Profiling Software User Manual

Profiling Software User Manual
Profiling Software
User Manual
Version 1.0a
Publication Number SFT-315000-000
Version 1.0a
Profiling Software User Manual
Profiling Software User Manual
Copyright © 2012 KIC. All rights reserved. Patents pending.
16120 West Bernardo Drive
San Diego, CA 92127
Phone: +1 858 673 6050
Fax: +1 858 673 0085
A Division of Embedded Designs Inc.
This document contains information that is proprietary to KIC. Said information, is copyrighted as is all associated
software and hardware. All rights are reserved. Patents are pending.
This document and the information contained in it may not be sold, duplicated, used, or disclosed, in whole or in
part, except as specifically authorized in writing by KIC. The information contained in this document and
associated software is subject to change without notice.
There are no warranties with respect to the information contained in this document, express or implied, except as
provided by written contract between KIC and the customer.
All KIC product names and logos are trademarks of Embedded Designs, Inc. All other trademarks used herein are
the property of their respective owners.
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Profiling Software User Manual
Version 1.0a
Software Licensing Agreement and Product Warranty
The KIC software is subject to the following license terms and conditions.
1.
2.
KIC SOFTWARE LICENSE
1.1
This is a software license granted by KIC, mailing address 16120 West Bernardo Drive San Diego, CA 92127.
1.2
The KIC software is licensed to you as the end user, and is not sold.
1.3
The KIC software is copyrighted material.
1.4
The KIC software is licensed for use with one or more pieces of associated hardware that together constitute a thermal process
management system. This license allows you to use the software with the purchased system. You must purchase additional copies of
the software if used with additional system hardware.
1.5
You may not change, modify, decompile, disassemble, or otherwise reverse engineer the licensed software or any associated
hardware.
LIMITED WARRANTY
2.1
KIC warrants that the system hardware and software are free from defects in material and workmanship under normal use. KIC
warrants that the system as a whole will perform substantially in accordance with the specifications set forth in the documentation
provided with it.
2.2
Warranty regarding rated temperature: Components of the system hardware are rated by KIC for proper performance up to a specified
maximum temperature. Any component that KIC determines to have been exposed to temperatures higher than the rated temperature
is not covered under this warranty.
2.3
Start of the Warranty period. The warranty period begins the day the KIC product is delivered to you as the first customer.
2.4
Obligations of KIC during The warranty period:
2.4.1 Return for complete refund: If, within the first thirty (30) days after the start of the warranty, the customer returns, for any
reason whatsoever, any of the purchased hardware or software in its original condition, KIC will refund the associated money
paid and accept the return as payment for any money owed.
2.4.2 Replacement: Within the first year of the start of the warranty, KIC will replace, on an exchange basis and without additional
charge, any product proven defective in materials or workmanship.
2.4.3 Correction of software: KIC will either replace or repair, without additional charge, any software that does not perform in
substantial compliance with its documented specifications. In the foregoing circumstances, KIC will deliver either corrective
code or a corrected copy of the software.
2.4.4 Final Remedy: If KIC is unable to replace defective media or provide a corrected copy of the software within a reasonable
amount of time, KIC will either replace the software with a functionally similar program or refund the license fees paid for use
of the software.
2.5
Exclusion of Other Warranties
2.5.1 KIC does not warrant that the functions contained in the software will meet your requirements or that the operation of the
software will be uninterrupted or error free. The Warranty does not cover any copy of the software that has been altered or
changed in any way by you or others. KIC is not responsible for problems caused by changes in the operating characteristics of
the computer hardware or operating system which are made after delivery of the software.
2.5.2
2.6
EXCEPT WHERE LIMITED BY LOCAL JURISDICTIONS, KIC SHALL NOT IN ANY
CASE BE LIABLE FOR SPECIAL, INCIDENTAL, CONSEQUENTIAL, INDIRECT OR
OTHER SIMILAR DAMAGES ARISING FROM ANY BREACH OF THESE WARRANTIES
EVEN If KIC OR ITS AGENT HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH
DAMAGES.
Other Conditions
2.6.1
THE WARRANTIES SET FORTH ABOVE ARE IN LIEU OF ALL OTHER WARRANTIES,
WHETHER ORAL, WRITTEN OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY
IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY
PARTICULAR USE. THE REMEDIES SET FORTH ABOVE ARE THE CUSTOMER’S
SOLE AND EXCLUSIVE REMEDIES. Only an authorized officer of KIC may make modifications to this
warranty, or additional warranties binding on KIC. Accordingly, additional statements such as advertising, collateral or
presentations, whether oral or written, do not constitute warranties by KIC and should not be relied upon as such. This
warranty gives you specific legal rights, and you may have other rights, which vary by state and/or country.
3.
LIMITATION OF LIABILITY
3.1
ii
In no case shall KIC's liability exceed the license fees paid for the right to use the licensed software or One Hundred Dollars
($100.00), whichever is greater.
Version 1.0a
Profiling Software User Manual
Table of Contents
INTRODUCING PROFILING SOFTWARE .................................................................................................. 1 INSTALLING THE SOFTWARE .......................................................................................................................... 2 STARTING THE SOFTWARE ............................................................................................................................ 3 SELECTING GLOBAL PREFERENCES ..................................................................................................... 5 DEFINING THE PROCESS WINDOW SETUP ...................................................................................................... 7 MONITORING HARDWARE STATUS ....................................................................................................... 12 RUNNING A PROFILE ............................................................................................................................... 13 SPECIFYING OVEN CHARACTERISTICS.......................................................................................................... 14 ATTACHING THERMOCOUPLES .................................................................................................................... 17 SELECTING THERMOCOUPLES FOR THE PROFILE .......................................................................................... 18 STARTING THE PROFILE .............................................................................................................................. 19 VIEWING THE LIVE PROFILE GRAPH .............................................................................................................. 20 VIEWING THE PROFILE AND STATISTICS ....................................................................................................... 22 MANUAL PROFILE PREDICTION .................................................................................................................... 22 ANALYZING THE PROFILE GRAPH DISPLAY .................................................................................................... 24 ANALYZING PROFILE DATA WITH THE GRAPH OPTION TOOLS .......................................................................... 26 USING PROFILE EXPLORER ................................................................................................................... 32 UNDERSTANDING THE COMMAND BUTTONS .................................................................................................. 33 COMPARING MULTIPLE PROFILES ................................................................................................................ 33 INSERTING SOFTWARE DATA FILES FROM AN OUTSIDE SOURCE ..................................................................... 37 PRINTING PROFILE DISPLAY SCREENS ............................................................................................... 38 PRINT FORMAT #1--PORTRAIT .................................................................................................................... 38 PRINT FORMAT #2--LANDSCAPE ................................................................................................................. 39 CHANGING PRINT FORMATS ........................................................................................................................ 40 PROFILING WITH A WAVE SOLDER MACHINE ..................................................................................... 42 WAVE SOLDER PROFILING .......................................................................................................................... 43 RUNNING A WAVE SOLDER PROFILE ............................................................................................................. 45 VIEWING THE LIVE PROFILE GRAPH .............................................................................................................. 52 PROFILE GRAPH DISPLAY ............................................................................................................................ 54 PROFILING THERMAL CURING PROCESSES ....................................................................................... 63 PROFILING TEMPERATURE VS. TIME PROCESSES ............................................................................ 64 CONSIDERATIONS WHEN USING THE PROFILING SOFTWARE ......................................................................... 64 PROCESS WINDOW SETUP ......................................................................................................................... 65 VIEWING THE LIVE PROFILE GRAPH DISPLAY ................................................................................................. 69 VIEWING THE PROFILE AND ITS STATISTICS .................................................................................................. 70 EXITING THE PROFILE SCREEN .................................................................................................................... 74 APPENDIX A: USING OPTIONAL SOFTWARE ....................................................................................... 75 USING NAVIGATOR FOR PROFILE OPTIMIZATION ........................................................................................... 76 USING AUTO-FOCUS .................................................................................................................................. 77 DISPLAYING STATISTICAL PROCESS CONTROL DATA ..................................................................................... 81 USING VIRTUAL PROFILING ......................................................................................................................... 84 APPENDIX B: WRITING DATA OVER A NETWORK ............................................................................... 95 APPENDIX C: USING THE PROCESS WINDOW INDEX TO QUANTIFY THERMAL PROFILE
PERFORMANCE ........................................................................................................................................ 97 CONTACTING KIC ................................................................................................................................... 100 iii
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Introducing Profiling Software
Used together with a profiler, the Profiling Software provides all the tools you need for basic thermal profiling. It
lets you:
•
Specify operating parameters
•
Define individual process setups
•
Monitor the status of your profiler hardware
•
Graphically display profile data for analysis
•
Manage data from multiple profiling runs
Optional programs
The functionality of the standard Profiling Software can be enhanced by using the optional software programs:
•
Navigator – automatically finds the optimal oven setup for each product you profile.
•
Auto-Focus – calculates the ideal initial oven recipe to avoid typical oven setup problems.
•
Power – optimizes profiles/oven settings for reduced energy use. (An option used with Navigator and
Auto-Focus.)
•
Statistical Process Control – displays profile data to chart Process Capability Index (Cpk) values.
•
Virtual Profiling – calculates virtual product profiles when the MVP fixture is run through the reflow oven.
These enhancement options are distributed on and activated from a software key—a removable USB thumb drive
that can be separately purchased from KIC.
Profilers
The software works with three different profiler models:
1.
SlimKIC 2000
2.
KIC Explorer
3.
X5
When first entering the software, it prompts you to indicate your profiler model. The software provides the same
functionality with any of the profilers. However, there are some differences in the user interface graphics between
the X5 and the other models, particularly in the startup and main screens.
When beyond the initial screens and running the program, the text and
graphics that appear reflect the model you selected, but the differences
are confined to the look of corresponding control buttons such as the
example shown at the right.
X5 Global Preferences Button
SlimKIC 2000 / KIC Explorer
Global Preferences Button
This publication primarily uses screens and graphics from the X5. But, while users of the other models may see
slightly different graphics, again, the features and functionality of the software are identical across all three models.
For specific information regarding your profiler, consult one of the following publications:
•
•
•
SlimKIC 2000 Profiler Hardware Guide, (Publication Number SLK-332310-000)
KIC Explorer Profiler Hardware Guide, (Publication Number EXP-330310-000)
X5 Profiler Hardware Guide, (Publication Number EXP-337310-000)
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Installing the software
Minimum PC requirements
•
•
•
•
•
•
Dual Core / 1GHz processor PC with 2GB RAM
2GB available storage
Video 1024 x 768 / 16-bit color
1 available USB port (for software key)
1 available USB port for data download (used with serial-to-USB adapter for SlimKIC 2000)
Microsoft® Windows® XP, Vista, or 7 (32-bit or 64-bit)
Note: Two additional powered USB ports may be needed for additional accessories.
Languages
The software supports the following languages:
•
•
•
English
German
Spanish
•
•
•
•
Japanese
Korean
Simplified Chinese
Traditional Chinese
The use of specific languages depends on the operating system:
•
English, German, and Spanish can be run on any of the supported Windows operating systems.
•
Japanese, Korean, Simplified Chinese, and Traditional Chinese cannot be used with English versions of
Windows operating systems.
•
To run the software in Japanese, the operating system must be Windows-Japanese version.
•
To run the software in Simplified or Traditional Chinese, the operating system must be Windows-Chinese
version.
To install the software:
1.
Insert the Profiling Software CD into your CD-ROM drive.
Note: The Profiling Software installation starts automatically.
2.
If the Profiling Software does not auto-start, go to Windows Explorer.
3.
Go to D:\Profiling Software Installation setup (or your CD-ROM drive letter)\*.exe, and doubleclick on the
installation file.
4.
Follow the instructions for the installation program as prompted on the screens.
Note: If you have a question regarding your hardware or software configuration, contact KIC Tech Support.
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Starting the software
Note: The Profiling Software presents two different interfaces based on the profiler you select in the profiler
selection screen.
To start the software:
1.
From the Windows Start button, navigate through the All
Programs list to locate and open the KIC software product
folder that was automatically setup during installation.
2.
Click on the Profiling Software icon/filename.
The profiler selection screen appears:
3.
Click on a radio button to select the profiler hardware you will use.
The Profiling Software displays the main screen associated with your selected profiler:
4.
Click on one of the buttons to begin one of the software function described below:
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Global Preferences
Run a Profile
Set units of measure, maximum
product start temperature, hardware
configuration, and password.
Begins the step-by-step procedure
for running a product profile.
Define/Edit Process Window
Profile Explorer
Create or edit Process Window files
for solder paste and profile
specifications.
Filing system used to manage and
view all profiles run using the
software.
Hardware Status
Show the status of the oven
controller (if applicable), the profiler,
and the optional software key.
Exit
Exits the program, closing the
application.
To end the software session:
1.
2.
Return to the main screen by clicking one of these buttons:
•
From the Global Preferences, Run a Profile,
or Define Process Window screens, click…
•
From the Hardware Status screen, click…
•
From the Profile Explorer screen, click…
or
or
or
Back on the main screen, click on the Exit button.
or
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Selecting global preferences
Figure 1: Preferences – Global Tab
You access the Global Preferences settings by clicking on the globe button on the main screen. You set your
preferences on the Global tab.
•
Units of measure – There are two drop down menus to choose units for Conveyor Speed and Distance, and
weight. (The Weight is only used with the Auto-Focus program.)
•
Product start temperature – The temperature of all the thermocouples attached to the product and the profiler
must be below this temperature to start a profile. This will insure that a profile is not started while the board is
still too hot. Input a value in the field or use Slider bar.
•
Profiling hardware – Specify the number of thermocouple channels (7, 9, or 12) available with your profiler
hardware and if you intend to operate it as basic datalogger or as a transmitter for wireless operation.
•
If you are running on an oven with communication compatibility with the Profiling Software, there will also be
a field to input the oven name. This oven name will be saved with the profile and can be sorted on in the Profile
Explorer.
•
Languages – Select the language that you wish to run the software. See important information about
Languages on page 2.
•
Engineer password – By checking this and entering a password you can control access to certain menus in the
software. See Restricting actions by password.
