[PageStream 2 document SP_MFG_3.DOC: 8.50 x 11.00 in, 66 objects] --- Page 11 --- 3.0 INCOMING INSPECTION 1. Application This procedure shall be applied for incoming inspection of all listed components. 2. Purpose To prevent the use of materials in the finished product which do not conform to the specifications. 3. Inspection method 3.1 Type Lot by lot acceptance sampling 3.2 Standard MIL-STD-105D normal inspection with single sampling 3.3 Level Inspection level II unless otherwise specified 4. Defect classification Critical defect - a defect likely to result in hazardous or unsafe conditions for individuals using maintaining, or storing the product. Major defect - a defect, other than critical, that is likely to result in failure, or to reduce materially the usability of the product for its intended purpose. Minor defect - a defect that is not likely to reduce materially the usability of the product for its intended purpose, or is a departure from established standards having little bearing on the effective use or operation of the product. 5. Acceptable Quality Level (AQL) The following AQL will be used unless otherwise specified. Critical defect: 0 Major defect: 0.65 Minor defect: 1.5 6. Inspection lots Many practical matters influence the formation of inspection lots. The following rules should govern decisions on this matter. 6.1 Within each lot, the factors that seem likely to cause marked variability in product quality should be as nearly constant as practicable. 6.2 Inspection lots should be as large as possible, subject to the foregoing rule. 7. Inspection results Inspection results must be recorded in the inspection report. Refer to the section for items to be inspected. 7.1 Rejected lots must not be used in any products unless the lot has been reworked, re-inspected and found to be qualified. 7.2 The inspection report must be submitted to Atari Quality Assurance for final approval. --- Page 12 --- 3.1 POWER SUPPLY C302866-001 117 VAC C302867-001 230 VAC DEFECT CLASS INSPECTION ITEM DEFECT CRIT MAJ MIN 1. Appearance a) scratch, dirt X b) damaged X c) loose parts X d) rating label X manufacturer's logo manufacturer's part number and revision serial number Atari part number and revision appropriate safety marks input power requirements rated output current and voltage e) outline dimensions X f) mounting bracket dimensions X 2. Spec drawing a) electrical parameter out of spec X compliance part must meet or exceed Atari drawing parameters b) physical dimensions X part must meet Atari drawing parameters c) material/finish X part must meet Atari drawing parameters d) operating conditions/safety requirements X part must meet or exceed Atari drawing parameters 3. Load test a) output #1: +5VDC ± 5% X Input voltage: nominal load current: 7.0 Amps b) output #2: +12VDC ± 10% X Input voltage: nominal load current: 0.2 Amps 4. Ripple test a) output #1: 100mv p-p X Input voltage: -10% from nominal load current: 7.0 Amps b) output #2: 100mv p-p X Input voltage: -10% from nominal load current: 0.2 Amps 4. +5VDC set point +5.05 ± 0.1 VDC X Input voltage: nominal load current: 4.0 Amps 5. Safety test a) dielectric withstand voltage: 1500 VAC, 10ma, 60sec X b) insulation resistance: 10 megohms minimum X --- Page 13 --- 3.2 KEYBOARD CA401297-001 US CA401297-003 UK CA401297-004 FRA CA401297-005 GER CA401297-006 ITA CA401297-009 