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SuperM.O.L.E.

Thinline Hardware Users Guide

Electronic Controls Design, Inc. 4287A SE International Way Milwaukie, OR 97222-8825 U.S.A. Phone (503) 659-6100 FAX (503) 659-4422 Toll Free (800) 323-4548 Internet: http//www.ecd.com

SuperM.O.L.E. Thinline Hardware Users Manual

A29-0200-61 Rev 1.1

Copyright 1992 Electronic Controls Design, Inc. All Rights Reserved Printed in U.S.A.

Foreign and U.S. Products of Electronic Controls Design, Inc. are covered by Foreign and U.S. patents or patents pending. No part of this Publication may be translated and/or reproduced or stored in a data retrieval system, or transmitted in any form or by any means without the express written permission of Electronic Controls Design. Information in this publication supersedes all previously published material. Specification and price change privileges reserved.

* The trapezoidal ECD logo is a registered trademark of Electronic Controls Design, Inc.

Table of Contents
SAFETY Precautions ................................................... 3 SuperM.O.L.E. Specifications ............................................. 4 Thermocouple Specifications ............................................. 5

Section 1. Introduction .................................... 6 How to Use This Manual .................................. 6


Terms Used in this Manual ....................................... 6 What You Need to Know to Use This Manual ......................... 6

An Overview of the SuperM.O.L.E. System .................. 7 About the Hardware ...................................... 8


Hardware Requirements ........................................... 8 Hardware Installation ............................................. SuperM.O.L.E. ................................................ M.O.L.E. Cables ............................................... Sensors ..................................................... Batteries .................................................... Optional: Critter Switcher ........................................ Optional: h-Factor Module ....................................... Optional: Boots ............................................... Optional: Hot Boxes ............................................ Optional: AeroM.O.L.E. Sensor .................................... Optional: UV Profile Sensor ...................................... 8 9 9 10 10 10 10 10 11 11 11

Section 2. Using the SuperM.O.L.E. System .................. 14 Introduction ............................................. 14 The Basics ............................................... 14
Setting Up an Experiment ........................................... 14 Collecting Data .................................................. 15

Applications ............................................. 18
Soldering: IR, Wave, and Vapor Phase Applications ........................ 18 Sensor Attachment ............................................. 18 Protective Enclosures for the M.O.L.E. ............................... 19 Baking and Food Processing Industry Application ......................... 20 Sensor Attachment ............................................. 20 Protective Enclosures for the M.O.L.E. ............................... 21 Finishing, Paint, and Powder Coatings Application ........................ 22 Sensor Attachment ............................................. 22 Protective Enclosure for the M.O.L.E. ............................... 24 Optional Accessories .............................................. 27 M.O.L.E Armor Chart ............................................. 29

Appendix A. Maintenance and Troubleshooting .............. 30


Checking the Thermocouples ........................................ 30 Replacing the Battery .............................................. 30 Calibration Verification and Troubleshooting............................. 31 General Troubleshooting Step ........................................ 31 SuperM.O.L.E. Hardware Problems ................................... 32 Wrong or erratic temperature readings: ........................... 32 SuperM.O.L.E. never times out: ................................ 33 Communications Problems .......................................... 33 How to Get Additional Help ......................................... 34 RECALIBRATION PROCEDURE ..................................... 35 RS-232 CABLE WIRING ............................................ 38

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SAFETY Precautions * WARNING *


The following Symbols may be present on the Product: CAUTION - REFER TO ACCOMPANYING DOCUMENTS. Whenever this internationally recognized symbol is used on the product, additional information concerning that particular feature or function appears in the manual ~ Alternating Current (AC) Power Direct Current (DC) Power

Never permit the SuperM.O.L.E. to exceed the maximum specified internal temperature (see the SuperM.O.L.E. specifications) as permanent damage may result. Never connect the input channels to objects at elevated electrical potentials. The input channels are not isolated from each other or from the data port common. Never operate the SuperM.O.L.E. in flammable or explosive atmospheres. Such usage constitutes a fire or explosion risk. When removing the SuperM.O.L.E. from any temperature environment, whether in a Hot Box or not, be careful of extreme temperatures and use protective gloves. Battery Warnings: Replace Battery with the same type only. Use of another battery may present a risk of fire or explosion. Battery may explode if mistreated. Do not recharge, disassemble, or dispose of in fire. Do not expose to temperature above 100C (212F). Dispose of used batteries promptly and properly. Keep batteries away from children.

Do not submerse the SuperM.O.L.E. into liquids. Do not subject the SuperM.O.L.E. to drops or sharp blows. Do not excessively stress the RS-232 connector. Extended exposure to temperatures below the specified minimum may damage the battery pack. Extended exposure to temperatures above the specified maximum may damage the battery pack or the SuperM.O.L.E. itself. Your warranty will not cover damage caused by neglect or abuse of this product.

NOTE:

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SuperM.O.L.E. Specifications INPUTS: TEMPERATURE MEASUREMENT RANGE: INTERNAL OPERATING TEMPERATURE RANGE: Temperatures outside this range may result in inaccurate readings and reduced battery life. Absolute Maximum Warranted Internal Temperature: WARNING ACCURACY: PROGRAMMABLE SAMPLING PERIOD: 150F (65C*) *Exceeding this temperature may result in permanent damage! Within 1C. at 38C. Channel to channel compliance within 1C. 0.1 seconds to 24 hours with 1 channel active; 0.2 seconds to 24 hours with 5 channels active. HARDWARE REAL-TIME CLOCK/CALENDAR: OPEN THERMOCOUPLE DETECTION. NUMBER OF SAMPLES AVAILABLE vs NUMBER OF CHANNELS ACTIVE: 1 minute/month at 25C All five channels 1-1875, 5 channels; 1-2142, 4 channels; 1-2500, 3 channels; 1-3000, 2 channels; 1-3750, 1 channel. Up to 5 type K thermocouples -100F to +1200F (-73C to +649C) 32F to 122F (0C to 50C)

Battery Specifications Custom Battery Pack: ECD Part No. SF30-0038-00, 3V/6V DC, 650mAh

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Thermocouple Specifications Thermocouples: Type K, Teflon insulated. (Other insulations available.)

