6550 Wedgwood Rd.

Maple Grove, MN
55311
CCI 5000 Series
763-694-4100 In-line Handler

Technology Overview

USA, CANADA, MEXICO,

MALAYSIA, CHINA,
UNITED KINGDOM

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CCI 5000 Series In-line Handler
The CCI 5000 Series In-line Handler separates the dependence between automation, fixturing and
measurement hardware as with other in-line PCBA probe based test stations, while adding a standardize
quick change fixture interface. The CCI 5000 series in-line is a unified in-line handler that is software and
hardware agnostic, enabling adaptability to a variety of off-the-shelf lower cost ICT, flash and functional test
software and hardware.

Overview Modular Fixturing for Maximum Equipment Reuse

• Configurable for in-line A key to achieving the maximum value from automated test
automated in-circuit test (ICT), equipment is using the same test equipment and fixture
flash programming and/or mechanics to test multiple products. Circuit Check's 5000 Series
functional test In-line Handler achieves this by using interchangeable fixturing.
• Supports many open hardware Interchangeable components enable the same test system to be
standards quickly reconfigured with new tooling for different products. This
• Integrated rack and cabinet maximizes equipment re-use while minimizing the cost for each
• Fully controllable conveyor new test. The CCI 5000 series in-line supports probes on the
throughput topside, bottom-side and multi-stage, while also being adaptable
• Smaller footprint vs to through connector test.
comparable solutions
• Modular fixturing
• Bottom, top or multi-stage
stage probing
• Ergonomic straight in-out,
slide-in fixtures with fail-safe
operation
• Both rapid and smooth press
actuation
• Specially designed board
alignment verification
• Operator safe operation with
light curtains, emergency stop
and key-lock controlled access
• SMEMA compatibility

Scalable Instrumentation for Flexible Measurements and Programming

The CCI 5000 series in-line is configured to customer specific test needs in order to maximize performance
at a lower investment, supporting many suppliers of ICT, functional, and flash programming hardware and
software.

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Expandable Automation for a Balanced Production Line Portfolio

A key to test strategy design is evaluating and matching a board’s test requirements to the most effective
means to meet those requirements. The CCI 5000 series in-line allows the PCBA manufacture to more
easily manage tester resource portfolio though a unified in-line automation system matched to customer
defined test needs for balanced ICT, flash and functional test. The CCI 5000 series can be configured as:

Single Bay
 One slide-in fixture with optional fail-discharge shoot
Double Bay
 Two slide-in fixtures to support programming and test
Triple Bay
 Three slide-in fixtures to maximize production line beat-rate and throughput

Figure 1 shows an example CCI 5000 series in-line configured as a two-bay system for in-circuit test and
product flash, with a failed product discharge chute. The CCI 5000 series in-line defect disposition chute
assists to support a paperless repair process and prevent potential pass-through of failed product.

Figure 1. Dual-bay CCI 5000 Series In-line Handler with Fail Chute

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 Integrated Control of Fixture Actuation and Conveyor Speed for Optimized Beat-rate

The CCI 5000 series in-line includes a dedicated industry-standard PC executing a sequenced based
conveyor control software tool (Figure 2). Using a simple text editor, each bay’s conveyor speed and fixture
actuation can be controlled. The user can control the fixturing press for both rapid and smooth press
actuation, while also having control of bay specific conveyor speed to achieve an optimum production beat-
rate.

Figure 2. CCI 5000 Series in-line conveyor user interface

Benefits of Automation in PCB Assembly

Testing printed circuit board subassemblies often is considered separate from the manufacturing process.
Due to increased productivity demands, personnel limitations and quality, integration of test and automation
can deliver many benefits:

• More easily support just enough test- Automation integrated with test allows for faster more efficient
design of throughput algorithms. Functional tests performed in-line can be evaluated on the basis of
detectable faults compromised by line beat-rate.
• Simplify recording of calibration and performance data to ISO9000 and FDA requirements- Automation
combined with test allows for paperless repair and fault numbers to be collected automatically.
• Eliminate possibility of product accidentally forwarded to the next station while assuring that the correct
failure data is available for Quality and Repair departments- Automation with test allows failure analysis
to be logged automatically, while also enabling product to be automatically removed from a line.
• Support concurrency in test by allowing multiple UUTs to be tested at the same time- Automation which
supports testing concurrency can save valuable floor space. Example: testing a product for parametric
functionality (i.e., amplitude, distortion, etc.), while testing another in parallel for functionality can help
reduce total test time, thus improving manufacturing beat rates.
• Addresses mission critical industries such as the Military, Aviation, and Medical- Automation linked to
test can reduced operator intervention allowing for simplified validation to Quality standards.
• Compatibility with existing assembly processes- Automation that supports SMEMA and test allows
common communication to central monitoring sites with real-time views of test data and beat-rate.

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Specifications
Each CCI 5000 Series In-line Handler is assembled to a customer’s application needs, comprising of
device-under-test (DUT) measurement instrumentation interconnects, signal types and counts, power
sources, and management software.