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Restricting actions by password
At various point s in the software you can restrict the ability to perform certain functions by protecting access to
them with passwords. You enable password protection by clicking the Engineer Password check box on the Global
Preferences screen:
After the password is established, the software will prompt for entry when a protected function is attempted. For
example, clicking the Global Preferences button on the main screen displays the prompt shown below:
Similar password protection applies to the functions listed below:
•
Saving or deleting Process Windows or changes to Process Windows in the Process Window screen
•
Removing ovens on the first Run a Profile screen
•
Deleting a profile in the Profile Explorer
•
Accessing the Optimization tab on the Profile Graph and Statistics screen
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Defining the Process Window setup
Deselect this check box
to assign separate specs
for each thermocouple
used. See details below.
Figure 2: Process Window Setup
Process Window name – Name of the Process Window file that includes the statistics chosen and limits for those
statistics, along with whatever text is typed in the Description field. See Figure 2.
•
Solder paste menu - A read only library list of numerous solder pastes along with the statistics and limits
suggested by the paste mfg., also included is a User-Defined option in the list which allows you to create a spec.
of your own. See below for additional details.
•
Edit specs – Screen allowing you to edit or choose statistics and limits for a chosen solder paste or define your
own specs
•
Wave – This radio button switches between the process specs and the Wave process specs for the selected
Process Window. Set up a Process Window specific to Wave TCs for Wave Solder profiling.
•
Read only text box – Shows the paste name, statistics name, and limits for a Process Window chosen, edited,
or saved by you. To edit select the Edit Specs button.
•
Same specs for all TCs – By deselecting this checkbox, you can assign separate specifications for each
individual thermocouple you are using. After deselecting the checkbox, you’ll need to click on the Edit Specs
button to choose which statistics will be used and what spec limits will be set for each thermocouple used. This
option would be used if you had component specific specifications that differ from the general solder paste
specs. Another use for this would be if you wanted to monitor the actual board temperature as well as
component temps. You would then only select the statistics for that TC that are relevant. If you wish to use the
same specifications for all thermocouples, put a check mark in the box.
•
Select TC to view – This dialog box will appear only if the Same Specs for all TCs checkbox is deselected. By
clicking on the dropdown menu, you can view the specifications that have been defined for that number
thermocouple. If a description was included, it will be displayed next to Label.
•
Process Window description – Field allowing for freehand notes for a particular Process Window.
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Selecting a solder paste
Figure 3: Solder Paste List
Solder Paste menu - Once you have clicked on the Solder Paste Menu you will have a list of pastes to choose from.
Use the scroll bar on the right to find your paste, and then click on the paste in the list. See Figure 3.
•
Clicking on the green check will accept that paste and load its specs automatically. You will then return to the
Process Window screen, after being presented disclaimer information.
•
Clicking on the picture of the paste jar and tube will give you technical support information for the solder paste
Mfg. that you chose.
•
Clicking on the red X will cancel your selection and return you to the Process Window screen without making
any changes.
Note: The solder paste list is updated periodically. Check the Internet for updates -- www.kicthermal.com
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Editing Process Window specifications
Figure 4: Process Window – Edit Specs
Process Window name is listed at the top of the screen. See Figure 4.
There is a single drop down list at the top that contains all of the available specifications that can be applied to your
Process Window. These specifications are specific limits or a group of limits that define the overall Process
Window for your product. These specifications include Slope, Preheat, Soak, Peak temperatures, and Time above
temperatures.
Spec details – The Spec details coincide with the selected Specification. For each Specification selected, enter the
Temperature, and Time limits. These limits are usually dictated by the solder paste used. The Profiling Software
uses the limits to measure the profile PWI.
Note: Changes made within this screen will have a direct effect on the profile PWI value.
Once you complete all spec modifications, click on the green check button to apply your changes. Clicking on the
red X (cancel) button will cancel your changes and exit.
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Assigning separate thermocouple specifications
Figure 5: Process Window – Separate Specs
TC selection & label
If you choose to assign separate specs for each TC, click the Edit Specs button and the screen will now appear with
an additional area for TC Selection & Label. See Figure 5.
•
•
Select - Use the Select drop-down menu to select the TC whose specifications you wish to view/edit. The Spec
Details for the selected TC is displayed.
TC label – This area will allow you to type in a description or label to identify that particular TC. If left blank,
the TCs will simply be identified as TC2, TC3, etc.
Note: When separate specs are being used, this is the only place where you can select or deselect which TCs will be
used for a profile.
Once you have completed all edits of the specs you can click on the Green Check button and your changes will be
applied. Clicking on the Red X (Cancel) button will cancel your changes and exit. See Figure 5.
Note: If you are having trouble defining your process specifications, contact us at [email protected]
Select TC to view – Drop-down menu containing the
TCs that have already been defined. (Previous step)
See Figure 6.
Figure 6: Process Window – Separate Specs – Select TCs
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Saving the Process Window
Figure 7: Save Process Window
To create a Process Window:
1.
Choose a solder paste from the Solder Paste menu.
2.
Edit the specs if necessary. See Page 9 for details.
3.
Enter a name the Process Window.
4.
Save the Process Window.
To save - Click on the green check (Save and Exit) button. A dialog box will appear asking if you want to save the
changes to the new Process Window file. See Figure 8.
Figure 8
Clicking on Yes will save it and exit to the main screen. You can click on No and click on the red X “cancel button”
to exit without accepting or saving any changes.
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Monitoring Hardware Status
Figure 9: Hardware Status
Oven Controller – Shows the status of the connection between the Profiling Software and any connected oven.
Contact KIC for details about connecting your reflow oven.
Profiler status panel– Names the currently selected profiler (X5, SlimKIC 2000, or KIC Explorer) and displays the
following information:
• Profiler communication status
• COM port – when connected.
• Temperature display – for all connected thermocouples.
• Battery Voltage.
• Internal Temperature – of profiler.
• Maximum Temperature Capability – This value determines the maximum temperature that the profiler can
read.
Software Key – Shows the status of any software key that is connected. Displays the functions associated with the
software key.
Note: Only one software key can be connected at any given time. The Profiling Software will not detect multiple
software keys. If you have purchased new software options that require an additional software key, contact KIC
Technical Support, [email protected]
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Running a profile
The Run a Profile button will guide you through a series of screens, which will finish at a completed and graphed
profile. To move through these screens you can use the Back, Next, or Cancel buttons located at the bottom of the
screen.
Figure 10: Run a Profile Screen #1
Settings on the Name Product and Select Process Window:
Product Name – Enter in a unique product name (long file names are acceptable) or choose an existing product
name from the drop down list.
Process Window – Choose a Process Window from the drop down list. These Process Windows are created in the
Define/Edit Process Window screen which is accessed from the Profiling Software main screen.
Application – Select your Application type/profiling fixture from the drop down list.
Sample Rate - Select the number of samples per second from the drop down list for each product.
Set Trigger – Manually set the Middle and profile End temperature triggers for each product.
• Note: The Profile start temperature trigger is determined by the Maximum Product Temperature at Start
of Profile setting in the Global Preferences screen. The start trigger value is always 2ºC above this value.
•
Note: For Temperature vs. Time profiling, trigger temperatures are not used. Instead a Profile Stop
button is displayed in the bottom-right hand corner of the profile graph screen.
Oven Name – Enter a unique oven name or choose an existing oven from the drop down list. The oven will have
information about the number of zones saved with it as well as other zone information. This is entered on the next
screen.
Remove Oven button will delete the oven name currently displayed in the field.
• If you are running the software on an oven controller computer that is communication compatible with
the Profiling Software the number of zones is already known and the oven name will be entered in the
Global Preferences screen, not on this screen. In addition, the Enter Oven Setpoints and Conveyor Speed
screen is skipped because the Profiling Software already has the recipe information from the oven
controller.
Enable Auto-Focus – Enables or disables the Auto Focus tool for the current profile (requires software key).
Profile Description – Allows for freehand typing of any notes you may want to include with this profile.
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Specifying oven characteristics
To ensure accurate profile data, you may need to enter specific information into the software about the oven(s) you
intend to use--information that changes the default values used by the software’s predictive algorithms. These
default values are stored in an oven initialization file that the software creates when you first enter the name of a
new oven. The software adds the extension .kiccfg to the name you entered and stores the file in this location:
C:\Profiling Software\Ovens
Unless you specify otherwise, the software works with the following initialization file default assumptions:
•
The zones are uniform and consecutive with no large gaps between them.
•
The minimum temperature for all zones is 70° C.
•
The maximum temperature for all zones is 350° C
•
Default setpoint values start at 100° C and increases at 5° intervals at each zone.
At the start of the profiling process, the software displays a series of screens that let you change the default values in
the file to accurately reflect your equipment. You will likely need to set some values, such as the length of oven
heating zones, and min/max temperature limits only once--when you first set up the oven. Others, such as
temperature setpoints and conveyor speed values that make up an oven recipe, you may change frequently to match
to new products.
To identify a new oven to the system:
1.
On the Name Product and Select Process Window screen, type a new,
unique name in the Oven Name field.
2.
Click the next arrow button.
The Verify the Length of Each Zone and the
Minimum and Maximum Setpoint Temperatures
screen appears.
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Profiling Software User Manual
In the Number of Zones field, type in the quantity for the oven.
The screen populates with numbered zones and associated temperature fields:
4.
Deselect the All Zone Lengths are the same check box.
The screen populates with default length values:
5.
Type new values in the Length fields.
6.
If needed, type in replacement values for the minimum and maximum
temperature setpoint values.
7.
Click the back arrow button to save the settings or click the next arrow button
to save the settings and display the next screen to specify an oven recipe.
To specify an oven recipe:
1.
On the Name Product and Select Process Window screen, select an
oven from the Oven Name field pull down list.
2.
Click the next arrow button.
The Enter Oven Setpoints and Conveyor
Speed screen appears.
Note: This screen does not appear when the Profiling Software is communicating with an oven controller.
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3.
Type in new temperature values for the top of the oven zones.
4.
If the bottom of the zones are to have different setpoint
values than the top, deselect the Top and Bottom Setpoint
are the same checkbox.
The bottom row of fields becomes editable (white).
5.
Enter new temperature values in the bottom row fields.
6.
Type in a value in the Conveyor Speed field.
7.
Click the next arrow button
to advance to the thermocouple attachment phase of running a profile.
Note: If the zone lengths of your oven have been changed since you first
characterized the unit in the software, or you just want to check the current
settings, use the Zone Length button to display the Verify the Length of Each
Zone and the Minimum and Maximum Setpoint Temperatures screen.
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Attaching thermocouples
Thermocouples (TCs), attached to solder joints or other important sites on the board, directly measure the
temperature at the point that the TC bead is in contact with the PCB. The TC measurements are collected by the
profiler and the software to create thermal profiles.
As part of the running a profile process, the software displays illustrations that show how to attach thermocouples
using aluminum tape. These images also appear in the procedures that follow.
The system works with two kinds of TCs—standard TCs and the air TC. Standard TCs record the temperature data
for various sites on the board. The air TC gets specific positioning because its temperature triggers the start of the
profile data processing, aids with TC shifting, and improves the prediction capabilities of the software.
Attaching the Air TC
There are two important considerations regarding the Air TC:
1.
It must be attached at the leading edge
of the board, extending one inch (25
mm) in front of the leading edge of the
board.
2.
It MUST be plugged into channel 1
on the profiler.
Attaching standard TCs
Attach the standard TCs at selected sites on the
board, and plug them into the remaining
connectors on the profiler. Order is not
important, unless you plan on labeling where
each TC is attached.
When selecting a position for the standard TCs,
you want to measure points on the product that
represent the mass-range of the product. Select
at least one position that is a high mass (large
component) area of the board and at least one
position that is a low-mass (small component)
area of the board. If you can develop an
acceptable profile for the low and high-mass
areas of the board, you can process the other
areas of the board within the same parameters.
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Selecting thermocouples for the profile
Figure 11: Run a Profile screen #7 – Select TCs
Include thermocouple (TC) labels (20 char. Max) – Checking this will display a field below each TC that is
checked. Up to 20 characters can be used to describe the placement or location of that TC.
TC number check box – Place a check next to each TC channel that is going to be used for this profile. TC number
1 is always used for the AIR TC. You must have at least one other TC being used.
Note: If the selected Process Window has Separate Specs for TCs, then you must return to the Process WindowEdit Specs screen in order select/deselect TCs or change their text labels.
Live reading – When the profiler is on and either plugged into the download cable for data logging or transmitting
to the receiver which is plugged in, you will see live temperature updates for the TCs plugged into the profiler. The
TC checkbox must be checked as well to get the temperature updates. If you do not see live temperature readings
recheck all the cable and or computer connections.
Battery voltage – This displays a live reading of the profiler battery voltage. The software will recognize if your
battery voltage is too low to complete the profile and not allow you to start a profile until the batteries have been
replaced.
Profiler internal temperature – This displays the internal temperature of the profiler. If the temperature is too
high to complete the profile and stay under the maximum temperature rating for the unit, it will not allow you to
start the profile. You must wait until the profiler is cool enough. The software will let you know what temperature
you will have to drop below.
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Starting the profile
Before you can start the profile run, you need to make sure your profiler is powered on and ready and that the oven
temperature has stabilized. Depending on the settings in the profiler and in the software, you may have to initialize
the profiler at times. The software will let you know when this is necessary. This is done by attaching the cable
from the receiver to the back of the SlimKIC 2000 or by connecting the communication cable directly to the
KIC Explorer or X5. Click on OK when it gives the message that the initialization was successful.
To start the profile:
1.
On the Select the Thermocouples for the profile screen, click on the Start Profile button.
The software asks if the oven control TC’s are within 2 degrees of the setpoint value:
2.
Click the appropriate response button:
If you click YES the next screen in the profile
sequence appears, prompting you to place the
profiler and board into the oven:
3.
Follow the further on-screen
instructions.
If you click NO, the software asks if the stabilizing oven is
getting closer to 2 degree limit:
•
Click YES to wait for the oven to stabilize within the 2degree limit and continue profiling.
