BGA/CSP 3000 Series

Rework Machine

SERVICE ENGINEERS GUIDE

NOTE: These procedures are to be followed only by fully competent persons experienced in
Electro-Mechanics. Failure to comply with this stipulation could result in personal injury.

Page 1 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
Introduction

The documents in this manual are derived from a collection of individual work
sheets, accumulated over a period of time, that detail methods of adjustment and
repair of the BGA/CSP 3000 series machines. If the particular procedure you are
after is not included please contact Technical Support at Metcal UK as other
sheets may already be available or, if not, can be written on request.

Useful contacts:

Colin Chandler Technical Services Manager

E-mail: cchandler@uk.okinternational.com DDI: +44 (0) 2380 489012

Rob James Senior Service Engineer

E-mail: rjames@uk.okinternational.com DDI: +44 (0) 2380 489014

Page 2 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
Contents

Title Page
BGA/CSP 3000 INSTALLATION CHECK SHEET 4
REPLACING HALOGEN LAMPS 5
REPLACING THE VISION ARM CONTROL PCBA 6
REPLACING THE UNDERBOARD HEATER CONTROL PCBA 7
CHANGING PREHEATER COILS 8
REPLACING THE HEATER CONTROL TRIAC 10
BGA/CSP 3000 SERIES PRE-HEATER MODIFICATIONS 11
ADJUSTING SOFTWARE UNDER-BOARD HEATER TOP LIMITS 13
CHANGING FAN CONTROL PCBA 14
CHANGING BLOWER ASSEMBLIES 15
BGA-3528/2028 HEIGHT SET 16
TO CLEAN FLUX RESIDUES FROM THE REFLOW OVEN VACUUM PIPE 17
REPLACING THE DRIVE BELT HEATER ARM 19
ADJUSTING THE Z-AXIS BELT TENSION - HEATER ARM 20
REPLACING THE DRIVE BELT AND RESETTING THE BELT TIMING VISION ARM 22
SETTING THE MICRO-PLACER THETA CONTROL 27
LENS AND MIRROR REPLACEMENT 28
XY TABLE CLAMP INSPECTION AND REPAIR. 29
CALIBRATION PROCEDURE FOR ARM ASSEMBLIES 31
SCHEMATIC DIAGRAM OF MAIN UNIT PARALLEL WIRED COILS 34
SCHEMATIC DIAGRAM OF MAIN UNIT SERIES WIRED COILS 35
SCHEMATIC DIAGRAM OF MICRO-PLACE R 36
SCHEMATIC DIAGRAM OF CONTROL BOX 37
CAMERA POWER-SUPPLY WIRING 38
TOP HEATER WIRING 39
TO BYPASS AN UNKNOWN OR LOST PASSWORD (do not show to operators ) 40
OPTICAL SYSTEM CALIBRATION ALL MACHINES 42
OPTICAL SYSTEM CALIBRATION ADDITIONAL FOR BGA MACHINES 47
VERIFICATION OF TEMPERATURE REPEATABILITY 49
EXAMPLE PROFILE REPEATABILITY TEST 50
SPARES KITS 53
NOTES PAGES FOR YOUR OWN USE 54

Page 3 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
The following procedure is used by OK International Service Engineers in the UK
and may be useful as a loose guide to OK International GMCs & Distributors:

BGA/CSP 3000 INSTALLATION CHECK SHEET

When notification received that a BGA requires installation, take a copy of the quote from the
Customer Services Quotations file. Check what has been quoted for - training, free nozzles etc.
Call customer and confirm when they will be ready for the installation i.e. that they have:
i/ sufficient space, ii/ adequate power outlets and iii/ a suitable computer. Ask for names of people
who fit the training categories on the quote. Decide how much training is required and whether an
overnight stop is required. Usually one complete days training is quoted. This includes the set up
and installation. If additional days are required due to numbers of trainees, these may be
chargeable and must be pre-booked to avoid disruption to other customers. Ask for a map of their
site if location is unknown to the installation engineer.

Create a new customer file in the BGA Installation Folder if one is not already in existence and
store any relevant information within it.

On arrival, liase with the contact and confirm that sufficient space is available for the installation
i.e. that no old BGA -2000 equipment etc is to be removed first. The engineers on the training
schedule should be with you from the unpacking stage.

Bring kit into work area and unpack. Check contents to be correct and in good condition. See
manual for components included in kit.

Engineering Training Time required approx. 3-4 hours

System set up (how to connect & install the system)
System mechanical calibration / calibration checks
Basic machine operation and controls
Software installation and set up
Use of software to control machine click and drag temperature bars, copying/saving profiles etc.
Generation of rework profiles
Storage and recording profiles / traces
Security features
Hands on rework / profile generation.
Offer to rework a customers component on one of their PCBs as a training exercise.
General advice/discussion on best techniques of rework
Use of stencilling flux dip systems & best techniques suitable for application.
General maintenance
Ask if they are satisfied with the training
Operator Training Time required approx. 2-3 hours
Basic machine operation and controls
Selecting and using pre-determined rework profiles for removal and replacement
Use of micro stencils, flux deposition etc
Setting considerations and operation of micro placer.
Hands-on use of machine.
General cleanliness and maintenance.
Ask if they are satisfied with the training.

Detail brief report of installation and pass to relevant parties.

Complete, sign and have the customer sign the installation copy of the Service Report sheet, offer
them a duplicate and bring back the signed copy to give to the TSD Administrator to keep in the
BGA Installation Folder.