Measurement Capabilities Mechanical Specifications Chassis

Functional Test
• Analog inputs and outputs -
static and waveform I/O
• Digital I/O
• >6.5 digit DMM
• Oscilloscopes
• Waveform generators
• Switching
• CAN, SPI, I2C, MOST, custom
specific interfaces and
communication protocols

ICT Test
• Analog in-circuit addressing
shorts, opens, analog
components.
• Digital with multiple logic
thresholds
• Active and passive components

In-System Programming
• Device-under-test (DUT) site
flashing
• Multi-site flashing

Board Handling Automation

• Support for hands-off
automated product interfacing

Power Conditioning
• Supply of all necessary voltages
• Emergency shutdown

Test and Programming

Environments
• NI TestStand®, CCITest,
CIMTest, NI LabVIEW®, NI
LabWindows/CVI®
• C/C++/C#
• Hardware integration specific

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Mechanical Specifications Fixturing

Conveyor power 24VDC

Conveyor speed 0 to 60 feet per minute (conveyor
only. Does not include fixture
actuation or test times)
Maximum board size 13 inches x 11 inches
Minimum board size 3.5 inches x 3.0 inches
Top side clearance Configurable to customer
requirements.
Bottom side clearance 1.75 inches
Fixture actuation method Pneumatic drive
Board thickness .030 inches to .250 inches
Board shape Can be irregular as long as two
sides are parallel to each other and
are a minimum of 3.5 inches long
Board weight Maximum of 1.5 Lbs./inch
Board alignment Fixed by guide pins
Maximum probe test points Quantity determined by test
equipment selected.
Fixture interface Interface blocks with solid pins
Fixture type Quick change base and top drive
plate (can be configured per
customer requirements)
Fixture lock mechanism Automatic
Through-connector test YES
Supported ICT Contact CCI for vendor options
Supported Functional Test Modular PXI and traditional rack-
base instrumentation
Supported Flash Contact CCI for vendor options

Operator Interfacing

The CCI 5000 series in-line operator interfacing is configurable to existing in-house operating procedures.
The CCI 5000 series in-line can operate completely autonomously, be controlled by way of touch-panel
display, or directed through traditional keyboard function keys. Emergency stop on/off button/switch for
safety, as well as system keypad control locks with removable key to secure recipe operation are standard
features. Light-bar sensors, contact switching and magnet door sensors help ensure operator safely.

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Flexible Solutions Specific to Verification and Production
Circuit Check test systems are based upon modular technologies to accelerate deployment and enable
capital equipment reuse. For over 35 years, Circuit Check is the partner of choice delivering more than
1000’s of solutions and 100,000 fixtures worldwide.

Circuit Check understands the needs for test platforms that must operate in
Engineering Expertise
production test environments, while at the same time, Circuit Check test
systems preserve measurement correlation to design and validation. Table
Certified Project
1 lists common test components and compares their use in design and
Management
production environments.
• Dedicated project
managers
• Corporate-wide MRP
• Time, cost and risk
management

Factory Line Automation

• Indexed, rotary tables
• Palletized systems
• Lean cell manufacturing

Industry Standards
• CE, UL and ISO
compliant, CSA
certified,
• ITAR, IEC, IEEE
• IPC-A-610 (cable
assembly standard)
• IPC-A-620 (PCB
assembly standard)
• Broadband, RF

Test Systems
• Model and design –
CAD, documentation
• Electrical – wiring,
labeling Table 1. List of test components and application use.
• Mechanical –
pneumatics, shielding

Test Fixturing
• SolidWorks® modeling
• Complete machining
Total System Support
centers on-site
• Quick-change fixtures
and adapters Circuit Check supports all aspects of the system development process
including electrical and mechanical design, software development,
Test Software fabrication, system integration, deployment and support. With a modular
• LabVIEW®, functional test system from Circuit Check based upon commercial off the
LabWindows/CVI®, shelf instrumentation, our customers accelerate deployment of production
TestStand® test strategies at reduced investment costs.
• C/C++, .NET, C#

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Appendix A: Terms and Conditions
Notices:
No part of this manual may be reproduced in any form or by any means including electronic storage and
retrieval or translation into a foreign language without prior agreement and written consent from Circuit
Check Inc. as governed by United States and international copyright laws.

Warranty:
The material contained in this document is provided “as is,” and is subject to being changed, without notice,
in future editions. Further, to the maximum extent permitted by applicable law, Circuit Check Inc. disclaims
all warranties, either express or implied, with regard to this material and any information contained herein,
including but not limited to the implied warranties of merchantability and fitness for a particular purpose.
Circuit Check Inc. shall not be liable for errors or for incidental or consequential damages in connection
with the furnishing, use, or performance of this document or of any information contained herein. Should
Circuit Check and the user have a separate written agreement with warranty terms covering the material in
this document that conflict with these terms, the warranty terms in the separate agreement shall control.

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