Flying Scorpion FLS980Dxi – Flying Probe Tester

Scorpion FLS980 Flying Probe Tester

The FLS980™ Series of Flying Probe testers, help ensure that tomorrow’s technologies don’t outpace today’s test capabilities. Acculogic’s production board test systems offer highly advanced, scalable solutions to solve a wide range of test challenges. Our automated test systems are made to accommodate a variety of applications and customers. We offer an unbeatable combination of reliability, accuracy, precision and throughput.

Why you should consider the FLS980:
  • Superior Test Access
  • Exceptional Test Coverage
  • Ultra High Accuracy
  • Patented Multi-Probe System
  • Power-On and Advance Function Testing
  • Design Recreation Tool
  • Support for large boards



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Tight quality control measures together with time to market pressures are compelling manufacturing companies to choose effective yet lean test and quality assurance strategies in their production processes. Flying probe testers require no test fixtures, have few restrictions on board access, and can test boards with virtually unlimited number of nets. They also allow developers to complete test programs in a short time. For these reasons and more, flying probe testers have become indispensable tools in today’s electronic manufacturing.

Test Access

Gain unmatched accessibility to test points on the UUT. You can rely on the FLS980 to test boards whose layout, size or technology encumber traditional in-circuit testers and other flying probes.


With an ultra high accuracy probe module, the FLS980 tester maximizes physical access and guarantees repeatable probing of fine pitch devices and small components down to 01005.


Attain superior throughput with FLS980’s double sided, multi-probe system and a selection of test strategies to significantly reduce test times without impacting test coverage or repeatability.


FLS980’s high speed analog measurement system provides 4-wire measurements capability on all 22 flying probes. All probes can perform in-circuit tests as drivers, sensors, or guards on discrete and integrated analog/digital components.

Probing Angle

FLS980’s variable angle probe modules rely on a patented design to tilt from -6 degrees to +6 degrees, in any direction and probe targeted test points, covering an area of approximately 60mm x 60mm on the UUT.

Multi-Probe Systems

FLS980 systems can be configured with up-to 22 Probe Modules on top and bottom side to ensure maximum test coverage and minimal test time. System can be configured with a mix of the variable and fixed angle probe modules.

Intuitive Software

Test program generation for the FLS980 test platform is highly automated, simple and intuitive. The automatic test program generator and operating software manages all aspects of test program development.

Vectorless Test

CScan is a patented technique used to test open pins as well as the polarity of electrolytic capacitors. The CScan functionality detects open pins on devices and connectors located on the top and/or bottom side of the board.

Boundary Scan

Boundary scan is an integral part of the FLS980; digital test patterns generated by Acculogic’s powerful ScanNavigator software are delivered to the UUT through Probe Modules or board carrier system.

Vision Test

The dual-sided vision system provides optical inspection for defects such as presence, absence, orientation and part markings. Test coverage is enhanced by adding this capability to electrical tests.

Design Recreation Tool

Also known as Reverse Engineering. With Acculogic’s Genesii Design Recreation software, you can recreate the required file (netlist) for test program generation.


This functionality measures the distance between the probe and the UUT, and is used to determine the coplanarity of the UUT, and to measure the height of components.



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Test Access

FLS-Flying-Probe-double-sided-test-probing-angleShrinking component sizes and denser chip scale packaging technologies are posing new challenges to test engineers. Test pads, traditionally installed on PCBs, are being eliminated from many designs thus reducing physical access. Flying Probers are required to operate with unprecedented precision in order to meet the new challenges. The FLS980 Production Test Platform uses highly repeatable closed loop linear motor drives and joystick-like variable angle probe modules to maximize physical access and guarantee repeatable probing of fine pitch devices and small components like 0201, 01005. The FLS system offers double-sided probing and up to 22 probe modules on the component and solder side of the Unit Under Test (UUT) to facilitate efficient single pass testing.


FLS-Flying-Probe-tester-accuracyDue to its modular and scalable architecture, the FLS980 guarantees superior probing precision and repeatability. Precise Closed Loop planar linear motors (shuttles) with “AccuFast™ Drive System” (1 micron minimum step size, +/-10 micron positioning repeatability) independently move probe modules and cameras. The probe modules utilize equal-length identical probes to contact target points on the UUT. Each probe module is able to set the probing angle from 0º to 6º from vertical in any direction. The combination of shuttles’ positioning and joy-stick like probe motion ensures unmatched accessibility to points on the UUT. You can now test boards whose layout, size, and technology defy testing on traditional in-circuit and other moving probe testers. The FLS980 system architecture ensures repeatability. Closed Loop Drives for shuttles and probe modules ensure precise and repeatable positioning of the probes.
  • Riding on a 12 micron air gap, shuttles travel free of friction and with no mechanical contact on the stator plane and therefore operate free of wear.
  • High resolution fiducial detection cameras, precise lighting, and advanced image processing software ensure precise and repeatable detection of fiducial marks on the UUT as well as correct compensation for any offsets.
  • The electronic measurement system relies on precision circuits and components for reliable and repeatable measurements.
  • Integrator Pro™ system control software with sophisticated motion control and measurement algorithms ensures robust and repeatable operation.

