Bungard COMPACTA 30 User manual

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Preface
Professsional equipment for laboratory pro-
totyping of through-hole plated PCBs up to
210 x 300 mm size. Clean system in luding
built-in rinsing ompartment. Maintenan e
free and made for easy pro essing and
handling. This parti ular ma hine type is op-
timized in terms of spa e requirements and
osts. COMPACTA 30 is suitable for the
Dexter 3 D pro ess (known on the market as
the ABC hemi al system).
Features:
Pro essing sequen e for the ABC panel
plating (tenting) te hnique:
Cleaner
Conditioner
Pre-dip
Catalyst
Salt remover
Copper plate
Equipment:
5 treatment tanks, 2 of them with heaters
1 galvani opper bath
1 triple- as ade rinse with flow ontrol
1 spray rinse tank with magneti valve, foot
swit h and flow ontrol
1 free tank (i.e. for hemi al tinning)
Rectifier:
1 Re tifier for opper plating 6 V / 40 A,
seperate urrent and voltage display and
setting. Residual ripple < 0.1 % DCU
Bath control:
2 PTFE/PFA oated heaters, ontrolled by
analogue instruments, full digital timers with
ount-down, auto-reset and beeper. Air in-
je tion into the opper plating bath. Board
movement by DC gear motor, adjustable
speed.
Options:
Digital timers
Additional required equipment:
Chemi als, anodes, anodes holder and
board holder
Technical Data
Dimensions
Treatment Tanks Galvanic
Tank
Len ht 400 mm 400 mm
Width 100 mm 300 mm
Depth 300 mm 300 mm
Content a. 10 l a. 30 l
Dimesions (Width x Depth x
Height): 88 m x 100
m x 135 m
Workin Hei ht 95 m
Wei ht 80 kg
Heatin 2 x 400 W
Rectifyer 1 x 6 V, 40 A
Bath Movement DC Gear Motor
Electrical Con-
nection
220 V, 50 Hz, 6.3 A
COMPACTA 30
Through hole plating ma hine
Instru tions for use

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Safeyt Instructions
1. The ma hine is designed for through hole
plating of PCBs. Only use the apparatus for
its des ribed appli ation. For any other ap-
pli ation please onta t us.
2. Che k hemi al resistan e of the tanks
against your hemi als. Chemi als supplied
by Bungard are suitable to be used with this
ma hine. Please onta t us if you use differ-
ent kind of hemi als. Mix hemi als outside
of ma hine in a suitable ontainer.
3. To avoid the risk of ele tri sho k, do not
remove the asing or open the ba k. There
are no user servi eable parts inside. Leave
servi ing to the experts! Keep this unit out of
the rain and away from moisture.
Pay attention to the warning signs on the
ma hine.
4. Read all the safety instru tions and all the
operating instru tions thoroughly before us-
ing the unit for the first time. Keep these
safety instru tions and operating instru tions
somewhere safe in ase you need to refer to
them again in the future.
5. In your own interest pay heed to all the
safety warnings on the unit and in the oper-
ating instru tions. Follow the instru tions on
operation and use of the unit in every re-
spe t.
6. Wherever you put the unit, always ensure
there is suffi ient ventilation. For the et hing
and plating units in some ir umstan es an
exhaust system is ne essary. This mainly
depends on the hemi als used.
7. Do not put the unit anywhere near
sour es of heat, su h as radiators, hot air
shafts, oven et ..
8. Conne t the unit only to the power sour e
indi ated in the operating instru tions or on
the unit. We assume that your power sour e
is in a ordan e to the regulations of your
ountry.
9. Follow the manufa turer's re ommenda-
tions for leaning the unit.
10. If you are not going to use the unit for
some time, remove the plug from the so ket.
11. Take great are to ensure that no liquids
or other foreign bodies an find their way in-
side the unit through the openings in the
asing.
12. The unit should only be repaired by qual-
ified personnel. Never try to do more in the
way of maintenan e to your unit than the op-
erating instru tions allow. Beyond that, al-
ways onsult an expert for repair work.
