Contac S4

User manual

Order code: 10057789

Version: 3.0
Publisher LPKF Laser & Electronics AG
Osteriede 7
30827 Garbsen
Germany
Phone: +49 5131-7095-0
Fax: +49 5131-7095-90
Email: info@lpkf.com

Date of issue 15.10.2020

Copyright © 2020 LPKF AG
This document and its contents in whole and in parts are subject to
copyright. The reproduction, translation or duplication of the contents
as photocopy or any digital form requires written permission of
LPKF Laser & Electronics AG.
Translation of the German original document
Contac S4 General information

General information
This document contains all information for the intended use of the system/product
delivered. This document is intended for persons with basic knowledge of installation
and operation of software-controlled systems. General knowledge of operational
safety as well as basic knowledge of using PCs running Microsoft Windows ® are
required.
 Read this document and possibly associated safety data sheets carefully before
first start-up and usage of the components.
 Observe the safety regulations as well as the regulations on operational health
and safety and protection of the environment.
 Use the system/product only in a technically perfect condition.
 Observe all labels and safety signs on the system/product.
 Never remove the safety signs and replace or clean them if not readable anymore.
 Persons who install, operate, uninstall, or maintain our systems/products must not
be under the influence of alcohol, other drugs, or medication that impairs the
ability to react.
 Use only approved spare parts and accessories in order to prevent injuries due to
unsuitable spare parts and accessories.
 Observe the technical data and ambient conditions specified in this document.

Validity
This document is part of the system/product and corresponds to the technical state at
the time of publication. This document has always to be present at the system/product
and has to be available to the operating personnel without restrictions, in a complete
and legible form and at all times. If the operator changes, this document has to be
handed over together with the system/product. The operator has to ensure that all
safety measures specified in this document are observed.
The operating personnel must have read and understood this document before
performing any task. A basic requirement for safe work is observance of all safety
notes and steps. This document contains important information about the
system/product that has to be observed when installing, first starting up, or
maintaining the system/product. Its structure allows trained personnel to perform all
tasks.
LPKF Laser & Electronics AG (abbreviated to LPKF in the following) reserves the right
to make changes in respect to the content of this document. The figures in this
document serve as basic understanding and can differ from the actual state of the
system.

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General information Contac S4

Structure of warning messages and safety notes

The safety notes and warning messages in this document identify hazards and risks
and they are created in accordance with ANSI Z535.6-2011 and the standards series
ISO 3864.
The warning messages are structured as follows:
• Warning sign (only for injuries)
• Signal word indicating the hazard class
• Type and source of the hazard
• Consequences of non-observance
• Measures to avoid the hazard

+ SIGNAL WORD
Type and source of the hazard!
Consequences of non-observance.
 Measures to avoid the hazard.
 Further measure(s) to avoid the hazard.

Warning messages can also be embedded in the format of the surrounding text in
order to avoid a visual disruption in a sequence. In this case, they are distinguished as
follows:

Type and source of the hazard!

Consequences of non-observance.
 Measure(s) to avoid the hazard.

Warning messages are classified in hazard classes represented by the signal word. In
the following, the warning messages are described in accordance to their hazard
classes:

DANGER
Type and source of the hazard!
This warning message indicates a hazard of high risk that causes death or serious
injury if not avoided.
 Measures to avoid the hazard.

WARNING
Type and source of the hazard!
This warning message indicates a hazard of medium risk that can cause death or
serious injury if not avoided.
 Measures to avoid the hazard.

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Contac S4 General information

CAUTION
Type and source of the hazard!
This warning message indicates a hazard of low risk that can cause minor or
moderate injury if not avoided.
 Measures to avoid the hazard.

NOTICE
Type and source of the hazard!
This warning message indicates a hazard that can lead to possible property
damage.
 Measures to avoid the hazard.

Text styles
Various text attributes, notations, and text structures facilitate reading the document.
The text attributes (highlightings) inside this document are defined as follows:

Attribute Function
italic highlights elements of the user interface and of control elements of
the system
bold highlights important information and keyboard input
Courier New highlights file paths
[ ] highlights elements of buttons on software user interfaces
highlights keys of the keyboard

Tasks or procedures that are described in steps are compiled to sequences in this
document. A sequence consists of at least three components: objective, step, and
result.

Component Description
Indication of an objective. The sequence starts here.

1. Indication of a sorted list of steps. The specified order must be

observed.
2.
3.
Indication of an intermediate result that is followed by further steps or
the result.
Indication of the result. The sequence is finished.

Indication of a single step.

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General information Contac S4

Additional information
The following symbols are used to indicate additional information:
This note indicates especially useful information.

Advanced information
This advanced information indicates special knowledge.

Registered Trademarks
Product and brand names are trademarks of LPKF Laser & Electronics AG, registered
among others at the US Patent and Trademark Office: LPKF® and the company logo,
# 2,385,062 and # 2,374,780; SolarQuipment®, # 3,494,986; ProConduct®, #
3,219,251; Allegro®, # 3,514,950.
Microsoft® and Windows® are brand names or registered trademarks of Microsoft
Corporation in the USA and/or other countries. All other trademarks belong to the
respective owner.
Issued patents, if applicable, are listed in the appendix.

Limited liability
All data, notes and instructions in this document have been prepared with
consideration to the statutory standards and regulations, the present state of
technology, as well as our many years of knowledge and experience.
LPKF accepts no liability for damage due to:
• non-observance of this document
• improper use of the system/product
• employment of personnel that is not sufficiently qualified
• unauthorized modification
• technical changes
• unauthorized manipulation of the safety devices
• use of spare parts that are not approved by LPKF

The actual scope of delivery can deviate from the explanations and presentations
given here, due to custom designs, the utilization of additional order options, or due to
the most recent technical changes.
We reserve the right for technical modifications of the product for reasons of improved
usability and future development.
The responsibilities agreed in the delivery contract, the General Terms and Conditions
as well as the delivery conditions of the manufacturer and the statutory regulations
valid at the time of the conclusion of the contract are effective.

Warranty
Please note that the warranty is subject to the current regulations in combination with
the current General Terms and Conditions.
All information and instructions in this document have been compiled in observance of
current regulations and the current state of the art. Before working with the

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Contac S4 General information

system/product, this document has to be read carefully. The manufacturer assumes

no liability for damage and faults due to non-observance of this document.
LPKF Laser & Electronics AG provides a 12-months warranty if the following
conditions are met:
• The warranty starts on delivery.
• The warranty covers defects in material or manufacture. During the warranty
period, such defects are remedied without cost by replacement or rework of the
defective parts. This service is provided by the LPKF Service.
• The operating conditions described in this document have been complied with.
• The maintenance work described in this document has been executed and
documented at the specified maintenance intervals.

For further information on wear parts refer to the chapter scope of delivery.

Customer service
For technical information contact our LPKF Service:
Address LPKF Laser & Electronics AG
Service & Support Rapid Prototyping
Osteriede 7
30827 Garbsen
Germany
Phone + 49 5131 7095-1333
Fax + 49 5131 7095-90
Email support.rp@lpkf.com
Internet www.lpkf.com

In our continuous effort to improve our documentation we are asking you to give us
your feedback if you notice any discrepancy when working with the system/product, or
if you have any comments or suggestions for improvement.
At the moment of packaging, the system/product has been equipped with the latest
software version and with the software and hardware documentation currently valid.
By now, new versions of the documentation as well as new software versions might be
available.
For all the latest news and updates visit the support area of our homepage:
http://www.lpkf.com/support.

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Contac S4 Contents

Contents
1 Safety .................................................................................................................. 11
1.1 Intended use ............................................................................................... 11
1.2 Residual risks .............................................................................................. 11
1.3 Basic hazards ............................................................................................. 11
1.3.1 Electrical hazards .......................................................................... 12
1.3.2 Thermal hazards ........................................................................... 12
1.3.3 Hazards by materials or substances ............................................. 13
1.3.4 Mechanical hazards ...................................................................... 13
1.4 Responsibility of the operator ..................................................................... 15
1.5 Personnel requirements .............................................................................. 16
1.6 Personal protective equipment ................................................................... 17
1.7 Safety signs ................................................................................................ 17
1.8 Safety devices ............................................................................................. 19
1.9 Actions in case of an emergency ................................................................ 20
1.10 Environmental protection ............................................................................ 20
2 Technical data .................................................................................................... 22
3 Structure and function ...................................................................................... 23
3.1 Brief description .......................................................................................... 23
3.2 Scope of delivery ........................................................................................ 25
3.3 Type label ................................................................................................... 26
3.4 System components ................................................................................... 27
3.4.1 Tanks............................................................................................. 27
3.4.2 Touchscreen ................................................................................. 28
3.4.3 PCB holder .................................................................................... 28
3.5 Optional modules, accessories, extras ....................................................... 29
3.6 Connections ................................................................................................ 30
3.7 Displays and control elements .................................................................... 31
3.8 Software ...................................................................................................... 32
4 Transport and storage ....................................................................................... 35
4.1 Transport inspection ................................................................................... 35
4.2 Transporting the system ............................................................................. 35
4.3 Storage........................................................................................................ 36
4.4 Packaging ................................................................................................... 36
4.4.1 Handling packaging material ......................................................... 36
4.4.2 Symbols on the packaging ............................................................ 37
5 First startup ........................................................................................................ 38
5.1 Safety .......................................................................................................... 38
5.2 Requirements of the place of installation .................................................... 39
5.2.1 Climatic conditions ........................................................................ 39
5.2.2 Minimum required space ............................................................... 40
5.2.3 Floor .............................................................................................. 41
5.2.4 Connections provided by the customer ......................................... 41
5.3 Preparations ................................................................................................ 42
5.4 Connecting the system ............................................................................... 44
6 Operating the system ........................................................................................ 49
6.1 Safety .......................................................................................................... 49
6.2 Preparations for use .................................................................................... 50
6.3 Typical production process ......................................................................... 50
6.4 Special tasks ............................................................................................... 62
7 Maintenance ....................................................................................................... 66

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Contents Contac S4

7.1 Safety .......................................................................................................... 66

7.2 Maintenance schedule ................................................................................ 67
7.3 Maintenance tasks for the maintenance personnel of the operator............ 69
8 Troubleshooting ................................................................................................ 76
8.1 Fault display ................................................................................................ 76
8.2 Fault table ................................................................................................... 76
9 Disassembly and disposal ................................................................................ 77
9.1 Safety .......................................................................................................... 77
9.2 Preparations ................................................................................................ 77
9.3 Proper disposal of the chemicals ................................................................ 77
9.4 Disposing of the system .............................................................................. 78
10 Appendix ............................................................................................................ 79
10.1 List of figures ............................................................................................... 79
10.2 List of tables ................................................................................................ 80
10.3 Index ........................................................................................................... 81
10.4 EC Declaration of conformity ...................................................................... 82

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Contac S4 Safety

1 Safety
This chapter provides an overview of all important safety aspects for protecting
persons as well as for a safe and fault-free operation of the system/product. There are
further warning messages in the sections of the individual lifecycle stages.

