LPKF ProtoMat S43 User manual

LPKF ProtoMat S
Manual
Order Code: 1000447

ProtoMat S
Manual
Version 0.9
English
LPKF Laser & Electronics AG
Osteriede 7
D-30827 Garbsen
Germany
Phone [phone]
Fax [phone]
Email [email protected]

ProtoMat S
2©2011 LPKF AG
Publisher LPKF Laser & Electronics AG
Osteriede 7
D-30827 Garbsen
Germany
Phone: [phone]
Fax: [phone]
Email: [email protected]
Order code 10000447
File name ProtoMat_S_HB_V0.9_ENG.docx
Version 0.9
Creation date 28.03.2011
Print date 28.03.2011
Copyright © 2011 LPKF AG
This document and its contents in whole and in part are subject
to copyright. The reproduction, translation or duplication of the
contents as photocopy or any digital form requires written
permission of LPKF AG.
Product and
brand names 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.

ProtoMat S
©2011 LPKF AG 3
General information General information
Introduction
All information about assembling, start up,
operating and maintenance, respectively
troubleshooting of the delivered machine are
provided by this product manual. This manual
is written for persons with a basic knowledge
of installing and operating software controlled
machines. General knowledge about safety at
work as well as basic knowledge about PC
handling, based on Microsoft Windows®
operating system, is required.
Availability
This document must be available in complete
and legible condition at the workplace near
the machine. Any person, allowed to operate
the machine, must read and understand this
manual. The machine owner has the duty to
ensure that all safety instructions, described in
the manual, will be heeded by the operators.
Notation
To facilitate the reading and understanding of
the document information text attributes, text
notations and text structures are used. The
text attributes (highlighting) inside this
document are defined as follows:
Attribute Function
Bold Important information
Italic Brand name
Bold + Italic LPKF Brand name
[…] Button
\...\ Input or output field
<…> Check box
{…} Radio button
>…>…> Menu path
/…/ Pointer to a numeric character
inside an image
Images
All pictures or graphics of this document are
framed. Every figure is characterized with a
continuously numbered title, for example “Fig.
1: Overview“. Numeric character inside the
image is used for the identification of specified
components or operation steps. Sideward
showing arrows inside the image are used to
indicate an activity direction.
Tables
Any technical data, facts or special context
will be organized in tables. Every table is
characterized with a continuously numbered
title, for example “Tab. 1: Scope of delivery“.
The table will be created with a highlighted
headline and labelled columns.

ProtoMat S
4©2011 LPKF AG
Genral information
Procedure descriptions
For this manual step by step procedures or
workflows are compiled to operation sequen-
ces. An individual operation sequence
consists of at least three components
Title+Step+ Result.
Component Description
■Title Short description of the
expected result – charac-
terized with a prefixed “■“.
1. Step A consecutively numbered
order of the individual work
item of the described
procedure.
➨Partial
result
Partial result of an operation
step. The operation sequence
is continuously progressed.
♦Result Result of the operation
sequence - characterized with
a prefixed “♦“.
Symbols and signal words
Inside this document the following symbols
will be used to indicate important information:
Symbol Description
Safety instruction
WARNING – dangerous hazard
to people
ATTENTION – a machine
damage is possible
Note
The note will be used for any
information about the optimal
solution for a realisation of a
specific function or operation.
Note
The memo will be used for any
additional information about a
function or operation step.
© Copyright
® Registered Trademark
Registered trademark
The LPKF logo and the LPKF product names
are registered trademarks of LPKF Laser &
Electronics AG.
Microsoft and Windows are brand names or
registered trademarks of the Microsoft Cor-
poration in USA and/or international.
All other brand names belong to the respec-
tive owner.
Standards
The following standards and guidelines had
been pursued for the creation of this
document:
Standard Description
DIN 5008
05-2005
Rules for writing and layouting
VDI 4500
Bl.1,2
11-2006
Technical documentation -
Definitions and legal basics
IEC 62079
11-2001
Preparation of instructions -
Structuring, content and
presentation
ISO 12100-2
02-2003
Safety of machinery - Basic
concepts, general principles for
design - Part 2: Technical
principles
DIN EN
60204
01-2006
Safety of machinery - Electrical
equipment of machines - Part 1:
General requirements

