IONOGRAPH BT SERIES

Ionic Contamination Test Systems

OM-416-1073-1 Revision 5

7645 Woodland Drive, Indianapolis, IN 46278-2707

Customer Service: P 317. 244.1200 F 317.240.2073
E [email protected]
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 BT Series ..................................................................................3
1.3.2 PowerView™ ..............................................................................................4
1.4 Operating principles ........................................................................................5
Section 2 Specifications ............................................................................................9
Section 3 Installation ..............................................................................................11
3.1 Installation Site ..............................................................................................11
3.2 Unpacking .....................................................................................................11
3.3 Making the Connections ................................................................................11
3.4 Filling the Test Cell ........................................................................................13
3.5 PowerView .....................................................................................................14
3.5.1 Installing the Software .............................................................................14
3.5.2 PowerView Overview ................................................................................14
3.5.3 Configuring PowerView ...........................................................................16
Section 4 Operation................................................................................................25
4.1 IPA Verification ..............................................................................................25
4.2 Calibration ....................................................................................................27
4.2.1 When is calibration required? ..................................................................27
4.2.2 Materials required for calibration ............................................................27
4.2.3 Calibration procedure .............................................................................27
4.3 Verification ....................................................................................................30
4.3.1 When is Verification required? .................................................................30
4.3.2 Materials required for Verification ...........................................................30
4.3.3 Verification procedure .............................................................................30
TABLE OF CONTENTS

4.4 Running A Test ..............................................................................................33

Section 5 Maintenance............................................................................................35
5.1 Replacing Extract Solution .............................................................................36
5.2 Replacing the DI Columns..............................................................................37

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.

The Ionograph is an extremely sensitive machine and is susceptible to Electrostatic

Discharge (ESD). Good ESD practices must be adhered to while operating this
equipment. Excessive, direct or indirect, ESD may interfere with data collection,
causing the displayed resistivity to stop updating (Performance Class C). Should this
occur during testing, data should be considered corrupted and be discarded. To clear
the error the software must be restarted.

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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.

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 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 BT Series

Convenient Bench Top models, the Ionograph BT series, offer quick and accurate
testing of individual components, small devices or complete assemblies. The BT series
enable users to match the test cell size with common substrate sizes to provide
enhanced testing accuracy. The BT series consists of two components:

Remote Hydraulic Unit (RHU)

The RHU is constructed of stainless steel providing for corrosion resistance, cleanliness
and long term durability. The RHU contains the test cell, conductivity sensor, pump,
flow meter, and DI column/s. It is available in the following sizes:

BT LP is equipped with a 14” x 20” x 2.63” test cell

BT MP is equipped with a 12” x 14” x 2.54” test cell

BT SP is equipped with a 6" x 6" x 1.13" test cell

Electronics Control Module (ECM)

The ECM contains the power supply for the RHU, control circuitry and communication
components. It connects to the RHU via cable and can be positioned up to 6’ (182cm)
away from it. The ECM connects to the computer via a USB Type A to Type B cable.

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INTRODUCTION

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. 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

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 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.

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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.

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 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 SPECIFICATIONS

Input Power: 115VAC, 1A, 50/60Hz

230VAC, 0.5A 50/60Hz

Fuse: 5x20mm time lag

1A (115V), 0.5A (230V)

USB Charging outlet: 5VDC, 2A Max

Control Box Dimensions: 9.6" x 10" x 3.9" (244 x 254 x 99)

Test Cell Dimensions:

SP 6" x 6" x 1.13" (152 x 152 x 29)

MP 12" x 14" x 2.54" (305 x 356 x 64.5)

LP 14" x 20" x 2.63 (356 x 508 x 67)

Fluid Volume:

SP 1.6L 0.42 US Gal

MP 10L 2.64 US Gal

LP 15L 3.9 US Gal

Sound Level: <70dB

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INSTALLATION

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 OPERATION

SECTION 3 INSTALLATION
3.1 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 placed on a level, and stable structure such as a workbench.

3.2 UNPACKING
1. Position the box near where the unit will be placed.

2. Cut the banding (if applicable).

3. Cut the tape securing the flaps on top.

4. Remove the top piece of foam.

5. Remove the ECM.

6. Remove the next piece of foam.

7. Slide the top portion of the box up away from the base.

8. Grab the RHU from the base and lift it up out of the bottom piece of foam.

WARNING: To prevent injury to individuals and/or possible damage to the

machine, two people are required when lifting the unit.

9. Place the unit where it will be used.

3.3 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.

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OPERATION

Do not to turn on the RHU until the test cell is filled with extract solution, as
pump damage can occur.

The instrument power connection is made

using the supplied safety power cord. For
international customers the power cord is
unterminated. 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. Insert the cable to the
back of the ECM and then plug it into a
properly grounded receptacle. After
connecting the power cable connect the
inter-connecting cable from the RHU to Figure 6: BT Series Machine Information Label
the ECM. The final connection will be the
ECM to the PC using the supplied USB cable.

Some devices plugged into the PC-or other devices or programs using virtual
COM ports-could cause communications problems. Powerview should be
allowed a dedicated computer for optimal operation.

