Bench-top BGA Rework System

Bench-top BGA Rework System
INSTRUCTION MANUAL
Thank you for purchasing Aoyue BGA9000A Bench­top Rework System Please read the manual before using the unit. Keep manual in accessible place for future reference.
TABLE OF CONTENTS
Package Inclusion
…….……………...……………….…
3
Product Specification
………………………………………..
4
Special Features
………………………………………..
4
Care and Safety Precaution
………………………………………..
5
Advantages of Infrared
………………………………………..
5
System Parts Guide
………………………………………..
6
Parts Diagram / Panel Guide ………………………………………..
7-8
Operating Guidelines
9
…...…………..…..………………..…
Operating Procedure
Removing a component
……….…..…....…………………….
Replacing a component ……….…..…....…………………….
10
11-12
Reworking Tips
……….…..…....…………………….
13
Glossary
……….…..…....…………………….
13
This manual is structured to enable a technician
with no previous knowledge of the system, to
become familiar with the operation and
maintenance of the equipment. The safety section
of the manual explains the inherent dangers
presented by any type of desoldering/soldering
equipment and warnings to minimize the risk of
injury through ignorance.
2
PACKAGE INCLUSION
Soldering
Soldering Iron
Tip with Heater Cartridge
(LF-I, LF-K, LF-1403)
Soldering Iron Holder
Connecting Cord
Main Unit
Power Cord
Optimizer System
LCD Monitor
LCD Monitor Holder
Monitor Connecting Wire
Light Optimizer Connecting Wire
Replacement Suction Nozzle ( 6 pcs.)
Vacuum Pen
Infrared
Welding Goggles
Connecting Cord
Air Tube for Pump
Vacuum pencil
Suction Caps (L, M, S)
Others
Solder Paste
Solder Flux
Lubricant for Adjust Ladder (3 pcs.)
Tools for Micro Adjust System
Product Manual
Instruction CD
3
PRODUCT SPECIFICATION
MAIN UNIT
Power Input
220V / 110V
Frequency
50 ～ 60 Hz
Dimension
530 x 480x 550mm
Weight
65kgs. SOLDERING IRON
Power Consumption
75W
Temperature Range
200～480°C
Heating Element
Ceramic Heater
Output Voltage
24V PRE-HEATER
Power Consumption
450W
Temperature Range
100～350°C
Heating Element
Quartz Infrared
Output Voltage
220V INFRARED SOLDERLIGHT GUN
Power Consumption
150W
Temperature Range
200～480°C
Heating Element
Halogen Light Source
Output Voltage
15V
SPECIAL FEATURES
◆ A stand­alone X Y axis adjustment placement method & non­contact rework station featuring the split vision control technologies. ◆ Innovative adjust method of using micro controls to position component instead of PCB. ◆ Micro­processor controlled time and temperature parameters for maximum performance. ◆ Lead­Free Compatible with split vision system. ◆ Uses infrared heat wave technology instead of the conventional hot air. ◆ Equipped with high precision optimizer that has dependable accuracy to handle complex components such as BGA’s, QFP’s and Micro SMD’s. ◆ The system has a versatile PCB holder that has board capacity of up to 280 X 430mm. ◆ Precision solder. Lessen the distortion of PCB due to heat. Probability of repair repetition is lower.
4 CARE and SAFETY PRECAUTIONS
NOTE: For the purpose of this manual, care refers to care for the unit to avoid damages whereas safety pertains to safety of the user/ operator of this system. The following should be carefully understood and are to be observed properly as to avoid accidents,
● Check that all wires are properly connected before plugging in the unit. Some connecting point carries high voltage that may result to extensive damage when not handled properly. ● Make sure that all moving parts of the system is locked (by locking knobs), before moving the unit. ● Temperature may reach a high of 500°C when turned on. ­ Do not expose the naked eye to the Infra Red light. It may cause serious eye damage. ­ Do not allow the Infra Red light to come into contact with any exposed skin for a ● long period of time, otherwise tissue damage may result. Handle with Care ­ Do not spill any liquid to the system. ● ­ Unit contains delicate parts, do not hit or drop unit. Do not tamper with the electrical control unit or any wiring ­ you may be subjected to ● a severe electric shock. To avoid overheating, disconnect plug when not to be used for a long period of time. Turn off power during breaks. ● To eliminate the possibility of burns, allow time for the equipment to cool before ● commencing maintenance. Use only genuine replacement parts. Turn­off power and let unit cool before replacing parts. ADVANTAGES OF INFRARED REWORKING
◆ Cost Efficient — Uses Spot Size focusing method, no need for costly air nozzles required in the conventional heating systems. ◆ Reliable — Heat is from light source, disruption or damaging of neighboring components due to air pressure are eliminated. ◆ Versatile — Infrared method has capability to reach components that are usually unreachable by the traditional iron and tools. ◆ Broadview — Enables user to view the whole component rework processing. Helps avoid removing a component too soon thus damaging the pads and points.
