IR6500 professional BGA Rework station

Build it yourself for $500 –PART 1

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Parts needed to build an infrared BGA rework station - 1 Parts list
• 1x - Computer Case (HTPC) for
ATX boards
• 4x - M5 - 10mm Hand Knob
Tightening Screw
• 1x - GX16 male female, 4Pin
• 2x – 7-hole Terminal Block
Connection
• 1x - BGA Jig Support Clamp with
Computer Case (HTPC) M5 - 10mm GX16 male female, 4Pin 7-hole Terminal Block Connection 4PCS Screws for IR6500
Hand Knob Tightening Screw
• 6x - 30/40A 250V AC High Current
Switches
• 1x - 3W DC12V 24V LED CNC
Machine Tool Light Flexible L40cm
• 1x - BGA IR6500 Infrared upper
heater top head built-in 450W
ceramic plate for ACHI IR6500

BGA Jig Support Clamp with 4PCS 30/40A 250V AC High Current 3W DC12V 24V LED CNC Machine
Screws for IR6500 Switches Tool Light Flexible L40cm

BGA IR6500 Infrared upper heater

top head built-in 450W ceramic
plate for ACHI IR6500

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Parts needed to build an infrared BGA rework station - 2 Parts list
• 1x - PC410 Temperature Controller
Panel For BGA Rework Station
with RS232 Communication
Module
• 1x - REX-C100 VAN PID
Temperature Controller Digital
Display Thermostat SSR Relay
Output
• 2x - Original Omega K Type
PC410 Temperature Controller Panel REX-C100 VAN Omega K Type Thermocouple Wire
Thermocouple Wire sensor with
PID Temperature Controller Magnetic Holder for bga rework
machine bga repair
• 4x – 240x60mm 600W Infrared
bottom ceramic heating plate for
BGA rework station for BGA
machine IR6500
• 1x - Serial 9 Pin DB9 RS232
Motherboard Com Port Ribbon
Cable
• 1x – 64Amp CNC 230V 50/60 HZ
RCBO MCB 30mA Residual Current
Circuit Breaker With Over Current
And Leakage Protection

serial port Serial 9 Pin DB9 RS232

240x60mm 600W Infrared bottom Motherboard Com Port Ribbon 64Amp CNC 230V 50/60 HZ RCBO
ceramic heating plate Cable MCB 30mA Residual Current Circuit
Breaker

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Parts needed to build an infrared BGA rework station - 3 Parts list
• 4m – 3 wire electrical wire
• 2x – Connector terminal kit
• 2x - Industrial Solid State Relay
SSR 50A with Protective Flag SSR-
50DA 50A DC control AC
Industrial • 2x – Connector strip
Solid State Relay SSR 50A
• 1x - 12V 1A Power Supply Module,
AC 100V-240V to DC 12V Switching
Power Supply Board
3 wire electrical wire Connector terminal kit • 1x - Monitor Arm for VESA screen
till 34 inch

Connector strip 12V 1A Power Supply Module

Monitor Arm for VESA screen till 34 inch

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Parts needed to build an infrared BGA rework station - 4 Parts list
• 3x – Aluminium profile 2020
extrusion length 1 m
• 4x – Corner connections with
screws for 2020 aluminium profile
• 3x – set of 20 M4 Standard Drop In
T-Slot Carbon Steel for 2020
• 1x – set of 50 allen socket head
screw M4x16
• 8x - SK8 rod mount
• 1x – Rod 8 mm x 100 cm for X- of Y-
Aluminium profile 2020 extrusion Corner connections with screws for M4 Standard Drop In T-Slot Carbon Set of 50 as
length 1 m 2020 aluminium profile Steel for 2020 allen socket head screw M4x16
• 1x – Set of 50 set allen socket head
screw M4x10
• 1x – Set of 10 M5 Standard Drop In
T-Slot Carbon Steel for 2020

SK8 rod mount Metal rod 8 mm x 100 cm Set of 50 M5 Standard Drop In T-Slot Carbon
allen socket head screw M4x10 Steel for 2020