SPA CA401297-010 SWG CA401297-012 SWD CA401297-020 SWF DEFECT CLASS INSPECTION ITEM DEFECT CRIT MAJ MIN 1. Appearance a) scratch, stain, dirt X b) color/finish flaw X c) damaged X d) loose parts X e) missing keycap X f) wrong keycap X g) rating label X manufacturer's logo manufacturer's part number and revision serial number Atari part number and revision country designation h) outline dimensions X 2. Spec drawing a) electrical parameter out of spec X compliance part must meet or exceed Atari drawing parameters b) physical dimensions X part must meet Atari drawing parameters c) material/finish X part must meet Atari drawing parameters d) operating conditions X part must meet or exceed Atari drawing parameters 3. Function test a) initialization X (production b) key matrix, all keys function normally X test cartridge) c) joy 0 X d) joy 1 X --- Page 14 --- 3.3 FLOPPY DRIVE C303073-001 2MB DEFECT CLASS INSPECTION ITEM DEFECT CRIT MAJ MIN 1. Appearance a) scratch, stain, dirt X b) color/finish flaw X c) damaged X d) loose parts X e) rating label X manufacturer's logo manufacturer's part number and revision serial number Atari part number and revision f) outline dimensions X 2. Spec drawing a) electrical parameter out of spec X compliance part must meet or exceed Atari drawing parameters b) physical dimensions X part must meet Atari drawing parameters c) material/finish X part must meet Atari drawing parameters d) operating conditions X part must meet or exceed Atari drawing parameters 3. Alignment test a) rotation speed X (alignment disk) b) index pulse position X c) head azimuth alignment X d) head radial alignment X 4. Function test a) format X (production b) read/write X test cartridge) c) disk change X d) write protect X --- Page 15 --- 3.4 HARD DRIVE C302486-001 CP2044 C302597-001 CP2064 C302598-001 CP2084 C302489-001 ST9051A ASSIGN ST9052A ASSIGN ST9077A ASSIGN ST9096A ASSIGN ST9144A DEFECT CLASS INSPECTION ITEM DEFECT CRIT MAJ MIN 1. Appearance a) scratch, stain, dirt X b) color/finish flaw X c) damaged X d) rating label X manufacturer's logo model number manufacturer's part number and revision firmware revision serial number e) outline dimensions X 2. Spec drawing a) electrical parameter out of spec X compliance part must meet or exceed Atari drawing parameters b) physical dimensions X part must meet Atari drawing parameters c) material/finish X part must meet Atari drawing parameters d) operating conditions X part must meet or exceed Atari drawing parameters 3. Function test a) initialization X b) controller test X c) DMA read/write test X 4. System benchmark a) benchmark comparison test X --- Page 16 --- 3.5 ELECTRICAL PARTS C303077-001 SPEAKER FALCON 030 CABLE PERITEL FALCON 030 C303031-001 CABLE SCSI II FALCON 030 C070349-001 AC CORD US C070483 AC CORD CONTINENTAL C100273 AC CORD ITA C100274 AC CORD SWISS C100944-001 AC CORD AUS C303066-001 AC CORD UK CABLE 2MM 44P C303032-001 ADAPTER ST VIDEO FALCON 030 C303033-001 ADAPTER VGA VIDEO FALCON 030 CA070025 MOUSE STE 302883 FAN 12V 40*40*10MM DEFECT CLASS INSPECTION ITEM DEFECT CRIT MAJ MIN 1. Appearance a) scratch, stain, dirt X b) color/finish flaw X c) damaged X d) marking X manufacturer's logo manufacturer's part number and revision serial number or date code appropriate safety marks Atari part number and revision e) outline dimensions X 2. Spec drawing