each component. 50  CREATING THE TEST LIST GRS550 User Manual...

  • Page 75: Creating Test Points Manually

    Creating a new board From the File menu choose New Board: the GRS550 clears all data and displays the table area (a green rectangle approximately at screen center).

  • Page 76: Manual Programming Tool Bar

    Keep Out points: see Excluding areas of the board from testing. As the GRS550 uses the three alignment points to determine board height, position and orientation at test time, all alignment points should be chosen from points exactly level with the board surface (i.e.

  • Page 77: Choosing Alignment Points

    — e.g. an inside corner of a circuit board track. Choose an object that has been etched onto the board — don’t rely on silk screened or printed characters (e.g. circuit references). CREATING THE TEST LIST  53 GRS550 User Manual...
  • Page 78 Click Save to save the first alignment point. Select and Save the second alignment point. Select and Save the third alignment point. Click Create to confirm the alignment points. 54  CREATING THE TEST LIST GRS550 User Manual...

  • Page 79: Creating Components Manually

    Use the camera and joystick to locate the data point and click Save. The GRS550 creates the component and assigns it a test point (denoted by the orange dot). With the component defined, click CREATE. Repeat for all single point components.

  • Page 80: Creating Single In-Line Packages

    Following the on screen instructions, move the crosshair to the last pin and click Save then click CREATE to create the component. The component will be added and displayed in its correct location with test points assigned within the table area. 56  CREATING THE TEST LIST GRS550 User Manual...

  • Page 81: Creating Small Outline Ic (Soic) Devices

    Move to the first pin on the second side of the device and click Save. SOIC device with first pin highlighted Click CREATE; the device is located in position on screen in the table area with a test point allocated to each pin. CREATING THE TEST LIST  57 GRS550 User Manual...

  • Page 82: Creating Dual In-Line Package Devices

    Save. DIL device with first pin on second side highlighted Click CREATE. The device is located in position on screen in the table area with test points assigned to each pin. 58  CREATING THE TEST LIST GRS550 User Manual...

  • Page 83: Determining Device Pin Pitch And Count

    Snap to nearest standard pitch check box. Pitch and Pins count dialog with derived pitch of device Move the crosshair to the last pin and click Verify. The GRS550 calculates and displays the number of pins and steps back over each pin to confirm the position of each pad.

  • Page 84: Creating Quad Flat-Pack Devices

    Note: it is recommended that users save board and device information frequently during the programming process. The diagram below contains a selection of device types located on a board layout, alignment point, single point, SIL, SOIC, DIL and QFP. 60  CREATING THE TEST LIST GRS550 User Manual...

  • Page 85: Copying Devices

    Apply. Move the camera crosshair over pin 1 of the component to be created, click Save then COPY. Repeat for each device to be copied. CREATING THE TEST LIST  61 GRS550 User Manual...

  • Page 86: Adding A Qr/Bar Code Position

    This is perfectly acceptable as long as the code is within the reading window of the QR Code reader. For fine tuning the Bar/QR Code Reader, see also “Bar Code Reader” in “Prober” – “Prober Diagnostics” 62  CREATING THE TEST LIST GRS550 User Manual...
  • Page 87 The result of the bar code reading process is automatically transferred to the Test Summary and to the “Save Board Snapshot” serial number text box, eliminating manual operator input: CREATING THE TEST LIST  63 GRS550 User Manual...

  • Page 88: Linking Schematics To The Board Type

    Open. The schematic file will be copied to the folder containing the GSR550 database file and renamed to the name of the GRS550 database file but with the .pdf file extension. The resulting schematic file will be displayed by Adobe Reader in the Schematic View window.

  • Page 89: Setting Alignment Points

    3rd Alignment Point on rear left of board By using the positions of the alignment points, the GRS550 determines the true physical dimensions of the board in both, X and Y direction and applies scaling factors to align the CAD Data with the physical board size.

  • Page 90: Excluding Areas Of The Board From Testing

    Advanced Keep Out options Add Keep Out Point (A) Delete Keep Out Point (D) Keep Out tool bar Add Keep Out Component (C) Remove Keep Out Component (R) 66  CREATING THE TEST LIST GRS550 User Manual...

