LPKF ProtoMat E34 User manual

ProtoMat E34/E44
User manual
Order code: 10053639
Version: 1.0

Publisher
LPKF Laser & Electronics AG
Osteriede 7
30827 Garbsen
Germany
Phone: [phone]
Fax: [phone]
Email: [email protected]
Date of issue
2016-03-07
Copyright
© 2016 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

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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 have 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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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!
 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.
 Measure 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.
 Measure to avoid the hazard.

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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.
 Measure to avoid the hazard.
NOTICE
Type and source of the hazard!
This warning message indicates a hazard that can lead to possible property
damage.
 Measure 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.
2.
3.
Indication of a sorted list of steps. The specified order must be
observed.
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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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.
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.
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.

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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
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.
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
[email protected]
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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Contents
1Safety ...................................................................................................................11
1.1 Intended use ................................................................................................11
1.2 Residual risks ...............................................................................................12
1.3 Basic hazards ..............................................................................................12
1.4 Responsibility of the operator ......................................................................14
1.5 Personnel requirements ...............................................................................15
1.6 Personal protective equipment ....................................................................16
1.7 Safety signs .................................................................................................17
1.8 Actions in case of an emergency .................................................................17
1.9 Environmental protection .............................................................................18
2Technical data .....................................................................................................19
3Structure and function .......................................................................................20
3.1 Brief description ...........................................................................................20
3.2 Scope of delivery .........................................................................................20
3.3 Type label ....................................................................................................22
3.4 System components ....................................................................................23
3.4.1 Total view .......................................................................................23
3.4.2 Processing head ............................................................................23
3.4.3 Processing table .............................................................................24
3.4.4 Vision system .................................................................................24
3.5 Optional modules, accessories, extras ........................................................25
3.6 Connections .................................................................................................26
3.7 Displays and control elements .....................................................................28
3.8 Software .......................................................................................................29
3.9 Modes of operation ......................................................................................30
4Transport and storage .......................................................................................31
4.1 Transport inspection ....................................................................................31
4.2 Transport ......................................................................................................31
4.3 Storage.........................................................................................................32
4.4 Packaging ....................................................................................................32
4.4.1 Handling packaging material ..........................................................32
4.4.2 Symbols on the packaging .............................................................33
5First startup .........................................................................................................34
5.1 Safety ...........................................................................................................34
5.2 Requirements of the place of installation .....................................................34
5.2.1 Climatic conditions .........................................................................34
5.2.2 Minimum required space ................................................................35
5.2.3 Workplace of the operating personnel ...........................................36
5.2.4 Floor ...............................................................................................36
5.2.5 Connections provided by the customer ..........................................36
5.3 Preparations .................................................................................................37
5.4 Connecting the system ................................................................................37
6Operating the system .........................................................................................42
6.1 Safety ...........................................................................................................42
6.2 Preparations for use .....................................................................................43
6.3 Typical production process ..........................................................................43
6.3.1 Switching on the system ................................................................43
6.3.2 Preparing the data ..........................................................................46
6.3.3 Processing the material .................................................................52
6.3.4 Switching off the system ................................................................59

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6.4 Special tasks ................................................................................................60
7Maintenance ........................................................................................................67
7.1 Safety ...........................................................................................................67
7.2 Maintenance schedule .................................................................................67
7.3 Maintenance tasks for the maintenance personnel of the operator ............68
8Troubleshooting .................................................................................................70
8.1 Fault display .................................................................................................70
8.2 Actions in case of an error ...........................................................................72
8.3 Fault table ....................................................................................................72
9Disassembly and disposal .................................................................................74
9.1 Safety ...........................................................................................................74
9.2 Preparations .................................................................................................74
9.3 Uninstalling the system ................................................................................74
9.4 Disposing of the system ...............................................................................75
10 Appendix .............................................................................................................76
10.1 List of figures ................................................................................................76
10.2 List of tables .................................................................................................77
10.3 EC Declaration of conformity .......................................................................78
This document describes two systems that resemble each other. ProtoMat E34 and
ProtoMat E44 are identically constructed, differing only in a few characteristics. The
following always describes the system. For comprehensibility and practicability of the
instruction steps, it does not matter which of the two systems is described. The
characteristics that serve for differentiation are marked clearly in this document.

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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 ProtoMat E34 has been specially designed for producing single-sided circuit
board prototypes while the ProtoMat E44 has been designed for producing circuit
board prototypes of up to four layers. Both systems can also be used to create signs
and housing components.
The system is approved for the following processing procedures and materials:
Processing procedures
 Milling and drilling of single-sided and double-sided base material
 Milling and drilling of multi-layer material (E44 only)
 Milling of SMD solder paste stencils
 Engraving of signs or housing panels
 Drilling of plane materials
Materials
 GFRP and CFRP base material
 PTFE or ceramic-filled base material
 Plastics such as:
 Polyoxymethylene
 ABS copolymers
 Necuron ®
Any other kind of usage is considered as not intended. The manufacturer is not liable
for any damage resulting from this, the operator alone bears the risk. Part of the
intended use is also to follow the instructions for safety, operation, and maintenance of
the system that are described in this user manual.
In case of doubt contact the LPKF Service to receive more information on alternative
materials or processing procedures.
 Only control the system with the system software that is included in the scope of
delivery.
The system may only be operated with an extraction system that is sufficiently
dimensioned and has an integrated HEPA filter.
 Only use qualified and approved extraction systems.
Contact the LPKF sales department or your local sales representative if you plan to
use another extraction system.
Improper use
The system must not be used for processing highly combustible materials like e.g.
paper or wood, sealed containers, hollow parts, textiles, or food.
Do not use the system with a different or modified software.

