IONOGRAPH SMD V SERIES

Ionic Contamination Test Systems

OM-416-1073-1 Revision 1

7645 Woodland Drive, Indianapolis, IN 46278-2707

Customer Service: P 317. 244.1200 F 317.240.2073
E SCScustomerservice@SCScoatings.com
COPYRIGHT SPECIALTY COATING SYSTEMS
Make certain that everyone associated with this machine becomes knowledgeable about the
material contained in this manual before using the equipment.
 TABLE OF CONTENTS
Section 1 Introduction ..............................................................................................1
1.1 Safety ..............................................................................................................1
1.2 Ionic Contamination ........................................................................................2
1.3 The Equipment ................................................................................................3
1.3.1 Ionograph SMD V ......................................................................................3
1.3.2 PowerView™ ..............................................................................................3
1.4 Operating principles ........................................................................................5
Section 2 Installation ................................................................................................9
2.1 Installation Site ................................................................................................9
2.2 Making the Connections ..................................................................................9
2.3 Filling the Test Cell ........................................................................................10
2.4 Installing the Software ...................................................................................11
2.5 Powering Up ..................................................................................................11
2.5.1 PowerView Overview ................................................................................12
2.5.2 Configuring PowerView ...........................................................................13
Section 3 Operation................................................................................................24
3.1 IPA Verification ..............................................................................................24
3.2 Calibration ....................................................................................................26
3.2.1 When is calibration required? ..................................................................26
3.2.2 Materials required for calibration ............................................................26
3.2.3 Calibration procedure .............................................................................26
3.3 Verification ....................................................................................................29
3.3.1 When is Verification required? .................................................................29
3.3.2 Materials required for Verification ...........................................................29
3.3.3 Verification procedure .............................................................................29
3.4 Running A Test ..............................................................................................32
Section 4 Maintenance............................................................................................35
TABLE OF CONTENTS

4.1 Replacing Extract Solution .............................................................................35

4.1.1 Draining the System ................................................................................36
4.2 Replacing the DI Columns..............................................................................37
Section 5 LIMITED WARRANTY POLICY ....................................................................39

II
 INTRODUCTION

SECTION 1 INTRODUCTION
1.1 SAFETY
This machine has been designed to be used as described herein. Operator safety and
safe reliable operation were key elements in the design. The machine complies with all
applicable sections of NFPA article 79, of the National Electric Code (NEC). All
commercially standard components used in this machine have a minimum of UL
and/or CSA ratings. Components built to CE standards have been used wherever
possible. Any local or regional certifications required above and beyond the
aforementioned are the responsibility of the customer.

Improper operation or service of this equipment can result in serious injury or death.
Use of this machine for anything other than its intended purpose may create a safety
hazard and void the equipment warranty. Read and understand this manual before
installing, operating, or servicing this equipment.

For safe usage, it is essential that the operator

read and clearly understand the contents of this
manual before installing or using this instrument.

Flammable IPA is used in the Ionograph. Eliminate all potential sources of spark or fire.
The use of this equipment may expose personnel to potential health and safety
hazards. The owner/operator should review Material Safety Data Sheets (MSDS) and
provide the recommended fire safety equipment, spill containment materials,
protective garments, and first aid supplies necessary for the safe handling of Isopropyl
Alcohol.

1
INTRODUCTION

1.2 IONIC CONTAMINATION

During the life cycle of any device that uses electronic circuitry, both performance and
long term reliability can be adversely affected by the presence of ionic contamination.
Residual ionic contamination can cause corrosion and electrical current leakage across
insulating surfaces. The speed of circuit and assembly degradation increases
dramatically when coupled with exposure to humidity in normal environments.

Ionic residues come from a variety of sources during the chemical processing and
manufacturing of electronics. Typical contamination sources include:

 Metal Cleaners  Processing Equipment

 Chemical Etchants  Rinse Stations
 Plating Chemicals  Environment (Dust, CO2)
 Fluxes  Perspiration

Microelectronic contamination is even more

critical, as even a trace of ionic residues from a
human sneeze can cause catastrophic failure.
By eliminating the amount of ionic residues on
electronic circuits and assemblies, products
can be produced to intended levels of
performance, minimizing reliability risks in the
field. A number of industrial and military
specifications for ionic contamination have
been developed, and are widely used as both
incoming and in-process quality control, as
Figure 1: Example Contaminated Circuit
well as after final assembly.

The Ionograph offers the capability for simple, accurate measurement of residual ionic
contamination on various substrates. The Ionograph is simple to operate, and is
exceptionally accurate for residual ionic measurement of bare circuit boards,
assemblies, passive components, and microelectronic parts. Ionograph uses include
process monitoring, making process improvements in cleaning/rinsing stations and
collecting data for use in statistical process control programs. The Ionograph is ideal
for integration into any production facility or laboratory.

2
 INTRODUCTION

1.3 THE EQUIPMENT

SCS Ionographs are designed to be a simple, fast and accurate means of testing for
ionic contamination as compared to the expensive, time consuming, and highly
technical alternative of chromatography. Ionographs have a full range of capacity and
controls to meet the needs of any lab or manufacturer.

SCS Ionographs:

 Determine the cleanliness of electronic components, assemblies with SMT devices, and bare
or assembled circuit boards.
 Provide an accurate, repeatable and rapid method for determining cleanliness on location.
 Provide immediate process control results, negating the need for outside laboratory testing.
 Verify proper cleanliness of surfaces prior to the application of conformal coatings or
potting compounds.
 Comply with current industrial specifications such as ANSI/J-STD-001 and IPC-TM-650 as
well as obsolete military specifications, e.g., MIL-STD-2000A.