Page 4 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Replacing Halogen Lamps

When replacing a lamp be careful not to touch the bulb section with your fingers
or its glass may become contaminated lamps supplied by Metcal come with a
protective glass cover. Also note that these lamps get quite hot during normal
operation and precautions should be taken against the risk of burns.

Use the smallest (0.05) Hex driver supplied

in the accessory kit to undo the two screws
that hold the lamp cover on. Undo these

Side Lamp fitted

in its housing.
Loosen here to Lamps are push fit.
gain access Push up an away to
remove.

Lamp Specification:
Metcal Part Number 19510 Slacken these screws to
12V 20W Flood (30 o ) reposition lamp angles

There is an additional lamp mounted just below the lens assembly. This can be
changed in a similar manner.

Page 5 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Replacing the Vision Arm Control PCBA (P/N - 20781)

This PCBA controls the 12VDC power supply to the camera, the lamps and the
micro-placer vacuum pump.

1. Unplug Power cable to unit

2. Take ESD precautions

3. Remove securing screws from back-plate at rear of machine, behind

Micro-placer Arm. (See drawing below.)

4. Remove the three wired plugs from the PCBA

5. Undo the three screws and remove the suspect PCBA

6. Undo the nut and bolt for the power transistor (D13)

7. To fit new PCB, reverse the above steps

VIEWED FROM BACK

UNDO x4

REMOVE
PCBA IS THIS
FITTED COVER
INSIDE
HERE

Page 6 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Replacing the Underboard Heater Control PCBA (P/N 20734)

Note - This procedure does not apply to BGA-359X systems. For these, refer to
page 8 for instructions on lifting the base plate the Heat Control PCBA is
situated on the inside of the front left hand side-wall when viewed from the front.
Once you have access to the PCBA, go to step 4 below.

1. Unplug Power cable to unit

2. Take ESD precautions

3. Remove securing screws from back-plate at rear of machine, behind BGA

oven tower. (See drawing below)

4. Remove the three wired plugs from the PCBA

5. Undo the three screws and remove the suspect PCBA

6. To fit new PCBA, reverse the above steps

VIEWED FROM BACK

REMOVE
THIS
COVER

UNDO X5 PCBA IS
FITTED
INSIDE
HERE

Page 7 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Changing Preheater Coils

1. Remove mains from the back of the unit.

2. Undo and remove the eight dome nuts and spring washers from the
underside of the base-plate:

Undo x8

3. Raise the front of the base-plate and support. Support bars are available
from the UK Tech. Services Dept (quote part number BGA-PROP). The
base-plate pivots on the two rear fixing bolts. Great care must be taken
not to disturb the support (s) Do not leave the machine unattended in
this condition.

Using 2 x BGA -PROP tools

Page 8 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
4. You now need to move the heater box forward. To do this, undo the four
screws at the base of the heater box and then undo the 4 jubilee clips that
secure the heater coils to the box. Now gently move the box towards the
front of the machine. See below:

Undo x 4

5. Follow the wires coming from the coil assembly and remove them from the
terminal block. You will now be able to ease the coil assembly from the fan
assembly and remove.

6. Feed the connecting wires back through the grommet mounted in the
elbow piece. You will now be able to remove the defective coils as shown
in the picture below:

Note: - later models are fitted

with a thermal trip device.
This w ill need to be removed
and refitted at this stage.

Page 9 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 7. Replacement is the reverse of removal but first check if the heater box
requires modification (see page 13 for details). Also, ensure that you feed
the wires from the coils to the terminal block in the correct manner for their
type e.g. when operating with a 230VAC supply, 250V coils are wired in
parallel & 120V coils are wired in series. (See Below)

EXAMPLE OF WIRING 120V

HEATER COILS IN SERIES FOR
230VAC MAINS SUPPLY

8. Please see pages 34 & 35 for Wiring Schematics of both series and
parallel-wired versions.

9. Below is a rough guide to your heater wiring configuration if you have

any doubts, please contact one of our Technical Support groups.

Mains Power Supply Voltage Heater P/N Series or Parallel Area

100VAC AC-700 -PH-SET-100 S Japan etc
115VAC AC-525 -PH-SET P USA
115VAC AC-700 -PH-SET P USA
230VAC AC-525 -PH-SET S Europe etc
230VAC AC-700 -PH-SET S Europe etc

Replacing the Heater Control TRIAC

If the TRIAC appears to be faulty (supplying voltage to the

coils when the heater is turned off) it can be swapped out
BTA26
at this point using solder and fresh heat-shrink insulation 6000B

with the connections shown opposite. The TRIAC is

mounted on the inside of the base tray next to the main
terminal block. The tab of this device is insulated so a
power transistor mounting kit (mica was her and insulating
Black Yellow
washer) is not strictly necessary.
Blue

Page 10 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 BGA/CSP 3000 Series Pre-Heater Modifications

The following procedures have been determined to increase pre-heater reliability

and performance. There are two modifications on this procedure. The first is the
Software Source Code Modification and the second is the Grate Modification.
When these modifications are done in tandem, heater life can increase to 8000
hours (this is greatly dependant on temperature and cycle time). These
modifications are recommended only when heaters are repaired in the field.

Software Source Code Modification

The extended life testing has shown that when the software source code is
modified to the maximum 250 C, heater life is decreased. To increase heater
life, the maxi mum temperature setting at the software source code should be at
maximum 240 C. This means that, if already using this 250C temperature, the
initial software source code modification should be changed from 250C to 240C
to increase heater life and optimise pre-heater effectiveness. The modification
instructions are detailed on page 15. Note: this modification is targeted primarily
at those companies already running their systems at max power although is
available to those who require greater under board heat capability for thermally
demanding applications such as Lead-free solder, thick multi -layer circuits,
ceramics etc.

