Pace TF-1800, TF-2800 User Manual

TF-1800

&

TF-2800

BGA Rework Station

MANUAL NO. 5050-0588

Revised 5-20-19, for software version 2.03

TABLE OF CONTENTS

Safety ........................................................................................................................................................ 1

Specifications............................................................................................................................................ 1

Packing Lists............................................................................................................................................. 2

Hardware Overview and Identification .................................................................................................... 4

Set up ........................................................................................................................................................ 5

Software Overview ................................................................................................................................... 6

The Profiler Screen (Production Mode) ............................................................................................... 1

The Profiler Screen (Developer Mode) ................................................................................................ 8

The Component Alignment Screen .................................................................................................... 10

The Setup Screen ................................................................................................................................ 12

The Debug Screen............................................................................................................................... 14

Operation ................................................................................................................................................ 16

General Overview............................................................................................................................... 16

Procedure ............................................................................................................................................ 17

Production Mode ............................................................................................................................ 17

Developer Mode ............................................................................................................................. 18

Small Components.......................................................................................................................... 20

Maintenance............................................................................................................................................ 21

Replacement & Spare Parts .................................................................................................................... 22

Warranty ................................................................................................................................................. 23

WARNING

Read the safety & setup information sections in this manual before

installing and using your new rework system.

Safety

1. Do not touch heaters or heater accessories during operation.

2. After powering down the system, be sure to let everything cool off before touching.

3. Make sure there is adequate ventilation or use fume extraction equipment.

4. Do not operate near combustible vapors.

5. Do not leave the equipment unattended while it is on.

6. Do not open the rear access door without first disconnecting the main power cable.

Specifications

Top Heater

Vacuum Approx. 25 in/Hg at vacuum pick; 4 in/Hg at accessory port

Optics 1080p color camera with a dichroic image splitting prism

Positioning Accuracy

(Z travel)

Video Up to 240x zoom, Quad-Field imaging and image capture.

Component Nest Maximum: 65x65mm (2.5” sq) Minimum: 1mm square

300 Watt Inductive-Convection Heater with a temp. range of 100°328°C (212°-624°F), and max. airflow 30 SLPM

Precision stepper motor with .0011” (28µm)accuracy

8007-0574 for 120V, 50/60hz, dedicated 20 amp supply required

Part number TF-1800

Size TF-1800

Weight TF-1800 45kg (100lbs)

Preheater TF-1800

PC Board Size TF-1800 Maximum 12” x 12”; No minimum

Part number TF-2800

Size TF-2800

Weight TF-2800 90kg (200lbs)

Preheater TF-2800

PC Board Size TF-2800 Maximum 24” x 24”; No minimum

(1600 watt max.) 8007-0575 for 230v, 50hz, dedicated 10 amp supply required (1600 watt max.)

737mm (29”) H x 686mm (27”) W x 737mm (29”) D

1000 Watt Medium/Long wave infrared with a temp. range of 100°-221°C (212°-430°F). 1.5” of height adjustment.

8007-0582 for 120V, 50/60hz, dedicated 20 amp supply required (2200 watt max.) 8007-0583 for 230V, 50hz, dedicated 10 amp supply required (2200 watt max.)

737mm (29”) H x 1188mm (44”) W x 965mm (38”) D

1900 Watt total Medium/Long wave IR with a temp. range of 100°221°C (212°-430°F) for the center and an auxilliary 0°-150°C (0°302°F) around the edge. 1.5” of height adjustment.

Packing Lists

8007-0574 TF 1800, 120 VAC 8007-0575 TF 1800, 230 VAC

Part Id Description

1107-0037 PC MONITOR, 24" Widescreen, LCD 1332-0134* POWER CORD, DOM DETACHED 1332-0093** POWER CORD,DETACHABLE,230V 1332-0280** Power Cord, Type G, to C13, 230V, Fused 1332-0287** AC Adapter, Type G to Type A/B (US) 1332-0288** AC Adapter, Type E/F to Type A/B (US) 3008-0383 Cable, HDMI to HDMI, Male to Male, 1M 5005-0119 SHIPPING CRATE, TF1800 / IR3000 A03 6020-0257 COMPUTER, INTEL NUC613SYH loaded build 6993-0306 IR/TF Monitor Arm Kit 7008-0324* TF1800 machine, 120V 7008-0325** TF1800 machine, 230V 7950-0158 TF1800 PACKOUT

* Only included with 120V units (8007-0574) ** Only included with 230V units (8007-0575)