•
Click NO if the oven has stabilized, but is still not within
two degrees of the setpoint values. In the oven software,
change the setpoint values to the temperatures the control
thermocouples are currently reading. The Profiling
Software will recalculate the zone separation capability.
Clicking OK on the next screen allows the Navigator to
suggest a new recipe that your oven will more likely be
able to control to. From there, you will step through
running the profile. Change the values, return to the main
screen, and start the profile sequence over.
IMPORTANT NOTE: All profilers have a maximum operating temperature that, to avoid damage, should never be
exceeded. See the product datasheet for temperature tolerance information:
Profiler model
SlimKIC 2000
KIC Explorer
X5
Maximum operating temperature
105°C/220°F
85°C/185°F
85°C/185°F
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Viewing the live profile graph
Figure 12: Live Profile Graph Display
The Live Graph screen shows the real-time plot of the product going through the oven. This will only appear for the
profiler-RF models or for Temp vs. Time profiles. During the live profile all of the tabs on the screen are
inaccessible. The only action that you can take at this point is to cancel the profile by clicking on the RED X button
or the Profile Stop button for Temp vs. Time.
The Live Profile Graph display will remain on your screen until the profiler has achieved the trigger temperature
that determines the profile end.
Profile status
The bottom part of the screen will keep you apprised of the progress of the profile in reference to the profiler
hardware status. Status messages include:
20
•
Waiting for the Air TC to exceed the start trigger temperature.
•
Profile started- Waiting for the Air TC to exceed the midpoint trigger temperature.
•
Profile will stop when all thermocouples drop below 80 Celsius.
•
SlimKIC currently retransmitting.
•
SlimKIC retransmission successful!
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During the live profile:
•
The live profile is plotted on the graph. (Profilers with wireless only.)
•
The current temperatures for each thermocouple and the delta between them are displayed in a small
window in the upper-left hand corner of the profile graph. The elapsed time is also displayed, profiler
transmitter models only.
•
The current oven temperature setpoints and conveyor speed for this profile is displayed beneath the
Statistics table.
Profile retransmission
While a profiler with wireless capability transmits the live profile data to the Profiling Software; it simultaneously
stores the profile data in its memory. Once the profiler detects that all of the thermocouples have cooled below the
profile-end trigger value, it will begin retransmitting the profile data to the Profiling Software via the SlimKIC 2000
receiver or KIC Explorer/X5 Base Station. When retransmission begins, the profiler will send the profile in data
packets. The retransmission status is displayed at the bottom of the screen. See Figure 13.
Figure 13: Retransmission of Profile Data, RF Profilers only
When all of the data packets have been received, the software will display a message asking you to turn the profiler
off, choose OK. Failing to turn the profiler off will drain the batteries.
Next, the software will automatically analyze the profile data and presents the profile and statistics. If you
purchased the Navigator option, the predicted oven settings will be displayed as well.
See Figure 14 through Figure 17.
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Viewing the profile and statistics
Figure 14
General Tab – Shows graph, statistics, and recipe
Figure 15
General Tab – Graph view (double-click on graph)
Figure 16
General Tab – Statistic view (double-click on stats table)
Figure 17
Description Tab – Shows Description notes, statistics, and
recipe
Manual profile prediction
The Profiling Software has automatic (Navigator), and Manual Prediction capabilities. The standard Profiling
Software installation includes Manual Prediction capabilities.
Manual Prediction gives you the flexibility to easily predict changes to the oven settings (temperature settings,
conveyor speed), and view the results without having to spend the time actually running the profile. This feature is
very helpful to minimizing the time spent fine tuning or developing a thermal profile.
Figure 18: Original/Predicted setpoints – Manual Prediction
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Figure 19: Original/Predicted setpoints – Navigator (Optional)
This is an example of how the Profiling Software (standard and with Navigator) lists the PWI, and oven settings for
the profile. This table is divided into the original section (top), and the Predicted section (bottom). See Figure 18.
The original values represent the oven settings at the time the profile was run. The predicted values represent the
prediction results as determined by the Navigator software. See Figure 19.
If you purchased the Navigator software option, the Profiling Software will automatically generate results that are
best suited for the selected Process Window. In the event you wish to modify the prediction results of the
Navigator, you can do so. See Figure 20.
To predict changes to the oven settings, or modify the Navigator prediction results, click on the zone you wish to
change. In the example below, zone 1 has been selected. See Figure 20.
Figure 20
Type the new temperature setting, and then press Enter. The Navigator will predict the results of that change, and
then automatically update the PWI, predicted Statistics, and the profile graph. The new predicted results will be
displayed on the graph in a dotted-line format. This format enables you to easily determine the difference between
the original and predicted profiles. See Figure 21.
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Analyzing the profile graph display
Original profile plot
(solid lines)
Predicted profile plot
(dotted lines)
Figure 21: Graph Display
The PWI for the profile is displayed in the bottom-left corner of this screen. If the measured PWI is below 100%,
the value will be displayed in green. See Figure 21. If the measured PWI is 100% or higher, the value will be
displayed in red. See Figure 22.
A PWI under 100%
is acceptable
A PWI above 100%
is unacceptable
Figure 22: Profile PWI
Note: This display method enables you to easily identify whether the profile is in- or out-of-spec.
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Adjusting the appearance of the profile graph
The Graph Controller screen lets you modify the
appearance of the profile graph. To open the Graph
Controller, click on the TC column header or click,
anywhere just outside the profile graph.
Auto Scale – The Auto Scale feature automatically
adjusts the X and Y axis scales to fit all of the data in the
profile graph. When the feature is disabled, you must
input the scale settings manually.
Selecting thermocouples to view
The TCs section lists the thermocouples used for the
profile. By selecting All you are selecting that all the
thermocouples used for the original profile will be
displayed on the profile graph. In the event that you
wish to view the profile without one or more
thermocouples, you can deselect individual
thermocouples, or deselect the All check box, and
choose only the thermocouples you wish to view.
Figure 23: Graph Controller
Excluding disconnected thermocouples
If a thermocouple has become disconnected during the profile, the profile results (PWI) may be affected due to an
erratic reading. In the event a single or multiple thermocouples become disconnected from the product during the
profile, you can deselect the affected thermocouple(s). The Profiling Software will recalculate the PWI, and update
the profile statistics based on the remaining thermocouples selected. You must select at least one product
thermocouple.
Enabling graph display features
The Graph Controller screen includes check boxes that let you specify these display features:
Grid – Enables/disables the view of the X and Y-Axis scales.
Reference lines – Enables the view of Reference Lines displayed on the profile graph. These lines represent any
temperatures referenced in the selected Process Window.
Zone lines – Enables the view for the oven zone lines on the profile graph.
Predicted TCs only – Removes the original profile plot form view, displaying only the prediction profile plot on the
graph.
Zero decimal – When viewing the Pointer tool, this setting enables or disables the decimal display. When
unchecked, the software will display one decimal point.
Internal temp – Enables the view of the profiler’s internal temperature profile plot on the graph.
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Analyzing profile data with the graph option tools
The Graph Option menu includes tools to let you explore
profile data in closer detail. To view the menu (Figure 24),
right-click anywhere within the profile graph area.
Figure 24: Graph Options
Viewing temperature data at selected points
The Examine option lets you use the mouse pointer to display temperature values at any
selected point along a graph line.
Wherever the pointer is moved across the profile, the data shown in Figure 25 appears:
•
The first column is the actual temperature for each TC.
•
The second column is the temperature of the predicted profile data – based on
setpoint or belt speed changes.
•
Figure 25: Graph Pointer
The Delta T for both actual and predicted TC data.
• The Time during the profile at which the pointer is placed
To disable the Examine view, right-click on the graph and deselect Examine.
Enlarging graph details with the zoom option
You can get an enlarged view of selected areas of the profile display.
Right-click on the graph to display the Graph Option Menu, then select
the Zoom option. See Figure 26. A chart appears on the left side of the
graph. See Figure 27.
Figure 26: Zoom Option
Figure 27: Graph Option Menu - Zoom
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Using your mouse pointer, click and drag the view window in the graph over the area you wish to enlarge.
Figure 28: Graph Option Menu - Zoom
To disable the Zoom view, right-click on the graph, and deselect the option.
Move TC line
The Move TC line feature allows the user to manually move the thermocouple plot
on the profile graph. This is used to fine-tune the profile or make corrections in the
event the Profiling Software did not properly display the plot. See Figure 29.
Select the thermocouple you wish to move and then click and drag the highlighted
plot and move it to the desired location on the profile graph. See Figure 30.
Figure 29: Move TC Line
Figure 30: Move TC Line
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Move Zone line
The Move Zone line feature allows the user to manually move the zone separation lines on
the profile graph. This is used to fine-tune the profile or make corrections in the event the
Profiling Software did not properly display the zones.
Figure 31: Zone Resize
Figure 32: Move Zone Line
Zone Resize
Select to move the first line (zone beginning) or the last line (Zone
ending) and then click and drag it to the desired location on the profile
graph. See Figure 33.
Figure 33: Zone Resize
Reset
The Reset feature will reset the profile and undo any changes you have
made to the graph using the Graph Option Menu. Select the TC Line, or
Zone Line option. See Figure 34.
Figure 34: Reset
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Profile screen buttons
There are four buttons at the bottom of the profile screen.
Edit/Define Process Window – Choose this button to either view or edit the process
specification(s) for the product used in this profile.
Copy to clipboard – Choose this button to copy the profile data to the windows clipboard. You
can then paste the data to a different application.
Print – Choose this button to print a copy of the profile that is currently on your screen.
Main menu– When finished viewing or analyzing the profile select this button to either run
another profile with this product or return to the Profiling Software main menu. You will be returned to the Profile
Explorer if the profile was opened from there.
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Upon exiting the graph screen
Do you want to run another profile with this
product? See Figure 35.
If you select No, you will be returned to the Profiling
Software main screen or the Profile Explorer if the
profile was originally opened from there.
Figure 35
If you select Yes, you will need to choose from the
Original or Predicted recipe settings. See Figure 36.
Original – The same recipe settings used when this
profile was originally run.
Predicted - The recipe settings as predicted by the
Navigator option, or a standard prediction manually
input by you.
Figure 36
For both the original and predicted recipe settings, the software will automatically send the selected recipe
information to the oven controller. If there is no communication between the Profiling Software and the Oven
controller, the Profiling Software will display a dialog box showing the recipe information. You must manually
enter this recipe information in the oven control software. See Figure 37.
Figure 37
Profiling Software will automatically apply the changes to the Run a Profile –Enter Setpoints screen. You will exit
to the Run a Profile –Enter Setpoints screen. If you are running on the oven controller PC, and the oven is
compatible with the Profiling Software the oven recipe will automatically be updated.
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Saving changes to the profile:
Any changes to the Description Notes or the Process
Window can be saved with the profile. See Figure 38.
This will permanently update this profile with the
changes. Changes to the Process Window saved here
only save the changes with the profile. To save the
changes to Process Window file see next dialog box.
See Figure 39.
Figure 38
Saving changes to the Process Window:
If you have made changes to the Process Window
from the Graph screen you can save these changes
when you exit the graph screen. The Process Window
will permanently have these changes whenever it is
used to profile from this point forward.
The software will take you to the Edit Process
Window screen in order to save the changes that you
have made.
Figure 39
The first dialog – “Do you want to run a profile with this product?” will appear each time you exit the graph screen.
Click on No if you do not wish to profile.
You will be sent back to the main menu if you had just completed running a profile. If you opened the profile from
the Profile Explorer you will be returned to the Profile Explorer. The other two dialogs will only appear if changes
are made to the Description notes or Process Window.
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Using Profile Explorer
Figure 40: Profile Explorer
The Profile Explorer is a data file management tool that creates a folder for each unique product you name when
profiling. The software gives the folder the product name, and under that folder, all the profiles for that product are
saved. See Figure 40.
•
The list of product folders is in the upper left of the Profile Explorer. Click on a folder to display the
profiles in the profile section at the bottom.
•
The profile section can be sorted by click on any of the column headers. Single clicking on a profile will
display the Profile Description in the upper-Right corner.
•
Double clicking on a profile will display the graph and statistics for that profile.
•
Clicking on the Display Graph… button will also display the profile.
Note: The default data path can be changed, see page 95 for details.
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Understanding the command buttons
Save button – Blue floppy disk allows you to save a profile to another folder or to a floppy disk.
Delete button (trashcan) – Allows you to delete the selected profile.
Display profile button – Displays the profile for viewing or analysis.
Main menu button – In the lower right corner returns you to the Main Menu.
Optional Buttons (Only displayed if software key is detected)
Product dimensions button (Ruler) – For Auto-Focus users, allows you to edit the length, width, and
weight of the selected product. Whenever the product dimensions are changed in the Profile Explorer, all the
profiles in the directory will be updated automatically.
MVP - Virtual profile – Select this button to run a Virtual Profile using the MVP profiling fixture.
SPC – display charts – Select this button to display the SPC charts for the selected profiles in the SPC
Column.
Comparing multiple profiles
The Profiler Explorer screen can display profile data in an overlay mode that lets you simultaneously compare
multiple profiles in a single chart. Overlay mode lets you combine the plotted data from up to three profiles into a
single display file that can be saved for future reference.
To create an overlay profile:
1.
In the lower-left corner of the Profile Explorer screen,
click the Overlay radio button to switch the Profile Mode
from Standard.
Overlay Mode option buttons appear to the right, a
Profile Overlay selection column appears in the profile
list, and the Overlay icon joins the other command buttons
along the bottom of the screen.
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2.
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Click the checkboxes to select the profiles that you want
to overlay, choosing the last selected as the target profile.
Note: As shown below, the target profile appears highlighted in blue. The overlay display compares the
other selected profiles against the target. View target profile information in the Profile Overlay Graph
Controller (Figure 43).
Target Profile
(Highlighted)
Overlay Icon Button
Figure 41: Profiling Software Profiler Explorer – Overlay Option
3.
Click the Overlay icon.
The data for the selected profiles appear plotted in a single chart with statistics displayed in a table as
shown below:
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Figure 42: Overlay Option – Graph display
The curves for each TC are shown in different
colors while distinct shapes (square, circle, and
triangle) indicate the different profiles in the
overlay view.
4.
