FAQs
Technical
PDR offers various different pickup tips ranging from 01005 size to a larger BGA size. We can also manufacture speciality tips for speciality components. Please take a look at our tip chart.
Our lamps can illuminate for 50 hours at 100% power however we are only using 100% power for the last 20% of the profile. This means that our lamps typically can last around 300 Hours of cycle.
PDR's largest system, the IR-E6 XL Evolution, can handle PCB's up to 24". As this system features a Gantry heating head we can reach every corner of the PCB with ease.
There is no minimum PCB size our rework systems can handle. We would reccomend using a PCB pallet to help with the heat transfer on micro PCB's.
Anything inside the visible IR beam will reach reflow. If the adjacent components are heat sensitive, you can mask them off with some reflective tape. As you have the visible heating spot you can work out which components you need to protect if need be.
If the adjacent parts are not heat sensitive then you do not need to worry too much as there is no airflow on our systems which means that the components will not blow about if they have reached reflow.
Lens attachments are PDR's alternative to Hot-Air Nozzles, except you do not need to purchase a new one each time you work on a new component as we just adjust the size of our heating spot with an adjustable Iris.
Since 1987, PDR has eliminated the need for Nozzles with a simple hassle free solution. The majority of our customers will purchase two lens attachments, This way they can cover the majority of components. When choosing a Lens Attachment, you have to remember that we have a MIN/MAX spot size for each Lens and whatever is inside the spot is going to reach reflow.
Because 150W's is all the energy a PDR rework systems requires to precisely reflow a component, connector, module etc. PDR's ultra-efficient top heater system is powered by a 15v Tungsten Halogen Light Source, yet able to achieve the same temperatures and with greater thermal control than competing technologies. Therefore, a PDR System utilizes less energy to get the job done... which in turn helps to reduce your Firm's overall energy consumption, which in turn helps the planet.
PDR has active customers using our equipment to rework and repair 01005's. We would recommend a IR-E3M evolution system for small cap rework as it is fine tuned for Micro.
PDR has active customers using their system for 55 x 55mm BGA's. This is the largest size component that can be handled on a standard PDR System. If you have a component larger than 55x55mm, PDR Engineering is capable of providing a solution according to your specific needs on a case by case basis. Please inquire with PDR Engineering Services should you require a grater than 55x55mm heating area.
PDR has recently acquired serial number 0025 which was made in 1987. This system still works and is capable of melting solder. PDR rework systems are made from the finest components available therefore our machines often last 10+ years before customers decide to upgrade to the latest spec.
We recommend that you Do Not Allow the Infra-Red spot from the lens unit to make contact with exposed skin (including fingers) other than for a very short period (less than 5 seconds), since tissue damage (burning) may result.
Tests
Extensive tests have been conducted covering both Electrical and Infra-Red safety aspects on all of PDR's products. The tests were administered by a National Physical Laboratory-approved establishment: ERA based at Leatherhead, Surrey, England.
Results
The Infra-Red system was tested for its maximum emission produced during working operation and the following results obtained:
- On a non-reflective surface, i.e. FR4 substrate, if one's eye is placed 150mm away looking down at an angle one could be subjected to approximately 0.9mW/cm2 at full power.
- On a reflective surface, i.e. polished aluminium at a normal distance of 300mm, one would be subjected to approximately 0.9mW/cm2.
Explanation
These levels are about 10% of the maximum recommended.....It was very hard to establish this because there are no European/US regulations that cover it. They cover Laser...but this is not a laser technology.
Also IR is not a 'ionizing' radiation and is not causing cancer or anything like that. The IR source is very similar to a Tungsten-Halogen display lamp. Any discomfort could be due to the brightness....it doesn't bother many people but it possibly could.
- Focused IR heating process
gentle, effective and instantly/precisely controllable, producing an ultra-high yield. - No nozzles, focus hoods, tooling or shields
an iris adjuster precisely sets the IR spot size from Ø4 - Ø70mm. - No interference with adjacent components
they are not overheated or blown away. - Easy to set up and use
uncomplicated and simple to operate. - Excellent mechanics
precise component/PCB handling. - Auto-profiling software
makes thermal profiling easy to accomplish and repeat. - Modular and upgradeable
systems can easily be configured to meet current and future requirements.
The short answer, Yes we can.
PDR has solved the biggest myth in BGA/SMD Rework by a simple roll of Thermoactive tape. As IR reflects of shiny surfaces, we are unable to heat the component efficiently on its own. To solve this, we use a black thermoactive tape to create non reflective component and therefore can rework the component in the usual way with 99% Yield.
This is a common misconception with PDR's Focused IR fabricated by Hot-Air competition.
In principle a component is subjected to a ‘micro oven’ environment, being carefully heated to reflow from above and below.
Focused IR is generated from a 150w tungsten-halogen lamp. An IR spot is projected through a series of special lenses and focused on to the component. The component being heated is isolated from adjacent by adjusting the IR spot to size with an iris.
As well as heat from above, there are quartz IR heaters to preheat the PCB from below, non-contact sensors measure component and PCB temperatures during the process.
In a multi-zone process all temperatures and times are easily adjusted and controlled. The process is exceptionally clean, easy to create and precisely repeatable.
PDR's infrared technology is not like any other IR system on the market. PDR's IR technology is different, we use short wave IR and project the light energy through a lens unit to create a Visible Focused IR Beam. It is called Focused IR because we are focusing the IR energy through the PDR lens unit and therefore creating a focusable and size adjustable heating spot/area to perform rework. Other competitive IR technologies use Medium wave IR for the top heater, which is what PDR uses to preheat the PCB from underneath. Standard Non-visible/Non-Focusable IR Systems usually look like a standard heating panel and are not visible to the eye leading to guesswork as to what is actually being heated.
General
We recommend that you Do Not Allow the Infra-Red spot from the lens unit to make contact with exposed skin (including fingers) other than for a very short period (less than 5 seconds), since tissue damage (burning) may result.
Since 1987 we have successfully supplied over 4500 systems to the world's electronics industry.
PDR was formed in 1985 by Philip Gibbs, David Lowrie and Roger Gibbs and our first pioneering IR system was launched in 1987. Over 35 years later, PDR is still at the forefront of SMD rework, X-Ray and Test technologies working with many of the world's top names in,
• Mobile Phone, PDA, Tablet, Laptop, Desktop, Server repair
• Consumer electronics, Set-top, TV, Game Console repair
• Aerospace, Weapons, Avionics, Automotive, Transport electronics
• Control and systems repair, R&D, assembly and repair rework
To support our customers, we provide a Gold Standard Sales and Technical Support service from our PDR regional offices plus a global network of professional sales/support partners and since 1987 we have successfully supplied over 4500 systems to the world's electronics industry.
There are many different Rework. X-Ray and Test System choices to choose from but our customers feel comfortable choosing PDR, returning to us time and time again to benefit from our advanced precision thermal engineering Rework Systems, X-Ray imaging quality, and highly accurate and affordable Thermal Testing Solutions.
Tests
Extensive tests have been conducted covering both Electrical and Infra-Red safety aspects on all of PDR's products. The tests were administered by a National Physical Laboratory-approved establishment: ERA based at Leatherhead, Surrey, England.
Results
The Infra-Red system was tested for its maximum emission produced during working operation and the following results were obtained:
On a non-reflective surface, i.e. FR4 substrate, if one's eye is placed 150mm away looking down at an angle one could be subjected to approximately 0.9mW/cm2 at full power.
On a reflective surface, i.e. polished aluminium at a normal distance of 300mm, one would be subjected to approximately 0.9mW/cm2.
Explanation
These levels are about 10% of the maximum recommended.....It was very hard to establish this because there are no European/US regulations that cover it. They cover Laser...but this is not laser technology.
Also, IR is not a 'ionizing' radiation and is not causing cancer or anything like that. The IR source is very similar to a Tungsten-Halogen display lamp. Any discomfort could be due to the brightness....it doesn't bother many people but it possibly could.
Philip Gibbs
David Lowire
Roger Gibbs
PDR was formed in 1985 by Philip Gibbs, David Lowrie and Roger Gibbs and our first pioneering IR system was launched in 1987.
PDR offers an industry leading 2 years standard warranty on its rework system.
PDR's infrared technology is not like any other IR system on the market. PDR's IR technology is different, we use short wave IR and project the light energy through a lens unit to create a Visible Focused IR Beam. It is called Focused IR because we are focusing the IR energy through the PDR lens unit and therefore creating a focusable and size adjustable heating spot/area to perform rework. Other competitive IR technologies use Medium wave IR for the top heater, which is what PDR uses to preheat the PCB from underneath. Standard Non visible/Non Focusable IR Systems usually look like a standard heating panel and are not visible to the eye leading to guess work as to what is actually being heated.
PDR recommends having your PDR system fully serviced by an Authorized Service Partner once a year. During this visit, a comprehensive "check out" of your system is performed to include the maintenance and lubrication of your system, minor part replacement, software checks/upgrades, safety checks, as well as the calibration of the controller and temperature devices (Sensors/Pyrometers). This service will ensure that everything is working how it should be and help you to keep your system in good shape for years to come.
For general use, we recommend calibrating the split beam prism once a month, or if you have knocked the prism or moved the system we would recommend checking the calibration. The calibration of the prism takes around 30 seconds and is very simple to do. A split beam optical alignment tool is included with each PDR System sold. Instructions to perform this calibration activity can be found in your PDR manual and/or additional FAQ topics on this website.
PDR can also provide a Calibration Checking Kit which will allow you to calibrate the controller and sensors/pyrometers without a factory visit. This process is easy to perform and PDR provides detailed instructions on how to do this if you choose this option. Please check with your local PDR Distributor regarding how to obtain a "Calibration Checking Kit" for your PDR System.
Yes... if your firm is on record as the original purchaser of a PDR System, PDR will provide download links to download any patches/updates necessary to keep your original software version running up to date and efficiently.
PDR's Next Generation Software Development Program is constantly producing new features and specialized modules to provide innovative tools to lend intelligence to the rework process. These tools are designed with the specific intent to simplify the rework process for the system operator by incorporating both general and application-specific tools to enhance both the operator experience and ultimately your Organization's rework precision capability. PDR recommends the purchase of PDR's latest software in 2-3 year intervals to take advantage of the latest in PDR Software. Software upgrades are priced reasonably and new features are intuitively mastered by the operator. PDR also offers online training sessions that are available for new users and/or experienced PDR operators wanting a brush up on Software Features and Best practices.
Please check with your PDR Representative regarding software pricing, online training, and software support.
Yes and No.
Yes - PDR Software offers many automated and semi-automated profiling features to assist the user when creating and executing profiles. Automatically Create new profiles easily with PDR Thermo-Active Suite Software and run daily profiles with PDR's Dynamic In Process Control Capabilities. PDR Systems' intelligent software capabilities allow novice users to master the profiling process quickly and easily.
Fully Automated Rework.
PDR believes that a Rework System should offer the customer the option of both a manual process as well as the option for an automated process to provide the greatest degree of flexibility in a single rework system. This concept is also applied to upgrading our Rework Systems from manual to automated should a customer initially choose manual mechanics, yet later decide to upgrade to automation mechanics.
Good News for Rework Professionals is about to arrive! Imagine a Rework System that gives Your Team the Flexibility Advantage in any environment! Coming in 2021 is PDR Rework System Automation, specifically conceived to provide greater control over your budget, your time, and the need to address new and challenging rework tasks. Stay tuned for this exciting new development as PDR releases new systems in 2021.