Part Id Description

1001-0001 STENCIL,COMPONENTS,LEADS 1100-0100 PACE Mousepad, 9-2014 1100-0231 TOOL,NOZZLE/CHIP ASSY 1100-0303 NOZZLE CHANGE PAD 1132-0070 TOOL, 3/32" BALL_END SCREWDRIVER 1340-0174 K-TYPE THERMOCOUPLE 40 GA 3008-0295 Cable, USB-A / USB-B, Male, 6' 3008-0931 CABLE,1M,USB3.0,TYPE A MALE,TYPE B MALE 4018-0100-P1 OPTICAL ALIGNMENT 6000-0245 FLUX TRAY ASSEMBLY 6000-0247 STENCIL PLATFORM ASSY. 6000-0448 CENTERING CLAMP ASSY 6000-0453-P4 ODD-SHAPED BOARD HOLDER KIT 6016-0033 SET, HEX KEY TF1700/2700 6993-0276 KIT, TF VACUUM PICK 7 SIZES 6993-0312 MICRO CHIP NESTING KIT 6993-0313 JAWS KIT, SQUARE COMPONENT 6993-0314 JAWS KIT, RECTANGULAR COMPONENT 7027-0001-M HANDPIECE, PV-65, PIK-VAC CD5050-0459 CD,PACE MANUALS 7 LANG. 1 EA

Qty

1 1 2 2 1 1 1 1 1 1 1 1 1

Qty

1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1

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8007-0582 TF 2800, 120 VAC 8007-0583 TF 2800, 230 VAC

Part Id Description Qty UM

1107-0037 PC MONITOR, 24" Widescreen, LCD 1 EA 1332-0134* POWER CORD, DOM DETACHED 1 EA 1332-0093** POWER CORD,DETACHABLE,230V 2 EA 1332-0280** Power Cord, Type G, to C13, 230V, Fused 2 EA 1332-0287** AC Adapter, Type G to Type A/B (US) 1 EA 1332-0288** AC Adapter, Type E/F to Type A/B (US) 1 EA 3008-0383 Cable, HDMI to HDMI, Male to Male, 1M 1 EA 5005-0169 SHIPPING CRATE, TF2800 1 EA 6020-0257 COMPUTER, INTEL NUC613SYH loaded build 1 EA 6993-0306 IR/TF Monitor Arm Kit 1 EA 7008-0328* TF2800 machine, 120V 1 EA 7008-0329** TF2800 machine, 230V 1 EA 7950-0159 TF2800 PACKOUT 1 EA

* Only included with 120V units (8007-0582) ** Only included with 230V units (8007-0583)

Part Id Description Qty UM

1001-0001 STENCIL,COMPONENTS,LEADS 1100-0100 PACE MousePad, 9-2014 1100-0231 TOOL,NOZZLE/CHIP ASSY 1100-0303 NOZZLE CHANGE PAD 1132-0070 TOOL, 3/32" BALL_END SCREWDRIVER 1340-0174 K-TYPE THERMOCOUPLE 40 GA 1348-0700-01 LEG,BOARD HOLDER,KIT 5.25LG 1351-0902 LABEL, WARNING, LIFTING 1405-1047 SCR,SKT,8-32X2.25,SSNAHS 3008-0295 Cable, USB-A / USB-B, Male, 6' 3008-0931 CABLE,1M,USB3.0,TYPE A MALE,TYPE B MALE 4018-0100-P1 OPTICAL ALIGNMENT 6000-0245 FLUX TRAY ASSEMBLY 6000-0247 STENCIL PLATFORM ASSY. 6000-0448 CENTERING CLAMP ASSY 6000-0453-P4 ODD-SHAPED BOARD HOLDER KIT 6000-0463 PCB ANTI-SAG SUPPORT MECHANISM, TF2800 6016-0033 SET, HEX KEY TF1700/2700 6993-0276 KIT, TF VACUUM PICK 7 SIZES 6993-0312 MICRO CHIP NESTING KIT 6993-0313 JAWS KIT, SQUARE COMPONENT 6993-0314 JAWS KIT, RECTANGULAR COMPONENT 7027-0001-M HANDPIECE, PV-65, PIK-VAC CD5050-0459 CD,PACE MANUALS 7 LANG.

1 EA 1 EA 1 EA 1 EA 1 EA 4 EA 1 EA 1 EA 4 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA 1 EA

Hardware Overview and Identification

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A) Pik-Vac switch and mount – The switch will activate the vacuum pump for 15 minutes so that

components can be handled manually with the included PV-65 Pik-Vac tool.

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B) Thermocouple Inputs – Up to 4 K-type thermo-couples can be used to measure temperatures.

Temperature readings are displayed in real time via the TF software.

C) Emergency Stop – This button can be used to cut power to the machine immediately in case of an

emergency.

D) Board Holder with Board Support Wand – Fine adjustment of the board holder can be made in the X

and Y directions by using the micrometer knob on the front of the unit and right side of the holder itself. The board holder also has a support bar to help prevent sag of large/heavy boards.

E) Bottom Heater Height Adjustment – Used to bring the bottom heater closer to the workpiece for faster

heating.

F) On/Off switch – Used to turn the machine on or off. Always turn the machine on before opening the

software, and allow the software to close before turning off the unit.

G) LCD Monitor – Displays software package from PC (not shown).

H) Reflow Head – Contains inductive-convection heater for fast and efficient top heating of components.