When finished analyzing the data, click the Profile Explorer button.
A message appears, prompting you to save the overlay profile:
5.
Click Yes.
Note: After saving overlay profiles you can display them
exclusively by selecting the Show Saved Overlay Profiles option
on the Overlay Mode panel.
Note: While viewing multiple profiles, the prediction capabilities are disabled.
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Adjusting the appearance of the overlay graph
Target profile Info
Figure 43: Overlay Option – Graph Controller
The Profile Overlay Graph Controller screen lets you modify the view of the Profiling Software-multiple profile
graph display. To open the screen, click on the TCs column header in the Process Window data table. The screen’s
features are described below:
Auto Scale – The Auto Scale feature automatically adjusts the X, and Y axis scales to fit all of the data in the profile
graph. When the Auto Scale feature is disabled, the user must manually input the minimum and maximum scale
settings for the X, and Y axis scale of the profile graph.
Target Profile – Displays the profile information for the profile selected as the Target Profile. The Target Profile is
the highlighted profile when selecting multiple profiles from the Profile Explorer Main Screen.
List Compare Profiles – Displays the profile information for the profiles that have been selected. Scroll to view
the information. Deselect the check box to remove the profile from the graph.
Selecting thermocouples to view
The TCs section is a list of the thermocouples used for the profile. By selecting All you are selecting that all the
thermocouples used for the original profile will be displayed on the profile graph. In the event that you wish to view
the profile without a particular or multiple thermocouples, you can deselect individual thermocouples, or deselect
the All check box, and choose only the thermocouples you wish to view.
Deselecting thermocouples
You can deselect thermocouple(s). The Profiling Software will recalculate the PWI, and update the profile statistics
based on the remaining thermocouples selected. You must select at least one product thermocouple.
Grid – Enables/disables the view of the X, and Y-Axis scales.
Reference lines – Enables the view of Reference Lines displayed on the profile graph. These lines represent any
temperatures referenced in the selected Process Window.
Zone Lines – Enables the view for the furnace zone lines on the profile graph.
Zero Decimal – When viewing the Pointer tool, this setting enables or disables the decimal display. When
unchecked, the software will display one decimal point.
Internal Temp – Enables the view of the profilers’ internal temperature profile plot on the graph.
Number of seconds to calculate slope over- User defined field for entering the time in seconds to calculate the
Slope values for the Pointer/Slopes feature.
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Inserting software data files from an outside source
Profiling Software data files can be sent or received via floppy disk or email. In order to view them using the
Profiling Software, copy them to the Profiling Software\Profiles folder using Windows Explorer.
The next time you enter the Profile Explorer screen, the software will automatically create folders for those profiles
based on the profile name and move the profiles to the correct folders.
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Printing profile display screens
The Profiling Software will print profiles only from within the profile display screens. There are two print formats
available. Print Format #1 is the default.
Select the print button at the bottom of the screen to print a profile. A print dialog box will appear.
See Figure 44.
Print Format #1--Portrait
Figure 44: Print Options Screen – Print Format #1
Enter the “Company Name” and “Site ID.” Check the items you wish to include on your profile printout.
Press the Print button to print the report.
Press the Print Preview Button to display a preview of the report. See Figure 45.
Print Format # 1 Print Preview
Figure 45: Sample Print Preview for Report Format #1. Report is printed in Portrait layout.
Includes the Company Name, Site ID, Date, Statistics, Profile Information, Setpoints,
Profile Graph, Statistic Limits and Profile Description.
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Print Format #2--Landscape
Note: To change from the default portrait format to the landscape format (#2) you need to change a value in the
configuration file. See Changing print formats.
Figure 46: Print Options Screen – Print Format #2
Enter the “Company Name” and “Site ID.” Check the items you wish to include on your profile printout. See
Figure 46.
Press the Print button to print the report.
Press the Print preview button to display a preview of the report. See Figure 47.
Below are the additional options available with Print Format #2:
Memo Box –Enables/Disables a Memo Box area for Draft, Review and Approval Signatures and Dates.
Lead Free Logo – Enables/Disables the Lead-Free Logo display area.
Lead Free Logo Path – When “Lead Free Logo” is enabled, specify the path to any BMP image file that you want
to appear in the Lead Free Logo display area on the report. The default image is the Lead-Free logo image
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Print for mat # 2 Print preview
Figure 47: Sample Print Preview for Report Format #2. Report is printed in Landscape layout.
Includes the Company Name, Engineer, Date, Statistics, Process Window, Setpoints,
Profile Graph, Profile Description, Lead-Free Logo Area and Memo Box Area
Optionally, you can print the contents of any screen in the Profiling Software by pressing F9 on your keyboard. The
F9 function will not work while viewing the Profile Printout Setup dialog box.
Note: Before printing a profile make sure you have installed a printer on the computer.
Changing print formats
You can change the print format from the portrait default to the landscape alternative by editing the Profiling
Software Configuration file.
To change to the landscape print format:
1.
Exit the Profiling Software application if it is running.
2.
Using Windows Explorer, find and open the
Profiling Software folder.
3.
Inside the folder, find the PSConfig file, and
double-click it.
The PS Config screen appears.
4.
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In the print format panel, click the radio
button for Alternative Format:
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Click Apply, and then click OK.
The alternative format is saved and the next profile report you print will be in landscape orientation.
To switch back to the default print format:
1.
Exit the Profiling Software application if it is running.
2.
Using Windows Explorer, find and open the Profiling Software folder.
3.
Inside the folder, find the PSConfig file, and double-click it.
4.
The PS Config screen appears.
Click the Restore Default button.
5.
Click Apply, and then click OK.
The format switches back to the default and the next profile report you print will be in portrait orientation.
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Profiling with a wave solder machine
KIC profilers can be used to measure thermal profiles in a wave solder machine. The process is very similar to
profiling a solder reflow oven. The Profiling Software guides you through the process.
Note: KIC does not recommend installing this software on an oven controller PC if you plan to run wave solder
profiles. Contact KIC for instructions should the need arise. [email protected]
Wave Surfer profiling fixture
Wave Surfer is a wave solder machine accessory
specifically designed for use with the KIC
profilers. See Figure 48.
The Wave Surfer has embedded thermocouples
that give wave specific data including conveyor
speed each time you run it through your wave
solder machine.
Using the Profiling Software Wave Surfer users
can collect profile and wave data and using the
Navigator and SPC option(s) to optimize their
process.
Figure 48: Wave Surfer Fixture
The Wave Surfer simplifies wave soldering profiling. The device is used to routinely check the wave machine.
Using the Process Window Index, the machines performance is measured each time a pass is made based on your
selected Process Window.
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Wave solder profiling
This section will outline the steps necessary to setup and run a wave solder profile using your profiler and Profiling
Software. This section is written assuming you have a basic understanding of the Profiling Software and its
functions before attempting to run profiles on a wave solder machine.
Global Preferences
Unit of measure – Wave solder machines generally use the Fahrenheit scale for preheat and solder pot temperature
measurements. If necessary change the temperature units to Fahrenheit.
Product start temperature – This temperature setting can be changed. It is up to you to determine what
temperature setting will work best for their process.
Maximum product temperature at start of profile – This setting will determine the maximum product
temperature before the software will allow you to start a profile. If any of the thermocouples connected to the
profiler or your product measure above this setting, the software will not allow you to proceed. You will be
prompted with a message stating that one of the selected TCs is not reading valid temperatures. You will have to
wait until the thermocouple or the object your thermocouples are connected to cools below this temperature setting
before the Profiling Software will allow you to proceed. This software feature helps you to collect consistent profile
data by always beginning the profile with the same or nearly the same product temperatures.
The Profiling Software also uses this setting to determine the profile start - temperature trigger value. The profile
start–temperature trigger is always set 2ºC above the “Maximum product temperature at start of profile”. If the
maximum product temperature at start of profile is set to 31ºC, the profile start–temperature trigger is automatically
set to 33ºC, which is the default setting. When the Air TC reads above 33ºC, the profile will begin.
Process Window
The Profiling Software does not contain a list of fluxes or materials used specifically for wave soldering; only a list
of solder pastes generally associated with solder reflow. In most situations, users defining a Process Window for a
wave solder process will have to define their own specifications.
Select the line item at the top of the list- Define your own spec from the Solder paste Menu. You will be
automatically directed to the Edit Specs window where you can enter your unique process specifications. Enter your
process specifications, when finished; select the Green check button.
Including the wave portion of the profile
Select the Wave checkbox to activate the wave specific process specs. When the Wave checkbox is checked the
Profiling Software will display profile statistics for the wave portion of the profile when viewing the completed or
saved profile. See Figure 49.
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Figure 49
If you have followed the above directions, you should be looking at the Process Window screen. If you are satisfied
with the settings and wish to apply these specifications to all the thermocouples used, type a descriptive name in the
top field and select the green check button. Select Yes when prompted to save the Process Window file.
If you want to use different specifications for one or more thermocouples, you can do so.
Note: When running wave solder profiles with the wave on, the profilers use two wave TCs in addition to the Air
TC to collect wave specific data. The Wave TCs will connect to channels #2 and 3 on the profiler. See the
“Connecting Wave TCs” section of this manual for details, page 48.
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Running a wave solder profile
RUN A PROFILE
Figure 50: Profiling Software Main Screen
From the Profiling Software main screen select the Run a Profile button. See Figure 50.
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Name Product and Select Process Window/Application type
Figure 51: Run a Profile Screen #1
•
Select your Product Name from the list. If you are profiling a new product type the name.
•
Select your Process Window from the list.
•
Select your process type from the Applications list. The Profiling Software profile and prediction results are
based on this setting. It is imperative that your select the correct Application type. Failing to do so can affect
the profile results. For wave solder select to run the profile with the wave On or Off using extra thermocouples
to measure wave characteristics such as Dwell Time, Parallelism, and solder temperature. Select the Wave
Profile option to run a profile without the wave characteristics data .
•
If you select Wave On, the Profiling Software will utilize two wave TCs in addition to the Air TC. The
Wave TCs will measure: wave Dwell Time and Parallelism when profiling with the wave on. The Air TC
must be positioned to run through the wave(s).
•
If you select Wave On, the Profiling Software will display preheat and wave profile data, but offer
prediction results only for the pre-heat section of the profile. . The Air TC must be positioned to run
through the wave(s).
•
If you select Wave Off, the software will not display wave charachteristics data
•
If you select Wave Profile, you can run with or without the wave on. If you choose to run the profile with
the wave on, the only wave data that will provided is the solder temperature. . The Air TC must be
positioned to run through the wave(s).
•
If you purchased the Wave Surfer select Wave Surfer from the Applications list.
•
Select the Sample Rate from the drop-down list.
•
Select your oven name from the list. If you’re profiling on a new oven or machine, type the name in the “Oven
Name” field.
•
Optionally you can type notes or descriptions for this profile in the “Profile Description” field. These notes will
be stored with the profile and can be edited later if necessary.
When you are finished with your selection, choose the Forward Arrow button to proceed. See Figure 51.
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Zone length, minimum and maximum temperature settings
If you typed a new oven name, the
Profiling Software also requires you to
enter the length of each zone as well as
the minimum and maximum zone
temperature settings. This information
will help the Profiling Software narrow
the possibilities of prediction results that
your oven can actually achieve. See
Figure 52.
For wave solder processes you are
required to enter the distance from the end
of the last preheat zone to the beginning
of the main wave. Enter this value in the
field labeled Distance from end of last
preheat zone to the main wave.
Once you have finished entering this
information select the Forward Arrow
button to continue.
Figure 52: Run a Profile Screen #3
Entering temperature setpoints and conveyor speed
If you typed a new oven name, the Profiling Software requires you to enter the number of heated zones or pre-heat
zones in your wave solder machine. See
Figure 53.
If your process requires different top and
bottom setpoints, deselect the check box
labeled Top and Bottom setpoints are the
same This will allow you to enter
different values for top and bottom heaters
in each zone. If your oven has top and
bottom heaters, but not in all of the heated
zones, just enter the same value as the
actual setpoint in that zone for both the
top and bottom setting.
This is also where you will enter the
temperature settings for each zone or preheater in your wave solder machine and
the conveyor speed setting. In the field
marked Solder temperature enter the
setting for the solder pot temperature from
your wave solder machine.
Figure 53: Run a Profile Screen #2
When you have finished entering this information select the Forward Arrow button to continue.
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Connecting the Air TC
The next screen shows directions for attaching the
Air TC to your product. It is important to follow
these instructions. See Figure 54.
The Air TC starts and stops the profile automatically,
measures the oven, and provides useful profile
information.
In certain processes it may be beneficial to wrap the
end of the Air TC with tape to give it more surface
area. KIC recommends wrapping the Air TC when
profiling:
• Wave Solder.
• Anytime IR heat is present.
Figure 54: Run a Profile Screen #4 – No Wave Surfer
Wave Surfer
Wave Surfer users connect the designated thermocouples to the
corresponding channels on the profiler.
Make sure the retainers holding the profiler are in place and
secure. See Figure 55.
If any of the embedded thermocouples are damaged or show
signs of wear replace them.
Note: In addition to the instructions given, it is very important
that you position the “Air TC” so that it touches the wave(s). The
“Air TC must pass through the wave in order to provide accurate
profile results. Of course if you are profiling a Wave Solder
machine with the wave off, the Air TC position is not critical to
the profile results.
Figure 55: Run a Profile Screen #4 – Wave Surfer
Select the Forward Arrow button to continue.
Connecting wave TCs
The next screen will depict thermocouple attachment
for wave solder profiling with the wave on. The
Profiling Software utilizes two Wave TCs in addition
to the Air TC to collect wave specific data. See
Figure 56.
One Wave TC is placed on the right side of the board
and one on the left side near the leading edge of the
profile board.
Note: KIC recommends using high temperature
solder to connect both Wave TCs.
The wave TCs will measure Wave Dwell Time and
Parallelism when profiling a wave solder machine
with the wave on.
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Figure 56: Run a Profile Screen #5
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Select the Forward Arrow button to continue.
The next screen will depict the placement of the
Wave TCs and instructs what slot/channel of the
profiler to connect each Wave TC to.
