Pace XR4000 Service Manual

XR 4000 Real-Time

X-Ray Inspection System

Operation Manual

Rev A-3-2001-PRM

P/N 5050-0516

PACE USA PACE Europe

9030 Junction Drive Sherbourne House,
Annapolis Junction, MD 20701 Sherbourne Drive
USA Tilbrook, Milton Keynes
MK7 8HX
United Kingdom

Tel: [phone] Tel: [phone]

Fax: [phone] Fax: [phone]

1. XR 4000 Safety Information
IMPORTANT: READ THIS FIRST

It is essential that the operator of the XR 4000 read and understand the following
safety war nings PRIOR to operation.

The XR 4000 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 4000 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 4000 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
manual 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 4000 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 4000 should be turned off before any attempt is made
to clear the inspection chamber.

• PACE strongly recommends that all personnel operating the XR 4000 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 4000.

• 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
4000 warning of possible x-ray exposure. Any warning lamps and signals should
be checked prior to operating the XR 4000.

• The electrical circuits of the XR 4000, 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 4000, 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 inclu des
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 recommended
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 the 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 more 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 curtains) 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 4000

The XR 4000 Real Time Inspection System is a powerful
tool in the quality control and process verification of all
aspects of microelectronics manufacturing. The XR 4000
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 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 4000 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

115 V Unit

230 V Unit

A. XR 4000 as a stand-alone inspection station

Place the XR 4000 in a location where it will not be in the way and will not be
damaged. Images can be displayed on either a monitor, the XR 4000 PC, or
one of PACE’s BGA rework systems, depending on the option purchased.

Familiarize yourself with the back of the XR 4000. Note that the 115 V
system has a multi strip mounted on the back to plug in the PC, video
monitor, or other accessories.

Foot Pedal
Connection Composite Video Out

Locate the foot pedal, composite video cable, and power cord. These should
be connected as shown in Figure 1. The power cord should be connected to a
properly grounded 120 VAC power supply.

A-1. If the PC package was

AC Power Receptacle

Figure 1. The back of the XR 4000

purchased, first, install the PC

mounting brackets on the side of
the XR 4000 as shown. Next,
mount the PC on the side of the
XR 4000 as shown in the figures
to the right.

On the back of the computer, locate the video acquisition card and
connect the included video input cable. One of
the B/C connectors should then be connected to
the video out on the back of the XR 4000. The
BGA cable should be installed from the VGA
connector on the video acquisition card to th e

VGA Video Cable Connection

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