1.1 Intended use

The system can be used for through-hole plating of double-sided and multi-layer PCBs
and for galvanic strengthening of copper surfaces. When copper build-up is completed
the PCBs can be tin-plated. Drilled holes with a diameter of at least 0.2 mm and an
aspect ratio of 1:8 can be plated.
Use only the described chemicals approved by LPKF for filling the tanks.
Operate the system only in a well-ventilated room and wear the described protective
equipment.
The following protective equipment is required for safe usage of the system:
• Splash goggles
• Protective gloves
• Chemical-resistant gloves

Improper use
 Never fill the tanks with other chemicals than the chemicals indicated and
approved by LPKF.
 Do not operate the system with a different or modified software.
 Only use materials and objects for through-hole plating that are approved by
LPKF. Contact the LPKF Service if in doubt.

1.2 Residual risks

No residual risks have currently been identified, if the intended use as well as all
safety regulations are observed. Any identified residual risks and their avoidance are
listed in the form of safety instructions starting in chapter 1.3. Non-observance can
cause personal injuries and property damage.

1.3 Basic hazards

Always comply with the warning messages listed here and in the individual sections of
this documentation to reduce the risks of injuries and property damage and to avoid
dangerous situations.

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1.3.1 Electrical hazards

DANGER
Danger to life by electrical shock!
Touching energized parts causes a direct danger to life by electrical shock. Damage
to the insulation or damaged individual parts can be dangerous to life.
 Use only the mains cable included in the delivery or a mains cable approved by
LPKF.
 All work on energized components of the system must be performed by a
qualified electrician.
 If the insulation is damaged, switch off the power supply immediately and
initiate the repair.
 De-energize all energized components of the system or equipment, before
working with them. Ensure that the system or equipment is de-energized for the
whole time of the task.
 Never bridge or deactivate fuses.
 Always keep moisture away from energized parts because it can cause a short
circuit.

1.3.2 Thermal hazards

CAUTION
Danger of burns by touching the heated liquid!
The liquid in tank 1 is heated to approx. 55 °C (131 °F) and can cause burns in case
of skin contact.
 Avoid contact with the liquids.
 Always wear your personal protective equipment.

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1.3.3 Hazards by materials or substances

WARNING
Health hazard by contact with chemicals!
Contact with the chemicals can cause serious damage to health:
Inhalation can irritate/harm nose, throat, and lungs and cause allergic respiratory
problems.
Skin contact can cause burns, allergies, and hypersensitivity.
Eye contact can irritate the eyes and mucous membranes with burning and tears
and can cause impaired vision and serious eye damage.
Ingestion can cause burns of mucous membranes, throat, esophagus, and
stomach and cause gastrointestinal complaints. Stomach pain, diarrhea, and
vomiting can also occur.
 Always read the safety data sheets before working with chemicals and always
observe the instructions given therein.
 Work in well-ventilated rooms.
 Wear your personal protective equipment.
 Avoid direct contact with the chemicals.
 Take off clothes that are contaminated with chemicals immediately.
 Wash your hands thoroughly after work.
 Consult a physician in case of complaints after contact with chemicals.

WARNING
Health hazard by inhalation of fumes!
Inhalation of the resulting fumes can cause health damage.
 Work only in rooms with an air change rate of at least 4/h.

NOTICE
Damage by inadequate tap water quality!
An inadequate tap water quality (e.g. due to excessive chlorine content) can
degrade the process results.
 Use distilled water for all process steps in case of inadequate tap water quality.

1.3.4 Mechanical hazards

CAUTION
Risk of crushing injury by movement of the motorized frame!
The motorized frame moves during the through-hole plating process and can cause
crushing injuries.
 Do not grasp the motorized frame during through-hole plating.

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Safety Contac S4

CAUTION
Risk of injury by sharp glass splinters!
The cover at the top of the system is made of safety glass. Damage to the glass
produces splinters that can cause cutting injuries.
 Wear your personal protective equipment.
 Remove the broken glass with a vacuum cleaner.
 If broken glass enters a tank, empty the tank and filter the liquid.
 Contact the LPKF Service.

CAUTION
Tripping hazard by hoses and cables!
Hoses and cables are routed to the system. If the hoses and cables are laid
inappropriately they pose a tripping hazard for the operating personnel.
 Always ensure that the hoses and cables do not pose a tripping hazard.

CAUTION
Danger of slipping by leaking or spilled liquids!
Spilled or leaked liquid constitutes a slipping hazard for the operating personnel.
 Wear your personal protective equipment.
 Remove the chemicals according to the instructions in the safety data sheets.

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Contac S4 Safety

1.4 Responsibility of the operator

Operator
The operator is the person/company who operates the system/product themselves for
industrial or commercial purposes, or makes it available to a third party for use and
has the product responsibility for the safety of the system operator/user, the personnel
in general, and other persons present.

Operator's obligations
The system/product is used in the industrial sector. The operator of the
system/product is thus subject to the statutory obligations for occupational health and
safety.
In addition to the safety instructions in this document, the safety, accident prevention,
and environmental protection regulations must also be observed at the
system’s/product’s place of operation.
The following applies in particular:
• The operator must inform himself about the effective industrial safety regulations
and determine additional hazards in a risk assessment that result from the special
working conditions at the system's/product’s place of operation. The operator has
to implement these in the form of operating procedures for the operation of the
system/product.
• During the total operating life of the system/product, the operator has to check and
ensure that the established operating procedures comply with the current state of
the rules and standards and adapt them, if necessary.
• The operator has to define clear-cut responsibilities for installation, operation,
trouble-shooting, maintenance, and cleaning.
• The operator has to make sure that all persons who are working with the
system/product have read and understood this document. Furthermore, the
personnel has to be trained and informed about the dangers on a regular basis.
• The operator has to provide the required personal protective equipment and
instruct the personnel to wear it.
• The operator has to instruct the personnel to maintain a clean and tidy workplace.
Eating and drinking at the workplace and especially while operating the
system/product must not be permitted.

The operator is also responsible to keep the system/product in good working order.
Thus, the following applies:
• The operator has to ensure that the maintenance intervals stated in this document
are observed.
• The operator has to check all safety devices for proper function and completeness
on a regular basis.

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Safety Contac S4

1.5 Personnel requirements

WARNING
Accident hazard due to insufficiently qualified personnel!
Insufficiently qualified personnel cannot assess the risks of using the
system/product and put themselves and others in danger.
 Allow only qualified personnel to use the system/product.
 Keep insufficiently qualified personnel out of the working area.

The different tasks described in this document require different qualifications of the
persons who are to perform these tasks.
If no personnel qualifications are listed in the individual chapters of this document, the
operating personnel is intended to perform the tasks.
Only persons who can be expected to perform the tasks reliably are authorized to
perform the tasks. Persons whose ability to react is impaired e.g. by drugs, alcohol, or
medicine, are not authorized.
This document uses the following qualifications for persons for the different tasks.

Qualified electrician
A qualified electrician is able to perform work on electrical systems and to detect and
avoid possible dangers on his/her own based on his/her professional training, know-
how and experience as well as knowledge of the applicable standards and
regulations.
The qualified electrician has been trained for the special field where he/she works and
knows the relevant standards and regulations.

Maintenance personnel of the operator

Maintenance personnel are those persons who are designated by the operator to
perform simple maintenance tasks (e.g. cleaning the system/product, removing parts
from the system/product). The operator has to ensure that the personnel is suited for
performing the work.
The maintenance personnel is able to perform his/her work and to detect and avoid
possible dangers on his/her own based on his/her professional training, know-how and
experience as well as knowledge of the applicable standards and regulations.
The maintenance personnel has been trained for the special field where he/she works
and knows the relevant standards and regulations.

Service personnel
Service personnel are persons who are authorized by the manufacturer LPKF for
servicing the system/product. These tasks may only be performed by the LPKF
Service.

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Operating personnel
Operating personnel trained by the operator is able to perform his/her work and to
detect and avoid possible dangers on his/her own based on the training performed by
the operator, his/her professional training, and his/her know-how and experience.
The operating personnel has been trained by the operator for the special field where
he/she works and knows the relevant standards and regulations.

1.6 Personal protective equipment

Personal protective equipment protects against health or safety risks when working
with the system.
The individual sections of this manual each point out the personal protective
equipment (PPE) that has to be worn during the different tasks of working on the
system.

Personal protective equipment for working with hazardous substances and

chemicals
• Splash goggles (e.g. EN166)
• Chemical-resistant gloves (compliant with EN ISO 374-1:2016)
• Closed work clothes

 Always read the safety data sheets before working with hazardous substances
and chemicals and always observe the instructions given therein.

Description of the personal protective equipment

Splash goggles
Splash goggles protect the wearer's eyes against chemicals, dust,
and splinters.

Chemical-resistant gloves
Chemical-resistant gloves protect the hands against immediate
skin contact with hazardous substances. Refer to the safety data
sheet for the required glove material and thickness.

Protective gloves
Protective gloves protect the hands against friction, abrasions,
puncture hazards and deep cuts as well as when touching hot
surfaces.

1.7 Safety signs

This chapter lists the safety signs/pictograms that are applied to the system and
describes their meaning.

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Safety Contac S4

WARNING
Risk of injury by non-observance of safety signs!
The safety signs on the system instruct you on safe usage of the system. Non-
observance of the safety signs can cause severe injuries.
 Always observe the safety signs.
 Never remove the safety signs.
 If a safety sign is no longer legible, clean or replace the safety sign.

Safety signs at the housing

Risk by defective system!
Injury or property damage possible.
Remedy defects of the system
immediately. Switch off the system
and disconnect it from the power
supply.

Warning! Corrosive chemicals!

Wear your personal protective
equipment.
Avoid contact with eyes or skin and
do not inhale fumes.

Warning! Chemicals hazardous

to health!
Wear your personal protective
equipment.
Avoid contact with eyes or skin and
do not inhale fumes.

Warning! Environmentally
hazardous chemicals!
A release of the chemical (e.g. by
improper disposal) can cause
damage to the environment.

Warning! Irritant chemicals!