Probing Angle

Acculogic-FLS980-Flying-Probe-Probing-Angle Warping of printed circuit boards is a common issue that should be taken into account in SMT board assembly, inspection and test processes. During Flying Probe test, board warp changes the physical position of target points by an offset. When probing angle is 0 degrees from vertical, board warp will cause no probing errors, however, as the probing angle increases, the probing error also increases. A 0201 chip on a board with 0.5 mm warp using 15 degree probing angle cannot be probed dependably. Decreasing probing angle to 3 or 4 degrees reduces warp related uncertainty, and leads to reliable probing.
Offering optimum probing, FLS980’s Advance probe modules rely on a patented design to probe target boards Omni-directionally on the horizontal, and -6 to +6 degrees on the vertical planes. As probing angle increases the probe slippage factor increases. Probe slippage can lift pads and vias and leave unacceptable marks on the target.

Probe Module Types

The FLS980 automated test systems can be configured with up-to 22 Probe Modules on top and bottom side to ensure maximum access and optimum test time. There are 5 types of probe modules available for the system:
Probe Module TypeApplication/When to Use 
APM800FAdvanced general purpose probe module with variable tilt from -6 to +6 degrees. For probing difficult to access pads due to component density
or height.
BPM720Ultra high accuracy, fixed angle +6º probe module for probing devices as small as 01005, where probing precision is critical.
VPM 400Probe module capable of carrying application specific mini-fixtures for bed of nail testing on Flying Probe. A mini-fixture could be used when several test points are grouped together in a fixed pattern, for example a boundary scan header. Also, high frequency measurements can be carried out by (patent pending) probes at up to 8GHz.VPM400 Flying Probe Module
CSM800CScan probe module for testing open pins on connectors and ICs.CSM800
System can be configured with a mix of the variable and fixed angle probe modules. The flying probe drive system has a positioning accuracy of 1 micron minimum step size, +/-10 microns positioning repeatability, which provides reliable probing of target sizes as small as 100 microns ( 4 mils) in production environment. To probe even smaller targets in special applications Acculogic provides higher precision probe modules and cameras as future upgrades.
Probe Module Specifications:
  • 3D Programmable Angle 0° – 6° (+6° for fixed angle)
  • Programmable Speed 15 – 1500 mm/s
  • Programmable Pressure 0.5 – 3.0N
  • Choice of Probe Tip Radius 50 µm – 500 µm
  • Choice of Probe Tip Styles Needle, cup, dome
  • Max Probing Height 42mm
  • Maximum component Height 85mm

Available Probe Tips



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Test times on a Flying Probe system depends mainly on the number of test steps and speed of probe movement. Shorts Test consume a large part of overall test time. The FLS980’s flexible measurement system provides a host of test strategies including Boundary Scan (JTAG) and NetScan™ to significantly reduce test time without impacting test coverage or repeatability. In addition AccuFast™ Closed Loop Drive system boosts speed and acceleration by 4 times over open loop systems.
Key Features of AccuFast Drive System™
  • Significantly faster than open loop systems (4x)
  • High acceleration (4x)
  • Enhanced probing accuracy
  • Three times better dynamic response +/- 1 degree rotation
  • Automatic orthogonality between X and Y axis
  • Sensorless homing (no adjustments)
  • DSP based motor controller
  • Built-in linear and parabolic interpolation (more efficient shuttle movements)
  • Low energy usage (50% reduction)

Boundary Scan (JTAG) testing can reduce the overall “shorts” and “opens” test time by up-to 80%.

Patented Multi-Probe System

The FLS system has a modular architecture that is expandable to 22 probes. The probe modules have easily interchangeable probe tips. A range of probe tip styles are available off the shelf. In addition to providing excellent test coverage on densely populated circuit boards, this flexibility makes the FLS980x an ideal solution for testing backplanes where direct contact with connector pin tips is required.

