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TF 2500 BGA
Service Manual
44 pgs3.55 Mb1

Pace TF 2500 BGA Service Manual

TF 2500 BGA Rework Station
Operation and Maintenance Manual
Manual Number 5050-0544
Rev B
Table of Contents
Packing Contents, Standard Items..................................3
Specifications ..................................................................3
Parts Identification...........................................................4
Safety Information ...........................................................6
Features ..........................................................................6
Set-Up.............................................................................7
System Connections.............................................7
Start up................................................................. 7
Inserting/ changing vacuum pick...........................8
Inserting/changing nozzle.....................................8
Set up screen features.......................................... 9
Alignment screen features..................................10
Production screen features.................................11
Production Mode Record Manager features.......12
Profile development screen features ..................13
Development Mode Profile Manager ..................15
Inspection screen features..................................17
Prism Calibration ................................................18
Operation.......................................................................20
Production...........................................................20
Component removal............................................23
Profile development installation procedure.........24
Temperature, Time, and Airflow Control........................26
Available Nozzles, Accessories, and Optional Items.....26
Maintenance..................................................................26
Heater Replacement......................................................27
Adjustments and Alignments.........................................38
Regulation .....................................................................42
Service and Warranty....................................................43
System Operations Manual
Page 2 of 44
System Operations Manual
1. Packing Contents, Standard Items Description
Part Number TF 2500 8007-0430 (120V) 8007-0431 (230V) PC 6000-0233
Keyboard -
Mouse ­Monitor 1107-0032 Vacuum Pick 1272-0005-P1 Vacuum Pick Kit 6993-0060 Suction Cups 6993-0202-P1 Alignment Board 4018-0100-P1 Mounting Platform Stencil 1321-0725 Mounting Platform Flux Dip 1321-0735 Hot Grip Removal Pad 1100-0307 Thermocouples (4) 1340-0174-P1 Hex Wrench Kit 6016-0034 Power Cord 1332-0224 Video Cable 3008-0168
2. Specifications:
Part Number 8007-0410/8007-0411 Dimensions 737 mm H x 686 mm W x 737 mm D
(29” x 27” x 29”) Weight (w/o computer) 90 kg (200 lbs) Power Requirements 115 VAC, 60 hz or 230 VAC, 50 Hz
2600 watts PC Pentium 4, 256M Ram, Floppy, CD Top Heater Adjustable convective air (air or N2),
Maximum 20 SLPM, 1200 watts
100 to 400 deg C, 212 to 750 deg F Bottom Heater IR, One 400 Watts
IR Six 150 Watts
100 to 221 deg C, 212 to 430 deg F Vacuum 450 mm Hg Optics High resolution, Dual Color Vision
Overlay System Positioning Accuracy (Z travel) +/- 25 umeters (0.001”) Video 2 Composite Video (external)
1 “S” Video (Internal)
17” Integrated color Flat Panel
Monitor PC Board Size 610mm x 610 mm, 24” x 24” Component Size 65 mm x 65mm, 2.56” x 2.56” max.
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System Operations Manual
TF 2500 Parts Identification
F
Figure 1
Page 4 of 44
System Operations Manual
A. LCD Display Monitor Displays PC Software B. Cooling Fan The component and PCB are cooled by the cooling fan, which can be set to activate automatically after the
reflow cycle is complete or operated manually.
C. Board Holder The board holder is fully adjustable in the X direction
only. Fine adjustment of both the X and Y direction is achieved by using the adjusting knobs on the end of the holder for X and on the front of the machine for Y.
The right side of the holder is spring loaded to hold the
PCB securely.
D. Emergency Off Switch In case an emergency shut down is necessary, press
this button. E. Mouse Used to enter information into software. F. Keyboard Used to enter information into software.
G. Reflow Head Contains the top-side heater and moves up and down
via an electric motor that is controlled through the
software. The reflow head is clutched to prevent
excessive downward force from being applied.
H. Sensor Input The sensor inputs are K-type thermo-couples.
Measured temperatures are displayed through the PC software in real time for use in making profile graphs.
