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Summary of Contents for PDR X410
- Page 1 PDR IR REWORK SYSTEMS OPERATORS MANUAL SOFTWARE CONTROLLED SYSTEMS X410/XT3/XT5/D2/D3/D35/E2/E3/E6 www.pdr-rework.com version : 2.01...
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Page 3: Worldwide Technical Support
This product was manufactured by PDR, UK and is supplied by a worldwide network of professional distributors who provide a full range of sales, local service and support services. For latest information on Technical Support, new products, upgrades or who to call for assistance contact us at PDR Europe, Asia, Africa, Middle-East and South America – PDR Email: support@pdr.co.uk... - Page 4 Safety Health and Safety at Work It is vital that PDR users familiarise themselves with the requirements of local health and safety legislation prior to using the system. Warnings and Cautions For the purposes of this manual a warning refers to a danger of injury to the operator whereas a caution refers to a danger of damage to the equipment.
- Page 5 PDR Focused IR Safety Statement Extensive tests have been conducted covering both Electrical and Infra-Red safety aspects on all of PDR's products. The IR tests were administered in 1986 by a National Physical Laboratory approved establishment: ERA based at Leatherhead, Surrey, England.
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Page 6: Installation
Installation This section is not intended to be a step by step guide to installing the PDR, the systems are complicated instruments and need to be installed by PDR approved technicians, however, this section includes key points to consider before commencing installation. - Page 7 Quartz IR PCB Preheater Advanced Software Control Precision XY PCB Table www.pdr-rework.com...
- Page 8 Professional Installation - The PDR System is a sophisticated instrument and should always be installed by personnel trained by PDR, or by a PDR Distributor. All PDR systems are robust and forgiving but installing them incorrectly will result in a loss of performance and dissatisfaction with the products.
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Page 9: Reference Information
Understanding and Using the PDR Rework system This section has 4 main parts Reference Information – The Science in SMT Rework Principles of Operation Control and Settings Operating Procedures – Preparation, Soldering and Desoldering Reference Information... - Page 10 0.5-1.5°C/second or less. This will minimize the potential for thermal shock on the components due to varying heat capacities. The preheat zone also begins the volatilization of some of the solvents added to the cream for printing and releasing. www.pdr-rework.com...
- Page 11 Consideration of the basic science is vital. As well as the method of heating, it is as important to conduct extensive research, testing to get the ability to control a process in a repeatable manner. www.pdr-rework.com...
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Page 12: Principles Of Operation
Principles of Operation Overview The principle of operation of the PDR IR Rework system is that whilst being heated from above and below, a single SMD is subjected to similar temperature/time profile during rework, as it experiences during reflow in the original production process. - Page 13 Principles of Operation (continued) The PDR Rework system is designed for rework single/double sided and mixed technology PCB assemblies. The top heat/component heating is derived from a 150 Watt short wave IR lamp focused through a lens system. The bottom heat/PCB preheater delivers 750-3000 Watts medium wave IR.
- Page 14 The 150 Watt Infra-Red (IR) Lamp is located in the lamp housing at the top of the unit. The lamp emits short wave IR radiation at approximately 1.0um Upper Lens Assembly The purpose of the upper lens assembly is to collimate the radiation from the IR Lamp into a formatted beam before projection through the iris assembly. www.pdr-rework.com...
- Page 15 (Note: To use PCB Preheat/backheat T/C #2 must be plugged into its socket even if it is not used. If it is not plugged in the controller will sense a sensor ‘break’ and will switch off the backheater) www.pdr-rework.com...
- Page 16 Control System The PDR Rework systems use the PDR T5 controllers which are PC controlled using PDR software. The main PDR Type 5 control box is used to provide electrical power to the various functions…top heat, back heat, vacuum, thermocouple inputs etc.
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Page 17: Control And Settings
Control and Settings The PDR Rework System is controlled by PDR ThermoActive V4 or V5 software. This section illustrates different screens and features. There are 3 main screens (Run Mode, Settings and Logging). There are two channels used for control - T/C#1 for component temperature, T/C#2 for PCB temperature. - Page 18 The file name = the profile = component type, ident, location etc. Folder Name = Topline 967001 (PCB ident) File name = BGA 225-U1-F700-01.lmd Starting and Stopping ‘Start’ begins the cycle. ‘Stop’ stops the cycle. Vacuum and Align Turn Align On/Off www.pdr-rework.com...
- Page 19 PDR ThermoActive V4.03/V5+ - Control Settings Auto Profiling Software The general principle of the PDR V4/V5 software is that there is a component/PCB temperature target ‘glide-slope’ and the system will use thermocouple information to control the process as desired. There are 3 modes to choose from to use the software: ...
- Page 20 PCBs. Profiles that you develop will probably not vary very much from original defaults and they generate better understanding of reworking with the PDR Rework system. For more detailed technical information contact your PDR representative for help.
