LPKF S64 User manual

ProtoMat S64/S104
Basic reference to the detailed
documentation
Order code: 10073612
Version: 1.0

Publisher
LPKF Laser & Electronics AG
Osteriede 7
30827 Garbsen
Germany
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Date of issue
13.03.2019
Copyright
© 2019 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
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General information
This basic reference contains the basic safety instructions and a selection of the
information on the system.
The detailed documentation of this system and further documentation for the used
software is supplied in PDF format on the data medium.
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.
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/product.
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 danger level
 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:

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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.
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!
These messages contain information on possible property damage that causes no
injury.
 Measure to avoid the hazard.
Text styles
Various text attributes, spelling, and text structures facilitate reading the document.
The text attributes (highlightings) inside this document are defined as follows:
Attribute
Function
italic
highlighting elements of the user interface and of control elements of
the system
bold
highlighting important information and keyboard input
Courier New
highlighting file names and file paths
[ ]
highlighting buttons of software user interfaces
highlighting keys

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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.
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.
This symbol indicates an intermediate result.
This symbol indicates a final result.
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.

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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
[e-mail]
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.

ProtoMat S64/S104
Contents
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Contents
1Scope of this basic reference ..............................................................................9
1.1 Overview of the supplied documentation .......................................................9
2Safety .................................................................................................................. 10
2.1 Basic hazards ............................................................................................. 10
2.1.1 Mechanical hazards ...................................................................... 10
2.1.2 Electrical hazards .......................................................................... 11
2.1.3 Thermal hazards ........................................................................... 11
2.1.4 Hazards by materials or substances ............................................. 11
2.1.5 Other hazards ............................................................................... 11
2.2 Personnel requirements .............................................................................. 12
2.3 Personal protective equipment ................................................................... 13
2.4 Intended use ............................................................................................... 14
3System description ............................................................................................ 16
3.1 Technical data ............................................................................................. 17
3.2 Type label ................................................................................................... 19
3.3 Scope of delivery ........................................................................................ 20
3.4 EC Declaration of conformity ...................................................................... 21
4Transport and storage ....................................................................................... 23
4.1 Transport inspection ................................................................................... 23
4.2 Packaging ................................................................................................... 23
4.2.1 Unpacking the system ................................................................... 24
4.3 Transporting the system ............................................................................. 33
4.4 Storage........................................................................................................ 34
5First startup ........................................................................................................ 35
5.1 Safety .......................................................................................................... 35
5.2 Requirements of the place of installation .................................................... 35
5.2.1 Climatic conditions ........................................................................ 35
5.2.2 Minimum required space ............................................................... 36
5.2.3 Workplace of the operating personnel .......................................... 37
5.2.4 Floor .............................................................................................. 37
5.2.5 The system's center of gravity ...................................................... 38
5.2.6 Connections provided by the customer ......................................... 38
5.3 Preparations ................................................................................................ 39
5.4 Connecting the system ............................................................................... 39
5.4.1 Connecting the extraction system ................................................. 40
5.4.2 Connecting the compressed-air supply ......................................... 43
5.4.3 Establishing a connection between the camera and the PC ........ 44
5.4.4 Establishing a connection between the system and the PC ......... 45
5.4.5 Connecting the system to the mains power supply ...................... 47
5.4.6 Connecting the PC to the mains power supply ............................. 48
5.4.7 Dummy tool ................................................................................... 48
5.5 Software ...................................................................................................... 49
5.6 Reading the user manual ............................................................................ 50
6Appendix ............................................................................................................ 51
6.1 List of figures ............................................................................................... 51
6.2 List of tables ................................................................................................ 51
6.3 Index ........................................................................................................... 52

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This document describes systems that resemble each other. ProtoMat S64 and
ProtoMat S104 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 Scope of this basic reference
Please note that this basic reference does not replace the detailed documentation on
the data medium.
Read the detailed documentation before working with the system.
Observe the information, instructions and safety instructions in the detailed
documentation to ensure a safe and smooth operation of the system.
1.1 Overview of the supplied documentation
The following documentation is supplied in printed form:
Documentation
Description
Basic reference to the detailed
documentation
Quick guide for first startup
Table 1: Overview of the printed documentation
The following documentation is supplied on the data medium:
Documentation
Description
Basic reference to the detailed
documentation
Quick guide for first startup
User manual ProtoMat
S64/S104
Documentation for the ProtoMat S64/S104
CircuitPro PM Compendium
Documentation of the software CircuitPro PM
How-to guide CircuitPro PM
First steps, practical tips and basics of the system software
CircuitPro PM
Unpacking instructions
Instructions for unpacking the system
Table 2: Overview of the documentation on the data medium