1.3.1 Ionograph SMD V

The SCS Ionograph SMD V is a floor model commonly used for larger circuit boards in
high-volume production environments. Submerged agitation jets and heated extract
solution provide outstanding sensitivity, operation efficiency and the ability to test
ultra-fine pitch components with ease and accuracy.

The SMD V offers users the ability to test components with a heated or non-heated test
solution. IPC-TM-650 describes the benefit of a heated solution to “accelerate and
improve the efficiency of extraction of ionic material from poorly accessible regions,
such as under surface-mounted components.” In addition to increasing cleaning
efficiency, a heated system also ensures temperature consistency of the test solution,
whereas solution temperature in an unheated system can vary due to circulation pump
friction created during the testing process.

1.3.2 PowerView™
Ionographs are controlled by SCS’s proprietary, PowerView software. PowerView is
specifically developed for programming and operating SCS Ionograph series ionic
contamination test equipment. The Windows® based program establishes
contamination testing parameters and calibrates equipment for repeatable, accurate
measurements. The collected data is transmitted to, and stored on the controlling
computer and can be archived, exported and analyzed. Users can create, save and run
unlimited test profiles. This feature provides unparalleled ease of analysis and
flexibility in creating data charts and tables.

3
INTRODUCTION

Other features of PowerView include:

 Operates on Windows® XP and up  Network connectivity

 Enhanced 32 and 64 bit user interface  Increased data filter capabilities
 Simplified database export capabilities  Multi-level password protection
 Enhanced, interactive graphical summaries  Built-in profile system
 PDF test results for ease of dissemination  Robust reporting of test results

The computer can be purchased with the Ionograph or sourced separately. A security
dongle (provided with the software kit) must be connected to the computer to be able
to perform tests.

PowerView software is not copy-protected. You may make as many copies as you like.
You may also distribute the program to others. However, in order to perform
calibrations, verifications and execute tests, a security key (Figure 2) must be installed
on the computer. All other aspects of the program will function normally. Special
software routines have been encoded into PowerView to look for the key and to double
check for a counterfeit. The setup of a fully functioning PowerView program requires
the connection of this security key into a USB port on the PC, a link established
between your PC and ECM, and the PowerView software installed on the hard drive.

Figure 2: Security Key

4
 INTRODUCTION

1.4 OPERATING PRINCIPLES

The Ionograph operates using the dynamic method. A purified extract solution, of DI
water and IPA, continuously circulates over the test sample. The solution dissolves the
extractable ionic contaminants from the surface of the sample. As the ions are
extracted the solution becomes more conductive. A probe measures the electrical
conductivity of the solution approximately every 2 seconds and the results are stored
in memory. The measured values are integrated to arrive at a total change in
conductivity.

Test Cell

DI Columns

Probe Housing/
Probe
Pump Flow Meter

Figure 3: Flow Diagram

Test samples have many different kinds of ionic contaminants on them. The same
mass of different contaminants will cause varying changes to the conductivity. The
probe only measures the total change in conductance and does not differentiate
between the different types or report the quantity of each contaminant being
extracted.

To provide standardization, a reference measure of contamination is associated with

the conductivity readings. For the Ionograph the reference is sodium chloride, or NaCl.
The result obtained from the measurement is expressed as the equivalent amount of
NaCl that would have been found on the test sample had all the contamination
measured been purely NaCl residues.

5
INTRODUCTION

After passing through the conductivity probe, the solution passes through a flowmeter
which gauges the fluid flow rate. Solution contaminants are then removed by high
efficiency deionization columns and the solution is pumped back across the part in the
test cell for further extraction of ionic contaminants. The process continues until one
of the following occurs: the duration of the profile’s timed test has been reached,
cleanliness of solution reaches initial levels (baseline), or the solution cleaning rate is
lower than specified “sensitivity” level.

The final result of total, or cumulative, contamination is determined by summing all

the contamination removed by the DI columns throughout the duration of the test.
The amount of contamination removed is directly proportional to the integration of the
conductivity of the fluid over time. The proportionality constant is determined through
a “calibration” of the machine using a known amount of ionic contamination
(Standardizing Solution #3), and “verified” by a second test of the same method.

Before testing, a standard of conductivity is established by allowing the solution to

circulate with no sample in the tank. This is referred to as the "baseline." The
following graph shows a typical test of a circuit board, and where the baseline would
be. Note that the conductivity increases as extract solution cleans the contamination
off the part. Then as the test "winds down," less and less contamination is found.

Figure 4: Typical Test Result

The baseline is established by the calibration process and is important for instrument
accuracy because it allows sources of error to be "factored out" of the final answer. The
primary source of error is atmospheric carbon dioxide, which readily dissolves into
solution and ionizes. This ionization results in unstable or inaccurate conductivity
readings. As seen in Figure 4 the area under the shaded portion shows part of the
conductivity is a result of carbon dioxide absorption. The Ionograph baseline is also
important because it assures that the extract solution is free of contamination once the
conductivity/resistivity stabilizes.

6
 INTRODUCTION

Ionic contaminants, whether from flux residues or any other source, ionize very quickly
in alcohol/DI water solutions, and are thus able to be detected. The key is that some
ionic contaminates ionize to different degrees, especially in the presence of stronger
ions. As a solution becomes more saturated with ionic material, it becomes more
difficult to promote and detect the weaker ions. Because the Ionograph continuously
purifies the extract solution, a condition of "infinite dilution" exists, preventing any
saturation effects on accuracy; thus all ions (contamination) are detected.