- Page 21 Allows PCB Preheaters to stay warm during standby. Normally set to 5 – 10% Power Preferences Go here to change software skin to different colours Backheater Zone Control Switches PCB Preheater Zone 2 (outer) on or off. Selected/checked = on www.pdr-rework.com...
- Page 22 Summary The information in this section helps give you a very basic explanation of the system. To use the system see the next sections of ‘Operating Procedures’. www.pdr-rework.com...
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Page 23: Operating Procedures
Switch on and warm up The following simple procedure will warm the system up a. Switch on the PDR T5 Controller, Lightbox and PC b. Allow system to warm up - 5 to 10 minutes Selecting a Profile to use The following simple procedure will get you started, a. - Page 24 www.pdr-rework.com...
- Page 25 T/C 2 – A contact K-type T/C or an optional IR non-contact thermocouple - T/C 2 is attached to/aimed at the PCB about 25-50mm away from component and is used to display/control the PCB temperature. www.pdr-rework.com version : 2.01...
- Page 26 It is vital to use correct materials for successful rework. We use two types, a low solids liquid flux for general rework and a gel/paste flux for QFP/BGA rework. The above tools/fluxes are available from PDR separately, or as a BGA Rework Start-Up Kit and SMT/BGA Flux Kit. www.pdr-rework.com...
- Page 27 The procedure while preparing to rework SMT/BGA components is as follows, Switch on and warm up Select settings or 'profile' required for PCB/component Sort, aim and attach thermocouples Select lens attachment and set lens height + spotsize Sort tools and fluxes required www.pdr-rework.com...
- Page 28 The procedure for aligning and placing a BGA with the BGA alignment system is as follows: 1. (X410 0nly) lock pick-up and vision arms (using the black locking levers at the rear of the arms) before alignment and placement.
- Page 29 4. Adjustments done, now retract/move Prism out of the way, to the left. Now carefully place component onto fluxed pads. Next, move the Pick-up up and out of the way. Finally position/move the IR Lens system into position ready for reflow. www.pdr-rework.com...
- Page 30 Reflow - The Rework Procedures These procedures are quite simple really, the final actions to use the PDR Rework system but take for granted that all other parameters have been successfully taken care of. To solder or de-solder, the procedures are as follows, Soldering a BGA ...
- Page 31 Standby and Shutdown The PDR Rework system is a heating system and therefore it could be very hot in places after use. Be careful to not allow anything to be placed on the PCB Preheater/backheater. Never leave a PCB in the PCB jaws during stand ...
- Page 32 The IR lamp may be changed by the following procedure: Ensure that the equipment is switched off and mains cable is removed from the mains supply. Slacken the small screw securing the lamp housing to the lens unit. Lift off housing. www.pdr-rework.com...
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Page 33: Calibration Procedures
Thermocouple inputs - use a thermocouple simulator to input known temperatures (100°C and 200°C) and check readings are within +/- 2°C. The PDR Rework system uses software - calibration adjustments can be made there - see settings screen, thermocouples. - Page 34 Bearings - PDR use mostly THK linear bearings of the highest quality and our experience shows bearings will last the life of the system. We have 15 year old systems coming back to PDR for servicing with bearings responding well to light cleaning (with dry cloth) to remove any flux residues or dirt.
- Page 35 There should be no flux residue on this assembly but if there is, moisten the cloth with IPA alcohol to carefully remove any residue. Calibrate as follows: 1. Place ‘Prism alignment plate’ in PCB jaws 2. with pick-up and vision arms locked, pick up top alignment plate 3. Lift plate to top of pick-up z-axis travel www.pdr-rework.com...
- Page 36 5. Look at the CCTV monitor. X-axis is out (below left) and Y-axis is out 6. Physically adjust the prism assembly to correct the errors. Unlock and adjust (A) to correct X-axis error and unlock (B) and rotate prism body to correct Y-axis error www.pdr-rework.com...
- Page 37 So every month a quick check will ensure it is calibrated. If in use components are being placed off centre the prism assembly may need calibration. Remember always lock pick-up and vision arms (using the black locking levers at the rear of the arms) before calibration is carried out and lock arms during alignment and placement. www.pdr-rework.com...
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Page 38: General Troubleshooting
Check T/C#2 is plugged in. Or, this may be caused by either blown mains or a backheater fuse. The PDR T5 controller has 2 fuses, one for each PCB preheater zone, located above the mains input socket. If any malfunction occurs with the backheater you should check these fuses. Both fuses are Anti-surge (T), 20mm type, 15A/250V. - Page 39 Warranty Period, from the date of delivery from PDR or a PDR authorised distributor until one year hence. Should this product not be in good working order PDR will, as its option, repair or replace the product at no additional charge except as set forth below: This warranty covers failure due to faulty materials or workmanship.
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