Grate Modification

All systems manufactured before the serial number identified below can benefit
from the grate modification. The current build of BGA and CSP systems are
manufactured without the fitted grate. For identification purposes, a
nomenclature decoder is available. Please reference the relevant serial number
below.

Nomenclature Decoding

B5 - 2 - 1407 - 010723 - BP

B = BGA 0 = 100 VAC Serial Lot Code Heater Type

C = CSP 1 = 115 VAC Number
2 = 230 VAC
Serial Number

Serial Number Affected < 1407

Page 11 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 BGA-3591/3592 or Large Heater Upgrade Process

Remove Electrical Power from the machine & raise top of machine as
normal for heater change to take place.
Once the heater box is accessible, remove the grate. This can be lifted
out without dissembling the heater box as long as the white, heater liner is
not forced up against the grill (see below).
If the heater is pressed against the grill, lightly pull outwards & upwards to
remove the grate.

CSP 3501, BGA-3501/3502 or Small Heater Upgrade Process

Remove to top off machine as normal for heater change to take place.
Reach into the heater area and push the grate up, flattening grate to the
exhaust baffle (see below). Note - Removal Is Not Necessary.

Grate In Housing Grate Removed for Clarity

Push up on baffle till

plate is horizontal (see
Removed Grate photo
opposite).

Once the machine has been re-assembled, test for functionality and perform an
Insulation Safety test. If you have any further questions please contact your local
Metcal Technical Support team.

Page 12 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Adjusting software under-board heater top limits.

1. On the computer connected to the rework machine, find the file BGA_1CFG
in your BGA Folder (directory).
2. Right -mouse-click on this file and select Open With
3. Choose Notepad but uncheck the box that says Always use this program to
open this file. Click on OK
4. The following window will be displayed

5. On the 2nd line you will see that the number 392 appears in 4 places. This is
the degrees F of the preheater top limit. (200 DegC)
6. To adjust this top limit, simply over type the new desired figure in degrees F
each time 392 appears. To convert C to F use: Deg C x 9/5 then + 32 = Deg
F. - Note: do not exceed 240C (464F).
7. Now save file as a .cfg file i.e. select all files when selecting save as type
(See below) or the file will be converted to text and may not work.

464 464 464 464

Page 13 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Changing Fan Control PCBA

1. Remove mains from the back of the unit.

2. Raise the front of the base-plate and support as shown on page 8.

3. You now need to undo the mounting nut at the corner of the PCBA.
Now gently lift the PCB up and pull off the two connectors.

Undo this nut

4. Replacement is the reverse of removal but when refitting the new

PCBA, make sure the optical sensor of the PCBA is positioned close to
the white dot on the blower motor.
 Changing Blower Assemblies

1. Remove mains from the back of the unit.

2. Raise the front of the base-plate and support as shown on page 8.

3. You now need to move the blower backward. To do this, undo the
blower mountings as shown in the first picture below. Now gently move
the blower towards the rear of the machine as in second picture below.

Gently pull blower

Undo fan away from elbow
mountings section
here x3

Blower separates from coil

assembly here.

4. Follow the wires coming from the blower and cut them just before the
connector. Also cut the wires on the other side of the connector and,
using terminal block (or similar), reconnect the fan to the supply wires
colour for colour as shown below:

5. Replacement of the blower assembly is the reverse of removal.

 BGA-3528/2028 Height Set

This procedure describes how to set

the lower height limit on the top heater
assembly. In order to do this you will
need the medium size hex key supplied
wth the machine. You will also have to
fit the micro-oven, relevant to your
application, to the head. Note
procedure this is not necessary on
newer machines fitted with z-axis stop
screws fitted.

First of all undo the hex key fixing

screws that secure the ring to the
head marked here with red
arrows.

Now that the head assembly is

loose in the ring, fit a flat piece of
material such as an inverted
calibration plate, or similar, onto the
X -Y table, immediately below the
micro-oven head.

Place a thin spacer (e.g. flat credit Inverted Spacer

card) under the head and lower the Cal plate
Head assembly onto the spacer
card.

Continue to bring the fixing ring down around the head until you hit the limit of
travel. Now you can retighten the hex nuts.

If you now lift the head assembly again and remove the spacer card, you should
find that lowering the head onto the flat plate is not possible as it will hover just
above the plate at approximately the same thickness as the spacer used. This
will mean that when you lower the head over your component it will not crash into
the PCB. If a larger oven-to-PCB-surface distance is required, e.g. - to clear
adjacent components, simply follow the above procedure but use a spacer of
adequate dimensions. You will find that most micro-oven nozzles are the same
height and no further adjustment will be necessary, however, it may be worth
checking this height setting the first time a new nozzle is fitted.

Page 16 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 To Clean Flux Residues from the Reflow Oven Vacuum Pipe

Please Note - Do not attempt to open the head assembly yourself, instead, units that cannot be
cleared need to be reworked by our Engineers. Advance exchange units are available from the
Service Department of OK International (UK). Our exchange policy for faulty Micro Ovens is as
follows. If within warranty, we will advance replace the unit with a reconditioned item to the
address given provided that the customer returns the unit to us (preferably in the packaging we
send the exchange unit in). If not in warranty, we require a Purchase Order number to cover the
cost of repair BEFORE we will send out a replacement, reconditioned unit. At the time of
releasing this document we offer an exchange unit for the fixed price of 250GBP please call for
confirmation of price and availability. If faulty units are not returned within 1 month, the user will
be charged the price of a new BGA-3528.

