XR 3000 Real-Time
X-Ray Inspection System
Operation Manual
Rev A, 4/2002BMS
P/N 5050-0511
PACE USA PACE Europe
9893 Brewers Court Sherbourne House,
Laurel, MD 20723 Sherbourne Drive
USA Tilbrook, Milton Keynes
MK7 8HX
United Kingdom
Tel: (301) 490-9860 Tel: (44) 1908 277666
Fax: (301) 604-8782 Fax: (44) 1908 277777
1. XR 3000 Safety Information
IMPORTANT: READ THIS FIRST
It is essential that the operator of the XR 3000 read and understand the following
safety warnings PRIOR to operation.
The XR 3000 is designed to provide safe and efficient operation. However, any
equipment producing ionizing radiation (x-rays) must be considered hazardous
and should be treated accordingly. When operating this equipment, observe the
following:
?? PACE strongly recommends that all maintenance be performed by a
qualified service technician.
?? The XR 3000 x-ray tube produces high voltages of up to 70,000 volts.
Under no circumstances should the case be disassembled or modified as
severe electrical shock may occur.
?? The XR 3000 is designed to ensure adequate radiation shielding. Even
so, always be aware that the ionizing radiation (x -rays) can constitute a
distinct hazard if not employed in strict accordance with instructions
provided in this manu al for maximum operator safety.
?? Exposure to excessive quantities of radiation can be dangerous to your
health. Avoid not only direct radiation exposure, but also to secondary or
scattered radiation which occurs when an x-ray beam strikes or has
passed through any material.
?? Do not insert any part of the body into the inspection chamber while x -rays
are on. Although the XR 3000 operates at an extremely low x-ray dose,
unnecessary radiation exposure should be avoided. If an item becomes
jammed or lodged in the inspection area, the XR 3000 should be turned
off before any attempt is made to clear the inspection chamber.
?? PACE strongly recommends that all personnel operating the XR 3000
wear a radiation film dosimeter badge. See Section 15. This badge
records an exposure history for the operator and acts as a constant
reminder to the operator to use caution and safe work practices when
operating the XR 3000.
?? The radiation exposure dosage received by personnel working with x-ray
inspection equipment should not exceed those limits set by local
regulations relating to ionizing radiation.
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?? Adequate warning signs and symbols should be displayed in the vicinity of
the XR 3000 warning of possible x-ray exposure. Any warning lamps and
signals should be checked prior to operating the XR 3000.
?? The electrical circuits of the XR 3000, although enclosed for operator
protection, must be considered as a potential hazard. Strict observance of
safety practices pertaining to operation and maintenance is essential.
Proper electrical grounding must always be used.
?? Before operating the XR 3000, all personnel designated or authorized to
operate the unit, as well as those supervising its operation, should have a
full understanding of how it works. Additionally, they should be familiar
with established radiation safety exposure practices sanctioned by the
National Bureau of Standards Handbook, “X-ray Protection” HB93,
pertaining to x-ray protection.
?? Service personnel should read this manual and be familiar with its
contents before attempting to adjust or repair this equipment.
2. Radiation Safety Information
Federal, State and Local Radiation Regulations (US ONLY)
This cabinet x-ray system was designed to conform to U.S. and Food and
Drug Administration (FDA) requirements as stated in the Code of Federal
Regulations, Title 21 (21CFR). These requirements (often referred to as the
CDRH or BRH regulations) govern the design and manufacture of all
equipment that produces ionizing radiation. Such equipment includes
television sets and microwave ovens, as well as cabinet x -ray systems. In
fact, the maximum allowable radiation emission for cabinet x-ray systems is
the same as that set for television sets and microwave ovens. Therefore,
respect to radiation emission, a properly maintained and operated cabinet xray system is a safe as a television or microwave oven.
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Warning: Failure to adhere to the following warnings may result in
exposure to radiation:
?? Do not operate the x-ray system unless all system components and
features are in good repair.
?? Never attempt to remove any system component or bypass any
system function.
Several features are included in the system design to provide for radiation
safety. The controls (including key switches), control circuitry, leaded
components (including the leaded acrylic windows), physical barriers,
interlocks, and status and warning indicators each contribute to overall
radiation safety.
The Federal Aviation Administration (FAA), Occupational Safety and Health
Administration (OSHA), most state and some local government agencies
typically have specific standards regarding operational safety and constraints
regarding the modification of x-ray systems conforming to 21CFR (mentioned
above).
