SHENZHEN ZHUOMAO TECHNOLOGY CO., LTD.

BGA Rework Station ZM-R5860C Instruction Manual

Address: Building A, Donghua Industrial Park, Sanwei, Xixiang, BaoAn, Shenzhen TEL: 0755-29929955 29929956 Http: //www.szzhuomao.com FAX: 0755-29929953 E-mail: [email protected]

Contents
A. Preface .......................................................................................2 B. Structures....................................................................................3 C. Specifications ............................................................................4 D. Operations..................................................................................5 E. Installation................................................................................12 F. Packing list................................................................................13

A. Preface
Shenzhen ZhuoMao Hi-tech Co., Ltd. is a high-technology company located in the western district of BaoAn. Thanks to its proximity to the international airport and container terminal, this part of the booming industrial city of Shenzhen is rich in modern business opportunities. BGA repair turnkey solutions are the heart of ZhuoMao activities. A strong R&D team supports a dynamic workforce of over fifty people. A well established sales network and after-sales service has built ZhuoMao a strong reputation in China among high profile customers. The main products of ZhuoMao are BGA Rework Station and some other devices (BGA Mounting, BGA Reballing Machine, and BGA Soldering Machine), BGA Testing Machine (main board testing, video card testing, digital camera testing, and mobile chip testing) Devoted to put in practice the motto Specialized, Innovative and Dedicated, the company is focused on its customers satisfaction and has set up a network of local offices to tailor its offer to an expanding market. Developing new solutions to help customers tackle issues always more diverse and complex keeps ZhuoMao engineering teams to the forefront of the technology and rewards its products with the most prestigious awards and recognition in China and abroad. Because ZhuoMao understands BGA repair is a critical activity needing speed, accuracy and user-friendliness, its machines are designed for you to REGAIN SATISFACTION.
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B. Structures

C. Specifications

Specifications Power supply Total power Top Heater Bottom Heater IR Temperature control

Description
Single phase AC220V10 50/60Hz

4.8KW Hot Air: Hot Air: 0. 8K W 1.2KW others: 0.1KW

Infrared plates: 2.7K W Imported

K-type thermocouple (Closed Loop)

Heating independent, the precision is 3-5C

Electric material: PLC programmable controller + Large-screen TFT Touch Screen+high precision intelligent

temperature control module

PCB size Positioning Power required Machine dimensions Weight color

Max: 410x370 mm

Min: 22x22 mm

V-type PCB clamping | 10~20 m X-Y table adjust. Single Phase AC 220 V (10%) | 50 Hz | 5.2 kW L630mm W650mm H690mm 40 kg black

D. Operations
1. Set the program.
a. Turn on the electric power supply of the whole machine. The following image will appear on the touch-screen. (The original password is 8888)

b. Click Ent.

c. Click Setting, and then Temp. setting.

d. Input the proper temperature parameters.

Introduction of the interface (take the above one for example): Preheat : The temperature of upper and lower heater rises from room temperature to 165 in 30s at a speed of 3 /s (the slope). Keep warm: The temperature of upper and lower heater rises 165 to 195 in 30s at a speed of 3 /s (the slope). CalefactiveThe temperature of upper and lower heater rises 195 to 225 in 30s at a speed of 3 /s ( the slope). Jointing: The temperature of upper heater rises 225 to 245 in 45s at a speed of 3 /s (the slope). The temperature of lower heater rises 215 to 230 in 45s at a speed of 3 /s (the slope). And so forth Alarm time: the time of the alarming. Alarm in advance: the time between finishing the heating process and starting alarming. Cool time: the time the cross-flow fan works.

The following are the temperatures for reference

Lead BGA temperature curve welding 1. Upper temperature curve adjustment, nozzle 41*41. Press SET to adjust. r1:3.00 r2:3.00 r3:3.00 r4:3.00 r5:3.00 3. L1:160 L2:185 L3:230 L4:240 L5:225 d1:30 d2:30 d3:45 d4:25 d5:25 4. 2. Upper temperature curve adjustment, nozzle 38*38. Press SET to adjust. r1:3.00 r2:3.00 r3:3.00 r4:3.00 r5:3.00 L1:160 L2:185 L3:225 L4:240 L5:225 d1:30 d2:30 d3:45 d4:25 d5:25

Upper temperature curve adjustment, nozzle 31*31. Press SET to adjust. r1:3.00 r2:3.00 r3:3.00 r4:3.00 r5:3.00 L1:160 L2:185 L3:210 L4:225 L5:205 d1:30 d2:30 d3:45 d4:20 d5:25

Third temperature zone adjustment.Press SET for 5 seconds to adjust. r1:2.00 r2:2.00 r3:2.00 L1:135 L2:165 L3:185 d1:30 d2:45 d3:240

Lead-free BGA temperature curve welding 1. Upper temperature curve adjustment, nozzle 41*41. Press SET to adjust. r1:3.00 r2:3.00 r3:3.00 r4:3.00 L1:165 L2:200 L3:245 L4:255 d1:30 d2:30 d3:50 d4:35
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2.