This job is less messy and easier to do if the Head Assembly if first removed
from the machine. Allow the unit to cool before commencing.

Extend the vac pipe out from the main body and
offer the spray-flux pipe up to the vac pipe. Spray
flux into the vac pipe ONLY when the join is
sealed to prevent eye damage. People with
sensitive skin should wear protective gloves.

Pull off the vac pipe out from the elbow joint at the
top of the main body and again offer the spray-flux
pipe up to the vac pipe. As above, spray flux into
the vac pipe ONLY when the join is sealed.

Page 17 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
If the pipe is still blocked, the use of some thin gauge wire (or similar) may be
required and the previous steps repeated until the pipe is cleared.

Once the obstruction has been cleared, refit the silicon vacuum pipe to the top of
the unit and then blow any excess flux cleaner through the head assembly from
the end that connects to the control box as below:

Blow air in here.

DO NOT SUCK!

Block off here

Page 18 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Replacing the drive belt Heater Arm

1. First of all, remove the side panel on the opposite side of the z-axis lever (5
hex-screws) with a 1/16 hex key. Remove the spring from the bearing runner
(Fig.1.) then release the belt tension screw. (Fig.2.).

Figure 1 Figure 2

2. The cog belt (P/N AC-BELT-R) should now slip off of the driver cog and,
with a little gentle persuasion, the two small, toothed gears.

3. Undo the 2 screws that hold the belt fixing plate onto the slider assembly. The
belt will now lift away.

4. Re-assembly is the reverse of removal but remember to set the cam pin
correctly when refitting the spring so that your assembly approximately
matches Figure 3.

When the slider is at

its lowest position
the cam pin should
be here

Figure 3

Page 19 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Adjusting the z-axis belt tension Heater Arm

1. First of all, remove the side panel on the opposite side of the z-axis lever (5
hex-screws) with a 1/16 hex key. If you wish to adjust the tension with the
slide bearing in place, go to Step.4. However, it is easier to set the tension if
the slider assembly is first removed from the machine.

2. To remove the slider assembly, first undo the spring from the bearing runner
(Fig.1. on previous page) then release the belt tension screw. (Fig.2 on
previous page) The cog belt should now slip off of the driver cog and, with a
little gentle persuasion, the two small, toothed gears.

3. If your system has an LED to indicate vacuum seal (later models), trace the
wires back to its connectors and after noting their positions, undo. Cut away
the nylon ties that secure the wires to the arm body.

4. Undo and remove the 6 screws that secure the slider assembly (front plate) to
the arm (Fig.1 below.) and lift this mechanism away and towards you. Turn
this assembly over to gain access to the tension set screws. (Fig. 2 below).

Tension setscrews

3 1
2

Figure 1 Figure 2 Adjuster lock nuts

5. Release the lock nuts and setscrews by one or two turns at each of the three
adjustment points.

6. Now, while holding the centre lock-nut (1) secure, screw its setscrew
clockwise until finger-tight. (Fig.3 below.) Next turn this screw counter-
clockwise a little at a time until the slider moves smoothly but not too much so
that it becomes sloppy. This procedure involves a degree of experimentation

Page 20 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 to set this just right but when you are happy with the slider tension, tighten the
lock nut while keeping the setscrew in place. Repeat this process for the other
two setscrews.

Lock nut
Adjusting the
set screw

Figure 3

7. Re-assembly is the reverse of removal but remember the following:

Set the cam pin correctly when refitting the spring so that your
assembly approximately matches Figure 3 on page 19.
If you are refitting the LED wires, use new nylon ties and ensure the
wires do not rub the moving parts. If the 2 pin connector has fallen into
the arm cavity, it can be accessed by undoing the plate under the arm
(Fig. 4 below)

Figure 4

Undo this plate

(4 x 1/16 hex screw)
to access connector

Page 21 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Replacing the drive belt and resetting the belt timing Vision arm

1. The first thing you will need to do is

gain access to the lift mechanism.
This is done by removing the
camera from its mount and then
removing the five hex bolts (use a
3/32 hex key) that secure the side
plate to the arm assembly
(locations circled yellow in fig.1.)
The lens assembly can remain
attached to the side plate.

Figure 1

2. Gently lift the lens assembly and its mounting plate off of the dowels on
the arm assembly and release the two spade connectors that fit onto the
power switch as in fig.2

Figure 2

Page 22 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
3. Now the lens assembly can be
rested on the X-Y table use
bubble-wrap or similar to prevent
scratching. As Fig.3

Figure 3

4. Remove the stop-lever assem bly by undoing its fixing bolt (blue circle in
Fig.4). Take care not to loose any of the small parts. This stop lever and
the timing pin, on the large cog, prevent the accidental damage to the
prism by inhibiting downward movement of the vacuum pick-up when the
prism is in its forward position.

Hex screw
used to fix belt
to bearing

Note the solenoid and loom have

been removed in this picture for
clarity but can be left in place when
following this procedure.
Figure 4

5. Release the belt tension by undoing the tension set screw (yellow circle in
fig.4)

6. Now remove the belt from the large cog and 2 gear wheels then undo the
hex screw that secures the belt to the bearing runner. Lift away the old
belt and screw.

Page 23 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
7. Transfer the screw and washer to the new belt (P/N AC-BELT-V) and
refit to the bearing runner. Refit the belt to the 3 cogs but do not reset the
belt tension at this point.

8. Fig.5 shows how the timing pin should be positioned when the prism is in
its forward position and the vacuum pick-up head is in its top position.

