operation manual protolaser s - north forge technology...

Operation Manual

ProtoLaser S

Artik

eln

um

me

r:1

24

50

7

ProtoLaser S

Operation manual 2.0, English

LPKF Laser & Electronics AG Osteriede 7 D-30827 GarbsenGermany

Phone ++ 49 - 51 31 - 70 95 - 0 Fax ++ 49 - 51 31 - 70 95 - 90E-Mail [email protected] http://www.lpkf.com

ProtoLaser S

Copyright© 2008 LPKF AG The distribution or copying of this manual or parts thereof in any form, as well as the use of its content, requires the written permission of LPKF AG. Subject to modifications. Translation of German originalArticle number: 124 507

Operation manual 2.0 Rev.: 30.09.2009 3

Table of contents

1 Product description 9

1.1 Brand and type labeling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.2 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.3 System requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111.4 Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121.5 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.6 Accessories (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.6.1 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2 Safety notes 18

3 Function description 33

3.1 Application range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4 Transport and storage 36

4.1 Transport notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364.1.1 Transportation lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5 Installation and start-up 43

5.1 Checklist for starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445.2 Positioning conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455.3 Installation and mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.3.1 Installing LPKF software and driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515.3.2 Connecting the exhausting unit (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . 575.3.3 Connecting the local compressed air system . . . . . . . . . . . . . . . . . . . . . . . . 595.3.4 External compressed-air system (optional). . . . . . . . . . . . . . . . . . . . . . . . . . 605.3.5 Cooling fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605.3.6 Connect the PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615.3.7 Connect the mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5.4 System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

4 ProtoLaser S

6 Operation 77

6.1 Switch-On the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776.2 Handling the software CircuitMaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 796.3 Adjustment of the laser source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 946.4 Switching off the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

7 Troubleshooting 95

7.1 Error code table motion I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 967.2 Error code table laser module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 977.3 Optimization of the processing quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

8 Maintenance and service 102

8.1 Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1028.2 Maintenance and service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1038.3 Service and maintenance by owner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

8.3.1 Extraction system TEKA LMD 508 (optional). . . . . . . . . . . . . . . . . . . . . . . 1048.3.2 Exhausting unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1048.3.3 Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1078.3.4 Air filter laser module/cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1138.3.5 List of exchange parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

8.4 Service and maintenance by manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . 1148.4.1 Laser source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

9 Storage 115

10 Appendix 116

10.1 List of figur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11610.2 List of tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11910.3 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12010.4 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Preface


Preface

Congratulations on the purchase of your ProtoLaser system. During the construction process of this system the main focus was placed on an easy operation, great usability and highest user safety. The laser, which has been available since 1960, is a source of radiation that has opened up completely new experimental possibilities for scien-tific research and has found very quickly application in the technical-industrial sector. The reasons for this are the special characteristics of laser radiation, which is distinguished by extremely high energy density, monochromatism, coherence and beam focusing properties. This is why the laser was used very soon in a wide range of scientific and technical fields.The LPKF ProtoLaser S is a laser system especially developed for proto-type production. This allows you to manufacture prototypes at low cost in just a few process steps. In addition, the laser system can be used for 2D structuring of metal layers, for structuring microconductors in copper and for abrasion-resistant marking and for engraving.This manual explains to you step by step the handling of the hardware of your ProtoLaser system. Prior to the first start-up / first operation, you should have completely read this manual. Please make sure to follow the safety regulations given in this manual.

Symbols used

6 ProtoLaser S

Symbols used

Registered trademark and brand identifications

Microsoft and Windows are brand identifications or registered trademarks of Microsoft Corporation in USA and/or other countries.All other trademarks belong to the respective companies.

WARNING

Danger to life or health.This symbol is used to highlight dangerous situations which pre-sent a danger for life or health if the safety notes are not adhered to by the user.Danger prevention information will be explained.

CAUTION

Hazards caused material damage.This symbol is used to identify hazards which will cause material damage if the safety notes are not adhered to by the user.Danger prevention information will be explained.

Tip: This symbol will be used to identify information on how to avoid malfunctions and improve the system efficiency.

Hints to this manual



This manual contains important handling information about the ProtoLa-ser S. This manual is written for persons who are trained by authorised LPKF service staff and are familiar with the basic functions of the win-dows operation system. Knowledge about safety and well behaviour inside the production areas is required. Also the knowledge about using a computer with the opera-tion system Windows 2000/XP is required.