Typically, an x-ray system must be registered with the appropriate state
agency, by the physical possessor of the system, regardless of the legal
owner. Frequently, registration must occur prior to the x-ray system being
placed into service. Regulations may require initial and periodic inspections by
a government agency or a qualified vendor. In addition, the regulations may
require the implementation of standardized operating procedures, specialized
training, the distribution and use of exposure monitoring badges and posting of
radiation exposure warnings and other special notices. Radiation safety
requirements may differ slightly from one jurisdiction to another. It is the
users responsibility to ensure that the x-ray system is installed and
operated in compliance with all applicable governmental regulations.
Failure to comply may result in substantial penalties.
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3. Radiation Safety Guidelines
To ensure the health and safety of the operator and all others in the vicinity of
operating x-ray inspection equipment, the following guidelines are recomm ended
for establishing a basic radiation safety program.
Note: Federal, State, and some local government agencies
may have more stringent regulations concerning the operation
and use of equipment that produces ionizing radiation (x-rays).
The requirements of these governing agencies supersede the
recommendations made by the manufacturer.
1. A copy of the operating instructions should be kept at the machine at
all times.
2. Personnel operating the equipment should be trained in the proper and
safe operation of the machine.
3. Radiation surveys should be performed periodically to ensure that the
amount of radiation being emitted by the machine is less than
0.5mR/hour. We recommend performing a radiation survey:
?? Following initial installation – before placing th e x-ray system
into service.
?? Whenever the x-ray system is relocated.
?? Whenever the x-ray system receives a strong jolt (e.g., being
dropped ore than one inch or struck sufficiently hard to dent or
deform the exterior cabinet).
?? Whenever a leaded component (such as the x-ray generator,
shielding, inspection tunnel curtains, LXDA or collimator cover)
is removed for any reason or period of time.
?? Annually – from the date of the most recent radiation survey
4. All controls and indicators should be checked daily to ensure proper
operation.
5. Do not operate the x-ray system if it is not in good repair. Do not
attempt to remove or bypass any controls (e.g. foot pedals and key switches), interlocks, status indicators, leaded components (including
the inspection tunnel cu rtains) or physical barriers. In the event of
failure or breakage, these items should only be replaced by a qualified
service technician using factory-approved parts.
6. Service of the equipment should only be performed by or under the
instruction of trained PACE personnel.
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Many users choose to issue periodic radiation film badges to assure employees
that they are not being exposed to significant levels of radiation and to provide
added assurance that radiation emissions are well within regulatory limits.
4. Radiation Safety Training
PACE can provide or make referrals to those who can, operation and radiation
safety training to ensure that the facility is in compliance with all state and federal
radiation regulations.
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5. Operation
Bare Board
Hole/Pad Offset
BGA Voiding
Leaded Component
Non-Co planarity
Leaded Component
Opens
XR 3000
The XR 3000 Real Time Inspection System is a powerful
tool in the quality control and process verification of all
aspects of microelectronics manufacturing. The XR 3000
provides rapid, real-time x-ray inspection for production
and rework environments. Its self-contained console
design supports easy customizing for numerous
applications, including multi-layer PCBs, small hole
drilling, large back-planes and assemblies with advanced
components, such as BGAs, ?BGAs and chip-scale
packages.
In bare board applications, it can be used to check for
interlayer shift and drilled hole-to-pad offset. Inspection is
performed following lamination, to determine the
presence and degree of interlayer shifts. At the onset of
either conventional or small hole drilling, inspection is
used to qualify hole -to-pad alignment. In addition to
enhancing product quality, x -ray inspection enables users
to control costs by eliminating defective boards early in
the production process. It can also be used to quality
control incoming boards from vendors or customers so
that defects can be detected before problems occur.
For surface mount components, it is used to verify
lead/pad co planarity, shorts, opens, and solder bond
quality. It can be used to check resistors and capacitors
as well as IC’s for internal damage and verify adjustments
throughout the placement and reflow processes.
For BGA’s, the XR 3000 can be used to check for all
potential defects including: shorts, opens, misregistration, non-wetting, solder ball voids, and
delamination. X-ray is used to verify proper reflow
profiles for advanced packages, and to control rework
process.
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6. Set Up
A. XR 3000 as a stand-alone inspection station
Place the XR 3000 on a stable work platform of sufficient capacity to
adequately support the XR 3000. The monitor used to view the images
should be placed on the work surface next to the XR 3000 and not on top of
the XR 3000 as it is not designed to support a monitor and the monitor may
fall.
Locate the foot pedal, composite video cable, and power cord. These should
be connected as shown in Figure 1.
Figure 1. The back of the XR 3000
The other end of the composite video cable should be connected to the
composite video input on the video monitor. The power cord should be
connected to a properly grounded 120 VAC power supply.