Pick-up head
held at top
position

Move pin to this

Figure 5 approximate position

9. If the timing pin is in the wrong position, lift and hold the pick-up head to its
uppermost point, slip the bel t off of the large cog and then rotate the cog
until the pin is roughly in the position shown in fig.5

10. Refit the timing stop lever assembly. It may be useful to fit a wire tie or
small rubber band to ease fitment of the arm assembly as Fig.6b below:

Remove tie after fitting

assembly to arm.

Correct order of parts

in stop lever assembly

Figure 6b

Figure 6a
Page 24 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
11. If the spring assembly is fitted correctly it should look like fig.7.

Spring pushes lever

onto cog

Figure 7

12. If all is well, reset the belt tension

by applying moderate pressure to
the tensioning mechanism and
tightening its hex bolt fig.8.

Figure 8

13. Check that the timing is still set correctly by first sliding the prism fully
backwards to make sure that the pick-up head goes all the way up and
down and then bring the prism fully forwards to make sure that the lock
mechanism does not allow the vacuum nozzle to touch the prism. If the
vacuum nozzle is able to touch the prism, redo from step 8.

14. If you are unable to slide the prism backwards and forwards it is most
likely that the arm is the wrong side of the prism-slider pin. This can be
easily remedied by gently lifting the locking arm around the pin as in
fig.10. (Green arrow)

Page 25 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Pin should be
this side of arm

Figure 9
x P
15. When you are satisfied that the timing is correct, refit the spade
connectors to the Power switch and refit the side cover to the arm
assembly. A quick check of the vision system calibration is advisable.

Page 26 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Setting the Micro-Placer Theta Control

NOTE it is a good idea to use good quality unworn, imperial hex keys
throughout the operation as these very small (0.05) screw heads are prone to
rounding-off.

1. First undo and remove the four cover -plate screws at each corner (circled
yellow). Tip - If one of the screws cannot be undone, you can rotate the
cover-plate anti-clockwise once the other three are removed.

2. Slacken off the cam lock-screw (circled red) and turn the theta adjustment
knob so the flat surface of the cam rod is toward the front and the
rotational travel is roughly equal in either direction.

3. Now retighten the same screw until it hits the s urface of the cam and then
slacken it again by a quarter of a turn. This should give you the correct
setting.

4. Occasionally, if the theta movement will not return you need to slacken,
re-tension and retighten the back-force grub screw (circled green)
However, sometimes it is also necessary to apply a little light oil to the
moving parts.

Page 27 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Lens and Mirror Replacement

Note due to the fact that the mirrored surface is on the topside of the glass, no
cleaning agents should be used on the mirror(s). Instead, use a soft bristled
brush or soft lint-free cloth to remove dust etc.

Page 28 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 XY table clamp inspection and repair.

If the X-Y table locks become weak i.e. the table slips after locking, you will need
to follow the procedure below.

This is where the X-axis

clamp washers are housed.
Undo the 2 screws through a
hole in the bottom table plate.
Undo

Next undo the 4 screws that hold

the micrometer block in place. You
will need to hold the block in place
to stop it springing out.

Page 29 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Now you can slide the micrometer block and
clamp bar (Blue box) sideways and the clamp
housing (Orange box) down. Be careful to
not loose the 2 washers inside.

P/N 20499 P/N 20496

Cross section of assembled clamp

side view.
Here are the clamp washers removed from their housing. If
the top flat washer is worn and grooved, simply turn it over
or replace with one of similar thickness. If the bottom spring
washer is broken, replace it. (You can use a washer from one
of the 8 base-plate acorn bolts if the correct part is not
available).

Reassembly is the reverse of the above. Procedure for the Y-axis is similar.

Page 30 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Calibration Procedure for Arm Assemblies

The purpose of this calibration procedure is to ensure that the distance between
the placement head to the Micro Oven is in the correct position. So, that when
the X-Y table is moved from the Placement to Reflow position, the device will be
immediately under the Micro-oven Nozzle. As the process is rather lengthy and
involved, we suggest that it s hould only be followed when strictly necessary.

1) Co -planarity Adjustment for Oven Head Assembly (older machines only)

(a) Ensure that the Board Holder is locked into position underneath
the Micro Oven Nozzle.

(b) Install a known flat board (or, after removing the top plate, use
the gun-sight Alignment Plates turned upside down) into the
Board Holder rails.

(c) Install a Micro Oven Nozzle (use the largest one you have
available) onto the BGA Head assembly and lower the nozzle
onto the flat board (inverted gun-sight Template).

(d) Unlock front setscrew A (See figure 1) on the oven holder ring
assembly and pivot the angle of head / nozzle so that the Micro
Oven sits perfectly flat with the gun-sight Template. If the head
assembly still feels restricted and will not pivot, loosen the two
supplemental setscrews B (See figure 1 below) with a 7/16
Hex key.

Screw A

Screws B

Fig. 1

Page 31 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 (e) Lock all screws. Now that the co-planarity between the Micro
Oven and gun-sight Template has been calibrated, this
adjustment should never need to be altered.

2) X-axis Calibration:
(a) Remove the Micro Oven Nozzle from the BGA Head Assembly
and fit the lower calibration gun-sight plate, face up, under the
oven head assembly with the cross-hair pattern roughly centred
to the Head assembly.

(b) Lower the vacuum tube inside the Micro Oven Head Assembly
and lock into place so that the vacuum tube is protruding from
the Heater Assembly. Lower the head assembly so that the
vacuum tube is approximately 1mm away from the gun-sight
pattern.