Provisioning

For all activities with the ProtoLaser S system the manual must be availa-ble complete and readable. Every person who is authorised to work with the system must have access to this manual.The facility owner has to ensure that only persons who have read and understood this manual or are informed about the contents of this manual are authorised to work on the system.

Conventions used in this manual

bold text The following information will be written in bold text:• switches, operating devices, labeled interfaces

for example Power switch.• software elements:

– menu items, for example Data > Open...– input items, select items and select lists, for example. Tool Select

List– software buttons; for example Cancel– windows, dialog items, for example input windows Tool Positions

italic text The following information will be written in italic text:• proper names, for example Windows• software-messages, for example. „The file will be started...“

(Notice the quotation marks aren´t message parts!)


8 ProtoLaser S

activity challenges Indented headlines indicate the starting of an activity queue and refer the desired target. If the activity queue starts with a roman numeric character further activities must be done to reach the working target. An indented sentence started with a numeric character requests an action.The end of an activity sequence will be marked with square brackets. If applied the expected result or next activity step will be mentioned.Example:

Start up the machine for the first time

Assure the power feeding for the machine before starting up.

1. Insert the power plug into the power socket.2. Put the main switch to position I.[ ] The operation light is on.

figures Bold numeric characters are used for numbering (1) or dimensioning (50 mm).Bold numeric characters enclosed with bracket inside a continuous text (for example (1)) are used for the indication of graphic numbering.

Product description


1. Product description

1.1 Brand and type labeling

The type label is applied on the rear side of the system. When questions arise concerning the identification of the system and the corresponding equipment, always indicate the serial number that is stated on the label when calling the LPKF service personnel.

Fig. 1: Type label

1 System type label2 Serial number3 Laser class4 Wavelength5 Laser Power

6 Power connection value in volt7 Power Frequency in Hz8 Number of phases (power connection)9 Power consumption

1

2

9

3

8

4

5

7

6

Scope of delivery

10 ProtoLaser S

1.2 Scope of delivery

System components ProtoLaser S

System housing

Laser source

• Laser control / electronics

• Laser head

Laser machining head

• Scanning head

• Camera

• Lens

• Cooler

X/Y Vacuum table

Mechanical Z-axis

PC (provided by costumer)

USB PCI Adapter

Documentation

ProtoLaser S manual LogbookCircuitCAM manualCircuitMaster manualAcceptance certificate

Software

Program CD-Rom incl.

• CircuitCAM

• CircuitMaster

• Manuals in pdf format

• Driver

Product description


1.3 System requirements

One PC for data preparation with CircuitCAM and for the machine control software CircuitMaster for ProtoLaser is required. PC system requirements for the ProtoLaser S control software:

Additional material

Connection set

Starter kit incl.

• Lens cleaning tissue

• Sinter backing plate for vacuum table

• FR4 base material 18 µm

• FR4 base material 35 µm

• LPKF Cleaner

• Special plastic grease ISOFLEX TOPAS 5051

• Special ball collet MICROLUBE GB0

• Protection gloves

Minimum configuration

IBM compatible processor Intel Pentium IV 3 GHz (not Celeron), for example Intel® Core ™ 2 Duo E6300 2.8 GHz, 2MB L2 Cache FSB 1066 MHz, Speed Step Technology

1 GB DDR2 RAM or higher

2 GB free disk space on the internal hard disk (minimum)

Graphic card with min. 32 MB grafic RAM

1 x PCI port

1 x USB 2.0 interface

CD-ROM drive

15" VGA monitor• Resolution 1,024x768 / High Color (16 Bit)

OS: Windows XP, 32 Bit (english or multilingual version)

Manufacturer

12 ProtoLaser S

1.4 Manufacturer

LPKF Laser & Electronics AGOsteriede 7D-30827 Garbsen Germany

Recommended configuration

IBM compatible up Intel Pentium IV or higher (like Dual Core 2 GHz), forexample Intel® Core ™ 2 Duo E7300 2.66 GHz, 2MB L2 Cache FSB 1066 MHz, Speed Step Technology, EM64T XD-Bit