THERMOCOUPLE RESPONSE TIME Wire Size Still Air 800-100 F .001 in. .005 in. .015 in. 0.05 sec. 1.00 sec. 10.00 sec. 60 Ft./Sec. Air 800-100 F 0.004 sec. 0.080 sec. 0.800 sec. Still H2O 200-100 F 0.002 sec. 0.040 sec. 0.400 sec.

Environmental Limitation Specifications Altitude up to 2000 meters Maximum relative humidity 80% RH from 0C to 31C, decreasing linearly to 17% RH at
50C. Pollution Degree 2 (Normally only dry pollution, but with temporary conductivity caused by condensation)

NOTE: Tests have shown that because of the sensitive nature of the measurement and logic circuits, the following precautions must be observed: Minimize exposure to ESD Events. If the M.O.L.E. or one of its thermocouples receives an 8kV electrostatic discharge during the dataogging sequence, the M.O.L.E. may switch itself OFF. To retreive the data, simply download the data that was recorded prior to the event. If a new data collection sequence is started without downloading first, the existing data stored in the M.O.L.E. will be lost. Keep strong electromagnetic fields away. The thermocouple wires serve as an antenna for electromagnetic radiation. If a field strength of 3 volts per meter is present (usually due to close proximity of radio transmitters) while the M.O.L.E. is logging, the accuracy of the data may be compromised. This interference is compounded by using long thermocouple wires, as well as the effect of the thermocouple wires acting as a tuned antenna. Cleaning Instructions. The product must never be immersed in water or any other cleaning agent. Simply wipe off the exterior of the enclosure with a cloth dampened with water. To prevent product damage, do not clean the product using organic solvents, including alcohols.

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Section 1 Introduction
How to Use This Manual
The SuperM.O.L.E. Thinline Hardware Users Manual explains how to use Electronic Controls Designs SuperM.O.L.E. System. This system is a powerful yet simple process monitor and data analyzer. The SuperM.O.L.E. Thinline Manual is easy to use. The sections contain the following information: Section 1 Section 2 Introduction includes an overview of the SuperM.O.L.E. System plus hardware installation instructions. Using the SuperM.O.L.E. System provides instructions for using the M.O.L.E. hardware in specific industrial applications. Contains a maintenance and troubleshooting guide.

Appendix

Terms Used in this Manual Electronic Controls Design, Inc. (ECD) produces several models of the SuperM.O.L.E. (or Multichannel Occurrent Logger Evaluator) for use in a wide variety of applications. In this manual, we will use M.O.L.E. to refer to both the SuperM.O.L.E. and SuperM.O.L.E. Thinline data recording devices. SuperM.O.L.E. for Windows (SMFW) is the software you use to control the M.O.L.E. and to analyze data (an MSDos version is available upon request). Refer to the SMFW Manual (A35-0909-00) for Software installation and use instructions. What You Need to Know to Use This Manual This manual is written for users of varied experience. If a section covers information you already know, feel free to skip to the next section. You do not need to be a computer expert to read this manual or use the SuperM.O.L.E. system. Most instructions are fully described.

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An Overview of the SuperM.O.L.E. System


M.O.L.E.s are battery-powered devices with five sensors that measure and record the temperature of materials, objects, or devices that are remote, moving, or otherwise difficult to access. The M.O.L.E. is housed in a stainless-steel case to withstand high or low external temperatures, and it comes with several optional protective cases that are water and temperature resistant. SuperM.O.L.E. Systems include the SuperM.O.L.E. and SuperM.O.L.E. Thinline (M.O.L.E.) data recorders plus SuperM.O.L.E. for Windows (SMFW) software for your IBM - compatible PC. The M.O.L.E. is especially useful in conveyorized processes such as Wave and IR Soldering, Food Processing and Baking, Finishing and Powder Coating, or UV Curing. It is also a powerful tool for monitoring the temperature of static objects that must be left unattended and which cannot be easily accessed by hard wiring. Attach the M.O.L.E. to your PC to set up experiments. With SMFW software, you set up the M.O.L.E. to collect exactly the data you want. After the experiment, reattach the M.O.L.E. to the PC and use SMFW to read and analyze the collected data. SMFW software is designed to display easily understood graphs and statistics to help you evaluate a process. (refer to your SMFW manual, ECD Part #A35-0909-00) The M.O.L.E. can collect up to 3750 data points at intervals of hours, minutes, seconds, or tenths of a second. You can delay the start of data collection a specified amount of time, or trigger data collection by entering a threshold value for channel 1. The M.O.L.E. has five channels you can enable, disable, and specify as thermal or several optional sensor types. SMFW features: a simple to use mouse user interface control of the M.O.L.E. monitoring device instantaneous graphs, statistics, and predictions menus of powerful options colorful graphs and profiles you can print at any time analytical tools for general and highly specific industrial applications

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About the Hardware


This section provides information about the M.O.L.E. data recorder and instructions to install M.O.L.E. hardware. Optional hardware is available when you order a M.O.L.E.; its installation is described here also.

Hardware Requirements
Before you can use the M.O.L.E., you need a PC that is compatible with SMFW software. What is required to run SMFW? CPU, RAM: Any computer that runs PC-DOS or MS-DOS version 3.20 or later. At least 640 Kbytes of RAM. Disk Drive: At least one 5.25" DSDD (360K), or HD (1.2M), or one 720K or 1.44M 3.5" floppy disk drive. A hard disk is required. Mouse: Microsoft, Logitech, or compatible mouse, plugged into either a dedicated mouse port or COM1 serial port. If you have a serial mouse and only one serial port, you need a Critter Switcher from ECD. You also need the appropriate mouse driver program (Mouse.Com or Mouse.Sys). Video: CGA, EGA, VGA, or Hercules graphics adapter and appropriate video monitor (EGA/VGA preferred). Printer (optional but recommended): IBM-compatible, graphics-capable printer, connected to any parallel printer port. See the Readme file on the SMFW software diskette for a list of supported printers.