(c) Ensure that both the X and Y-Axis of the board holder are in the
locked position. Using the micrometers to make fine adjustments
in both the X and Y-axis, adjust the board holder position so that
the vacuum tube (without vacuum pad) is perfectly centred in the
gun-sight pattern.

(d) Transfer the whole board holder sideways so it is underneath the

placement head and ensure that the board holder locks into
position. Install the smallest vacuum pipette onto the placement
head.

(e) Ensure that the vacuum pipette is at its optimum focal point (See
figure 2). This can be accomplished by simply making sure that
the vacuum pipette is in contact with the height block when resting
on the bare component slide.

Fig. 2

(g) Access the prism so that an image of the circular vacuum pipette
is overlaid with the gun-sight crosshairs on the monitor. Do not
make any fine adjustments with the micrometers at this point!

Page 32 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 (h) With a 7/64 Hex Key, loosen the two setscrews located towards
the front of the unit where the RBH-D transfers and locks into
position underneath the placement head (see figure 3)
Setscrews

Fig. 3

(i) Now that the setscrews are loose, the above assembly should be
manipulated in the x-axis until the vacuum pipette is centralised
in reference to the gun-sight pattern on the monitor.

(j) After calibration of the x-axis has been accomplished, retighten

these setscrews.

3) Y-Axis Calibration:
(a) While the image is still visible on the monitor, adjust the Y-Axis
Micrometer so that the image of the vacuum cup and the gun-
sight are perfectly overlaid in the Y-Axis.

(b) Transfer and lock the Board Holder into place under the Reflow
Head Assembly.

(c) Lower the Micro Oven Head assembly so that the vacuum tube is
within approximately 1mm above the gun-sight alignment
template.

(d) If the Y-axis alignment requires adjustment, loosen the four

screws that secure the entire Reflow Arm assembly to the base
with a 9/64 hex key. In a similar to the above calibration
procedure for the x-axis, simply manipulate the placement head
so that the vacuum pipette is centralised in reference to the gun-
sight cross-hair pattern (figure 4). Retighten the entire reflow
head assembly to complete the arm calibration procedure.

Fig.4
Loosen these screws to
Calibrate Y Axis
Page 33 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Page 34 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Page 35 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Page 36 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Page 37 of 55
Page
BGA/CSP 3K Service Engineers 37 of
Guide Rev55
1
BGA/CSP 3K Service Engineers Guide Rev
 Camera power -supply wiring

+12vdc on pin 6 (red)

CONNECTOR FROM
BACK OF VISION ARM
TO OLD CAMERA
P/N: 20006

+12vdc on pin 1 (Red)

0v on pin 3 (green)

0V on pin 2 (green)

CONNECTOR (P/N 7039/1030)

FROM ADAPTOR TO NEW
CAMERA P/N: AC-CAMPAL

Page 38 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
This diagram is for reference or
testing purposes only. These units
should not repaired in the field.
Please refer to page 17 for our
exchange policy details.

Page 39 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 To bypass an unknown or lost password:

This information should NOT be passed onto operators Two methods are
possible, either via the software or by using the control box programming keys.

Software Method:

Type 10701 and

double-click in here
with mouse cursor

To reset the password - go to Security, select Change Password and type in the
number again as above. Doing this will mean that when you are asked the
password next time, all you will have to do is click OK or press Enter on the key
board.

Hardware Method (Control Box)

If a module is in a locked state, the user will not have the ability to change
between profiles and / or modify profile settings. Inadvertantly, the user may lock
the system and subsequently forget their three-digit code. The procedure below
will enable the user to enter a new code into the BGA-1 Module, erasing the prior
code from the memory of the module.

1) Ensure that the system is in a Module Profile (ie. L4, P10) and not in a
Library Profile. Also, ensure that the (Time / TC) switch is in the Time
position.

Page 40 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
2) On the face of the BGA-1 Module, press and hold the following keys in
this particular sequence:

a) Lock
b) Down Arrow (corresponding with the lower display)
c) Zone

3) The top display should now read 000 while the lower display flashes
Cod.

4) Press and hold the up arrow that corresponds with the upper display until
914 is displayed.

5) Press the Lock button.

6) The module will now display the previously selected Module Profile.

7) Press Lock again. You will notice the upper display reads 000 and the
lower display reads Cod. This indicates that the previous code has been
erased from the memory of the BGA-1 Module and no code is currently
stored.

8) Enter your new three-digit code in the upper display and then press Lock
to enter your new code into the module.

Page 41 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Optical System Calibr ation Procedure All Machines

This and the following procedure is intended to be used as a guide to accompany

the technical calibration procedure detailed in the User Guide supplied with each
new machine. Copies of the User Guide are available in PDF/har d format from
your local Technical Support Group.

Beam Splitter Calibration:

1. With the vacuum head assembly

at the top position install the
10mm (middle sized) vacuum
pipette and lock the X-Y table into
the left hand, micro-placer side.

2. Place the gun-sight Alignment

assembly (P/N: 20066) onto the
board holder and lift off the top
plate.

3. Position the center of the gun-

sight pattern under the vacuum
pickup head. (Lower the head until
the vacuum cup almost touches
the gun sight alignment plate.)

4. After the gun-sight is roughly

aligned by eye, raise the pipette a
little, lock the table X & Y clamps
then refit the top calibration shim
so that it is face down on the two
location pins.

Page 42 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
5. Pick up the top shim with the
vacuum pipette and raise the
vacuum head back to its top stop
position. Draw the prism
assembly to its forward stop-
point.