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Parts needed to build an infrared BGA rework station - 5 Parts list
• 1x - SV2-4 Blue Furcate Cable Wire
Connector 100PCS/Pack Furcate
Pre-Insulating Fork Spade 16-
14AWG Wire Crimp Terminals
SV2.5-4 SV
• 2x – K Type Panel Mount
Thermocouple Miniature Socket &
Plug Connector Thermocouple
Plugs and Sockets Sensor
• 2x - 50PCS 25Set MPD FRD PVC
Bullet Shaped Female Male Butt
Insulating Terminal Electrical
SV2-4 Blue Furcate Cable Wire K Type Panel Mount Thermocouple M4 Height 10 mm Aluminum flat Audio Wire Crimp Connector
Connector 100PCS/Pack Furcate Pre- Miniature Socket & Plug Connector washer aluminum Bushing gasket
Insulating Fork Spade 16-14AWG Thermocouple Plugs and Sockets Spacer Non-threaded standoffs • 2x - Heat Shrink wrapped
Wire Crimp Terminals SV2.5-4 SV Sensor Shrinking Insulation Sleeving
Thermal
• 2x – 20pcs - M4 Height 10 mm
Aluminum flat washer aluminum
Bushing gasket Spacer Non-
threaded standoffs

50PCS 25Set MPD FRD PVC Bullet

Shaped Female Male Butt Insulating
Terminal Electrical Audio Wire Crimp
Connector
Heat Shrink wrapped Shrinking
Insulation Sleeving Thermal

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Total price
Amount Description Price (euro)
1 Computer Case (HTPC) for ATX boards – (second hand) 28

4 M5 - 10mm Hand Knob Tightening Screw 3

1 GX16 male female, 4Pin 2

2 7-hole Terminal Block Connection 7

1 BGA Jig Support Clamp with 4PCS Screws for IR6500 12

6 30/40A 250V AC High Current Switches 11

1 3W DC12V 24V LED CNC Machine Tool Light Flexible L40cm 11

1 BGA IR6500 Infrared upper heater top head built-in 450W ceramic plate for ACHI IR6500 42

1 PC410 Temperature Controller Panel For BGA Rework Station with RS232 Communication Module 55

1 REX-C100 VAN PID Temperature Controller Digital Display Thermostat SSR Relay Output 11

2 Original Omega K Type Thermocouple Wire sensor with Magnetic Holder for bga rework machine bga repair 20

4 240x60mm 600W Infrared bottom ceramic heating plate for BGA rework station for BGA machine IR6500 52

1 Serial 9 Pin DB9 RS232 Motherboard Com Port Ribbon Cable 3

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Total price
Amount Description Price (euro)
1 64Amp CNC 230V 50/60 HZ RCBO MCB 30mA Residual Current Circuit Breaker With Over Current And Leakage Protection 5

4 3 wire electrical wire (1m in total 4 m) 3

1 Connector terminal kit 3

2 Industrial Solid State Relay SSR 50A with Protective Flag SSR-50DA 50A DC control AC 8

2 Connector strip 3

1 12V 1A Power Supply Module, AC 100V-240V to DC 12V Switching Power Supply Board 5

1 Monitor Arm for VESA screen till 34 inch (second hand) 26

3 Aluminium profile 2020 extrusion length 1 m 35

4 Corner connections with screws for 2020 aluminium profile 11

3 Set of 20 M4 Standard Drop In T-Slot Carbon Steel for 2020 15

1 Set of 50 allen socket head screw M4x16 4

8 SK8 as-bevestiging 31

1 Rod 8 mm x 100 cm voor X- of Y-as 7

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Total price
Amount Description Price (euro)
1 Set of 50 allen socket head screw M4x10 cilinderkop 5

