Keysight i3070 Series 5i Inline In-Circuit Test System

Fixturing Guidelines

Board Placement 2
Board Specifications 6
Fixture Specifications 7
Fixture Guide Pins and Floating Concept 16
Lean Inline Fixture for Large Boards 18
ID Block 19
Additional Control Signals 24
Board Placement
When the IN-LINE keyword is specified in the board file, Fixture Consultant
automatically rotates the fixture graphics 90 degrees so that it shows the same view
as the actual i3070 Series 5i system.

Default Placement
The default placement of the board is at the center of the modules, and the default
keepout area places the edge of the board along the fixture X-coordinate of 145552.
That is, 11063 tenth mils from the edge of the fixture (fixture X-coordinate 156615),
which is equivalent to 28.1 mm.
The board may be moved along the fixed rail for best placement if necessary

Manual Placement
If you are using a previous release of the i3070 software that does not support the
use of the IN-LINE keyword, you must control the placement by catering for a
reference keepout area so that the board is not placed or lean into the critical area.
As shown in Figure 1, the fixed rail of the conveyor partially blocks a probing area
that extends 28.1 mm (11063 tenth mils) from the edge of the fixture. Use the
following keepout coordinates as a guideline:
KEEPOUT
145552, 94700
156615, 94700
156615, -85290
145552, -85290
145552, 94700

If the board overlaps x-coordinate 145552, you will

potentially develop a fixture that may not to be able to load in
the board during production testing.
Leave a gap of 1-2 mils.

The fixture orientation is the same, whether the board direction is left-to-right or
right-to-left for your system. If both system types are present in production, it is
recommended that the board be placed in the center of the fixture. In such cases,
the board stopper in the testing zone must be adjusted during production setup
(see Adjust Board Stopper).
If is only one system type in the production line and the preference is not to adjust
the board stopper, you can fix the board placement coordinates for all projects.
However, doing so will mean losing some flexibility in avoiding blocked resources
(especially critical resources) during test development. If you intend to fix board
placement for all projects, it is recommended that you check with the fixture vendor
on the keepout area for fixture guide pins and bushing, to ensure that the board
does not lean into this area.

2 i3070 Series 5i Inline Fixtures

Figure 1 Board Placement

Additional Keepout Areas

• Moveable rail
Keepout for moveable rail if there is top access:
38.4 mm + 5 mm design error tolerance (15118 tenth mils + 1969 tenth mils)
• Transfer pins
Place transfer pins as far as possible from the conveyor rails (minimum 3 mm
away). Recommended areas for transfer pins are between the conveyor rails or
behind the moveable rail (areas highlighted in yellow in Figure 2).
• Fixture guide pins and bushing
Fixture guide pins and bushing are needed for aligning the top and bottom
fixture. The bushing design generally depends on the fixture vendor. If you
intend to fix the board placement for all projects, check with the fixture vendor
on the keepout dimensions required for best board placement coordinates so
that you do not need to set up the board stopper during production
changeover.
Typically the keepout will range from 40 mm to 50 mm (areas highlighted in
purple in Figure 2). The recommended minimum keepout distance from the
board edge to the center of the alignment pin is 45 mm (for pin diameter of
12 mm).

i3070 Series 5i Inline Fixtures 3

 Figure 2 Transfer pins and keepout areas

• Optional board stopper

An optional board stopper on the moveable rail of the conveyor is useful to
minimize the skew that can occur if the board is stopped only by the fixed rail
board stopper, especially large boards.
If the system is equipped with the optional board stopper, note that part of the
board stopper extends behind the conveyor rail. A keepout area is necessary to
ensure the i3070 software does not place transfer pins there. See
Specifications for Optional Board Stopper.

4 i3070 Series 5i Inline Fixtures

 Specifications for Optional Board Stopper
The dimensions of the optional board stopper are given below. A keepout area is
necessary during fixture development.

Figure 3 Optional board stopper

i3070 Series 5i Inline Fixtures 5

Board Specifications
Figure 4 Board Specifications

Free Area at Board Edges

– No probing allowed in this area.
– Components must not be located Tooling Pins
Minimum clearance in or lean into this area. Tooling pin bushing must not be located in or
3.0 mm (0.12 in) lean into free area of board edge

Tooling Holes
– Use diagonally opposing holes
Wid th PCB – Diameter:
2.54 to 4.45 mm (0.100 to 0.175 in)
Recommended 3.175 mm (0.125 in)

Minimum clearance
3.0 mm (0.12”)
Length

PCB i3070 inline system i3070 Lean inline system

Wid th
Minimum 60 mm (2.36 in) 60 mm (2.36 in)
Maximum1 350 mm (13.8 in) 370 mm (15.0 in) (Bypass conveyor not installed)
350 mm (13.8 in) (Bypass conveyor in use)
Maximum tolerance: ±0.125 mm
Length
Minimum 50 mm (2.0 in) 50 mm (2.0 in)
Maximum1 350 mm (13.8 in) 410 mm (16.1 in)2 (Bypass conveyor not installed)
350 mm (13.8 in) (Bypass conveyor in use)
1. Without top side and dual stage probes
2. See Lean Inline Fixture for Large Boards on page 18

