METCAL QX2 CONVECTION REWORK SYSTEM USER GUIDE

METCAL QX2 CONVECTION REWORK SYSTEM USER GUIDE Test Equipment Depot - 800.517.8431-99 Washington Street Melrose, MA 02176 - TestEquipmentDepot.com Metcal is an OK International Company Copyright 1999, Metcal, Inc. All Rights Reserved 7036-0540 Rev. A

TECHNICAL AND CUSTOMER SERVICES: HERE TO HELP YOU If you have difficulty setting up your system, diagnosing problems, or replacing any part, please give your local Metcal representative a call. METCAL QX2 SYSTEM USER GUIDE SYSTEM OVERVIEW........................................................ 2 SYSTEM SET-UP........................................................... 4 SYSTEM OPERATION........................................................ 5 REMOVE MODE............................................................ 6 ATTACH MODE............................................................ 7 SET-UP MODE & CALIBRATION................................................. 8 BOARD HOLDER OVERVIEW, SET-UP & OPERATION.................................. 9 PREHEATER OVERVIEW, SET-UP & OPERATION.................................... 10 VACUUM CUP ATTACHMENT, REMOVAL, & MAINTENANCE........................... 11 NOZZLE ATTACHMENT & REMOVAL............................................ 12 FOCUSED CONVECTION NOZZLES............................................. 13 TROUBLESHOOTING....................................................... 14 ERROR CODES........................................................... 15 WARRANTY............................................................. 16

2 17 3 1 SYSTEM OVERVIEW 9 10 18 4 5 7 8 6 SYSTEM OVERVIEW The Metcal QX2 Convection Rework System is designed to remove or to re-attach SMT components from a PCB safely and easily. To reflow the solder joints, the QX2 uses carefully controlled focused hot air. The QX2 includes a semi-automatic vacuum pick-up system that can be used to lift reflowed components from the board. For precise process control, the QX2 displays the temperature and time for all operations. The Metcal QX2 Convection Rework System consists of a power supply, a controller, a work tray, and a nozzle removal tool. Optional accessories include a 355 mm x 508 mm board holder that allows the PCB to be fixed in place and a 152 mm x 152 mm convective preheater that provides under-board heat to reduce board warping. The power supply provides airflow, vacuum and heat. It has a movable arm that holds the heater head assembly, which contains the heating element and the vacuum pick-up. Because no additional tool stand or work frame is needed, the QX2 saves valuable work space. 14 The controller is all that is needed for you to control the power supply. It is attached to the power supply by a cable, and it may be moved anywhere within the cable s reach. You can place it in the most convenient location. 1 Power Supply 2 On/Off Switch 3 Power Cord 4 Heater Head Assembly 5 Heater 6 Vacuum Pick-Up Tube 7 Theta Rotation/Nozzle Removal Lever 8 Nozzle (Sold Separately) 9 Movable Arm 10 Z-Axis Knob 11 Controller Cable 12 Controller 13 Work Tray 14 Nozzle Removal Tool 15 Board Holder (Optional) 16 Preheater (Optional) 17 Auxiliary Thermocouple Port 18 Power On Light 13 15 16 11 12 The work tray provides a working surface for the PCB if you have not purchased the optional board holder. Note that the preheater cannot be used with the work tray; it must be used with the board holder. The QX2 uses focused convection nozzles that are designed to fit specific components. Nozzles are available separately so that you may select only the nozzles needed for the application. The work tray can also be used to store nozzles. The nozzle removal tool provides a way to hold hot components or hot nozzles removed from the QX2. Simply hold the scoop side under the heater head to catch a hot component. To remove nozzles, see Nozzle Removal (p.12). The Z-axis knob allows fine adjustment of the height of the nozzle over the board. The theta rotation lever is for positioning the nozzle squarely over the component without needing to rotate the entire board. This lever is also used for quickly removing the nozzle. Rotating the lever until it stops in either direction ejects the nozzle. 2 3