The entire head moves up and down via an electric stepper motor that is controlled through the software.

I) Optics Housing – Contains the High-Def (1080p) Optical Alignment System (Camera, Prism and

lighting.) The optics housing extends and retracts automatically as needed during the process.

J) Cooling Fan – The component and PCB are cooled by the cooling fan, which is activated automatically

during the cool down zone or operated manually as needed.

Set up

1. Connections –

a. The TF-x800 series machines use a self-contained air pump, therefore shop air is not required.

b. Place the PC next to the machine and connect the provided USB/HDMI cables.

c. Assemble the monitor arm kit onto the right side of the TF machine, then attach monitor and

d. Set out wireless keyboard and mouse, make sure they are turned on and the wireless receiver

e. Plug in the power cords for the PC, Monitor, and the TF unit.

2. Accessories –

a. Insert a vacuum pick-

If desired, an external pressurized Nitrogen source can be used instead.

connect to PC.

has been plugged into the PC.

i. Select the smallest vacuum pick that can lift the component. If the component cannot

be reliably picked up, move to a larger vacuum pick but keep in mind this may slow down heating of the component in relation to the surrounding area.

ii. The vacuum pick will thread into the shaft in the middle of the large circular opening on

the bottom of the heater head assembly. Never use tools to tighten the vacuum pick as doing so can damage the threads or bend the pick.

b. Insert an appropriate nozzle-

3. Power on –

a. Make sure everything is connected to an appropriate power source.

b. Turn on circuit breaker on back of the TF machine.

c. Turn on PC and monitor.

d. Turn on the switch at the front of the machine.

e. Once PC has finished booting up and the TF machine is running, double-click on the TF-1800

software icon.

i. Ideally, the inside of the chosen nozzle should be about 3 mm larger than the

component being worked with to allow for proper air flow. A smaller nozzle can be used if neighboring components are too close, or the heater head can be positioned higher above the surface during reflow. Both of these options will change the performance and efficiency of the unit.

ii. The nozzle will attach to the ball detents in the underside of the heater head in the large

square opening surrounding the vacuum pick.

i. The 120V TF-x800 requires a dedicated 20amp circuit.

ii. The 230V TF-x800 requires a dedicated 10amp circuit.

Software Overview

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The Profiler Screen (Production Mode)

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A) Progress Bar – A Visual reference indicating progress status of the process.

B) Abort Button – Used to abort current process.

C) Start Process – Used to begin the removal or installation process from the home position.

D) Start Heating – Click this button to initiate heating by the primary heater as directed by the selected

profile.

E) Profile Name – Displays the name for the active profile.

F) Profile type – Indicates if the loaded profile is an install or removal.

G) Load Profile – Click here to select an existing profile.

H) Preheater Indicators – Reference showing if the main and/or auxiliary pre-heater is at an acceptable

temperature for starting the currently loaded profile.

I) Cycle Heating – This button will move the heater head down into position over the board assembly and

run the thermal profile, skipping all set-up and alignment steps. For use when manually placing components.

J) Preheater Temperature – Shows the current temperature of the main pre-heater.

K) Cooling Fan – Turns the external cooling fan on or off. (Fan runs automatically during the cool down

portion of the thermal profile.)

L) Developer Login – Used to enter “Developer Mode” for profile creation and editing.

M) Sensors – The current and peak temperatures for any attached K-type thermocouples will be shown in

real time during a profile run. Also displays how long the thermocouple has spent above the temperature for the solder being used to be completely liquid.

N) Time Above Liquidus – Reference to the

liquidus temperature set in the current thermal profile.

O) View Reference Image – Used to view the

reference image associated to the current profile, if one was added during development.

P) Save Production Run – For saving

temperature graphs and other information from a production run in a .PDF for later reference. If “Log Sensor Data” is checked, saving the production run will also create a time-tagged CSV file including information thermocouple data and heater commands. The file will be named with text input to the block shown here as “Production_Run_Name” and a time stamp.

Q) Exit – Exits the TF software.

R) Shelf – Used to change brightness of the under-shelf lighting illuminating the back of the board holder.

S) Preheater Position – Indicates what height to set the preheater for the currently loaded profile.

T) Stairs Slope – Controls the temperature slope measurement in the profile graph. Selecting two points

on the same temperature curve will display the temperature over time (or slope) for that portion of the curve. When Stairs Slope is checked, selecting a point outside of an existing slope measurement will create a new measurement from the nearest end of the existing slope. When Stairs Slope is not engaged, selecting a point outside of an existing slope will lengthen the slope measurement to that point of the temperature curve.

U) Comments – This block can be used by the operator to enter information about the production run to the

file created by the Save Production Run feature.

V) Instructions – This block will display any information left by the developer for the currently loaded profile.