Another significant feature to enhance accuracy is the true calibration feature. By

adding a known amount of contamination (sodium chloride), the Ionograph compares
the measured quantity to the known quantity. From this, the calibration factor is
calculated to correct future test results. This is extremely effective in assuring
accuracy. The graph in Figure 5 is typical of what one might expect when performing
chemical calibration.

Figure 5: Typical Calibration Result

Notice that the conductivity rises almost immediately, indicating that the ion detection
is virtually 100%. Unlike most contaminants and corrosive residues encountered in
daily production, this is very typical of sodium chloride or #3 standardizing solution,.
The Ionograph tests to a definite endpoint, thus assuring complete removal and
measurement of contamination.

7
INTRODUCTION

8
 INSTALLATION

SECTION 2 INSTALLATION
2.1 INSTALLATION SITE
WARNING: Before installation, please review the Safety section of the
introduction for important site selection and hazard considerations.

The site selected for the Ionograph depends on the particular situation. However, the
following requirements must be met for optimal operation of the instrument. The site
must:

 Be non-smoking and spark free. Flammable IPA is used in the Ionograph.

 Be adequately ventilated to dissipate IPA vapors.
 Be an ESD controlled environment.
 Provide enough space for easy access to all sides of the unit.
 Be positioned on a level surface.

2.2 MAKING THE CONNECTIONS

The Ionograph operates on either 115 or 230 volts, 50/60 Hz. The operating voltage is
determined at the time of order and the equipment is configured as such. Refer to the
Machine Information Label (Figure 6) for the voltage.

The instrument is supplied with an unterminated power cord. It is the responsibility of

the owner to provide and attach the proper plug. To prevent possible ESD damage to
the instrument, connect the power cable first. Plug the power cord into a properly
grounded receptacle. After connecting the power cable connect the PC using the
supplied USB cable.

Figure 6: Machine Information Label

9
INSTALLATION

2.3 FILLING THE TEST CELL

Caution: Care should be exercised when using isopropyl alcohol solutions.
Prevent exposure to open flames and other ignition sources, and use gloves
and safety glasses in case of splashes.

The Ionograph operates with an extract solution containing a mixture of 75% Isopropyl
Alcohol and 25% DI water. The amount of extract solution necessary depends on the
size of the test cell, see Table 1. Premixed solution is available for purchase from SCS
in the contiguous 48 states. If purchased from SCS the solution will be at, or slightly
above1, the ideal testing ratio and can be poured directly into the test cell. See below
for directions. If the solution will be sourced from a third party it must be a mixture of
>99.8% pure Isopropyl Alcohol and 25% Deionized water >10 MΩ.

NOTE: Failure to use the proper purity of Isopropyl Alcohol and DI water can destroy
the DI columns ability to remove ions from the extract solution!

Test Cell Size Approximate Solution Volume

18” x 20” 8 Gal, 30 L
20” x 26” 11 Gal, 40 L
26” x 30” 17 Gal, 64 L
26” x 38” 22 Gal, 81 L
Table 1: Test Cell Volumes

Pour the solution into the test cell and fill about half way. Although it is highly
unlikely, leakage is possible, it is a good idea to check before starting up, remove the
panels to inspect the instrument to see if any leaks can be observed. If no leaks are
seen fill the remainder of the test cell to the scribe line on the left end of the tank.
Again, inspect to ensure that there are no leaks.

The left side of the test cell contains the two pairs of submerged jets, as well as a
liquid level sensor. The liquid level sensor is located just above the spray jets. The
pump is automatically deactivated when the solution falls below the level sensor.

1 The IPA may be slightly higher than 75% by volume to allow for evaporation

10
 INSTALLATION

2.4 INSTALLING THE SOFTWARE

To install the software load the CD labeled PowerView Software into the PC disk drive.
The InstallShield Wizard will open. When prompted press the Next button. The next
screen will show where the software will be installed on the hard drive. Click the Next
button. The next screen will indicate the wizard is ready to begin installation. Click on
the Install button. A User Account Control window may open asking if you want to
allow the program to make changes to the computer. Click on the Yes button. When
the InstallShiel Wizard Completed window opens click on the Finish button.

If, after the PowerView installation, Windows has not correctly identified drivers for one
or more USB devices, pull up the Windows Device Manager screen. The drivers for the
resistivity probe can be found in the PowerView install directory in the subfolder
“Probe”.

The security key drivers must also be installed, separate from PowerView. The install
file is located in the “Security Key Drivers” subfolder in the PowerView directory.

2.5 POWERING UP
Once the connections are made, the test cell is filled and the PowerView software is
installed you may now power up the instrument. To do so, simply press the Main Power
button located on the front of the unit (Figure 7).

Open the PowerView software on the computer. After the software has connected with
the instrument, click on the I/O button in the upper left hand corner of the Main screen
(see Figure 8). Click on Enable Pump. Allow the pump to operate for 45 minutes to
ensure all air is evacuated from the system. Observe for any leaks during this time. If
heated solution will be used in the process click on the I/O button and select Enable
Heater. Enabling the pump and the heater allows the software to have control of them.
The software will cycle them on and off as needed.

Figure 8: I/O Menu

Figure 7: Main Power Button

11
INSTALLATION

2.5.1 PowerView Overview

The Main screen of PowerView software is pictured in Figure 9. All functions and
features of the software are accessed from this screen. The four rows of data, within
the red rectangle in Figure 9, display information about the resistivity/conductivity,
solution temperature, Percent IPA%, and the flow rate. The columns divide the data into
categories of: System Status, Current Value, Target Value and Unit of Measure.

Figure 9: PowerView Main Screen

All functions, and access to other screens, are executed with the two rows of buttons,
enclosed in the blue rectangle of Figure 9. The functions can also be executed via the
Menu button in the upper left hand corner of the Main screen window. The following
sections describe in detail what the buttons are for.