Wear your personal protective
equipment.
Avoid contact with eyes or skin and
do not inhale fumes.

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1.8 Safety devices

This chapter describes the safety devices of the system and their function.

Fig. 1: Tank covers Fig. 2: Fuse

Figure Description
The covers (figure 1) protect the operating personnel
against inadvertent contact with chemical baths that
are not in use. They also reduce evaporation and
thus loss of chemicals.

The fuse (figure 2) prevents damage to the system

and injury to the operating personnel caused by
overcurrent (e.g. due to a short circuit).

Table 1: Safety devices

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Safety Contac S4

1.9 Actions in case of an emergency

Preventive measures
• Always be prepared for fires and accidents!
• Keep first aid equipment (first aid kit, blankets etc.) and fire-fighting equipment
functioning properly and close at hand.
• Instruct the personnel on incident reporting, first-aid equipment, and rescue
equipment.
• Keep access routes clear for emergency vehicles.

Response to fire and accidents

• Immediately execute an emergency stop.
• Switch the main switch to 0 (OFF).
• Disconnect the supply of external components as quickly as possible.
• Recover persons from the danger zone if safe to do so.

1.10 Environmental protection

NOTICE
Environmental hazard by improper handling of substances!
Improper handling of environmentally hazardous substances, especially improper
disposal, can cause considerable damage to the environment.
 Take appropriate measures immediately if environmentally hazardous
substances are accidentally discharged into the environment. If you are in
doubt, inform the appropriate local authorities about the damage and ask for
appropriate measures that have to be taken.

This system uses several environmentally harmful substances. These may cause
long-term adverse effects in the aquatic environment. The substances must not enter
surface waters, drains, or soil.
Spent chemicals must not be emptied into the drains, they have to be filled into the
containers intended for disposal.
Check which local and national regulations apply and observe these. For
recommendations on disposal refer to the safety data sheets. If the regulations differ
from the recommendations, observe the regulations.
The following environmentally hazardous substances are used:
• Cleaner 110
• Cleaner 210
• Copper Plater 400
• Electroless Tin Liquid
• ViaCleaner Part 1

The following substances are not classified as environmentally hazardous. It is

possible, however, that large quantities or frequent release are harmful to the
environment and especially surface waters. Avoid the release of the following
substances into the environment:
• Activator 310
• Shine 410
• ViaCleaner Part 2

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Handling of wastewater
The wastewater produced when rinsing the PCB can have a high copper content and
must not be discharged into the drain without treatment. Check which local and
national regulations apply and observe these.
The PCB cleaning system that is optionally available from LPKF filters and retains the
copper particles contained in the waste water If you are using this system when
through-hole plating, the water thus filtered may be drained off safely.

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Technical data Contac S4

2 Technical data
General data
Data Value Unit
IP Code (IEC 60529) IP20 –
Service life 10 years

Climatic conditions
Data Value Unit
Temperature range (operation) 20 to 25 °C
Temperature range (storage, transport) -30 to 60 °C
Max. humidity, non-condensing 90 %

Electrical data
Data Value Unit
Power supply 110/230 V
50/60 Hz
Output power 750 VA

Mechanical data
Data Value Unit
Dimensions (width x height x depth) 856 x 450 x 540 mm
Weight (without packaging) without anodes: 60 kg
with anodes: 77

Process data
Data Value Unit
Maximum base material size 230 x 330 mm
Maximum PCB size 200 x 300 mm
Process temperature range 20 to 25 and 55 (tank 1) °C
Maximum aspect ratio 1:8 –

Emissions
Data Value Unit
Sound pressure level LpA (EN ISO 3744) < 70 dB (A)
Sound power level LwA (EN ISO 3744) < 70 dB (A)
EMC emission class A -

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Contac S4 Structure and function

3 Structure and function

This chapter describes the technical structure and the functions of the system.

3.1 Brief description

The Contac S4 is used for through-hole plating of PCBs and for galvanic
strengthening of copper surfaces. This creates an electric connection between the
different layers of the PCB. The through holes can have a minimum diameter of 0.2
mm (> 8 mil). They are plated using the black-hole process.
The system is suited for processing double-sided and multi-layer PCBs. The process
consists of the following six phases:
1. Cleaning the PCB
2. Conditioning the PCB
3. Activating the PCB
4. Active cleaning of the drilled holes
5. Copper-plating the PCB
6. Tin-plating the PCB

The fifth phase uses an air injection to create a more homogeneous copper deposition
on the surface of the PCB.
The active cleaning of the drilled holes after applying Activator 310 enabled bonding of
the copper to the inner copper layer. This is especially important for plating micro vias
and blind vias.
The tin-plating option is intended for applying a tin layer on copper surfaces of PCBs.
The tin layer is chemically deposited, i.e. without electric current, and is intended to
protect the copper surface against corrosion and to improve solderability. This also
ensures further processing after a period of storage.

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Structure and function Contac S4

Reverse Pulse Plating

Reverse Pulse Plating (RPP) is implemented in the special LPKF control circuit that
monitors the whole through-plating process.
Conventional electroplating results in increased deposition of material on the rims of
the via holes due to the distribution of flux lines. This ridge buildup (dog-bone effect)
during metal deposition occurs especially at a large depth-to-diameter ratio of the via
holes (see 2 in the following figure).

Fig. 3: Dog-bone effect

1 With dog-bone effect 2 Without dog-bone effect

Reverse pulse plating uses short inverted pulses during which the circuit board acts
as the anode. This causes parts of the built-up material spikes to be removed so that
the overall copper deposition is more uniform (see 1 in the figure above).
The RPP function is activated in the copper plating profile as default, but it can be
deactivated in the menu Profiles for newly created profiles.
It is recommended to use the RPP function for PCBs with holes of diameters < 0.4
mm. The RPP function is also to be used if a uniform layer thickness and less board
margin losses are desired.
The PCB surface is slightly matte after copper plating with RPP. If you desire a more
glossy surface, start another copper plating cycle with 75% of the original amperage
without RPP for 15 to 30 minutes.

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3.2 Scope of delivery

This chapter provides an overview of the system's scope of delivery. For information
on optional modules, accessories and extras refer to chapter Optional modules,
accessories, extras on page 29.
• Contac S4 system
• Contac S4 user manual
• Mains cable (110 V)
• Mains cable (230 V)
• Protective gloves
• Protective goggles
• Squeegee for Activator
• Measuring cylinder
• Skimmer
• 3 x Draining tubes (80 cm)
• 2 x Pipettes
• 2 x Spray bottles

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Structure and function Contac S4

3.3 Type label

The type label is located at the housing of the system. For information on identifying
the system and the relevant equipment, specify the system model and the serial
number on the type label when you contact the LPKF Service.

Fig. 4: Type label

Name Description
Model System type
Version Version number
Serial No. Serial number
Voltage Operating voltage
Frequency Line frequency
Phase Number of phases
Fuse Fuse protection
Power Power rating
Manufactured Year of manufacture
Made in Slovenia Country of origin
Table 2: Type label

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Contac S4 Structure and function

3.4 System components

This chapter describes the components of the system. First of all, make yourself
familiar with the individual components of the system before starting the operation.
Before operating the system, also inform yourself about the important software
elements and the different operation modes.

Fig. 5: System overview

1 Glass cover (safety glass) 5 Recessed grip
2 Touch screen 6 Retainer for PCB holders
3 PCB holder 7 Process tanks
4 Cover for drain valves 8 Deposit for tank covers

3.4.1 Tanks
The system has six tanks for the individual phases of the through-hole plating process.
The PCBs can be inserted into the tanks after fastening to the PCB holder. The tanks
can be individually covered which prevents excessive evaporation of the chemicals
and inadvertent contamination. Contamination of bath 3 can render the Activator 310
chemical useless and necessitate complete replacement.
Tank 1 is heated to 55 °C at the start of the system if sufficiently filled. A sensor
determines the fill level of the tank. If it is too low, an error message is displayed.
Tank 5 is equipped with an air injection that constantly keeps the contained chemical
in motion. Thus, a more uniform distribution of the copper components and a more
uniform through-hole plating is enabled. This function is activated as soon as the
copper plating phase is started.
The chemicals in the tanks can be drained via drain valves inside the system. The
drain valves are accessible behind a cover on the front of the system.

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Structure and function Contac S4

The system contains the following tanks:

Function Chemical Capacity Heated?

Tank 1 Cleaning Cleaner 110 5 liters yes, 55 °C
Tank 2 Conditioning Cleaner 210 5 liters no
Tank 3 Activation Activator 310 5 liters no
Tank 4 Active cleaning ViaCleaner Part 1 & 2 5 liters no
Tank 5 Copper plating Copper Plater 400 15 liters no
Tank 6 Tinning Electroless Tin Liquid 5 liters no
Table 3: Tank overview

3.4.2 Touchscreen
The system has a touch screen that can be operated with bare fingers or gloves on.
The touch screen is chemical-proof.

Fig. 6: Touch screen

3.4.3 PCB holder

A PCB is fastened to the PCB holder for the through-hole plating process so that they
can be inserted into the tanks. The PCB holder can be used for all tanks, no matter
whether they use a current or not.
The PCB holder is mounted into a motorized frame that moves the PCB during the
process in order to remove potential air bubbles from the PCB.

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Fig. 7: PCB holder

3.5 Optional modules, accessories, extras

The following consumables are required for filling and using the tanks:

Description Quantity
Cleaner 110 5 liters
Cleaner 210 5 liters
Activator 310 5 liters
Copper Plater 400 15 liters
Shine 410 0.5 liters
Electroless Tin Liquid 5 liters
ViaCleaner Part 1 5x1l
ViaCleaner Part 2 250 g
Table 4: Consumables

The following items are needed additionally:

• Distilled/De-ionized water
• Containers for disposal of spent chemicals
• Sink for rinsing the PCBs

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Structure and function Contac S4

3.6 Connections
The connectors are on the right side of the system:

Fig. 8: Connectors
1 On/Off button 3 Main switch
2 USB port 4 System power inlet

The USB port (2) can be used to install newer versions of the system software.

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3.7 Displays and control elements

This chapter describes the displays and control elements of the system. First of all,
make yourself familiar with the individual components of the system before starting the
operation.

Fig. 9: Touch screen

Figure Description
The touch screen is used for operating the system, it
reacts to touch with bare fingers or with chemical-
resistant gloves.