SYSTEM SET-UP Place the main unit on a suitable workbench where you are not restricted for space and can operate the unit in a comfortable manner. If using the optional convection preheater, connect the cables and place the unit underneath the heater head as described in the preheater instructions on page 9. Place the work tray (or optional board holder) below the heater head. Plug the power cord extending from the main unit (and optional preheater) into a grounded wall socket of an appropriately rated input line voltage. WARNING: To provide protection against the risk of electrical shock, connect only to properly grounded outlets. Connect the cable with phone-style connectors into the jacks on the back of the controller and the back of the power supply. Choose a nozzle and vacuum cup suited to your rework task. Attach the vacuum cup by pushing it onto the vacuum tube. It is not necessary to hold the tube. (See Vacuum Cup Attachment, p.11) Attach the nozzle by pressing in firmly into the bottom of the heater head. (See Nozzle Attachment, p.12) Click the power switch located on the back of the main unit to the On position. The controller display will show Metcal QX2 for a few seconds. The rework system is now set up and ready to rework your first component. WARNING! PLEASE READ FOR YOUR SAFETY! The air exiting the heater is VERY HOT. Do not put your hand or any other part of your body under the heater head when the system is on. The heater housing, nozzle and vacuum cup are all VERY HOT during and after use of the system. Do not touch them with your bare hand until they have been allowed to cool. DO NOT ASSUME THAT THE SYSTEM IS COOL JUST BECAUSE THE POWER IS OFF. Always allow the system to cool before storage or re-packing. SYSTEM OPERATION Airflow, vacuum, and timer are operated with the controller. The controller has a mode selector switch that allows you to select the mode of operation: Remove or Attach. There is also a single Start/Stop button that controls the two cycles. The controller has an airflow selector that allows you to adjust the volume of airflow. This determines the rate at which thermal energy is transferred from the heater to the printed circuit board. The LCD screen on the controller will display the following information: OPERATION ICON When the system is operating, the controller will display one of three animated icons: Indicates the system is operating in Remove mode. Indicates that removal is complete, but the vacuum cup is still holding the component. Indicates the system is operating in Attach mode. TIME Depending on the mode of operation, the timer will either count up or down. In the Remove mode the display counts up and in the Attach mode the display counts down. The +/- keys allow you to adjust the reflow time. -/+ Keys Start/Stop Button Mode Selector Airflow Selector Operation Icon Time Display Temp. Display Remove Mode Attach Mode A fire may arise if not used with care. Be careful when using the QX2 in places where there are combustible materials. Never use the system in the presence of an explosive atmosphere. Be aware of your surroundings; heat may be transferred to materials which are out of sight. Do not apply heat to the same location for a long period of time, and never leave the QX2 unattended when in use. To avoid the risk of electric shock, always plug the system into a properly grounded outlet. If the supply cord is damaged, it must be replaced by the manufacturer or its service agent or a similarly qualified person in order to avoid a hazard. TEMPERATURE Air temperature is displayed on the right, while cycle time is displayed on the left. The temperature may be displayed in C or F, and the hot air temperature at the heater or the temperature of an auxiliary thermocouple may be chosen (see Set-up Mode & Calibration, p.8). 4 5

Test Equipment Depot - 800.517.8431-99 Washington Street Melrose, MA 02176 - TestEquipmentDepot.com REMOVE MODE Install a vacuum cup onto the vacuum tube extending from the reflow head. (See Vacuum Cup Attachment, p.11) Select a rework nozzle that corresponds with the component you wish to remove. Insert the nozzle into the reflow head by firmly pushing the nozzle up until it clicks into place. (See Nozzle Attachment, p.12) Lift the heater head until it locks in the up position to allow clearance. Raise the heater head fully by rotating the Z-axis knob until it comes to a stop. Place the printed circuit board that you wish to rework on the work tray or board holder. Position the board holder or work tray so that the component to be reworked can be easily accessed by the rework nozzle. Lower the heater head assembly until it locks in the down position. Move the work tray or board holder so that the component to be removed is centered with reference to the nozzle. Fine adjustments in the theta rotation axis can be made by rotating the lever. Note: The component should be centered with respect to the nozzle so the leads do not hit the nozzle when the component lifts from the board. Using the Z-axis knob, lower the heater head until the nozzle completely encapsulates the component. The nozzle should remain 1-2 mm above the component leads, and should not be in contact with the component or PCB. ATTACH MODE After preparing the site, align the component you wish to attach to the PCB with its mating land pattern. Rotate the mode selector so that it is in Attach mode. You will notice that the vacuum tube automatically lifts out of the way. Lower the heater head and move the work tray (or optional board holder) so that the component to be attached lies centralized in reference to the nozzle. Fine adjustments can be made to the theta (rotation) axis at this point by rotating the theta rotation lever. Lower the heater head until the nozzle completely encapsulates the component to be attached by rotating the fine Z-axis adjustment knob. The nozzle should remain 1-2mm above the component leads, and should not be in contact with the board or component. You will notice the time of the last full cycle is displayed on the controller. You may user the +/- keys to adjust the rework cycle time. If you just performed a removal cycle, the time displayed is that removal time. If you are re-attaching the same component, you may wish to add 15 30 seconds to the time to ensure complete reflow. Press the Start/Stop button. The hot air cycle will now begin, counting down from the displayed value. Once the timer gets to :00 the unit will shut off airflow and indicate that the placement cycle is now complete. 6 Ensure that the mode selector is in the Remove position, and that the main power switch is on. Switch the airflow selector to the setting that best corresponds with the application. If you are unsure which setting to use, start with the lowest setting, Setting 1. This setting is the safest for the component and the PCB. To achieve faster removal times, increase the airflow setting. WARNING: Higher airflow settings will increase the component temperature rise rate. The table below provides sample airflow settings at the default Temperature Setpoint of 350ºC for three component sizes to maintain maximum component temperature rise rates below 5ºC/s. Component Setting PLCC 20 1 QFP 100 1, 2 QFP 208 1, 2, 3 Press the Start/Stop button. You will now notice the hot air flowing from the flutes of the nozzle and the timer counting up. WARNING: The nozzle and the exhausted air will be hot. If you have a preheater that is properly connected to the power supply, the preheater will start automatically at the same time. If you do not wish to use the preheater, you may turn it off. Alternatively you may turn it on before turning on the power supply. (See Preheater Operation, p.10) When the removal cycle is complete, the component will automatically lift from the printed circuit board. The preheater will shut down and the hot air from the power supply will automatically stop. The removal time will remain stored for a subsequent attachment cycle. Lift the nozzle up by raising the heater head. The vacuum cup will continue to hold the component. Flip over the nozzle removal tool so that the bottom plate is facing up and acting as a scoop. Place the tool directly underneath the component and push the Start/Stop button. The component will fall into the tool and the vacuum pump will turn off. 7