System Status

 Resistivity/Conductivity: Displays High/Low/OK as related to the Target Value

 Temperature: Displays High/Low/OK as related to the Target Value
 Percent IPA%: Displays Current/Recheck Due as determined by the Verification
Interval entered in the Configuration screen (See § 2.5.2.1)
 Flow Rate: Displays OK unless the flow rate is to low

12
 INSTALLATION

Current Value

 Resistivity/Conductivity: Displays the current measured value

 Temperature: Displays the current measure value
 Percent IPA%: Displays the IPA% as last measured
 Flow Rate: Displays the flow rate of the solution

Target Value

 Resistivity/Conductivity: Displays the value as determined by the last calibration

 Temperature: Displays the value as determined by the last calibration
 Percent IPA%: Displays the value as determined by the default set in
configuration (See §2.5.2.1)
 Flow Rate: Factory default set to 50

Unit of Measure

The unit of measure can be changed in the Configuration screen (See § 2.5.2.5)
 Resistivity/Conductivity: Displays Ω-cm or Ω-in
 Temperature: Displays Degrees F or Degrees C
 Percent IPA%: Displays %
 Flow Rate: Displays cc/sec

2.5.2 Configuring PowerView

Clicking on the Configuration button opens the Configuration screen. Across the top of
the configuration screen are eight tabs. Details of each tab’s contents and purpose are
in the following sections. If any changes are made to the configuration you must click
the Apply or Save button for them to be saved. PowerView will then need to be closed
and re-opened for the changes to take effect.

2.5.2.1 Calibration and Verification

This screen is used to set the
following calibration and Verification
parameters:

Baseline:
 Target: This sets the Resistivity (or
conductivity) that must be attained
for an acceptable baseline. The
Tolerance figure sets an alarm
level (how much above baseline) to
indicate when corrective steps are Figure 10: Configuration: Calibration and Verification

required.

13
INSTALLATION

 Tolerance: In order to assure

maximum test accuracy, it is
necessary to begin tests at or very
near the same baseline and at or
near the same solution Baseline
Target at which the calibration was
performed.
Verification

 Interval: This sets the time allowed

between Verifications. When the
time limit is reached, the words
"Recheck Due" appear on the Home
Figure 11: Configuration-Database
screen beside "Percent IPA."
 Tolerance: This sets how close the verification test result must be in order to pass.
If the result is outside the set limitation during a test, you must recalibrate.
Calibration:

 Concentration: PPM of the Standardizing Solution #3 as indicated on the bottle label.

 Dosage: Set at the factory to a default of 2mL.
 Sensitivity: This is the rate that resistivity/conductivity must change per minute for
the test to continue. The sample screen shows a setting of 2 MΩ per minute,
meaning that the test will continue as long as the resistivity changes by at least 2
MΩ every 60 seconds. As the test gets closer to completion, the rate of change
slows until finally the change is less than 2 MΩ in a 60 second period and
PowerView stops the test. Enter a sensitivity value between 1 and 30MΩ/min. The
higher the value entered the less sensitive the calibration will be.

2.5.2.2 Database
The database tab provides links to the following three databases used by PowerView:

User Account Setup:

Used to Add, Edit or Delete users of PowerView software. There is no limit to the
number of users that can be added. There are two levels of access in PowerView.

1. Operator:
Has access to IPA Verification, Run Test and Log In/Out
2. Supervisor:
Has access to everything

14
 INSTALLATION

To Add users click the Add button. Enter the User

name. Select access Level the user will have. Enter
and confirm the user’s password. Passwords are
case sensitive and must be any combination of at
least six, letters, numbers or symbols.

To Edit a user, click on the User name and click the

Edit button. Make the changes and click the OK
button.

To Delete a user, click on the User name and click

the Delete button Figure 12: Test Profile Management

Manage Test Profiles:

This screen is used to Create, Edit or Delete Test Profiles. A Profile is a set of test
instructions assigned to specific substrates. By assigning each substrate a unique
profile the test instructions do not have to be entered every time a test is run. The
number of Profiles that can be created
and stored is limited only by the
available memory of the PC. New
profiles will use the default unit of
measure (inches or centimeters). To
change the default units of measure
see §2.5.2.5.
To create a profile:

1. Click the New button

2. Enter a Name for the profile
3. Enter the substrate part
number
4. Enter a substrate nomenclature
(Optional) Figure 13: Configuration-User Account Setup
Intended to store the name of
the substrate for which the profile was created.
5. Enter a comment for the substrate (Optional)
Input comments to store with this profile.
6. Substrate size can be entered either by:
a. Enter the length and width of the substrate
Enter a value from 0.1 to 50. The software will calculate the total area of the
substrate.

15
INSTALLATION

b. Enter 0 in both fields. A dialog box will open requesting a value of .1 to 50 be

entered. Click on the OK button. Enter the area in the area field.
7. Enter the fail point for the substrate
This field is required and should contain a numeric value from .1 to 100. This
value represents the pass/fail limit of a test, measured in micrograms equivalent
NaCl per square unit area.
8. Enter the desired sensitivity (Automatic Termination)
Enter a numeric value from 1 to 30. This is the percentage the current resistivity
must change by to continue the test.
Tests will conclude when the resistivity has:
 Re-attained the baseline resistivity or
 Re-attained 75% of the baseline and increased in value less than the value of
resistivity, measured one minute before, multiplied by the sensitivity value
Sensitivity Example: Assume a sensitivity setting of 3%. If during a given test, the
resistivity is found to be 100.00MΩ/cm, and then one minute later if the resistivity
has failed to increase by at least 3% of 100 MΩ/cm the test will be terminated.
9. Select either Automatic or Timed termination
If a Timed test is selected, enter a value of 1 to 120 minutes in the Duration box
10. Click Save

To Edit a profile, click on the profile name and click the Edit button. Make the changes
and click the Save button.