Top Side Components

Maximum: 90.0 mm (3.54 in)
PCB
Bottom Side Components
Maximum: 30.0 mm (1.18 in)
Nominal Board Thickness
Minimum: 0.60 mm (0.023 in)
Maximum: 4.00 mm (0.157 in)

6 i3070 Series 5i Inline Fixtures

Fixture Specifications

Fixture Overview
The concept and structure of the inline fixture are the same as the Simplate Express
(short wire) fixture for the i3070 Series 5 systems. The inline fixture is separated into
a top half and a bottom half with side wall changes; but the same best practices
apply.

Figure 5 Fixture Overview

Fixture lock pin

ID block

Top fixture

Recess on L-bracket
required for fixture
lock
Bottom Fixture

See the additional guidelines for the inline fixture in the following sections:
• Bottom Fixture
• Top Fixture

i3070 Series 5i Inline Fixtures 7

 Bottom Fixture
The bottom fixture consists of the probe plate, floating support plate, probes,
p-pins, and fixture electronics.
Note the following guidelines:
• The dimensions of the fixture side wall and L-brackets are critical. The
L-bracket must be a single solid piece so that the fixture will not wobble when
pulled down by the system. The screw hole design for securing the L-bracket
and side wall must tighten towards the side wall. This is to enhance the overall
fixture strength when the fixture is engaged against the test engine.
• Do not place any labels in the conveyor area.
• Place all connectors (Board Align, Board Orientation, VTEP and CET control
signals) at the front of the fixture for easy connection and removal when
changing the fixture.
• The fixture guide pins and bushing for aligning the top and bottom fixtures
should be positioned on a diagonal. See Figure 10.
Other aspects of the fixture design can be determined or varied by the fixture vendor
according to the PCBA shape, size and thickness.
For details, see the following diagrams:
• Bottom Fixture Overview
• Bottom Fixture Dimensions
• Bottom Fixture: Maximum Height

8 i3070 Series 5i Inline Fixtures

Figure 6 Bottom Fixture Overview
Front view before compression

i3070 Series 5i Inline Fixtures 9

Figure 7 Bottom Fixture Dimensions

Dimensions in mm

10 i3070 Series 5i Inline Fixtures

Figure 8 Bottom Fixture: Maximum Height

Tooling Pin Placement

Follow standard practice for tooling pin design, and ensure that tooling pins are
positioned away from the conveyor rails and the bushing flush with the probe plate
(example A in the diagram below).
In case it is necessary to place the tooling pin near the rails, ensure the tooling pin
bushing does not lean into the conveyor belt area (example B). If necessary, cut
away any part of the bushing that interferes with the conveyor (example C).
Otherwise, the bushing should be flush with the probe plate so that it does not
interfere the conveyor rails.

Figure 9 Examples of tooling pin placement

i3070 Series 5i Inline Fixtures 11

 Top Fixture
The top fixture consists of the top plate, probe plate, strengthening rods, probes,
transfer pins, fixture guide pins, and the ID block.
Note the following guidelines:
• The dimensions of the fixture top plate, which interfaces with the Press, must
conform to the specified values. The length and width can be less than the
specified values but must not exceed 0.5 mm tolerances. This is to ensure the
top fixture is not oversized and can be installed in the system. Neither should it
be undersized as the fixture must be loaded on the guide rails at both sides of
the system.
The thickness of the top plate is 8 mm with a negative tolerance of 0.1 mm
(-0.1 mm) only.
• The maximum height or thickness of the top fixture should be 184.6 mm based
on a PCBA thickness of 1.6 mm. The 184.6 mm measurement is from the top
surface of top plate to the bottom of the PCBA, excluding component height
and in compression mode.
• The fixture guide pins and bushing for aligning the top and bottom fixtures
should be positioned on a diagonal. See Figure 10.

Figure 10 Fixture guide pins and bushing

Fixture guide pin

Other aspects of the fixture design can be determined or varied by the fixture vendor
according to PCBA shape, size and thickness.
For details, see the following:
• Top Fixture Dimensions
• Top Fixture Height After Compression

12 i3070 Series 5i Inline Fixtures

 Figure 11 Top Fixture Dimensions

Dimensions in mm

i3070 Series 5i Inline Fixtures 13

 Top Fixture Height After Compression
To maximize the output of the Press force, the top fixture height should not be more
than specified. While it can be less than the specified thickness, it should not be so
low that the Press cannot reach it in the final press position.
The specified height of 184.6mm is measured from the top surface of top plate to
the bottom of the PCBA, excluding component height and in compression mode.
The limits of the Press action is defined by a set of learned Press positions saved in
a “fixture profile”. If the same standard profile is used for all fixtures of the same type
and thickness, controlling the fixture dimensions is critical. Any deviation in the
fixture dimension could mean under- or over-pressing, with potential damage to
the board from the latter.
If it is not possible to control the fixture dimensions as precisely as possible, it is
recommended that a unique fixture ID and fixture profile be used for each fixture.

