Bungard CCD User manual

ccd_manual_e Page 1 /36
Bungard CCD
Translation of the Original instructions
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 2 /36
Table of content
General.........................................................3
Mechanic:..................................................4
Spindle:.....................................................4
Drive system:........................................5
Software:...............................................5
Technical Data..............................................6
General.....................................................6
omparison...............................................6
Applications...............................................7
Options......................................................7
Accessories...............................................7
Amount of delivery.....................................7
EG- Konformitätserklärung...........................8
Intended Use.................................................9
Safety instructions.........................................9
General.....................................................9
Emergency Stop Facilities.........................9
Protection against contact with moving
parts..........................................................9
Location...................................................10
Noise.......................................................10
Dust.........................................................10
Power supply...........................................10
Maintenance............................................11
Tools.......................................................11
Software licenses....................................11
Documentation........................................11
Installation Manual RoutePro3000..............12
Short Instructions/Setup..............................14
Maintenance...............................................23
Fixing the boards........................................24
lamp fixing........................................24
Span fixing..........................................24
Reference pins / Isolation milling........24
Adhesive tape.....................................24
Vacuum fixation..................................24
Drilling bare boards.............................25
Pre-sensitized base material...............25
Etched P Bs......................................25
Routing...............................................25
Engraving............................................25
Modules and Extensions.............................26
Drill and route parameter.............................29
Standard drill...........................................29
Parameter...........................................29
Spade type drill........................................30
Microvia-drill ...........................................30
Slot drill....................................................30
Flex drill...................................................30
Isolation milling tool ................................31
Routing parameters............................31
S /FT......................................................32
Routing parameter..............................32
RPU ........................................................33
Routing parameter for RPU..............33
V- ut-Router ........................................34
3-Flute router...........................................35
Diamond patterned router........................35
ontour finishing router...........................35
Guarantee...................................................36
Disclaimer of warranty.................................36
opyright....................................................36
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 3 /36
General
The D is a high quality computer controlled
drilling and milling machine with semi-automatic or
automatic tool change. It allows direct processing of
Excellon or Sieb&Meyer drill data or HP/GL data for
the P B production (drilling, milling, isolation rout-
ing) and milling / routing of plastics, aluminium and
other metals.
In addition, the D can be upgraded with an at-
tachment for dispensing of solder paste or glue, a
laser imaging head for exposing photoresists and a
camera for calibration and inspection tasks.
Starting April 2016
Step resolution 3,18 (Premium - 1 µm)
Chip technology 32-bit
Data connection Direct USB-port for easy installation
Data transmission Buffer mode optional. Thus substantially improved mil-
ling behaviour and milling pattern
Cabeling hainflex cable
Table Precision aluminium table, both sides milled over, for
approximately zero height tolerance
PM 3.000 – 63.000 (Premium: 3.000 - 100.000)
Torque adaption Adjustable via machine configuration
Vacuum contact switch 1 Switch-plug with solid state 2000W max integrated in
ontroller
Power failure correction PF • with protection against short circuit, overload and
overvoltage
Dosing Fixture: 1 potential-free switching output for dosing
Laser exposure integrated ontroller for UV laser exposure 250mW
Adding automatic tool change Pneumatic switching output f.automatic tool change
Cover switch 4mm connection socket for cover switch/emergency
stop
Software RoutePro3000
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 4 /36
Mechanic:
•rigid and flat construction with low moving weights and high quality bearings for high-speed position-
ing
•Machine bed with universal fixation system, suitable for clamp or span fixing or for reference pins (fi-
ducials). Fixing pcbs with reference/fixing pins at no extra costs by using our standard backing
boards. As an option a vacuum table can mounted underneath the base table to allow vacuum fixa-
tion of the P B