SET-UP MODE & CALIBRATION The Set-up mode will allow you to change some settings of the QX2 system. To enter this mode, turn off the main power, hold down the +/- keys simultaneously and turn the main power on. The LCD will display a prompt to enter an Access Code. Use the +/- buttons to change the number of your code. The default code from the factory is 000. Push the Start/Stop Button to submit the code and enter the Set-up Mode. A form for you to write down your code is provided with the unit. It also tells you the universal access code number that will always work in case you forget your code. You may wish to store it separately. Once you are in the Set-up mode you will have the menu options listed below. Cycles: Displays the number of Remove and Attach cycles that the system has run. Hours: Displays the cumulative run time. BOARD HOLDER OVERVIEW The board holder provides a self-centering mechanism for holding a PCB from 50 mm x 50 mm to 360 mm x 460 mm in size horizontally at a distance of 120 mm from the workbench surface. SET-UP Place the board holder on a workbench with a level surface. The unit is now ready for use. Wheel Clamp Rail Temp Units: The default setting for this is C. The set up mode offers you the option of changing this to F by pushing the + or - button. Setpoint: The default temperature is set to 350 C. This is the temperature of the air exiting the heater. If you wish to adjust this set point, you can hold down the +/- keys to set the desired temperature. The setpoint can be adjusted between 250 C and 450 C. Unless you have unusual process conditions, it should not be necessary to change the setpoint. Display: The default setting is for the controller to display the temperature of the air exiting the heater. By pushing the + or - button, you can change this setting to have the controller display the temperature from the auxiliary thermocouple port. New Code: Allows you to change the Access Code used to enter the Set-Up mode. Use +/- to change the code. Calibrate: Allows you to enter the calibration mode. Use + or - to change to Y and then push the Start/Stop Button. The calibration procedure requires a Thermocouple Calibrator. Please contact Metcal Customer Care for assistance. Set Defaults: Allows you to return all settings to the factory defaults. The following are the factory settings: Access Code: 000 Temp Units: C Setpoint: 350 C Display: Internal Calibrate: none (clears any new calibration settings) OPERATION Rotate the wheel of the board holder assembly clockwise or counterclockwise to move the clamp rail in or out to accommodate the size of the PCB to be reworked Position the PCB between the clamps. The clamps may be adjusted by sliding them along the rails, to avoid interference with any components on the edge of the PCB. They should support each corner equally if possible. Tighten the clamps gently by rotating the wheel. Do not overtighten: the PCB may break or the clamps may be damaged. The clamps will flex to accommodate thermal expansion of the PCB during the rework process. For all the menu options, pushing the Start/Stop Button enters your changes and cycles to the next option. To exit the Set-up mode, turn the main power off. 8 9