Z-Axis fine
6. Turn the Z-Axis, fine-adjustment
adjustment.
knob fully counterclockwise and
then turn back clockwise.
Adjust the illumination and the
macro zoom lens to obtain a clear
picture of the gun-sight pattern on
the monitor.

7. The upper ring on the lens is

used to adjust the aperture (i.e.,
how much light the camera sees).

8. The zoom is adjusted by rotating

the middle ring.

9. The focus on the zoom lens is

adjusted by rotating the large ring
located at the bottom of the lens

Page 43 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
If you need to reposition the image on
the screen use the two knurled knobs
here.

10. The image on the monitor should

look similar to this

11. If necessary, adjust the

illumination (top and bottom) Beam Splitter Assembly top
by rotating the light view
adjustment knobs to obtain a
clear picture of both images.
While viewing the screen,
superimpose the images of
the two plates. This alignment
is achieved by adjusting the PRISM
calibration set screws on the
prism assembly with a 0.05
Hex Key. Do not move the
board holder and be careful
not to touch the top pattern
plate. If you do touch it, go
back to step 5.
Calibration Set Screws

12. Using a 0.05 hex wrench turn

both calibration set screws until proper alignment is achieved.

Page 44 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
Height Set Block Calibration:

1. Now that the Beam Splitter Assembly is correctly set, turn the upper lamp
control knob down so that the top plate is not illuminated.

2. Adjust the Zoom lens ring to maximum magnification and focus, as best
you can, on the bottom plate image. This is best accomplished with the
Aperture lens ring biased to give a darker, sharper image.

3. Turn down the illumination on the lower image and turn up the illumination
on the top image DO NOT ADJUST THE FOCUS.

4. Using a 0.05 Hex key turn the Top

Z-Adjuster Set Screw in a clockwise Top Z-
direction and observe the image on Adjuster Set
the monitor. Screw

5. If the image becomes clearer,

continue turning the hex key until
the image is at its optimal focus
point. If the focus appears to get
worse, turn the screw counter-
clockwise while at the same time
applying gentle upward (clockwise) Turn knob this way if
pressure on the large Z-Axis knob. turning the Adjuster Set
Adjust the Set Screw until focus is at Screw counter-clockwise.
its most clear.

6. If you now balance the illumination on the upper and lower images you
should see that they are both in focus which indicates that both calibration
plates are the same distance from the center if the prism.

Page 45 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
7. Once these two distances are
balanced, adjust the setting of the Loosen screw to adjust
Height Adjustment Block (P/N- height
19993) by setting it so that, after
placing it onto the chip carrier, it
will just slide under the gun-sight
pattern plate. This block will now
provide a reference gauge for
adjusting the height setting when
placing components in normal
use.

Set Block height to

match arrowed distance

The optical system is now calibrated.

Page 46 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Optical System Calibration Procedure Additional for BGA Machines

If your system is fitted with Split Mirrors there are additional steps to the previous
procedure. The aim of this procedure is to set the 2 mirrors so that they are on
the same plane and give an unbroken image when the split vision facility is not
required.

1. Follow steps 1 to 5 of the previous

procedure but do not fit the top
calibration plate (as in operation 4), as A
only one image is required to set the
mirrors correctly. Set the lighting and
focus until you have an image
something like this. However, Do not
be concerned if you are unable to get a B
complete, unbroken circle at this stage.

2. Turn the split vision adjustment knob

counterclockwise until you no longer
have an effect from this action on the
image of pattern on the screen.

3. Now turn the knob clockwise until you

notice the that two corners A & B start
to move toward each other then
continue to turn the knob clockwise by
Split Vision
an additional (approximate) turn.
Control Knob

4. Using the smallest, 0.05, hex key turn

Calibration
screws C & D counterclockwise until
F setscrews
there is no effect of this action on the
screen. I.e. the image does not move.
NOTE - only use a rotary motion do
not press onto the screw. This action
will take the pressure off of the first E D
mirror and give you a known position to
adjust from.

Page 47 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
5. Turn screw D clockwise until the image
on the screen just starts to move, then
continue to turn the knob clockwise by D
an additional (approximate) turn from
this point. Repeat this step for screw C .
C
you will now have set the first mirror to
a reference point. =
Note hex driver is
inserted at the same
angle as the split
vision control knob.

6. Turn both of the screws E & F F

counterclockwise until there is no effect
of this motion on the image on the
screen as you did for D & C above. This
action will take the pressure off of the
second mirror and give you a known
position to adjust from.
E

7. Turn screw F clockwise until the

vertical gun-sight lines are lined up and
continuous. Next turn screw E
clockwise until the horizontal gun-sight
lines are lined up and continuous as
shown in step 1 (not broken as shown
opposite). You may find that you need
to switch between screws E & F once
or twice until you are happy with the
line-up.

8. Finally, check the mirrors are set

correctly by turning split vision knob clockwise 45 and back
counterclockwise until the target lines line up again in both vertical and
horizontal directions. The image should look as shown in step 1. If the
lines are broken, repeat the above from step 2.

Page 48 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Verification Of Temperature Repeatability

Calibration of hot-air rework equipment is extremely difficult to verify due to the

variability of both the airflow rate and the position of the heat-sensing device. It is
possible, however, to achieve is a verification repeatability of temperature under
the repetition of set conditions.