2 GB DDR 2 RAM or higher

8 GB free disk space on the internal hard disk

Graphic card NVIDEA with min. 512 MB grafic RAM

1 x PCI port

2 x USB 2.0 interfaces

DVD-ROM drive

17" or 19 " TFT monitor (VGA)• Resolution 1,280x1,024 / High Color (16 Bit)

OS; Windows XP 32 Bit (english or multilingual version)

Internet access

Phone + 49 - 51 31 - 70 95 - 0 Fax + 49 - 51 31 - 70 95 - 90E-Mail [email protected] http://www.lpkf.com

Product description


1.5 Certification

European declaration of conformity (German)

Konformitätserklärung nach Maschinenrichtlinie 98/37/EG Anhang II ADer Hersteller/Inverkehrbringer

erklärt hiermit, dass folgendes Produkt

den Bestimmungen der oben gekennzeichneten Richtlinie(n) - ein-schließlich deren zum Zeitpunkt der Erklärung geltenden Änderungen - entspricht.Bei einer nicht mit dem Hersteller abgestimmten Änderung der bezeich-neten Maschine verliert die Erklärung für dieses Gerät ihre Gültigkeit.Wir unterhalten ein von der BVQI zertifiziertes Qualitätssicherungs-system nach ISO 9001 und haben daher bei der Entwicklung und Her-stellung folgende EG Richtlinien und EN Normen beachtet:

LPKF Laser & Elektronics AGOsteriede 7D-30827 Garbsen

Produktbezeichnung: StrukturierlaserSerie-/Typenbezeichnung: ProtoLaser S

Certification

14 ProtoLaser S

Angewandte harmonisierte Normen

Weitere angewandte EU-Richtlinien• EMV-Richtlinie 2004/108/EG• Niederspannungsrichtlinie 2006/95/EG

Ort: GarbsenDatum: 20.08.2008

______________________________(Unterschrift) Herr Bernd Lange

EN 418:1992 Sicherheit von Maschinen - NOT-AUS-Einrichtung, funktionelle Aspekte - Gestaltungsleitsätze

EN 954-1:1996 Sicherheit von Maschinen - Sicherheitsbezogene Teile von Steuerungen - Teil 1: Allgemeine Gestalt-ungsleitsätze

EN 1050:1996 Sicherheit von Maschinen - Leitsätze zur Risikobeurteilung

EN 626-1:1994 Sicherheit von Maschinen - Reduzierung des Gesundheitsrisikos durch Gefahrstoffe, die von Maschinen ausgehen - Teil 1: Grundsätze und Fes-tlegungen für Maschinenhersteller

EN 60204-1:1997 Sicherheit von Maschinen - Elektrische Ausrüstung von Maschinen - Teil 1: Allgemeine Anforderungen

EN 60529:1991 Schutzarten durch Gehäuse (IP-Code)

EN 60825-1:1994 Sicherheit von Laser-Einrichtungen - Teil 1: Klassifi-zierung von Anlagen, Anforderungen und Benut-zerrichtlinien

EN 61000-6-2:2001 Elektromagnetische Verträglichkeit (EMV) -Teil 6-2: Fachgrundnormen - Störfestigkeit - Industriebereich

EN 61000-6-4:2001 Elektromagnetische Verträglichkeit (EMV) - Teil 6-4: Fachgrundnormen - Fachgrundnorm Störaussend-ung - Industriebereich

EN 12100-1 Sicherheit von Maschinen - Grundbegriffe, allge-meine Gestaltungsleitsätze - Teil 1

EN 12100-2 Sicherheit von Maschinen - Grundbegriffe, allge-meine Gestaltungsleitsätze - Teil 2

Product description


European declaration of conformity

EC Declaration of Conformity in accordance with Machinery Direc-tive 98/37/EC, Appendix II AThe manufacturer/seller

hereby declares that the laser system

meets the regulations of the directive(s) specified above - including their modifications applicable at the date of declaration.In case of making any modification to the machine not authorized by the manufacturer, the declaration for this unit shall become void.We maintain a quality assurance system according to ISO 9001 that has been certified by the BVQI, which is why our developments and produc-tions are in compliance with the following EC directives and EN stand-ardst:

LPKF Laser & Elektronics AG

Osteriede 7

D-30827 Garbsen

Product designation: Structuring laser

Serial/Type designation: ProtoLaser S

Certification

16 ProtoLaser S

Applied harmonized standards

Further used European directives• EMC-directive 2004/108/EC• Low-Voltage Directive 2006/95/EC

