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]

ccd_manual_e Page 11 /36
For the connection of safety switches (e.g. hood switches) a shielded cable should be used, it
must be kept as short as possible. This cable - just like all remaining connection/feeder cables
between ontroller and D - should not be laid parallel to power cables in order to prevent in-
ductive or capacitive linking of high-energy transients and thus possible over voltage damage in
the ONTROLLER.
Not avoidable crossings with power cables must be right-angle implemented to keep couple-strain
as short as possible.
If in the proximity of the machines high inductive loads are operated like e.g. strong electric mo-
tors, exhaust fans, contactors etc., the employment of an opto coupler can be necessary for the
connection of the hood contact/safety switch.
All damages due to over voltage, overheating, humidity, dust, corrosion or inappropriate connec-
tion of external or electronic devices are excluded of the guarantee. These repairs will be
charged.
Maintenance
It is important that you regularly remove all dust and shavings from the machine. To clean and lub-
ricate the steel shafts, especially those below the aluminium extrusions on the X-axis, use a cloth
and some acid-free machine oil. On each end of the linear bearing housings, there are lubricating
felt stripes. Regularly apply some oil to them.
The shafts on the Z-axis do not need special lubrication but must also be kept clean.
Note: The machine must not be used in corrosive or inflammable atmospheres. If it will not be
used for a longer period or prior to transporting it, all steel shafts should be well lubricated.
The drive belts must also be kept clean from dust and shavings but must not not be lubricated.
The belts are subject to wear. If they show damages like lateral fray-out or deformed teeth they
should be replaced.
Tools
Only tools with ring (collar) should be used. The distance flange determines the spindle el-
evation over the table. The distance from the top edge of the ring to the tool tip is 21 mm. It
is mounted to the spindle at the factory in a way that a drill (with ring is 0.5 mm over the machine
table when the Z axis is completely down. You should not change this setting. Otherwise the
mechanical position of the Z axis will be different from the one assumed by the driver software.
Damage to the machine table may then result.
Software licenses
Please note that licenses may be linked to the computer. Before you change the computer or re-
install the operating system, you must deactivate the licenses!
Documentation
Our distributor / reseller in your country is encouraged and in charge of translating the German
and / or English manual coming with the machine into your native language. A declaration of EU
conformity is appending.
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 12 /36
Installation Manual RoutePro3000
System requirements:
D with ontroller 2006 or younger.
omputer with Windows XP SP3 till Windows 10 64 bit. 1,3 GHz Processor, 6 GB
main memory and 200 MB free disc space.
Internet connection during setup and registration. The internet connection is ne-
cessary to install updates like Visual ++ and Framework 4. In addition you can
register your RoutePro3000-version and, if there, activate licenses for special
modules (laser, dispense, calibrate etc.).
After installation you can of course work offline.
Procedure:
Read the manual of RoutePro3000. onnect D to your computer. Then install
RoutePro3000: Double-click on “SetupRoutePro3000.exe” and follow the routine.
Depending on your system Microsoft Framework 4 and Microsoft Visual ++ will
be installed automatically. If you do not have the latest firmware on your D
controller, then your controller will be flashed automatically. A restart of Route-
Pro3000 may be required in this case (With machines younger than 2016, it can
be necessary to do the upgrade manually (see below).
If you use special modules like laser, calibration or dispensing, then please read
the special instruction for these modules coming with the hardware and refer to
the applying help topics in the RoutePro manual/help system.
The standard version of RoutePro3000 is for free, but after a trial time of 14 days,
you need to fill out a register form. The registration process is described in the
help file. Please note: from 2014 on you do not need to apply for a license any
more. After filling out the registration form you can directly work. With internet
connection and without. In addition you have the chance to create error reports,
which help us to help you either to directly solve your problem or to get informa -
tion where a bug fix may be required.
After successful registration you can test all available modules for a trial period of
14 days.
To test the modules, please go to options and wait till your desired modules shows up at the
field available modules. lick on your desired module. After that you can activate your test li -
cense. It may be necessary to restart RoutePro3000.