  • Page 91: Advanced Keep Out Options

    The pad will not be included in the test list. Excluded pads are shown in a darker shade of their original colour. Click the Delete Keep Out Point button or press D to remove the deleted test point. CREATING THE TEST LIST  67 GRS550 User Manual...
  • Page 92 Out Component button or press R. Remove Keep Out Component Note: if components are designated Keep Out after the test list has been compiled it will be necessary to reallocate test points. 68  CREATING THE TEST LIST GRS550 User Manual...

  • Page 93: Excluding Test Points And Components By Window

    CAD information) it will probably be most appropriate to test every point on the board. For data derived from CAD files the GRS550 can intelligently allocate test points: to test all multi-pin devices, i.e. devices with more than 2 pins...

  • Page 94: Test Points Tool Bar Functions

    Test Points command from the Test Points menu) to display Allocate Test Points the Allocate Test Points dialog box and specify the nodal button impedance test parameters and how test points are allocated. 70  CREATING THE TEST LIST GRS550 User Manual...

  • Page 95: Test Parameters

    Charge via their respective text boxes. The default settings will probably be found suitable for most testing. See Defining Test Conditions for a discussion of voltage ranges and frequencies and signature shapes for nets. CREATING THE TEST LIST  71 GRS550 User Manual...

  • Page 96: Test Point Allocation

    When all options have been specified, click Allocate to generate the test point list. The GRS550 software generates the test point file and displays a report summarising test point allocation.

  • Page 97: Editing The Test Point List Manually

    ******************************************************* GRS550 Test Point Allocation Report ******************************************************* Unable to Allocate Net Test Point to Selected Surface : N08083 Unable to Allocate Net Test Point to Selected Surface : N146056 Total Test Points (One Test Per Net) : 311 Test Points Eliminated...

  • Page 98: Adding A Test Point

    O key. Move the crosshair to the new location and click Offset Test Point the Offset Test Point button or press the O key — the test point button will appear at the new location. 74  CREATING THE TEST LIST GRS550 User Manual...

  • Page 99: Jogging A Test Point (For Device Based Allocation)

    Offset Test Points Up button Offset Test Points toolbar Offset Test Points Down button The diagram above shows the effect of offsetting the test points for one whole side of a DIL package. CREATING THE TEST LIST  75 GRS550 User Manual...

  • Page 100: Offsetting Test Points On Round Pads

    Offsetting test points on round pads The GRS550 Offset Test Points Toolbar allows test points to be offset in all directions, up, down , left and right, This will be found especially useful for offsetting test points on round pads.

  • Page 101: Removing Component Test Points

    The Safe Fly Height command (in the Prober menu) allows the operator to record the height of the tallest component on the board under test. The GRS550 uses the setting to clear tall Set Safe Fly Height for Prober button components during testing.
  • Page 102 5mm, else this may result in damage to the PCB and the probe head. Low Profile Flight turned on provides another significant saving in test time.  Use this feature with caution! 78  CREATING THE TEST LIST GRS550 User Manual...

  • Page 103: Moving Round The Grs550 Display

    Moving round the GRS550 display The toolbar incorporate the functions for viewing, panning and zooming the board data. Board data viewing tools The button function are as shown below; the keyboard shortcut keys are shown in parentheses. Zoom In (+) Zoom Out (–)

  • Page 104: Rotating The Display

    Locate the crosshairs over a new point and Mark with the M key to move to the destination point. If necessary, e.g. when working with large design netlists, use the zoom and pan facilities while marking points. 80  CREATING THE TEST LIST GRS550 User Manual...

  • Page 105: Viewing Individual Layers

    Track data — turn track data on or off  Test Point Data The GRS550 displays all data by default; uncheck an item to remove it from the display Net Information Select the Net Information command from the Display/Info menu to display summary information on the currently displayed CAD Netlist.

  • Page 106: Highlighting Nets

    To highlight nets for display (during fault tracing, etc.) select the Display/Info menu. (See the Point and Click method to highlight nets using keyboard shortcuts.) The Display/Info menu provides the commands to: 82  CREATING THE TEST LIST GRS550 User Manual...

