FLUX CONDENSER / COOLING MODULE

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The operating principle of the new Condenser Tube Flux Collection System is a series of thin wall heat conductive condenser tubes over a series of collection sumps in the condenser base. The condenser tubes provide approximately 3780 in2 (24387 cm2) of primary cooling surface to condense hot flux vapors onto the tube walls. The tubes are positioned vertically in a “U” shape to allow condensed liquefied flux to drain into the collection sumps under the tubes.

Cooling air from outside the oven cools the external surfaces of the condenser tubes. The flow direction of the cooling air is opposite the direction of the flux vapor flow to provide the most efficient cooling. The flux vapor exhaust volume is approximately 100 to 125 scfm (2.8 to 3.0 m3/min) maximum, while the waste cooling air volume is approximately 200 to 225 scfm (5.6 to 6.2 m3/min) maximum.

The extracted flux vapor enters the removable flux cooling modules at temperatures ranging from 160 °C to 200 °C. Within the cooling module the flux vapor is cooled to between 45 °C to 55 °C and condenses inside the cooling modules. Remaining diluted vapor is then ducted to an exhaust port at one end of the oven’s top shell and is mixed with the clean waste cooling air which ranges from 55° to 65 °C.

The flux cooling modules are easily removed by lifting straight up and out of rear of the oven’s top shell. The weight of each clean cooling module is 19.5 lbs (8.8 kg). Each cooling module is equipped with two handles on its top surface.

Each cooling module is secured to the collector base with a set of four screw-style clamps.

The clamps require the use of a flat head screwdriver, to prevent operators from accidently opening the modules. Each cooling module is also equipped with a safety interlock switch.

Since hot flux vapor enters the cooling modules at temperature ranging from 160 to 200 °C, switches turn off the flow of flux out of the oven to prevent an operator or technician from contact with flux vapor. Removal of a cooling module while running product through the oven may result in flux vapors escaping out the end tunnels and may also affect zone temperatures within the oven.

SELF-CLEANING OF COOLING MODULES & COLLECTOR BASE

Over time, the inside surface of the cooling module tubes will collect a layer of flux film or crystals (snow flakes), decreasing cooling and condensation efficiencies. The time period for this may vary depending on the type of solder paste flux used, the weekly consumption rate of paste, and oven temperature profiles. Removal of this thick film or crystals in the condensation cooling tubes is performed automatically within the oven with or without any operator or technician intervention.

This automated self-cleaning process resides within the oven’s software; not requiring any operator intervention. The initiation of the self-cleaning cycle is recorded in the process job’s event file. The automated self-cleaning cycle timer is factory programmed to be initiated every 168 hours (weekly) to 672 hours (monthly) of oven operating time. The length of time between cleaning will depend on the average solder paste consumption rate. Most industry solder paste consumption rates range from 6.0 to 14.0 kg per week.

When the self-cleaning cycle is initiated, flux cooling air blowers B4, B5, and B6 (refer to Figures 5 thru 9) are turned “OFF.” The flow of flux vapor continues to be pulled out of the oven through the flux collection system without disturbing the oven’s internal temperature profile. The cooling blowers remain “OFF” for the duration of the cycle (20 to 40 minutes depending on oven configuration and zone temperatures). During this time the incoming hot vapor liquefies any thick flux film or crystals within the cooling tubes. The liquefied flux drains from the tubes into the bottom of the collection chambers. When the cycle time is completed, the cooling blowers are turned back “ON” automatically.

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