13. Set up apparatus only in a suitable room.
Apparatus filled with hemi als must be
pla ed on hemi al resistant floors. In the
ase of overflow or leakage see safety data
sheets. No hemi als are allowed untreated
in the sewerage. In some ase absorber
tanks are ne essary.
Be ause of possible exothermi rea tions
please mix hemi als in a suitable ontainer
outside of the ma hine. We re ommend to
use sulphuri a id 36% instead of the 98%
on entrate.
The use of the apparatus is not allowed in
the residential area; keep away from hil-
dren.
14. Only run the unit with tanks ompletely
filled. Control the liquid level daily.
15. Close the drain valves before refilling the
ma hine.
16. Personal safety regulations:
The following safety pre autions should al-
ways be observed when handling hemi als
(et hing agent, a ids, lyes, et .):
a) Wear goggles and prote tive gloves for all
w o r k .
b) If ne essary only work under an extra tor
hood or at least in well ventilated rooms.
) Avoid onta t with skin, eyes and mu ous
membranes at all osts.
d) Take off lothing soaked in austi sub-
stan es immediately.
e) Rinse splashes on skin immediately with
opious amounts of water.
f) In the event of a idents or feeling unwell,
always onsult a do tor.
COMPACTA 30
Through hole plating ma hine
Instru tions for use

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Equipment
The ma hine is designed for through hole
plating of PCBs . It has 6 treatment tanks, a
double stati rinse and a spray rinse.
Heatin
Use the heating elements only when the
tanks are filled with solution. Using the
heater without liquid will ause irreversible
damage!
Control the level daily. If a tank with heating
element is not used, fill the tank with water.
Three tanks are equipped with PTFE oated
heating elements, 230 V 400 W ontrolled
by thermostat.
The heating element is not prote ted against
overheating. For prote tion devi es please
onta t us.
Control panel
•Main swit h
•2 p . temperature ontroller with swit h
•Conveyer with low voltage D.C.-gear mo-
tor, speed adjusting and swit h
•Swit h for air inje tion
•Sit h and potentiometers for the re tifier
•Fuses
Start the ma hine by turning on the main
swit h. Ea h heating element is equipped
with a separate swit h. If the adjusted tem-
perature is rea hed, the green signal of the
swit h disappears.
Ti mer
Press MIN and Se button at the same time
to reset timer to zero.
Press MIN button to advan e minute digits.
Press and hold MIN button for speed setting.
Press SEC button to advan e se ond digits.
Press and hold SEC button for speed set-
ting.
After time setting is ready, press
STRART/STOP on e and timer will start to
ount down.
Battery repla ement: Follow the arrow dire -
tion to open the battery, insert a new 1,5V
“AAA” battery as indi ated by the polarity
symbols marked and lose battery over.
Set Up
Examine the ma hine on any apparent
transport damage and in that ase immedi-
ately onta t us and the freight forwarder.
Please set up ma hine in a well ventilated
area, equipped with the ne essary water and
power supply.
Use the adjustable feet at the base to level
the ma hine.
In addition to delivery you need for ommis-
sioning the following parts:
1 set of anodes with holders and bags
1 or more PCB holder.
1 Chemi als set for initial filling
On site will be fabri -reinfor ed hose 1 / 2
"required for water supply and 1" PVC tubing
and hose lamps for the ourse.
COMPACTA 30
Through hole plating ma hine
Instru tions for use

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Power supply:
The onne tion must be made to 230V 50
Hz. The nominal urrent host is max. 8A.
We re ommend using a residual urrent ir-
uit breaker.
Water supply:
The water onne tion is made at the 1/2”
Nozzle whi h is lo ated at the front right. In
order to fix the hose take off the side door.
Please use a fabri reinfor ed hose and se-
ure it with a hose lamp.
The COMPACTA is equipped with a solen-
oid valve to prevent overflow in the ina tive
state. The valve opens only when the COM-
PACTA is turned on. You an onne t the
power supply for the solenoid valve on the
swit h output at the
water treatment plant
IONEX A or B. Then
the water supply is
interrupted when the
water level in the
IONEX is too high.
The box to onne t
the able is lo ated
behind the front right
side door of the
COMPACTA (see pi ture).