Hardware Installation
When you purchase the SuperM.O.L.E. system, you receive the following hardware: SuperM.O.L.E. cable connectors sensors extra batteries handy carrying case
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Optional hardware features include: Critter Switcher h-factor module Boots Hot Boxes AeroM.O.L.E. UV Sensor

These hardware items are described in the following sections. SuperM.O.L.E. SuperM.O.L.E. is compact and durable. One end of the SuperM.O.L.E. includes the points of attachment for five sensors. The attachment points are color- coded to match the colors seen in the SMFW displays. The other end includes a nine-pin plug to connect the M.O.L.E. to the PC, the start button, and the indicator LED. M.O.L.E. Cables Cables are included in your hardware package to connect the M.O.L.E. to the PC serial port. Note: Your mouse may also attach to a serial port. If your PC has only one serial port, ECD offers the optional Critter Switcher that supports both the M.O.L.E. and the mouse from one serial port. (Refer to the description of Critter Switchers below.) The M.O.L.E. requires a nine-pin connector. The PC serial port might be a nine-pin or a 25-pin connector. The appropriate cables and adaptors are included to support both types of serial port connectors. The M.O.L.E. is battery powered when collecting data. You connect it to your PC at two times: before an experiment, SMFW tells the M.O.L.E. how often to take a reading and how many readings to take. after an experiment, SMFW reads the data from the M.O.L.E.

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Sensors Five sensors (K-Type thermocouples) are part of your hardware package. You can order from a wide selection of sensors to meet the needs of any application. For more information about sensors in specific applications, see the section titled: Using the Super M.O.L.E System. You can attach up to five sensors to the M.O.L.E. per experiment. Plug the sensor wire to the M.O.L.E. channel. The SMFW software helps you keep a record of the M.O.L.E. channel number associated with the location and the type of sensor when you analyze the data. Numbered tags with adhesive are included with the package so you can label the sensor wires for easy recordkeeping. Batteries Because the M.O.L.E. is battery powered, it is important to make sure the batteries are operating properly. SMFW keeps track of the status of the batteries and reports it in several ways. When you need to change batteries, use the instructions in the appendix titled: Maintenance and Troubleshooting. Optional: Critter Switcher This device is only used with MDMG Software and cannot be used with SMFW. The optional Critter Switcher is useful when your PC has only one serial port because both the mouse and the M.O.L.E. require serial port connections. This device is an adaptor that plugs into the PCs serial port and supports both the mouse and the M.O.L.E. The points of attachment are clearly labeled on the Critter Switcher. Optional: h-Factor Module The optional h-Factor module records temperatures and heat transfer rates. The h-Factor module includes two cables that connect to channels 1 and 2 of the M.O.L.E. Optional: Boots The optional SuperM.O.L.E. Boot is a water resistant protective box for use when the M.O.L.E. environment includes moisture or other contaminants. The Boot completely encloses the M.O.L.E., allowing sensor wires to exit through slits. The Boot also provides moderate thermal protection. See the Armor Chart at the end of Section 3.

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Optional: Hot Boxes The optional SuperM.O.L.E. Hot Box is an insulated stainless steel box for use when the M.O.L.E. environment includes temperatures in excess of 122F (50C), above the maximum temperature allowed for proper operation of the M.O.L.E. and its battery. The Hot Box insulates the M.O.L.E., keeping the internal temperature lower for a longer period of time while allowing the sensors to exit through slits. The Hot Box is a better thermal barrier than the Boot. Optional: AeroM.O.L.E. The AeroM.O.L.E. Air Velocity Profiler is designed to measure air flow in a single plane at three evenly spaced horizontal locations. Its basic measurement range is 0 to 3500 feet per minute at standard atmospheric pressure and normal room temperatures. The AeroM.O.L.E. is not intended for use where absolute accuracy is required, but rather where relative air flow is important. Such information about air flow within a process can allow design or process personnel to determine if correct and uniform air flow exists throughout a process. Optional: UV Profile Sensor The UV Profile Sensor can measure UV light intensities from 0 to 5 Watts per square centimeter. (or 0 to 5,000 mW/sqcm) Although the UV sensor is somewhat sensitive to heat, it has been designed to withstand the same harsh thermal environments as the SuperM.O.L.E. GOLD.

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Section 2 Using the SuperM.O.L.E. System


This section includes step-by-step instructions for using the SuperM.O.L.E. System in your application.

Introduction
First, read the basic information that tells you how to: set up the M.O.L.E. to record your data collect data read data from the M.O.L.E. and create new data files

Then read information about your specific application. The following applications are described: Soldering: IR, UV, Wave, and Vapor Phase Baking and Food Processing Finishing Painting and Power Coatings

The Basics
The SuperM.O.L.E. System is based on performing experiments. At the beginning, you document the conditions under which data is collected, then you collect the data, then you analyze it, and finally you prepare a report. Everyone should read all of the basics. Information about performing an experiment is presented from start to finish.

Setting Up an Experiment
The M.O.L.E. depends on your computer and SMFW software to control how it collects data and to interpret the information it records. You might need to perform several kinds of experiments to get the kind of information you want, or you might need to perform the same experiment repeatedly through time to monitor one process. Either way, you need to set up an experiment at least once. If the M.O.L.E. already contains data that you want to read (from a previous experiment) skip ahead to: Reading Data from the M.O.L.E. to the PC.