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3.8 Software
The system is controlled with the pre-installed firmware called EPIC (Electroplating
Integrated Control). The firmware assists you during the through-hole plating process
by displaying the instructions and the processing time of the current phase or other
important information (e.g. the current temperature of tank 1). The firmware also starts
certain functions (e.g. air injection) automatically as soon as the corresponding phase
is started.
Default profiles are preset for certain materials and processes. Custom profiles that
are optimized for your purposes can also be created. You can set the duration of
certain phases, the amperage in tank 5 etc. individually in these profiles.
You can also display information on the state of the chemicals and thus determine in
time which tank contents have to be replaced.
The system is operated using the touch screen on the top side of the system.

Fig. 10: User interface

1 Main menu 4 Special process properties
2 Current process phase and step 5 Process duration
3 Active profile 6 Navigation bar

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Profiles
The process parameters can be adjusted and stored in the profiles. The parameters
are defined for PCBs of specific sizes and should only be used for these sizes to
achieve optimum results. Sizes that differ from the defaults can be defined in user-
defined profiles.

Fig. 11: Profile view

The following parameters can be defined in a profile:

Name Description
Name Profile name
Height and width Dimensions of the PCB (in mm)
Cleaning (tank 1) Duration (in minutes) and temperature (in °C) of the first process
phase.
Conditioning (tank 2) Duration (in minutes) of the second process phase.
Activation (tank 3) Duration (in minutes) of the third process phase.
Active cleaning (tank 4) Duration (in minutes) of the fourth process phase. This is
calculated automatically.
Copper-plating (tank 5) Duration (in minutes) of the fifth process phase and thickness of
the deposited copper layer (in µm). The functions RPP, Air, and
Pause can be activated additionally.
Tinning (tank 6) Duration (in minutes) of the sixth process phase and thickness
of the deposited tin layer (in µm).
RPP Reverse pulse plating see page 24.
Air Activates the air injection.
Pause Activates/Deactivates a pause for turning the PCB around after
the first half of the copper plating phase. This achieves a
homogeneous copper plating of both sides.
Table 5: Profile parameters

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Structure and function Contac S4

The following profiles are available by default:

Dimensions Tanks (duration in

(in mm) minutes)
No. Name Height Width 1 2 3 4 5 6 RPP Air Pause
1 Copper Plating Profile 305 230 15 5 15 / 90 0 On On On
2 Tin Plating Profile 305 230 0 0 0 / 0 30 Off Off Off
Table 6: Profiles overview

Please note that the duration for tank 4 cannot be set manually. The system calculates
the duration automatically based on the temperature of the bath.
You can also create and edit new profiles. For further information refer to page 62.

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Contac S4 Transport and storage

4 Transport and storage

This chapter contains important information on transport, packaging and storage of the
system.

CAUTION
Risk of crushing injury by improper transport of the system!
Body parts can be crushed by improper transport of the system.
 Wear your personal protective equipment.
 Carry the system only at the recessed grips.
 When setting the system down, ensure that no body parts get pinched or
crushed.

4.1 Transport inspection

Check the delivered goods immediately upon receipt for completeness and for
transport damage.
If transport damage is evident, proceed as follows:
 Do not accept the delivery or only with reservations.
 Record the extent of damage on the transport documentation or on the delivery
note of the transport company.
 Initiate a complaint.

4.2 Transporting the system

Ensure that the following requirements are met before performing the steps below:

Prerequisites
• Wear safety shoes
• Wear protective gloves
• Work with another person
• System is switched off.
• System is not filled with chemicals.

The system weighs 60 kg (without anode plates) and has to be carried by two
persons. The system has a recessed grip on both sides for lifting the system.

Fig. 12: Recessed grip

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 Transporting the system

1. Ensure that the system is switched off.
2. Ensure that all chemicals have been drained.
3. Remove the mains cable.
4. Lift the system with another person simultaneously at the two recessed grips.
5. Set the system down at the intended place.
 The system has been transported.

4.3 Storage
 Store the system in its original packaging according to the symbols on the
packaging.
 Store the packages under the following conditions:
− Do not store outdoors.
− Store dry and dust-free.
− Do not expose to aggressive substances.
− Protect against sunlight.
− Storage temperature: 15 °C - 35 °C (59 °F - 95 °F)
− Relative air humidity: 60 % max, non-condensing.
− If storing for more than 3 months, check the general condition of all
components and the packaging on a regular basis.

4.4 Packaging
The packaging is chosen according to the transport conditions.
The packaging is to protect the system from transport damage, corrosion, and other
kinds of damage until installation.
 Keep the packaging in its original form.
 Only remove the packaging just before installation.

4.4.1 Handling packaging material

 Dispose of the packaging material according to the current laws and local
regulations.

NOTICE
Environmental hazard by wrong disposal of packaging!
Wrong disposal of packaging material can cause environmental hazards.
 Dispose of the packaging material environmentally friendly.
 Observe the local disposal regulations and hire a specialized company for the
disposal, if necessary.

 The system may only be shipped in the original packaging of LPKF. Contact the
LPKF Service if you need the packaging.

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4.4.2 Symbols on the packaging

Observe the following symbols on the packaging when transporting the system:

Top
The arrowheads of the symbol indicate the top side of the
package. These always have to point upwards, otherwise,
the contents could be damaged.

Keep dry
Protect packages against moisture and keep them dry.

Fragile
Identifies packages with fragile or sensitive contents.
Handle the package with care, do not drop, and do not
subject it to shocks.

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First startup Contac S4

5 First startup
This chapter contains important information on first startup of the system.

5.1 Safety
Observe the following safety instructions for the first startup of the system:

DANGER
Danger to life by electrical shock!
Touching energized parts causes a direct danger to life by electrical shock. Damage
to the insulation or damaged individual parts can be dangerous to life.
 Use only the mains cable included in the delivery or a mains cable approved by
LPKF.
 All work on energized components of the system must be performed by a
qualified electrician.
 If the insulation is damaged, switch off the power supply immediately and
initiate the repair.
 De-energize all energized components of the system or equipment, before
working with them. Ensure that the system or equipment is de-energized for the
whole time of the task.
 Never bridge or deactivate fuses.
 Always keep moisture away from energized parts because it can cause a short
circuit.

WARNING
Accident hazard due to insufficiently qualified personnel!
Insufficiently qualified personnel cannot assess the risks of using the system and
put themselves and others in danger.
 Allow only qualified personnel to use the system.
 Keep insufficiently qualified personnel out of the working area.

WARNING
Health hazard by contact with chemicals!
Contact with the chemicals can cause serious damage to health:
Inhaling can irritate nose, throat and lungs and can cause allergic respiratory
problems.
Skin contact can cause chemical burns, allergies, and hypersensitivity.
Eye contact can irritate the eyes and mucous membranes with burning and tears
and can cause impaired vision and serious eye damage.
Ingestion can cause chemical burns of the mucous membranes, throat,
esophagus, and stomach and can cause gastrointestinal complaints.
 Read the provided safety data sheets carefully.
 Work in well-ventilated rooms.
 Wear your personal protective equipment.
 Avoid direct contact with the chemicals.
 Take off contaminated clothes immediately.
 Wash your hands thoroughly after work.

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NOTICE
Property damage due to contaminants on the anodes!
Contaminants like e.g. finger prints interfere with the copper release of the anodes
and cause a particle discharge that contaminates the bath.
 Touch the copper anodes only with clean protective gloves.

NOTICE
Property damage by spilled liquids!
Spilling liquids over electrical components can cause a short circuit.
 Switch the system off and disconnect it from the power supply.
 Remove the liquid with dry paper towels.
 If Copper Plater 400 has been spilled, contact the LPKF Service.
 Let the system dry at room temperature, at least one day before the next start.

5.2 Requirements of the place of installation

Before installing the system, the following requirements of the place of installation
have to be ensured.

5.2.1 Climatic conditions

The following climatic conditions have to be ensured for operating the system:

Climatic conditions
Data Value Unit
Temperature range (operation) 20 to 25 °C
Temperature range (storage, transport) -30 to 60 °C
Max. humidity, non-condensing 90 %

Ventilation of the place of installation

The choice of the place of installation must ensure that 4 air exchanges per hour are
possible.
The following table provides an overview on air exchange rates that you can achieve
by opening the windows of the laboratory.
The values in the table are guidelines and can vary strongly depending on the
building, room size, window sizes, and ambient temperature. The operator has to
ensure that the required air exchange is always achieved during operation.

Window position Air exchanges per hour

Window tilted 0.8 – 4.0
Window fully open 9.0 – 15.0
Window fully open and opposite door or Up to 40.0
opposite window fully open (cross ventilation)
Table 7: Air exchange depending on window position

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First startup Contac S4

Great differences between the indoor temperature and the outdoor temperature
enhance the air exchange via opened windows. LPKF recommends to ensure air
exchange by cross ventilation in case of warm outdoor temperatures.

5.2.2 Minimum required space

System dimensions
• Width: 891 mm (~35.1")
• Depth: 562 mm (~22.1")
• Height: 450 mm (~17.7")

Minimum space requirements for operation and maintenance

• Width: 991 mm (~39.0")
• Depth: 1562 mm (~61.5")
• Height: 800 mm (~31.5")

A space of approx. 10 cm to the right of the system has to be kept clear for
maintenance. In front of the system, at least 1 m of space should be available for
operation and movement. On the left side of the system should be enough space for
using the retainers. Additionally, on the right side of the system there should be a
safety distance of 1 m to the water connection (e.g. sink).

Fig. 13: System dimensions - front view

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Fig. 14: System dimensions - top view

5.2.3 Floor
The floor has to be level and antistatic and has to have a sufficient load-bearing
capacity for the total weight of the system (117 kg with filled tanks). We recommend to
use a sturdy, fixed table without casters.

WARNING
Risk of injury by loss of stability!
Loss of stability due to an improper floor or missing locks can cause uncontrollable
movement or tilting of the system. This can cause serious injuries.
 Ensure that the floor is even and has a sufficient load-bearing capacity.
 Secure the system properly so that it cannot roll away unintentionally.

5.2.4 Connections provided by the customer

Electrical data
Data Value Unit
Power supply 110/230 V
50/60 Hz
Output power 750 VA

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First startup Contac S4

5.3 Preparations
The copper anodes have to be installed before the system can be put into operation.

NOTICE
Property damage due to contaminants on the anodes!
Contaminants like e.g. finger prints interfere with the copper release of the anodes
and cause a particle discharge that contaminates the bath.
 Touch the copper anodes only with clean protective gloves.

 Installing the copper anodes

1. Take the copper anodes and the anode bags out of the packaging.
2. Put the anodes into the bags with the holes at the mouths of the bags.

Fig. 15: Copper anode in bag

Notice! Damage by falling copper anodes!