ProtoMat S Content
©2011 LPKF AG HB V0.9/Mrz-11 5
Table of contents
1Product description............................................................................. 9
1.1 Product characteristics ............................................................................................. 9
1.2 Type label ............................................................................................................... 10
1.3 Scope of delivery .................................................................................................... 10
1.3.1 Accessories .................................................................................................. 11
1.3.2 Provided components of the operator .......................................................... 11
1.3.2.1 Control computer ..................................................................................... 11
1.3.2.2 Dust extraction......................................................................................... 12
1.4 Manufacturer........................................................................................................... 13
1.5 EC declaration of conformity................................................................................... 14
1.5.1 ProtoMat S43................................................................................................ 14
1.5.2 ProtoMat S63................................................................................................ 16
1.5.3 ProtoMat S103.............................................................................................. 18
2Safety notes ....................................................................................... 21
2.1 Device safety .......................................................................................................... 21
2.2 General safety notes............................................................................................... 23
3Functional description ...................................................................... 25
3.1 Function .................................................................................................................. 25
3.1.1 Permitted machining materials ..................................................................... 25
3.2 Equipment design ................................................................................................... 26
3.2.1 Housing......................................................................................................... 26
3.2.2 Working area ................................................................................................ 28
3.2.3 Mill/drill head................................................................................................. 29
3.2.3.1 ProtoMat S43........................................................................................... 29
3.2.4 Mill/drill head................................................................................................. 30
3.2.4.1 ProtoMat S63/103.................................................................................... 30
3.3 Conditions of use .................................................................................................... 32
3.3.1 Disclaimer ..................................................................................................... 33
3.4 Technical Data ........................................................................................................ 34
3.4.1 ProtoMat S43................................................................................................ 34
3.4.2 ProtoMat S63................................................................................................ 35
3.4.3 ProtoMat S103.............................................................................................. 36
3.5 Emissions................................................................................................................ 37
3.5.1 Acoustic emission......................................................................................... 37
3.5.2 Material emission.......................................................................................... 37
3.6 Protection of persons .............................................................................................. 37
3.7 Disposal of waste material...................................................................................... 37

Content ProtoMat S
6HB V0.9/Mrz-11 ©2011 LPKF AG
4Transport and storage....................................................................... 39
4.1 Transport................................................................................................................. 39
4.1.1 Transport lock............................................................................................... 39
4.2 Storage ................................................................................................................... 39
5Installation.......................................................................................... 41
5.1 Assembly conditions ............................................................................................... 41
5.2 Unpacking the device ............................................................................................. 42
5.3 Installation and commissioning............................................................................... 42
5.3.1 Installation..................................................................................................... 42
5.3.1.1 Remove the transport lock ...................................................................... 43
5.3.1.2 Connecting the circuit board plotter......................................................... 44
5.3.2 Commissioning ............................................................................................. 45
5.3.3 Remove the dummy tool............................................................................... 46
6Operation............................................................................................ 47
6.1 Production process ................................................................................................. 47
6.2 Start system ............................................................................................................ 48
6.2.1 Tool status monitoring .................................................................................. 49
6.2.2 Grafical user interface .................................................................................. 50
6.2.2.1 Menu bar ................................................................................................. 51
6.2.2.2 Function bar............................................................................................. 52
6.2.3 Window Processing ...................................................................................... 53
6.2.3.1 Manual control of the mill/drill head......................................................... 54
6.2.3.2 Select head.............................................................................................. 55
6.2.3.3 Operate.................................................................................................... 56
6.2.3.4 Move to Position ...................................................................................... 57
6.2.3.5 Head actions............................................................................................ 58
6.3 Establish a connection............................................................................................ 59
6.4 Place material ......................................................................................................... 61
6.5 Tool setup ............................................................................................................... 62
6.5.1 Tool colour code ........................................................................................... 64
6.6 Manual drilling......................................................................................................... 65
6.7 Manual milling ......................................................................................................... 68
6.8 Automatic mode ...................................................................................................... 73
6.8.1 Specify production type ................................................................................ 74
6.8.2 Loading the CBF file ..................................................................................... 76
6.8.2.1 Production of the printed circuit board..................................................... 78
6.9 Dispense ................................................................................................................. 80
6.9.1 Mount dispense set ...................................................................................... 81
6.9.2 Dispense process ......................................................................................... 82