To Delete a profile, click on the profile name and click the Delete button. A dialog box
will open to confirm the deletion.

Recall Saved Tests:

This screen is used to view, graph and

print saved tests.

The window on the right lists all

available test result files found on the
hard drive.

 Click on one of the files to display

its information in the area on lower
left
 Click on the column headers to Figure 14: Recall Saved Tests
change the order to ascending or

16
 INSTALLATION

descending
 Use the Filter options to make it easier to locate the desired file. Select one of the
options in the filter drop down box then click the Apply Filter box
 To search for tests conducted on particular dates click the Search specific date
range box and select the Start and End dates
The Graph button will produce a report of the selected test.

The Graph All button will open a graph for all of the tests listed in the available tests
window. This graph will provide a summary of test results and is a valuable tool for
spotting trends.

2.5.2.3 Barcode
This screen is used to configure
barcodes. If barcodes will be used in
the process:

1. Select Use Barcodes check box

2. Select the communications port
the barcode scanner is
connected to on the PC
3. If partial barcodes are
acceptable select Enable partial Figure 15: Barcode

barcode use check box

To setup barcodes:

1. Click the Barcode Setup button

The window seen in Error!
eference source not found. will
open
2. Click on the Add button
3. Scan the barcode
4. Select which test profile will be
associated with the barcode
5. Click on the bottom Add button

Figure 16: Barcode Setup

17
INSTALLATION

2.5.2.4 Printing Options

This screen is used to select the type of reports, to modify the appearance of reports,
and to select whether reports, will printout automatically.

The top six lines are for company information. This information appears in the upper
left hand corner of the reports.

To add a company logo to the reports:

1. Click the Choose Company
Logo button
2. Navigate to the image that will
be attached
3. Select the image
4. Click on the Open button

The image will appear in the upper

right hand corner of the reports. The
program will size the graphic to fit the
Figure 17: Printing Options
space available. An example of a test
report can be seen in Figure 18.

The Auto Print options, at the bottom of the screen, allow for specific graph formats to
print automatically when a test is completed. Any combination, or all three, can be
selected.

Note: The Contamination graph is not an option when running a calibration.

18
 INSTALLATION

Figure 18: Test Report Example

19
INSTALLATION

2.5.2.5 System Options

The System Options tab contains the
software default settings. From this
screen the following formats can be
changed:
 Resistivity or Conductivity
 Fahrenheit or Celsius
 Inches or Centimeters

If Terminate on Failure is selected, in

the Termination section, tests will end
two minutes after a failure is detected. Figure 19: System Options

If Auto Only is checked profiles set to automatic termination will stop ≅ two minutes
after a failure is detected.

If All Tests is checked every test will terminate two minutes after a failure is detected.

Sometimes when a timed test is run the resistivity/conductivity does not return the
baseline within the allotted time. When this happens, because the software thinks there
is more contaminants to be removed, the test results will indicate a failure. To avoid
the possibility of false failures select Ignore Baseline conditions for timed tests. With
this selected the test will just report the results as tested within the allotted time.

Selecting Play tone on test completion will play a sound to let operators know that a
test has finished and they can remove the substrate.

PowerView software is designed to work with both the Ionograph benchtop models and
SMD models. The machine type will need to be selected so the software will know how
to operate the unit.

If security is not of concern the log in can be bypassed by selecting Disable Log In.
When this option is checked every user will have access to all functions of the software.

Password Expiration (days) can be set to 1 to 90 days. This will require users to create
a new password. To prevent having to create new passwords select Disable password
protection.

20
 INSTALLATION

2.5.2.6 IPA Maintenance

IPA Tolerance

The idea ratio of IPA to DI water is

75:25 or 75% total IPA in the extract
solution. The default allowable
tolerance range is +/
- 2%. It is
recommended to keep these settings;
however, they can be adjusted on this
screen.

Verification Figure 20: IPA Maintenance

The Verification Interval is the number of days allowed before a recheck is due of the
IPA percentage. The default is 7 days. This can be adjusted from 1 to 30 days. The
evaporation rate of IPA is significantly faster than DI water. Therefore the percentage of
IPA in the extract solution will decrease over time. This interval will need to be set at a
rate often enough to prevent the IPA percentage from dropping below the tolerance
level. It is recommended to start with a low interval and work up as determined by the
experience.

The Solution Temperature and Temperature Tolerance sets the heater for the desired
temperature and the tolerance (± degrees) you desire. If the temperature gets out of
the desired range, a message appears and testing cannot begin (without an override by
a Technician level password

Solution Dosage refers to the volume of extract solution within the test cell. For
volume levels refer to Table 1on page 10. Enter the appropriate volume in the box.

An IPA Verification can be run from this screen by clicking on the IPA Verification
Walkthrough button.

2.5.2.7 Language
Currently the only language available is English.

21
INSTALLATION

2.5.2.8 Graphing
This screen allows the operator to
change various formats of the graphs
as displayed on the screen and
printed out in the reports. When
making changes select either Run
(graph displayed on screen) or Report
(graph that will be printed) in the drop
down box labeled Window. Items that
can be changed include:
Figure 21: Graphing
Displayed Mode: Options are
Resistivity, Conductivity or Contamination

Data Points: The color, thickness, symbol shape and size can be customized to the
user’s preference.