After 14 days a license has to be acquired. Please note that special hardware needs to be ob -
tained for the modules (laser head, camera, etc.). To apply for a license, you need to have a
omputer with internet connection. If you do not have an internet connection, please contact
us to apply for an offline license.
In Regards of the license system, please read the corresponding chapter in the RoutePro3000
help. The topic is there very well explained.
For different machines it can be necessary to use a different routine:
New machines
The SetupRoutePro3000.exe file is located on the D. All necessary files, including the ma-
chine and tool parameters, are located in this setup. The documents,
licenses, and projects folders are also stored on the D, so that you
can, for example, read the help before the installation, or have ac-
cess to the licenses without installing RoutePro3000.
Existing machines with outePro3000: We created a separate file
“UpdateRoutePro3000.exe”. This file does not contain the resource
data and thus your already existing parameters for machine and
tools will not be overwritten. This Update version can also be down-
loaded from our homepage.
Make sure your resource data are in the correct location.
(standard: :\Program Files\RoutePro3000\Resources)
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 13 /36
Existing machines younger than 2016 (CCD3000)
For an update, it may be necessary to update the firmware. For
machines older than 2016 (Atmel versions), this happens
automatically. For machines younger than 2016 ( D3000-Alvidi),
the controller must be updated manually . When you start the update
for RoutePro3000, the warning message appears that the firmware is
not up-to-date. In this case, open the UpgradeFW.exe file. This is
usually found at: : \ Program Files (x86) \ RoutePro3000 \ Firmware
Upgrade. Follow the instructions of the software. Then you can start RoutePro3000 normally.
Existing machines with outePro2008
The SetupRoutePro3000.exe file is located on the D. All necessary files including the machine and tool parameters
are in this setup. The documents, licenses, and projects folders are also stored on the D, so that you can, for example,
read the help before the installation, or have access to the licenses without installing RoutePro3000. After installation,
you have to transfer the specific machine parameters of your machine (correction factors, table, sensor and tool
positions) from RoutePro2008. Alternatively, you can change your old machine configuration (routepro.rpc) via the
OPTIONS - MACHINE – (tooth wheel) - IMPO T PC
If you have a new machine the D coming with the machine is already adapted to your specific machine. No further ac -
tion beyond registration and activating licenses need to be done. Still we recommend to compare the machine paramet -
ers at options – machine with the PDF print out coming with the machine.
If you update from RoutePro2008 to Route Pro3000, you need to
establish the correct parameters for your machine. Process like
this: Start RoutePro3000 and go to options and machine. Hoover
over the D-picture and insert correct parameters for XYZ-mo-
tors, spindle, tool slots, sensor and table. You can copy the values
from your RoutePro.ini-file of your older Software RoutePro2008.
Alternatively you can print screenshots from your RoutePro2008
software and copy the values from the screenshots.
Please note: there is one exception concerning the Z-position of
the tool slots. In RoutePro2008 the z-position of the tool slots was
0.5 – 1 mm less than z-max. E.g. if z-max was 37.65, then z-posi-
tion of the tool slots was approx. 37.00mm. In RoutePro3000 the
table is the 0-Position of the z-axis and you almost put the tool to
0. So now you have to insert 0.5 – 1.0 mm in the AT -
tool position table.
Attention: Back up your RoutePro3000 version regularly
and also the associated licenses. If you want to change
the computer or re-install the operating system: First,
deactivate the licenses!
Only after successful deactivation the licenses are
available on the new computer!
For more details on installing and using RoutePro3000,
see the RoutePro3000 Help. Now you can use the RoutePro3000 software with your D.
The current RoutePro3000 version is available at:
http://www.bungard.de/downloads/software/UpdateRoutePro3000.zip
Have fun with your CCD and the new software outero3000!
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 14 /36
Short Instructions/Setup
You need:
•if possible a second person to lift the ma-
chine off the box
•a small screw driver to secure the cables
•a multiple socket
•a drill backing board
•adhesive tape
•P B material
•tolls (drills/routers)
Examine the packaging for transport damage.