B. XR 3000 used with the TF 2000 or TF3000 BGA/CSP Rework Center
Place th e XR 3000 on a stable work platform of sufficient capacity to
adequately support the XR 3000. The work platform can be the same as the
work platform supporting the TF 2000/TF3000 or may be a separate one as
long as it is close enough to allow for the connection of the composite video
cable to the PC.
Locate the foot pedal, composite video cable, and power cord. These should
be connected as shown in Figure 1.
The other end of the composite video cable should be connected to the
composite video input on the video capture card on the PC. See Figure 2.
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The power cord should be connected to a properly grounded 120 VAC power
supply.
Composite Video Connection
Figure 2: Back of TF 2000 PC or TF3000.
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7. XR 3000 Initial Power-up and Operational Test
The system should be fully set up according to the System Setup Section before
starting these procedures.
1. To turn on the power, turn the key to the ON position. The key is required
to turn on the power and cannot be removed unless the key has been
returned to the off position. The green system light should also turn on
when the key is engaged.
2. Make sure that there is nothing inside the inspection chamber and
depress and hold the foot pedal. The image on the PC or video monitor
should change from a flat light gray image to a brighter, slightly grainy
image. This is the blank x-ray image.
3. Release the foot pedal and the image should return to its original state.
4. Depress the foot pedal again and now look at the control panel. The red
“x-ray on” light should illuminate and remain on for as long as you hold
down the foot switch. Release the foot pedal.
5. Place a component (such as a circuit board) inside the inspection
chamber directly underneath the x-ray tube.
6. Depress and hold the foot switch. Th e x-ray image of the component
should now be visible.
7. Move the component while the foot switch is depressed. The image
should move with the component. The image will display a trail behind the
component, which will disappear when the component has stopped
moving. This is a normal occurrence and is a function of the image
processor. The video processor included with this system is preset to 8
frame averaging. Averaging makes the x-ray image less grainy and can
be adjusted to improve image quality but with an increase in motion lag.
Refer to the section on the image processor for further information.
8. Images may be captured electronically when the XR 3000 is used with the
TF 2000 PC or TF3000 PC and software.
Your system is now ready for use. Please refer to the individual component
sections found later in this manual for further adjustment.
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8. XR 3000 Adjustment Features
A. Introduction
The XR 3000 is fitted with an XRTV Zoom X-Ray camera. The zoom camera
magnification can be varied from 7x t o 40x. The memory button can be used
to store a magnification setting and to quickly return to that setting.
The XRTV Zoom X-Ray camera utilizes the latest servo-control and
microprocessor technologies to produce sharp, high resolution images at any
magnification. The camera automatically monitors and adjusts the focus and
exposure parameters.
B. Camera Operation
The camera is controlled through the button and two switches mounted on the
XR 3000 control panel. See Figure 3.
Figure 3: XR 3000 Control Panel
When the power is turned on, the camera automatically sets itself to 14X
magnification. This is the magnification setting that is stored in memory when
the unit leaves the factory.
The camera operates in either the ZOOM control mode or th e GAIN control
mode; set by the rocker switch on the control box panel. See Figure 3. To
adjust the image magnification, place the control switch in the ZOOM setting.
The camera magnification is controlled by the +/- rocker switch. Press the
rocker in the + direction to increase the magnification. Press the rocker in the
- direction to decrease the magnification.
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The memory button can be used to store and quickly return to a preset
magnification and focus setting. This function is useful if a video
measurement system is used. To store the current magnification and gain
setting, press and hold the MEMORY button for three seconds. The camera
will beep to indicate that the current setting has been stored in memory. To
restore the magnification and gain setting from memory, press and release
the MEMORY button. The camera magnification will quickly return to the
setting stored in memory.
Manual gain control is enabled by placing the mode switch in the “GAIN”
position. Press the rocker in the + direction to increase the gain. Press the
rocker in the - direction to decrease the gain. Press the rocker once for each
step on gain. After setting the gain, the rocker can be switched to the ZOOM
mode without losing the manual gain setting. Automatic Gain Control is
enabled if the mode switch is set to GAIN and then back to ZOOM without
using the +/- rocker switch.
As shipped from the factory, the startup setting stored in memory is 14x
magnification and auto focus mode.
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9. Troubleshooting
A. Self-Diagnostics
The XRTV zoom camera is equipped with self -diagnostic features that help to
debug certain problems that may hinder system performance. This selfdiagnostic feature will help to identify if the x-ray source is emitting x -rays,
and if the camera control microprocessor and the camera itself are
functioning normally.
