Orbotech DP-100SL Operating instructions

DP-100SL™
Site Preparation Guide
October 2003
Revision A

NOTICE
This document and the information contained herein belong to Orbotech Ltd.
(“Orbotech”) and may be used only as authorized by Orbotech in writing. No
part of this publication may be reproduced in any way without the prior
written consent of Orbotech.
Orbotech makes no representations or warranties with respect to the contents
hereof. Any and all implied warranties of fitness for particular purpose, other
than as specified in this manual, are hereby expressly disclaimed.
This document is subject to change without notice.
Catalog No. 0353444A
Orbotech® is a registered trademark of Orbotech Ltd.
The Orbotech and DP-100SL names are trademarks of LIS GmbH and
Orbotech Ltd. Other brand and product names referred to herein are the
trademarks of their respective owners.
Published by: Corporate Customer Support
Technical Publications Dept.
Orbotech, Ltd.
© 2003 Orbotech Ltd. All rights reserved.

The DP-100SL system is manufactured by Laser Imaging Systems GmbH & Co. KG,
Prüssingstraße 41, 07745 Jena, Germany, and by Orbotech Ltd., P.O. Box 215, Yavne, Israel
81002. The system complies with the following standards:
EN 60825, EN 60204
21 CFR CH.I (4-1-92 EDITION) & 1040.10
The DP-100SL system is a Class 1 laser product.

DP-100SL v
Site Preparation Guide
Table of Contents
1 - Introduction.............................................................................1
About This Guide ...................................................................................................1
About the DP-100SL™ ..........................................................................................1
Intended Use ..........................................................................................................3
Safety Considerations .............................................................................................3
Caring for Your System ..........................................................................................7
Noise Level .............................................................................................................7
2 - DP-100SL Physical Description .............................................9
Configuration .........................................................................................................9
Size and Weight ...................................................................................................10
Hose Lengths ........................................................................................................11
3 - Facility Physical Requirements ............................................13
Safety Requirements ............................................................................................13
Height Requirements ............................................................................................15
Floor Area ............................................................................................................16
Access — Doors and Hallways ..............................................................................17
Floors, Walls, Ceilings and Furniture ....................................................................17
Yellow Room Illumination ....................................................................................18
4 - Environment & Climate .......................................................23
Clean Room .........................................................................................................23
Climate Control ....................................................................................................23
5 - Electricity ...............................................................................27
Power Requirements ............................................................................................27
Grounding ............................................................................................................28

vi Table of Contents
Voltage Transients ............................................................................................... 28
Electrical Protection ............................................................................................. 30
Power Connectors ............................................................................................... 30
6 - Vacuum Pump.......................................................................31
7 - Communication ....................................................................33
Phone Lines ......................................................................................................... 33
Network .............................................................................................................. 33
8 - Air...........................................................................................35
Compressed Air ................................................................................................... 35
9 - Shipment and Delivery......................................................... 37
Shipping Information and Responsibility .............................................................. 37
Crates .................................................................................................................. 37
Equipment ............................................................................................................ 38
Personnel ............................................................................................................. 38
Clearances ........................................................................................................... 38
A - Approved Materials .............................................................39
Dry Film Resists ................................................................................................. 39
Films ..................................................................................................................... 41
Proof Materials .................................................................................................... 41
B - Customer Site Preparation Checklist................................43

DP-100SL 1
Site Preparation Guide
Chapter 1
Introduction
About This Guide
This guide provides site preparation information for the DP-100SL. It is
the customer's responsibility to ensure that the site at which the system is
installed conforms to all instructions and guidelines described in this
document, so as to enable proper system installation and full system
performance.
Please contact the local Orbotech representative with any questions
regarding the site preparation procedure.
About the DP-100SL™
The DP-100SL is a laser direct imaging system that receives PCB data
from CAM workstations and plots it directly on resist-coated panels.
Loading and unloading of the PCBs is done manually. The standard
configuration is a standalone system, as illustrated in Figure 1.1.