PREHEATER OVERVIEW The preheater is designed to aid in the removal or the re-attachment of components from a PCB safely and easily. The preheater uses forced convection to heat the entire PCB evenly to just below the melting temperature of solder, allowing easy component placement and removal, while minimizing the possibility of warping the PCB. SET-UP Plug the phone-style cable into the jack on the bottom of the preheater. Place the preheater on a suitable workbench and stretch out the power cord and the phone style cable behind the preheater. WARNING: To provide protection against the risk of electrical shock, connect only to properly grounded wall outlets. Option 1 Lift the QX2 and place it over the preheater cables so that the cables are in the grooves under the QX2. Place the three tabs in the back of the preheater over the three slots in the base of the QX2. The preheater On/Off button and airflow control knob will be facing you. Gently pull the preheater cables from the back of the QX2 to remove any slack. Plug the phone-style connector into the jack on the back of the QX2. Plug the preheater power cable into a grounded outlet. Option 2 Place the preheater on the workbench ensuring that On/Off button and airflow control knob are facing either your right or left. Plug the phone-style connector into the jack on the back of the QX2. Plug the preheater power cable into a grounded outlet. The preheater is now set-up and ready to aid in the rework of your first component. VACUUM CUP ATTACHMENT Remove the nozzle (see Nozzle Removal, p.12.) Choose a vacuum cup that is properly sized for the component and the nozzle. Push the vacuum cup up onto the vacuum tube. The vacuum tube will automatically stop with the correct length of tube extended for the vacuum cup. DO NOT hold the tube at the top or the cup will not be attached properly. Be sure that the cup is attached level, so it will rest flush on the component. Vacuum cups that are cocked may not hold a component. Remove the nozzle. REMOVAL Use the notch in the Nozzle Removal Tool to pull the vacuum cup from the vacuum tube. WARNING: The nozzle, cup and heater head may be hot. MAINTENANCE A clean and pliable vacuum cup is critical to proper component removal. Vacuum cups will degrade over time and should be changed when they become brittle, cracked, or torn. They should also be wiped cleaned of dirt and debris as necessary. (See also Troubleshooting, p.14). VACUUM TUBE MAINTENANCE Over time, the vacuum tube may become clogged, especially if you have been using flux, which can condense inside the tube. To clean the tube, first turn the system off and allow it to cool. Then remove the flexible vacuum hose from the top of the tube at the top of the heater head, and remove the vacuum cup from the bottom of the tube. Run a stiff wire or rod (maximum diameter: 1.53mm) through the tube to clean it out. Airflow Control On/Off Button OPERATION The preheater delivers hot air to the bottom of the PCB. There are four power settings, controlled by the airflow control knob (see figure above). The settings correlate to power delivery of 150 to 950 watts, resulting in a PCB temperature range of 90 to 120ºC, with an average across-board temperature gradient of 2ºC/cm. Choose a power setting appropriate for your application. Use a higher setting for larger PCBs and quicker removals. Use a lower setting for smaller PCBs and lower temperature ramp rates. To start the preheater, press the On/Off Button. If the preheater is connected to the QX2, it will turn on or off automatically with the QX2 operation cycle. To start the preheater before the QX2, simply press the On/Off button prior to operating the QX2 unit. 10 11

NOZZLE ATTACHMENT Insert the nozzle into the bottom of the heater head by pushing up firmly until it clicks into place. NOZZLE REMOVAL Position the nozzle removal tool so that the flexible arms surround the nozzle. Turn the theta rotation lever fully in either direction until the nozzle releases from the heater head. WARNING: The nozzle may be hot. FOCUSED CONVECTION NOZZLES Nozzle P/N Component Type NZ-Q11 PLCC 20 NZ-Q13 PLCC 28 NZ-Q17 QFP 44 NZ-Q18 QFP 52/80 NZ-Q19 PLCC 44 NZ-Q22 PLCC 52 NZ-Q23 BQFP 100 NZ-Q27 PLCC 68 NZ-Q28 BQFP132 NZ-Q32 PLCC 84, QFP 208 NZ-Q33 QFP 120/128/144/160 NZ-Q1415 PLCC 32 NZ-Q1925 QFP 100 NZ-D1113 SOL 20 NZ-D1116 SOL 28 NZ-D1420 TSOP 24-28/40-44 NZ-D2109 TSOP 28-32 NZ-D2113 TSOP 48 More nozzles may be available; contact your local Metcal representative for details. 12 13

TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE SOLUTION No display on controller No power Be sure power cord is plugged into the power supply and a grounded outlet and the power switch is ON. Same as above Controller not Be sure the controller cable is plugged into the connected controller and the power supply. Same as above Blown fuse or other Call Metcal RMA Department. internal circuit failure. ERROR CODES The QX2 is programmed to identify certain problems in the proper function of the system. If one of these problems occurs, the system will shut down and one of the following error codes will appear on the controller display. The system must be turned off to reset the error message. Int Temp Error The internal temperature of the power supply is too high and may damage the electronic circuitry. If this error occurs repeatedly, the QX2 should be moved to a cooler location. The nozzle won t stay when The nozzle removal lever is Rotate the lever away from the stopping point and inserted into the heater head stuck in the release position try inserting the nozzle again. The removal complete icon Vacuum tube pushed too high Remove and re-attach the vacuum cup per the appears immediately upon by a tall component. directions in this user guide. Then use the Z-axis starting a removal. knob to lift the nozzle farther from the component during removal so the vacuum tube is not pushed up as far. The removal complete icon Same as above Same as above appears after 5 seconds, the vacuum cup is still holding the component, but the component is still attached to the board. The removal complete icon No vacuum cup, or vacuum Attach a vacuum cup per the directions in this appears after 5 seconds, and cup is too small guide. See p. 11. the vacuum tube has pulled away from the component without removing it. The removal complete icon Dirty, torn, cracked or Remove the old vacuum cup and install a new appears before the hardened vacuum cup one per the directions in this user guide. component is removed, and (See also Maintenance - Vacuum Cup ) the vacuum cup has pulled off the component. Same as above Vacuum cup is crooked on Remove and re-attach the vacuum cup per the the vacuum tube and doesn t directions in this user guide. rest flush on the component. Same as above Low vacuum due to a Replace the vacuum cup and clean the vacuum clogged or leaking tube, tube per the directions in Vacuum Tube filter, or pump Maintenance. If the problem persists, contact Metcal Customer Care. Same as above, except it Vacuum cup is too cold and Hold the top of the vacuum tube for at least five mainly occurs when the therefore too stiff to hold seconds until the vacuum cup can hold for itself. machine is just started or with a new vacuum cup The component lifts from the Component leads are caught Be sure you are using the correct nozzle for that board, but the hot air does on one of the nozzle flutes component. Nozzles are designed to allow space not stop. for the component leads. (See the Nozzle Selection Chart) Same as above Same as above Be sure the part is centered under the nozzle when the cycle begins. Same as above The vacuum cup is pushed Remove and re-attach the vacuum cup per the too far onto the tube, so it directions in this user guide. can t rise enough Same as above, except only The spring is too weak Contact Metcal Technical Services for with very large components to lift the component instructions on how to increase the spring tension. Overtemp Error Heater Error Control Timeout Comm Error The temperature of the heater is too high. Contact Metcal Technical Services if this error occurs repeatedly. The controller has not detected a temperature from the heater, indicating a broken heater or thermocouple. The power supply and controller have been out of communication for too long. This error will occur if you unplug the controller cable while the system is on. The power supply or controller got a signal that it did not understand. If it happens repeatedly, contact Metcal Technical Services. 14 15

WARRANTY Metcal, Inc., warrants the QX2 system against any defects in materials or workmanship for one year from the date of purchase by original owner. Metcal warrants all other products except consumables (e.g. vacuum cups) against any defects in materials or workmanship for one year from the date of purchase by the original owner. If the product should become defective within the warranty period, Metcal, Inc. will repair or replace it free of charge at its sole option. The replacement item(s) will be shipped, freight prepaid, to the original purchaser. The warranty period will start from the date of purchase. If the date of purchase cannot be substantiated the date of manufacture will be used as the start of the warranty period. To return a failed unit for repair or replacement, follow the steps outlined below. This offer does not apply to any previously opened, modified, repaired, altered, misused or damaged unit. RETURN PROCEDURE Call Metcal at 44 1703 489100 to obtain a returned material authorization (RMA) number. Proof and date of purchase must be on file for the returned product(s). Ship materials, freight prepaid, to Metcal, Eagle Close, Chandler s Ford, Eastleigh, Hampshire, SO53 4NF England. Input voltage Convection system Heater Rated current Air flow Preheater Heater Rated current Heating surface Weight Convection Rework System Board Holder Preheater Outer Dimensions (W x D x H) Convection Rework System Board Holder Preheater SPECIFICATIONS 220-260 VAC, 50/60 Hz 550 W 2.5 amps 20 to 50 liters/min 950 W 4.5 amps 152 mm x 152 mm 8.2 kg 2.5 kg 2.9 kg 292 mm x 521 mm x 361 mm (Operating) 292 mm x 427 mm x 533 mm (Stored) 521 mm x 381 mm x 127 mm 208 mm x 394 mm x 64 mm Vacuum Operator control interface Component removal Component attachment Nozzle attachment/removal FEATURES Self-contained Moveable controller with: Start/Stop button Airflow control Time control LCD display Remove/attach control Automatic component lift off and heater shutoff Manual, timer controlled Push on, quick release Component temperature monitoring Auxiliary thermocouple port 16 17