To use the self-diagnostic feature, power off the entire x-ray system at the
main power switch. Turn the system back on with the main power switch. Go
to the camera controls. The camera controls should be making an audible
beep and, if equipped with a lighted Zoom/Gain switch, the LED should also
be flashing. As soon as the beeping starts (about 4 seconds after start-up)
hold down the memory button until the beeping stops. You will notice that the
image processor will not boot up and that there will be no image on the
monitor. Depress and hold the footswitch. After about 3 seconds, the
camera control box should let out a continuous beep and the AGC LED (if so
equipped) should turn on. Now release the foot switch and the LED should
turn off and the beeping should stop. The beeping and lighting of the AGC
LED signifies that the x-ray source is emitting x-rays and that the x-ray
converter inside of the camera is functioning properly. Now, press and
release the memory button. The camera control box should begin its start-up
beeping. This is testing the camera and microprocessor communications.
After about 5-7 seconds, the beeping should stop and a video signal will now
be present. Note that the image processor should now boot up properly and
an x-ray image should now appear on the monitor. If there ever was a
problem with your x-ray system, you may be asked to perform this test if you
call PACE for technical support.
B. Blurry Image
The XRTV Zoom camera employs an advanced focus system, which keeps
the image in constant focus. On occasion, the focus system will drift. This
problem occurs most often if the magnification is changed while the x -ray
source is not on. In most cases, the camera control system will refocus the
camera within 1-2 seconds. If the image appears out of focus for longer than
a few seconds, change the magnification setting while the x-ray source is on.
This should give the camera enough information to let it lock onto the proper
focus. In general, it is best to change the magnification only when the x -ray
source is on. Changing the magnification when the x-ray source is off will not
cause any damage; it will just take a few extra seconds for the camera to lock
into focus.
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C. General Problems
If the camera does not appear to operate properly, switch off the power, wait
a few minutes and switch the power back on. If the camera is still not
operating properly, call PACE.
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10. Specifications
?? Operating voltage: 120V, 50/60 Hz or 230V, 50Hz
?? Energy sensitivity: less than 15kV to greater than 160 kV
?? X-Ray Tube – 52 kVA
?? Resolution: greater than 20 line pairs per millimeter; can easily resolve a 1
mil bond wire
?? Magnification: 7 - 40x
?? Maximum field of view: 1 inch diameter circle
?? Maximum PCB size: 24” x 24” (610mm x 610mm)
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11. RTVA Image Processor
The RTVA (Real-Time Video Averager) is an image processor used in the XR
3000 X-ray system. It uses video frame averaging to smooth the inherently
grainy image coming from the X-ray camera. It is located inside of the XR 3000
housing.
The RTVA is adjustable by using the front mounted switch marked “FRAME
AVERAGING”. See Figure 3. This adjusts the amount of frames that the RTVA
averages before sendin g the video out to the monitor. When using the switch,
please note the following frame averaging settings:
(Note that image trailing will occur at higher settings.)
Setting Effect
0 BYPASS. There is no averaging in this setting
1 2-frame averaging
2 4-frame averaging
3 8-frame averaging
4 16-frame averaging
The RTVA image processor also has a “CAPTURE” ability that is designed to
hold the current image. To use this option, just switch the front -mounted
CAPTURE/LIVE switch to the “Capture” position. See Figure 3. To return to
normal operating mode, return the switch to the “LIVE” position.
Please note that there are no user serviceable components inside. If the
component is suspected of being faulty, please call PACE.
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12. XR 3000 Maintenance
The XR 3000 system has been designed for simple maintenance. The only
suggested maintenance is to keep the unit visibly clean and to keep the system’s
calibration up to date. Any mild surface cleaner, like Windex, may be used to
clean the system. If you find that your system is coming close to its calibration
date, please contact PACE to schedule a calibration.
It is very important that you contact PACE early so that we may schedule service
at a convenient time.
Warning: The acrylic and vinyl around the opening of
the XR 3000 contain lead. Always wash your hands
immediately after use. Eating and drinking without
washing your hands may cause you to ingest lead.
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13. Troubleshooting
Quick Tips
The first thing to do is to
start the
system. This can solve most
In the event that your system exhibits problems, this section will familiarize you
with the basic steps to troubleshoot the
problem as well as what information PACE
will require in order to give you the best
possible service.
1. The first step in troubleshooting is that
the system must be completely shut
down and re-started. You can do this
by turning the keyed power switch, located on the front of the system, to
the “Off” position.
2. Turn the power back on.
3. There are three categories that are used to troubleshoot the system:
Power: The power category covers all problems that include lack of
power to a component or to the full system. Power problems
would include:
- The system not powering up.
- The x-ray controller’s red light does not turn on.
- The system’s green light does not function.