a) electrical parameter out of spec X compliance part must meet or exceed Atari drawing parameters b) physical dimensions X part must meet Atari drawing parameters c) material/finish X part must meet Atari drawing parameters d) operating conditions/safety requirements X part must meet or exceed Atari drawing parameters 3. Function test a) improper fit X ( assembly part into b) requires adjustment X final product) c) malfunction X --- Page 17 --- 3.6 PCB PARTS A. Fab PCBs C302763-001 1/4 MEG PCB C302767-001 14 MEG PCB C303006-001 FALCON 030 PCB DEFECT CLASS INSPECTION ITEM DEFECT CRIT MAJ MIN 1. Appearance a) scratch, stain, dirt X b) damaged X c) tooling hole location and size tolerance X d) component hole location and size tolerance X e) conductor pattern irregularities X conductive trace width reduced less than 25% f) conductor pattern defects X conductive trace width reduced greater than 25% g) thickness X h) warp and twist greater than 1.5% X j) laminate defects X measling, crazing, blistering, delamination k) plating defects X PTH, solder plating, solder mask l) silk screen printing defects X m) vendor ID, date code X n) outline dimensions X 2. Spec drawing a) electrical parameter out of spec X compliance part must meet or exceed Atari drawing parameters b) physical dimensions X part must meet Atari drawing parameters c) material/finish X part must meet Atari drawing parameters d) operating conditions X part must meet or exceed Atari drawing parameters B. Integrated circuits C025988-001 PC900 PHOTO COUPLER 6P DIP purchase to AVL C070447 TL497A SW REGULATOR 14P DIP purchase to AVL C070734-003 LM78L09 9 VOLT REG 3P TO92 purchase to AVL 100117 MC1377 ENCODER 20P DIP purchase to AVL C101762-003 DRAM 256K*4 FAST PAGE 80NS SOJ purchase to AVL C103803-001 LM386 AUDIO AMP 8P SOIC purchase to AVL C104522-001 LM555 TIMER 8P SOIC purchase to AVL C302096-001 AJAX FDD CTRL 28P DIP 600MIL purchase to AVL C302624-004 74HC04 14P SOIC purchase to AVL C302624-244 74HC244 20P SOIC 300MIL purchase to AVL C302799-002 PSG 2MHz 44P QFP purchase to AVL C302824-001 3 X 8BIT DAC 44P PQFP purchase to AVL C302829-001 VIDEL 120P PQFP purchase to AVL C302830-001 GAL16V8-12 DIP 20P ECLK purchase to AVL C302831-001 GAL16V8-12 DIP 20P UDS/LDS purchase to AVL --- Page 18 --- B. Integrated circuits C302832-001 GAL16V8-12 DIP 20P DSACK purchase to AVL C302833-001 GAL16V8-12 DIP 20P AS/BG purchase to AVL C302834-001 GAL20V8-12 DIP 24P DSP purchase to AVL C302889-008 74LS08 14P SOIC purchase to AVL C302889-074 74LS74 14P SOIC purchase to AVL C302889-373 74LS373 20P SOIC 300MIL purchase to AVL C302892-004 74HCT04 14P SOIC purchase to AVL C302893-006 7406 14P SOIC purchase to AVL C302897-001 SCSI CTRL 44P PLCC purchase to AVL C302900-001 LM387 DUAL PRE-AMP 8P DIP purchase to AVL C302902-001 FPU MC68882 16MHZ 68P PLCC purchase to AVL C302941-001 DRAM 1MEG*4 FAST PAGE 80NS SOJ purchase to AVL C302942-001 DRAM 4MEG*1 FAST PAGE 80NS SOJ purchase to AVL 302995-001 CUSTOM COMBEL AT4181 208P QFP purchase to AVL C302996-001 CUSTOM SDMA AT4182 144 QFP purchase to AVL C302997-001 MC3486 16P SOIC purchase to AVL C302998-001 LM556 14P SOIC purchase to AVL C302999-001 EPROM 4MB 44P PLCC purchase to AVL C303001-001 MC68LC030 132P QFP purchase to AVL C303002-001 DSP56K 80P QFP purchase to AVL C303003-001 STEREO AUDIO CODEC 44P PLCC purchase to AVL C303004-001 