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Assuming you have already installed the hardware and software using instructions in first section of this manual and the SMFW manual, here are the steps to perform an experiment using the SuperM.O.L.E. System. 1. Before you begin an experiment, gather a list that describes the product and conditions youre about to test. Calculate and write down the duration of your process. Document the prescribed conveyor length and speed, or the prescribed process time. This information is added to the data file, and you should have it handy when you read the data collected from the the experiment. 2. Connect the M.O.L.E. to your PC using the 9-pin cable and serial port on your computer. (Refer to Section 1 for details about hardware installation.) 3. Start SMFW. 4. Choose Set Clock in the M.O.L.E. menu to confirm that the M.O.L.E. clock is correct. If not, enter the correction and click Continue. 5. Choose the Configure option in the M.O.L.E. menu. You see a window of options that control the way the M.O.L.E. records data. 6. Indicate which of the five M.O.L.E. channels you want to record data. 7. Indicate how often you want the M.O.L.E. to record a data point. You can choose any interval from 24 hours to one tenth of a second. 8. Enter the number of data points you want M.O.L.E. to record. When you choose the number of active channels and an interval, SMFW displays the maximum number of data points it can record and the amount of time it will take to record. 9. Choose whether you want to use a trigger temperature or to delay recording data and enter your criteria. Entering delay points is useful if you need to use a Hot Box. It enables you to delay recording data after you press the M.O.L.E. start button while you close the Hot Box and put it in position in your process. 10. Click the Send button to send this configuration to the M.O.L.E. The M.O.L.E. will remain configured this way until you change it or until battery failure. 11. Click Set if you want this configuration to be the default that you see whenever you choose this menu option. 12. Disconnect the M.O.L.E. from the PC and you are ready to begin collecting data.

Collecting Data
The M.O.L.E. begins to record data when you press its start button unless you set a trigger temperature or point delay using the Configure option in the M.O.L.E. menu. However, before you start the M.O.L.E., you need to consider attachment of the sensors to objects in your process and protecting the M.O.L.E. from extreme heat, cold, or moisture. Details about connecting sensors to test items and
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appropriate enclosures for the M.O.L.E. are included in the application sections. The following procedures are always applicable. 1. Determine if you need an enclosure for the M.O.L.E. Refer to the Armor Chart at the end of this section and heed limit warnings. * WARNING * Never permit the M.O.L.E. to exceed the maximum specified internal temperature, as permanent damage may result. Your warranty will not cover damage caused by exceeding the maximum specified internal temperature. 2. Attach sensors to test articles using specific information for your application. Be sure you employ the sensors consistently with the way you configured the M.O.L.E. For example, if you configured the M.O.L.E. to employ only Channels 1 through 3, be sure you attach the sensors to the same three channels. 3. Unwind the sensor leads from their winding sticks and attach the sensor wires to the M.O.L.E. in the appropriate channel (the plugs are polarized). Unused channels can have their wires wound completely up on the winding stick. The M.O.L.E. channel numbers are shown below.

If you use fewer than five sensors, add a shorting strap in each of the unused M.O.L.E. connectors. To make a shorting strap, remove the screws of an unused male inline connector, open the connector, and attach a piece of wire as shown below:

4. When the process to be monitored is stabilized, press the M.O.L.E.'s start button to initiate recording (or delay time).
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Note: You need to press the start button even when you use the trigger temperature feature in the M.O.L.E. configuration. 5. Put the M.O.L.E. in its enclosure if necessary. 6. Pass the (enclosed) M.O.L.E. through your process, usually following your product. 7. As your product and the M.O.L.E. emerge from the process, either carry the test article with sensors attached and the M.O.L.E. in its enclosure to a table, or detach the sensors from the test item and carry just the M.O.L.E. in its enclosure to a table. Use gloves if necessary (note the availability of Hot Gloves on the accessories page). 8. Remove the M.O.L.E. from its protective enclosure. HANDLE CAREFULLY as the case may still be hot. Use your Hot Gloves to remove the M.O.L.E. from the enclosure and wait a few minutes for the M.O.L.E. to cool. 9. If the LED beside the start button has stopped blinking, disconnect the sensors and bring the M.O.L.E. back to your computer. Sensors should remain attached to the M.O.L.E. until the LED stops flashing, indicating that data is no longer being recorded. Note: If you remove a sensor before the experiment is complete, the data for that sensor might be corrupted and result in the message "SuperM.O.L.E. Not Responding" when you read the data from the PC. You can force the M.O.L.E. to stop recording data at any time by pressing and holding the start button. The LED glows continuously for about a second, then the LED turns off, indicating that you can release the switch. Since you can accidentally erase all the recorded data using the same start button, new users should experiment with this feature. The M.O.L.E. is now ready to transfer data to the PC for analysis (refer to the SMFW manual (A35-0909-00) for further instructions).

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Applications
The M.O.L.E. is a highly sophisticated data recorder that can be used in a remarkable variety of applications. Some features of the M.O.L.E. were designed for general use, while others were adapted for specific applications. Earlier sections present information that everyone can use. The following sections contain application-specific information. The following sections describe using the M.O.L.E. in the following applications: Soldering: IR, Wave, and Vapor Phase Baking and Food Processing Finishing Painting and Power Coatings UV Cured Coatings

Each section contains information about sensors, protective enclosures for the M.O.L.E., special analysis features, and accessories.

Soldering: IR, Wave, and Vapor Phase Applications


The M.O.L.E. is a highly effective monitor of the performance of soldering processes. It is especially popular for monitoring the temperatures of surface mount components. For effective process maintenance, all heating and freezing in your manufacturing process (including UV Curing) should periodically be profiled. From an engineering and quality control standpoint it is particularly important to profile a new assembly, as well as periodically profile all assemblies manufactured on site. Prepare the assembly you wish to profile and provide a fixture for supporting the M.O.L.E., which travels directly behind the test article. (Consult the factory for rigorous applications.) Sensor Attachment The following steps describe sensor attachment in this application. 1. Attach thermocouples with tape such as Kapton Polyamide tape strips, an adhesive such as Loctite 411, or high temperature solder - all included with your SuperM.O.L.E. kit. 2. Attach sensor leads to a flat surface; preform the end of the wires to ensure

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intimate contact, as shown below, and tape the insulating sleeve down or apply a small amount of adhesive.