•You can fix the P B at the machine zero position. Devices for span fixing included, clamp fixing for
heavy-duty milling possible
•Integral depth limiting device for isolation milling and engraving on uneven surfaces is part of deliv-
ery, work level is roughly set by the Z stepper motor and fine adjustment is done with the micrometer
screw of the depth limiter
•Removable, spring-load pressure foot for drilling of flexible and uneven P Bs
•Stack processing of several boards at once is possible (typical stack: three 1.6 mm thick boards plus
one underlay/base sheet)
•Working depth not limited by depth sensor, only by flute length of the tool (standard: 5..10 mm)
•All common P B drills/mills with 1/8" shank, with industry-standard length setting by collar can be
used
•ontrol unit, full set of cables
•Independent controller to connect the D to any standard P via USB or serial port
Spindle:
•KaVo high precision spindle motor, 150 Watt, 63 000 RPM, with heavy-duty long-life bearings, includ-
ing 1/8" (3.2 mm) chuck
•Software controlled spindle speed. Electronic spindle load control with software feedback. Spindle
quick start and quick stop
•Drill speed: 5 hits/s (=18.000 holes per hour)
•MTC: Fast, semi-automatic tool change by quarter turn of the fixing knob. The machine is locked
there, no height recalibration required
•ATC: Automatic tool change, simultaneous 16 out of 99 tools per Job
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 5 /36
•ATC/XL: simultaneous 25 out of 99
tools per Job
•ATC: drill break detection and length
calibration
Drive system:
•High load-2x2-phase stepper motors on
all 3 axis for real milling applications and
correct adjustment of the cutting speed
for all tools
•Maximum position speed per axis:
9000/mm/min (=150 mm/s)
•Maximum working speed per axis:
9000/mm/min (=150 mm/s), individual
setting for every tool independent from
the positioning speed
•Step resolution: Software selectable: 1
mil, ½ mil, ¼ mil (= 6.35 Micrometer). (Premium: 1 µm)
•Precision: +/- 1 step
•Position accuracy:20 ppm (0.002%) over the entire work space (9,9 µm with a work area of 495 mm)
Software:
•Fully integrated Windows control software for online machine control in real time, with convenient
user interface, including full tool management and plausibility checks
•RoutePro3000 for Windows XP - Windows 10 64-bit, project-related work flow, expandable by mod-
ules (laser exposure, fiducial recognition, dispensing and much more. See at:
http://www.bungard.de/index.php?option=com_content&view=article&id=155&Itemid=191&lang=eng-
lish)
•Resolution: 0,0001mm (0,1µm)
•Use of open format standards such as Excellon or Sieb & Meyer drill data and HP/GL data for milling.
These can be opened and edited with a simple text editor
•You can individually adjust position speed for X-, Y- and Z-axis as well as the working speed (feed),
spindle speed (RPM) and depth for each tool. This results in:
•continuous use of the appropriate cutting speed over the entire RPM-range, no need for 100 000
RPM spindles, no excessive wear of expensive bearings
•All machine parameters (speed, acceleration ramps, X / Y / Z dimensions / scaling, tool break detec-
tion) can be individually set in the RoutePro software
•Simple Teach-In Function for drill and route data (to copy an existing board)
•Smallest tool diameter: 0.1 mm (zyl. Micro cutter at 63 000 1/min)
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 6 /36
Technical Data
General
Power supply: 110-240 V, 50-60 Hz + vacuum cleaner(2000W)
ange of PM: 3.000 – 63.000
Travelling speed: 1 – 9000 mm/min
Software resolution: 0,01µm
Mechanical resolution: step resolution: Software selectable: , 1/4 mil, 1/16 mil (= 3.175 Mi-
crometer)
Tool diameter: 0.1mm – 3,145mm (recommended, bigger tool diameter possible)
Position accuracy: 20 ppm (0.002%) over the entire work space:
Maximum position speed per axis: 9000/mm/min (=150 mm/s)
Maximum working speed per axis: 9000/mm/min (=150 mm/s), individual setting on a per-tool basis,
independent from position speed
Drill speed: 5/s (= 18.000 holes/h= 300 holes/min)
equired accessories: omputer, AT : compressed air 6 bar
Board fixation: span fixing, clamp fixing, reference pin system, stack processing
possible
Option: vacuum fixation
Comparison
CCD/2/Eco CCD 2
CCD/
2/AT
C
CCD/
MTC
CCD/
ATC
CCD/XL/
MTC
CCD/XL/
ATC CCD/Premium
Weight kg 30 30 35 49 80
Dimension mm 700x550x3
00 700x550x300 700x800x300 950x950x300 950x950x300
Working area mm 270x325x3
8270x325x38 325x495x38 500x600x38 400 x 500 x 64
Tool change nein nein 16 nein 16 nein 25 30
Software resolution 0,01 µm 0,01 µm 0,01 µm 0,01 µm 0,01 µm
Mechanical resolu-
tion 3,175 µm 3,175 µm 3,175 µm 3,175 µm 1 µm
PM 5.000 -
35.000 3.000 - 63.000 3.000 - 63.000 3.000 - 63.000 5.000 - 100.000
Table Spe-
zial-MDF Aluminium Aluminium Aluminium Aluminium
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 7 /36
Applications CCD/2/
Eco
CCD/2 CCD/2/
ATC
CCD/
MTC
CCD
/ATC
CCD/XL/
MTC
CCD/XL/
ATC
CCD Pre-
mium
Milling and drilling single-
and double-sided PCBs
Milling/drilling F- & mi-
crowave substrates
( )
Milling/drilling multilayer
with up to 16 layers *
Contour routing of PCBs
Milling flexible, rigid-flex
PCBs **
( ) ( ) ( ) ( ) ( ) ( ) ( )
Engraving front panels/la-
bels
Machining cut outs in front
panels
Milling SMT soldering paste
stencils
Housing production
Wave solder pallets
Panel cutting, eworking
PCBs
Test adapter drilling
Inspection templates
*) we generally recommend to etch at least the inner layers of a multilayer P B
**) For flexible materials vacuum fixation is a nice option
Options
Vacuum table, protection hood or protection rack, converter software Iso am, fiducial recognition and calib-
ration with camera, laser exposure of photo resists, aluminium work table, routers engine adapter for plastic
milling and many more.