See Figure 57.
It is very important to follow these directions.
•
Plug the Left-Wave TC into the #2 slot of
the profiler.
•
Plug the Right-Wave TC into the #3 slot of
the profiler.
When you have properly connected your Wave TCs,
select the Forward Arrow button to proceed.
Figure 57: Run a Profile Screen #6 – Wave-On
Connecting product TCs
The next screen will depict placement of the
thermocouples used for profiling the product (Product
T’s). See Figure 58.
Product TCs are connected to the product in key
locations across the product. The selected locations
need represent the highest and lowest- mass areas of
the product or even specific temperature sensitive
components.
Once you have connected your Product TCs to your
product, connect them to the profiler stating with slot
or TC #4.
Select the Forward Arrow button to continue.
Figure 58: Run a Profile Screen #6
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Selecting the thermocouples and starting a profile
This screen displays the live readings from the profiler for all thermocouples selected, as long as the hardware is
properly connected. See Figure 59. Make sure your profiler has a fresh battery and is powered on.
Selecting thermocouples - To select a thermocouple, check the box next to the thermocouple number. The live
temperature is displayed beneath each thermocouple label.
Thermocouple labels - Optionally you can check the box to include thermocouple labels. When this box is checked
you can type a text label for each selected thermocouple. 20 character maximum.
Figure 59: Run a Profile Screen #7
Distance from the Air TC – Measure and enter the
distance from the Air TC to each thermocouple used,
including the Wave TCs.
Select the Help Measurement (Tape Measure Help)
button for an example of how to correctly measure
the distance from the Air TC. See Figure 60.
Figure 60: Wave-On TC measurements
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Once you have selected your thermocouples, you are ready to profile.
Make sure your profiler hardware is properly connected to the computer. You will be able to view the live readings
for each selected thermocouple. If you do not see the live readings, the profiler hardware is not connected properly.
Recheck the cable connections.
Select the Start Profile (green traffic light) button to begin profiling.
The Profiling Software requires that the selected thermocouples read valid temperatures below the maximum
product temperature at start of profile as set in the Global Preferences screen. The default setting is 31ºC/88ºF.
If any of the selected thermocouples read too high, the following message Figure 61 appears:
Figure 61
When the Profiling Software detects valid temperatures for all of the selected thermocouples, it will allow you to
start the profile.
Note: In certain situations the Profiling Software may display other messages with directions in addition to what is
outlined below. Read these messages and follow these directions carefully.
Next, the Profiling Software will ask you to verify
the oven is stable. See Figure 62.
•
•
•
•
•
Yes – The software will prompt you to put
the profiler and the board in to the oven.
No – The software will ask if the oven is
getting closer to the setpoints.
See Figure 63.
Yes – The software will return to previous
screen to wait untill the oven is ready, oven
setpoints within 2.0ºC/3.6ºF.
No – The software will ask you to change
the oven setpoint temperatures to the
temperatures that the control thermocouples
are currently reading, and then press OK.
Figure 62
Figure 63
The Profiling Software will have you enter the new setpoints and then recalculate the capability of your oven.
Then continue forward through the Thermocouple Attachment screens until you get to the Select thermocouples
screen. Then select the Start Profile button (Green traffic light) to start the profile, once the oven has stabilized.
If you selected yes, the software shows a picture of and instructs you to put the SlimKIC 2000 and the board into the
wave machine, and then select the Arrow Forward button. Next, the software will display the Live Profile graph.
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Viewing the live profile graph
The live profile graph display only appears when you’re using a profiler in wireless mode—not as a datalogger. The
live profile graph display will show the profile plot on the graph for the current profile that is running. See Figure
64.
Figure 64: Live Profile Graph Display
While the profiler is in the oven, and until the profile has ended, the software will continue to display the live profile
graph. The other tabs at the top of the screen; Description, and Optimization are inaccessible. See Figure 64.
•
The live profile is plotted on the graph.
•
The current temperatures for each thermocouple and the Delta between them are displayed in a small
window in the upper-left hand corner of the profile graph. The elapsed time is also displayed.
•
The current oven temperature setpoints and conveyor speed for this profile is displayed beneath the
statistics table.
•
The profile status is continually updated throughout the profile. Wireless models only.
The Live profile graph display will remain on your screen until the profiler has achieved the trigger temperature that
determines the profile end.
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Profile retransmission
Retransmission is only available in profilers with RF transmit capability.
While the profiler transmits the live profile data to the SlimKIC Receiver or KIC Explorer/X5 Base Station; it
simultaneously stores the profile data in its memory.
Once the profiler detects that all of the thermocouples have cooled below the profile-end trigger temperature, it will
begin retransmitting the profile data to the software via RF. The profiler will send the profile in data packets. The
retransmission status is displayed at the bottom of the screen. See Figure 65.
Figure 65: Profiler status – RF models
When all of the data packets have been received, the software will display a message asking you to turn the profiler
off, choose OK. Failing to turn your profiler off will drain the battery.
Next, the software automatically analyzes the profile data and presents the profile and profile statistics. If you
purchased the Navigator option, the predicted oven settings will be displayed as well.
If the Air TC or either Wave TC does not touch the wave(s), the Profiling Software will display an error message:
See Figure 66.
Figure 66
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Profile graph display
Once the software opens the Profile Graph Display, all the tabs at the top will be accessible. The General Tab will
show the profile results for both the Preheat and Wave sections of the profile. You can select either the Preheat tab
or the Wave tab above the Statistic table. See Figure 67.
Preheat tab
The Preheat tab represents only the section of the profile before the wave. The software draws a blue rectangle
around the area that is considered preheat. The profile statistics and setpoints which are shown below the profile
graph depict only the preheat section of the profile, the profile data inside the blue rectangle. See Figure 67.
Information regarding the Wave TCs are displayed in a window at the upper-right hand corner of the profile graph.
This information includes; Dwell Time, Parallelism, and the solder temperatures for the wave(s).
Figure 67: Profile Graph Display
Profile Information from the Wave TCs displayed in a window at the upperRight hand corner of the profile graph. See Figure 67 and Figure 68. This
information includes; Dwell Time and Parallelism in seconds, and the Solder
temperature setpoint and actual for the wave(s) portion of the profile.
The Dwell Time is measured by the Wave TCs. The Parallelism is the measured
time difference between when the Wave TC-Left, and Wave TC-Right hit the
wave.
The Solder Temperature setpoint is input by you before the profile when
entering oven setpoint information. The solder temperature value is measured
by the Air TC during the profile.
Figure 68: Wave Information
Navigator – The Navigator software option will optimize only for the preheat section of the profile. The Navigator
will not predict changes to the wave section of the profile.
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Statistics - Below the profile graph is the Profile Statistics. The statistics are a numeric representation of the profile
and how well the profile fits the selected Process Window. The statistics for this profile and the predicted profile are
shown. A percentage value is displayed in each cell beside the Statistic value. This percentage represents the
amount of Process Window being used. A PWI under 100% indicate the profile fits within the selected Process
Window, a PWI 100% or higher indicates the profile has exceeded the selected Process Window. The software only
displays PWI values for the Preheat Statistics.
Original/Predicted Setpoints - Below the profile Statistics is the oven temperature and conveyor settings. The
original setpoints represent the oven settings when this profile was run; the predicted settings represent the
recommendation of the Navigator prediction software. If you did not purchase the Navigator option, the software
will display the same oven settings for the original and predicted statistics. Navigator is an optional software
capability that automatically finds the best profile for your product based on your solder paste specifications.
Note: The Profiling Software will not show the predicted setpoints should you want to print the profile. If you wish
to print the predicted setpoints, you can do so by pressing the F9 key. The F9 function key will print any active
profile screen of the Profiling Software.
Wave tab
The Wave tab will show profile information specific to the wave portion of the profile. The software draws a blue
rectangle around the area that is considered Wave. The profile statistics and setpoints which are shown below the
profile graph depict only the Wave section of the profile. See Figure 69.
Wave PWI – If you entered wave-specific Process Window specs when setting up your Process Window then the
Wave PWI will also be displayed when viewing the Wave tab. See Figure 69.
Figure 69: Profile Graph Display – Wave Tab
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Manual profile prediction
The Profiling Software has automatic (Navigator), and manual prediction capabilities. The standard Profiling
Software installation includes manual prediction capabilities.
Manual prediction gives you the flexibility to easily predict changes to the oven settings (temperature settings,
conveyor speed), and view the results without having to spend the time actually running the profile. This feature is
very helpful to minimizing the time spent fine-tuning or developing a thermal profile. See Figure 70.
Figure 70: Original/Predicted setpoints – Manual Prediction
Figure 71: Original/Predicted setpoints – Navigator (Optional)
This is an example of how the Profiling Software (standard and with Navigator) lists the PWI, and oven settings for
the profile. This table is divided into the Original section (top), and the Predicted section (bottom). The original
values represent the oven settings at the time the profile was run. The predicted values represent the prediction
results as determined by the Navigator software. See Figure 71.
If you purchased the Navigator software option, the Profiling Software will automatically generate results that are
best suited for the selected Process Window. In the event you wish to modify the prediction results of the
Navigator, you can do so.
To predict changes to the oven settings, or modify the Navigator prediction results, click on the zone you wish to
change. In the example below, zone 1 has been selected. See Figure 72.
Figure 72
Type the new temperature setting, and then press Enter. The Navigator will predict the results of that change, and
then automatically update the PWI, predicted Statistics, and the profile graph. The new predicted results will be
displayed on the graph in a dotted-line format. This format enables you to easily determine the difference between
the original and predicted profiles. See Figure 73.
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Analyzing the profile graph
Preheat Section of Profile Graph
Predicted profile plot
(dotted lines)
Original profile plot
(solid lines)
Figure 73
The PWI for the profile is displayed in the bottom-left corner of this screen. If the measured PWI is below 100%,
the value will be displayed in a Green font. If the measured PWI is 100% or higher, the value will be displayed in a
red font. See Figure 74.
A PWI under 100%
is acceptable
A PWI above 100%
is unacceptable
Figure 74: Profile PWI
Note: This display method enables you to easily identify whether the profile is in or out-of-spec.
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Graph Controller
The Graph Controller allows you to modify the view of
the profile graph. To open the Graph Controller, click
on the TC column header or click, anywhere just
outside the profile graph.
Auto scale – The Auto Scale feature will automatically
adjust the X, and Y axis scales to fit all of the data in
the profile graph. When the Auto Scale feature is
disabled, you must manually input the minimum and
maximum scale settings for the X and Y axis scale of
the profile graph.
Selecting thermocouples to view
The TCs section is a list of the thermocouples used for
the profile. By selecting All you are selecting that all
the thermocouples used for the original profile will be
displayed on the profile graph. In the event that you
wish to view the profile without one or more
thermocouples, you can deselect individual
thermocouples, or deselect the All check box, and
choose only the thermocouples you wish to view.
Figure 75: Graph Controller – Wave-On
Deselecting thermocouples
If a thermocouple has become disconnected during the profile, the profile results may be affected due to an erratic
reading. In the event a single or multiple thermocouples become disconnected from the product during the profile,
you can deselect the affected thermocouple(s). The software will recalculate the PWI, and update the profile
statistics based on the remaining thermocouples selected. You must select at least one product thermocouple.
Grid – Enables/disables the view of the X, and Y-Axis scales.
Reference lines – Enables the view of Reference Lines displayed on the profile graph. These lines represent any
temperatures referenced in the selected Process Window.
Zone lines – Enables the view for the oven zone lines on the profile graph.
Predicted TCs only - Removes the Original profile plot form view, displaying only the prediction profile plot on
the graph.
Zero decimal – When viewing the Pointer tool, this setting enables or disables the decimal display. When
unchecked, the software will display one decimal point.
Internal temp – Enables the view of the profiler’s internal temperature profile plot on the graph.
Display Wave TCs – Enables the display of the Wave TCs and the Divider Timestamp Line on the profile graph
Distance from Air TC – Displays the Distance from the Air TC for each thermocouple. You can edit these values.
These values were originally entered before the Profile start.
Wave TC 1/TC 2 – Distance from Air TC to each Wave TC.
Distance Between Last Preheat and Wave – This is the distance from the main wave to the last preheat zone. You
can edit this if necessary. This value was originally entered by you in the Enter Oven Setpoints and Conveyor Speed
screen.
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Graph option menu
To view the graph option menu, right-click anywhere within the profile graph area. See
Figure 76.
Examine line
The Examine line feature displays the temperature for the location of the pointer on the
profile graph. See Figure 77.
Figure 76: Graph Option
menu
Wherever the pointer is moved across the profile, the following data will be displayed:
•
The first column is the actual temperature for each TC.
•
The second column is the temperature of the predicted profile data – based on
setpoint or belt speed changes.
•
The Delta T for both actual and predicted TC data.
•
The time during the profile at which the pointer is placed
Automatic calculation of Delta T + Delta (or range) for all stats
Figure 77: Graph Pointer
The software will automatically calculate, and display in the statistical chart, the Delta for
both the original and predicted profile data for all TCs for all Statistics. This is the range
of the highest to the lowest value for any given specification. This information is strictly being displayed and is not
factored in to the PWI value and is not used in the Navigator or Auto-focus calculations.
Zoom
You can also view the profile by zooming in to get a better view of a particular area
of the profile display. Right-click on the graph, this will bring up a menu. See
Figure 78. Select the Zoom and a chart will appear on the left side of the graph.
Figure 78: Graph Option Menu - Wave
Figure 79: Graph Option Menu – Zoom
Using your mouse pointer, click and drag the view window in the graph over the area you wish to enlarge.
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To disable the Zoom view, right-click on the graph and deselect Zoom.
Move TC line
The Move TC line feature allows the user to manually move the thermocouple
plot on the profile graph. This is used to fine-tune the profile or make corrections
in the event the software did not properly display the plot. See Figure 80.
Select the thermocouple you wish to move and then click and drag the
highlighted plot and move it to the desired location on the profile graph. See
Figure 81.
Figure 80: Graph Option Menu – Move TC Line
Figure 81: Move TC Line
Move zone line
The Move Zone line feature allows the user to manually move the zone separation
lines on the profile graph. This is used to fine tune the profile or make corrections in
the event the software did not properly display the zones.