W) Bottom Heaters – The icons here are used to turn on/off the different sections of the preheater for the

TF-2800. The TF-1800 uses a single unified pre-heater and does not have auxiliary heaters. When any of the auxiliary heaters for the TF-2800 are turned on, a new entry is added to each phase of the profile the as well as to the profile graph.

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X) Phase Indicators – These colored blocks show the numerical values of the different variables for each

profile phase and correspond to the colored lines on the Profile Graph.

• Magenta – Time

• Green – Air flow

• Red – Top heater

• Orange – Bottom heater

• Grey – Auxiliary bottom heaters (if turned on.)

Y) The Profile Graph – This chart will display real-time information about the temperature profile.

The Profiler Screen (Developer Mode)

The developer mode contains all of the options from the production mode with a few key additions and changes.

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A) Install/Removal – Select to create either an Installation or Removal profile.

B) Profile Buttons

I. Load Profile – Same as the production mode, it will load a previously saved profile.

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II. Save Profile – Click to save the current profile.

III. Save Profile As – Click to rename profile.

IV. New Profile – Used to create a brand new profile. Saves existing thermal, time and flow settings

on screen, but clears all heater head and camera distance settings used during automatic operations.

C) Automation Options – The TF-1800 has the capability to remember heater head position to automate

different steps in the installation or removal processes.

I. Auto Placement – When checked, the TF-1800 will automatically place the component using

distance settings input during the first profile development run. If unchecked the heater head and component will have to be manually controlled for each placement.

II. Auto Flux Dip – When checked the software will insert a step for an automated flux dip process

using the position settings stored by the profile.

III. Active Cooling – Allows for an increased yet controlled cooling of the part by using the main

blower inside the heater head. If unchecked, the heater head will rise after the Reflow Phase to allow the component to air cool or use the cooling fan.

IV. Align Holder – Checking this box will add a step in the process which guides the user through

alignment of the vacuum pick and centering nest for working with components ranging between 15mm.

V. Micro Chip – This automation routine is intended for use in installation profiles of components

smaller than 1mm square, or whenever it would be more convenient to pick-up a component from the board instead of a component nest.

VI. Auto Removal (not pictured) – This option takes the place of the other automation options when

creating a removal profile. When checked, the TF-1800 will automatically remove the component at the end of the heating cycle.

D) Mode Indicator – The person developing the profile can use this box to switch back and forth between

the two versions of the Profiler Screen, without having to log completely out of the developer mode.

E) Developer Logout – Click this to logout of

developer mode. Until the developer is logged back in profiles may only be loaded and run, no changes can be made to them.

F) Trial and Graph options – These four

columns control information displayed on the profile graph while a profile is run during development, as well as what is seen by anyone later running the profile from Production Mode.

I. Trial Number – Selects active trial.

II. Sensors Used – Selects which

thermocouple profile graphs will be recorded during a profile run.

III. Show Trial Graph – Can be used to

display the profile graphs of multiple trial runs in the Profile Graph Chart for comparison.

IV. Production Sensor – This is used to

select which thermocouple profile graph will be displayed on the production screen as the primary reference, once the profile has been saved.

G) Clear buttons – Pressing clear will reset the current and highest temperature for the respective sensor.

H) Profile instructions/specifications block – This block can be used to store text notes or instructions about

the profile for future reference during production runs. This information cannot be changed by the production mode user.

The Component Alignment Screen

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A) Main Camera Image – This is the main camera viewport. The image is a combination of looking down

at the top of the board, and looking up at bottom of the component. This allows the user to align the solder balls or leads of a component to the corresponding pads on the board.

B) LED controls – The two sliders in this column control LED intensity for the light shining up at the

component part and down at the PCB.

C) Abort – Pressing this button will abort the operation and return to the previous screen while also

returning the heater head and camera arm to their home positions.

D) Quad-Field Imaging – These four viewports, or quadrants, allow portions of the Main Camera Image to

be viewed in more detail when fine tuning alignment without the need for adjusting the Main Camera Image. Use this feature by left-clicking a point in the Main Camera Image and it will appear in the associated Quad-Field viewport.

E) Grid Overlay – This will show grid lines in the Quad-Field Imaging viewports. The grid lines can be set to

black or white, and the +/- buttons will adjust the grid size.

F) Contrast – Adjusts the color contrast of the camera.

G) Brightness – Increases/decreases amount of light let into the camera. Changes made will appear

delayed on screen.

H) Alignment Complete – Once the component and board have been properly aligned, click this button to

continue on with the rest of the profile.

I) Attach Reference Image – Only appears in Developer Mode. Allows the developer to link saved images

to a profile for reference during production runs.

J) Snap and Save Camera Image – Allows the user to save images on the hard drive.

K) Quad Zoom – Use this to increase/decrease digital magnification of the Quad-Field Imaging.

L) Focal Distance – Depending on the sizes and distances of components and the board from the camera,

changing the focal distance of the camera may help when aligning the BGA.

M) Dzoom Slider – Used to zoom the Main Camera Image up to 9x. The slider bars below and beside the

Main Camera Image can be used to reposition the view.