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1.2 Residual risks
No residual risks have currently been identified, if the intended use as well as all
safety regulations are observed. 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.
Mechanical hazards
WARNING
Risk of injury by moving components!
Moving components can cause serious injuries e.g. crushing injuries or cuts.
 Never grasp moving components when the system is operating.
 Observe the follow-up time of the spindle. Before doing any work in the
processing area or on the processing head, ensure that no component is still
moving.
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.
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.
 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.

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Thermal hazards
CAUTION
Burn hazard by hot surfaces!
During processing, some system components can heat up so much that direct
contact can cause burns.
 Always wear your personal protective equipment.
Hazards by materials or substances
WARNING
Health hazard by faulty extraction!
When processing materials, gases or dusts hazardous to health can be produced.
 Ensure that the extraction system is switched on and is working properly.
 Observe the maintenance intervals of the extraction system.
 Check the connection to the system regularly.
1 Verantwortung des Betreibers

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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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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.
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.

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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
Depending on the application and the material to be processed, the operating
personnel has to wear the required protective equipment, including:
 Safety shoes protection class 1
 Protective gloves
 Respirator mask
 Hearing protection (safety earmuffs or single-use earplugs)
Description of the personal protective equipment
Protective glasses with side shields
The protective glasses with side shields serve for eye protection in
case of flying debris and liquid splashes.
Respirator mask
Respirator masks protect against hazards from harmful substances
in gases, vapors, and particles.
Safety shoes
Safety shoes protect the feet against crushing injuries, falling
objects and from slipping on slippery surfaces.
Protective gloves
Protective gloves protect the hands against friction, abrasions,
puncture hazards and deep cuts as well as when touching hot
surfaces.

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1.7 Safety signs
This chapter lists the safety signs/pictograms that are applied to the system and
describes their meaning.
WARNING
Risk of injury by nonobservance of safety signs!
The safety signs on the system instruct you on safe usage of the system.
Nonobservance 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
Safety isolation, Class III
The system is equipped with a
safety isolation and uses a safety
isolating transformer according to
DIN VDE 0570-2-6 or EN 61558-2-
6. As long as the isolation is not
damaged, the voltage of live
components that are accessible
during operation presents no
danger of electric shock.
1.8 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.

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1.9 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.
The following environmentally hazardous substances are used:
Lubricants
Lubricants, such as greases and oils, contain toxic substances. They must not be
released into the environment. They have to be disposed of by a waste management
company.
Cleaning agents
Solvent-containing cleaning agents contain toxic substances. They must not be
released into the environment. They have to be disposed of by a waste management
company.

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2 Technical data
Operating conditions
Data
Value
Unit
Temperature range (operation)
15 to 25
°C
Temperature range (storage, transport)
15 to 35
°C
Max. humidity, non-condensing
60
%
IP Code ( IEC 60529) of the power supply unit
IP20
-
Service life
10
Years
Electrical data
Data
Value
Unit
Power supply
100 to 240
V
50/60
Hz
Output power of the power supply unit
120
W
Mechanical data
Data
Value
Unit
Dimensions (width x height x depth)
370 x 300 x 450
mm
Weight (without packaging)
15
kg
Weight (with packaging)
20
kg
Process data
Data
Value
Unit
Rotation speed range
E34: up to 30 000 (variable)
E44: up to 40 000 (variable)
min-1
Travel speed
100 (diagonally)
mm/s
Drilling performance
100 strokes
min-1
Collet
3.175 (1/8")
mm
Processing area with processing table (x/y/z)
229 x 305 x 5
mm
Resolution (x/y)
+/- 0.8 (0.04)
µm (mil)
Repeatability
+/- 5 (0.2)
µm (mil)
Accuracy using the reference-hole system
+/- 20 (0.8)
µm (mil)
Emissions
Data
Value
Unit
Sound pressure level LpA (EN ISO 3744)
< 70
dB (A)
Sound power level LwA (EN ISO 3744)
71 (without extraction system)
dB (A)
EMC emission class
A
-

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3 Structure and function
This chapter describes the technical structure and the functions of the system.
3.1 Brief description
The system consists of three essential functional units:
 Processing table
 Processing head with:
 Milling spindle
 E44: additionally with camera
 xyz positioning system
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 25.
 ProtoMat version E34 or E44
 Power supply unit with:
 Mains cable 230 V AC
 Mains cable with US standard plug 115 V AC
 Drilling underlay plate
 Data medium Documentation
 Data medium CircuitPro PM
 Basic reference ProtoMat E34/E44
 Accessories bag ProtoMat E series containing:
 1 x Soft brush
 2 x Reference-hole strips 100 mm (red)
 1 x 19-mm-wide adhesive tape (roll of 10 m)
 2 x Reference-hole drills 1/8" shaft, 17 mm, d = 2.95 mm
 5 x Dowel pins 3m6x8 (ISO 8734)
 1 x Mains cable 125 V AC
 1 x USB cable
 1 x Press-fit tool (for dowel pins)
 1 x Extraction hose
 2 x Set screws with Torx drive and rounded head
 1 x Torx wrench T20
 1 x Collet brush 4 mm
 1 x Flanged bushing Ø12
Data medium Documentation
The data medium contains the following:
 User manual ProtoMat E34/E44
 Basic reference ProtoMat E34/E44
 User manual CircuitPro PM
 How-to guide CircuitPro PM