3. Spray the Metered Mist after applying adhesive; hold the lead in place until it sets. Follow the instructions supplied with the adhesive. Note: Only when making a soldered connection should the junction bead (the actual sensing point) be covered. 4. Label the sensors so you know which channel they are attached to using numbers supplied in your SuperM.O.L.E. System kit. Protective Enclosures for the M.O.L.E. If your process uses a conveyor, place your assembly, with the M.O.L.E. attached, on the conveyor, elevating the M.O.L.E. so it will not touch hot surfaces or liquids such as solder waves. It is recommended that the M.O.L.E. be placed on a trailing tray or fiberglass board behind the item being profiled. In static experiments, place the M.O.L.E. so that it does not directly contact hot objects or surfaces if possible. Use the Thinline Boot enclosure which came with your SuperM.O.L.E. System kit to protect the M.O.L.E. The Hot Box or Super Hot Box may also be appropriate protection for the M.O.L.E., depending on your application. The Silver Slipper is sold as an option and gives a margin of safety for Wave Soldering and Radiant IR, but is not recommended for convection ovens. The Thinline Boot is recommended for Convection IR and Vapor Phase processes. One of the above protection methods will be appropriate for all profiling except when the times and temperatures on the Armor Chart (refer to last page in this section) indicate a need for the Super Hot Box. See: Optional Accessories for further information.

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Baking and Food Processing Industry Application


ECD offers the SuperM.O.L.E. Thinline Baking Kit especially designed for baking and food processing industry applications. This precision instrument will provide you with years of convenient, dependable service if properly cared for. Sensor Attachment Sensors (thermocouples) can be used to measure the internal temperatures of food items or the ambient temperature inside an oven or freezer. Measuring oven or freezer temperatures help you analyze temperature control accuracy, baffle adjustments, aging of elements, seasonal ambient shifts, etc. The consistency of many food products lend themselves to simple sensor insertion, as shown below. Whether the process is dough going into a proofing or baking oven, the cooking of precooked meat products, baked or fried packaged foods, or the freezing of doughs and other food products, there is always a sensor and technique for the job of temperature profiling.

The .005" (5 mil) sensors that come with your kit are small enough to insert into the smallest baked goods and are the most versatile. A .010" (10 mil) sensor will stand up to more abuse. An .018" (18 mil) sensor is more stout and can be more easily inserted into stiffer media. Sheathed type sensors are widely available. They are useful for probing meats, and other dense material. As long as the thermocouple is a K-Type (indicated by a Yellow connector), it can be used with your SuperM.O.L.E. Baking Kit. The optional Thermocouple Probe Spreader (see: Optional Accessories) is
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useful when you are measuring ambient oven or freezer temperatures. The Probe Spreader, shown below, keeps sensor wires from touching each other, avoids possible entanglement, and enables you to profile ovens or freezers when there is nothing to attach the sensor to.

Your process most likely uses a conveyor. It is recommended that the M.O.L.E., in an enclosure (typically, the Hot Box), be placed on a trailing pan or rack behind the product being profiled. In static experiments, place the M.O.L.E. so it does not contact hot objects or surfaces if possible. Protective Enclosures for the M.O.L.E. Use the proper M.O.L.E. enclosure for the test you are performing. The Hot Box which came with your profiling Kit will be used for all profiling except when the times and temperatures on the Armor Chart (refer to last page in this Application section) indicate a need for the Super Hot Box. The Thinline Boot or Super Hot Box may also be appropriate protection for the M.O.L.E. depending on your application. See Optional Accessories for further information. The FDA-Approved Thinline Boot is recommended for cooling and freezing applications. This enclosure provides a liquid-tight seal which prevents condensation or moisture damage. As your product and the M.O.L.E. emerge from processing, pull the sensors out of the food products, rack the food, and, using your Hot Gloves, carry the M.O.L.E. and enclosure to a table. Remove the SuperM.O.L.E. from the enclosure.

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Finishing, Paint, and Powder Coatings Application


ECD offers the SuperM.O.L.E. Thinline Finishing Kit especially for the finishing, paint, and powder coatings application. This precision instrument will provide you with years of convenient, dependable service if properly cared for. Sensor Attachment The available temperature sensors you have chosen with your Finishing Kit allow attachment to the wide variety of products whose finish and coatings are cured in ovens. As shown in the following figure, the clamp-on sensors are appropriate for most applications.

Note: When profiling long, hanging objects, you might need to hang the M.O.L.E. from a longer hook so the sensor leads can reach from the top to bottom.
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For smooth ferrous surfaces, the magnetic sensors are appropriate. Among each of these types, you can choose between a surface contact or an air sensor. The air or ambient sensors are appropriate for profiling the actual oven temperature over the height range of the product. The contact sensors measure the effect of the oven (IR or Radiant Heat augmented by forced air) on the actual heat absorbed by the product and coating. As long as a temperature sensor is a K-Type thermocouple (indicated by a Yellow connector), it can be used with your SuperM.O.L.E. Thinline Finishing Kit. Always use the correct probe for the job at hand. Four thermocouple probes designed especially for the finishing industry are shown below. Each probe is designed for a specific application but there is no limit on their use. If you did not order these optional probes with your Kit, you can order them at any time. See Optional Accessories for further information.