ProtoMat S Content
©2011 LPKF AG HB V0.9/Mrz-11 7
6.10 Shutdown the System............................................................................................. 85
6.10.1 Saving the CBF file....................................................................................... 85
6.10.2 Exit CircuitPro............................................................................................... 86
6.10.3 Switch off the circuit board plotter ................................................................ 86
6.10.3.1 Shutdown and switch off the PC ............................................................. 86
6.10.4 Switch off the dust extraction........................................................................ 86
7Troubleshooting ................................................................................ 87
8Maintenance/servicing ...................................................................... 89
8.1 Regular maintenance.............................................................................................. 89
8.2 Maintenance ........................................................................................................... 90
9Storage ............................................................................................... 91
9.1 Shutdown ................................................................................................................ 91
9.2 Storage ................................................................................................................... 91
9.2.1 Disposal ........................................................................................................ 92
10 Appendix ............................................................................................ 93
10.1 Tools and consumables.......................................................................................... 93
10.1.1 Tools ............................................................................................................. 93
10.1.1.1 Tool set 1/8“............................................................................................. 94
10.1.1.2 HF and micro wave tool set 1/8“.............................................................. 95
10.1.2 Consumables................................................................................................ 95
10.1.2.1 Base material........................................................................................... 95
10.1.2.2 Multilayer-Material ................................................................................... 96
10.2 Glossary.................................................................................................................. 97
10.3 List of figures........................................................................................................... 98
10.4 List of tables.......................................................................................................... 100
10.5 Index ..................................................................................................................... 101

Content ProtoMat S
8HB V0.9/Mrz-11 ©2011 LPKF AG
ddd

ProtoMat S Product description
©2011 LPKF AG HB V0.9/Mrz-11 9
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1 Product description
This chapter provides information about the mill/drill potter system ProtoMat S.
1.1 Product characteristics
Using a moving speed of 150 mm/s and a motor speed of 40,000 to 100,000
min-1 the ProtoMat S produces high-end and complex printed circuit board very
fast and professionally. With a resolution of 0.25 µm this machine provides
highest precision.
The extensive equipment and the high grade of automation as e.g. automatical
exchange of tools, head illumination and a camera for detection of fiducials
make the ProtoMat S extremely comfortable in its operation. The modern and
ergonomically shaped soundproof housing facilitates easy handling. The safe
and comfortable employment of the circuit board plotter is thus possible in any
working environment without any additional effort.
As an optional accessory you can easily install a camera, a vacuum table and a
status light.
The ProtoMat S is controlled using the easy to operate software CircuitPro.
Moreover the software is able to import several CAD formats and to generate
production data from these files.
Fig. 1: ProtoMat S
series

Product description ProtoMat S
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1.2 Type label
The type label is located at the right side of the machine housing besides the
mains switch.
If any questions occur concerning identification of your machine and the
corresponding equipment please always quote the serial number according to
the type label to the LPKF service.
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1.3 Scope of delivery
The scope of delivery of the ProtoMat S Series includes:
Tab. 1: Scope of
delivery
Quantity Description
1 ProtoMat S series, inclusive sound proof housing
1 Power cable with safety plug (230 V AC), length 1,5 m
1 Power cable with US plug (115 V AC), length 1,5 m
1 USB connection cable, 5 m
1 Drill underlay material with the dimensions 229 x 305 mm (9 x 12“)
1 Base material FR4 with the dimensions 229 x 305 mm (9 x 12“)
1 Tool set with:
2 Reference hole stripes
5 Reference hole pivots (3 x 8 mm)
1 Force fitting tool for reference hole pivots
4 Fuses 10 A (T10L 250 V)
2 Reference hole drill, spiral drill 2.95 mm
1 Fixing tape (to be dissolved residual-free)
1 Maintenance and service set
1 Solder Paste cartridge for machines with dispense set
1 CD-ROM
1 Software CircuitPro
1 Set of operation manuals, consisting of
1 Operating manual CircuitPro
1 Operating manual ProtoMat S
Fig. 2: Type plate
/1/ Machine type /4/ Operating voltage
/2/ Serial number /5/ Mains frequency in Hz
/3/ Year of production /6/ Power consumption in VA
1
2
3
4
5
6