Accessories
Measuring microscope ompressor Accessory set Drills and Routers
Drill backing boards Reference pins ooling device P Bs with or without photoresist
Amount of delivery
mechanic unit
control unit with complete cabling
Superb and sturdy high frequency spindle with eddy current brake and load control
Integrated mechanical milling depth limiter and pressure foot
RoutePro3000 (Windows XP - Windows 8 64bit) for drilling and milling
Powerful, adjustable (500. .1500 W) vacuum cleaner, integrated start adapter for vacuum cleaner
Set of Allen Keys; AT : Air hose
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 8 /36
EG- Konformitätserklärung
EG-Konformitätserklärung/Declaration of Conformity
Hersteller / Supplier: Bungard Elektronik GmbH & o. KG
Rilkestraße 1
51570 Windeck Germany
Bevollmächtigte Person für die Zusammenstellung
der technischen Unterlagen:
Person in charge
Jürgen Bungard, Geschäftsführer /general director
Rilkestraße 1
51570 Windeck Germany
Produkt: Bohr- und Fräsanlage Bungard D
Drilling and milling machine Bungard D
Hiermit erklären wir, dass die oben beschriebenen Maschinen allen einschlägigen Bestimmungen der Maschinen-
richtlinie 2006/42/EG entspricht.
Die oben genannte Maschine erfüllt die Anforderungen der nachfolgend genannten Richtlinien und Normen:
We hereby declare that the machines described above complies with all relevant provisions of the Machinery Directi-
ve 2006/42/E .
The above machine meets the requirements of the following guidelines and standards:
Maschinenrichtlinie 2006/42/EG / Machinery Directive 2006/42/EC
EMV- ichtlinie 2014/30/EG / EMC Directive 2014/10830EC
Niederspannungsrichtlinie 2014/35/EG / Low Voltage Directive 2014/35/EC
DIN EN 60204-1 Sicherheit von Maschinen - Elektrische Ausrüstung von Maschinen - Teil 1: Allgemeine Anforde-
rungen / Safety of machinery - Electrical equipment of machines - Part 1: General requirements
DIN EN ISO 14121-1 Sicherheit von Maschinen - Risikobeurteilung - Teil 1: Leitsätze / Safety of machinery - Risk
assessment - Part 1: Principles
DIN EN ISO 12100-1 Sicherheit von Maschinen - Allgemeine Gestaltungsleitsätze, Risikobeurteilung und Risikomin-
derung / Safety of machinery - Basic concepts, risk assessment and risk reduction
DIN EN 55014-1 2012-05 Elektromagnetische Verträglichkeit, Anforderungen an Haushaltsgeräte, Elektrowerkzeu-
ge und ähnliche Elektrogeräte, Teil 1: Störaussendung / Electromagnetic compatibility Requirements for household
appliances, electric tools and similar electrical appliances Part 1: Emission
DIN EN 55014-2-2009-06 Elektromagnetische Verträglichkeit - Anforderungen an Haushaltgeräte, Elektro-werkzeu-
ge und ähnliche Geräte - Teil 2: Störfestigkeit - / Electromagnetic compatibility - Requirements for household app -
liances, electric tools and similar apparatus - Part 2: Immunity
Niederspannungsrichtlinie / Low Voltage Directive 2014/35/EG
Maschinenrichtlinie / Machinery Directive 2006/42/EG/37/EG
Windeck, 10.1.2017
Jürgen Bungard Geschäftsführer
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 9 /36
Intended Use
The machines are determined for drilling and milling (routing) printed circuit boards and for milling
(routing) and engraving aluminium plates. A special application is dosing of pastes or liquids onto
panel-shape work pieces and the laser exposure of photo resists and solder mask. Any other type
of application is permissive only with our consent.
