Peter:
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I'm using the setting Caswell Europe suggest (0.14A & 90F)
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In that case, there is a major discrepancy between UK & US instructions. I strongly suggest you contact Caswell technical support and get the numbers sorted out definitively. I do not have Caswell Europe manual, so don't know how to advise you further.
However, I have visited
Caswell UK web site, and it appears to have contradictory information:
They claim it is the "new formula", but specify 30ºC & 25 mA/sq-in, which are the figures from the
OLD formula.
The kit is supplied with "Copy Cad/Zinc Crystals with Activator (New Formulation)". There is no "activator" used in the US kit, so it may be that the chemicals are significantly different. If that is the case, then my advise may be worthless. Contact Caswell technical support and sort it out.
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It took at least 5 minutes for the acid dip to remove this layer.
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That's clearly too long, it shouldn't take more than a few seconds. So something is definitely amiss.
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no one else mentions having to do so much work to reach the plating.
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Once you've got the process worked out, it is not hard at all, and you should not be having these difficulties.
If you do suspect contamination of the electrolyte, filter it and try again. But in any case, contact Caswell & get the numbers sorted out.
Sean