N) Sharpness Slider – Adjusting this changes image clarity. Too little will cause blurriness but too much will

make the image appear grainy.

O) Focus Slider – Allows for manual adjustment of the camera focus, when auto focus is checked the slider

is grayed out.

P) Zoom Slider – This slider controls the optical zoom of the Main Camera Image. The slider bars below

and beside the Main Camera Image can be used to reposition the view.

The Setup Screen

A) Use Timeline Bar – Turns on/off

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the progress meter at the top of the Profiler screen.

B) Use Fahrenheit Units –

Switches the default temperature units to Fahrenheit from Celsius.

C) Use Nitrogen – Check this when

using a pressurized nitrogen supply instead of the ambient air from the internal pump.

D) Show Heater Arm Position –

This checkbox will add an entry to the Profiler screen called

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“Arm Pos” which displays a numerical value corresponding to the heater head position.

E) Wait for Main Preheater Ready

– Checking this box will prevent

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starting a profile until the preheater has reached the

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temperature setting for the Preheat Zone.

F) Wait for Aux Preheater Ready –

Checking this box will prevent anyone from beginning a profile until the auxiliary preheaters have reached the temperature setting for the Preheat Zone.

G) Auto Activate Preheater while

idle – Checking this box will

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allow the preheater to begin heating as soon as the machine is turned on, before a profile is loaded.

H) Allow Micro Chip Option – This

controls whether or not the Micro Chip automation process will be available for selection on the Profiler screen.

I) Nozzle Cool Up Steps – This sets the distance between the PCB and nozzle during Active Cooling.

Lifting the nozzle will allow increased airflow and faster cooling.

J) Liquidus Temp (C) – This is where to input the temperature used for calculating the “Time above

liquidus” shown on the Profiler screen. The liquidus temperature will vary depending on your specific solder.

K) Prism Alignment – This function is used to calibrate/verify the camera prism is properly aligned.

L) Initial Centering Nest

Adjustment – This can be used to extend the camera arm and component tray for realigning the component nest without having to run a profile.

M) Abort Process – Stops

any action the machine is performing and goes back to the home position.

N) Heater Arm Steps

Down – This controls the position the heater head will descend to before initiating auto or manual placement protocols.

O) Nozzle Tuning Settings

– The settings here control how many “steps” the heater head will move when the respective button is pushed during manual positioning.

P) Password Reset – The items in this section are used to reset or change the developer password. If the

current password is forgotten, you will need to contact PACE for a temporary access code.

Q) Manage – This section of the setup screen hosts several shortcuts directly to the folders containing the

information stored by the TF software. The default locations for these folders are;

• "C:/Pace/Profiles" – Where profiles are stored as .dat file along with an .pdf showing an image of the developer’s Profiler Screen.

• "C:/Pace/LogFiles" – This folder has the logs containing time stamped .csv files from the sensor, heater, and flow meter for profiles ran with the Log Data box checked on the Profile Screen.

• "C:/Pace/Reports" – The .pdf reports created when “Save Production Run” is utilized from the Profile Screen are stored here.

• "C:/Pace/Images" -- This is the storehouse of .jpg images the developer has put in for reference during profiles run in production mode.

• "C:/Pace/Snapshots" -- This is the storehouse of .jpg images saved from profiles run in production mode for later examination.

The Debug Screen

The Debug Screen is used to troubleshoot/test various aspects of the TF-1800 machine. The screen can be broken down into three sections. The Setup Commands on the left will make the machine perform an action. Status Request Commands will read off what the software believes to be the current setting, position or status of the different parts of the machine. The bottom area contains read outs for the Status Request commands along with a command selector to change available options (for future BGA equipment).

To the left is the Setup Commands portion of the Debug screen. Each box deals with activating a different aspect of the TF-1800 machine. The user can select or change options, then press the associated button in the box to implement the changes.

For example, the vacuum pick can be made to move into the up position by first selecting the up bubble and then pressing the button labeled “Pick Solenoid” to activate the command.

The red buttons in the middle will turn on/off the respective item. The button will turn green to indicate the item is on.

Below are the various Status Request Commands. These will query what information the machine and software are sharing. Checking the “Display ASCII Sent/Received Packets” box will output information that may be helpful when attempting to diagnose problems the machine may be having or simply examining how different parts/functions of the machine operate in detail.

Operation

General Overview

There are many variables that need to be considered for each component removal or installation. Acceptable ramp rates and maximum temperatures of the items used in the operation should be obtained from the appropriate sources. The rework cycle can generally be broken down into five parts as follows;

Pre-heat Phase

This part of the cycle is primarily to warm the work piece up to a low, even temperature to reduce the chance of thermal shock or stress damage to the components being worked on, as well as components elsewhere on the PCB.

Soak Phase

The soak phase allows the temperatures to further normalize across the PCB and components while

also beginning to gently bring the temperature up in preparation for the push through the ramp and reflow phases. Boards with large ground planes or other heat-sinking materials and components will benefit from a longer soak period to ensure uniform temperatures.