Measurement System

FLS980 systems can be configured with Acculogic’s patented Mini-Flying Fixture which provides the functionality of a small bed-of-nail access in the flying probe system, i.e. “Flying Fixture”. This customizable Probe Module can be used in functional testing, digital, boundary scan (JTAG) testing and more. Its low cost and flexibility makes Flying Mini-Fixture an indispensable addition to the system. High speed (up-to 1000 measurements/sec) and precision analog measurement system provides 4-wire measurements capability for all 22 flying probes (top and bottom side).
All probes can perform in-circuit tests as drivers, sensors, or guards on discrete and integrated analog/ digital components. Analog component testing including resistors, capacitors, inductors, diodes, Zeners, transistors, FETS, thyristors, opto-couplers, switches, trimmers, relays, fuses and connectors is available on the FLS980. These include 2-wire and 4-wire tests, device ON and OFF tests using two sets of separately available stimulus/ measurement resources. Also, power-on testing for voltage regulators and operational amplifiers are possible using the voltage measurement module.


Test program generation for the FLS980 flying prober is highly automated, simple, and intuitive. The process starts by using the XMatic™ software to translate UUT data from any of the 35-plus commonly used CAD formats. CAD data is merged with the Bill of Materials, and other relevant information to create an output file that contains data elements required to automatically generate test programs.
Integrator Pro™ is the automatic test program generator (ATPG) and operating software that manages all aspects of test program sequencing, debugging, optimizing, and execution on the FLS980. The IntegratorPro also manages all physical resources of the tester including motion, vision, electrical stimulus and measurement. Integrator Pro supports many different plug-in modules such as Boundary Scan, BodeScan and FlashScan etc. which enhance test coverage and increase execution speed. An easy-to-use scripting language opens up internal resources of the tester, providing users with maximum flexibility to write complex test protocols with simultaneous use of multiple probe modules.
Integrator Pro Features:
  • Automatic program generation software
  • Built-in Boundary Scan (JTAG)
  • Automatic multi-level guard assignment
  • QuickTest™ for quick test program development
  • Auto-debug (unattended)
  • Test Sequence with logical flow control
  • Interactive board description editor add/modify test points, package etc.
  • Panelization support
  • Program and motion optimization
  • Powerful Script language for functional and advance testing
  • Test coverage report generation
  • Statistical Process Control (SPC)
  • RepairMatic™ graphical repair station software
The Integrator Pro is also equipped with an impressive set of tools for statistical process control, test execution flow management, and test coverage report generation. Interfaces to automatic repair processes, and automatic test program management (version control) are available.
BodeScan™ is a unique built in network analyzer that extends the system fault coverage to small value resistors, capacitors, and inductors in complex networks found on RF boards.



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Vectorless Test

PinScan™ Patented Open Pin Detection suite PinScan is a complimentary suite of analog and digital test techniques for detecting Opens on ICs, including BGAs, as well as connectors and polarized capacitors.
  • CScan™ is a patented technique used in vectorless testing of ICs and connector pins. CScan is used to test open pins as well as the polarity of electrolytic capacitors. CScan functionality detects open pins on devices located on the top and/or bottom side of the board.
  • ChipScan™ is a patented 3-pin technique for vectorless open testing on digital IC pins. It exploits the parasitic diodes/transistors in each digital IC, and tests each pin for open faults. Power up is not required in order to use ChipScan. This method is particularly useful where bus structures are used. ChipScan detects wire bonding defects, open pins and cold joints. ChipScan functionality is available on all probes covering top and bottom side of the unit under test.
  • ScanProbe™ is a digital technique that uses flying probes to detect opens on digital IC pins of devices that are IEEE-1149.1(JTAG) compliant. ScanProbing is fast and repeatable, uses the digital and boundary scan capability of the FLS980 for fault detection.
  • Active CScan™ combines the coverage of CScan with the power of Boundary Scan. It draws the best from each technology to increase the test coverage and reduce the test time therefore enhances overall capability of Flying Scorpion
  • ThermoScan™ uses the mechanical capability of its flying probe to automatically move an infrared temperature sensor over the PCB to measure the powered PCB temperature pattern. This new test method bridges the gaps between conventional test technologies.

Boundary Scan

Boundary scan (JTAG) is a test methodology based on IEEE 1149.1 standard. Compliant Semiconductors, when installed on a circuit board, allow the interconnecting nets and digital clusters such as memory devices to be tested on the FLS980. Furthermore, Boundary Scan offers a comprehensive board-level protocol for programming flash and other programmable devices.
Integration of boundary scan with flying probe systems is no longer an option but a requirement since the combined strategy improves test coverage and test time. Boundary scan is an integral part of the FLS980; digital test patterns generated by Acculogic’s powerful ScanNavigator software are delivered to the UUT through Probe Modules or board carrier system. The FLS980 flying prober goes beyond interconnect testing by providing full digital test capability when and where needed. This technological break-through is made possible by merging Acculogic’s two powerful software suites, the “Integrator Pro” and the “ScanNavigator”.
  • Fully integrated hardware and software
  • IEEE 1149.1 and IEEE 1149.6 supported
  • Support for multiple scan chains up-to 8
  • Scan and non-scan testing
  • Automatic test optimization
  • Automated test generation and intelligent diagnostics

“Boundary Scan, not an afterthought but an Integral part of the System.”