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 OPERATION

3.4 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 Solution Volume

BT SP (6” x 6” x 1.13”) 1.6 L
BT MP (12” x 14” x 2.54”) 10 L
BT LP (14” x 20” x 2.63”) 15 L
Table 1: Test Cell Volumes
Although highly unlikely, leakage is
possible. Before filling the test cell
the first time, remove the side
panels to inspect for leaks while
filling. Slowly pour the extract
solution directly into the test cell
until the level increases to between
the upper and lower fill indicators
as seen in Figure 7. If the solution
level is not sufficient the DI
columns will be unable to efficiently
remove ions. Figure 7: Fill Lines

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

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OPERATION

3.5 POWERVIEW
3.5.1 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 InstallShield 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.

3.5.2 PowerView Overview

The Main screen of PowerView software is pictured in Figure 8 on page 15. All
functions and features of the software are accessed from this screen. The four rows of
data, within the red rectangle in Figure 8, 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.

All functions, and access to other screens, are executed with the two rows of buttons,
enclosed in the blue rectangle of Figure 8. 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 § 3.5.3.1)
 Flow Rate: Displays OK unless the flow rate is to low

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 OPERATION

Figure 8: PowerView Main Screen

Current Value

 Resistivity/Conductivity: Displays the current measured value

 Temperature: Displays the current measured 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 § 3.5.3.6)
 Flow Rate: Factory default set to 50

Unit of Measure

The unit of measure can be changed in the Configuration screen (See § 3.5.3.5)
 Resistivity/Conductivity: Displays Ω-cm or Ω-in
 Temperature: Displays Degrees F or Degrees C
 Percent IPA%: Displays %
 Flow Rate: Displays cc/sec

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OPERATION

3.5.3 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.

3.5.3.1 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 sets an alarm level (how
much above baseline) to indicate
Figure 9: Configuration: Calibration and Verification
when corrective steps are required.
 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 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.

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 OPERATION

3.5.3.2 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, Figure 10: Configuration-Database

Run Test and Log In/Out

2. Supervisor:
Has access to everything

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 11: Configuration-User Account Setup

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 §3.5.3.5.

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OPERATION

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)
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 Figure 12: Test Profile Management
Enter a value from 0.1 to 50. The software
will calculate the total area of the substrate.
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.

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 OPERATION

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
change the order to ascending or
descending
 Use the Filter options to make it
easier to locate the desired file. Figure 13: Recall Saved Tests
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.

3.5.3.3 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 14: Barcode

barcode use check box

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OPERATION

To setup barcodes:

1. Click the Barcode Setup button

The window seen in Figure 15
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

3.5.3.4 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.
Figure 15: Barcode Setup

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 16: Printing Options
space available. An example of a test
report can be seen in Figure 17.

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.

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 OPERATION

Figure 17: Test Report Example

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OPERATION

3.5.3.5 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 18: 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 to 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.

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 OPERATION

3.5.3.6 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 19: 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
experience.

The Solution Temperature and Temperature Tolerance are irrelevant to the BT series.

Solution Dosage refers to the volume of extract solution within the test cell. For
volume levels refer to Table 1on page 13. Enter the appropriate volume in the box.

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

3.5.3.7 Language
Currently the only language available is English.

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OPERATION

3.5.3.8 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 20: 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.

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 OPERATION

SECTION 4 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.

4.1 IPA VERIFICATION

1. On the Main screen (Figure 8 on page 15) 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 21: IPA Verification Window 1

2. Turn power switch off on the ECM

Figure 22: IPA Verification Window 2

3. Remove the lid from the RHU

4. Gently place hydrometer in test cell

Figure 24: Reading Hydrometer

Figure 23: IPA Verification Window 3

5. Enter the specific gravity, as indicated on the hydrometer, (Figure 24)

6. Click the Next button
The window in Figure 25 will open

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OPERATION

Figure 25: IPA Verification Window 4

7. Click Next.

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

8. If the window in Figure 26 opens, skip to step 12 otherwise continue

Figure 26: IPA Verification Window 5

9. If the window in Figure 27 opens press the OK button

IPA Verification Window #3 (Figure 23) will reopen

Figure 27: Adjust IPA Notice

10. Adjust the alcohol concentration by adding pure IPA or DI water

11. Return to Step Number 2
12. Click on the Finish button
The Main screen will be displayed
Current value will display the new, measured, IPA concentration

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 OPERATION

4.2 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.

4.2.1 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

4.2.2 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!

4.2.3 Calibration procedure

1. Gather the required materials (see §4.2.2)
2. Turn the Ionograph on
3. Turn the Computer on
4. Open the PowerView software
5. Perform an IPA Verification §4.1
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 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 28 on page 28) 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.

27
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 29 will open.
10. Click on the Yes button
Figure 30 will open
11. Click on OK Figure 28: Calibration Window

Figure 29: Resistivity Warning

12. Remove the test cell lid

Figure 30: Add Calibration Solution

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

14. Replace the test cell lid
At the conclusion of the calibration the window in Figure 31 will open

Figure 31: Calibration Finished

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 OPERATION

15. Click the OK button

The window in Figure 32 will open

Figure 32: 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 33)

Figure 33: Comment Dialog Box

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

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OPERATION

4.3 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.