Ramp Phase

The ramp phase is where important things in the solder process start to happen. The temperature should begin climbing in order to activate the flux.

Reflow Phase

This is where everything comes together and the solder reaches liquidus. The lowest set temperature possible should be used to ensure safety of the component and PCB. Refer to manufacturer specifications

for temperature requirements of the materials being used.

Cool Down Phase

The cool down phase is used to bring the temperature of the component, solder joints, and PCB down below solder melt or reflow temperatures. This is beneficial for plastic component packages which can hold heat for a long time. Some components (such as CBGA or ceramic ball grid arrays) should be allowed to cool naturally without any external assistance. These types of components are sensitive to thermal shock and can be damaged by heating or cooling too quickly.

Procedure

It is recommended to conduct a trial operation each day before commencing with production to ensure the heater temperatures will be uniform and that everything is operating correctly. It is important to verify if the machine is providing adequate airflow. Insufficient airflow can be detrimental to the job at hand and possibly cause damage to the machine itself if there is not enough airflow when the heater element is in operation.

Before operation, check for any components on both the top and bottom of the PCB that may not fit in the TF-1800. Ensure the components are not going to crash into the heater head or camera arm as they move up/down and in/out. Also check that the bottom heater will not be obstructed and does not make physical contact with components on the board as this could cause uneven heating.

Production Mode

Example component installation – Note: If at any time you need to abort the process, click on the red abort button.

1)

Turn on the TF machine and PC, and then run the TF software.

2)

Navigate to the Production Mode screen if not already there.

3)

Load a profile using the Load Profile button.

4)

Install the proper vacuum pick.

5)

Install the proper nozzle.

6)

Click “Start Process” and follow the onscreen instructions which will guide you through the following steps.

7)

Place the PCB between the arms of the board holder and position the board so the red laser point is in the center of the placement site and tighten the board holder retention screw.

8)

Apply flux to the board if needed, and attach any thermocouples desired for additional process monitoring. Adjust the Board Support Wand as needed.

9)

Place the component in the mounting plate on top of the camera housing. The component needs to have the same orientation as the nozzle. Click “okay”.

10)

The BGA workstation will pick up component. If the vacuum pick fails to pick up the component, reset the component in the nest and click retry.

11)

If Auto Flux Dip is selected, replace the component nest with the flux dip tray and follow onscreen directions. After fluxing is complete, restore flux dip tray and component nest to their original locations.

12)

Slide component nest out of the way, towards the back of the machine so the optics are unobstructed.

13)

The component alignment screen will appear and the heater head will move down to the focal position.

14)

Adjust the zoom and lighting as needed in order to see the pads on the PCB as well as the solder balls or leads on the component. Then using the theta adjustment and X/Y micrometers, align the component to the PCB.

15)

After alignment is complete, click the Alignment Complete button to prepare for heating.

16)

If auto placement is active, the heater head will place the component and nozzle into position over the board. Otherwise, use the onscreen adjustments to manually lower the heater head into final position.

17)

Make sure any extra thermocouples being used are in the correct location and click the Start Heating Button.

18)

The selected temperature profile will run.

19)

Allow the PCB to cool and remove.

Example component removal – Note: If at any time you need to abort the process, click on the red abort button.

1)

Turn on the TF machine and PC, and then run the TF software.

2)

Navigate to the Profiler Screen if not already there.

3)

Load a removal profile using the Load Profile button.

4)

Install the proper vacuum pick.

5)

Install the proper nozzle.

6)

Click “Start Process” and follow the onscreen instructions which will guide you through the remainder of the procedure outlined in the following steps.

7)

Place the PCB between the arms on the board holder and tighten the retention screw.

8)

Position the board so the red laser point is roughly in the center of the component.

9)

Click on Start button.

10)

Allow PCB and component to cool before touching.

Developer Mode

Developer Mode has all the same features of Production Mode, with a few additions to allow the creation and editing of installation and removal profiles. There are 2 recommended methods for developing a profile. The first method involves an actual component installation, while the second uses a previously installed package. Either method can be used to develop a reliable profile. However, there are some issues and considerations to be aware of with each.

When developing a profile by doing a complete component installation, it is critical to make sure the thermocouples remain in contact with the solder throughout the entire process. Unreliable data could be generated should a thermocouple lose contact with the solder. If measuring temperature at the top of the package, it is best to use a preinstalled component, as the thermocouple wire will typically cause the component to not lay flat on the PCB which will cause problems with the install.

When using a previously installed package, the placement of the thermocouples is important. For best results the sensors must be in contact with the existing solder joints. This task can be accomplished by drilling through the bottom of the PCB into a solder joint and attaching the thermocouple, or by sliding the thermocouple under the package. When sliding a thermocouple under a component, it is critical that the thermocouple be in contact with the solder. Information from the thermocouples will assist in determining the proper time and temperature parameters. It is imperative for the thermocouple sensor bead to be in contact with the solder (preferred), the PCB and/or the component so that it is not floating in the open and measuring only the air temperature.