 Put padding (e.g. expanded material) into tank 5 before installing the anodes.

3. Hang one copper anode by its two holes onto the gray pins on the left wall of
tank 5.
Take care that the small hole at the edge of the anode points to the front of the
system and that the anode bag is not jammed between the anode and the pins.

Fig. 16: Gray pins

4. Hang the other copper anode by its two holes onto the gray pins on the right wall
of tank 5.

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Fig. 17: Installing the copper anodes

5. Fasten the anode plates to one titan bracket each using a flat-bladed screwdriver.

Fig. 18: Fastening the anode to the titan bracket

 The copper anodes have been installed.

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First startup Contac S4

5.4 Connecting the system

The following tasks have to be executed to start up the system.
• Filling the tanks
− Filling tank 1 (cleaning)
− Filling tank 2 (conditioning)
− Filling tank 4 (active cleaning)
− Filling tank 5 (copper plating)
− Filling tank 6 (tinning)
− Filling tank 3 (activation)

• Connecting the system to the power supply

• Initializing the system

The tanks have been cleaned and rinsed before delivery, thus the chemicals can be
filled without delay.

Ensure that the drain valves are closed to prevent leakage of the liquids.

 Filling tank 1
1. Remove the cover of tank 1 and put it into the holder slot.
2. Fill tank 1 with Cleaner 110 up to the mark.
Ensure that tank 1 is always sufficiently filled. Replace evaporation losses with
Cleaner 110, use de-ionized water only if necessary.
3. Place the cover back onto tank 1.
 Tank 1 has been filled.

 Filling tank 2
1. Remove the cover of tank 2 and put it into the holder slot.
2. Fill tank 2 with Cleaner 210 up to the mark.
3. Place the cover back onto tank 2.
 Tank 2 has been filled.

 Filling tank 4
1. Remove the cover of tank 4 and put it into the holder slot.
2. Fill ViaCleaner Part 1 (four bottles 1l each) into the 5l jerry can included in the
delivery.
3. Fill ViaCleaner Part 2 into the 5l jerry can.
4. Mix the ViaCleaner solution thoroughly.
5. Attach the spout to the jerry can's muzzle.
6. Fill the ViaCleaner solution into tank 4.
7. Place the cover back onto tank 4.
 Tank 4 has been filled.

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 Filling tank 5
1. Remove the cover of tank 5 and put it into the holder slot.
2. Fill tank 5 with Copper Plater 400 up to the mark.
3. Add 40 ml of Shine 410 to tank 5.
4. Put the floating balls into tank 5.
5. Place the cover back onto tank 5.
 Tank 5 has been filled.

 Filling tank 6
1. Remove the cover of tank 6 and put it into the holder slot.
2. Fill tank 6 with Electroless Tin Liquid up to the mark.
3. Place the cover back onto tank 6.
 Tank 6 has been filled.

Tank 3 should be filled last to avoid malfunction of the chemical caused by inadvertent
splashes.

Never pass the Cleaner liquids through the same tube as the Activator liquid. This
could cause contamination and quality losses in processing.

 Filling tank 3
1. Remove the cover of tank 3 and put it into the holder slot.
2. Shake the jerry can filled with Activator 310 for approximately one minute.
The Activator liquid is very sensitive and can easily become unusable. Tank 3 has to
be absolutely dry before filling in Activator 310.
3. Fill tank 3 with Activator 310 up to the mark.
4. Place the cover back onto tank 3.
 Tank 3 has been filled.

It is recommended to store the containers for later disposal of the chemicals.

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First startup Contac S4

 Connecting the system to the power supply

1. Check whether the main switch is switched to 0 and switch it to this position if not.

Fig. 19: Power supply

2. Plug the mains cable into the appliance inlet.

Fig. 20: Mains cable plugged into appliance inlet

3. Plug the mains cable into the wall socket.

Fig. 21: Mains cable plugged into wall socket

 The system has been connected to the power supply.

The system has to be initialized after connecting and filling. This requires a PCB that
subsequently, however, cannot be processed any further. Thus, you should use a
dummy PCB that is not intended for further processing.

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Initialization
The initialization of the copper anodes takes 240 minutes. Initialization creates a thin
homogeneous phosphorus layer that helps creating shiny copper layers. Insufficient
initialization can cause matte and inhomogeneous copper layers to be deposited
during the first process runs.

 Initializing the system

1. Switch the main switch on the right side of the system to I (On).

Fig. 22: Main switch On

2. Press the On/Off button for at least two seconds.

Fig. 23: On/Off button

 Tank 1 is heated.
3. Follow the instructions on the touch screen.
 The process view is displayed.
4. Tap on .
 The following view is displayed:

Fig. 24: Main menu

5. Tap on [Settings].
 The following view is displayed:

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Fig. 25: Settings | General

6. Switch to the tab Service.

Fig. 26: Settings | Service

7. In the line Anode replacement tap on [Service].

8. Fasten the dummy PCB to the PCB holder.
9. Rinse the dummy PCB with water.
10. Insert the dummy PCB into tank 5.
11. Tap on .
 The displayed processing time is counted down.
12. Wait until the time has elapsed.
 The next task is displayed.
13. Remove the dummy PCB from the tank.
14. Let the dummy PCB drip off into tank 5.
15. Rinse the dummy PCB with water.
16. Dispose of the dummy PCB according to regulations.
 The system has been initialized.

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6 Operating the system

This chapter contains important information on operating the system and the
associated software programs.

6.1 Safety

WARNING
Health hazard by contact with chemicals!
Contact with the chemicals can cause serious damage to health:
Inhaling can irritate nose, throat and lungs and can cause allergic respiratory
problems.
Skin contact can cause chemical burns, allergies, and hypersensitivity.
Eye contact can irritate the eyes and mucous membranes with burning and tears
and can cause impaired vision and serious eye damage.
Ingestion can cause chemical burns of the mucous membranes, throat,
esophagus, and stomach and can cause gastrointestinal complaints.
 Read the provided safety data sheets carefully.
 Work in well-ventilated rooms.
 Wear your personal protective equipment.
 Avoid direct contact with the chemicals.
 Take off contaminated clothes immediately.
 Wash your hands thoroughly after work.

WARNING
Health hazard by inhalation of fumes!
Inhalation of the resulting fumes can cause health damage.
 Work only in rooms with an air change rate of at least 4/h.

CAUTION
Risk of crushing injury by movement of the motorized frame!
The motorized frame moves during the through-hole plating process and can cause
crushing injuries.
 Do not grasp the motorized frame during through-hole plating.

NOTICE
Property damage due to missing cover!
A cover missing on a tank can cause the bath to be not ready for use or to become
completely unusable (by evaporation or contamination).
 Cover the tanks that are not in use with the provided covers.

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Operating the system Contac S4

NOTICE
Property damage by contamination of the activation bath!
The activation bath is very sensitive to contaminants and can become unusable if
even slightly contaminated.
 Avoid any contamination of the activation bath.
 Always cover the activation tank when not in use.
 Never compensate evaporation losses with water. Replenish with Activator 310
up to the mark.

NOTICE
Property damage by spilled liquids!
Spilling liquids over electrical components can cause a short circuit.
 Switch the system off and disconnect it from the power supply.
 Remove the liquid with dry paper towels.
 If Copper Plater 400 has been spilled, contact the LPKF Service.
 Let the system dry at room temperature, at least one day before the next start.

6.2 Preparations for use

Before working with the system check the following settings and conditions:
• Ensure that the room temperature is between 20 and 25 °C.
• Check the fill level of tank 1.
• Check whether copper sulphate crystals have formed in tank 5 put the crystals
back into the bath if present.
• Place a spray bottle filled with distilled or de-ionized water next to the system.

6.3 Typical production process

This chapter describes a typical production process.
The following tasks are executed:
• Process preparation
• Process sequence
During the through-hole plating process, all required steps are prompted and
described by messages on the screen.

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Process preparation
This chapter describes the preparations for the process of copper plating a PCB with
subsequent tin plating. The following tasks are executed:
• Switching on the system
• Selecting a profile
• Setting the copper plating rate

 Switching on the system

1. Switch the main switch on the right side of the system to I (On).

Fig. 27: Main switch On

2. Press the On/Off button for at least two seconds.

Fig. 28: On/Off button

 Tank 1 is heated.
3. Follow the instructions on the touch screen.
 The following view is displayed:

Fig. 29: Process view

 The system has been switched on.

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Operating the system Contac S4

Before starting the through-hole plating of the PCB, you should select the correct
profile. This defines which steps you will execute and how long the PCB will dwell in
the tanks. For information on creating and editing profiles refer to page 62.

 Selecting a profile
1. Tap on .
 The menu is opened.

Fig. 30: Main menu

2. Tap on [Profiles].
 The profile overview is displayed:

Fig. 31: Profiles overview

3. Tap on [Select] of the desired profile.

Select the profile Copper Plating Profile for the following process.
 The process view is displayed with the selected profile.
 The profile has been selected.

The pre-set values for the copper plating rate are only default values. You may have
to set better fitting values for copper plating your PCB.

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 Setting the copper plating rate

1. Tap on .
 The following view is displayed:

Fig. 32: Main menu

2. Tap on [Settings].
 The following view is displayed:

Fig. 33: Settings | Machine

3. Tap on [Password].
 A dialog for entering the password is displayed.

Fig. 34: Entering the password

4. Enter the password 31415 and tap on [Done].

5. Tap on the pre-set value in the field Avg. plating rate [µm/min].

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Operating the system Contac S4

Fig. 35: Selecting the value

6. Enter the desired value for the copper plating rate (in this example 0.14).

Fig. 36: Entering the value

7. Tap on [Done].
 The modified value is displayed in the field Avg. plating rate [µm/min].

Fig. 37: Value modified

 The copper plating rate has been set.

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Process sequence
This chapter describes the process of copper plating a PCB with subsequent tin
plating.
• Starting the process
• Preparing the PCB
• Conditioning the PCB
• Activating the PCB
• Active cleaning of the PCB
• Copper-plating the PCB
• Tin-plating the PCB
• Switching off the system

 Starting the process

 Open the process view by tapping on .

Fig. 38: Process view

 The first step is displayed.

 The process is started.

 Preparing the PCB

1. Loosen the two screws on the side so far that the PCB can be inserted into the
PCB holder.

Fig. 39: Screws on side

2. Insert the PCB into the PCB holder in such a way that it is aligned to the middle.
3. Tighten the screws on the side until the PCB is safely fastened.
4. Rinse the PCB for at least 30 seconds with water.
You can use clean tap water instead of distilled or de-ionized water.
5. Tap on [OK].