1 SV2-4 Blue Furcate Cable Wire Connector 100PCS/Pack Furcate Pre-Insulating Fork Spade 16-14AWG Wire 4
Crimp Terminals SV2.5-4 SV
1 2pcs/lot Omega K-Type Thermocouple Sensor Temperature Wire for IR6000 IR6500 IR9000 BGA 6
Rework Station BGA Machine Repairing
2 50PCS 25Set MPD FRD PVC Bullet Shaped Female Male Butt Insulating Terminal Electrical Audio Wire 5
Crimp Connector
1 Heat Shrink wrapped Shrinking Insulation Sleeving Thermal 4

2 M4 Height 10 mm Aluminum flat washer aluminum Bushing gasket Spacer Non-threaded standoffs 4

1 Set of 10 1x –M5 Standard Drop In T-Slot Carbon Steel for 2020 1

Maximum (all new products) TOTAL 599

Minimum (second hand pc case and TOTAL 442

monitor arm)

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PC410 – Top heater / temperature controller

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PC410 – Top heater / temperature controller

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REX-C100 – Bottom heater

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REX-C100 – Bottom heater

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REX-C100 – Bottom heater

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220V Wiring
Chassis Ground

Power

Main power
switch N PC410 PIN 2
Block connection REX C100 PIN 1
Top Heater
Bottom heater
12V power supply input

64Amp CNC 230V 50/60 HZ RCBO

MCB 30mA Residual Current Circuit
Breaker

PC410 PIN 1
REX C100 PIN 2
Relay Top Heater PIN 2
Relay Bottom Heater PIN 2
L 12V power supply input
Block connection

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REX-C100 – Bottom heater
L N
Block connection Block connection

-
FROM PIN 7 -
PC410

OUT 2
FROM PIN 6 +
PC410 +
Bottom heaters
OUT 2

On/off switch
Bottom heater 3 + 4

K Thermocouple
bottom

On/off switch
Bottom heater 1 + 2
Relay
Bottom heater

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12V power supply for LED and FAN’s
On/off switch
LED

LED

FAN

12V power supply

L N
Block connection Block connection On/off switch
Top FAN

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PC410 COM port L
Block connection
N
Block connection

- + Power

RX TX GND

TO SSR+ on REX-
C100 TO SSR+ - +
PIN 4 Bottom heater
Relay + -

Top heater
STOP

RUN

Relay
Top heater
K Thermocouple
top

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REX-C100Thread
– Bottom
M6
heater

Thread M4
4x 34 cm

2 cm

16,5 cm 2,5cm

13 cm

1cm
1,5cm

2x 37,5 cm
(rod)
2x 33 cm
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Pinout Top Heater G16 – 4 pin

PIN 4 = phase
PIN 1 = +12V
AC 220v t0
(fan)
heating coil

PIN 3 = neutral PIN 2 = GND

AC 220v t0
heating coil

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Building – IR6500 BGA Rework station
Build it yourself for $500 –PART 2

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REX-C100 – Bottom heater

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 IR6500 BGA Rework station
Calibration & Settings –PART 3

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Zero Calibration – PC410
Calibrating a PC410 temperature
controller involves ensuring that it
accurately measures and controls
temperature within the desired range.
zero calibration is to ensure
accurate readings when no
temperature difference exists
between the setpoint and the
actual temperature.

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Zero Calibration – REX-C100
Calibrating a REX-C100 temperature
controller involves ensuring that it
accurately measures and controls
temperature within the desired range.
zero calibration is to ensure
accurate readings when no
temperature difference exists
between the setpoint and the
actual temperature.

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Ice point calibration – step 1 - Prepare Ice Bath

Start by preparing a stable ice bath. Fill a

container with crushed ice or ice cubes and
add just enough water to cover the ice.

Stir the mixture to ensure a uniform

temperature throughout. Let the ice bath
stabilize for a few minutes to ensure the
temperature reaches equilibrium.

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Ice point calibration – step 2 - Verify Ice Point

Use a calibrated reference thermometer to

measure the temperature of the ice bath.

It should read very close to 0°C (32°F). The

accuracy of the reference thermometer is
crucial, as any error in its measurement will
propagate to the calibration process.

