Electroless Copper Plating Line purchase description.pdf

ELECTROLESS COPPER PLATING SYSTEM

FY11

Statement of Work/Purchase Description

1. SCOPE

The Electroless Copper Plating System is a hoist driven, programmable, wet process system designed for use with Atotech chemistry for printed circuit board manufacturing. The Atotech Noviganth Electroless Copper line of chemicals is a proven process which has been used by the Government for approximately twenty years. This statement of work outlines the requirements for the procurement of an Electroless Copper Plating System, Turn-Key Installation.

2. REQUIREMENTS

STEP TYPICAL TIME TEMP (F)

Load - - - - Glass Etch 30-45s 125 Rinse 1 1-2m RT Cleaner 10 120 CF Rinse 2 A,B 1-2 RT Micro Etch 2 80 CF Rinse 3 A,B 1-2 RT Pre-Dip 1 72 Activator 5 104 CF Rinse 4 A,B 1-2 RT Reducer 3 86 Reducer – dilute 1 86 Electroless Cu 1 15-45 80 Electroless Cu 2 15-45 80 CF Rinse 5 A,B 1-2 RT Sulfuric Acid 1 RT Rinse 6 1-3 RT Multibond SO B Activator 2 135 Multibond SO Oxide 2 150 CF Rinse 7 A,B 1-3 RT Dry 10 160 Unload - - - -

TECHNICAL

Construction - The System shall be fabricated from durable non-pigment polypropylene with stainless steel fasteners. All framework shall be corrosion resistant steel. All pressure piping shall be S-80 PVC. All drain piping, S-40 PVC.

Panel Size – The maximum panel size for the basket and tank design is 18 x 24 in. The smallest panel to be processed is anticipated to be 10 x 10 in. Typical panel is 16 x 18 inches. Panel thickness is anticipated to range from .003 to .140 in.

Material Handling - The System required provides the capability for processing one set of 8 panels (18 x 24 in max.)

in stainless steel baskets. Each basket should hold 8 panels (18 x 24 in.) on 1/2 inch centers. The Government must approve the basket design prior to construction. Six (6) baskets are required with the system.

Automatic Hoist - The hoist system shall be designed such that all placement of ventilation ducts, process piping and electrical conduit will be confined within the hoist footprint. The hoist shall be fabricated from corrosion resistant steel, capable of supporting the weight and properly conveying six fully loaded baskets.

Load/Unload - The Load and Unload stations must be located at the same end of the System. The Load and Unload station shall include 4 carts. Baskets will be placed into and removed from the cart by the hoist. The carts shall be front loaded into individual docking stations. Carts must be able to be removed from the docking station for offline loading and unloading of the baskets. Sensors shall be provided to detect cart and basket presence.

Electroless Copper Tank - Each station shall consist of a single cell tank and be constructed from polypropylene.

The tank shall be equipped with an overflow weir through a filter (bag type). A pump shall be provided to force overflow over the weir and through the filter bag.

An air sparger shall be provided for customer hook-up to low pressure air. Air shall be sparged into both the process area of the tank as well as the filter area.

Dryer - The dryer must utilize electric heat with a rapid recovery design permitting the dryer to be turned ON only when a basket is in the dryer. This quick recovery design reduces energy cost by turning off the dryer when it is not in use. The dryer shall be fabricated from stainless steel and be internally ducted to pass hot air over the basket.

Dryer motors shall be located externally to assure cool motor operation. Exterior walls must be insulated to conserve energy and to provide operator safety.

CF Rinses - Rinses shall feature air agitation and counter flow to form cascade rinsing. Water shall be supplied to the rinse tank by a computer controlled valve to minimize usage.

The water ON time at each rinse tank shall be programmable such that water turns ON when a basket enters the tank and turns OFF at the end of the programmed time.

Tank Material - All tanks shall be fabricated from polypropylene with individual tank construction determined by process operating temperatures. Room temperature tanks (RT) shall be fabricated from 1/2 inch PP. Heated Tanks over 130F shall be fabricated from 3/4 PP.