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Operating the system Contac S4

 The process time and the temperature of the bath in tank 1 are displayed.

Fig. 40: Process time and bath temperature

 The PCB has been prepared.

Contaminants at the inside of the PCB holder can impair copper plating. Clean these
surfaces with a coarse sponge and water if necessary.

 Cleaning the PCB

1. Wait until the temperature display shows 50 °C.
2. Remove the cover of tank 1 and put it into the holder slot.

Fig. 41: Holder slots for the covers

3. Insert the PCB into tank 1 so that the pins on the tank's edge fit into the openings
of the PCB holder.
4. Lift the front end of the PCB holder for approx. 3 cm and knock it several times (8
to 10 times) on the frame before setting it down again.
5. Fasten the PCB holder by hand-tightening the knurled screws.

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Fig. 42: Knurled screw

6. Wait until the temperature display shows 50 °C again.

7. Tap on .
 The processing time is counted down.
8. Wait until the time has elapsed.
 The next task is displayed.
9. Loosen the knurled screws of the PCB holder.
10. Remove the PCB from the tank.
11. Place the cover back onto tank 1.
12. Rinse the PCB for at least 30 secondes with water.
 The PCB has been cleaned.

 Conditioning the PCB

1. Remove the cover of tank 2 and put it into the holder slot.
2. Insert the PCB into tank 2 so that the pins on the tank's edge fit into the openings
of the PCB holder.
3. Fasten the PCB holder by hand-tightening the knurled screws.
4. Tap on .
 The processing time is counted down.
5. Wait until the time has elapsed.
6. Loosen the knurled screws of the PCB holder.
7. Remove the PCB from the tank.
8. Place the cover back onto tank 2.
9. Rinse the PCB for at least 30 seconds with water.
10. Using the provided spray bottle (filled with de-ionized water), spray the PCB on
both sides to remove remaining tap water from the drilled holes.

Fig. 43: Spraying the PCB

11. Remove the de-ionized water by knocking on the PCB above a sink.
You can also dry the drilled holes using oil-free compressed air.
 The PCB has been conditioned.

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The following task describes how to remove excess Activator liquid by knocking. If
you have a vacuum table and a nonwoven filter mat, you can use these as a clean
alternative to knocking for removing the excess Activator liquid. For information on
this method refer to page 64.

 Activating the PCB

1. Remove the cover of tank 3 and put it into the holder slot.
2. Insert the PCB into tank 3 so that the pins on the tank's edge fit into the openings
of the PCB holder.
3. Fasten the PCB holder by hand-tightening the knurled screws.
4. Tap on .
 The processing time is counted down.
5. Wait until the time has elapsed.
6. Loosen the knurled screws of the PCB holder.
7. Remove the PCB from the tank.
8. Swipe the Activator liquid from both sides of the PCB using the squeegee and let
the liquid drip back into tank 3.

Fig. 44: Swiping off the Activator liquid

9. Knock on the almost dry PCB above a suitable tank (e.g. a sufficiently large sink)
to remove excess Activator liquid from small drilled holes.
10. Place the cover back onto tank 3.
11. Remove the PCB holder.
12. Dry the PCB in a drying cabinet at 50 °C for 10 minutes.
13. If you are using FR4 material with extra copper foil, remove the foil after drying.
14. Fasten the PCB to the PCB holder.
 The PCB has been activated.

 Active cleaning of the PCB

1. Remove the cover of tank 4 and put it into the holder slot.
2. Insert the PCB into tank 4 so that the pins on the tank's edge fit into the openings
of the PCB holder.
3. Lift the front end of the PCB holder for approx. 3 cm and knock it several times (8
to 10 times) on the frame before setting it down again.
4. Fasten the PCB holder by hand-tightening the knurled screws.
5. Tap on .
 The processing time is counted down.
6. Wait until the time has elapsed.

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7. Loosen the knurled screws of the PCB holder.

8. Remove the PCB from the tank.
9. Place the cover back onto tank 4.
10. Rinse the PCB for at least 30 seconds with water.
 The PCB has been cleaned.

 Copper-plating the PCB

1. Remove the cover of tank 5 and put it into the holder slot.
2. Insert the PCB into tank 5 so that the pins on the tank's edge fit into the openings
of the PCB holder.
3. Lift the front end of the PCB holder for approx. 3 cm and knock it several times (8-
10 times) on the frame before setting it down again.
4. Fasten the PCB holder using the knurled screws.

Notice! Damage by excessive waiting period!

 Stat the process immediately after inserting the PCB into tank 5.

5. Tap on .
 The displayed processing time is counted down.

Fig. 45: Process view of copper plating

6. Wait until the time has elapsed.

7. Loosen the knurled screws of the PCB holder.
8. Remove the PCB from the tank.
9. Let the PCB drip off into tank 5.
10. Using the spray bottle, spray the PCB slightly on both sides above tank 5 and let
the water drip into the tank.
The de-ionized water can be used to compensate evaporation losses.
11. Rinse the PCB for at least 30 seconds with water.
12. Dry the PCB as quick as possible with warm air (e.g. using a hair-dryer).
Dry the PCB as quick as possible to avoid oxidation of the copper.
 The PCB can now be processed further (e.g. using a ProtoMat system).
 The PCB has been copper-plated.

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Operating the system Contac S4

Tin-plating the PCB

Tin-plating of the PCB is optional, but it can be advantageous for further processing
because the tin-plated PCB is protected against corrosion and can be soldered more
easily.
The following PCBs can be tin-plated:
• Unprocessed PCBs
• Through-plated but not milled PCBs
• PCBs milled with an LPKF ProtoMat and through-plated

 Tin-plating the PCB

1. Change to the Tin Plating Profile (see page 52).
2. Open the process view by tapping on .

Fig. 46: Process view

3. Tap on .
4. Rinse the PCB for at least 30 seconds with water.
5. Brush and polish the PCB gently with a non-woven pad or a PCB brushing
machine.
Clean the holes as well to remove possible chips and burrs.
6. Fasten the PCB to the PCB holder if not yet done.
7. Remove the cover of tank 4 and put it into the holder slot.
8. Insert the PCB into tank 4 so that the pins on the tank's edge fit into the openings
of the PCB holder.
9. Lift the front end of the PCB holder for approx. 3 cm and knock it several times (8
to 10 times) on the frame before setting it down again.
10. Fasten the PCB holder by hand-tightening the knurled screws.

Fig. 47: Tin-plating the PCB

11. Tap on .

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 The processing time is counted down.

12. Wait until the time has elapsed.
13. Loosen the knurled screws of the PCB holder.
14. Remove the PCB from the tank.
15. Place the cover back onto tank 4.
16. Rinse the PCB for at least 30 seconds with water.
17. Stir the contents of tank 6 with a fiberglass rod to avoid sedimentation of the
chemicals.
18. Insert the PCB into tank 6 so that the pins on the tank's edge fit into the openings
of the PCB holder.
19. Fasten the PCB holder by hand-tightening the knurled screws.
20. Tap on .
 The processing time is counted down.
The maximum layer thickness of the deposited tin layer is approx. 1 µm. The preset
process duration of 30 minutes should be sufficient to achieve this layer thickness.

21. Loosen the knurled screws of the PCB holder.

22. Remove the PCB from the tank.
23. Rinse the PCB for at least 30 seconds.
24. Rinse the PCB with warm water.
25. Dry the PCB as quick as possible with warm air (e.g. using a hair-dryer).
26. Remove the PCB holder.
 The PCB has been tin-plated.

 Switching off the system

1. Ensure that no PCB is in any of the tanks.
2. Check that all covers are on the tanks and cover the tanks if necessary.
3. Open the menu.

Fig. 48: Menu

4. Tap on [Shutdown] to open the dialog Shutdown.

5. Tap on [YES].
Alternatively, you can shut down the system by pressing the On/Off button for at
least three seconds and swiping across the touch screen from top to bottom.
 The touch screen is switched off and tank 1 is no longer heated.
 The system has been switched off.

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Operating the system Contac S4

6.4 Special tasks

This chapter describes tasks that are not part of the typical production process.
The following tasks are described:
• Creating a new profile
• Editing a profile
• Preparing the vacuum table
• Activating the PCB (using a vacuum table)

 Creating a new profile

1. Tap on .
 The following view is displayed:

Fig. 49: Main menu

2. Tap on [Profiles].
 The following view is displayed:

Fig. 50: Profiles overview

3. Tap on next to an existing profile.

 The following view is displayed:

Fig. 51: Creating a new profile

4. Enter the name for the profile.

5. Enter the dimensions of the PCB.

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Contac S4 Operating the system

Use the profile only for PCBs having the entered dimensions. These are used for
calculating the amperage.
6. Enter the other parameters.
7. Tap on [Save].
 A new profile has been created.

 Editing a profile
1. Tap on .
 The main menu is displayed:

Fig. 52: Main menu

2. Select [Profiles].
 The profile overview is displayed:

Fig. 53: Profile overview

3. Tap on next to the profile to be edited.

The default profiles cannot be edited. The icon cannot be selected for these
profiles.
 The profile view is displayed:

Fig. 54: Profile view

4. Edit the parameters of the profile.

5. Confirm your entries by tapping on [Save].
 The profile has been edited.

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Operating the system Contac S4

 Preparing the vacuum table

Ensure that the following prerequisites are met before performing the described tasks:

Spare parts and auxiliary supplies

• Vacuum table (not included in the scope of delivery)
• Nonwoven mat (not included in the scope of delivery)

1. Connect the extraction hose of an extraction system to the vacuum table.

2. Fasten a new nonwoven mat onto the vacuum table if necessary.

Fig. 55: Vacuum table with nonwoven mat

 The vacuum table has been prepared.

 Activating the PCB (using a vacuum table)

You can also remove excessive Activator 310 using a vacuum table instead of the
knock method. This is simpler and cleaner but requires a vacuum table and a
nonwoven filter mat.
1. Remove the cover of tank 3 and put it into the holder slot.
2. Insert the PCB into tank 3 so that the pins on the tank's edge fit into the openings
of the PCB holder.
3. Fasten the PCB holder using the knurled screws.
4. Tap on .
 The displayed processing time is counted down.
5. Wait until the time has elapsed.
6. Loosen the knurled screws of the PCB holder.
7. Remove the PCB from the tank.
8. Swipe the Activator liquid from both sides of the PCB using the provided squeegee
and let the liquid drip back into tank 3.
If you are through-hole plating a PCB without extra copper foil, you have to use a
squeegee with rubber blade to remove the Activator liquid. You can thus swipe the
liquid from the PCB without removing it from the drilled holes.