SRAM 32K X 8 28P SOJ purchase to AVL C303030-001 LF347 14P SOIC purchase to AVL C398016-001 1488 14P SOIC purchase to AVL C398017-002 1489A 14P SOIC purchase to AVL C398106-001 68901 52P PLCC purchase to AVL C398109-001 8530 SCC 44P PLCC purchase to AVL C398112-030 26LS3016P DIP purchase to AVL C398112-031 26LS31 16P DIP purchase to AVL C398170-001 RTC DS1287 DIP 24P 600mil purchase to AVL C398173-074 74ACT74 14P SOIC purchase to AVL C398173-157 74ACT157 16P SOIC purchase to AVL C398784-001 68B50 24P DIP purchase to AVL DEFECT CLASS INSPECTION ITEM DEFECT CRIT MAJ MIN 1. Appearance a) anti-static packing X b) damaged X c) marking X manufacturer's logo manufacturer's part number date code Atari part number (custom ASICs only) d) package style X e) outline dimensions X 2. Spec drawing a) manufacturer not approved X compliance approved sources listed on MANMAN only b) wrong device type X approved mfr p/n listed on MANMAN only --- Page 19 --- C. Connectors C014386-05 SOCKET DIP 300MIL 20P purchase to spec C014386-11 SOCKET DIP 300MIL 24P purchase to spec C070033 DIN FEMALE R/A 5P purchase to AVL C070129 CINCH R/A 40P purchase to AVL C070133-002 DSUB FEMALE R/A 25P purchase to AVL C070446-002 HEADER POLARIZED 1X9 purchase to AVL C070645-005 SOCKET CONN STRAIGHT 2X15 purchase to AVL C070645-008 SOCKET CONN STRAIGHT 2X25 purchase to AVL C070761 SHUNT 2P purchase to spec C100013-001 HEADER STRAIGHT 1X2 purchase to spec C100307-001 HEADER STRAIGHT 1X3 purchase to spec C101901-005 HEADER STRAIGHT 2X15 purchase to AVL C101901-008 HEADER STRAIGHT 2X25 purchase to AVL C101990-001 JACK STEREO 3.5MM purchase to AVL C300269-001 DSUB MALE R/A 9P purchase to AVL C302387-044 HEADER 2MM STRAIGHT 2X22 purchase to AVL C302821-001 DSUB HD FEMALE R/A 26P purchase to AVL C302822-001 SCSI-II FEMALE R/A 50P purchase to AVL C302823-001 DSUB MALE R/A 19P purchase to AVL C302967-001 SOCKET PLCC SMT 44P purchase to AVL C302967-003 SOCKET PLCC SMT 68P purchase to AVL C303005-008 HEADER LOCKING STRAIGHT 1X8 purchase to AVL C398064-002 DSUB HD FEMALE R/A 15P purchase to AVL C398087-001 MINI DIN FEMALE R/A 8P purchase to AVL CA070023-009 CABLE 280MM 4P purchase to AVL CA070024 CABLE FLAT RIBBON 34P purchase to AVL DEFECT CLASS INSPECTION ITEM DEFECT CRIT MAJ MIN 1. Appearance a) finish flaw X b) damaged X c) marking X manufacturer's logo manufacturer's part number d) outline dimensions X 2. Approved source Applies only to parts indicated by purchase to AVL compliance a) manufacturer not approved X approved sources listed on MANMAN only b) wrong device type X approved mfr p/n listed on MANMAN only 3. Spec drawing Applies only to parts indicated by purchase to spec compliance a) electrical parameter out of spec X part must meet or exceed Atari drawing parameters b) physical dimensions X part must meet Atari drawing parameters c) material/finish X part must meet Atari drawing parameters d) operating conditions X part must meet or exceed Atari drawing parameters --- Page 20 --- D. Capacitors / Resistors C070450-(TAB) ELEC (value)UF 35V 20% AX purchase to spec C070474 CERA TRIMMER 5-30PF purchase to spec C070499-(TAB) ELEC (value)UF 16V 20% AX purchase to spec C101205-472 ELEC 4700UF 16V AX purchase to spec C101212-(TAB) ELEC (value) 50V 20% AX purchase to spec C101219-(TAB) CERA CHIP (value)PF 50V 5% purchase to spec C101220-(TAB) CERA CHIP (value)PF 