ProtoMat S Product description
©2011 LPKF AG HB V0.9/Mrz-11 11
1
1.3.1 Accessories
The following components can be delivered as accessories:
Tab. 2:
Accessories
Quantity Description
1 Tool set 1/8“
1 HF tool set 1/8“
1 Dust extraction with auto switch feature
1 Vacuum table to fix work pieces
1 Vision System for detection of fiducials
1 Measuring microscope to check milling tracks and drillings
1 Status Light
1.3.2 Provided components of the operator
The following components are not included in the delivery and have to be
provided by the operator.
1.3.2.1 Control computer
A control computer with the following characteristics has to be supplied by the
operator:
Tab. 3: PC data Component Rating
CPU IBM compatible from Intel Pentium IV or higher
(comparable to Dual Core 2 GHz)
RAM At least 1 GB DDR2 RAM
Hard disk 2 GB free space on internal disk
Graphic board NVIDEA with at least 512 MB graphics memory
Screen resolution 1280 x 1024 / High Colour (16 Bit)
Monitor 17“ VGA colour monitor

Product description ProtoMat S
12 HB V0.9/Mrz-11 ©2011 LPKF AG
1
1.3.2.2 Dust extraction
A dust extraction with the following characteristics has to be supplied by the
operator:
Tab. 2: Data for
dust extraction
Attribute Data
Exhaust power 0 - 280 m3/h
Low pressure 20,000 Pa
Connecting adapter Ø 50 mm
Sound level 62 dB (A)
Collection efficiency > 98 %
Power consumption 1.1 kW
Note
We recommend using a dust extraction unit type LPKF Air
Management System.

ProtoMat S Product description
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1.4 Manufacturer
LPKF
LPKF Laser & Electronics AG
Osteriede 7
D-30827 Garbsen
Germany
Phone [phone] - 70 95 – 0
Fax [phone] - 70 95 - 90
Email [email protected]
Internet http://www.lpkf.com
LPKF Service
LPKF Laser & Electronics AG
Service Rapid Prototyping
Osteriede 7
D-30827 Garbsen
Germany
Phone [phone] - 70 95 - 0
Fax [phone] - 70 95 - 90
Email [email protected]
Internet http://www.lpkf.de/support/index.htm

Product description ProtoMat S
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1.5 EC declaration of conformity
1.5.1 ProtoMat S43
EC declaration of conformity in accordance with machinery directive 2006/42/EG,
Appendix II A
The manufacturer/seller
LPKF Laser & Electronics AG
Osteriede 7
30827 Garbsen
Germany
hereby declares that the following product
Product name LPKF ProtoMat S43
Product type: Mill/drill plotter
conforms to the provisions of the directive identified above – including the
modifications effective at the time of this declaration.
This declaration refers to the product status where the product was placed on
the market. Parts or modifications installed afterwards by the operator are not
taken into consideration. Any subsequent modification shall invalidate the
declaration for this product.
The following harmonized standards are applied:
EN 60204-1:2007 Safety of machinery - Electrical equipment of
machines - Part 1: General requirements
The following domestic and international standards (or parts/clauses of this
standards) and specifications are applied:
EN ISO 12100-2:2004 Safety of machinery - Basic concepts,
general principles for design - Part 2:
Technical principles
EN ISO 12100-1:2004 Safety of machinery - Basic concepts,
general principles for design - Part 1: Basic
terminology, methodology
EN ISO 14121-1:2007 Safety of machinery - Risk assessment -
Part 1: Principles (ISO 14121-1:2007)
We maintain a quality assurance system according to DIN EN ISO 9001 that
has been certified by DeuZert - Certification number: A 40583 22 00 1.
Person authorized to compile the documentation: Rainer Aschenbeck
Address of the person: see manufacturer address