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9. Place the PCB onto the vacuum table.

Fig. 56: Vacuum table with PCB

10. Start the extraction system and wait for approx. 30 seconds.
11. Switch off the extraction system.
12. Turn the PCB over.
13. Start the extraction system and wait for approx. 30 seconds.
14. Switch off the extraction system.
 The excess Activator liquid has been removed.
15. Remove the PCB from the vacuum table.
16. Place the cover back onto tank 3.
17. Remove the PCB holder.
18. Dry the PCB in a drying cabinet at 50 °C for 10 minutes.
19. If you are using FR4 material with extra copper foil, remove the foil after drying.
20. Fasten the PCB to the PCB holder.
 The PCB has been activated.

Once the PCB has been activated you can proceed to the phase for active cleaning of
the drill holes on page 58.

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Maintenance Contac S4

7 Maintenance
This chapter contains important information on the maintenance of the system.
Proper maintenance and proper handling of the components, e.g. the PCB holders,
are basic requirements for flawless functioning of the system.
Maintenance has to be performed and documented regularly according the
instructions of the manufacturer.
The system is designed for a service life of 5 years of one-shift operation (10 hours
per day). The specific maintenance intervals are valid for one-shift operation at 5 days
a week.

7.1 Safety
Follow the safety instructions below for your own protection and for the protection of
other persons in the vicinity of the maintenance work. The maintenance personnel
must ensure that the described prerequisites for the planned maintenance tasks are
fulfilled and they must observe the special warning messages for the individual
maintenance tasks.
Contact the LPKF Service for maintenance or repair tasks that go beyond the tasks
described in the maintenance schedule for the maintenance personnel of the operator.

DANGER
Danger to life by electrical shock!
Any physical contact to energized components or cables can cause death by
electrical shock and/or fire.
 Disconnect the system from the mains supply before performing maintenance
tasks.

WARNING
Health hazard by contact with chemicals!
Contact with the chemicals can cause serious damage to health:
Inhaling can irritate nose, throat and lungs and can cause allergic respiratory
problems.
Skin contact can cause chemical burns, allergies, and hypersensitivity.
Eye contact can irritate the eyes and mucous membranes with burning and tears
and can cause impaired vision and serious eye damage.
Ingestion can cause chemical burns of the mucous membranes, throat,
esophagus, and stomach and can cause gastrointestinal complaints.
 Read the provided safety data sheets carefully.
 Work in well-ventilated rooms.
 Wear your personal protective equipment.
 Avoid direct contact with the chemicals.
 Take off contaminated clothes immediately.
 Wash your hands thoroughly after work.

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NOTICE
Property damage by contamination of the activation bath!
The activation bath is very sensitive to contaminants and can become unusable if
even slightly contaminated.
 Avoid any contamination of the activation bath.
 Always cover the activation tank when not in use.
 Never compensate evaporation losses with water. Replenish with Activator 310
up to the mark.

NOTICE
Property damage by spilled liquids!
Spilling liquids over electrical components can cause a short circuit.
 Switch the system off and disconnect it from the power supply.
 Remove the liquid with dry paper towels.
 If Copper Plater 400 has been spilled, contact the LPKF Service.
 Let the system dry at room temperature, at least one day before the next start.

7.2 Maintenance schedule

The following table lists the maintenance tasks that are to be performed by personnel
trained for these tasks.

Maintenance schedule for the maintenance personnel of the operator

Component/ Interval Task to be performed Remark
Assembly
System Daily to weekly Clean the system. Use a sponge and
water to clean the
housing.
Perforated plate Daily to weekly Clean the perforated Disconnect the system
plate with the main from the power supply.
switch For cleaning use a
slightly damp cloth.
PCB holder If necessary Remove the copper layer Hang the PCB holder
(without PCB) into
tank 4 for several
hours.
Tank 3 After non-usage Stir contents with glass Any foam created by
(Activation) (≥ 1 day) fiber rod for 2 to 3 stirring has to dissolve
minutes. before using the bath.
Tank 6 (Tin When bath is spent Replenish Electroless The bath is spent after
plating) Tin Liquid 8 to 10 PCBs of A4
form factor.
See page 73.
Tank 5 (copper Weekly Check visually for copper Put crystals back into
plating) sulphate crystals. tank 5.
Tank 5 After 100 ampere hours Add Shine See page 72.
(Copper plating)
Tank 5 Every 3 weeks Filter tank 5. See page 70.
(Copper plating)

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Maintenance Contac S4

Component/ Interval Task to be performed Remark

Assembly
Tank 1 Every 3 months or in Replace Cleaner 110. Empty the tank
(Cleaning) case of significant color completely and refill.
change
Tank 2 Every 3 months or in Replace Cleaner 210. Empty the tank
(Conditioning) case of significant color completely and refill.
change
Tank 3 Yearly or after Replace Activator 310. Empty the tank
(Activation) malfunction of the bath. completely and refill.
Tank 5 Yearly Replace Copper Plater Empty the tank
(Copper plating) 400. completely and refill.
Tank 6 (Tin Yearly Replace Electroless Tin Empty the tank
plating) Liquid. completely and refill.
Tank 6 For times of prolonged Fill the bath into a This prevents
(Tin plating) non-usage nonmetal jerry can. oxidization of the bath.
Fuse When necessary Replace fuse See page 74.
Table 8: Maintenance schedule for the maintenance personnel of the operator

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Contac S4 Maintenance

7.3 Maintenance tasks for the maintenance personnel of the

operator
This chapter describes in detail the individual maintenance tasks that the maintenance
personnel of the operating company may perform.

 Draining a tank

Prerequisites Spare parts and auxiliary supplies

• Bath 1 has cooled down (before draining • Tube
tank 1).
• The floating balls have been removed • Jerry can
(before emptying tank 5).
• The system is switched off.
1. Remove the cover from the front of the system.

Fig. 57: Cover for drain valves

2. Attach the tube to the relevant drain valve.

Fig. 58: Drain valves

1 Tank 1 (Cleaner 110) 4 Tank 4 (ViaCleaner Part 1 & 2)
2 Tank 2 (Cleaner 210) 5 Tank 5 (Copper Plater 400 & Shine 410)
3 Tank 3 (Activator 310) 6 Tank 6 (Electroless Tin Liquid)

3. Insert the other end of the tube into a jerry can.

Use the original jerry can if the chemical was delivered in a jerry can.

4. Turn the lever of the valve to the front.

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Maintenance Contac S4

Fig. 59: Turning the lever of the valve

 The contents of the tank drains into the jerry can.

5. Wait until the liquid has drained completely.
6. Turn the lever of the valve to the right.
7. Push on the ring of the valve and pull out the tube.

Fig. 60: Ring on drain valve

8. Repeat the steps 2 to 7 for all tanks you want to drain.

9. Fasten the cover to the front of the system.
 The tank has been drained.

 Filtering Copper Plater 400

Prerequisites Spare parts and auxiliary supplies

• Visible suspended particles or • Jerry can
contaminants in tank 5 • Tube
• The system is switched off. • Fuel filter (alternatively several coffee
filters or a folded filter paper)
• Copper Plater 400
• De-ionized water

1. Remove the cover from the front of the system.

2. Attach the tube to the drain valve of tank 5.
3. Attach the fuel filter at the other end of the tube.
4. Insert the end of the tube into a jerry can.

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Contac S4 Maintenance

Fig. 61: Filtering Copper Plater 400

5. Turn the lever of the valve to the front.

 The contents of the tank drains into the jerry can.
6. Wait until approx. 5 liters of the tank's content have drained.
It is sufficient to filter this partial amount because the contaminants accumulate at the
bottom of the tank and are already flushed out with this amount. If suspended
particles or contaminants occur at the surface of the tank, the whole contents of the
tank have to be filtered.

7. Close the valve.

Instead of using a fuel filter you can also use several stacked coffee filters or a folded
filter paper.

8. Pour the filtered liquid back into tank 5.

9. Fill up tank 5 with Copper Plater 400 up to the mark.
10. Moisten a cloth with de-ionized water.
11. Wipe the rim of the tank with the cloth.
12. Place the cover back onto tank 5.
13. Switch on the system (see page 51).
14. Tap on .
15. Tap on [Settings].
16. Select the tab Service.

Fig. 62: Settings | Service

17. In the line Copper plating filter tap on [Reset].

 The remaining time is reset.
 Copper Plater 400 has been filtered.

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Maintenance Contac S4

 Add Shine

Prerequisites Spare parts and auxiliary supplies

• 100 ampere hours have been used since • Shine 410
the last replenishment • Dummy board
• The system is switched on.

1. Finish the current plating process with all pending steps.

2. Tap on .
3. Tap on [Settings].
4. Select the tab Service.

Fig. 63: Settings | Service

5. In the line Shine tap on [Service].

6. Add 17 ml of Shine 410 to tank 5.
7. Re-initialize the system with a dummy board (9" x 12"). Use the following
parameters:
− Tank 1: 15 minutes
− Tank 2: 5 minutes
− Tank 5: 90 minutes at 10 A; RPP off
 The remaining time is reset.
 Shine has been added.

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Contac S4 Maintenance

 Replenish Electroless Tin Liquid

Prerequisites Spare parts and auxiliary supplies

• Tin-plating bath is spent. • Electroless Tin Liquid (5 liters)
• Jerry can (non-metal)
• Tube
• De-ionized water

1. Remove the cover from the front of the system.

2. Attach the tube to the valve of tank 6.

Fig. 64: Drain valve of tank 6

3. Insert the other end of the tube into a clean, dry non-metal jerry can.
4. Turn the lever of the valve to the front.
 The contents of the tank drains into the jerry can.
5. Wait until the liquid has drained completely.
6. Close the valve.
7. Push on the ring of the valve and pull out the tube.

Fig. 65: Ring on drain valve

8. Attach the cover to the front of the system.

9. Remove the cover of tank 6 and put it into the holder slot.
10. Fill tank 6 with new Electroless Tin Liquid up to the mark.
11. Place the cover back onto tank 6.
12. Start the system (see page 51).
13. Tap on .
14. Tap on [Settings].

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Maintenance Contac S4

15. Select the tab Service.

Fig. 66: Settings | Service

16. In the line Tin plating tap on [Reset].

 The remaining time is reset.
 Electroless Tin Liquid has been replenished.