2Chapter 1
Introduction
The DP-100SL is capable of exposing large format images on inner and
outer layers, SBU and flex PCBs, printing highly accurate 2 mil lines and
spaces at ¼mil resolution.
The system is compatible with the existing production processes, operating
in a yellow room environment; it can expose all UV-sensitive dry or liquid
resists, with a wide range of substrate thicknesses. Clean room conditions
prevail in the internal imaging area of the system, ensuring that both the
panels and the optical elements are not contaminated during the printing
process.
Figure 1.1 DP-100SL Laser Direct Imaging System

DP-100SL 3
Site Preparation Guide
Intended Use
The DP-100SL is intended for the manufacturing of printed circuit boards.
It is designed to allow exposure of UV-sensitive resists, films, and similar
materials typical of the circuit board industry. However, because of the
numerous interrelations between substrate and laser imaging as the
exposing technique, the system may only be used with such UV-sensitive
materials that have been specifically approved by the manufacturer.
Approved materials are listed in Appendix A— Approved Materials.
Substrate dimensions with resist:
• max. substrate size 660.4 mm x 812.8 mm (26" x 32")
• max. exposable area 609.6 mm x 812.8 mm (24" x 32")
• max. substrate thickness 5 mm (0.196")
The machine must not be used in any way other than specified in this
manual or in the DP-100SL User Guide.
Safety Considerations
The DP-100SL is a Class 1 laser product containing high-voltage power
supplies and laser light sources. There is no danger to persons or
equipment when the system is operated in accordance with the directions
provided by Orbotech in this and other publications. All high-voltage
power supplies and laser sources are located behind protective panels.
During system service, with panels removed, the system may reach Class
4 laser radiation. Under those conditions, the imager room should have
fireproof walls and furniture and should be locked from the inside. During
service a red warning light on the outside of the room should be activated,
and all personnel in the vicinity of the system must wear protective
goggles. For a description of the safety requirements in the site, refer to
Chapter 3— Facility Physical Requirements.

4Chapter 1
Introduction
Do not remove any of the system’s protective panels.
Professional heavy-equipment movers should be employed to unload the
system and transfer it to the site. The customer is responsible for providing
necessary equipment such as forklifts with extra extension or cranes for
the unloading and unpacking of the equipment. Size and weight of system
units is listed in Table 2.1 on page 10.
System installation, disassembly, maintenance and repair must be
performed only by authorizes Orbotech customer support engineers, in
order to comply with all applicable safety requirements regarding the use
of laser devices.
Laser Safety
The DP-100SL system is classified as a Class 1 laser product, in
compliance with EN60825-1 standard.
Laser Definition
A Coherent Paladin 355-4 class 4 laser is used as main light source.
The Paladin is a 355 nm diode (UV) pumped solid-state mode-locked laser,
with the following specifications:

DP-100SL 5
Site Preparation Guide
The imager unit should be located in a room that can be closed off
during periodic maintenance and repair. At the user level, the imager
is a Class 1 laser device (no special protection needed) during all standard
operations. However, during certain service procedures, Class 4 will be
reached, and therefore a warning light must be installed (see Chapter 3).
Main Wavelength 355 n m
(350-360nm UV light) quasi-cw power of 10W
Secondary Wavelengths: 1064nm
(1060-1070nm UV light)
quasi-cw power less 0.2W
532nm
(520-540nm green light)
quasi-cw power less 0.2W
Minimal Beam Diameter 0.05 mm
Minimal Beam Divergence 0.5°
Pulse Rate 80MHz
Pulse Energy 125 n J
Pulse Length 5 … 20 ps
Max Power 10 W
Note
A class 2 measuring sensor (wavelength 660nm) is also used.

6Chapter 1
Introduction
System installation, disassembly, maintenance, and repair must be
performed only by authorized Orbotech customer support engineers, in
order to comply with all applicable safety requirements regarding the use
of laser devices.
Orbotech recommends that you provide laser safety training to all
employees who work on or around the laser system so that these employees
understand the bio-effects of lasers and laser radiation.
Full eye protection by safety goggles is required when machine is open
during service/maintenance (i.e. laser reaches Class 4) in compliance with
standard DIN/EN207. (See “Safety Goggles” on page 14).
Fire Equipment
Portable fire extinguishers must be on hand and in visible location in the
direct vicinity of the machine. Recommended type: carbon dioxide (CO2).

DP-100SL 7
Site Preparation Guide
Caring for Your System
• Only materials which have been approved by the manufacturer may be
used with the system.
• The system must not be used for temporary storage of any objects. The
shielding panels have a load capacity of up to 10 kg, designed for
carrying necessary work materials.
• Do not place any objects on the movable cover plates.
• Leaning, sitting, or stepping on the system is strictly forbidden.
• The machine must not be used in any way other than specified in this
manual or in the DP-100SL User Guide.
Noise Level
The system’s noise level is 70 dB (A). The noise level of the vacuum pump -
installed in separate room- is 86 dB (A).