G. Optics Housing Contains the camera and beam splitter (prism). The
housing is retractable and should be kept in the retracted
position when not in use. The lights for the optics will
turn on/off automatically when the housing is
extended/retracted.
J. Bottom Side Heater Used to warm the PCB from the underside. It is an IR
type heating source.
K. On / Off Switch Used to turn the system on or off. When turning off the
system, always turn off the PC using the Windows
interface first. L. Computer Brain of the system. Contains the TF 2500 software.
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System Operations Manual
3. Safety Information
a. Do not contact the Heater or its peripheral parts during operation. b. Once turned off, let the unit cool completely before contacting. c. When using fluxes, use fume extraction equipment or use in a well-ventilated
area to minimize operator exposure to fumes. d. Do not use near combustible vapors. e. Do not leave the equipment unattended when in use. f. Do not open rear panel without disconnecting power cable. g. Do not lift or lean on PCB holder rails.
4. Features
a. The TF 2500 is ideal for post assembly rework, repair, and low volume/short run
production operations. The TF 2500 can remove and install PBGAs, CSPs, FCs,
LGAs, LCC’s and other SMDs. b. Featuring unparalleled thermal performance, the TF 2500’s flexibility and state of
the art process software means no other system is easier to use. The TF 2500 is
a PC driven, semi-automated system that requires a Pentium ® 4 PC featuring
Windows XP® Professional Operating System. The unique standard software
package offers much more than just an operator interface. TF 2500’s advanced
vision and placement system is highly accurate and can quickly magnify even the
smallest components for easy alignment. TF 2500 uses a combination of
convective top heating coupled with powerful IR bottom heating for an effective,
repeatable heating process. c. Economical and easy to use, the TF2500 Rework System delivers high-end
BGA/CSP functionality, moving far beyond expensive, bulky rework machines by
offering unparalleled performance at an affordable price. d. REFLOW FUNCTION
e. ALIGNMENT AND PLACEMENT FUNCTION
i. Unequalled programmability and process control ensures successful,
repeatable installations.
ii. The powerful and responsive 1200 Watt top heater, with closed loop
temperature control, coupled with proven TF 1500 nozzle design ensures uniform temperature distribution when heating.
iii. High power bottom heaters allow for successful and repeatable reflow at
safe, low temperatures.
iv. Profiles are programmed through the PC software.
v. Creating the perfect profile is easy with real time adjustment of profile
parameters through the PC.
vi. Store and recall an infinite number of profiles.
vii. Two pre-defined profiles for use as baselines when developing custom
profiles are included.
viii. Self contained, no external air supply or vacuum connections required.
Can also be used with N
from external source.
2
ix. Semi-automated, motorized reflow head.
x. Four thermo-couple sensor inputs ensure successful profile development
and monitoring.
xi. External fan to cool PCB and component to below solder melt
temperatures after reflow.
i. The component is held by a precision vacuum placement pick, which is
located within the heater assembly.
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ii. High resolution Dual Color Vision Overlay System (VOS) with color
the back o
500
iii. Color Camera with 300x zoom capability, featuring auto-focus zoom. iv. Lighting system uses “Ultra Bright” Red and Blue LEDs for maximum
v. Independent lighting controls for component and PCB to maximize
vi. Retractable optics housing protects VOS from dirt and contamination.
vii. Precise micrometer adjustment for X, and Y axis with Theta adjustment
viii. High-flow vacuum pick holds component securely.
ix. Images are viewed through the PC in standard or full screen viewing
f. PRE-HEAT FUNCTION AND BOARD HOLDER
i. Fully adjustable, precision, spring loaded board holder with top or bottom
ii. Rugged, stable board platform to hold and support the PCB.
iii. Unique board holding fixtures that are able to hold very small and odd iv. Board supports are standard with the system.
v. Integrated, powerful, IR pre-heater with closed loop temperature control
5. Set-Up
a. System Connections
i. Monitor
ii. Keyboard – connect cable to computer. iii. Mouse – connect cable to computer. iv. Connect cables between PC and back of TF 2500 according to labels.
v. Connect video cable (3 wire - 1 S video and 2 BNC terminations) to PC vi. Connect power cords to TF 2500 and PC.
b. Start up
i. Verify the on circuit breaker on back of unit is in the “ON” position.
ii. Verify Emergency Stop (Big Red Button on Front of Unit) is not engaged. iii. Turn on power switch
iv. Turn on computer.
v. Turn on monitor. vi. Mouse click on TF 2500
vii. Read and accept
viii. The TF 2500 comes
System Operations Manual
camera and dichroic prism. VOS does not require routine calibration, eliminating costly downtime and operator frustration.
contrast of lands and solder balls on component. overlay contrast.
ensures placement accuracy.
options.