  • Page 107: Displaying Highlighted Nets

    Displaying Highlighted Nets. Activate the Fault Entry area on the Toolbar. The GRS550 will use the Fault Entry method selected via the Configure menu. Press OK in the Fault Entry area to confirm the selected nets or to dismiss the Fault Entry area.

  • Page 108: Point And Click

    From the Fault Entry tab select Net Name. Press F on the keyboard — the Fault Entry area on the Toolbar is activated: Enter the name for the net(s) and click OK. The GRS550 will highlight the selected net(s). Fault Entry: Net Number From the Fault Entry tab select Net Number.

  • Page 109: Querying Pads And Test Points

    In All Layers mode the highlighted nets will be coloured as detailed in the Reference Section – GRS550 DISPLAY WINDOW COLORS. Querying pads and test points Query Pad The Query Pad function (Display/Info menu) allows the user to display detailed device, net and position information for the pad.

  • Page 110: Query Test Point

    Component View pane to query the pin. If Track Cursor Position is turned on (Prober|Prober Options), as each pin is queried the camera is located over the pin in the Camera View. 86  CREATING THE TEST LIST GRS550 User Manual...

  • Page 111: Testing Boards

    Test parameters can be varied on a pin by pin basis from those set during test point allocation to accommodate charging effects or to specify more effective voltage and frequency ranges. The Test List toolbar The Test List tools are described below TESTING BOARDS  87 GRS550 User Manual...

  • Page 112: The Test List Pane

    Test critical nets only (see CNT function) Retest all failed pins Stop test Inspection view The Test List pane The Test List pane lists all the components defined for the board. The components can be sorted by column heading. 88  TESTING BOARDS GRS550 User Manual...

  • Page 113: The Component Pane

    Nets are shown in grey, the pads are displayed in green and the test points are shown in orange. After testing the component, test points that failed the nodal impedance test are shown in black. TESTING BOARDS  89 GRS550 User Manual...

  • Page 114: Modifying Test Parameters For Individual Devices

    The GRS550 normally retracts the probe a short distance as it moves from pin to pin on a device. Click the Force Safe Fly Height check box to force the GRS550 probe to retract to the safe fly height between test points on the same device. Use this feature when testing components with a height of more than approx.

  • Page 115: Setting Test Tolerances

    To view details of a device click the Component Pins List button. The Component Pins List displays net and test information for the Component Pins List selected device. button TESTING BOARDS  91 GRS550 User Manual...

  • Page 116: Component Test Parameters

    (requiring that the reference signatures be re-acquired). If the test parameters are modified for a single component pin the settings for the whole component are shown in grey. 92  TESTING BOARDS GRS550 User Manual...

  • Page 117: Acquiring Reference Signatures

    To acquire signatures for every test point on the board under test click the Test All button. The GRS550 will probe every test point on the board, sensing the height of each component. With reference signatures acquired for the board, use the Save Database command to store the signatures along with the net data.
  • Page 118 The GRS550 displays a warning dialog if “Confirm before saving open circuit pins” has been activated in the GRS Configuration – Prompts Tab.

  • Page 119: Inspection Mode - Verifying Probing Accuracy

    Camera View window. This allows the operator to verify the actual probe position visually. Use the Slow Touch Button to move the probe down at the actual selected position to verify the correct probing position. Slow Touch button TESTING BOARDS  95 GRS550 User Manual...

  • Page 120: Testing Components

    Test List and click the Test Selected Test Selected button button to test the component. The GRS550 tests the device and displays its test result (PASS or FAIL) as a green tick or a red cross. Test results for each device are shown in the Component windowpane;...

  • Page 121: Sorting Signatures

    Sorting signatures Signatures may be sorted by voltage range, by error (percentage deviation from the reference signatures) or by pin number. Right- click the signature view and choose the sort range as appropriate. TESTING BOARDS  97 GRS550 User Manual...