Open the lid of the packaging, remove anchoring straps
and, with the help of a second person, lift the machine out
of the box and set it to its destination. The ground should
be level and stable. Align the 4 levelling feet so that the
machine does not wobble. Examine the machine for pos-
sible transport damages.
Manual test: With no cable connected, check manually
whether all three axis move freely. heck if the supplied
spindle easily rotates.
Setup: Install the supplied Spindle. With the manual
spindle (4010) connect power cable to machine.
With the AT (4054) also connect air supply to the socket
of the Y-axis. The spindle is factory set in a way so that a
drill or milling tool with the correct length (21 mm from the
tool tip to top of the ring; 38mm total length) can be
lowered to a maximum of 0.5 mm above the table. Thus
touching the table with the tools is not possible.
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 15 /36
MTC, ATC: onnect the
two 15-pin cables from
the control unit to the
connections on the back
of the mechanics. Make
sure that the plugs are
properly seated and the
plugs tightly screwed!
The cables cannot be
interchanged. Then
connect the cable on the
controller. Insert the
spindle cable between
the controller and the
machine. Then establish
the USB connection
between the controller
and the P (short cable
connection
advantageous) and then connect the power supply. onnect the vacuum cleaner to the
controller and insert the suction hose.
ATC: connect machine to compressed air supply (6-8 bar, oil free; not included in deliver)
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 16 /36
The machine is delivered with a dongle for the cover
switch. If the dongle is not inserted into the socket on
the controller ( D/2: connection box), the machine
does not move. In the dongle there are 2 connectors
bridged. If a hood is subsequently to be connected with
the cover switch, then the dongle must be opened, the
bridge must be removed and the cables from the door
switch connected to the "bridge contacts".
CCD/2 and CCD/2/Eco: the machine has a
separate power supply. Please connect the
power cable, the connecting cable to the
machine and the vacuum cleaner. An
adapter from Schuko to a cold plug is
included.
On the left-hand side of the machine are
the USB connection from the machine to the P and the plug for the power supply.
Now please insert the spindle into the spindle holder and connect the connection cable.
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 17 /36
In the picture on the right you can see an axis and
zero-point overview. All D machines are set up,
so that the motor connection box with the cables is
located on the left and the stepper motor of the Y-
axis facing the front. On the right there are the tool
slots (AT -machines). If you stand in front of the
machine that way, then the machine zero is on the
front left, the X-axis is on the table level between
motor connection box and tool slots, the Y-axis is
the upper cross traverses and the Z-axis with the
spindle sits on the traverse and moves vertically.
The only exception is the D/2 and the D/2/Eco:
this machine is set up in a way that the RS232 port
and control diodes are pointing forward. Again, the
zero point is at the front left, but the Y-axis is in
the table level of the table and the X axis is the
cross-traverses over the table and on this X-axis
hangs the Z-axis with the spindle.
RoutePro3000 installation software:
Insert the supplied D into your computer drive and
start SetupRoutePro3000.exe. Depending on the
system, the Windows Framework 4 and Windows
Visual C ++ modules must be installed on your
system. This usually happens automatically if your P
is connected to the Internet. Possibly a reboot is
required. In the first dialog, click Register. Enter your
contact information in the next dialog. The
transmission of contact data is voluntary. An Internet
connection is not required to use the software.
The machines from 2016 are usually recognized
automatically. A driver installation is not required. If
problems arise in this regard, please contact [email protected]e.
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 18 /36
After successful installation your screen
should look like this:
Please check the settings of the machine by
clicking on the Options tab and then on ma-
chine. You will see a picture of a D. If you
hover the mouse over the different functional
areas of the machine, you will notice a colour
change. lick on the areas to open the function
dialogue. If you drive over the table, you can ac-
cess the table settings for example.
In each function dialogue there is a small tooth
wheel. lick on this tooth wheel and you can either
load a different machine configuration (be careful!
Your machine only works correctly with the correct
machine configuration!) or access the advanced
features, such as correction factors.