Magnetic Attachment Ambient Sensor

Hand Clamp Ambient Sensor

Hand Clamp Surface Sensor

Magnetic Attachment Surface Sensor

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Your process most likely uses a conveyor. It is recommended that the M.O.L.E., in an enclosure (typically, the Hot Box), be placed on a trailing rack behind the product being profiled. In static experiments, place the M.O.L.E. so that it does not directly contact hot objects or surfaces if possible. As your product and the M.O.L.E. emerge from processing, detach the sensors from the test article, and, using your Hot Gloves, carry the M.O.L.E. enclosure to a table. Protective Enclosure for the M.O.L.E. Make sure to use the Hot Box enclosure which came with your profiling Kit to protect the M.O.L.E. The Thinline Boot or Super Hot Box may also be appropriate protection for the M.O.L.E. depending on your application. See Optional Accessories for further information. Use the proper enclosure or type of enclosure for the test you are performing. The Hot Box which came with your profiling Kit will be used for all profiling, except when the times and temperatures on the Armor Chart (refer to the last page in this Application section) indicate a need for the Super Hot Box. The FDA-approved Thinline Boot is recommended for cooling and freezing applications. This enclosure provides a liquid-tight seal which prevents condensation or moisture damage.

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Optional Accessories
Battery For SuperM.O.L.E. Thinline Custom long-life 6 volt lithium battery, good for hundreds of experiments. Battery For SuperM.O.L.E. Custom long-life 6 volt lithium battery, good for hundreds of experiments. Type K Male Inline Thermocouple Connector For connecting your own thermocouple or making a shorting plug. Set of Five 0.005" by 3 Long Thermocouples, Teflon coated leads Our smallest Type K thermocouple for fastest response, with connectors. Set of Five 0.005" by 7 Long Thermocouples, Teflon coated leads Our smallest Type K thermocouple for fastest response, with connectors. Set of Five 0.010" by 3' Long Thermocouples, Teflon coated leads Micro-sized Type K thermocouples for general-purpose use, with connectors. Set of Five 0.018" by 3 Long Thermocouples, Teflon coated leads More stout type K thermocouple for easier insertion, with connectors. Thermocouple Probe Spreader Adjustable in width, this assures thermocouples remain in place in transit. Hand-Clamp, Ambient Sensor with 6-foot cable Clamp type for complex or non-ferrous surfaces. Hand-Clamp, Surface Sensor with 6-foot cable Clamp type for complex or non-ferrous surfaces. Magnetic-Type, Ambient Sensor with 6-foot cable For smooth surfaces. Type K thermocouple, with connector. Magnetic-Type, Surface Sensor with 6-foot cable For smooth surfaces. Type K thermocouple, with connector. Set of Five 6 Long Pressure-Sensitive Contact Sensors Reusable adhesive type. Teflon insulation Type K thermocouple. 9-Pin IBM PC Compatible Interface Cable SuperM.O.L.E. to 9-pin D IBM PC serial interface connector. 25-Pin IBM PC Compatible Interface Cable SuperM.O.L.E. to 25-pin D IBM PC serial interface connector. Sensor Extension Cable, 6-feet Doubles the length of any sensor. For profiling large product or up and down line. SF30-0038-00

SF30-0036-00

SJ33-0013-00

SY15-0216-05

SE28-0180-65

SY15-0216-10

SY15-0220-18

SM31-0280-75

SE31-0290-61

SE31-0290-62

SE31-0290-63

SE31-0290-64

SE31-0290-65

SE00-2787-26

SE00-2787-25

SE31-0290-60

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SuperM.O.L.E. SILVER SLIPPER Reduces internal temperatures by up to 50%. Ideal for IR (radiant heating) applications (requires 1" clearance). SuperM.O.L.E. Thinline BOOT Enclosure of choice for Convection IR. Good for use in Vapor Phase Reflow, Aqueous and Solvent Washing (requires 1-1/4" clearance). SuperM.O.L.E. Thinline Food Compatible Boot For freezing and chilling applications, 'wet' processes such as sanitizing. SuperM.O.L.E. Thinline HOT BOX For 900F/10 minute oven profiling (requires 1-3/4" clearance). Super HOT BOX For 450F 40 minute oven profiling (requires 5-1/8" clearance). M.O.L.E. HOT GLOVES For handling hot enclosures. SuperM.O.L.E. UV Profile Sensor Expands use to profile UV curing ovens for conformal coating and adhesives applications. Monitor UV lamp output life as well. May mix with thermocouples. M.O.L.E. Data Manager GOLD Software User's Manual, Additional SuperM.O.L.E. Thinline Hardware User's Manual, Additional SuperM.O.L.E. for Windows Manual, Additional

SM00-2786-25

SM30-0200-70

SM30-0200-75

SE31-0290-80

SE29-2686-90

SE29-2686-88

SE30-0090-00

SA31-0900-01 SA29-0200-61 SA35-0909-00

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SuperM.O.L.E Armor Chart

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Appendix A. Maintenance and Troubleshooting


Information about maintaining and troubleshooting in this appendix covers the thermocouples, battery, software, wiring, and other parts of the system.

Checking the Thermocouples


Erratic readings may be caused by open thermocouples or loose connections. Check the thermocouples visually for breaks, crimps, or crushed insulation. With an ohmmeter or continuity indicator, check the thermocouples at the plugs. Tighten any loose or suspect connections. Replace any thermocouples which still do not work right.