Tank Size - Listed below are the ID tank sizes. (Typical inside dimensions are shown):

Station L W D Process Tanks 40 12 36 Rinses 40 12 36 CF Rinses A,B 40 25 36 Electroless Copper 40 18 36

Note: Tank length (40 in.) is comprised of a process zone = 19 in., basket clearance = 6 in. and support zone = 15

in. The support zone provides space for heaters, pumps, filters, etc. Other dimensions will be considered if proven to work with a fully loaded basket as specified earlier.

Tank Drains - All tanks shall be provided with drains and valves . Tanks shall have bottoms which slope to the drain.

Filtration: The following processes must be filtered as indicated. The filter shall accommodate standard filter cartridges which are locally available. The filter outlet shall be fitted with an eductor for improved tank agitation and mixing.

Process Type Approx. Turns/Hr.

Glass Etch Cartridge 3-5 Cleaner Cartridge 3-5 Micro Etch Cartridge 3-5 Pre-Dip Cartridge 3-5 Activator Cartridge 3-5 Reducer Cartridge 3-5 Electroless Cu (2) Bag 5-7

Multibond Oxide Cartridge 3-5

Pumps – the following tanks shall be equipped with vertical in-tank process pumps:

Process Tank Size Material Function

Glass Etch ¼ PP Filter Pump Cleaner ¼ PP Filter Pump Micro Etch ¼ PP Filter Pump Pre-Dip ¼ PP Filter Pump Activator ¼ PP Filter Pump Reducer ¼ PP Filter Pump Copper 1,2 ½ PP Filter Pump Multibond B ¼ PP Filter Pump Multibond Oxide ¼ PP Filter Pump

Agitation - Mechanical agitation (work rod) must be provided along the full length of the machine (except dryer).

The agitation stroke shall be +/- 1 inch and the frequency adjustable (0–8 rpm). The following chart lists additional agitation methods to be used in the System:

Process Agitation Method All Filtered Processes Solution CF Rinses Air Single Rinses Air Electroless Cu Air, Solution

NOTE: The air agitation must be plumbed such that the air to any individual tank may be turned off without turning off the air to all the tanks. Each air – filtered station must have its own air shut-off valve.

Vibration – The following chemical process tanks shall include basket vibration. The vibration must be pneumatic and include a pressure regulator to provide frequency and amplitude adjustment. Vibration shall be automatically controlled by the PLC system to provide programmable ON and OFF cycles.

Glass Etch Cleaner

Micro Etch Activator Electroless Copper 1,2 Multibond Oxide

Process Heat - Electric immersion heaters shall be used. All process tanks with electric immersion heaters must be provided with an indicating digital temperature controller (+/- 1 F). Heaters must be internally fused for overheat protection and interlocked to the liquid level. A low liquid level must be provided to turn OFF heater operation and turn ON an alarm to indicate the fault.

Heated Process Material Power (KW) Glass Etch Teflon 4 Cleaner Quartz, Porcelain, PTFE 4 Micro Etch Quartz, PTFE 2 Pre-Dip Quartz, Porcelain, PTFE 2 Activator Quartz, Porcelain, PTFE 2 E'less Copper (2) Quartz, Porcelain, PTFE 3 Multibond B Teflon, Stainless Steel, or Titanium 4 Multbond Oxide Teflon, Stainless Steel, or Titanium 6 Reducer Quartz, Porcelain, PTFE 2

Ventilation - Ventilation shall be provided for all chemical process tanks on the system. The Industrial Ventilation Handbook guidelines must be used for the system design. The main system duct shall run the full length of the system, terminating with a transition for Government hookup Government supplied plant ventilation system.

Drip Covers – There shall be provided a drip cover between tanks. The drip covers serve to assist the ventilation system by providing a ducted air path.

Piping & Valves- All piping on the system shall be PVC. Pressure lines must be S80 PVC and Drain lines, S40 PVC. All liquid valves on the system shall be ball valves with Viton seals.

DI Water Supply - The DI rinse tanks will be connected to a DI supply line.

Low Pressure Air Piping – Copper and CF Rinse tanks shall be connected to low pressure air piping (S40 PVC).

Each tank connection includes a throttling valve.

Drain Lines – Multiple drain lines shall be provided. The Government will specify the rinse tank and drain line assignment.

Controls – System controls shall feature a PLC and color Touchscreen operator interface. The touchscreen must provides control over all components. Alarms must be displayed as they occur with corrective action information.