Please compare the values in the machine
configuration of the software to the docu-
mentation provided with the machine.
Function Test in manual Operation:
lose the machine configuration and go to
the tab Manual Operation.
heck the function of the axis by clicking on
the arrow buttons. When you first click on
one arrow, the machine will perform a refer-
ence drive. Make sure that the control di-
odes light up when reaching the 0-position.
You can also check the function of spindle
as well as camera, dispenser or laser, if there.
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 19 /36
(ATC) tool slots
At the front of the machine there is a bar with 16 tool slots, numbered
from 0 to 15 (XL: 26 pots). Number 0 always takes up the test pin, the
routers and drills are located in the remaining round aluminum slots.
Each tool can be moved up and down in the slot and is urged upwards
by a spring. The position of the slots is stored to the software via
entries in the configuration menu.
The drill break sensor is located to the left of tool slot 0. The operating
software checks each drill for breakage after use. This sensor is also
used to detect too long tools and sort them out so that they can not
cause any damage.
Tool change MTC + CCD/2)
To open the chuck, press the button at the top of the spindle until it
locks and turn it to the left. Repeat this until you can remove the tool from the chuck. For better
access, you can lift the spindle, but it is not recommended to lift it completely out of the holder.
Tool change during the program execution is carried out with energized motors. The current
position of the axes is thus locked.
ATC: heck the function of the tool
changer. Go to tab General and click
on Open to load the project file
ccd_P B_-15tools. (XL-Version: -25
Tools). This project file is located after
a normal installation at :\Program Files (x86)\RoutePro3000\Projects\ccd_P B_15-tools
Go to tab un CNC and click on the tri-
angle STA T. The next dialogue asks
you to place the tool to the correspond-
ing tool slots. Make sure that the tools
have a length of 38 mm and the distance
between the top of the ring to the tool tip
is 21 mm. Furthermore, a test tool must
be in the spindle and the tool slot 0 must
be empty. heck the correct fitting of the
tools in the slots. Since there are toler-
ances in the ring diameters, it can be ne-
cessary to adjust the slots. You can eas-
ily widen them with a screwdriver and
tighten them by pressing from outside
against the lamellae.
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]

ccd_manual_e Page 20 /36
Press OK. The machine now moves to the tool sensor, checks the test tool and places it in slot num -
ber 0. Then the spindle moves back to the sensor to check whether the tool was correctly dropped.
After that it continues to slot number 1 to load the first tool. The length of tool 1 is checked at the
sensor, the spindle starts and a positioning and drilling movement is performed. After that the ma -
chine checks if the tool is not broken and sets the tool again in slot 1. This cycle is repeated until all
14 (XL 25 ) tools are checked. Please be prepared to either press the ESCAPE key ( = emergency
stop ) on your keyboard or click on the red X in the top left in the RoutePro3000 window to directly
stop the machine in case the tools were not picked properly or a collision is about to happen. This
may happen in case of a transport damage or if you drive the machine with incorrect parameters.
Make sure that the LEDs of the limit switches and the tool sensor go on and off again when the ma -
chine reaches the corresponding positions.
After the last tool, the spindle picks again the test tool and moves to the machine zero point.
All Ds: Make a first drill and routing at-
tempt!
To do so load the project file
ccd_P B_quickstart.xml. You will find this
file on your -drive at: :\Program Files
(x86)\RoutePro3000\Projects. This is a
single sided board with 3 different drills, a
simple isolation and a cut-out-routing.
Fix a standard drill backing board using the
provided clamps on the machine table. Now fix a
P B with at least 160 x 100 mm dimension
about 5 mm off the machine zero point (in this
project the offset for X and Y is set to 10 mm,
we recommend first to use this setting when you
create a new project. Always compare the thick-
ness of your backing board and your P B with
the values shown in the software !!!l!)
Bungard Elektronik GmbH & o. KG, Rilkestraße 1, 51570 Windeck – Germany
Tel.: [phone] - 0, Fax: [phone] - 29, E-mail: [email protected]