  • Page 122: Displaying Live Signatures

    Select the Test All button to test the whole board. Test All button Testing multiple components using Auto Align The GRS550 provides an Auto Align function to automatically align the camera crosshair onto the board´s fiducial using a powerful image processing algorithm.

  • Page 123: Displaying The Test Summary

    “Align” button. Displaying the test summary At the end of each test or group of tests the GRS550 displays the test summary detailing the test statistics and results. TESTING BOARDS  99...

  • Page 124: Clearing Test Results From A Component

    Use the Display Summary Report After Test option from the Prompts tab of the Configure menu to allow the GRS550 to display the PASS/FAIL summary. If the Bar Coder Reader option is installed and the Bar /QR Code position learned, then the barcode serial number is displayed as well.

  • Page 125: Cnt Critical Net Test

    Loading a list of nets using File – Import – Import CNT The required format of the CNT *.xml list is as follows: <CriticalNets> <CriticalNet Name="N05254"> </CriticalNet> <CriticalNet Name="D11"> </CriticalNet> <CriticalNet Name="N24176"> </CriticalNet> <CriticalNet Name="N06893"> </CriticalNet> </CriticalNets> TESTING BOARDS  101 GRS550 User Manual...
  • Page 126 Once nets have been declared as “CNT”, use the CNT button to test these nets only. If a subsequent full test is required, click on Test all devices Test all devices with Auto Align 102  TESTING BOARDS GRS550 User Manual...

  • Page 127: Replacing Reference Signatures For A Component

    Nodal Impedance button reference signature for comparison. Using alternate signatures The GRS550 allows the operator to store up to five reference signatures for each test point on a board. For example, sets of signatures for devices from different vendors can be stored as reference. This can eliminate spurious device failures caused by slight variations in signatures in good devices from different manufacturers.

  • Page 128: Using Board Snapshots

    Using board snapshots The GRS550 allows the operator to save the board database along with the test results for the board as a snapshot. The board snapshot may then be used for offline repair. From the File menu choose the Save Snapshot command; name the snapshot and click Save.

  • Page 129: Video Sectioning

    Video Sectioning button snapshot of the corresponding board area. Video Sectioned board To create a new video section of the board, ensure the board is aligned; click the Learn Frames button; the GRS550 steps TESTING BOARDS  105 GRS550 User Manual...

  • Page 130: Comparing Boards

    To compare the board under test with the reference board mount the board on the GRS550 table and align the board. Click the frame of interest; the GRS550 displays the Current (live) view of the board alongside the reference (Learnt) view.

  • Page 131: Simplified User Interface

    – System is in error state and requires urgent user interaction Exiting the program Select Exit from the File menu to leave the program. Ensure board data and results are saved before exiting. TESTING BOARDS  107 GRS550 User Manual...
  • Page 132 108  TESTING BOARDS GRS550 User Manual...

  • Page 133: Maintenance

    Like any complex mechanical system, the GRS550 does require some basic maintenance to ensure maximum uptime. The motion control system of the GRS550 is maintenance free but Polar Instruments GmbH will provide firmware updates from time to time to add new features and to optimize the motion dynamics.

  • Page 134: Replacement Of The Probe Head Linear Bearing

    Replacement of the probe head assembly After an extended period of use, the probe head assembly may need an overhaul or replacement. Polar Instruments GmbH offers an exchange program by taking back used probe heads against factory refurbished probe heads. Contact Polar Instruments GmbH for details.
  • Page 135 The Joystick X and Y values should dither around 128 when in center position. If required, adjust the values to near 128 using a small screw driver by pressing the +/- buttons on the back of the MAINTENANCE  111 GRS550 User Manual...

  • Page 136: Remote Troubleshooting

    If due to a company security policies, remote support is not possible, Polar Instruments GmbH will endeavour to provide support by telephone and E-Mail . 112  MAINTENANCE...

  • Page 137: Reference

    REFERENCE GRS550 Display Window Colours Loaded data colours The table below defines the colours for each layer. Layer Colour Pad Data for upper layer Green Pad Data for lower layer Magenta Pad and Trace data for all layers Grey Test points (assigned during Test Point...