Limit Lines: The color, thickness of the graph lines can be customized to the user’s
preference.

22
INSTALLATION

23
OPERATION

SECTION 3 OPERATION
Basic operation of the Ionograph includes chemical calibration, chemical verification,
and the actual testing procedures. The first time the instrument is used a Calibration
and Verification must be performed before conducting tests. Thereafter, verification
and an IPA % check should be done daily to ensure proper calibration is maintained.

3.1 IPA VERIFICATION

1. On the Main screen (Figure 9) of PowerView, click IPA Verification

This will begin a series of screens to walk the operator through the IPA
verification process. Follow the directions provided.

Figure 22: IPA Verification Window 1

2. Turn power switch off on the ECM

Figure 23: IPA Verification Window 2

3. Open the lid from the RHU

4. Gently place hydrometer in test cell

Figure 25: Reading Hydrometer

Figure 24: IPA Verification Window 3

5. Enter the specific gravity, as indicated on the hydrometer, (Figure 25)

6. Click the Next button
7. Click Next.

24
 OPERATION

Figure 26: IPA Verification Window 4

Note: If the IPA is not within range the software will require it to be adjusted

Figure 27: Adjust IPA Notice

8. If the window in Figure 28 opens, skip to step number 12 otherwise continue

9. If the window in Figure 27 opens press the OK button
IPA Verification Window #3 (Figure 24) will reopen
10. Adjust the alcohol concentration by adding pure IPA or DI water
11. Return to step number 2

Figure 28: IPA Verification Window 5

12. Click on the Finish button

The Main screen will be displayed
Current value will display the new, measured, IPA concentration

25
OPERATION

3.2 CALIBRATION
Calibration is done by introducing Standardizing Solution #3, which consists of a
known amount of contamination (~750 ppm NaCl/H2O), into the test cell. The
instrument recovers and records the amount of contamination. Ideally, this recovered
amount should equal the known amount introduced. However, slight discrepancies are
likely to arise. To account for this, a calibration factor is created by comparing the
known quantity added to the amount recovered. This calibration factor will be used to
correct future results for enhanced accuracy.

3.2.1 When is calibration required?

 When starting up the instrument for the first time
 After adjusting the alcohol concentration (±2%)
 When chemical verification fails
 After servicing the instrument

3.2.2 Materials required for calibration

 Hydrometer for measuring specific gravity during IPA check
 Pipette to dispense Standardizing Solution #3
 Standardizing Solution #3
NOTE: The shelf life of Standardizing Solution #3 is 2 years!

3.2.3 Calibration procedure

1. Gather the required materials (see §3.2.2)
2. Turn the Ionograph on
3. Turn the Computer on
4. Open the PowerView software
5. Perform an IPA Verification §3.1
6. Allow the Ionograph to cycle until the Resistivity’s “Current Value” settles

Note: The “Current Resistivity/Conductivity” will climb until it reaches its peak
value. The peak value should be >400MΩ and get go as high as 1100MΩ. The
speed at which the solution cleans up is dependent on its purity and the condition
of the DI columns. It will then fluctuate.

7. On the Main screen click the Run Calibration button

The Calibration window (Figure 29) will open. The top left section, of the screen,
displays a graph of the calibration as it is running. The top right section displays
the elapsed time of the test, the contamination found thus far, as-well-as the
contamination limit. The bottom portion of the window provides various details
about the current calibration.

26
 OPERATION

8. Use the pipette to prepare a

2mL dose of Standardizing
Solution #3
9. Click the Start button
If the resistivity/conductivity or
temperature is not within the
baseline tolerance, the window
in Figure 30 will open.
10. Click on the Yes button
Figure 31 will open
11. Click on OK Figure 29: Calibration Window

Figure 30: Resistivity Warning

12. Open the test cell lid

Figure 31: Add Calibration Solution

13. Dispense the Standardizing Solution #3 into the test cell

14. Close the test cell lid
At the conclusion of the calibration the window in Figure 32

Figure 32: Calibration Finished

27
OPERATION

15. Click on OK button

The window in Figure 33 will open

Figure 33: Comment Option

16. If a comment is to be added click Yes; otherwise click No

17. If yes was selected in step 16, enter the comment in the dialog box that opens
(Figure 34)

Figure 34: Comment Dialog Box

18. If auto print has been selected in the configuration a report will be sent to the
default printer

28
 OPERATION

3.3 VERIFICATION
Like chemical calibration, the verification procedure involves adding a known amount
of contaminants, to observe how accurate the readings are. However, the purpose of
calibration is to correct the output contaminant readings for various errors, while the
purpose of verification is to assure that the calibration factor remains legitimate.
Chemical verification does not involve any correction factors. It simply checks to see if
the reading falls within a ±5% error range of the actual amount of added contaminants.
The criterion for verification is simply pass or fail.

3.3.1 When is Verification required?

 Recommended daily to ensure calibration accuracy
 After performing a calibration
 After servicing the instrument

3.3.2 Materials required for Verification

 Hydrometer for measuring specific gravity during IPA check
 Pipette and suction bulb to dispense Standardizing Solution #3
 Standardizing Solution #3
NOTE: The shelf life of Standardizing Solution #3 is 2 years!

3.3.3 Verification procedure

1. Gather the required materials (see § 3.3.2)
2. Turn the Ionograph on
3. Turn the Computer on
4. Open the PowerView software
5. Allow the Ionograph to cycle until the Resistivity’s/Conductivity’s “Current
Value” is ≅ equal to the baseline

Note: The speed at which the solution cleans up is dependent on its purity and the
condition of the DI columns. It will then fluctuate.