Adjusting the parameters for each phase or step of the profile is done by moving the colored bars in each phase. More precise settings can be input using the up/down arrows next to each entry at the bottom of the temperature profile graph.

• Magenta – Time in seconds

• Green – Air flow in standard liters per minute

• Red – Top heater set temperature

• Orange – Bottom heater set temperature. (Note: As soon as a

temperature is put in the Preheat Zone for the bottom heater, the unit will begin warming to that temperature.)

• Purple – Auxiliary bottom heater temperature. (TF-2800 only.)

During the profile development process, up to 4 “trial runs” can be viewed for comparing and contrasting how well different settings work on a given application. The information displayed from each trial run can be altered using the buttons and check boxes above the temperature sensor readouts.

•

Trial Number – This column is used to designate which trial run is currently active for editing or being saved.

•

Sensors Used – Check off the boxes for the sensor inputs you would like to use when doing a new trial run.

•

Show Trial Graph – This will allow you to view the profile graphs from multiple trials at the same time.

•

Production Sensor – Use this to select the thermocouple temperature graph that will be the visible reference for the finished production profile. Sensor descriptions can be changed by the profile developer.

Your new TF machine will come with default installation and removal profiles. These can be used as starting points for new custom profiles. The TF software will memorize the distance traveled by the heater head during some parts of an installation or removal process. The included default profiles do not have any distances stored. When altering any other pre-existing profile to work with different components, after loading the profile you must clear the distance settings with the “New Profile” button or the heater head could crash.

Following is a sample outline of steps needed to develop an installation profile by doing a new component installation. The process is essentially the same as doing a production run, except with the ability to make changes.

I. Turn on the machine and PC, then run the TF software.

II. Navigate to the Developer Mode screen if not already there.

III. Load a profile using the Load Profile button.

IV. Install the proper vacuum pick.

V. Install the proper nozzle.

VI. Click “Start Process” and follow the onscreen instructions which will guide you through the

following steps.

VII. Place the PCB between the arms of the board holder and position the board so the red

laser point is roughly in the center of the component placement site then tighten the retention screw.

VIII. Apply flux to the board if needed, and attach any thermocouples desired for additional

process monitoring. Adjust the board support to the middle of the board.

IX. Place the component in the mounting plate on top of the camera housing. The component

needs to have the same orientation as the nozzle. Click “okay”.

X. The BGA workstation will pick up component. If the vacuum pick fails to pick up the

component, reset the component in the nest and click retry.

XI. If Auto Flux Dip is selected, replace the component nest with the flux dip tray and follow

onscreen directions. After fluxing is complete, restore flux dip tray and component nest to their original locations.

XII. Slide component nest out of the way, towards the back of the machine so the optics are

unobstructed.

XIII. The component alignment screen will come up and the heater head will move down

towards the focal position.

XIV. Adjust the zoom and lighting as needed in order to see the pads on the PCB as well as

the solder balls or leads on the component. Then, using the theta adjustment and X/Y micrometers, align the component to the PCB.

XV. After alignment is complete, click the Alignment Complete button to prepare for heating.

XVI. If auto placement is active, the heater head will place the component and nozzle into

position over the board. Otherwise, use the onscreen adjustments to manually lower the heater head into final position.

XVII. Make sure any extra thermocouples being used are in the correct location and click the

Start Heating Button.

XVIII. The TF unit will run the selected temperature profile.

XIX. Allow the PCB to cool and remove.

If the component installation was successful, it is a good idea to try it once more to check for consistency and then save it! If the component installation was not successful, examine the situation and make changes to the profile for another trial run. Temperature graphs from up to 3 previous trial runs will be available for comparison to current settings. When saving a profile, don’t forget to select the primary temperature sensor for future reference when repeating the profile in production mode.

Small Components

The TF-1800 and TF-2800 are capable of working with very small components, as small as 1mm square. When working with components ranging from 5mm down to 1mm there are some additional steps required for accurate placement during installation procedures.

The standard Centering Nest can accommodate components between the sizes of 65mm and 5mm. To work with smaller components, the Centering Nest should be exchanged with the Microchip Nest. An in-program walk through of this process is added to a profile whenever the “Align Holder” box is checked.

Once the Microchip Nest has been installed onto the TF machine , the appropriate component slot will need to be aligned to the vacuum pick so the component can be lifted. This is achieved by adjusting two screws. To adjust the nest forward and back, use the screw on the left that controls the stop block on the rail. To adjust the nest left/right, use the screw protruding from underneath the center of nest.