  • Page 138: Query Items (Display/Info)

    Delete test point Jog test point outwards Jog test point wards Offset test point Undo and return test points to original positions Name Alignment Point Remove Components Test Points Keep Out Areas Add Keep Out Point 114  REFERENCE GRS550 User Manual...

  • Page 139: Testing

    Delete Keep Out Point Add Keep Out Component Remove Keep Out Component Testing Ctrl + A Performs a Test All with Auto Align REFERENCE  115 GRS550 User Manual...

  • Page 141: Activex Remote Control Command Set

    ActiveX Remote Control command set The GRS550 allows full remote control via a GRS500 External Instruments Programming Interface. This enables control of the GRS550 and any other connected hardware through third party External Instruments software such as National Instruments LabVIEW/TestStand or button custom specific software.
  • Page 142 The GRS550 object has one class called ExternalInstruments The int parameters defined below are Int32, not Int16. Please ensure that you match the data types correctly. The Class currently has 42 member functions: A2  External Instruments Programming Interface GRS550 User Manual...

  • Page 143: Externalinstrumentsenabled

    Loads a *.grs file containing component coordinate and net information. A *.grs file may be generated manually via camera/joystick or via CAD data import. 6. TL_TestAll Public Function TL_TestAll() As Boolean  External Instruments Programming Interface  A1 GRS550 User Manual...

  • Page 144: Testall_Autoalign

    ' Call read barcode End Function Reads the barcode, requires the BarCode Reader option to be installed. Use this function in combination with “MoveToTestPoint(strComponent, strPin)” to move to the BarCode position. A2  External Instruments Programming Interface GRS550 User Manual...

  • Page 145: Tunebarcode

    Prints test results into a *.txt file. Use only for GRS type system. 15. PrintSignatures Public Function PrintSignatures(strfilename As String)  ' The test result is written to a csv file End Function External Instruments Programming Interface  A1 GRS550 User Manual...

  • Page 146: Printsignaturespassedtopdf

    ' Get Prober XYZ. Return coordinates in machine units End Function Returns the current X, Y and Z position in machine counts 20. Home Public Sub Home()  ' Home End Sub Homes the Prober A2  External Instruments Programming Interface GRS550 User Manual...

  • Page 147: Prober_Fasthome

    Request the prober to move to the absolute XY coordinate, with the origin 0,0 being at the bottom left of table. Coordinates will be in machine counts and need to be determined by using the GRS functions prior to using external instruments. External Instruments Programming Interface  A1 GRS550 User Manual...

  • Page 148: Movez(Intz)

    End Function Control Z-axis solenoid. Only for GRS Instrument, not for RITS/DVS. Valid parameter values for intProbePosition: 0=Probe Up 1=Probe Down 29. SetSwitchableCommons(intSwitchableCommonsValue) Public Function SetSwitchableCommons(intSwitchableCommonsValue As Integer)  ' Set Switchable Commons A2  External Instruments Programming Interface GRS550 User Manual...

  • Page 149: Switchcamera(Intcameraposition)

    Request the prober to use the Z-axis touch z option. Use only for GRS type system 32. TakeCameraSnapshot Public Function TakeCameraSnapshot(strSnapShotFilename As String)  ' Take Camera Snapshot. Write current camera bmp image to file End Function External Instruments Programming Interface  A1 GRS550 User Manual...

  • Page 150: Proberotate

    Move Z-axis stepper by specified number of number of machine counts, use this command only when RF Head is mounted (RITS/DVS Instrument). For GRS Type systems use “MoveZ” instead 37. SetLaserPointer Public Function SetLaserPointer(bIsEnabled As Boolean)  A2  External Instruments Programming Interface GRS550 User Manual...

  • Page 151: Rftouchz

    Public Function ImportCriticalNets(strfilename as String)  ' ImportCriticalNets. Imports critical nets for testing. (Defined xml-fileformat) End Function 42. TestCnt() Public Function TestCnt()  ' Test CNT. Tests only nets marked as critical. (Defined xml-fileformat) End Function   External Instruments Programming Interface  A1 GRS550 User Manual...

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