Drain:
The tanks are drained without pressure
through a 25 mm port (1”), whi h is lo ated
below the rinsing zones.Observe the regulat-
ory requirements when dis harging the drain
water.
Test:
To ensure that the fa ility was not damaged
in transit, we re ommend that you run them
first with water.
Please pro eed as follows:
1. Fill ea h treatment tanks with 10 liters of
water, but the galvani tank with 30 liters of
water.
2. Turn on the system with the main swit h.
3. Che k now the heating of all tanks by us-
ing the orresponding fun tion swit h. The
green lights indi ate the heating pro ess.
Upon rea hing the desired temperature, the
light goes off.
Set the temperature of the tanks at the ther-
mostats as follows:
Bath 1 Cleaner / Conditioner 65 ° C
Bad 4 Salt Remove 45 ° C
The remaining tanks operate at room tem-
perature.
4. Let the the ma hine now run for 2-3
hours with heating swit hed on and then turn
it off at the main swit h.
The next day, he k the tanks for possible
leaks. If everything is okay, you an drain
the water now through the respe tive drain
o ks. Please remove residual water inside
the ontainers with a lean, lint-free loth.
Do not forget to lose the drain valves again
Operation
Important Information
We ount the tanks from left to right starting
with 1st Bath. The fifth tank of the plant
serves as a reserve tank. It has no heating,
but an be used e.g. for the hemi al tin-
ning. Wait before using your equipment
please, until all the tanks are heated to
proper temperature. Before removing or in-
serting a board, always turn off the bath
movement. When rinsing, it is important that
all parts of the PCB holder whi h ame into
onta t with hemi als, are leaned thor-
oughly, so that no hemi als pollute the next
bath.
We generally re ommend to mix hemi als
outside of ma hine.
Close the over of the tanks dire tly after
ea h use.
After ea h emptying of the bath, please
make sure that the drain o ks are losed
again.
If the fill level at the a tivator (= Catalyst)
lowers , fill it up with ready-made solution. All
other baths are filled with distilled water.
COMPACTA 30
Through hole plating ma hine
Instru tions for use

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From time to time it may be ne essary to
he k the atta hment of the anodes to the
holding rod to ensure good onta t.
Make sure that the temperature in your work
and storage spa e never falls below 0 ° C.
Chemicals Set-up:
We supply Plating System hemi als pre-
mixed and ready for use. All bathes should
be filled up to about 20 mm below the top of
the tank. If that level lowers (e.g. due to
evaporation) you an fill the A tivator bath
with ready made atalyst solution -never with
water - but all other bathes with deionised
water. Refer to the Plating System Step do -
umentation for details.
The sequence of bathes is:
Bath 1: Cleaner Conditioner
Bath 2: Pre-Dip: First use the pre-dip solu-
tion for leaning of tank 3. Fill in the pre-dip
solution into tank 3 overnight and after that
re-use it to fill tank 2:
Bath 3: Catalyst
To stir the bath, always use a very lean
glass or plasti rod that you rinse in bath 2 -
never in water.
Bath 4: Intensifier
Bath 5: spare bath
This spare bath an be used e.g. for our
ele troless tin plating (SUR-Tin) at room
temperature. If not in use, please fill the tank
with plain water to avoid deformation of the
PVC walls.
Bath : Copper plating
Fix both anodes to the anode holders, use
anode bags to over anodes and use the
strings to form a knot so that the bags are
kept in pla e.
Make up the opper bath as per the append-
ing Bath Set up instru tions. The hemi als
for bath 6 must be mixed outside of ma-
hine, be ause of possible exothermi rea -
tions. We re ommend to use sulphuri a id
36% instead of the 98% on entrate.
Anode preparation:
For proper opper plating results it is ne es-
sary to run the anodes under working ondi-
tions but with redu ed urrent of 1 A / dm².
For that reason fix a lean and well brushed
PCB of 200 x 300 mm in a board holder.
Then mount the holder onto the agitation rod
and s rew it arefully. Start air agitation.
Start me hani al bath agitation.
Adjust agitation speed to about value 4 on
the s ale. A tivate re tifier and adjust a ur-
rent of:
1 A / dm² : 2 sides x 6 dm² x 1 A / dm² = 12
A .
