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  3. Electrovert OmniMax 10 Zone Reflow

Electrovert OmniMax 10 Zone Reflow

Overview

The Electrovert® OmniMax ™ series reflow soldering system is designed to deliver maximum thermal performance combined with process capability and control.  The OmniMax platform offers a combination of industry proven technologies in an easy to use, reliable and efficient reflow system for high-end production requirements.  From lead-free to hybrid processing, the OmniMax 10 zone oven delivers high performance thermal processing.  The OmniMax sets the standard in innovative technologies that save on lowest power and nitrogen consumption rates.

Benefits and Features

Proven Performance, World Class Results

Patented IsoThermal™ chamber technology is what differentiates Electrovert ovens from others.  In a reflow oven, the consistent thermal capability and control within the heated length is what matters most rather than the number of zones.  The OmniMax 10 uses a dual IsoThermal approach that produces ΔT’s less than ±2°C.  On thermally challenging heavily populated PCBs, the OmniMax outperformed competitive 10, 11, and 12 zone ovens in thermal capability, thermal uniformity, and energy consumption.

Advanced Heating Chamber Technology

The OmniMax and OmniES incorporate the patented IsoThermal™ Chamber Technology (ICT).  This is an advanced, efficient heating chamber design that provides maximum thermal performance.  Electrovert’s innovative approach to thermal transfer delivers highly efficient heat transfer throughout the entire process and product.  Consistent thermal performance of the ICT promotes excellent zone separation, minimizes cross board ΔT’s and allows for better control of time above liquidus.

Innovative Cooling

The patented cooling module in OmniMax/ES series is designed to provide process flexibility, to meet the cooling slope requirements on thermally challenging board assemblies, and to reduce the opportunity for flux dripping in the process area.  The air flow dynamics within the cooling zones are efficiently controlled for a balanced environment that can reduce nitrogen consumption up to 20-25%.  The design includes a patented dripless cooling which significantly reduces the potential for flux dripping in the cooling area.  The excellent separation between the heating and cooling area produces a tight control of time-above-liquidus.

Maintenance Reduction Technologies

When it comes to maintenance, Electrovert believes that ‘less is better’.  OmniMax/ES series ovens include innovative designs that reduce maintenance requirements, extend time between maintenance intervals, and minimize the time required to perform maintenance. These innovations include:

  • An industry-first dripless cooling module (patented).  The innovative design extends the interval between performing maintenance in the cooling area;
  • ‘Intelligent Flux Control’ is a patented design that consists of a two-stage filtration system that incorporates self-clean features, easy design, and provides the ability to perform full maintenance without stopping production;
  • A chamber design that seals the cross and width adjust shafts out from the process area;
  • Full and easy accessibility to all major assemblies.
Versatile Conveyor Systems

The robust conveyor systems on the OmniMax/ES series convection reflow ovens are designed for years of worry-free use in demanding production environments.  The design includes features such as:

  • Cross shaft and width adjust assemblies that are sealed out of the process area;
  • Robust conveyor rail extrusion and support assemblies that maintain rail parallelism;
  • Linear guides and precision screw shafts ensure a smooth motion and highly repeatable conveyor width;
  • Precision Center Board Support (optional);
  • Dual Track conveyor (with/without center board support) is optional for additional throughput capability.
Lead-Free Reflow

At the end of the final assembly process, each OmniMax and OmniES system undergoes vigorous tests that are designed to ensure that each system is lead-free validated and optimized.  Each system has multiple thermal profiles that are recorded utilizing a calibrated test vehicle.  The test vehicle simulates actual component temperatures and precisely verifies cross-board uniformity.  Cpk data is collected to verify machine performance and repeatability.  If the system is ordered with a nitrogen-inerted chamber, dynamic testing is performed to ensure that the chamber inerts to a low ppm atmosphere (tests are conducted in a simulated production environment).  The Electrovert promise is that each OmniMax/ES system is lead-free validated and optimized. In addition, the quality assurance data and reports are included in the machine documentation package that is provided with each oven.

Operations and Software

The software and controls of the OmniMax/ES were designed to be user-friendly.  The Windows® operating system is multi-functional and easy to use.  The 3D GUI provides the user a real-time view of the complete machine modules, operation, and product being soldered.  All Electrovert systems have a customizable ‘dashboard’ quick view screen.  Quick view allows engineers and operators to view critical machine parameters that are important to the process or application.

Enhanced Technology

Process Chamber Environment

The OmniMax/ES series reflow are designed for process flexibility.  All systems are available for reflow soldering in air or nitrogen.  OmniMax/ES series ovens are ‘nitrogen capable and ready’.  Converting from air to nitrogen is available as a field upgrade (consult with factory so that the serial # and configuration can be verified for compatibility).

Cooling

The air flow dynamics within the cooling chambers are outside and away from the process area for dripless cooling.  Each zone of the cooling chamber has independent access capability for ease of maintenance.  The patented diffuser plate eliminates the potential for liquid build-up that may drip into the process area.  All design aspects of the cooling section are focused on reducing and simplifying the maintenance process.

The cooling features are designed to provide complete process performance and flexibility.  Cooling for a nitrogen process is available in topside cooling, bottom side cooling, or a combination of top and bottom for maximum cooling requirements.

Closed-Loop Nitrogen Control

Electrovert’s closed-loop nitrogen control feature provides an automatic approach to maintaining and controlling PPM levels within the reflow zones.  Closed-loop nitrogen control has the potential to significantly reduce nitrogen consumption, especially in high-mix low-volume production environments.

Intelligent Flux Control

Intelligent flux control is a patented multi-stage flux collection system that significantly reduces maintenance in the process area.  Integrated features including self-clean, alarm-based notifications, and a multi-unit design provide effective and efficient flux collection.  The collection system is easy to access and enables maintenance without interrupting production.

OmniCheck Process Monitoring

The OmniCheck process monitoring system delivers cost-effective, continuous verification of process temperatures and conveyor speed.  OmniCheck offers redundancy to the OmniMax/ES standard control system and is 100% integrated into the machine software.  Thermal sensors are placed in close proximity to the board assemblies for each heating and cooling zone.  OmniCheck data is compatible with the machine standard data logging for product traceability and verification requirements.

Conveyor

A full range of conveyor features offer complete product and process flexibility supporting production throughput requirements.  The range of features includes mesh belt conveyor, pin chain conveyor, and pin and mesh combinations.  The precision center board support is synchronized with the pin chain and includes computer-controlled width positioning. It is auto-height retractable, and includes park features.

Barcode Scanning System

The barcode scanning system offers the ability to maximize productivity, process control, and traceability with an advanced set of features.  The user-friendly integrated software includes special features including automated recipe changeover, barcode association, barcode message formatting, and data collection.  The barcode scanning feature is available for single and dual lane conveyors, and is also field-upgradable.

Other Value-added Features
  • Independent high temperature safety circuit
  • External cooling
  • Light Tower
  • External Chillers
  • Calibrated lead-free QA test vehicle
Special Reflow Soldering and Curing Applications

In today’s business environment it is important to partner with suppliers who are willing to work on special applications and are committed to providing process solutions.  Contact Electrovert if you have a special product or application and are interested in finding a specialized solution.