5 SYSTEM PARTS GUIDE
Monitor
Optimizing
System
Welding
System
Adjust
Ladder
X Axis
Infrared Tool
Micro‐Adjust
System
Y Axis
Vision Tray
PCB Holder
Pre‐heater
Main
Power Switch
Soldering Iron
Receptacle
Digital Displays
Main Controls
6
PARTS DIAGRAM / PANEL GUIDE
BUTTON 1 2 3 4 5 6 7 8 9 (9a) (9b) 10 (10a) (10b) 11 (11a) (11b) 12 (12a) (12b) 13 14 DESCRIPTION Main Power Switch Soldering Iron Receptacle Main Vacuum Control Vacuum Switch Vacuum Nozzle Vacuum Pen Temperature Reset Button Optimizer System Power Switch PCB Optimizer ( Upper Light) IC Optimizer (Lower Light) Infrared Tool Power Switch Increase Temperature Decrease Temperature Automate IR Tool Switch Increase Time Decrease Time Pre­heater Power Switch Increase Pre­heater Temperature Decrease Pre­heater Temperature Soldering Iron Power Switch Increase Soldering Temperature Decrease Soldering Temperature Welding Time Display Soldering Temperature Display 15 Upper Panel Set Infrared Temperature Display Lower Panel Actual Infrared Temperature Display 16 Pre­heater Temperature Display
7
PARTS DIAGRAM / PANEL GUIDE
Rotating
adjustment
Left and right
adjustment
Up and down
adjustment
Infrared Tool
Handle
Welding
System Lock
Infrared Lamp
8
OPERATING GUIDELINES
SETTING UP THE UNIT
Working Area Equipment must be placed on a flat stable surface of at least one square meter and at a height that suits the user. The electricity supply must be dedicated and free from interference of other devices. NOTE: All moving parts of the unit must be locked in place before attempting to move the system to avoid misalignment and damage to the unit. Set up Connect the lines and tubes to their proper place. NOTE: Unit must NOT be plugged in while doing this procedure, for the safety of the operator. Soldering Iron Holder Figure 1.
1. Install solder wire to the solder iron holder. (Figure 1) 2. Attach the soldering iron cord assembly to the 6­pin output at the lower center area of the main unit. 3. Place soldering iron to the soldering iron stand as shown in Figure 1. BACK PANEL GUIDE
PC B1 B2 A1 Connecting Point
PC
B1
B2
A1
A2
A3
A4
A2 A3 A4 Description
Power cord for main power supply
Connecting tube for the Vacuum Suction Pen
Connecting tube for the Diaphragm Pump
8 pin receptacle
Connecting cord for the Diaphragm Pump
6 pin receptacle
Connecting cord for the Infrared Tool
5 pin receptacle
Connecting cord for Light Optimizer
3 pin receptacle
Connecting cord for Monitor
9 OPERATING PROCEDURE
Start Up ● Turn on the Main Power Switch (button “1”) and check if the Digital Display Panel ● lights up. Turn on the Optimizer (button “6”) and check the monitor. ● Press the Main Vacuum Switch (button “3”) and check if the pump is working. Removing a Component 1. Position the PCB in the PCB holder so that the portion to be reworked is directly above the Pre­ heater. Lock the PCB Holder to prevent the PCB from moving. 2. Press the Pre­heater switch (button“11”) , then set the desired temperature using buttons “11a” and “11b”. 3. Adjust the Y axis and the Welding System ( X axis) to position the Infrared tool right above the broken component. Lock it. 4. Put on your welding goggles. 5. Turn on the Infrared tool (button “9”) and adjust the Infrared focus light depending on the size of your component. Lock it using the locking knobs found on both sides of the Welding System.
Note: The Infrared focus light must be a little bigger than the component size. (the
smaller the focus light the hotter it is, and dewelding time should be shorter)
6.
To Automate: Set desired time of dewelding using buttons “10a” and “10b” , Set the Infrared to your desired temperature using buttons “9a” and “9b”. Then press the time
switch (button “10”) to start the countdown.
7. Infrared dewelding automatically turns off when the time countdown is finished. 8. After dewelding, turn off infrared tool (button “9”) then unlock the X axis and push Welding System to the left side. 9. Turn on Main Vacuum by pressing the Main Vacuum Control (button “3”), then use the Vacuum Suction Pen to remove the component.
REMINDER: When the vacuum switch in
pressed in, the vacuum nozzles is turned on.
When the vacuum switch is pressed out, the
suction pen is on.