Select to move the first line (Zone beginning) or the Last line (Zone ending) (See
Figure 82) and then click and drag it to the desired location on the profile graph. See
Figure 83.
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Figure 83: Move Zone Line
Move preheat and wave dividers
The Move Preheat and wave divider feature allows the user to manually move the
Preheat and Wave locations on the profile graph. This is used to fine tune the
profile or make corrections in the event the software did not properly display
these points.
Place the cursor over the blue wave divider line and then click and drag it to the
desired location on the profile graph. See Figure 85.
Figure 84: Move Preheat and Wave
Divider
Figure 85
Zone resize
Select to move the first line (Zone beginning) or the last line (Zone ending and then
click and drag it to the desired location on the profile graph. See Figure 86.
Figure 86: Graph Option Menu – Zone Resize
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Reset
The Reset feature will reset the profile and undo any changes you have
made to the graph using the Graph Option Menu. Select the TC Line, or
Zone Line option. See Figure 87.
Figure 87: Graph Option Menu -Reset
Tips for profiling wave solder
Listed below are tips for profiling wave solder machines using your profiler. Your process may not match the
picture below. Contact KIC technical support if you have any questions regarding wave solder profiling using your
profiler. [email protected]
•
Wave solder profiling is simplified with the Wave Surfer device. If you are not using a Wave Surfer device, use
a blank, spare board, or palette to carry the profiler on. It may be helpful to secure the profiler and thermal
shield to the board/palette.
•
During the profile, you can run the profiler in front or behind the profile board. See Figure 88.
•
Run the thermal shield upside-down to prevent any solder from contacting the profiler. See Figure 88.
•
Use a board stiffener when available. This will help prevent the board from sagging due to the weight of the
profiler.
•
•
•
This will also help prevent liquid solder from flowing onto the board, possibly contacting the thermal shield
or profiler.
It is helpful to raise the profiler thermal shield at least 1/8” to 1/4” off the carrier board/palette in order to
prevent any liquid solder from entering the thermal shield. See Figure 88.
You can run the profile with or without the spray fluxer active. If you choose to run wave solder profiles with
the spray fluxer on, you run the risk of contaminating the Wave Surfer or thermal shield. If operating properly
all the spray flux should be removed by the process.
Figure 88: Profiling Wave Solder Using a KIC Profiler
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Profiling thermal curing processes
The Profiling Software can be used to profile thermal processes that cure epoxy and other thermosetting polymers.
The procedure is similar to that used with reflow soldering, but may involve creating specifications aimed at your
specific cure application
To run a cure process profile:
1.
From the main screen, click the Run a Profile button.
The Name Product and Select Process Window screen appears.
2.
Select your Process Window from the pull down list.
3.
From the Application pull down, select Cure.
Note: To have valid profile data in a cure application, it is imperative that you correctly specify the
application type.
4.
Select from the pull down or enter an oven name in the Oven Name field.
5.
Add any appropriate production notes in the Profile Description field that you want stored with the profile.
(These can be edited later.)
6.
Click the Next arrow to proceed.
The software guides you through the command input screens needed to run a profile.
If you have any questions, contact KIC technical support at [email protected], (858)-673-6050.
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Profiling Temperature vs. Time processes
The Temperature vs. Time application lets you profile a variety of thermal processes beyond the more typical
soldering uses. These include rework, batch curing, environmental temperature cycling, and extreme temperature
(-150 to 1050 C) applications. It can be used with any thermal process or experiment that can benefit from plotted
temperature/time data.
Temperature vs. Time (T Vs. T) profiling differs from other applications in the following ways:
•
Profilers don’t use temperature triggers to start and stop the profile. These actions are performed manually.
•
TC #1 is not used as an Air-TC and operates as a normal TC. TC #1 can be included in Process Window
calculations. Data for TC #1 is displayed on the profile graph. Using any other application type, it is not.
•
Profiling Software prediction capabilities by design are not compatible with T Vs. T profiles. Neither
Navigator or Auto-Focus work on T Vs. T profiles. PWI is calculated for each profile.
•
The datalogger profiler must remain connected to the communication cable throughout the T Vs. T profile.
This includes profilers with wireless capability.
•
Profilers can utilize the RF option for wireless T Vs. T profiles.
•
Using T Vs. T, users can measure negative temperatures. Because temperature triggers are not used, the
software can display data as low as -150C.
Considerations when using the Profiling Software
This section outlines the special considerations you need to take into account when using the profiling software
formation necessary to set up and run a T Vs. T profile using your profiler and the software. This section is written
assuming you have a basic understanding of the software before attempting to run a T Vs. T profile.
Global Preferences
Units of measure – Set the unit of measure for each item. These settings will determine the units used to display
the profile graph.
Product start temperature - The default setting is 31C. This setting is used for T Vs. T profiling even though
temperature triggers are not used. Instead the profile can start as soon as the Start Profile button is selected and
as long as the product TCs are below this temperature setting.
Profiling hardware –Even if you have a profiler that has RF capability, the profiler must remain connected to the
communication cable throughout the duration of the T Vs. T profile.
Auto Focus tab – The Auto Focus feature by design is not compatible with T Vs. T profiles.
Note: If you have made any changes, be sure and select the green check mark button to save those changes when
exiting the Global Preferences screen.
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Process Window Setup
The Process Window is a set of limits applied to the profile data. You have the option of either not using a defined
Process Window in which case no PWI will be calculated, or define a Process Window and have the software
calculate and display a PWI for that profile.
Deselect this check box
to assign separate specs
for each thermocouple
used. See details below.
Figure 89: Process Window
Process Window Name – Name of the Process Window file that includes the statistics chosen and limits for those
statistics, along with whatever text is typed in the Description field.
•
Solder paste menu - A read only library list of numerous solder pastes along with the statistics and limits
suggested by the paste mfg., also included is a User-Defined option in the list which allows you to create a spec.
of your own. See below for additional details.
•
Edit specs – Screen allowing you to edit or choose statistics and limits for a chosen solder paste or define your
own specs
•
Wave – This radio button switches between the process specs and the Wave process specs for the selected
Process Window. Set up a Process Window specific to Wave TCs for Wave Solder profiling.
•
Read only text box – Shows the paste name, statistics name, and limits for a Process Window chosen, edited,
or saved by you. To edit select the Edit Specs button.
•
Same specs for all TCs – By deselecting this checkbox, you can assign separate specifications for each
individual thermocouple you are using. After deselecting the checkbox, you’ll need to click on the Edit Specs
button to choose which statistics will be used and what spec limits will be set for each thermocouple used. This
option would be used if you had component specific specifications that differ from the general solder paste
specs. Another use for this would be if you wanted to monitor the actual board temperature as well as
component temps. You would then only select the statistics for that TC that are relevant. If you wish to use the
same specifications for all thermocouples, put a check mark in the box.
•
Select TC to view – This dialog box will appear only if the Same Specs for all TCs checkbox is deselected. By
clicking on the dropdown menu, you can view the specifications that have been defined for that number
thermocouple. If a description was included, it will be displayed next to Label.
•
Process Window Description – Field allowing for freehand notes for a particular Process Window
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To run a temperature vs time process profile:
1.
From the main screen, click the Run a Profile button.
The Name Product and Select Process Window screen appears.
2.
Select your Process Window from the pull down list.
3.
From the Application pull down, select Temperature Vs Time.
Note: To have valid profile data in a Time Vs Temperature application, it is imperative that you correctly
specify the application type.
4.
Select from the pull down or enter an oven name in the Oven Name field.
5.
Add any appropriate production notes in the Profile Description field that you want stored with the profile.
(These can be edited later.)
6.
Click the Next arrow to proceed.
The software guides you through the command input screens needed to run a profile.
If you have any questions, contact KIC Technical Support. [email protected], (858)-673-6050.
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Selecting the thermocouples and starting a profile
This screen displays the live readings for all thermocouples connected to your profiler. Select the thermocouples by
clicking the check box next to each TC number. Make sure the profiler has fresh batteries and is powered on. See
Figure 90.
Selecting Thermocouples - To select a thermocouple, check the box next to the thermocouple number. The live
temperatures are displayed beneath each thermocouple label.
Thermocouple Labels - Optionally you can check the box to include thermocouple labels. When this box is
checked you can type a text label for each selected thermocouple. 20 character maximum.
Select this
button to start
a profile.
Figure 90: Run a Profile Screen #2 – Time vs. Temperature
Note: If the selected Process Window has Separate Specs for TCs, then you must return to the Process Window-Edit
Specs screen in order select/deselect TCs or change their labels.
Expected profile length – This value controls the X-Axis on the profile graph. Make sure to enter enough time to
complete your profile. Otherwise the profile plot will stop as soon as the Expected profile Length is achieved.
Data outside this time limit will not be displayed.
Note: to decrease the number of samples, enter a longer Expected Profile Length
Once you have selected your thermocouples, you are ready to profile.
Make sure your profiler hardware is properly connected to the computer. You will be able to view the live readings
for each selected thermocouple. If you do not see the live readings, then your profiler hardware is not connected
properly.
Recheck the connections. Temperature vs. Time profiles cannot begin until your profiler is connected via the cable,
and communication established.
Select the Start Profile (green traffic light) button to begin profiling. The profile will begin at this point.
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The software requires that the selected thermocouples read valid temperatures below the Maximum product
temperature at start of profile as set in the Global Preferences screen. The default setting is 31ºC/88ºF.
Note: If any of the selected thermocouples read too high, this message will appear. See Figure 91.
Figure 91
When the software detects valid temperatures for all of the selected thermocouples, it will allow you to start the
profile.
IMPORTANT NOTE: All profilers have a maximum operating temperature that, to avoid damage, should never be
exceeded. See the product datasheet for temperature tolerance information.
Profiler model
SlimKIC 2000
KIC Explorer
X5
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Maximum operating temperature
105°C/220°F
85°C/185°F
85°C/185°F
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Viewing the live profile graph display
The Live Profile Graph display will show the profile plot on the graph for the current profile that is running. See
Figure 92.
Live temperature readings and Delta
Temperature plot
Profile status
Figure 92: Live Profile Graph Display
While the profiler is in the oven, and until the run has ended, the software will continue to display the Live Profile
Graph. The Description tab at the top of the screen is inaccessible.
•
The live profile is plotted on the graph
•
The current temperatures for each thermocouple and the Delta between them are displayed in a small
window in the upper-left hand corner of the profile graph. The elapsed time is also displayed.
The Live Profile Graph display will remain on your screen until the Stop
Profile button is selected even if the profile time has completed and the profile
plot has ended. See Figure 92.
The software will display 2 messages when the Stop Profile button is pressed:
The first will ask you to confirm the Profile Stop. See Figure 93.
Figure 93
If you select No, then the profile continues.
If you select Yes, then the second message instructs you to turn your profiler
off. See Figure 94.
Figure 94
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Viewing the profile and its statistics
Figure 95: Profile Graph Display – Time vs. Temperature
The Profile screen General Tab displays the product name and profile start time at the top of the screen. The profile,
profile statistics and PWI are also displayed. See Figure 95.
Profile view – To maximize the profile display, double click inside the profile graph area. The profile graph will
change and be displayed in a full screen format. Double click again to return to normal view.
Statistics view – To maximize the Statistics view, double click inside the Statistics table area. The Statistics will
change and be displayed in a full screen format. Double click again to return to normal view.
Description tab
The Description tab contains a text area that displays
a description of the profile should you wish to enter
any. See Figure 96.
This text is the same text that you can enter in the
Select Product screen at the beginning of the Run
Profile Routine.
This text is also displayed in the Profile Explorer
view for each profile.
Figure 96: Description Tab – Time vs. Temperature
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Graph Controller
The Graph Controller allows you to modify the view of
the profile graph. To open the Graph Controller, click
on the TC column header or click, anywhere just outside
the profile graph. See Figure 97.
Auto Scale
The Auto Scale feature will automatically adjust the X,
and Y axis scales to fit all of the data in the profile
graph. When the Auto Scale feature is disabled, you
must manually input the minimum and maximum scale
settings for the X, and Y axis scale of the profile graph.
Selecting thermocouples to view
The TCs section is a list of the thermocouples used for
the profile. By selecting All you are selecting that all
the thermocouples used for the original profile will be
displayed on the profile graph. In the event that you
wish to view the profile without one or more
thermocouples, you can deselect individual
thermocouples, or deselect the All check box, and
choose only the thermocouples you wish to view.
Figure 97: Graph Controller – Time vs. Temperature
Excluding disconnected thermocouples
If a thermocouple has become disconnected during the profile, the profile results (PWI) may be affected due to an
erratic reading. In the event a single or multiple thermocouples become disconnected from the product during the
profile, you can deselect the affected thermocouple(s). The Profiling Software will recalculate the PWI, and update
the profile statistics based on the remaining thermocouples selected. You must select at least one product
thermocouple.
Grid – Enables/disables the view of the X, and Y-Axis scales.
Reference lines – Enables the view of Reference Lines displayed on the profile graph. These lines represent any
temperatures referenced in the selected Process Window.
Zero decimal – When viewing the Pointer tool, this setting enables or disables the decimal display. When
unchecked, the software will display one decimal point.
Internal temp – Enables the view of the profiler’s internal temperature profile plot on the graph.
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Graph Option menu
To view the Graph Option menu, right-click anywhere within the profile graph area.
See Figure 98.
Examine line
The Examine line feature displays the temperature for the location of the pointer on the
profile graph. See Figure 99.
Figure 98: Graph Option Menu
Wherever the pointer is moved across the profile, the following data will be displayed:
•
The first column is the actual temperature for each TC.
•
The second column is the temperature of the predicted profile data – based on
setpoint or belt speed changes.
•
The Delta T for both actual and predicted TC data.
•
The time during the profile at which the pointer is placed
Figure 99: Examine Line
Automatic calculation of Delta T + Delta (or range) for all stats
The software will automatically calculate, and display in the statistical chart, the Delta for both the original and
predicted profile data for all TCs for all Statistics. See Figure 99. This is the range of the highest to the lowest
value for any given specification. This information is strictly being displayed and is not factored in to the PWI value
and is not used in the Navigator or Auto-focus calculations.