50V 10% purchase to spec C101221-(TAB) CERA CHIP (value)UF 50V +80-20% purchase to spec C302904-(TAB) CERA CHIP (value)UF 50V +80-20% purchase to spec C302985-001 ELEC 0.1UF 35V 20% AX purchase to spec C303013-(TAB) CERA CHIP (value)UF 25V 10% purchase to spec C303020-103 CERA CHIP .01UF 50V 5% NPO purchase to spec C303021-(TAB) ELEC (value)UF 16V 20% AX purchase to spec C398069-001 TANT 15UF 25V +-20% RA purchase to spec C398768-001 MYLAR 1000PF 100V +-5% RA purchase to spec 14-5(TAB) RES CF (value) 1/4W 5% AX purchase to spec C060629 RES, JMPR 0 AX purchase to spec C070448 RES NET SIP 10K 9P purchase to spec 070567-006 RES NET SIP 1K 9P purchase to spec C070737-005 RES NET 220/330 SIP 8P purchase to spec C101008-(TAB) RES NET (value) SIP 9P purchase to spec C101013-(TAB) RES CHIP (value) 1/10W 5% purchase to spec C101021-(TAB) RES CHIP (value) 1/4W 5% purchase to spec DEFECT CLASS INSPECTION ITEM DEFECT CRIT MAJ MIN 1. Appearance a) packaged for machine insertion X b) finish flaw X c) damaged X d) marking X value tolerance e) outline dimensions X 2. Spec drawing a) electrical parameter out of spec X compliance part must meet or exceed Atari drawing parameters b) physical dimensions X part must meet Atari drawing parameters c) material/finish part must meet Atari drawing parameters d) operating conditions part must meet or exceed Atari drawing parameters E. Other purchased components C014384 FERRITE BEAD AXIAL purchase to spec C017222 1.5UH 5% AXIAL purchase to spec C017948-08 1UH AXIAL purchase to spec C070205 0.27UH 20% AXIAL purchase to spec C070471-002 220UH 10% AXIAL purchase to spec C100210 VARIABLE COIL 24UH purchase to AVL C100214 VARIABLE COIL 14UH purchase to AVL --- Page 21 --- E. Other purchased components C101403-102 NOISE FILTER 1000PF purchase to AVL C101411-680 68UH 10% AXIAL purchase to spec 31-1N4001 DIODE 1N4001 purchase to spec 33-2N3906 TRAN PNP 2N3906 TO92 purchase to spec 34-2N3904 TRAN NPN 2N3904 TO92 purchase to spec C060607 DIODE SWITCHING 1N4148 purchase to spec C070177 DIODE VARICAP 1SV69 purchase to AVL C303029-001 DIODE FAST RECOVERY 1N4935 purchase to AVL C025993-001 CRYSTAL 2.4576MHZ HC49U purchase to AVL C070176 CRYSTAL 32.084988MHZ HC49U purchase to AVL C070760 CRYSTAL 4.433618MHZ HC49U purchase to AVL C303023-001 OSC 3.672MHz 8P DIP W/DIS purchase to AVL C303023-002 OSC 25.175MHz OSC 8P DIP W/DIS purchase to AVL C303023-003 OSC 32MHz 8P DIP W/DIS purchase to AVL C303023-004 OSC 32.084988MHZ 8P DIP W/DIS purchase to AVL C303023-005 OSC 32.215905 MHZ 8P DIP W/DIS purchase to AVL C070119 SWITCH PB SPJ312U purchase to AVL C100184 RF MODU NTSC purchase to AVL C100185 RF MODU PAL I purchase to AVL C100186 RF MODU PAL B purchase to AVL C100209 DELAY LINE 3.58MHz purchase to AVL C100213 DELAY LINE 4.43MHz purchase to AVL C101403-102 NOISE FILTER 1000PF purchase to spec C101814 FUSE 5A AXIAL purchase to AVL 1. Appearance a) finish flaw X b) damaged X c) marking X manufacturer's logo manufacturer's part number value tolerance d) outline dimensions X 2. Approved source Applies only to parts indicated by purchase to AVL compliance a) manufacturer not approved X approved sources listed on MANMAN only b) wrong device type X approved mfr p/n listed on MANMAN only 3. Spec drawing Applies only to parts indicated by purchase to spec compliance a) electrical parameter out of spec X part must