PCB registration. Precise micrometer adjustment for X and Y adjustment ensures placement accuracy for repeatability.
shaped PCBs.
ensures process integrity by delivering heat evenly, time after time.
1. Connect power cord.
2. Connect video cable to the 9-pin connector on the Frame Grabber Card.
and connect the S video cable to S-video output on TF 2500.
Turn to release. on front of system.
System will beep.
External Air/Gas Connection
icon. license. configured for use with
the internal pump and
Figure 2: External Air/Gas supply on
f TF 2
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System Operations Manual
can be configured to use an external air/gas (N
) source. Go to the set-
2
up page in the software to select the desired air source (internal pump or external N
).
2
Warning: Do not run unit in N
turned on. (Figure 2) N
2
mode unless N2 supply is connected and
2
must be regulated down to 15 PSI before
connecting to TF 2500.
c. Inserting/changing vacuum pick.
i. Insert proper size vacuum pick. The diameter needs to be smaller than
the top of the component. The pick screws into place. (Figure 3a)
Vacuum Pick
Figure 3a
d. Inserting/changing nozzle. (Figure 3b)
i. Insert proper size nozzle. The nozzle should be 3 mm larger than the
outside of the component. If the proper nozzle size cannot fit onto the PCB due to adjacent components being to close, use a smaller nozzle
Retention Screw
or keep the nozzle approximately 1mm above the part. Align the nozzle under the square hole in the
Handle
reflow head. The nozzle snaps into place. If you have a component that
Nozzle
is at a placed on the PCB at an angle, the nozzle can be rotated by loosening the retention screw and turning the handle to the proper position. To rotate the nozzle, first loosen
Figure 3b
the retention screw in front of the housing.
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System Operations Manual
e. Set up screen features. (Figure 4)
Figure 4
i. Set Password. Setup and profile settings can be password protected.
ii. Set Language. Software text language can be changed. iii. Set temperature for Celsius or Fahrenheit. iv. Set black temperature reference lines on the profile graph.
v. Set setback time. Machine will go into setback after selected idle time.
Setback reduces heater temperatures during extended idle times to extend heater life.
vi. Set auto shutoff time. Machine will completely shut down after selected
idle time.
vii. Set the Air Source. Air or Nitrogen
viii. Program folders. Shows drive locations.
ix. Inspection sources.
x. Tech support number. xi. Initiate prism calibration sequence. Further explanation is in par. 5j.
xii. Initiate heater arm sensor test. Checks proper orientation and operation
of heater arm position sensors.
xiii. Initiate camera sensor test. Checks proper orientation and operation of
camera position sensor.
xiv. Initiate pick sensor test. Checks proper orientation and operation of pick
position sensor.
xv. Blower test. Checks operation of heater blower.
Cooling fan test. Checks operation of cooling fan. Vacuum pump test. Tests operation of vacuum pump.
xvi. Thermocouple test. Tests active thermocouple circuitry.
xvii. Shows error codes.
xviii. Resets Diagnostic tests.
xix. Run the activity log.
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System Operations Manual
f. Alignment Screen Features (Figure 5)
Figure 5
i. Full Screen. Click on here to view image full screen.
ii. Flip Image. Allows operator to flip the image horizontally or vertically. iii. Component/PCB alignment image. Proper alignment is viewed here
showing the PCB pads (blue) directly under the component pads (red).
iv. Zoom bar. The image can be zoomed in or out using this bar.
v. Focus bar. The image can be manually focused using the slider on this
bar or it can be automatically focused by checking the box by “auto.”
vi. Instructions. Follow these instructions to proceed through the alignment
sequence.
vii. Screen options.