6. On the Main screen click the Run Verification button

The Verification window (Figure 35) will open. The top left section, of the
screen, displays a graph of the verification as it is running. The top right section
displays the elapsed time of the test, the contamination found thus far, as-well-
as the contamination limit. The bottom portion of the window provides various
details about the current calibration.

29
OPERATION

7. Use the pipette to prepare a

2mL dose of Standardizing
Solution #3
8. Click the Start button
If the resistivity/conductivity or
temperature is not within the
baseline tolerance, the window
in Figure 36 will open.
9. Click on the Yes button
Figure 37 will open
10. Click on OK Figure 35: Verification Window

Figure 36: Resistivity Warning

Figure 37: Add Calibration Solution

11. Open the test cell lid

12. Dispense the Standardizing Solution #3 into the test cell
13. Close the test cell lid
At the conclusion of the verification the window in Figure 38 will open

Figure 38: Calibration Verified

30
 OPERATION

14. Click on OK button

The window in Figure 39will open

Figure 39: Comment Option

15. If a comment is to be added click Yes; otherwise click No

16. If yes was selected in step 15, enter the comment in the dialog box that opens
(Figure 40)

Figure 40: Comment Dialog Box

17. If auto print has been selected in the configuration, a report will be sent to the
default printer

Note: If verification fails repeat the verification process. If it continues to fail repeat the
calibration and verification.

31
OPERATION

3.4 RUNNING A TEST

1. From the main screen click on
the Run Test button
2. Choose the appropriate profile
from the list
If a profile has not been created
for the substrate, click the
Cancel button and see §2.5.2.2
3. Click on the OK button
The window in Figure 42 will
open
4. Select a lot number from the
drop down list, enter a new lot
number or click on the OK or
Cancel button
Figure 41: Select Profile Screen

Figure 42: Lot Number

The Contamination Test screen

(Figure 43) will open
5. Press the Start button
If the resistivity/conductivity or
temperature is not within the
baseline tolerance, the window
in Figure 44 will open. Figure 43: Contamination Test Screen

Figure 44: Resistivity Warning

32
 OPERATION

Note: For best accuracy, allow the resistivity to get within tolerance
6. If the resistivity/conductivity is within tolerance, the window in Figure 45 will
open

Figure 45: Add Test Subject

7. Click on the OK button

8. Place the test subject into the test cell
At the conclusion of the contamination test the window in Figure 46 will open

Figure 46: Comment Option

9. If a comment is to be added click Yes; otherwise click No

10. If yes was selected in step 9, enter the comment in the dialog box that opens
(Figure 47)

Figure 47: Comment Dialog Box

If auto print has been selected in the configuration, a report will be sent to the
default printer.

33
OPERATION

34
 MAINTENANCE

SECTION 4 MAINTENANCE
The Ionograph is designed to operate with minimal maintenance activities. A schedule
of recommended activities should include the following:

MAINTENANCE PERIOD
Update/adjust alcohol concentration daily depending on use (see § 3.1)
Monthly (see § 3.2)
Perform chemical calibration when changing IPA concentration
or when chemical verification fails
Perform chemical verification recommended daily depending on use (see § 3.3)
Replace alcohol/DI water solution every 6 months or depending on use (see § 4.1)
Replace ion-exchange columns every 12 months, depending on speed and degree of
clean-up § 4.2)
Clean the strainer basket every 12 months or as needed (see § 4.1.1)
Inspect hydraulics and fittings every 6 months

4.1 REPLACING EXTRACT SOLUTION

Supplies needed:

 Towels  2.5mm Hex key

 Catch pan  ¼ Nut driver
 Screwdriver  Philips screwdriver
Replace the extract solution every 6 months, if the SMD V is used regularly. The
solution will have to be drained and refilled as a part of most maintenance measures
(i.e. replacing conductivity probe, DI columns, or strainers). The procedure is the same
for solution replacement as it is for solution drainage and refill, except unused
solution will be used to refill the test cell in the case of replacement. Consequently,
one should try to do solution replacement at the same time as these maintenance
measures that require the solution to be drained. Follow the drainage directives in the
following section and refer to section 2.3 for instructions on filling the test cell with
solution.
WARNING: Draining the instrument and changing the DI columns may result
in exposure to isopropyl alcohol. Be certain that all necessary precautions
are taken to prevent eye and skin contact, vapor inhalation, as well as remove any
possible heat or ignition sources. Review MSDS documentation before beginning.

35
MAINTENANCE

4.1.1 Draining the System

The SMD V can be easily drained by first removing the rear panel. Connect the drain
hose to the drain fitting located at the bottom of the DI column assembly (see Figure
48). The instrument can be drained with the pump on. NOTE: the pump will not run if
the solution level is below the low-level sensor. To force the pump on to drain, open
the Diagnostics screen, click and hold the button circled in the figure below. Be certain
to turn the pump off after draining. It is harmful to run it while dry. You can also allow
the instrument to drain by gravity without the use of the pump. This method will take
longer, but will drain just the same. IMPORTANT: Do not let the pump run dry for
more than 15 seconds.

Drain fitting

Figure 48: SMDV Rear View and Diagnostics Screen

The Ionograph test cell is equipped with a strainer basket to trap small particles such
as solder balls, dirt, and photoresists. The strainer sits in the drain port at the bottom
of the test cell. Clean the strainer basket whenever the test cell is drained for
maintenance.

If the DI columns will be replaced at this time proceed to § 4.2

1. Remove the drain hose

2. To fill the test cell please refer to § 2.3.
3. After filling, always conduct hydraulic inspection to check for leaks.