Move TC line
The Move TC line feature allows the user to manually move the thermocouple
plot on the profile graph. This is used to fine-tune the profile or make corrections
in the event the software did not properly display the plot. See Figure 100. .
Select the thermocouple you wish to move and then click and drag the
highlighted plot and move it to the desired location on the profile graph. See
Figure 101.
Figure 101: Move TC Line
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Reset
The Reset feature will reset the profile and undo any changes you have made to
the graph using the Graph Option Menu. Select the TC Line, or Zone Line
option. See Figure 102.
Figure 102: Reset
Profile screen buttons
There are four buttons at the bottom of the profile screen.
View/Edit Window – Click this button to either view or edit the process specification(s) for the
product used in this profile.
Copy to clipboard – Click this button to copy the profile data to the windows clipboard. You can
then paste the data to a different application.
Print – Click this button to print a copy of the profile that is currently on your screen.
Profile Explorer screen – When finished viewing or analyzing the profile click this button to
either run another profile with this product or return to the Profile Explorer screen if the profile was opened from
there.
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Exiting the profile screen
Saving changes to the profile
Any changes to the Description Notes or the Process
Window can be saved with the profile. This will
permanently update this profile with the changes.
Changes to the Process Window saved here only, save
the changes with the profile. To save the changes to
Process Window file see next dialog box. See Figure
103.
Figure 103
Saving changes to the Process
Window
If you have made changes to the Process Window
while viewing a profile you can save these changes
when you exit the Profile screen. The Process
Window will permanently have these changes
whenever it is used to profile from this point forward.
See Figure 104.
The software will take you to the Edit Process
Window screen in order to save the changes that you
have made.
Figure 104
Note: These 2 messages will only appear if changes have been made while viewing the profile.
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Appendix A: Using optional software
The Profiling Software functionality can be enhanced by a number of available options, including Navigator, AutoFocus, Power, Statistical Process Control, and Virtual Profiling. The sections that follow describe each of the
options in detail.
The software options are distributed on and activated from a software key—a removable USB thumb drive that can
be separately purchased from KIC. The software key installs in any open USB port. Once connected, the Profiling
Software automatically enables the functions associated with each software option.
Note: Do not connect the software key to the computer before installing the Profiler Software. Install the Profiling
Software, and then connect the software key to a USB port.
To check that the software key is working properly, start the Profiling Software and display the Hardware Status
screen. The options available on the connected key appear in the Software Key field.
If the message No software key found appears, the Profiling Software does not detect the software key. The
problem might be with the USB port, the software key, or the software drivers. The software key drivers install as
part of the Profiling Software installation so reinstallation of the base software will likely repair any driver related
issues.
Contact KIC tech support for assistance, [email protected]
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Using Navigator for profile optimization
Figure 105: Optimization Tab
The Optimization Tab allows you to set the search functions of the Navigator Option. The Navigator will search
through millions of setpoint and conveyor speed combinations to find the optimal setting for each product. This
optimization is based on what options you select in this tab.
Original PWI – The Process Window Index for the original profile
Best PWI – The best Process Window Index that can be found based on the oven recipe optimization constraints
selected.
Speed change – The total change to the conveyor speed for the best oven recipe found.
Total setpoint change – The sum of all setpoint changes for the best oven recipe found.
Search Mode for Optimization
•
Minimize PWI – Search for the combination of setpoint temperatures and conveyor speed that will
minimize the Process Window Index.
•
Allow zone setpoints to change – This option will determine if Navigator will include zone setpoint
changes when predicting new solutions.
•
Allow conveyor speed to change - Choose whether to allow Navigator to vary the conveyor speed. If you
choose this feature, you can set the minimum and maximum speeds.
•
Maximize conveyor speed – Search for the setpoint temperatures that will maximize conveyor speed.
•
Minimize energy consumption – Optional Power Feature; Search for the oven settings that will minimize
the power consumption of the oven by finding setpoint solutions with slower conveyor speeds and lower
temperature settings.
Conveyor speed constraints
As long as the Allow Conveyor Speed to Change feature is selected, these options will be available.
Low – Select the minimum conveyor speed you would like Navigator to recommend for new products.
High - Select the maximum conveyor speed you would like Navigator to recommend for new products.
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Using Auto-Focus
If you have Auto-Focus available through the software key, its settings appear on the Auto-Focus tab that is part of
the Global Preferences.
Figure 106: Global Preferences – Auto Focus Tab
Selecting profile optimization settings
Search Mode for Auto-Focus
•
Minimize PWI – Search for the combination of setpoint temperatures and conveyor speed that will
minimize the Process Window Index (PWI).
•
Allow zone setpoints to change – This option will determine if Auto-Focus will include zone setpoint
changes when predicting new solutions.
•
Allow conveyor speed to change - Choose whether to allow Auto-Focus to vary the conveyor speed. If
you choose Allow to Vary you can set the minimum and maximum.
•
Maximize conveyor speed – Search for the setpoint temperatures that will maximize conveyor speed.
•
Minimize energy consumption – Optional Power feature; Search for the oven settings that will minimize
the power consumpotion of the oven by finding setpoint solucitons with slower conveyor speeds and lower
temperature settings.
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Conveyor speed constraints
Low – Select the minimum conveyor speed you would like Auto-Focus to recommend for new products.
High - Select the maximum conveyor speed you would like Auto-Focus to recommend for new products.
Setting product dimensions for Auto-Focus
Figure 107: Run a Profile – Auto Focus screen #1
If you have purchased the Auto-Focus software option, this screen will appear. Enter the length, width, and weight
of your product, and then choose the Forward Arrow button. See Figure 107.
•
•
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This product will be included in the Auto-Focus library from this point forward.
Make sure to measure using the correct units of measurement.
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Auto-Focus confirm screen
This screen is displayed in order to
confirm the product measurements as
entered by you. See Figure 108.
You have two options:
1. Use current Oven Recipe – use
the most recent oven recipe
setting for this product.
The next screen will display the
most recent setpoints and
conveyor speed for this product.
2.
Use Auto-Focus to find an inspec Oven Recipe – This will
initiate the Auto-Focus option
for this product.
Figure 108: Run a Profile – Auto Focus screen #2
If the Use Auto-Focus… button is selected, and no matching
product is found, this dialog box will appear, choose the OK
button. (Figure 109.)
You will be returned to the Confirm screen. Select the Use
Current Oven Recipe button and enter the oven setpoints and
conveyor speed you want to start with.
Figure 109
If the Use Auto-Focus… button is selected, but there are not
enough products in the database to confidently give an expected
PWI, this dialog box will appear. (Figure 110.)
If you select Yes, the next dialog box shows the Auto-Focus–
First Guess recipe in order for you to confirm.
If No, you will be returned to the Confirm screen. Select the
Use Current Oven Recipe button and enter the oven setpoints
and conveyor speed you want to start with.
Figure 110
If the Use Auto-Focus… button is selected and there are a
sufficient number of boards in the data base, the following
dialog box will appear: (Figure 111.)
If you select Yes, the next dialog box shows the Auto-Focus –
First Guess recipe in order for you to confirm.
If No, you will be returned to the Confirm screen. Select the
Use Current Oven Recipe button and enter the oven setpoints
and conveyor speed you want to start with.
Figure 111
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If you select YES, you will be prompted to Confirm the First Guess Recipe. See Figure 112.
Figure 112: Run a Profile – Auto Focus screen #3
Confirm the recipe and select the Forward Arrow button. If there is no communication with the oven controller, the
following dialog box appears: You must manually enter the recipe information on the oven. See Figure 113.
Figure 113
If there is communication with the oven, then the recipe is copied directly to the oven.
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Displaying statistical process control data
The Statistical Process Control (SPC) option displays profile data to chart Process Capability Index (Cpk) values.
When the profiling software detects the SPC option on the key, the SPC column appears in the Profile Explorer
screen:
SPC mini-charts for
selected profiles.
Click and drag Selector line…
Click a chart to enlarge.
SPC Column
Show Charts Button
Figure 114: Profiling Software Profiler Explorer – SPC Option
To view a product’s chart(s) and/or SPC data:
1. Select a product folder.
2. In the SPC column select the profiles to be charted by clicking the check box for each profile.
Note: MVP Users - Select either Baseline profiles or Virtual Profiles since the software can
only chart one type of profile at any given time.
3. Next, select the Show Charts button.
4. The charts for the selected profiles will be displayed in a full screen format.
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SPC chart display
Chart Display Controller Button
Figure 115: SPC Option – Chart Display
The Chart tab will display a control chart for the overall profile PWI and for each individual process specification
with upper and lower alarm limits as defined in the Process Window setup. The chart data will coincide with the
stored profile data for the selected board, date and time.
The control charts hold all of the historical profile data for your product as selected in the Profile Explorer SPC
column. Each chart contains data for every product thermocouple used during the profile.
Selector Line - Each chart has a Selector Line. The Board or Profile # will be displayed at the top of the screen;
along with the date and time that profile was run. You can move the Selector line position by clicking and dragging
the small triangle at the bottom of the Selector line in any chart window.
The Maximum PWI and Cpk for the selected board, date and time will be highlighted above the corresponding
chart(s). In the bottom-left corner of the screen, the PWI for the selected profile is displayed.
Chart display controller
Select the Chart Display Controller button (Upper-Right Corner) to:
1. Select the number of control charts to display
2. Enable/Disable Cpk.
3. Edit the minimum and maximum number of data points to calculate SPC (Cpk) data for the selected product.
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Viewing chart data
To view individual chart data, select a chart and then click inside the chart area. This will display that particular
chart in a full screen format.
Meter Window
Display Info Box
Figure 116: SPC Option - Chart Display, Full Screen
Move the mouse pointer over the chart data, and a Display Info box will appear. This Display Info box data
includes PWI, Cpk, date, and time for each board.
•
Meter window – Right click anywhere in the full screen chart area. A menu will appear, select Meter Window.
This will display a small data box in the upper-left corner of the profile graph. This data box will display the
historical – statistic data for any selected board. To select a board move your mouse pointer along the chart
data, at each data point the historical – statistic data for that board will be displayed. Right-click in the chart
area again and de-select Meter Window to disable this feature.
•
Point protector – When this feature is enabled, the charts will display individual data points for each board.
To activate this feature right click anywhere in the full-screen chart area. A menu will appear, select Point
Protector. This will display the individual data points on each control chart. De-selecting this feature will
remove the data points from the control chart, showing only a plot of the same data. By default, the Point
Protector will be enabled for charts containing 20 boards or less. Click in the full screen chart area again to
return to the regular Chart tab view.
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Using Virtual Profiling
The optional Virtual Profile feature is automatically enabled when the Profiling Software detects that the MVP
software key is connected to the computer. The Virtual Profiling feature requires the MVP (Manual Virtual Profile)
hardware in order to collect Baseline and/or Virtual Profile data.
The combination of MVP hardware and Virtual Profile software gives the user the advantage of not having to run an
actual instrumented profile board through the oven in order to check the product’s current thermal profile. Instead
the user simply runs the MVP through the oven and a Virtual Profile is calculated based on the MVP’s temperature
readings.
Required hardware:
•
•
•
MVP hardware kit, including MVP software key
Profiler
Profile board (instrumented with type K thermocouples.
Required software:
•
Profiling Software v1.0.0.0 or later
Standard profiles, or profiles run without the MVP profiling fixture cannot be used with the Virtual Profiling feature.
In order to utilize the Virtual Profiling feature you must run the profiles for your product(s) using the MVP profiling
fixture. These profiles are called MVP profiles.
There are 3 types of MVP profiles:
Baseline profile – The Baseline profile is used by the Profiling Software as a set of data to which it will compare or
measure a Virtual Profile against. Using the thermal profile data from the user’s profile board as well as the MVP
profiling fixture as a model the software can calculate the current Virtual Profile each time the MVP is run through
the oven.
Note: The default criterion for a Baseline profile is that the PWI is less than 90%. This maximum PWI value can be
changed in the Global Preferences screen.
Virtual profile – A Baseline profile must be established for any given product before a Virtual Profile can be run.
Once a Baseline profile has been established the user can then run a Virtual Profile using only the MVP profiling
fixture eliminating the need to run the actual profile board. The MVP is run through the oven and the Virtual Profile
is calculated based on the temperature readings of the MVP.
Verification profile – A Verification profile is run whenever the user wishes to verify the actual thermal profile of
the oven. A Verification profile requires the user to run a profile using their instrumented profile board along with
the MVP, similar to a Baseline profile. If the PWI of the Verification profile meets the Baseline profile criteria then
it becomes the new Baseline profile for that product.
Establishing a baseline profile
In order to obtain Virtual Profile data for a product a Baseline profile must first be established.
To run a baseline profile:
1.
Install Profiling Software v1.0.0.0 or later
2.
Connect the MVP software key to the computer
3.
Start the Profiling Software
4.
In the Global Preferences screen select the MVP check box and then enter the maximum PWI value to allow
Virtual Profiling.
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Figure 117: Global Preferences – MVP option
5.
Next run a profile by selecting the Run a Profile button from the main menu.
6.
In the Select screen, select your Product, Process Window, Application type, Sample Rate, Oven, and then
select the MVP profile check box. Notice the “Run a Baseline Profile” is grayed out and automatically selected
for you. Select the forward arrow button to proceed.
Figure 118: Run a Profile – Select Screen
7.
The next screen will have you enter the oven setpoints and conveyor speed. Then select the forward arrow
button to proceed.
8.
The next screen will graphically depict the connection of the MVP thermocouples to the profiler. Follow the on
screen directions and then select the forward arrow button to proceed.
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Figure 119: Run a Profile - Attach MVP Thermocouples
9.
The next screen instructs the user to insert the (instrumented) profile board into the MVP board clamps and then
attach the thermocouples to the profiler. Follow the on screen directions and then select the forward arrow
button to proceed.
Figure 120: Run a profile – Insert Profile Board and Attach Thermocouples
10. In the next screen the user selects the thermocouples to be used. Select the check box for each thermocouple
and then select the Start Profile button when ready. As long as the profiler is on and connected, the
temperatures for all connected thermocouples are below 31C, and the oven is within 2 degrees of the setpoint
temperatures the profile can begin.