DP-100SL 9
Site Preparation Guide
Chapter 2
DP-100SL Physical Description
Configuration
The DP-100SL comprises the following main units:
Figure 2.1 DP-100SL Site
DP-100SL
PLANT AIR
40µ & 5µ
FILTERED AIR
TEL
N/W
MAIN
POWER
SUN
W/S
e` N/W
TEL
LASER
SUPPLY BOX
CONTROL BOX
PUMP
HOSE
CABLE
N/W

10 Chapter 2
DP-100SL Physical Description
• Laser Imager Unit - including Power Connection Unit/Box and
Transformer (only in USA, Japan & Pacific)
• Laser Supply Box - containing Power Supply & Pump module and
Heat Sink/Chiller
• Vacuum System - comprising Vacuum Pump & Control Box
• Sun workstation with a Raster Image Processor (RIP)
The imager unit is connected to the workstation via Fast Ethernet.
It should be located in a yellow light room (as with standard contact
printers) with clean room conditions of class 100,000 or better
(US-Federal-Standard 209E).
Size and Weight
Table 2.1 lists weight and size information for the standard DP-100SL
units.
Table 2.1 Size and Weight of Standard DP-100SL Units (ready for operation)
Unit Width Depth Height Weight
DP-100SL Imager
(i.e. basic unit)
1654 m m
65.12 in
2644 mm
104.09 in
1755 m m
69. 11 in
2000 kg
4409 lbs
Laser Supply Box
(attached to basic unit)
110 0 m m
43.31 in
810 mm
31. 89 i n
510 m m
20.08in
100 kg
220 lbs
Vacuum Pump*
(in separate room)
334 m m
131. 50 i n
314 m m
123 . 62 i n
337 m m
132 . 68 i n
20 kg
44 lbs
Control Box (Vacuum)
(mounted on wall, at height
39.4 in/1m from floor)
300 mm
11 . 81 i n
16 0 m m
6.30 in
400 mm
15 . 75 i n
5.1 kg
11. 24 l b s
Sun Workstation**
(monitor, kbd, computer)
410 mm
16 . 14 i n
700 mm
27. 56 i n
420 mm
16 . 54 i n
15 k g
33 l b s

DP-100SL 11
Site Preparation Guide
*Dimensions refer to pump only (no add-ons included). Add-ons increase
Depth dimension by 400 mm (15.75 in).
** Measurements do not include a table on which the workstation is placed.
The customer must supply this table. Sun workstation measurements are
liable to change without notice.
Hose Lengths
Table 2.2 lists information on the size of the hose/s.
.
Table 2.2 DP-100SL Hose Lengths
Hose
Length
(standard
supplied)
Diameter
Compressed air line
(from the machine to plant air supply) 10 m 33 ft 0.39” (10 mm) outside
Note
For vacuum pump hoses/lines refer to Table 6.1, “Vacuum Line Lengths,”
on page 31.

DP-100SL 13
Site Preparation Guide
Chapter 3
Facility Physical Requirements
Safety Requirements
The DP-100SL should be installed in a room that can be isolated to
safeguard against laser hazards. These hazards can only arise during
periodic maintenance and service, in specific situations (hood open and
interlock neutralized). The safeguards described below are required during
such service procedures, and do not have to be activated during normal
usage of the system.
Preventing Access to the Imager Room during Service
The imager room door should have a lock that can be locked from the
inside to prevent access to the room. A box with a key to be used for entry
in case of emergency should be located next to the door, on the outside.
Note
The customer is responsible for ensuring conformance with local safety
regulations. As such, the requirements below can only be considered to be
recommendations.
!
Warning
When the DP-100SL cover doors are removed (servicing mode), the laser
becomes a Class IV hazard. In this situation, the laser beams diffused
reflection is extremely hazardous. Goggles must be worn. Service must
only be performed by an Orbotech qualified engineer.

14 Chapter 3
Facility Physical Requirements
Safety Goggles
When the DP-100SL is open, as during service and maintenance, all
personnel who come in contact with the machine must wear safety goggles.
Full eye protection by safety goggles is required, in compliance with
DIN/EN207 standard. The customer is responsible for providing safety
goggles for his operators.
If the DP-100SL is installed in an open space (not recommended), a method
must be available to completely isolate the unit from the rest of the room
during servicing procedures (example: relevant laser safety curtains).
External Warning Light
A red warning light should be placed on the outside of the imager room,
above the entrance. The light will be activated under certain service
conditions—when the laser is on, the hood up and the imager safety
interlock neutralized. The DP-100SL provides a 24V AC max 500mA for
the red light (see Figure 3.1, on page 15).
!
Warning
DP-100SL reaches Class4 laser radiation when open.
Note
It is the responsibility of the customer to provide and install a warning light
as described above.