1. Edit – Change Instructions.
2. Load – Loads saved profile.
3. Save – Saves changes made to instructions.
4. Reset – Returns to factory set instructions.
viii. Nozzle step adjustment. If component (red) cannot be aligned to PCB
(blue) or you cannot focus, adjust nozzle height up or down with this option until better alignment or focus is achieved.
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System Operations Manual
g. Production Screen Features (Figure 6)
Figure 6
i. Profile Name. Indicates currently selected profile. A new profile can be
selected from a list of saved profiles by clicking on the arrow.
ii. Record Manager. Temperature and time setting entered by the
developer can be viewed here. (Fig. 6a)
iii. Graph. A saved graph and, if thermocouples are used, an active trace
graph are viewed here.
iv. Fan On/Off Selector. Manual on/off switch for the cooling fan.
v. Status Bar.
1. System status – shows if system is “normal,” in “setback” or “shutdown.”
2. Heater status – Shows “ready” if bottom heater is in range. Shows “not ready” if bottom heater is not in range. The software will not continue until it is in “ready” status.
vi. Nozzle Step Indicator. Indicates how many steps the nozzle will lower to
properly position itself for operation.
vii. Abort Button. Click at any time to abort the process and return to the
beginning.
viii. Sequencing Button. Click here to proceed to next step in the operation.
ix. Pre-Heater indicator. Indicates which pre-heater is on and the current
temperature.
x. Sensor indicators. Real-time sensor readings can be viewed here if
thermocouples are used.
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System Operations Manual
h. Production Mode Record Manager Features (Figure 6a)
The record manager allows for a “record” of each individual reflow to be saved on the PC in a Portable Document Format (PDF) file format. The “Record” saves all profile information as well as a text field for the technicians comments (such as PCB or component ID #s) and a graph of the specific reflow cycle.
Figure 6a
i. Record Name. Indicates currently selected profile.
ii. Operator Comments. Comments made by profile developer will be
shown here.
iii. Graph. A saved graph and, if thermocouples are used, an active trace
graph are viewed here.
iv. File Management Options. Only “open record” will be active allowing the
operator to select profiles created by the developer. Once a profile is run, all of the file management buttons will become active. The “PDF Report” button created a (PDF) file of the record on the PC hard drive and the “Export Record” button creates a Comma Separated Value (CSV) file that can be opened by any standard spreadsheet software.
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i. Profile Development Screen Features (Figure 7)
System Operations Manual
Figure 7
i. Profile Name. Indicates currently selected profile.
ii. Clear Selected Trials. Only 3 trails can be viewed at a time.
iii. Graph. A saved graph and, if thermocouples are used, an active trace
graph are viewed here. Also, profile parameters can be adjusted by clicking and dragging the colored bars. Red = top heater, Orange = primary bottom heater, Yellow = secondary bottom heaters, Blue = Airflow, and Purple = time.
iv. Fan On/Off Selector. Manual on/off switch for the cooling fan.
v. Status Bar.
1. System status – shows if system is “normal,” in “setback” or “shutdown.”
2. Heater status – Shows “ready” if bottom heater is in range. Shows “not ready” if bottom heater is not in range. The software will not continue until it is in “ready” status.
vi. Nozzle Step Indicator. Indicates how many steps the nozzle will lower to
properly position itself for operation.
vii. Abort Button. Click at any time to abort the process and return to the
beginning.
viii. Sequencing Button. Click here to proceed to next step in the operation.
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System Operations Manual
ix. Pre-Heater indicator. Indicates which pre-heater is on and the current
temperature. To turn on or off individual secondary preheaters click on the graphic. While individual secondary preheaters can be turned on and off, they must all be set at the same temperature. They can be adjusted by dragging the yellow lines on the graph or through the profile manager.
x. Sensor indicators. Real-time sensor readings can be viewed here if
thermocouples are used.
xi. Profile Manager. Temperature and time setting entered by the developer
can be viewed here. (Fig. 7a)
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