Run the bath a ording to items 8 to 12 of
the Plating System Step 5 instru tions. An-
odes + opper bath solution are then ready
for use.
Rinse section:
The COMPACTA ABC unit is equipped with
a water saving triple as ade rinse se tion:
two as ading rinsing tanks with overflow
followed by one fresh water spray rinse tank.
Pre-rinse always in
the bath with the
highest water level
followed by the one
with the lower level.
Last rinsing step is
fresh water spray
rinse (a tivated by
foot swit h). It is
highly important to
lean not only the PCB but also the board
holder w i t h e v e r y rinsing step in order to
a v o i d ontamination of the following treat-
ment bathes.
ATTENTION: rinsing water has to be treated
with an antipollution unit su h as our IONEX
system. You must follow your lo al waste
water standards.
Do not leave the PCBs longer than ne es-
sary in the rinse.
We re ommend to hit the PCB 2.3 times
against the walls of the rinse. This helps to
remove water out of the holes and ensures
better onta t of the hemi als inside of the
holes.
COMPACTA 30
Through hole plating ma hine
Instru tions for use

Page / 8
Rectifier:
The re tifier has a separate on / off swit h.
Current and voltage are preset manually by
potentiometer and read out by analog ur-
rent and voltage displays.
The re tifier offers onstant urrent and on-
stant voltage supply.
For use with ABC hemistry we only need
onstant urrent supply.
For that reason adjust the voltage (un-
loaded) to approx. 2 V.
Then adjust urrent a ording to PCB sur-
fa e in use. Standard working urrent setting
is 3 A/dm².
Throu h Hole Platin process sequence:
Cut your PCB to size with our board utter
NE-CUT ensuring that the blank size is
about 20 mm larger than the required PCB
size.
Drill your blank board to the required hole
pattern by using our BUNGARD CCD or sim-
ilar. Note: allow + 0,05 to + 0,1mm extra dia-
meter for the drill bits be ause opper plat-
ing in the holes will redu e the effe tive dia-
meter.
After that use one of our brushing ma hines
(RBM series) for s rub leaning, washing
and drying (if no brushing ma hine available,
brush and lean manually).
Fix the leaned and deburred board in the
COMPACTA 3-finger board-holder and fix it
on the leftmost onveyor arm (bath1). Turn
on the swit h for the onveyor. Pro ess the
board in the bathes 1 to 4 and 6 from the left
to the right, in the sequen e and with the
timings from the en losed Pro ess Flow
Table.
A step indi ation of "R" in this Flow Table
means a rinse step, onsisting of a stati
rinse in ea h of the two as ade rinse tanks
and a subsequent spray rinse.
The aim of bath 2, the Pre-Dip, is to prote t
the expensive atalyst in bath 3 from intru-
sion of both other hemi als and rinse water.
That is why you must not rinse after Pre-Dip
but you have to go dire tly to the following
bath 3!
With the os illating frame still moving and
the re tifier swit hed on and preset and the
air agitation swit hed on you now fix the
board over the galvani plating bath.
Adjust orre t urrent immediately (without
urrent you risk to et h off all atalyst ap-
plied). Standard working urrent setting is 3
A / dm².
Example:
Board size 200 x 300mm = 6 dm², 3 A /
dm² x 2 sides at 6 dm² = 3 x 2 x 6 = 36 A.
Every minute in the opper plating bath will
apply 0,7µm opper.
Example:
18µm opper will be applied in 26 minutes of
opper plating.
Adjust timer a ordingly and leave board in
the plating bath as long as ne essary.
After that rinse arefully and dry the board
immediately to avoid oxidisation.
Cleaning and maintenance
Cleanin
The unit is made of PVC. Do not use organi
solvents to lean the ma hine. A loth is un-
der normal onditions suffi ient for leaning.
For very resistant dirt (for example baked on
residues) use sulphuri a id for tanks 1,4
and 6 or diluted hydro hlori a id for tanks 2
and 3. After leaning the inner of tank 3 re-
move all loth fuzzles and rinse the tank
walls and ground with demineralized water.