4.3.1 When is Verification required?

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

4.3.2 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!

4.3.3 Verification procedure

1. Gather the required materials (see § 4.3.2)
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 34 on page 31) 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 verification.

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 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 35 will open.
9. Click on the Yes button
Figure 36 will open
10. Click on OK Figure 34: Verification Window

Figure 35: Resistivity Warning

Figure 36: Add Calibration Solution

11. Remove the test cell lid

12. Dispense the Standardizing Solution #3 into the test cell
13. Replace the test cell lid
At the conclusion of the verification the window in Figure 37 will open

Figure 37: Calibration Verified

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OPERATION

14. Click on OK button

The window in Figure 38 will open

Figure 38: 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 39)

Figure 39: Comment Dialog Box

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

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 OPERATION

4.4 RUNNING A TEST

1. From the main screen click on
the Run Test button
Profile selection screen will
open (Figure 40)
2. Choose the appropriate profile
from the list
If a profile has not been created
for the substrate, click the
Cancel button and see §3.5.3.2
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
Figure 40: Select Profile Screen
number or click on the OK or
Cancel button

Figure 42: Lot Number

The Contamination Test screen

(Figure 41) will open
5. Press the Start button
If the resistivity/conductivity or
temperature is not within the Figure 41: Contamination Test Screen
baseline tolerance, the window
in Figure 43 will open.

Figure 43: Resistivity Warning

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OPERATION

Note: For best accuracy, allow the resistivity to get within tolerance
6. If the resistivity/conductivity is within tolerance, the window in Figure 44 will
open

Figure 44: 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 45 will open

Figure 45: 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 46)

Figure 46: Comment Dialog Box

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

34
 MAINTENANCE

SECTION 5 MAINTENANCE
The Ionograph is designed to operate with minimal maintenance activities. A schedule
of recommended activities should include the following:

MAINTENANCE PERIOD
Verify/adjust alcohol concentration daily depending on use (see § 4.1)
monthly
Perform chemical calibration when changing IPA concentration
or when chemical verification fails
Perform chemical verification recommended daily depending on use (see
§ 4.3)
Replace alcohol/DI water solution every 6 months or depending on use
Replace ion-exchange columns every 12 months, depending on speed and
degree of clean-up
Clean the in-line bowl filter every 12 months or as needed
Inspect hydraulics and fittings every 6 months

There are minimal supplies needed to maintain the Ionograph. They include the
following:

 Towels  Metric hex key set

 Catch pan  Nut driver set
 Phillips screwdriver

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MAINTENANCE

5.1 REPLACING EXTRACT SOLUTION

1. Using the Philips screwdriver, loosen the 2 quarter turn fasteners at the top of
the front panel

Figure 47: Panel Removal

2. Lift the panel up and away from the unit

The drain hose will be coiled up in the tray
3. Insert the free end of the drain tube into the catch pan
4. Open the drain valve

Figure 48: Drain Valve

5. Turn the system on to speed up draining

NOTE: Turn the system off immediately once the test cell is drained, to prevent
damaging the pump

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 MAINTENANCE

CAUTION: Drain the Ionograph in a safe location, away from any ignition or heat
source.

The Ionograph Test Module is equipped with an in-line filter to trap small particles
such as solder balls, dirt, and photoresists.

6. Gently twist the bowl counter-clockwise; then the screen can be removed,
cleaned, and rinsed with alcohol.
7. Check the condition of the O-ring, and replace if necessary
8. Re-install the screen and bowl

If the DI columns will be replaced at this time proceed to § 5.2

9. Close the drain valve

10. Slowly pour new extract solution into the test cell until full

5.2 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 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
1. Drain the extract solution
2. Loosen the hose clamps on the top and bottom of all DI columns
3. Pull the hoses off the DI columns
4. Replace the DI columns
5. Re-install all the hoses on the DI columns
6. Tighten all the hose clamps
7. Re-fill the test cell with extract solution
8. Perform IPA Verification
9. Perform Calibration

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MAINTENANCE

10. Perform Verification

Hydraulic inspection of an Ionograph Test Module in operation is very important, not

only as a matter of preventive maintenance, but assuring that repairs such as DI
column and conductivity probe replacements do not allow leakage of fluid out or air in.
To inspect, fill the Ionograph up with extract solution, and operate the Test Module
with the cover off. WARNING: Because electrical connections will be exposed, only
qualified people should perform this maintenance. Prevent any alcohol contact with the
control electronics, or any other heat source or open flames •

When inspecting the hydraulics, check for the following:

 It will take at least 45 minutes to purge most air bubbles after DI column
replacement. If air bubbles exist in the hydraulics, the conductivity will lower
dramatically, and prevent the instrument from working correctly.
 Fluid leakage around flow meter, conductivity probe, fittings, or the pump head
 Test Cell leakage
 A stable solution flow rate

38