All BGA systems are factory calibrated using special equipment, including the
external K-Type output on the side of the machine. Further, the profile
temperatures are software projections based on (but slightly different to) real time
thermocouple measurements. Therefore, it is not recommended for customers to
try and alter any settings on the system. However, the most critical thermal
sensor, the one that sits under the chip during profile generation, can be
calibrated. It can be checked and calibrated using customers independent
equipment in the following way:

1. Remove power from unit then unscrew the 2 BGA-1 Module mounting
screws, draw forward and turn Module sideways to view Adjustment Pot.

2. Making sure the PCB does not

short out against the case, re-
apply power.

3. Use a calibrated Thermocouple

Meter to measure a pot of
boiling water or oven at 100oC

4. Place the Metcal K-Type BGA

thermocouple into this water
and, if necessary, turn
Adjustment Potentiometer until Calibration
BGA-1 display measures potentiometer
100oC.

5. Replace Module with Power Turned Off.

6. Calibration is complete.

In addition, we recommend field verification by following a repeatability test set

up by the machine user or following the example below. We find this method
satisfies the requirements of our many hundreds of customers worldwide, many
of who are ISO9000 registered. It is critical that the tests be carried out in a
controlled manner i.e. ambient temps (no oscillating fans etc), time periods
between tests and differences in air-flow can all influence results.

Page 49 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
 Example Profile Repeatability Test

First, construct a test PCB that has 2 calibrated thermocouples embedded into
the centre and perimeter ball of a BGA e.g. 225 Plastic BGA. You can now use
this PCB for the repeatability test using the internal system measurement.
However, if you wish, you can use a separate data recorder (Datapaq, M.O.L.E.,
etc.) to conduct your tests. To ensure absolute repeatability, embed the
thermocouples as follows and then fix the chip down using Loctite Chip Bonder.

Chip Bonder
Chipbonder
Thermocouples

Using the internal system measurement run a total of 4 (or more if you wish)
profiles to test the repeatability of both the system and the profile board.

Examples of four tests are shown below. The first graph shown shows a
comparison of set temperatures between the first and second test for both the
top air and the preheater.

EXAMPLES
You can see from the graph, at the measured positions (Vertical dotted lines) we
have achieved a temperature ? of 1C on the Top air temperature and 5C on the
preheater temperature. The stated accuracy is 5C. so this falls within
specification.

Page 50 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
The next graph demonstrates the repeatability of the profile using the
thermocouple PCB. The thermocouple traces from the 4 tests have been overlaid
onto a single graph to demonstrate the temperature ?. Note that 2 of the traces
were from the outer ball and 2 were from the inner ball.

You can see from the graph that we have achieved the required temperature
delta of 10C (5C) despite comparing both centre and outer ball temperatures.
The temperature variance between the 2 centre traces and the 2 outer traces is
actually closer than this.
The following graphic shows the control panel settings from the BGA system.
Please note that there may be minor differences between machines.

Control Box Settings

Page 51 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
Source
graphs

Page 52 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
BGA Level 1 Spares Kit, 230V - Part No. SPARE-102

Part # Qty Description

17145 2 In-line vacuum filter
21104 3 Thermocouple fine gauge
19510 4 Halogen lamp
20066 1 Gun sight
19993 1 Height adjustment block
19219 2 Vacuum cup set
AC-BELT-R 1 Cog belt for Micro-Oven Z-Axis (was 19573)
17451 1 Air solenoid, Ye llow 12V. DC
19359 1 Air solenoid 28V AC
17789 5 Fuse (2.5A.) Control Box (230V.)
19329 5 Fuse (6A.) Base Unit (230V.)
20719 1 Vacuum pump
21205 3 405W Sub-Board Heater (230V.) obsolete, use AC-525-PH-SET
20002 1 Blower
21102 1 TRIAC BTA-26-600b
20759 1 Diode MBR-1545CT
20999 1 Over-temp switch
19511 1 Lamp Socket
19501 1 Vacuum Tube Assy.
41312 1 Micro-switch, Vac. Pick-up
21197 1 Vacuum Transducer
19732 1 BGA-1 Processor Module
19711 10 O-Ring for Vacuum pick-up (small)
19710 10 O-Ring fo r Vacuum pick-up (large)
20837 1 Switch, Main Power
16290 1 Switch, Pre-heater on/off
45878 1 Switch, placer on/off, pre-heater heat/cool
BGA Service centre spares 230V - Part No. SPARE-202
17449 1 Air Pump (230V.)
20784 1 Air & Vac Pump Driver PCB (230V.) control box
20102 1 Micrometer Head
20907 1 Beam Splitter Assy.
7039-9062 1 Control Box Complete (230V.)
19749 1 VTM-3 Temp Module
BGA-3528 1 Micro-Oven Assembly (3500 Series)
20835 1 Fan PCB
20734 1 Temp Control PCB (230V.)
19722 1 Pick-up solenoid
20781 1 Lamp, Pump Driver (Base Unit)
AC-CAMPAL 1 Camera, PAL
Green Cells suggested to be kept as 'swap-out' items for fast response.
Yellow Cells - strongly recommended
Blue Cells - Additional recommended parts not in SPARE -102/202
AC-525-PH-SET 2 525W Sub-board heater 115V (series wired for 230V)
AC-BELT-V 1 Cog belt for Placer Z-Axis (was 21089)
RS 215-426 1 PC RS-232 Data Cable - contact UK TSD
RS 297 -1522 1 Imperial Hex-Key Set - contact UK TSD
AC-700-PH-SET 1 700W Sub-board heater 115V for BGA-3592 only Page 53 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
NOTES

Page 54 of 55
BGA/CSP 3K Service Engineers Guide Rev 1
NOTES

Page 55 of 55
BGA/CSP 3K Service Engineers Guide Rev 1