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Ice point calibration – step 3 - Immerse Sensor
Immerse the temperature sensor into the
ice bath. Ensure that the sensor is fully
submerged and surrounded by the ice-
water mixture.

Allow sufficient time for the sensor to

reach thermal equilibrium with the ice
bath, typically a few minutes.

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Ice point calibration – step 4 - Adjust Calibration
If the thermocouple reading deviates
from the expected 0°C (32°F), you may
need to adjust its calibration.

The offset in temperature between the

thermocouple and the reference
thermometer can be adjusted in the
temperature controller

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Temperature calibration offset – REX-C100 – Pre-heater

Long press to get to the settings menu

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Temperature calibration offset – REX-C100 – Pre-heater

Press 1x to select a setting

Go to setting SC
(Sensor Correction)

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Temperature calibration offset – REX-C100 – Pre-heater
If the thermocouple reading
deviates from the expected 0°C

The offset in temperature

between the thermocouple and
the reference thermometer can
be adjusted in the temperature
controller

Decrease temperature offset. Increase temperature offset.

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Temperature calibration offset – REX-C100 – Pre-heater

Long press to get out of the settings menu

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Temperature calibration offset – PC410 – Top heater

zero calibration is to
ensure accurate
readings when no
temperature difference
PRESS key and hold
exists between the 3 seconds
setpoint and the actual
temperature.

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Temperature calibration offset – PC410 – Top heater

PRESS key to scroll to

parameter

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Temperature calibration offset – PC410 – Top heater

ADJUST the offset temperature

by pressing
Up / Down key

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Setting up – REX-C100 – Pre-heater Measured value (PV)

Indication LED’s
Set value (SV)
ALM1: Lights when alarm 1 output is turned on.

OUT1: Lights when control output is turned on. (SSRS)

ALM2: Lights when alarm 2 output is turned on.

Autotuning (AT) LED

Flashes when autotuning is activated.
(After autotuning is completed: AT lamp will go out)

Used for parameter calling up

and set value registration.

Shift digits when settings are

changed.

Decrease numerals. Increase numerals.

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Set bottom temperature – REX-C100 – Pre-heater

Press 1x

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Set bottom temperature – REX-C100 – Pre-heater

Set bottom temperature to

180 degrees

Decrease temperature. Increase temperature.

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Set bottom temperature – REX-C100 – Pre-heater

Press 1x to go back to the main screen

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Autotuning– REX-C100 – Pre-heater

Long press to get to the settings menu

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Autotuning– REX-C100 – Pre-heater

Press 1x to select a setting

Go to setting ARU
(Autotuning)

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Autotuning– REX-C100 – Pre-heater

Set value to 1
To set autotuning ON

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Autotuning– REX-C100 – Pre-heater

Press 1x to go back to the main screen

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Autotuning– REX-C100 – Pre-heater

Wait unit AT LED stops blinking

This can take a while (10-15 minutes)

Flashes when autotuning is activated.

(After autotuning is completed: AT lamp will go out)

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Setting up – PC410 – Top heater
It is lit when the time(TIME) is being displayed on
It is lit when the Manipulating value(MV) is the lower display Program parameter setup
being displayed on the lower display. Changes the indication on SV/MV/TIME display
It flashes when the controller is in
active communication with a host
It is lit in manual control computer

It indicates the
Process/Measured Value
Lower parameter key

It indicates the Setting value(SV),

Manipulating value(MV), or Time(TIME)
(The display can be changed by Raise parameter key
the 'DISP SELECT' key)

Indicates the step

number of program Auto / Manual operation selection

The LED indicator is lit

during program control
Parameter settings key
It indicates the pattern
number

During program control, "/"is lit when the PV is rising

During program control, "-"is lit when the PV is constant The LED indicator is lit when
During program control, "\"is lit when the PV is falling output1 is ON – TOP Heater Selects the program pattern Starts the program, changes the mode from fixed
(SSRS) number value control to program control
It is lit when the Setting Value(SV) It is lit when the Alarm 1 output is
The LED indicator is lit when
is being displayed on the lower ON
output2 is ON – BOTTOM Heater
display
SSRS