Safety
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2 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.
2.1 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.
2.1.1 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.
 Never open any covers when the system is operating.
 Observe the follow-up time. Before opening the cover, ensure that no
component is still moving.
WARNING
Risk of injuries by pressurized components!
Pressurized components (e.g. compressed-air supply) can move uncontrollably in
case of improper handling or in case of a defect and can cause serious injuries.
 Depressurize the components before working on them. De-energize the
residual energies.
 Always ensure that there is no unintended escape of compressed air.
 Defective components that are under pressure when operating the system have
to be replaced immediately by sufficiently qualified personnel.

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2.1.2 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.
2.1.3 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.
2.1.4 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.
2.1.5 Other hazards
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.

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2.2 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.
2.3 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.
Description of the personal protective equipment
Safety glasses with side shields
Safety 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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2.4 Intended use
The system has been developed especially for micro material processing and
approved for the following processing procedures and materials:
Processing procedures
 Processing of single-sided and double-sided base material
 Processing of multi-layer material
 Processing of SMD solder paste stencils
 Processing of solder stop films
 Engraving of signs or housing panels (e.g. front or rear plates)
 Drilling of plane materials using drilling tools
Materials
 GFRP or CFRP base material
 PTFE or ceramic-filled base material
 non-ferrous metals like
 aluminum acc. to DIN EN 573:EN AW-6012
 brass acc. to DIN EN 1412:CW603N
 plastics like
 polyoxymethylene
 ABS copolymers
 Necuron ®
The system may only be used for the processes and materials listed in this chapter. If
in doubt, contact the LPKF Service for alternative materials or processes.
The system is designed for a service life of 10 years used in one-shift operation (8
hours a day, 5 days a week).
The system is intended for use in a laboratory environment.
Only control the system with the system software that is included in the scope of
delivery. The system may only be operated with a sufficiently dimensioned extraction
system that includes a fine particle filter and active carbon filter. LPKF recommends
the LPKF extraction system with integrated HEPA filter and activated carbon filter.
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.
Contact the LPKF sales department or your local representative if you plan to use
another extraction system.
Only use qualified and approved extraction systems.
Any other kind of use 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 in this user manual with regard to
operation and maintenance of the system.

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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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3 System description
The ProtoMat S64/S104 is a circuit board plotter for structuring single-layer and multi-
layer circuit boards. The tool magazine can accommodate up to 20 different drilling
and milling tools (ProtoMat S104 only, 15 tools for ProtoMat S64) that can realize
among others the following applications:
 Processing of single-sided and double-sided circuit boards
 Processing of multi-layer PCBs
 Routing flexible and rigid-flex PCBs
 Processing of solder stop films
 Processing of SMD solder paste stencils
 Engraving of signs or housing panels
 Drilling of plane materials using drilling tools
 Milling of cut-outs and contour routing
 Processing 3D objects of up to 10 mm (~0.4 in) in height
 Applying solder paste with an integrated dispenser
 Processing of ceramic-filled base material
 Processing RF circuits (only ProtoMatS104 with corresponding RF tools)
The system is delivered with the user-friendly CircuitPro PM system software. The
software allows importing the following data formats: CAM, Excellon, Gerber,
GerberX, LMD, HPGL, DXF, Step, Iges, Sieb & Meyer, and ODB++
The data are prepared by CircuitPro PM and the toolpaths are computed
automatically. The tools required for your project are predetermined and are picked up
and adjusted automatically during processing:
 Isolation distances of 0.2 mm to 0.5 mm are produced using a Universal Cutter,
smaller isolation distances of 0.1 mm to 0.15 mm using a Micro Cutter.
 Cylindrical tools with diameters of 0.8 mm - 3 mm are available for producing wide
isolation distances and rub-outs.
 The drilling tools of 0.2 mm to 2.4 mm are used for drilling through the PCBs.
 Contour routing tools are available for cutting out PCBs and for producing drill
holes > 2.4 mm.
The system is connected to the PC via a USB 2.0 interface. In preparation of the
process the material to be processed is placed. For this, the system has a vacuum
table with a processing area of (W x H x D) 330.5 × 249 × 8 mm (~13.0 × 9.8 × 0.3 in).
Once the data and the system are prepared the process is started and runs fully
automatically. A stack light (optionally available) indicates the status of the system at
any time of the process.
Further characteristics of the system are:
 Milling spindle with a rotation speed of 60 000 rpm (ProtoMat S64) or 100 000 rpm
(ProtoMat S104).
 Integrated camera for recognizing fiducials to enable processing multilayer PCBs.
 Processing depth limiter that enables processing substrates with sensitive
surfaces
 Copper thickness measurement to determine the copper layer on your base
material (ProtoMat S104 only).
 Automatic control of the extraction system for switching on and off.