Control Panel - A free standing NEMA 12 industrial control enclosure shall be used to house all system control components. The control panel shall contain UL listed components.

Electrical Components - Electrical enclosures on the machine shall be non-metallic for corrosion resistance.

Temperature Control - Temperature controllers shall be digital, with visual and audible alarms. Temperature control shall be located on the PLC touchscreen. Temperatures must be monitored for alarm when outside of operation range and sensor failure.

Liquid Level Control - Liquid level controls shall be the float type with visual and audible alarms. They shall be provided for all heated tanks.

Alarms – All alarms must be displayed on the touchscreen. Alarm type and corrective action information must be displayed for operator reference. Visual indication of an alarm shall be provided via a light stick placed on the top of the main control panel. Audible annunciation shall be with a horn and acknowledge switch.

Tank Identification – All tanks shall be labeled with the process name.

Foot Print - The System shall be shipped as modules to be assembled on site. The following are the maximum overall dimensions.

Length = 42 ft.

Width = 6.5 ft.

Height = 9.5 ft.

Utilities - The System requires power, water, air, ventilation and drain for operation with final details To Be Determined (TBD) upon completion of System engineering.

Power: 460 VAC, Amps TBD, 60 Hz, 3 PH City Water: TBD gpm, est.

DI Water: gpm TBD, customer option Ventilation: TBD cfm Pressure Air: Blower is included Compressed Air: TBD cfm @ 80 psi Drains: PVC pipe, gravity, vented

Documentation - The following documentation shall be provided:

System Manual:

Control Synopsis Piping Schematic (PI&C), final Layout Drawing, final Electrical Schematics, final

Maintenance Schedules Troubleshooting Bill of Material

Timeway Charts

3.0 SERVICES REQUIRED

3.1 Of the Government:

402 EMXG/MXVD shall provide support and approval/disapproval of work, and compliance with site preparation requirements as required for installation.

3.2 Of the Contractor:

CONTROLLED AREA REQUIRMENTS

1. This project involves work in a controlled area, and contractors must be US citizens and must register at Building 624 (Avionics Visitor Control Center) upon any entrance or exit of the Avionics complex. Escorts are not required for contractors during normal working hours. Any contractor remaining in the Avionics Complex after normal working hours will be in violation of security policy if proper permission is not obtained from the 402 EMXG Security Manager. Alternative work times may be discussed with 402 EMXSS/MXDEAA.

2. All contractors shall obtain proper contractor’s badge from Robins Air Force Base Pass and ID Unit and shall present a picture ID to Visitor Control Center personnel prior to each entry to the Avionics Complex.

3. Visit Authorization Letters are required for all contractor visitors. They must be furnished at least 24 hours prior to the visit. Requests must be in writing (mail, Teletype or fax) from the Contractor on company letterhead or company form to the Visitor Control Center. The following information must be received in sufficient time for review prior to the visit:

Address to: 402 EMXSS/MXDSAA

VISITOR CONTROL CENTER

420 Richard Ray Blvd, STE 100

ROBINS AFB GA 31098-1640

(478) 926-3653--FAX (478) 926-2004

a. Full Name of Contractor Personnel

b. Date of Birth

c. Place of Birth

d. Job Title

e. Citizenship

f. Security Clearance Level, Date and Issuing Agency

g. Avionics Complex Personnel to be visited (Not the Security Manager)

h. Existing Contract Number

i. Purpose of Visit

j. Date and Duration of Visit (Not to Exceed One Year)

k. Contractor Security Officer Name and Signature, Address, Phone Number

HOURS OF SERVICE

The contractor shall provide service during the hours of 0600-1400 EST, Monday through Friday excluding government holidays, at the government’s facility at the following location:

569 EMXS/MXDPA

Building 640 Corner of 9th Street & Page Road Robins AFB GA 31098-1638

The service visit shall include installation of equipment with instructions and demonstrations for operating and maintaining the electroless copper plating system.

4.0 SCHEDULE

The desired completion date for installation service shall be NLT 365 calendar days after receipt of order.

5.0 GOVERNMENT POINTS OF CONTACT (POCs)

POC: The Administrative Contracting Officer or designated representative.