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Software configuration – PC410 – Top heater

PRESS key and hold

Go to the settings 3 seconds

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Software configuration – PC410 – Top heater

PRESS key to scroll the

parameters

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Software configuration – PC410 – Top heater

ADJUST value by pressing

Up / Down key

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Program parameter setting – PC410 – Top heater

Setting up the
temperature profile

Select the target pattern number

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Program parameter setting – PC410 – Top heater

Choose program parameter

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Program parameter setting – PC410 – Top heater

Display parameter name

Value parameter

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Program parameter setting – PC410 – Top heater

Display parameter name

ADJUST value by pressing
Up / Down key

Value parameter

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Self tuning – PC410 – Top heater

ADJUST target temperature

Witch Up / Down key

"Self-tuning" refers to a feature

where the controller can
automatically adjust its control
parameters based on the
characteristics of the system it's
controlling.

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Self tuning – PC410 – Top heater

PRESS key and hold

3 seconds

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Self tuning – PC410 – Top heater

PRESS key to scroll the

Parameter

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Self tuning – PC410 – Top heater

SET value to
ON

by pressing
Up / Down key

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Self tuning – PC410 – Top heater

PRESS key to scroll till you

are out of the settings screen

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Self tuning – PC410 – Top heater

On this screen the text

Will be blinking, this

means autotune is in
progress

OUT 1 LED will be on

(top heater on)

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Self tuning – PC410 – Top heater

Auto tune process is done

when the text

Is no longer shown

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Set temperature profile 0 – PC410 – Top heater
Profile 0 is used to autotune the
bottom heater (REX-C100)
PV OUT2 must be activated on the PC410
to power the bottom heater up.

PTN - 0
R1 = 1.00
L1 = 0
D1 = 888
R2 = END

hb = 255

D1

R1

L1

TIME

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Set temperature profile – PC410 – Top heater

In a Dwell period, the target

setpoint, which has been
Processed Value
attained, remains unchanged for
Measured Value
a fixed period.

A ramp consists of a
slope(linear gradient).
1 degree increase per
second

target setpoint

Preheat Preheat Soak Reflow Cool

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Set temperature – REX-C100 – Bottom heater
Set temperature to 185 degrees
Bottom heater 1 + 2 + 3 +4 ON
Top heater height => 3 cm
Temp
Time to reach 140 degrees on top of
140 degrees – Top the PCB = 8 min (480 seconds)
thermocouple

Step 2 of pattern 1 will

start – Top heater

185 degrees

480 seconds

140 degrees
Time

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Set temperature profile 1 – PC410 – Top heater Profile 1 is used to remove or reflow
BGA with leaded / unleaded solder.
PTN - 1 There is no specific reflow pattern for
R1 = 1.0 R2 = 1.0 R3 = 1.0 R4 = 1.0 R5 = 1.0 R6 = 1.0 R7 = 1.0 R8 = 1.0 XBOX, PS5, Switch it’s al about
PV L1 = 0 L2 = 190 L3 = 200 L4 = 210 L5 = 220 L6 = 235 L7 = 240 L8 = 255 temperature measurements and time!
D1 = 480 D2 = 66 D3 = 46 D4 = 32 D5 = 35 D6 = 200 D7 = 40 D8 = 40
- STOP PROGRAM Manually
hb = 320 If BGA is reflowed or removed

- BGA nudge test

- Removal BGA
- Reflowing BGA L8 D8
L7 D7
R8
- TOP HEATER OFF L6 D6
R7
- BOTTOM HEATER TO 185 degrees L5 D5
R6

L4 D4 R5

L3 D3 R4

L2 D2 R3 Leaded Lead free

L1 D1
R2

- TOP HEATER ON !! DANGER ZONE !!

R1
After 480 seconds

TIME

Preheat Soak Reflow Reflow Cool

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