14 i3070 Series 5i Inline Fixtures

Figure 12 Top Fixture: Front View After Compression

Diagrams are not to scale

Top fixture height = 184.6 mm (maximum height) – PCB thickness

i3070 Series 5i Inline Fixtures 15

 Fixture Guide Pins and Floating Concept
The function of the fixture guide pins is to align the top and bottom fixture when the
Press is engaged. The guide pins on the top fixture align with the corresponding
bushing on the bottom fixture. The guide pins should be positioned on a diagonal
(Figure 10).
It is recommended to build in a floating concept for the guide pins, which allows the
top fixture to self-adjust and align to the bottom fixture.
A simple floating concept is shown in the example below. The fixture vendor has a
free hand to implement any type of floating design. The recommended floating
guideline is to be within 2 mm from any extreme boundary. However control should
be maintained so as not to exceed 3 mm of floating motion from any extreme
boundary.

Figure 13 Guide pin example

Dimensions in mm

With a 2 mm clearance, the movement of the top jig is now 1.0 mm.

16 i3070 Series 5i Inline Fixtures

 Top Fixture Lock Pin
The top fixture lock pin indicates the correct orientation of the fixture (there is a
corresponding slot in the Press) so that the operator does not load the fixture in the
wrong direction.
The pull-in fixture lock cylinder secures the top fixture by the lock pin.
The location and specifications for the fixture lock pin are given below.

Figure 14 Top fixture lock pin

Dimensions in mm

i3070 Series 5i Inline Fixtures 17

Lean Inline Fixture for Large Boards
To support a board length of up to 410 mm on the i3070 Lean Inline system, the
fixture probe plate has to be extended, requiring corresponding adjustments to the
alignment pins and increase in probe plate thickness.
The specifications are given below.

Figure 15 Lean Inline fixture specifications for maximum board size

18 i3070 Series 5i Inline Fixtures

ID Block
• Fixture ID
• Pin Assignment
• ID Block Specifications
• ID Block – System Side
• ID Block – Fixture Side

Fixture ID
The main function of the ID block is to provide the fixture ID for the top fixture. If the
system is set up to use user-defined fixture profiles, the fixture ID signal (pin 5 to 12
in the first two rows) is used to verify that the top and bottom fixtures match, before
the system can go into Production Auto mode.
The fixture ID is similar to the Control card Autofile. The wire to ground signal is 1
(enable) while no wire connected is 0.
For example, signal connected to GND will read as 111111111111 (base 2) which
is equivalent to 4095 (base 10).

Pin Assignment
The ID block has three groups of 16 pins arranged in two rows each, for a total of
48 pins. The pin assignments are shown below. The first two rows of pins cannot be
reassigned but rows 3 to 6 can be changed.

Figure 16 ID Block – Pinout (system side front view)

2 4 6 8 10 12 14 16
1 3 5 7 8 11 13 15

2 4 6 8 10 12 14 16
1 3 5 7 8 11 13 15

2 4 6 8 10 12 14 16
1 3 5 7 8 11 13 15

i3070 Series 5i Inline Fixtures 19

i3070 Series 5i Inline Fixtures

Table 1 ID Block pinout for i3070 Series 5i inline system

Pin 2 Pin 4 Pin 6 Pin 8 Pin 10 Pin 12 Pin 14 Pin 16
AF1 AF3 AF5 AF7 AF9 AF11(MSB) Spare + (24V - T) board
(Signal 404) (Signal 406) (Signal 408) (Signal 410) (Signal 412) (Signal 414) orientation
Pin 1 Pin 3 Pin 5 Pin 7 Pin 9 Pin 11 Pin 13 Pin 15
AF0 (LSB) AF2 AF4 AF6 AF8 AF10 Auto GND – (Com - T) board
(Signal 403) (Signal 405) (Signal 407) (Signal 409) (Signal 411) (Signal 413) (Signal “–”) orientation

Pin 2 Pin 4 Pin 6 Pin 8 Pin 10 Pin 12 Pin 14 Pin 16

Spare Spare Spare J1.10 J1.8 J1.6 J1.4 J1.2
Pin 1 Pin 3 Pin 5 Pin 7 Pin 9 Pin 11 Pin 13 Pin 15
Spare Spare Spare J1.9 J1.7 J1.5 J1.3 J1.1