Replacing the Battery


1. Open the SuperM.O.L.E. Thinline case by lifting the cover off.

Apply steady pressure where indicated

REMOVING THE SuperM.O.L.E. Thinline COVER Note: Open the SuperM.O.L.E. case by sliding the case backwards, toward the end with the thermocouple connectors. 2. Carefully unplug the old battery and replace it with a new one of the same type (Part Number SF30-0036-00 for SuperM.O.L.E., Part Number SF30-0038-00 for SuperM.O.L.E. Thinline). After the new battery is installed, the LED will flicker rapidly for about one second then shut off. When you change batteries, the hardware configuration parameters of the SuperM.O.L.E. are reset to the following values: Log Interval = 1 second Trigger Temp = 0 Active Channels = all Trigger Slope = OFF Points Used = 1875 Points Delay = 0 3. Replace the lid as above.
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Calibration Verification and Troubleshooting


Because SuperM.O.L.E. is made with precision components with high temperature stability and tight tolerances, the analog to digital converter will remain stable for years. High quality components together with software algorithms based on the IPTS-68 standard for Type K thermocouples have been provided to yield the specified accuracy and long-term stability. Each unit has been tested at the factory before it is shipped. Depending on use, however, the temperature accuracy should be periodically verified using a suitable temperature standard. Any observed inaccuracies probably are not caused by calibration error but by any one of a number of other sources, primarily the following: 1. Poor thermocouple connections, open thermocouples, or using the wrong thermocouple types. Verify that the thermocouples are Type K, with red and yellow wires. Check for broken welds or insulation and ensure secure connections. Check the accuracy of your standard and that it is traceable to NIST. Be sure that you are using Type K wire to the standard. Be sure that your standard is cold-junction compensated, or use an ice-point reference.

2. Using a standard that is inaccurate or one not traceable to NIST*.

3. Contamination of SuperM.O.L.E. from water vapor or fluxes, or from dirt buildup should be removed by cleaning. Unplug battery and remove SuperM.O.L.E. from its case. Use a batch aqueous cleaner such as the ECD model 9300 with a 1% solution of an alkaline cleaner such as Indusco 1000 WL Aqua Flux Strip to remove all ionic contamination. Dry the SuperM.O.L.E. thoroughly before reassembling. Do not use solvent cleaners since they remove conformal coatings. Replace the battery. Refer to Replacing the Battery.

4. Extremely low battery. *NIST stands for National Institute of Standards and Technology.

General Troubleshooting Step


Check the appropriate section of the manual to be sure you are following the correct procedures. Check the specifications section if you are not sure what you are supposed to be able to do. Read the READ.ME file on the distribution disk for late information. Next, decide if the problem is with the (1) SuperM.O.L.E. Hardware: problem occurs while attempting to log data; or (2) Communications: occurs while attempting to communicate between SuperM.O.L.E. and PC; or (3) Software: occurs while attempting to use some other function of the SuperM.O.L.E.
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Software. Refer to the appropriate section below. Likelier or simpler problems are listed first in each section, so you should start at the top of the list and work your way down. If the problem is still unresolved go to the section How to Get Additional Help.

SuperM.O.L.E. Hardware Problems


This section describes problems that can occur with M.O.L.E. hardware. Wrong or erratic temperature readings: Open or intermittent thermocouple, cable, or connector. This will be indicated by individual channels being detected as Open on the profile plot. Check thermocouples, wires and insulation, and connectors visually for damage or loose connections. Tighten connections. Check with an ohmmeter or millivolt meter if available, or substitute a known-good thermocouple. Shorted thermocouple, cable, or connector. This is harder to find. A shorted thermocouple connector or cable creates a new thermocouple junction at the location of the short; therefore actual temperatures are record, but probably not the ones you wanted. If the short is intermittent, then the recorded temperatures may jump between that of the thermocouple and that of the shorted location. Visually check for shorts inside of connectors and for damaged insulation on the wires. Repair or replace any suspicious components. Wrong type thermocouple, connector, or wire. Wrong thermocouple types will give consistently wrong readings, either always high or always low. Wrong connectors or wrong wire types (used as an extension) create extra thermocouple junctions and uncontrolled temperature offsets. Use only Type K thermocouples, wire, and connectors. Thermocouple connector wired backwards. Typically causes high temperatures to read as negative (e.g., -150F.). Should be Yellow=Ch, Red=Al. Low battery. Change the battery. Conductive contamination inside the SuperM.O.L.E. This is known to cause spikes (abrupt jumps in value) in the recorded temperatures. Other kinds of errors are also possible. See: Calibration Verification and Troubleshooting for cleaning instructions. Incorrect calibration. If the recorded temperatures for all of the active channels are wrong in the same direction (e.g., all about 5% too high), then possibly the SuperM.O.L.E. has been incorrectly recalibrated. See the manual

section Calibration Verification and Troubleshooting for cautions and procedures, or return to ECD for recalibration.
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Internal temperature effects. The SuperM.O.L.E. has been subjected to an internal temperature in excess of the published specifications. Temperatures outside the specified operating range may cause incorrect readings and shortened battery life. Internal temperatures in excess of the specified maximum temperature may cause permanent, irreparable damage to your SuperM.O.L.E. SuperM.O.L.E. never turns on, cannot be read by software, LED doesnt flash while software is attempting to read: Battery dead or physical damage. Try replacing the battery with a fresh one. If this does not solve the problem, return the SuperM.O.L.E. to ECD for service. SuperM.O.L.E. never turns on, but the software can read and write the Hardware Configuration: Reed (magnetic) switch defective. Return to ECD for service. LED stays on steady (no flashing) when battery is replaced: Try removing the battery, waiting a minute, then plugging it again. If the problem is still there, the reed (magnetic) switch probably is damaged. Return the SuperM.O.L.E. to ECD for service. Try a fresh battery. SuperM.O.L.E. never times out: Points Logged could be set to zero. Check by reading the status. Points Logged or Points Delay (check for very brief flash) may be set much larger than intended, or Log interval much longer. Check by reading the status.

Communications Problems
Many strange software and communications problems are caused by Terminate and Stay Resident (TSR) programs or device drivers in the PC. These may be left over from a previously run program or may have been installed by the startup files, AUTOEXEC.BAT and CONFIG.SYS. To determine if this is the problem, you should try running the software on a bare PC, that is, one with no TSRs or device drivers. This requires you to boot up (restart) your machine using a floppy disk created for that purpose.