ProtoMat S Product description
©2011 LPKF AG HB V0.9/Mrz-11 15
1
The following EC guidelines are applied:
•EMC guideline 2004/108/EG
•Directive 2006/95/EC relating to electrical equipment designed for use
within certain voltage limits
Location: Garbsen
Date: 28. March 2011
Bernd Lange
(CTO)

Product description ProtoMat S
16 HB V0.9/Mrz-11 ©2011 LPKF AG
1
1.5.2 ProtoMat S63
EC declaration of conformity in accordance with machinery directive 2006/42/EG,
Appendix II A
The manufacturer/seller
LPKF Laser & Electronics AG
Osteriede 7
30827 Garbsen
Germany
hereby declares that the following product
Product name LPKF ProtoMat S63
Product type: Mill/drill plotter
conforms to the provisions of the directive identified above – including the
modifications effective at the time of this declaration.
This declaration refers to the product status where the product was placed on
the market. Parts or modifications installed afterwards by the operator are not
taken into consideration. Any subsequent modification shall invalidate the
declaration for this product.
The following harmonized standards are applied:
EN 60204-1:2007 Safety of machinery - Electrical equipment of
machines - Part 1: General requirements
The following domestic and international standards (or parts/clauses of this
standards) and specifications are applied:
EN ISO 12100-2:2004 Safety of machinery - Basic concepts,
general principles for design - Part 2:
Technical principles
EN ISO 12100-1:2004 Safety of machinery - Basic concepts,
general principles for design - Part 1: Basic
terminology, methodology
EN ISO 14121-1:2007 Safety of machinery - Risk assessment -
Part 1: Principles (ISO 14121-1:2007)
We maintain a quality assurance system according to DIN EN ISO 9001 that
has been certified by DeuZert - Certification number: A 40583 22 00 1.
Person authorized to compile the documentation: Rainer Aschenbeck
Address of the person: see manufacturer address

ProtoMat S Product description
©2011 LPKF AG HB V0.9/Mrz-11 17
1
The following EC guidelines are applied:
•EMC guideline 2004/108/EG
•Directive 2006/95/EC relating to electrical equipment designed for use
within certain voltage limits
Location: Garbsen
Date: 28. March 2011
Bernd Lange
(CTO)

Product description ProtoMat S
18 HB V0.9/Mrz-11 ©2011 LPKF AG
1
1.5.3 ProtoMat S103
EC declaration of conformity in accordance with machinery directive 2006/42/EG,
Appendix II A
The manufacturer/seller
LPKF Laser & Electronics AG
Osteriede 7
30827 Garbsen
Germany
hereby declares that the following product
Product name LPKF ProtoMat S103
Product type: Mill/drill plotter
conforms to the provisions of the directive identified above – including the
modifications effective at the time of this declaration.
This declaration refers to the product status where the product was placed on
the market. Parts or modifications installed afterwards by the operator are not
taken into consideration. Any subsequent modification shall invalidate the
declaration for this product.
The following harmonized standards are applied:
EN 60204-1:2007 Safety of machinery - Electrical equipment of
machines - Part 1: General requirements
The following domestic and international standards (or parts/clauses of this
standards) and specifications are applied:
EN ISO 12100-2:2004 Safety of machinery - Basic concepts,
general principles for design - Part 2:
Technical principles
EN ISO 12100-1:2004 Safety of machinery - Basic concepts,
general principles for design - Part 1: Basic
terminology, methodology
EN ISO 14121-1:2007 Safety of machinery - Risk assessment -
Part 1: Principles (ISO 14121-1:2007)
We maintain a quality assurance system according to DIN EN ISO 9001 that
has been certified by DeuZert - Certification number: A 40583 22 00 1.
Person authorized to compile the documentation: Rainer Aschenbeck
Address of the person: see manufacturer address