Pin 2 Pin 4 Pin 6 Pin 8 Pin 10 Pin 12 Pin 14 Pin 16

Spare Spare LEM_M LEM_R LEM_A CET PWR USB VCC Data -
Pin 1 Pin 3 Pin 5 Pin 7 Pin 9 Pin 11 Pin 13 Pin 15
Spare Spare ASRU SW GND ASRU SW GND ASRU SW GND CET GND USB GND Data +

Table 2 ID Block pinout for i3070 Series 5i Lean inline system

Pin 2 Pin 4 Pin 6 Pin 8 Pin 10 Pin 12 Pin 14 Pin 16
AF1 AF3 AF5 AF7 AF9 AF11(MSB) Spare +24V
(Signal 401) (Signal 403) (Signal 405) (Signal 407) (Signal 409) (Signal 411)
Pin 1 Pin 3 Pin 5 Pin 7 Pin 9 Pin 11 Pin 13 Pin 15
AF0 (LSB) AF2 AF4 AF6 AF8 AF10 Auto GND – (Com - T)
(Signal 400) (Signal 402) (Signal 404) (Signal 406) (Signal 408) (Signal 410) (Signal “–”)
20
Figure 17 ID Block Specifications

i3070 Series 5i Inline Fixtures 21

Figure 18 ID Block – System Side

22 i3070 Series 5i Inline Fixtures

Figure 19 ID Block – Fixture Side

i3070 Series 5i Inline Fixtures 23

Additional Control Signals
• Board Orientation Signal
• Board Sit Signal

Board Orientation Signal

An optional Board Orientation signal can be used to verify that:
• the orientation of the board is correct
• the board has stopped at the correct position for testing
To implement this, the board under test must be designed with a tooling hole or
reflector surface. A laser beam is transmitted through the tooling hole or reflected
off the board surface to verify the board positioning.
• Check through application – The transmitter and receiver are aligned with the
signal transmitting through the tooling hole of the board.
• Reflector application – The transmitter and receiver are positioned at an angle
so that the signal is reflected from the board surface.
Note that a clear space is required to house the sensors on both sides (top and
bottom) of the fixture. In other words, you will lose some pin card resources and no
probes can be located in the surrounding area of the tooling hole.

How It Works
As the board travels into the testing zone, it is detected by the stopper sensor.
When the board reaches the board stopper, the system checks for the board
orientation signal (007); if it is detected, the Press is automatically lowered to the
next position.
If the board orientation signal is blocked due to incorrect orientation or position of
the board, the Press is not lowered and an error message and alarm are triggered.

Figure 20 Board Orientation Signal

24 i3070 Series 5i Inline Fixtures

 An NPN laser beam signal with a minimum sense distance of 300 mm or more is
recommended for this application.

Table 3 Board Orientation Laser Thru Beam Sensor

Signal NPN
Power +24V DC
Sense Distance 300 mm
Connector Pinout (Transmitter) Pin 1 Pin 2
+ (24DC) – (Com)
Connector Pinout (Receiver) Pin 1 Pin 2 Pin 3
+ (24DC) – (Com) Signal 007 (Board Orientation)
Recommendation Optex, Keyence, Omron
Check with the vendor to find the model best suited for this
application.

Figure 21 Typical connection block diagram

If using reflective laser beam, the signal from the PLC needs
to be re-routed.

i3070 Series 5i Inline Fixtures 25

 Board Sit Signal
An optional Board Sit signal can be used to verify that the board is sitting flat on the
support plate. An extremely low beam sensor or dry contact sensor can be used for
this application.
A dry contact sensor (example shown below) is easy and cheapest to implement.
However, the PCBA weight and the number of sensors needed are important
factors to consider when developing the fixture. It is recommended to check with
the fixture vendor on the location of the board and number of sensors for effective
implementation.

Connect multiple micro switches in series, and connect them to the connector
provided at the system end (from the PLC), as shown in Figure 22. Use Pin 2 and 3
for the dry contact sensor (voltage free).

Table 4 Board Sit Signal

Pin Signal
1 + (24DC)
2 – (Com)
3 Signal 315 (Board Sit)

26 i3070 Series 5i Inline Fixtures

Figure 22 Connections for Board Sit Signal

Connector is labeled 315

During production testing (Auto mode), the Press will engage to the learned Board
Align position to check whether the board is sitting properly on the fixture support
plate.
If the board is sitting flat, all the switches close the circuit and provide a short signal
to the PLC input signal 315 (board sit). Then the Press can be lowered to the All
Probe position for testing.
If the board is not sitting flat on the support plate, one or more switches will not
close contact. The PLC will detect an open circuit and the Press will not be lowered
to the All Probe position. Auto operation will stop and an error message and alarm
are triggered to alert the operator to investigate.

i3070 Series 5i Inline Fixtures 27