The FLS980’s advanced boundary scan capabilities extends the testing to assemblies that contain a mix of Scan and non-Scan logic by providing Shorts Test between boundary scan nets and non-boundary scan nets where the non-scan nets have flying probe access.
  • Dramatic increase in test coverage by combined use of flying probe and boundary scan resources
  • More efficient shorts test using flying probes and higher throughput
  • Reusable Boundary Scan test patterns

Device Programming

FlashScan™– In-Circuit Device Programming for Programmable devices such as PLDs, Flash, PROMs are frequently used on most modern circuit board assemblies. In-production-programming (configuration) of these devices provides the flexibility for on-the-fly content changes as opposed to using pre-programmed parts. Device Programming on the FLS980 improves production efficiency by removing an extra step in the production process.
FlashScan™ is a multi-vendor integrated hardware and software suite that provides the FLS980 with capability to program and verify a wide range of devices.

Vision Test

OptiScan™ a multi-camera dual sided vision system with precise lighting, and advanced image processing software provides vision inspection for presence, absence and orientation of components such as decoupling capacitors, polarity of electrolytic capacitors and presence of mechanical parts. OptiScan uses the New GigE Vision Compliant camera, offers ultra-high image detail at up to 16 fps. It incorporates a 2/3-type High Speed Progressive Scan IT CCD, providing resolution of 1360 x 1024 SXGA. The robust camera has high shock and vibration resistance, which allows for delivery of outstanding performance. It is equipped with LED coaxial and lateral light control to provide homogeneous light on objects and allow for compensation of ambient light variations.
OptiScan Features:
  • Up-to 8 (4 top/4 bottom) high resolution CCD cameras (Minimum one per side)
  • Flexible target illumination
  • 1D and 2D bar code reader
  • Optical Character Recognition (OCR)
NanoScan™ is a flexible microscopy system that has been designed for viewing very small targets placed on the Flying Probe conveyors. The microscopy system can be mounted on a designated shuttle on the top or bottom stators. NanoScan is equipped with a high precision, long working-distance objective lens, cold fibre optic light, an optical column assembly installed on a vertical stage, a high resolution camera, and a focusing lens. The objective and focusing lens can be changed to create alternative combinations and obtain different magnifications from the microscopy system.
  • Magnification from X2 to X200
  • Working distance from 6 to 34 mm
Advance Function Testing
The FLS980 system’s open architecture supports integration of general purpose instrumentation through the FSM Switch Matrix Card. Acculogic provides device drivers for an extensive list of instruments.

Design Recreation Tool – Genesii

(also known as Reverse Engineering)
Servicing legacy products could be problematic for repair depots if there is no automated test or test system in place for this purpose. Tests programs can quickly identify what is causing boards to fail. If up to date board design information is available, then test programs can be easily generated. But what if design files are not available for test development? The consequence is a time consuming and expensive troubleshooting process. But with Acculogic’s Genesii Design Recreation software, you can recreate the required file (netlist) for test program generation.

Automated Netlist Generation

The process starts with a bare PCB and an assembled printed circuit assembly. Then, through image processing techniques, Gerber files are generated. Using Acculogic’s XMatic software, the Gerber files and parts information are processed to create an input file for the FLS980 Flying Probe platform. This input data is utilized by Genesii to intelligently map board connectivity as information is captured through probing pads on the board. After all PCB connections have been identified, the netlist file is complete and ready to use for test program development.

Laser Based Measurement – LaserScan

LaserScan is installed on a shuttle and allows certain critical functions to be performed with added precision in the FLS test systems.
  • It measures the distance between the probe and the UUT, thereby allowing precise targeting of the UUT test points when the flying probes travel at an angle
  • It is used to determine the coplanarity of the UUT and compensate for warps and bumps on the board
  • It is used to measure height of components, create package and board profiles, and append height

SPC Software

Statistical Process Control Software Integrator Pro’s SPC software is a powerful statistical process control (SPC) tool that analyzes and identifies variations in test results due to variations in process environment. Using a series of measurements made repeatedly on a single board or on batches of production boards, developers are able to identify measurements that are least stable. They can then examine these measurements for root causes of instability and alleviate the causes. SPC software allows developers to analyze test variance due to noise, component variation, drift, and system variance. Test limits can be updated automatically under user control to obtain solid production-ready tests.


Test Program Development Services - Acculogic Inc. Acculogic provides turn-key test program development for the Flying Scorpion FLS980 and Sprint FLS4510. Acculogic’s large team of fully trained and experienced test engineers provide advanced test programs with highest fault coverage and fast cycle time. Please click here to learn more.
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