Replenishment
On e your baths have been initially made
up, they an be easily replenished by simply
adding the appropriate produ t. See the in-
stru tions on the following Plating System
Step des riptions. Missing replenishment will
spoil the bath.
COMPACTA 30
Through hole plating ma hine
Instru tions for use

Page 7 / 8
Bath maintenance
The Analysis pro edures in the Plating Sys-
tem Step des riptions are for expert use
only. This is to say the bathes maintain
stable and working also without analyses,
only by replenishment. The Analysis pro ed-
ures are given for referen e of expert users -
who have a ess to the appropriate measur-
ing devi es.
For further information or help please give
us your fax or e-mail message in luding your
ma hine serial number and detailed problem
des ription. We will help immediately. Spare
parts are supplied with the understanding
that only qualified person will repair the unit.
Heatin
The heaters may be operated only when
ompletely filled tanks.
Overheating of the radiator) leads to a de-
stru tion of the PTFE oating and thermal
destru tion (fire hazard). Therefore, please
he k the level daily. The liquid level should
not be lower than approx. 60 mm from the
top.
The onve tion must not be disturbed by
mud or mounting hardware. Remove depos-
its on the heater surfa e at suffi ient inter-
vals.
Periodi ally, the fun tion of the thermostats
should be he ked using a thermometer.
Spray nozzles:
Highly al areous water an lead to blo k-
age of spray nozzles. The nozzles an be
extra ted from the PVC pipe. The rigidities
are removed with hydro hlori a id. A me h-
ani al leaning an lead to damage to the
nozzle.
Operatin panel:
The re tifiers are maintenan e free with the
ex eption of the fan. An annual, preventive
inspe tion is advantageous. This in ludes:
Inspe tion and leaning of the fan
Inspe tion of ele tri al onne tions
Clean the onta t surfa es of the DC on-
ne tions
Note: It is forbidden to onstru tive interfer-
en e of any kind to arry into the devi e.
Guarantee
All ma hines are submitted before distribu-
tion to examination on fun tion and ontinu-
ous operation firmness. On the ma hine we
grant a work warranty of 12 months to our
ustomers starting from pur hase date on
a ura y in material and pro essing. We
warrant at our hoi e by ex hange of in or-
re t parts or by repair of the ma hine in our
house. Old parts hange into our posses-
sion.
Disclaimer of arranty
All parts subje ted to wear are ex luded
from this warranty. Non-observan e of this
manual shall void all warranty laims.
We annot a ept subsequent laims from
damage or destru tion of workpie es worked
on in the ma hine, be ause we have no
knowledge or ontrol over the operating on-
ditions at your site. This is valid in a general
manner also for requirements from damage
to arti les, buildings and persons as well as
the environment.
We do not warrant that the fun tion of the
ma hine will meet the ustomer's require-
ments or that the operation of the ma hine
will to this regard be error free.
COMPACTA 30
Through hole plating ma hine
Instru tions for use

Page 8 / 8
In no event will we be liable to the ustomer
for any in idental, onsequential, or indire t
damages of any kind, in luding loss of profit
and prose ution for environmental pollution,
even if we ould have been aware of the
possibility of su h damages.
All information was arranged with great are.
We reserve ourselves however mistake and
te hni al hanges without previous an-
noun ement.
Running the ma hine in orroding, humid,
dusty, extremely hot or explosive atmo-
sphere happens at the operator's own risk
and responsibility.
We expli itly ex lude any warranty for dam-
ages resulting from running the ma hine in
in orroding, humid, dusty, extremely hot or
explosive atmosphere.
Copyright
(C) 2009 Bungard Elektronik
Electrical Circuit
COMPACTA 30
Through hole plating ma hine
Instru tions for use
E64
T 0 1
N e t z t e i l
E71
24V
X 1 3X 1 3
24V
0V
1
2
3
13
14
15
M
0 , 6 3 A
Foot swit h
Elektromagneti valve
50 Hz
220/230 V
8 A
L
Movement
2 A
Heating 2
4 0 0 W
2 A
Heating 3
4 0 0 W
X 1
Re tifier 6V 40A
M
Air inje tion
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