Safety instructions
General
The machines are not determined to be connected or combined with other machines. However,
they need to be connected to and be controlled by a compatible computer. The driver software is
supplied with the machines and is relevant for security.
The machines may only be operated by qualified operators. hildren and animals must be kept
off!
The machine is manufactured using tested components according to standard guide lines for elec-
trical safety. This does not relieve the user his duty of care when dealing with electrically powered
devices.
Before performing any maintenance switch off the machine and unplug it.
Emergency Stop Facilities
The ES ape button on the computer stops the spindle and the stepper motors. This is indicated
by a red message/icon on the computer screen. The main switch on the control unit or power sup -
ply unit cuts the machine from mains supply, but is not suitable for emergency stop: It does not al -
low programmed spindle lift and quick stop.
If the computer has stopped responding and thus the EMERGEN Y STOP button does not work,
you can stop the machine using the main switch of the control unit. In this case wait until the
spindle has come to a standstill.
Protection against contact with moving parts
There is a round metal tube with a spring included with the spindle. This drill pressure foot shall be
mounted to the spindle shaft to prevent incidental contact to the moving tool. Same function has
the depth limiter when routing. The use of depth limiter and pressure foot is obligatory in the sense
of the machinery directive and the general safety standards to ensure maximum work safety.
It is not possible to entirely envelop the tool, as this would make the drilling and tool change ac -
tions impossible. In case this pressure foot was not placed correctly, the following danger re-
mains:
WA NING: Do not touch the tool when the spindle is operational. Prior to any tool change action,
wait until the spindle has come to a complete stop.
Under normal operating conditions and with the given work piece materials, there is no special
danger from parts being propelled off the machine. However, special operating conditions or
heavy work pieces may require that the machine is encapsulated. A protection cover is available
as an option.
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 10 /36
Location
Put the machine onto a stable, even table and adjust the machine's 4 feet by turning them. A
stable desk and a proper setting are important to prevent vibrations etc. Make sure you have
enough room around the machine for tool change, mounting P Bs and maintenance work.
The machine may only be operated under normal temperature and humidity conditions, especially
only in absence of corrosive or inflammable vapours. At temperatures lower than 10 ° or higher
than 30 ° , there may occur the following problems: The spindle might not start running at low
temperatures. The stepping motors might run hot or step losses may occur at more than 30 ° in
the surrounding air.
In order to ensure a sufficient cooling, the equipment feet may not be removed, otherwise not
enough air will pass through the controller – Overheating and destruction of the end phase may be
the result.
The controller is designed to run at normal ambient temperatures (25° ) and should be operated
in an open set up with dry, dust and aggressive steam free environment.
If the controller is used within a closed cabinet or room temperatures higher than 25° , you have
to supply additional measures for ventilation.
Increased dust load must be prevented by suitable measures.
Operation in an aggressive, dusty, humid, extremely hot or hazardous environment is at the
user's own risk and responsibility.
The user has to care for appropriate precautions and protective devices, Any liability for damages
arising in such an environment by the operation, are hereby expressly excluded.
Noise
With the HF-spindle running at full speed and the vacuum cleaner on, the noise pressure level at
1 m distance is 86 dB(A). Operators have to wear ear protection.
Dust
It is necessary that the standard vacuum cleaner is always being used during operation on printed
circuit boards. The vacuum cleaner must be OFF during and after use of alcohol or other inflam -
mable or explosive liquids (i. e. used for cooling when milling aluminium). Individual operating con-
ditions may require that an extraction unit with higher rating or the optional protective enclosure be
installed.
Power supply
The machine power supply has a wide range A input. You can run it on any common single
phase mains supply. If the power cord supplied with the machine is not suitable for your country,
please replace it. In this case it is urgently required that you ensure correct grounding to PE.
Attention! You must disconnect the machine from the main supply and wait until D voltages
are low prior to opening the control unit or to pulling cards off from it. We deny any liability if al -
terations to any mechanical, electric or electronic components of the machine are made. Prior to
any manipulation to the control unit, check that the machine has been disconnected from the
main supply.
Please make sure to fix the cable connection with screws. Do not pull the cables while the ma -
chine is under power. First switch off controller and wait for potential equalization .
On the controller is a schuko socket. This is designed for the vacuum cleaner and is switched on
and off via the spindle automatic. If you want to connect other loads (such as a liquid cooling
valve for aluminum milling) to this socket, the power of the appliance should not exceed 2000 W.
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]