36
 MAINTENANCE

4.2 REPLACING THE DI COLUMNS

The deionizing columns contain a chemical resin designed specifically for ion removal
and are capable of cleaning a 75% alcohol-25% DI water solution to well over 500 MΩ.
As the DI columns collect more ions their ability to remove ions will decrease. They
may not deionize to the same level or take longer to deionize the extract solution.
Once spent, all the DI columns should be replaced at the same time. Re-conditioning
spent columns is not possible.

The columns should be replaced every 12 months or when:

 The solution requires extraordinary amount of time to clean up
 The baseline is unstable and does not deionize to 400MΩ for a 75% IPA solution
 The system is contaminated, affecting instrument performance and/or operation

SCS recommends replacing the extract solution and DI columns at the same time. Use
Figure 49 as a reference for the following instructions.
1. Drain the extract solution
2. Loosen the hose clamps at the top
and bottom of all DI columns
3. Remove the support bracket that runs
across the front of the DI columns
4. Pull the hoses off the top of the DI
columns
5. Pull the DI columns up from the hose
connections on the bottom
6. Install new DI columns into the hoses
on the bottom
7. Re-install the support bracket
8. Re-install the hoses to the top of the
DI columns
Figure 49: DI Column Assembly
9. Tighten all the hose clamps
10. Re-fill the test cell with extract solution § 2.3
11. After filling, always conduct hydraulic inspection to check for leaks.
12. Perform IPA Verification § 3.1
13. Perform Calibration § 3.2
14. Perform Verification § 3.3

37
MAINTENANCE

38
 WARRANTY

SECTION 5 LIMITED WARRANTY POLICY

I. Subject to the limitations hereinafter set forth, SPECIALTY COATING SYSTEMS
("SCS") warrants that all component parts manufactured by SCS are free from
defects in materials and workmanship for a period of twelve (12) months from
the date of shipment. SCS will replace materials for a period of twelve (12)
months from the date of shipment, and provide labor, if required, for a period
of six (6) months from the date of shipment to correct warranty defects.
II. Components such as gauges and meters, controllers, pumps, motors and valves
are warranted by their respective manufacturers and these warranties are
extended to the end user. Alcohol solutions and D.I. columns are not
warranted.
III. If, within the warranty period, any equipment or components manufactured by
SCS shall prove to SCS's satisfaction to be defective, such equipment or parts
shall be replaced or repaired, at SCS's option, at SCS's expense. Installation of
replacement equipment or parts shall be at the Purchaser's expense.
IV. The foregoing warranty shall be limited with respect to parts which are subject
to wear or chemical reactions or which have a variable life expectancy, including
but not specifically limited to, protective coatings, thermocouples, heaters,
seals, o-rings, drive belts, relays, lamps and bearings (but not including filters)
to a period of ninety (90) days from the date of shipment. Test cells are
warranted for six (6) months from the date of shipment.
V. SCS's obligation hereunder shall be limited to repair or replacement, F.O.B. SCS’s
factory, and shall be conditioned upon receipt of written notice of such defect
within ten (10) days after its discovery. Prior written approval is required, for
return shipment of equipment or components to SCS at SCS's expense.
VI. This warranty shall not apply to equipment or parts which have been repaired or
altered by any party other than SCS as, in SCS's judgment, adversely affects the
same, or which shall be subject to negligence, accident, damage or
circumstances beyond SCS's control (including fire, earthquake, flood or other
acts of God), or improper installation, operation, maintenance, or storage, or to
other than normal use of service. Improper operation of equipment or any part
thereof shall include, without limitation, operation under loads, speeds,
pressures or electrical current characteristics, or with supplies not
complying with SCS's specifications.

39
WARRANTY

VIII. SCS will not accept responsibility for repairs or the cost of any work done
without specific written SCS authorization.
IX. This warranty does not apply to used or second-hand equipment, nor does it
extend to any person other than the original Purchaser.
X. This warranty does not apply to equipment which is broken or damaged in
transit. In no event shall SCS be responsible for any liability, loss or damage of
such equipment delivered in good order and condition to a carrier or carriers at
any point of shipment.
XI. This warranty shall not cover, and SCS shall not be liable for, losses of supplies
or time, damages to materials, or consequential damages of any nature, arising
from or attributable to equipment sold to the Purchaser by SCS. This warranty is
strictly limited to the replacement or repair of the equipment or parts
purchased.
XII. SCS's liability to the Purchaser arising out of the supplying of this equipment or
its use, whether based on warranty, contract, or negligence, shall not in any
case exceed the cost of correcting defects in the equipment as herein provided,
and upon expiration of the applicable warranty period as aforesaid, all such
liability shall terminate.
XIII. EXCEPT AS OTHERWISE SET FORTH IN THIS LIMITED WARRANTY, THE EQUIPMENT
AND PARTS SOLD BY SCS TO PURCHASER ARE SOLD "AS IS" AND "WHERE IS" AND
"WITH ALL FAULTS," AND SCS DOES NOT MAKE AND SHALL NOT BE DEEMED TO
HAVE MADE, AND SCS HEREBY DISCLAIMS, ANY REPRESENTATION OR
WARRANTY, EXPRESSED OR IMPLIED, REGARDING THE DESIGN, CONSTRUCTION
OR CONDITION OF, OR THE QUALITY OF MATERIAL OR WORKMANSHIP IN,
THE EQUIPMENT OR PARTS, AND SCS MAKES NO WARRANTY OF
MERCHANTABILITY OR FITNESS OF THE EQUIPMENT OR PARTS FOR ANY
PARTICULAR PURPOSE.

SPECIALTY COATING SYSTEMS

7645 Woodland Drive
Indianapolis, IN 46278-2707
Telephone: 317-244-1200
Fax: 317-240-2073

40