meet or exceed Atari drawing parameters b) physical dimensions X part must meet Atari drawing parameters c) material/finish X part must meet Atari drawing parameters d) operating conditions X part must meet or exceed Atari drawing parameters --- Page 22 --- 3.7 FAB MECHANICAL PARTS C302784 TOP COVER C302774 BOTTOM COVER C302770 BOTTOM SHIELD C302769 TOP SHIELD C302779 I/O SHIELD C302780 COVER SHIELD C302771 PCB INSULATOR C302781 SPEAKER INSULATOR C302782 SPEAKER RETAINER C302777 NAMEPLATE C302775 FAN BRACKET C302772 HARD DRIVE BRACKET DEFECT CLASS INSPECTION ITEM DEFECT CRIT MAJ MIN 1. Appearance a) scratch, stain, dirt X b) color/finish flaw X c) warp and twist greater than 1.5% X d) damaged X e) dimension check X f) incorrect material X g)marking X manufacturer's logo serial number or date code Atari part number and revision 2. Function test a) improper fit X ( assembly part into b) requires adjustment X final product) c) malfunction X --- Page 23 --- 3.8 PRINTED MATERIAL C302778-TAB RATING LABEL (country) C300339-001 WARRANTY CARD US C302252-001 WARRANTY CARD FRANCE C026076-001 WARRANTY CARD GERMANY C103369-002 WARRANTY CARD ITALY C026075-001 WARRANTY CARD NET C100571-001 WARRANTY CARD SPAIN C302201-010 WARRANTY CARD SWITZERLAND C100653-001 WARRANTY CARD AUSTRALIA C103312-TAB WARRANTY SEAL (country) C302952-TAB OWNER'S MANUAL (language) C303072-001 APPLICATION MANUAL C303071-001 LANGUAGE DISK LABEL C303070-001 APPLICATION DISK LABEL HD UTILITIES DISK LABEL CA401340-001 INDIVIDUAL CARTON CA401343-001 SHIPPING CARTON DEFECT CLASS INSPECTION ITEM DEFECT CRIT MAJ MIN 1. Appearance a) scratch, stain, dirt X b) registration X no apparent variation c)color balance/ ink density X uniform across the page d) large solids and halftones, X dense, even, no mottling or ghosts e) flaws X smudges scumming wrinkles f) trimming X trims square variation greater than ±1/64 inch g) folding X no single fold varies greater than ±1/32 inch h) marking X Atari part number and revision country designation j) outline dimensions X 2. Spec drawing a) physical dimensions X compliance part must meet Atari drawing parameters b) material/finish X part must meet Atari drawing parameters c) artwork X correct artwork used --- Page 24 --- 3.9 OTHER PURCHASED PARTS C070571-004 SCREW, PHIL FLAT HD,M3X 12MM C070512-003 NUT M3 C070200-001 SCREW PAN HEAD M3*5 C070200-003 SCREW PAN HEAD M3X8 C070323-003 COLLAR B C070322-003 COLLAR A BLACK 18.5MM ST C303075-001 SCREW PPH 6-32x1" C070031 INDICATOR C070004-004 SCREW SELF TAP PAN HD 3*10 C070004-015 SCREW SELF TAP M3*7 C070012 RUBBER FOOT C302332-032 POLYBAG W/WARNING LABEL C070295 STYROFOAM LEFT ST/STE C070294 STYROFOAM RIGHT ST/STE C070293 CTN ACC BOX ST/STE C302332-014 POLYBAG W250xL200x0.04 DEFECT CLASS INSPECTION ITEM DEFECT CRIT MAJ MIN 1. Appearance a) scratch, stain, dirt X b) color/finish flaw X c) damaged X d) outline dimensions X e) incorrect material X f)marking X per specification drawing 2. Spec drawing a) physical dimensions X compliance part must meet Atari drawing parameters b) material/finish X part must meet Atari drawing parameters c) operating conditions X part must meet or exceed Atari drawing parameters --- Master page (repeated on pages; # = page number) --- [32 drawing objects, see SP_MFG_3.DOC.mR.svg] SIZE DRAWING NO. REV ® ATARI CORPORATION A SCALE NONE C302758-001 SHEET OF 1 _