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3.1 Technical data
General
Data
Value
Unit
IP Code (IEC 60529)
IP20
–
Service life
10
Years
Climatic conditions
Data
Value
Unit
Temperature range (operation)
20 to 25 (68 to 77)
°C (°F)
Temperature range (storage, transport)
-10 to 40 (14 to 104)
°C (°F)
Max. humidity, non-condensing
90
%
Electrical data
Data
Value
Unit
Power supply
100/240
V
50/60
Hz
Nominal power
250
W
Stability
+/- 10
%
Mechanical data
Data
Value
Unit
Dimensions (width x height x depth)
680 × 560 × 800
(~26.7 × 22 × 31.5)
mm
(in)
Weight (without packaging)
95 (~209.4)
kg (lbs)
Weight (with packaging)
135 (~297.6)
kg (lbs)
Load capacity
Data
Value
Unit
Min. distributed load
1.75
kN/m²
Min. point load on an area of 0.0007068 m²
0.0012
kN
Pneumatic data
Data
Value
Unit
Pressure
min. 6
bar
Standard volume flow
40 l/min @ 6 bar
Nl/min
Compressed-air purity acc. to ISO 8573-1:2010-04
Data
Value
Unit
Solid particles
5
Class
Water
4
Class
Oil
4
Class

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Process data
Data
Value
Unit
Rotation speed range
S64: 10 000 to 60 000
S104: 10 000 to 100 000
min-1
Max. structuring area (x/y/z)
305 × 229 × 8
(~12.0 x 9.0 x 0.3)
mm
(in)
Max. material dimensions (x/y/z)
330.5 × 249 × 8
(~13.0 x 9.8 x 0.3)
mm
(in)
Travel speed
150 (diagonally)
(5.9)
mm/s
(in/s)
Drilling performance
100 strokes
min-1
Collet (1/8")
3.175 (0.125)
mm (in)
Resolution (x/y)
0.47 (0.02)
µm (mil)
Repeatability
± 5 (0.2)
µm (mil)
Accuracy of camera
1.8
(~0.07)
mm/pixel
(mil/pixel)
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
–
Extraction system
Data
Value
Unit
Extraction air flow
at least 186
m3/h
Extraction fitting (Ø)
50
mm
Separation efficiency
> 98 (≙ filter class: at least
E12)
%

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3.2 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. 1: Type label S64/S104
Name
Description
Origin
Country of origin
Type
System type
Serial No.
Serial number
Year MFD
Year of manufacture
Voltage
Operating voltage
Frequency
Line frequency
Power
Rated power consumption
Table 3: Type label S64/S104

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3.3 Scope of delivery
 ProtoMat S64 or ProtoMat S104
 Data medium Documentation
 Data medium CircuitPro PM
 Basic reference ProtoMat S64/S104
 Accessories bag containing:
 1 × Mains cable US- C13, UL approved 125VAC/10A, length 2 m, color: black,
UL File Number: E88265 E88265
 1× Mains cable 230 V Schuko plug IEC 60884
 1× Soft brush
 2× USB cable for ProtoMat, plug A-B 3 m with snap-on ferrite bead
 1× PVC hose connector for extraction system, ProtoMat S64/ S104 and
ProConduct, PVC soft, black
 1× Unit for compressed-air connection, pneumatic tube 6 mm with 1/8"
adapter
 1× Collet cleaning kit
 1 × Filter mat
 1 × Collet wrench
 1× Working-depth limiter
 Lubricant, special plastic lubrication ISOFLEX Topas 5051
 Lubricant, Ravenol precision mechanics oil
 Screwdriver Torx 6
 Screwdriver Torx 10
 1× Fuse
 1 × Cleaning device for tools
Data medium Documentation
 User manual ProtoMat S64/S104
 Basic reference ProtoMat S64/S104
 CircuitPro PM Compendium
 How-to guides CircuitPro PM
 Product catalog Rapid Prototyping
 Unpacking instructions
Data medium CircuitPro PM
 Software CircuitPro PM
 CircuitPro PM Compendium
 How-to guides CircuitPro PM