Maintenance

VisiFilter (1309

-

0020

-

P1)

LUBRICATION:

The horizontal rails of the board holder should be checked daily for debris and dry spots. The rails can be cleaned and lubricated by wiping with an ISOVG32 oil (such as; Mobil Vactra No. 2 SLC, Mobil DTE Light 32, Shell Tonna S2 M 32) with a lint-free cloth or sponge. A light coating should be left in the ball races. Avoid applying excessive amounts, which may pose a fire hazard near the preheater.

The two vertical rails should be lubricated if the heater head is sticking or stuttering. All rail covers will need to be removed (4 screws and brackets) in order to access the outer races. Apply ISOVG220 grease (Mobil Vactra No 4) to rails. Depending on the service conditions, the rails should be lubricated as a preventative measure at least annually.

Vacuum pick bearings should be checked if pick does not fully descend to bottom position. Must remove theta adjust knob and 4 screws to remove heater head cover. Carefully clean off dust or debris from exposed parts of the vacuum tube with an anti-dust aerosol or lint-free cloth. Apply a thin coat of NLGI Grade 2 lubricant (Dupont Krytox GPL 205) to the circumference of vacuum tube near each bearing. Next, manually move the vacuum pick up/down to allow grease to contact the balls; rotate the theta adjust knob and repeat the up/down movement. Depending on the service conditions, the bearings should be lubricated as a preventative measure at least annually.

VACUUM LINE FILTER Check VisiFilter (rear door)

.

Replacement & Spare Parts

Part Number Description

6020-0219-P1 TF/IR High Voltage PCB 1336-0045-P1 Flow pump for 120v 1336-0046-P1 Flow pump for 230v 6993-0276-P1 TF vacuum pick kit – 7 size assortment 1198-0021-P1 Posifa TF Flowmeter 1198-0022-P1 Honeywell TF Flowmeter 1336-0049-P1 Fish Pump for pik-vacuum 6020-0157-P1 TF Sensor PCB 1263-0036-P1 Proportional Valve 3008-0295-P1 USB-A/USB-B Cable 1161-0008-P1 5x20mm Fuse Holder 1259-0135-P1 Vacuum Panel Mount Fitting 1334-0021-P1 Low Pressure Pump 6000-0239-P1 Laser Pointer 6000-0313-P1 Nitrogen Solenoid 7027-0001-P1 PV-65 Pik-Vac Vacuum Wand 1121-0927-P1 Micro-Vacuum Pik (20 gauge) 1340-0174-P1 K-type Thermocouples (package of 2)

6016-0033 Hex-Key Set 6000-0247-P1 Stencil Platform Assembly 6000-0245-P1 Flux Tray Assembly 1100-0231-P1 Nozzle/Chip tool 1100-0307-P1 Hot Grip Pad 1001-0001-P1 Leaded Component Stencil

PACE Incorporated

Pace Europe

Warranty

PACE warrants that this equipment will be free of defects in materials and workmanship for a period of one (1) year from the date of receipt by the first user. This warranty does not cover repair of replacement required as a result of misuse, mishandling or improper storage. Failure to perform recommended routine maintenance, alterations or repairs made other than in accordance with PACE’s directions, or removal or alteration of identification plates in any way will void this warranty. This warranty is available only to the first user, but the exclusions and limitations therein apply to all persons and entities.

This warranty does not apply to consumable items such as filters.

PACE MAKES NO OTHER WARRANTY, EXPRESSED OR IMPLIED, AND MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

PACE will, at its option, repair or replace and defective equipment or parts at its facility or other location approved by it at no charge to the user, or provide parts without charge for installation by the user in the field at the user’s expense and risk. User will be responsible for all costs of shipping equipment to PACE or other warranty location for warranty service.

EXCEPT FOR THE REMEDY ABOVE DESCRIBED, UNLESS OTHERWISE REQUIRED BY APPLICABLE LAW, PACE WILL HAVE NO OTHER OBLIGATION WITH REGARD TO ANY BREACH OF WARRANTY OR OTHER CLAIM WITH RESPECT TO THE EQUIPMENT, OR LIABILITY FOR ANY DIRECT, INDIRECT, CONSEQUENTIAL, OR INCIDENTAL LOSS OR DAMAGE CAUSED BY OR OCCURRING IN CONNECTION WITH ANY OF THE EQUIPMENT.

To obtain warranty service, contact the appropriate PACE company listed below

Do NOT return defective equipment or parts to PACE without obtaining prior authorization.

Any warranty or other claim with respect to the equipment must be made in writing and delivered to PACE (or local authorized PACE Distributor outside the U.S.) within a reasonable time of the expiration date of this warranty. Sufficient evidence of purchase and date of receipt must also be included, otherwise user’s rights under this warranty shall be deemed waived.

www.paceworldwide.com

346 Grant Road 11 Holdom Avenue Vass,NC 28394 Bletchley, Milton Keynes,

United Kingdom, MK1 1QU Tel: (877) 882-PACE Tel: (910) 695-7223 Tel: 011 44 1908 277666 Fax: (910) 695-1594 Fax: 011 44 1908 277777

Pace TF-1800, TF-2800 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual