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Author Topic: PCB Rework and replacing IC [PICS]  (Read 11460 times)
fromme
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« on: October 10, 2012, 02:40:39 PM »
I am new to this forum, so please donˇt hate me if this is a little bit OT, but I will try to show also something before and after ;o)

So, I received an IGT S2000 with some ICs blown and some damage to PCB. I will show here step-by step how I did rework of PCB and replaced an IC with a socket.

First thing was to understand the extent of damage to PCB

* 1. Dam1.jpg (91.32 KB, 855x642 - viewed 472 times.)

* 2. Dam2.jpg (120.73 KB, 855x642 - viewed 526 times.)
« Last Edit: October 15, 2012, 04:05:18 AM by fromme » Logged
fromme
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« Reply #1 on: October 10, 2012, 02:44:27 PM »
The damage for this IC was local, so it was worth to start removing the IC and clearing the burned area of tracks.

Before I cut the legs and desoldered, I made some pics to remember track routings, then I lifted the tracks from burnt area.

* 3. remove0.jpg (59.03 KB, 528x396 - viewed 442 times.)

* 4. remove1.jpg (90.15 KB, 528x396 - viewed 621 times.)
« Last Edit: October 10, 2012, 02:57:31 PM by fromme » Logged
fromme
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« Reply #2 on: October 10, 2012, 02:46:06 PM »
Lifted tracks from backside and started to cut the board.

* 5. remove2.jpg (96.38 KB, 528x396 - viewed 496 times.)

* 6. remove3.jpg (105.9 KB, 528x396 - viewed 512 times.)
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fromme
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« Reply #3 on: October 10, 2012, 02:47:20 PM »
Finished cutting the board and made a phase (step edge).

* 7. remove4.jpg (79.06 KB, 528x396 - viewed 474 times.)

* 8. remove5.jpg (101.86 KB, 528x396 - viewed 546 times.)
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fromme
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« Reply #4 on: October 10, 2012, 02:48:32 PM »
Designed new piece and used a CNC.

* 9. disain.JPG (8.11 KB, 162x191 - viewed 751 times.)

* 10. newpc1.jpg (60.19 KB, 528x396 - viewed 444 times.)
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fromme
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« Reply #5 on: October 10, 2012, 02:49:46 PM »
Then I cut and phased the piece and fitted in the hole.

* 11. newpc2.jpg (59.69 KB, 528x396 - viewed 470 times.)

* 12. replace1.jpg (78.09 KB, 528x396 - viewed 518 times.)
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fromme
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« Reply #6 on: October 10, 2012, 02:50:56 PM »
Used some slow epoxy and grinded the surface.

* 13. replace2.jpg (93.63 KB, 528x396 - viewed 541 times.)

* 14. replace3.jpg (92.01 KB, 528x396 - viewed 503 times.)
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fromme
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« Reply #7 on: October 10, 2012, 02:54:11 PM »
Installed new througholes, soldered the tracks, replaced some tracks and soldered the socket. And covered with lacquer.

Thats it!

* 15. replace4.jpg (92.28 KB, 528x396 - viewed 431 times.)

* 16. replace5.jpg (101.73 KB, 528x396 - viewed 501 times.)
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FORDSBS
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PET
« Reply #8 on: October 10, 2012, 03:15:55 PM »
 Congratulations Nice job, Ford
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Oscar Pompa
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« Reply #9 on: October 10, 2012, 04:16:34 PM »
Very Good Job Ford  YOU ROCK!!!

How long did you take in this job ??  Scratch Head
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FORDSBS
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PET
« Reply #10 on: October 10, 2012, 04:21:35 PM »
It was not me, it was fromme.
Ford
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Oscar Pompa
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« Reply #11 on: October 10, 2012, 04:34:29 PM »
upsS!!  Duh! jajaja

nice job Fromme !!!

i just woke up !!  zzzzzzz i didnt read properlly !! jajaja
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crgadyk
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« Reply #12 on: October 10, 2012, 05:47:10 PM »
Very impressive. With damage like that I would have never even thought about it being repairable.
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tkrozleski
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« Reply #13 on: October 10, 2012, 10:36:49 PM »
Beautiful work! I was not aware such a repair could be done like this.
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fromme
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« Reply #14 on: October 11, 2012, 01:30:25 PM »
Quote from: argelisho on October 10, 2012, 04:16:34 PM
Very Good Job Ford  YOU ROCK!!!

How long did you take in this job ??  Scratch Head



It took me  about 2 full days of work, whole process about 4-5 days(epoxy-oven, CNC, etc).
Nowadays it is usually cheaper to buy new PCB - so it is a hobby now, I just like to piddle with the boards sometimes.
Another problem with this kind of repair is that PCBs used in new electronics may have up to 20 layers. With similar technique I am able to cover only 6 layers (3 from one side and 3 from other), probably takes 2 weeks(never tried more layers).
Anyways only place where this kind of job would pay off is military systems(fighters, radars etc), where the PCBs cost hundreds of thousands, but they are not so anxious to outsource ;o( so I repair slots and pokers for fun ;o)
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startek2
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« Reply #15 on: March 01, 2013, 10:20:15 PM »
dang i think i would have just used jumper wires......
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