?? Do all components power up when the main power
?? Do all power-indicating lamps turn on?
?? Do all power outputs show the proper voltage?
?? Is the foot pedal connected?
simply try and reproblems right away.
switch is turned on?
Video: The video category covers the problems that affect the presence
of a video signal from the x-ray camera. Video problems would
include:
- No x-ray image on the monitor, but x-rays are present.
- The image processor on the system does not boot up.
- The x-ray image is fuzzy or out of focus.
?? Is the video cable attached properly?
?? Does an X-ray image appear on the monitor when the
foot switch is depressed?
?? Does the systems image processor boot up?
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?? Does the X-ray monitor have a light gray screen or
flicker?
X-Ray: The x-ray category covers the problems that affect the tube’s
emission of x-rays. The x-ray category includes:
- The red “X-Ray On” light is not turning on.
- There is no image on the monitor, but video signal is present.
- There are no x-rays being emitted from the x-ray source.
?? Does an X-ray image appear on the monitor when the
foot pedal is depressed?
?? Does the red “X-ray on” light turn on when the
footswitch is depressed?
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14. Replacement Parts
Description Part Number Image
Leaded Vinyl 4’ x 2’ sheet 1335-0248-P1
Replacement X-Ray Tube 4018-0101-P1
Replacement X-Ray Zoom
4018-0102-P1
Camera
RTV Image Averager 1199-0003-P1
PCB Carrier 8885-2000
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15. Model XR-3000 Design Safety Standards and Safe Operating Practices
Because of the low operating anode power of the XR 3000, real time x -ray
inspection system, it has been registered with the Center for Devices and
Radiological Health Branch of the FDA as an “Analytical X-ray System”. As
registered, the system has a number of safety features provided to minimize
any x-ray scatter reaching the operator.
A. Safety:
The X-Ray tube assembly is lead shielded with at least a ¾ inch space
between collimator and image plane to minimize any x -ray scatter. The
collimator insures that the x-ray beam size at the image plane is no more than
a one-inch diameter circle. The table assembly employs a lead acrylic view
panel and additional lead shielding. The highly sensitive x-ray camera
permits the x-ray tube to operate at low power (anode voltage of 52 kV and
anode current of 25 microamps) resulting in minimal x-ray scatter. All these
safety features result in a structure with radiation scatter at 5 cm from any
exposed surface less than 0.3 milliRoentgens per hour. (Radiation exposure
in an airplane at 30,000 feet during the day is greater than 0.4 milliRoentgen s
per hour.)
B. Radiation safety precautions for the use of XR 3000 Real Time X-ray
Inspection System:
It is imperative that the XR 3000 be operated only by trained personnel who
are familiar with the basic safety precautions to be taken when working with xray producing equipment.
1. The key to actuate the x-rays should not be left in the equipment when
the equipment is not being used and is unattended.
2. Operators should not place hands under the leaded acrylic panel in the
front.
3. The equipment should not be operated with any panels removed.
4. Operators should be familiar with the use of the Monitor-4 radiation
survey meter.
5. Service of the equipment must be performed by or under the
instruction of trained PACE personnel.
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C. Radiation monitoring:
Specific regulations regarding the monitoring of possible radiation leakage of
industrial x-ray cabinets are determined by the individual state or country.
There are a number of measures, which can be taken to provide a means of
cursory monitoring.
D. Dosimeter badges:
Dosimeter badges can be obtained from:
1) Siemens Dosimetry
Barrington Road
Hoffman Estates, IL 60195
(800) 666-4552 2501
2) R.S. Landauer & Co
2 Science Road
Glenwood, IL 60425
(708) 755-7000
Dosimeter badges can be placed by the equipment or worn by the
individual to constantly record any x-ray exposure. At the end of the
month a replacement dosimeter is sent and the present months dosimeter
is returned to the dosimeter service company. A report is issued monthly
tabulating any x-ray exposure received. A dosimeter service is most
useful in that documented records are established for the corporation
showing that no radiation leakage has occurred.
E. Radiation survey meters:
Radiation survey meters detect the presence of ionizing radiation and
display a value in units of mR/hr (milli Roentgens per hour). It is generally
a good idea to have, as part of a radiation safety program, a radiation
survey meter. The monitor –4EC survey meter is available from PACE.
The Monitor-4EX employs an energy compensated G-M tube to measure
the presence of radiation. It is calibrated to Cs-137. The Monitor-4EX can
be used to detect any radiation leakage from x-ray systems.
F. Radiation safety training:
PACE can provide or recommend providers of operation and radiation
safety training to ensure that the facility is in compliance with all state and
federal radiation regulations.
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