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Figure 121: Run a Profile - Select Thermocouples
11. The next screen will depict the MVP, profile board, and the profiler being loading onto the conveyor and
entering into the oven. Select the forward arrow button to proceed to the profile graph where the profile will be
displayed.
Figure 122: Run a Profile – Baseline Profile – Profiler Entering Oven
12. When the profile run has finished the software calculates the profile’s PWI value. If the PWI value is less than
90% (default max PWI value for Virtual Profiling)) then the profile qualifies as a Baseline profile. A Virtual
Profile can not be run until a Baseline profile for the product has been established.
Baseline profiles are listed in the Profile Explorer Profile Type column. They also have a “BL” designation as
the icon.
Figure 123: Profile Explorer – Profile Types - Baseline
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Running a Virtual Profile
Unlike Standard profiles which are initiated by selecting the Run a Profile button on the main menu, Virtual Profiles
can only be run from the Profile Explorer screen and only if a Baseline profile exists for the selected product.
To run a Virtual Profile:
1.
Connect the MVP software key to the computer
2.
Start the Profiling Software
3.
Select the Profiler Explorer button from the main menu.
4.
Select a Product folder.
5.
Select a Baseline profile
6.
Select the “Create VP” button.
Create VP button
Figure 124: Profiling Software Profile Explorer – Virtual Profiling Option
Next a message will appear asking “Do you want to start Virtual Profiling this product?” Select OK to continue;
Cancel to cancel the Virtual Profile. If you choose OK then you will be guided through the subsequent Virtual
Profiling screens.
Figure 125: Start Virtual Profiling Message
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Since the software already knows the Product name, Process Window, and Sample Rate for the product, the only
available actions are to select the Oven Name and/or type a profile description in the text field and then select the
forward arrow to proceed. Select the red X button to cancel the Virtual Profile.
Figure 126: Run a Virtual Profile – Select Screen
The next screen will graphically depict the connection of the MVP thermocouples to the profiler and inserting
/attaching the MVP Carrier. Follow the on screen directions and then select the forward arrow button to proceed.
Figure 127: Run a Virtual Profile – Attach MVP, Insert Carrier
In the next screen the current temperatures for the MVP thermocouples are displayed. Select the Start Profile
button. As long as the profiler is on and connected, the temperatures for both of the MVP thermocouples are below
31C, and the oven is within 2 degrees of the setpoint temperatures the Virtual Profile can begin.
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Profile Start Button
Figure 128: Run a Virtual Profile – Select Thermocouples screen
The next screen will depict the MVP, MVP Carrier, and profiler being loading onto the conveyor and entering into
the oven. Select the forward arrow button to proceed to the profile graph.
Figure 129: Run a Virtual Profile – MVP, Carrier, and Profiler Entering Oven
During the live profile there will no profile data displayed on the profile graph. When the profile has finished the
profile results including PWI, and the profile Statistics will be displayed on the profile graph.
The Virtual Profiles for each product are listed in the Profile Explorer Profile Type column. Virtual Profiles
also have a “VP” designation as the icon.
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Figure 130: Profiler Explorer – Profile Types
Virtual Profile
Figure 131: Profiling Software Profiler Explorer – Virtual Profile
Verification profiles
A Verification profile is run whenever the user wishes to verify the actual thermal profile of the product. A
Verification profile requires the user to run a profile using their instrumented profile board along with the MVP,
similar to a Baseline profile. If the PWI of the Verification profile meets the Baseline profile criteria then it
becomes the new Baseline profile for that product.
Follow these steps to run a Verification Profile:
1. Connect the MVP software key to the computer
2.
Start the Profiling Software
3.
Select the Profiler Explorer button from the main menu.
4.
Select a Product folder.
5.
In the Profile Type column select a Virtual Profile and then select the Display Graph button. The selected
Virtual Profile graph will be displayed.
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6.
From the profile graph screen select the Profiler Explorer button. A message will appear asking the user “Do
you want to run a MVP Verification profile with this product?” Select Yes.
7.
In the Select screen, select your Product, Process Window, Application type, Sample rate, Oven. In the MVP
profile area, notice the “Run a Baseline Profile” is grayed out and automatically selected for you. Select the
forward arrow button to proceed.
Figure 132: Verification Profiler Message
Figure 133: Verification Profile – Select screen
8.
The next screen will graphically depict the connection of the MVP thermocouples to the profiler. Follow the on
screen directions and then select the forward arrow button to proceed.
Figure 134: Verification Profile – Attach MVP Thermocouples
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The next screen instructs the user to insert the (instrumented) profile board into the MVP board clamps and then
attach the thermocouples to the Profiler. Follow the on screen directions and then select the forward arrow
button to proceed.
Figure 135: Verification Profile – Insert Profile Board and Attach Thermocouples
10. In the next screen the user selects the thermocouples to be used. Click the check box for each thermocouple and
then select the Start Profile button when ready. As long as the profiler is on and connected, the temperatures for
all connected thermocouples are below 31C, and the oven is within 2 degrees of the setpoint temperatures the
profile can begin.
Figure 136: Verification Profile – Select Thermocouples
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11. The next screen depicts the MVP, profile board, and profiler being loading onto the conveyor and entering into
the oven. Select the forward arrow button to proceed to the profile graph where the profile data will be
displayed.
Figure 137: Verification Profile – MVP, Profile Board, and Profiler Entering Oven
12. When the Verification profile is finished the software calculates the product’s thermal profile and resulting PWI
value. If the PWI value is less than 90% (default max PWI value) then the profile becomes the new Baseline
profile as shown below:
`
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Appendix B: Writing data over a network
The Profiling Software can easily be configured to write the collected data to a network drive location. This allows
data from one or even multiple systems to be stored in one centralized location (Server/Shared Hard Drive).
You must have a mapped network drive on the PC running the Profiling Software to the desired network location.
Due to the varieties of OS and network configurations, KIC cannot detail this step. We recommend you contact
your IT/Network administrator if you need assistance setting up a mapped network drive.
Once you have mapped the drive, create a “KIC” folder on the network drive and copy in the following folders from
the C:\Profiling Software directory – Log, Ovens, Process Specs, and Profiles. Once completed follow the steps
below on the PC where the Profiling Software is installed:
1.
Ensure the software is shutdown. Open Windows Explorer, and locate the file:
C:\Profiling Software\Log\PSDataPath.kiccfg
2.
Double-click on the PSDataPath.kiccfg to open it in Notepad. See Figure 138.
Figure 138
3.
Change the line AllowUserToManuallyChangeWorkingDataPathInThisIniFile=0 to the
value =1. See Figure 139.
Figure 139
4.
Change both the PSDefaultDataPath= and ProfileExplorerDataPath= lines to the desired
network location. See Figure 140.
Figure 140
5.
Once the PSDataPath.kiccfg file has been modified with the new locations, choose File/Save from
the drop down menu to save the changes.
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6.
Close Windows Explorer and start the Profiling Software.
7.
With the software running, go into Profile Explorer. You should now see the new data path directory
displayed in the upper right hand corner of the screen. See Figure 141.
Figure 141
All data collected in this Profiling Software application will now be written to the chosen network folder. It will
automatically create a subfolder named Profiles in the directory chosen. In that “Profiles” folder, it will create sub
folders for each product name, just as it would in the default Profiling Software directory.
You can now view the collected data from any PC on the network that is running the Profiling Software.
When selecting the folder, browse to the root directory of the main “Profiles” folder. For example, if the profiles are
in a directory called F:\Profiling Software/Profiles/ Board A, you would browse only to the F:\Profiling Software
folder.
Note: If there is no network connection when the software is started, the software will automatically change the data
path back to the default location of C:\Profiling Software\. To resume writing data to a network
location, you will need to repeat the steps listed above.
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Appendix C: Using the Process Window Index to
quantify thermal profile performance
The problem
While there are currently statistically valid methods for quantifying pick and place and screen printer performance,
there is no widely accepted method for comparing performance of thermal profiles, and thus, no quantifiable system
of ranking thermal process performance. Once a thermal profile has been run, it is judged as being either in or out
of spec, and perhaps subjectively judged as being OK, good, or really good. Efforts to track process performance
for SPC or QC generally focus on a single, or a small group, of profile statistics; for example, peak temperature of
one or two thermocouples on a golden board. The Process Window Index is a statistical method for ranking thermal
profile and thermal process performance.
Defining the Process Window Index
The Process Window Index (PWI) is a measure of how
well a profile fits within user defined process limits. See
Figure 142.
This is done by ranking process profiles on the basis of
how well a given profile “fits” the critical process
statistics. A profile that will process product without
exceeding any of the critical process statistics is said to
be inside the Process Window. The center of the
Process window is defined as zero, and the extreme edge
of the process window as 99%.
Figure 142: Process Window and PWI
A PWI of 100% or more indicates that the profile will
not process product in spec. A “Process Window Index”
of 99% indicates that the profile will process product
within spec, but it is running at the very edge of the
Process Window. A “Process Window Index” of less
than 99% indicates that the profile is in spec and tells
users what percentage of the process window they are
using: for example, a PWI of 70% indicates a profile that
is using 70 percent of the process spec.
Figure 143: The Process Window Index
(Single Statistic—Peak Temperature of one Thermocouple)
The PWI tells users exactly how much of their process window a given profile uses, and thus how robust that profile
is. The lower the PWI, the better the profile. A PWI of 99% is risky because it indicates that the process could
easily drift out of control. Most users seek a PWI of below 80%, and profiles with a Process Window Index
between 50% and 60% are commonly achieved (if the oven is sufficiently flexible and efficient).
Figure 143 shows the Process Window Index for the Peak Temperature of a single thermocouple. The Process
Window Index for a complete set of profile statistics is calculated as the worst case (highest number) in the set of
statistics.
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For example: if a profile is run with six thermocouples, and four profile statistics are logged for each thermocouple,
then there will be a set of twenty-four statistics for that profile, and the PWI will be the worst case (highest number
expressed as a percentage) in that set of profile statistics. Note that Figure 144 shows the user-designated critical
statistics for a single thermocouple.
Figure 144: The Process Window Index
(Multiple Statistics for a Single Thermocouple and Final PWI Calculation)
Calculating the PWI
To calculate the Process Window Index: i=1 to N (number of thermocouples); j=1 to M (number of statistics per
thermocouple); measured_value[i,j] is the [i,j]th statistic’s value; average_limits[i,j] is the average of the [i,j]th
statistic’s high and low limits; and range[i,j] is the [i,j]th statistic’s high limit minus the low limit.
Figure 145: Formula for calculating the PWI
Thus, the PWI calculation includes all thermocouple statistics for all thermocouples. The profile PWI is the worst
case profile statistic (maximum, or highest percentage of the process window used), and all other values are less.
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Benefits of ranking thermal profile performance
The analysis of thermal profiles with the Process Window Index offers four significant benefits. The first is that
profiles can be easily compared, and users can be confident that they are using the best profile their process can
achieve. Before the PWI was available for profile analysis, comparing profiles was subjective, and users could
never be certain they had the best profile for their product. The PWI provides an excellent opportunity for process
improvement and its use is a significant step towards Zero-defect Production.
The second benefit is that the PWI greatly simplifies the profiling process. When used in advanced profiling tools,
all profile statistics are reduced to a single number (the PWI) that even the most inexperienced operator can
understand. This means significant savings in terms of training costs and a reduction in defects caused by operator
error. It further means that in a few minutes, an inexperienced operator can setup an oven with the optimal profile, a
job that formerly could take an experienced engineer hours.
The third benefit is that because the PWI reflects the performance of the whole profile, it provides much better
indicator of process capability than tracking a single statistic. The PWI thus provides excellent data for SPC and
other QC monitoring programs while simplifying data gathering and reducing process monitoring costs.
Finally, the PWI gives users a simple method for comparing thermal process performance. Comparisons may be
made between individual lines on the shop floor, between processes at multiple plants, and between processes using
dissimilar equipment. The ability to quantify thermal process performance will give electronics assemblers a means
for comparing the performance of their soldering equipment. This is of value in selecting equipment, for buy off,
and for process troubleshooting.
Table 1 is the result of a series of tests comparing oven performance using several sizes of PCBs. Each board was
profiled in the given oven, and then an automated profile prediction tool was used to find the optimal profile for that
board in the given oven. After the oven setpoints were changed and the oven stabilized, a second profile was run to
confirm that the predicted PWI had been achieved. Table 1 shows that there is significant variation in oven
performance between various makes and models. In this test, Oven C had more zones than Ovens A and B, and
performed better, as would be expected.
Oven
Board Type
Manufacturer
Model
Motherboard
Cell Phone
Display
Adapter
Mainframe
A
B
C
X
Y
Z
PWI = 87%
PWI = 71%
PWI = 33%
PWI = 62%
PWI = 58%
PWI = 29%
PWI = 79%
PWI = 61%
PWI = 34%
PWI = 126%
PWI = 93%
PWI = 58%
Table 1: Comparison of Oven Performance – Best Achievable PWI
Conclusion
The simplicity of the Process Window Index makes its validity as a statistical tool readily apparent and its adoption
as an industry standard clearly offers a significant opportunity for the improvement of the soldering process. The
advantages detailed above point to its value in demystifying the soldering process and open the door to precision
control of a process that has been ignored for too long. Issues like the coming of Lead-free electronic assembly
mean that electronics assemblers can no longer be complacent about their soldering process. Sophisticated tools
utilizing the PWI as a standard for accurately measuring the thermal process will mean more efficient production,
improved and simplified process control, and higher quality final product.
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Contacting KIC
On the Web
You can find the latest KIC product news along
with a library of useful information at our website:
www.kicthermal.com or www.kic.cn
KIC Technical Support
KIC Tech Support is available by email:
USA: [email protected]
Europe: [email protected]
Asia: [email protected]
KIC Product Training
Contact KIC Customer Support by email, [email protected]
KIC Sales
Contact KIC sales:
USA: [email protected]
Europe: [email protected]
Asia: [email protected]
China: [email protected]
Find the KIC Representative in Your Area
Send an email, or visit our web page to find a local representative.
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