Upper temperature curve adjustment, nozzle 38*38. Press SET to adjust. r1:3.00 r2:3.00 r3:3.00 r4:3.00 L1:165 L2:195 L3:240 L4:250 d1:30 d2:35 d3:45 d4:25

r5:3.00 3.

L5:235

d5:25 4.

r5:3.00

L5:230

d5:25

Upper temperature curve adjustment, nozzle 31*31. Press SET to adjust. r1:3.00 r2:3.00 r3:3.00 r4:3.00 r5:3.00 L1:165 L2:190 L3:235 L4:245 L5:225 d1:30 d2:30 d3:45 d4:20 d5:25

Third temperature zone adjustment.Press SET for 5 seconds to adjust. r1:2.00 r2:2.00 r3:2.00 r4:2.00 L1:135 L2:165 L3:185 L3:210 d1:30 d2:45 d3:40 d3:240

No.: Click the number before Group, input the number you want to name it by.

Name: Click Name, the input interface of name will appear, and you can set the name. Click ENT to the set interface.

If you want to name with number, you can click Del and Alt.

2. Operation
a. Turn on the power supply of the machine, and click Operation.

b. Click Setting and Temp. setting.

c. Choose the right group of temperature profile.

d. If you want to work with the 2nd group, click DSP The 2nd group of settting will appear, then click Back.

e. Then the following interface will appear on the screen.

f. Fix the proper PCB and BGA as shown in the picture. Move the heater down to above the BGA, keeping a distance of 3-5mm between the bottom edge of the nozzle and the surface of BGA, as shown in the following picture. When the solder process is finished, there will be an alarming.

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E. Installation
In order to ensure the validity of BGA Rework Station, the installation should meet the following requirements. 1. Away from inflammable and explosives; 2. Away from water and other liquids; 3. Ventilated, dry place; 4. Stable and flat, free from tremor. 5. Less dust; 6. No heavy objects on the controlling box; 7. Not affected by airflow of air conditioner, heater or ventilator. 8. Leave a space of 30cm or more behind the rework station for the upper part to move and rotate. 9. Because the machine is equipped with a touch screen it must be put on the big platform to make sure it will never move from side to side.

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F. Packing list

NO. 1 2 3 4 5 6 7 8

Item BGA Rework Station Vacuum sucker Hot-air nozzle Temperature sensor Supporting screw Instruction manual Fixture Brush

Specification ZM-R5860C

Unit SET PCS PCS PCS PCS

Qty 1 2 5 1 6 1 6 1

ZM-R5860C

Copy PCS PCS

5th The use of external measuring galvanic

1 Function
1More accurate to measure the actual temperature of the part to be heated during the welding process.

2It is easy to move, so that it can be convenient to measure the temperature of the different parts of
the welded components during the heating process.

3 Calibration role, through appropriate adjustment, it will make the temperature of the welding parts get
close to the set temperature as much as possible.

2 Installation
1Check the galvanic lines, whether there are disconnected phenomena or not.

2Insert the galvanic Plug into the "outer galvanic Socket on the control panel according to the positive
and negative mark.

3After

GALVANIC installed correctly, click "DiSP SELE" button on the upper instrument panel, (the

button which is used to switch the displaying item), switch to "TIME", the corresponding galvanic current temperature will be displayed in the second line of instrumentation on the "SV" display window.

Stated: "DiSP SELE" is the button to switch the displaying items, when press it, the downstream sequence
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of display windows display setting no., output no., the remainder of the number of segments of running, corresponding to Panel "SV", "MV", "TIME "indicator light.

3 measurement
1PCB board will be installed on the rework station, with the galvanic fixed on the PCB board using foil
stickers.

2Adjust the height of the probe; With the probe galvanic head located in the top 1-2mm of the test site
(as shown in Figure 12)

Picture 29
(as shown in Figure 13)

Picture 30

3Adjust the related mechanical adjustment knob, so that the heating part just below the hot-air tube. 4Adjust the up and down adjustment knob of the hot-air head to make the distance between the edge
of PCB board side and the hot-air head is 3-5mm.

5Implementation of the welding / disordering process, that is to start the process of upper and lower
heater.

6Then
(picture )

it will show three curves of the green and red and yellow on the computer monitor screen

7Curve 1, the actual measurement temperature of the internal galvanic of the top heater (green) 8Curve 2, the actual measurement temperature of the external galvanic curve (red)
9Curve 3, the actual measurement temperature of the internal galvanic of the bottom heater (yellow)

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Picture 31

4Using the outer galvanic to adjust the temperature curve

Statement: In this operation, it may be due to improper operation to cause the temperature deviation of the device or even lose control, please caution! Take the upper hot-air tube as an example to make detailed description of adjustment method

1Set the temperature, the time, the slope and so on parameters of the upper heater

2Adjustment process proposed to do on a waste circuit board in order to prevent damage to the circuit
board and on-board electronic components.