Suction Pen
Vacuum Nozzle
10
OPERATING PROCEDURE
Replacing a BGA 1. Position the PCB in the PCB holder so that the portion to be reworked is directly above the Pre­heater. Lock the PCB Holder to prevent the PCB from moving. 2. Roll down adjust ladder and move the Y axis and Optimizer System (X axis) so that the Suction Nozzle is right above the to be reworked area of the PCB. Lock the X and Y axis. Suction Nozzle
3. Press in both Main Vacuum Control and Vacuum Switch to position BGA/component in the Suction Nozzle. 4. Turn on the Optimizer System (button “6”) and pull forward the Vision Tray just beneath the Suction Nozzle. 5. Turn on Main Vacuum Control (button “3”) and press in the vacuum switch (button “4”). 6. Put BGA/component on the suction nozzle. 7. Look into the monitor and use the Micro­Adjust System (see adjustment guide on page 11) to position the BGA/components. Move the Adjust Ladder up and down for more precise placement. Lights can also be adjusted for better visibility. Button “7” for better view of the print on the PCB and button “8” for better view of the component. 7. After BGA/component has been centered and positioned properly, push in the Vision Tray entirely and slowly roll down the Adjust Ladder, release the Vacuum Switch (button “4”) to let BGA/component fall down to its place on the PCB.
IMPORTANT : While rolling down the adjust ladder do not let BGA/component
touch/contact with the PCB, provide at least 1-2mm of space to let BGA naturally
fall into place when you release the vacuum. ( see Figure 1 and Figure 2)
Figure 1
Leaving a distance of 1-2mm before
releasing the vacuum and to let BGA /
component fall into place.
Figure 2
Vacuum is released and the 1.5-2mm
of space between suction nozzle and
BGA/component is shown.
11
OPERATING PROCEDURE Continuation 8. After releasing the vacuum and letting BGA/components fall to its place. Roll up the Adjust Ladder entirely. 9. Turn on the Pre­heater (button “11”) and set desired temperature using buttons “11a” and “11b”. 10. Release the lock of the Optimizer System and slowly push it to the right. 11. Adjust Y axis and Welding System (X axis) to position the Infrared Tool right above the BGA/component. 12. Put on your welding goggles. 13. Turn on the Infrared Tool (button “9”) and adjust the focus of the Infrared Light depending on the size of your BGA. Lock it using the locking knobs found on both sides of the Welding System.
Note: The Infrared focus light must be a little bigger than the component size. (the
smaller the focus light the hotter it is, and welding time should be shorter)
14. Set the Infrared to your desired temperature using buttons “9a” and “9b”.
To Automate: Set desired time of welding using buttons “10a” and “10b” , then press
the time switch (button “10”) to start the countdown.
Note: Welding time depends on the size of your BGA/component and the type of flux
that you use. Components often has their own suggested welding time.
15. Infrared welding automatically turns off when the time countdown is finished. 16. After welding, turn off infrared tool (button “9”) then unlock the X axis and push Welding System to the left side. 17. Unlock PCB holders and remove your reworked PCB.
REMINDER: The Pre-heater displays “OFF” when it has not reached set
temperature yet. It will automatically display actual temperature once
set temperature is reached.
IMPORTANT : Always put on your welding goggles when using the Infrared Tool.
12 REWORKING TIPS
● Always apply flux to joints before reflow. ● Before replacing a component, check if there is enough solder on the pads to solder new component. ● Before replacing a component, check that the new component does not have any bent leads. ● Use Flux Gel. When it turns the gel into a fluid/liquid, this indicates that the PCB is preheated and you can apply heat using the Infrared Tool. ● Flux Gel also helps placement of the component. ● If the Pre­heater temperature is too low or the preheating time too short, when you apply the Infrared Tool, the heat will be conducted away by the PCB's ground plane, which will increase the time it takes to reflow. ● The longer you preheat the PCB the less Infrared heat you need. ● When the solder is fully molten, tap the PCB, and watch the surface tension of the solder draw the component into perfect alignment.
GLOSSARY
Pre­heater The Pre­heater's function is to preheat the PCB and the attached component; this protects the PCB from delaminating and the component from thermal shock. The Pre­heater also equalizes the conductive effect of the ground plane of the PCB. The ceramic heater preheats the PCB and the heat conducts through the PCB and preheats the component, so when you apply the IR Tool there is no chance of thermal shock. The balance of heat energy supplied should be approximately 75% from the Pre­heater and 25% from the IR Tool. Optimizer System It uses light to create optic illusions that enable you to see clearly from above and beneath. Two source of light creates the illusion that one is on top of the other, therefore making it more easy to position the balls. Lights can be adjusted to be brighter or dimmer depending on the optimizing effect that you want. Goggles The goggles has two major functions, one is to enable you to see the focused infrared light for precision soldering, the other function is to protect your eyes from harmful effects.
13 Manufacturer: AOYUE TONGYI ELECTRONIC EQUIPMENT FACTORY Jishui Industrial Zone, Nantou, Zhongshan City, Guangdong Province, P.R.China http://www.aoyue.com
14