SuperM.O.L.E. not responding and/or SuperM.O.L.E. COMMUNICATION LINK NOT PERFORMING PROPERLY error messages: Try triggering the SuperM.O.L.E. with a magnet. If you cannot get the light to flash, you have a hardware problem with the SuperM.O.L.E. itself. See SuperM.O.L.E.
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Hardware Problems. If you can activate the SuperM.O.L.E. with a magnet, check for the following: Wrong PC port. Cable must be connected to either COM1 or COM2, whichever was selected on the Software Configuration screen. Cable wrong type (should be labeled SE00-2787-25 or possibly SE00-2787-26) or wrong orientation (end closer to label should go to SuperM.O.L.E., other end to PC). Conflicting use of COM port. Perhaps some other software, such as a mouse driver or communications program, is trying to use the COM port. Try booting from a bare floppy disk as described above. Cable defective or custom cable incorrectly wired. Refer to cable schematic in manual for correct wiring; check cable with ohmmeter or continuity tester. (Spare or replacement cables are available from ECD; see: Optional Accessories.) Battery very weak. Change battery. SuperM.O.L.E. damaged. Return for service. LED stays on steady (no flashing) when PC connected to SuperM.O.L.E.: Serial port left open (RTS active) from previous application or aborted experiment. Try reading the status of the SuperM.O.L.E. by going to the M.O.L.E. Configuration screen and clicking on read. If this does not cause the LED to go off, or if it doesnt stay off, try rebooting from a bare floppy disk, as described above. Cable or port problems. Refer to SuperM.O.L.E. not responding error, above.

How to Get Additional Help: Internet, http//www.ecd.com


If you still have the problem, help us to help you. Ideally, you should call from a telephone next to your computer so we can walk you through various tests. (Our telephone number is on the title page of the manual.) If that isnt practical, do the following: Print a directory listing of your SuperM.O.L.E. directory. DIR > PRN (This helps us tell if you have any wrong files.) Print the AUTOEXEC.BAT and CONFIG.SYS (if any) files in the root directory of your computer. COPY \AUTOEXEC.BAT PRN COPY \CONFIG.SYS PRN (This is because TSRs and device drivers loaded automatically by these files can cause problems. Also it's helpful to us in trying to reproduce your problem on our machines.)
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Print the DOS version number. VER > PRN (Also for our use in trying to reproduce the problem.) Use CHKDSK to print how much free RAM and disk space you have. CHKDSK > PRN (Just in case you haven't enough for the particular thing you are trying to do.) Write down the make and model of your computer, the processor type, number and kinds of disk drives, the amount of installed memory and video adapter type(s) you are using. (Because of possible incompatibilities and to help in reproducing the problem.) If you have Norton's Utilities or PC Tools, they will list most of these things for you, as well as other information of interest. If the problem involves printing, write down the make and model of your printer, as well as which port it is attached to (usually LPT1, but it varies). (Different printers require different methods of operation, especially for graphics.) If your problem only occurs if you run another program before SuperM.O.L.E., what is the other program? (Some programs don't leave the computer the way they found it.) Have this information on hand when you call, or mail or FAX it to us with a description of the problem: exactly what happens under what circumstances? Does it always happen the same way? Are there any error messages? If so, what are they?

CALIBRATION PROCEDURE
Warning: Do not attempt this calibration if you have never used a thermocouple calibrator, or you are unsure of the accuracy of your thermocouple calibrator. Equipment required: DC Voltage Standard and ICE Pointcell (*NIST Traceable) or Thermocouple calibrator for Type K thermocouples. IBM or compatible PC and MDM or SMFW software. Adjustment screwdriver SuperM.O.L.E. communications cable (Part number SE00-2787-25). Setup: Set the thermocouple calibrator for 100C or Voltage Standard to +4.095 VDC.
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Plug all five channels into the calibrator. Be sure to use Type K wire and connectors. Connect cable between SuperM.O.L.E. and PC. Start MDM / SMFW. Start a new experiment, the descriptions of the experiment are unimportant. Configure the SuperM.O.L.E. with the following parameters in the Configure option in the M.O.L.E. menu: 3/10ths second interval. Trigger Temp 1200. All channels active. Trigger Slope OFF. Points Used 100. Points Delay 0. Click [Send] to send the parameters to the SuperM.O.L.E. Click [Continue] to return to the Data Graph. Start the SuperM.O.L.E. using the start switch on the front, or using a magnet. The SuperM.O.L.E. will begin collecting data, as indicated by the LED flashing at a 3/10ths of a second interval. After 30 seconds, the SuperM.O.L.E. should be finished logging data, and the LED will turn off. Read data from the SuperM.O.L.E. by choosing Read Data from the M.O.L.E. menu. After data is read in (it is not necessary to save it), return to the Data Graph. The profile should show all channels reading about the same temperature (a spread of 1C between all channels is acceptable). If the profile is within 1C of the desired temperature, no calibration is needed. If the profile is off by more than 1C, remove the cover of the SuperM.O.L.E. (refer to directions for changing the battery). There is a trimpot located diagonally from the battery. If the profile shows all channels reading consistently low, turn the trimpot on the SuperM.O.L.E. circuit board clockwise. If the profile shows all channels reading high, turn the trimpot counter-clockwise. Two turns of the trimpot will change the temperature reading by about 1C. After adjusting the trimpot, replace the cover and start the SuperM.O.L.E. again. Read the data from the SuperM.O.L.E., plot it and repeat adjustment of the trimpot as needed to finish calibration.

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RS-232 CABLE WIRING


The cable supplied with the unit requires an IBM PC-type DB25P connector on the computer. The diagram below shows how it is wired:

SUPPLIED RS-232 CABLE WIRING

Also supplied is a 25-pin to 9-pin adapter for use on IBM PC/AT -compatible serial ports. If your PCs serial port is different from either, you will have to make an equivalent cable for your PC.

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NOTES

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