 Replacing the fuse

Prerequisites Spare parts

• The fuse is damaged. • Fuse: ESKA UL 522.226
Type: Slow blow fuses
Dimensions: 5 x 20 mm
Rated voltage: 250 V AC
Rated current: 8 A

1. Switch the main switch to O (off).

Fig. 67: Main switch off

 The system is switched off.

2. Disconnect the mains cable from the connector of the power supply.
 The system is disconnected from the power supply.
3. Press the locks of the cap on both sides simultaneously inwards.

Fig. 68: Pressing the locks together

4. Pull out the cap with the fuse.

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Fig. 69: Pulling the cap out

5. Replace the damaged fuse inside the cap with the new fuse.

Fig. 70: Fuse

6. Reinsert the cap.

Ensure that the locks are engaged.
7. Reconnect the mains cable with the connector of the power supply.
 The fuse has been replaced.

If the problem is not solved after replacing the fuse, contact the LPKF Service.

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Troubleshooting Contac S4

8 Troubleshooting
This chapter contains an overview of possible faults and measures for
troubleshooting.
If faults occur that cannot be eliminated by the following messages contact the
LPKF Service.

8.1 Fault display

Errors and pending maintenance tasks are displayed as messages on the user
interface.

Fig. 71: Error message

Remedy the displayed error and acknowledge the message by tapping on [OK]. If you
have any questions contact the LPKF Service.

8.2 Fault table

The following table contains possible faults and proposals how to clear them.

Fault Possible cause Remedy

Note
Bath 1 remains at room Immersion heaters or fuse Switch off the system and
temperature for heaters are defective. contact the LPKF Service.
Active cleaning liquid does not ViaCleaner Part 1 and Part Drain the active cleaning liquid
turn blue. 2 are not properly mixed. into a 5l canister and add
ViaCleaner Part 2. Mix the
solution thoroughly and pour
back into the tank.
Dispose of the current active
cleaning liquid.
Fill ViaCleaner Part 1 and 2 into
the 5l canister, Mix the solution
thoroughly and pour into the
tank.
Copper particles on the Copper particles are Drain tank 5 completely and
surface of the PCB dispersed in the plating bath clean it, filter the bath (see page
(tank 5). 69).
System cannot be switched No connection to power Check the mains plug.
on. supply.
Fuse damaged Replacing the fuse (see page
74).
Internal defect Switch off the system and
contact the LPKF Service.
Table 9: Troubleshooting

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Contac S4 Disassembly and disposal

9 Disassembly and disposal

This chapter describes the disassembly and the disposal of the system.
The following tasks may only be performed by the maintenance personnel of the
operator.

9.1 Safety

WARNING
Health hazard by contact with chemicals!
Contact with the chemicals can cause serious damage to health:
Inhaling can irritate nose, throat and lungs and can cause allergic respiratory
problems.
Skin contact can cause chemical burns, allergies, and hypersensitivity.
Eye contact can irritate the eyes and mucous membranes with burning and tears
and can cause impaired vision and serious eye damage.
Ingestion can cause chemical burns of the mucous membranes, throat,
esophagus, and stomach and can cause gastrointestinal complaints.
 Read the provided safety data sheets carefully.
 Work in well-ventilated rooms.
 Wear your personal protective equipment.
 Avoid direct contact with the chemicals.
 Take off contaminated clothes immediately.
 Wash your hands thoroughly after work.

NOTICE
Environmental hazard by improper disposal of the system!
Improper disposal of the system can cause hazards to the environment.
 Dispose of the system properly or contact the LPKF Service.

9.2 Preparations
The system has to be prepared as follows before disassembly and disposal:
• Switch off the system.
• Disconnect the system from the power supply.
• Wait until bath 1 has cooled down.

9.3 Proper disposal of the chemicals

For information on proper disposal of the chemicals refer to the included safety data
sheets.

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Disassembly and disposal Contac S4

9.4 Disposing of the system

The system is disassembled as follows:

 Uninstalling the system

1. Drain the tanks separately (see page 69).
Use the original containers of the chemicals if on hand except for Electroless Tin
Liquid. Use a clean, dry, and non-metal canister for Electroless Tin Liquid.
2. Rinse the tanks thoroughly.
3. Rinse tank 3 with distilled water or de-ionized water once more.
4. Remove the anodes with the anode bags from tank 5.
5. Remove the anodes from the anode bags.
6. Rinse the anodes and anode bags.
7. Brush the anodes with a plastic brush until shiny.
8. Dry the anodes and anode bags.
The anodes and anode bags may have to be replaced, depending on their
condition.
9. Dry the tanks.
 The system has been uninstalled.

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10 Appendix
This chapter contains navigation elements of the document.

10.1 List of figures

Fig. 1: Tank covers ................................................................................................ 19
Fig. 2: Fuse ............................................................................................................ 19
Fig. 3: Dog-bone effect .......................................................................................... 24
Fig. 4: Type label ................................................................................................... 26
Fig. 5: System overview ........................................................................................ 27
Fig. 6: Touch screen .............................................................................................. 28
Fig. 7: PCB holder ................................................................................................. 29
Fig. 8: Connectors ................................................................................................. 30
Fig. 9: Touch screen .............................................................................................. 31
Fig. 10: User interface ............................................................................................. 32
Fig. 11: Profile view ................................................................................................. 33
Fig. 12: Recessed grip............................................................................................. 35
Fig. 13: System dimensions - front view .................................................................. 40
Fig. 14: System dimensions - top view .................................................................... 41
Fig. 15: Copper anode in bag .................................................................................. 42
Fig. 16: Gray pins .................................................................................................... 42
Fig. 17: Installing the copper anodes ...................................................................... 43
Fig. 18: Fastening the anode to the titan bracket .................................................... 43
Fig. 19: Power supply .............................................................................................. 46
Fig. 20: Mains cable plugged into appliance inlet.................................................... 46
Fig. 21: Mains cable plugged into wall socket ......................................................... 46
Fig. 22: Main switch On ........................................................................................... 47
Fig. 23: On/Off button .............................................................................................. 47
Fig. 24: Main menu .................................................................................................. 47
Fig. 25: Settings | General ....................................................................................... 48
Fig. 26: Settings | Service ........................................................................................ 48
Fig. 27: Main switch On ........................................................................................... 51
Fig. 28: On/Off button .............................................................................................. 51
Fig. 29: Process view .............................................................................................. 51
Fig. 30: Main menu .................................................................................................. 52
Fig. 31: Profiles overview ........................................................................................ 52
Fig. 32: Main menu .................................................................................................. 53
Fig. 33: Settings | Machine ...................................................................................... 53
Fig. 34: Entering the password ................................................................................ 53
Fig. 35: Selecting the value ..................................................................................... 54
Fig. 36: Entering the value....................................................................................... 54
Fig. 37: Value modified ............................................................................................ 54
Fig. 38: Process view .............................................................................................. 55
Fig. 39: Screws on side ........................................................................................... 55
Fig. 40: Process time and bath temperature ........................................................... 56
Fig. 41: Holder slots for the covers .......................................................................... 56
Fig. 42: Knurled screw ............................................................................................. 57
Fig. 43: Spraying the PCB ....................................................................................... 57
Fig. 44: Swiping off the Activator liquid ................................................................... 58
Fig. 45: Process view of copper plating ................................................................... 59
Fig. 46: Process view .............................................................................................. 60
Fig. 47: Tin-plating the PCB .................................................................................... 60
Fig. 48: Menu ........................................................................................................... 61
Fig. 49: Main menu .................................................................................................. 62
Fig. 50: Profiles overview ........................................................................................ 62
Fig. 51: Creating a new profile ................................................................................ 62

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Appendix Contac S4

Fig. 52: Main menu .................................................................................................. 63

Fig. 53: Profile overview .......................................................................................... 63
Fig. 54: Profile view ................................................................................................. 63
Fig. 55: Vacuum table with nonwoven mat .............................................................. 64
Fig. 56: Vacuum table with PCB .............................................................................. 65
Fig. 57: Cover for drain valves ................................................................................ 69
Fig. 58: Drain valves ................................................................................................ 69
Fig. 59: Turning the lever of the valve ..................................................................... 70
Fig. 60: Ring on drain valve ..................................................................................... 70
Fig. 61: Filtering Copper Plater 400 ........................................................................ 71
Fig. 62: Settings | Service ........................................................................................ 71
Fig. 63: Settings | Service ........................................................................................ 72
Fig. 64: Drain valve of tank 6 ................................................................................... 73
Fig. 65: Ring on drain valve ..................................................................................... 73
Fig. 66: Settings | Service ........................................................................................ 74
Fig. 67: Main switch off ............................................................................................ 74
Fig. 68: Pressing the locks together ........................................................................ 74
Fig. 69: Pulling the cap out ...................................................................................... 75
Fig. 70: Fuse ............................................................................................................ 75
Fig. 71: Error message ............................................................................................ 76
Fig. 72: EC Declaration of conformity ...................................................................... 82

10.2 List of tables

Table 1: Safety devices ............................................................................................ 19
Table 2: Type label ................................................................................................... 26
Table 3: Tank overview ............................................................................................ 28
Table 4: Consumables .............................................................................................. 29
Table 5: Profile parameters ...................................................................................... 33
Table 6: Profiles overview ........................................................................................ 34
Table 7: Air exchange depending on window position ............................................. 39
Table 8: Maintenance schedule for the maintenance personnel of the operator ..... 68
Table 9: Troubleshooting .......................................................................................... 76

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10.3 Index
climatic conditions ........................ 39
B connections provided by the
brief description ................................ 23 customer ....................................... 41
floor ............................................... 41
C minimum required space .............. 40
chemical-resistant gloves ................ 17
customer service ................................ 7 S
safety devices .................................. 19
F safety signs ...................................... 17
fault table ......................................... 78 service personnel ............................. 16
first startup ....................................... 38 special tasks ..................................... 64
Splash goggles ................................. 17
L system
limited liability ..................................... 6 disposing of .................................. 80
list of figures ..................................... 81 system components ......................... 27
list of tables ...................................... 82
LPKF Service ..................................... 7 T
Technical data
O Climatic conditions .................. 22, 39
operating personnel ......................... 17 Electrical data ......................... 22, 41
Emissions ..................................... 22
P General data ................................. 22
Mechanical data ........................... 22
packaging
Process data ................................. 22
symbols on the packaging ............ 37
transporting the system .................... 34
protective gloves .............................. 17
typical production process ............... 50
Q W
qualified electrician .......................... 16
warranty ............................................. 6
R
requirements of the place of
installation ........................................ 39

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Appendix Contac S4

10.4 EC Declaration of conformity

Fig. 72: EC Declaration of conformity

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