3Implementation of the above process (3), installed the outer measured galvanic, in which the top of
the PCB board just below the hot-air tube.

4Close the lower part of the heating process, click on "Start" button to start the heating process, which
will on the computer monitor screen will be displayed on the upper curve of the measured temperature (green) and external galvanic measuring temperature (red) the two curves

5Green

curves represent the actual measurement of the galvanic temperature curve of the upper

heating wire inside, the red curve represents the actual measurement of the galvanic temperature outside. the smaller the gap between the green curve and red curve, the closer between the actual temperature and set temperature of the heating parts, more standard of the upper heating process; On the contrary, the greater the gap between the two curves, the greater the actual temperature deviate from the set temperature, the more non-standard of the upper part during the heating process.

6If the deviation between the two curves is too much, you should make the appropriate adjustments 7The specific adjustment method is as follows, because of the impact of the system processes and the
environmental, deviations in the objective is inevitable. If the temperature deviation does not affect the normal welding and desordering, non-professionals should avoid the following corrective actions!

A B

If the outer galvanic curve (red) lower than the upper one (green), adjust the internal hairdryer galvanic probe upward; If the outer galvanic curve (red) higher than the upper one (green), adjust the internal hairdryer galvanic probe downward;

C Adjustment must be small, try to control the amplitude of accommodation in 1mm or less; D Repeated several adjustments; E During adjustment process, the heated of galvanic probe is strictly prohibited from contacting
with any objects, so as not to affect the accuracy of measuring temperature;

After temperature adjustment, you should fix the probe, to avoid the probe vibration

measurement of the temperature of the equipment

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G H

The method of the adjustment applies only to the two parallel curves in a smooth uniform

deviation, and it is invalid to the temperature which is from top to bottom jitter free-laws regulating! The upper part of the internal galvanic Duct location: Remove the upper heater nozzle, at a

distance of 2-3cm at the edge wind-cone .

i operating the standard procedure to avoid the high-temperature burns! 8There is no booster thermocouple temperature curve on the bottom of the computer screen, so you
have to adjust the process of the lower part of the heaters by visual.

9fixed the galvanic line with foil stickers on the bottom of PCB board (as opposed to the upper heater
set back on the PCB board), so that the probe of the booster thermocouple is located just 2mm above the mouth of the bottom hot-air nozzle, and adjust the mechanical parts, make the upper hot-air nozzle deviate from the heated parts to avoid cold air affect the temperature of the heated parts.

10Set the parameters of the lower heating temperature, while closing the upper part of the heating
process, click on "Start" button to start heating

11Now you can see "SV which displayed on the panel of the upper programmable thermostat (also
click on the "DiSP SELE" button of the upper instrument panel, and switch to the position of the "TIME" indicator light) is the temperature of the external galvanic, with the abbreviation as the outer temperature; And PV is the temperature of the internal galvanic, with the abbreviation as the bottom temperature.

12The caution is same as the top heater. 13The methods of adjustment: A If the outer temperature is lower than the bottom, you should adjust the lower internal galvanic
probe downward.

B If the outer temperature is higher than the bottom; you should adjust the lower internal galvanic
probe upward.

6th Reballing Process

1. Fixed the BGA chip which need to be reballed on the under plate of the adjustable reballing kit, and then adjust the No-spring slider to fix the chip.

2. Choose the stencil according to the style of chip, then fix the stencil on
the top cover of the adjustable reballing kit and lock the four M3 screws, cover the cap. Adjust the four screws of the under plate to fit for the height of the chip.

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3. Check the alignment of the hole of the stencil and the welding spot of the chip, if it is in
misalignment, then remove the cover and adjust the fixed slider until it is in alignment.

4. Lock the fixed slider of the two no-spring slider, take out the BGA chip
and wipe a layer of solder paste, fixed the chip on the adjustable reballing kit again, cover the cap.

5. Put some solder balls into the kit, clutch and shake it to make all the balls stand on the welding spot, and at the same time, clear the superabundant balls.

6. Put the reballing kit on the desk, take out the top cover, and bring out the
BGA cheap carefully, and check it whether there are some balls on the wrong place or not, if it is, then make it right with tweezers.

7. The way of making the balls fixed is using the Reballing machine; it can heat the cheap medially. Up to now, we finished reballing.

7th Maintenance
1Upper heater(Pictured)

1. The replacement of fan:

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Remove the heater cover, and remove the insulation fiber block, then you can replace the fan.

2. The replacement of heating wire

Remove the heater cover the insulation fiber block and fan, remove the upper fixed block, then take out the hot wire. Then it can be replaced.

Bottom heater (as pictured)

heating tube heating coil fixer heating coil fixer wind ring fan fixer 6025 fan fan cover

The lower (second temperature zone) heating wire replacement (as pictured)
1 remove the fixed screw, take out the fan cover; 2 remove the 6025 fan 3 remove the fan fixer 4 remove the wind ring 5 remove the heating coil

3The bottom heating panel (pictured)

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heating pad lock screw fixed plate heating panel card heating box

Replacement of heating plate:

1. Demolition of locking screws (4), remove the heating plate and the assembly of the fixed plate,
placed on the table which is covered with a sponge (with heating plate surface facing down).

2. Removed the fixed heating plate card, you can break down the fixed plate and heating
assembly, remove the heating plate then it can be replaced.

plate

8th Safety Precautions The power supply of ZM-R6820G is AC220V,the temperature can arrive to 400.If
you do not operate inappropriately, it will cause damaging to the machine or even to the operator. So you must strictly abide by the following matters: 1. Don't blow to the rework station directly when it is working, or there will be a negative difference from the surface of the heating board, thus some parts will be burnt out. 2. After it is started, the high temperature area should not touch any objects, or it will lead to a fire or explosion. The PCB and other parts should be put on the PCB bracket. 3. No vibration. Handle it gently. 4. Don't touch the heaters with your hands when it is working, or you will get hurt. 5. Don't use combustible spray, liquefied and flammable gas near the rework station after it
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is started. 6. Don't try to re-equip the machine, or there may be a fire or an electric shock. 7. There are high-pressure parts in the circuit box. Don't disassemble it. 8. If some metals fall in the rework station when it is working, turn off the power immediately. After it is cooled down, get the metal out, and clean the machine. If not, there may a smell when the machine starts working next time. 9. When the rework station's temperature rises abnormally or smokes, turn off the power and inform the service technicians to repair it. Turn off the power of the circuit box and the machine while moving the rework station. Hold the plug when we remove the wire or it will lead to a poor contact then the machine can't work very well. 10. Turn off the power when stop using it. 11. Don't put the rework station on the wires, or there may be a failure, a fire, or an electric shock. 12. Before you use the machine, you must read the instructions attentively. Note: when the machine works, it will produce some smell. So ensure the comfortable, healthy and safe operation environment, please keep the air in circulation.

Under the following case, if it causes any damage, it will not in our guarantee;
1Do not operate according to the condition of the environment and methods of operation that the manual book required; 2The reason out of our product; 3Not the transformation and maintenance of our company; 4Do not operate accordance with the way of use that our company's products required; 5The case that the temporal level of scientific and technological of our company was impossible to predict; 6Natural disasters or man-made destruction and such non-responsibility of the Company premises, it will not in guarantee.

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Normal BGA welding and disordering parameters

for reference The temperature curve of lead welding
41*41 the temperature setting of the BGA welding preheating insulation upper time bottom time slope IR 38*38 160 30 160 30 30 180 185 30 185 30 30 heating 210 35 210 35 30 welding1 welding2 235 40 235 40 30 240 20 240 20 30 cooling 225 15 225 15 30

the temperature setting of the BGA welding

preheating insulation upper time bottom time slope IR 160 30 160 30 30 185 185 30 185 30 30

heating 210 35 210 35 30

welding1 welding2 225 40 225 40 30 235 20 235 20 30

cooling 215 15 215 15 30

31*31

the temperature setting of the BGA welding

preheating insulation heating 200 35 200 35 30 welding1 welding2 215 40 215 40 30 225 20 225 20 30 cooling 215 15 215 15 30

upper time bottom time slope IR

160 30 160 30 30 180

180 30 180 30 30

The upper is the reference temperature of the lead BGA

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The temperature curve of Lead-free welding 41*41 the temperature setting of the BGA welding
preheating insulation upper time bottom time slope IR 165 30 165 30 30 210 190 30 190 30 30 heating 225 35 225 35 30 welding1 welding2 245 55 245 55 30 255 25 255 25 30 cooling 240 15 240 15 30

38*38

the temperature setting of the BGA welding

preheating insulation upper time bottom time slope IR 165 30 165 30 30 210 190 30 190 30 30

heating 225 35 225 35 30

welding1 welding2 245 45 245 45 30 250 25 250 25 30

cooling 235 15 235 15 30

31*31

the temperature setting of the BGA welding

preheating insulation heating 220 35 220 35 30 welding1 welding2 240 40 240 40 30 245 20 245 20 30 cooling 235 15 235 15 30

upper time bottom time slope IR

165 30 165 30 30 210

190 30 190 30 30

The upper is the reference temperature of the lead-free BGA. Such as set 0 when the demolition of the cooling section of BGA.

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