Town: GarbsenDate: 20.08.2008

______________________________Mr. Bernd Lange (CTO)

EN 418:1992 Safety of machinery - EMERGENCY STOP device, functional aspects - principles for design

EN 954-1:1996 Safety of machinery - Safety-related parts of control systems - Part 1: General principles for design

EN 1050:1996 Safety of machinery - Principles for risk assessment

EN 626-1:1994 Safety of machinery - Reduction of risks to health from hazardous substances emitted by machinery - Part 1: Principles and specifications for machinery manufacturers

EN 60204-1:1997 Safety of machinery - Electrical equipment of machines - Part 1: General requirements

EN 60529:1991 Degrees of protection provided by enclosures (IP-Code)

EN 60825-1:1994 Safety of laser installations - Part 1: Classification of installations, requirements and user guidelines

EN 61000-6-2:2001 Electromagnetic Compatibility (EMC) - Part 6-1: Generic standards - Immunity for residential, com-mercial and light-industrial environments

EN 61000-6-4:2001 Electromagnetic Compatibility (EMC) - Part 6-4: Generic standards - Immunity for industrial environ-ments

EN 12100-1 Safety of machinery - fundamental terms, general layout guidelines - part 1

EN 12100-2 Safety of machinery - fundamental terms, general layout guidelines - part 2

Product description


1.6 Accessories (option)

The ProtoLaser S can be equipped with the following accessories:

1.6.1 Consumables

Item Item number

Compressor for pressed air 122 805

Exhausting unit 124 391

Laser safety goggles 108 439

Measuring microscope 113 495

Measuring slide 117 943

Tool set 118 005

Item Item number

Lens cleaning tissue 101427

Sinter backing plate for vacuum table 115901

FR4 base material 18 µm 113082

FR4 base material 35 µm 101049

LPKF Cleaner 115891

Special plastic grease ISOFLEX TOPAS 5051 102244

Special ball collet grease MICROLUBE GB0 106976

Protection gloves 121653

Filter set for exhaustion unit "TEKA LMD 508" 124514

Safety notes

18 ProtoLaser S

2. Safety notes

This chapter contains information about safety, the intended use and lia-bility if you are interacting with the ProtoLaser S.If, after reading this manual, a situation should arise in which you are not sure how to use or service the ProtoLaser S, you should contact LPKF Support or consult a system expert.

Safety notes

WARNING

Danger to life!Missing or inadequate fuse protection may result in deadly elec-tric shocks and/or cause fire.N e v e r bridge the automatic fuse switch!

WARNING

Risk of injury!Since the materials you are handling with have a small size and razor-sharp rough edges, a big risk of injury exists.Make sure to wear protective gloves!

WARNING

Health hazard!Direct contact of the laser beam with skin results in intensive burn and causes invisible interior injuries. Diffused light which contacts your skin over a space of time takes the same effects as well.Beware in any case of direct contact between the laser beam and the skin.

WARNING

Health hazard!Hazardous substances can be generated when materials are pro-cessed by the laser beam. These may be cancer-causing.Only use materials which are approved by LPKF for work with and always activate the provided exhausting unit during operation.

WARNING

Health hazard!All safety measures which are described in the material safety data sheets must be strictly adhered to!Keep the safety data sheets near by the system. It is necessary to read the safety data sheets carefully and to adhere to all required safety measures.

Safety notes


General safety notes

• Read the manual carefully before you start working with the system. If any obscurities occur please contact a competent person or the LPKF Support.

• Utilise this system only for its conventional use.

• Never use this system in an environment where danger of explosion or fire exists.

• Operate this system in permitted environments only.

• Make sure that unauthorized persons cannot enter the room. The international safety regulations specified for this class of laser product must be complied with.

• Never look directly into the beam, even if you are wearing laser protective goggles.

• Operate this system only with accessories which are approved by LPKF and with original LPKF tools.

• Operation with this system is only allowed if it is in a pro-per state. Before usage a visual check is required. In this process look out for defective cables and hoses.

• Make sure that all protection devices are working pro-perly. Bridging, avoiding of or switching of the protection devices is not allowed!

• Make sure that there is no risk of stumbling by cables or hoses.

• This system has only to be operated, maintained and repaired by persons who are authorized.

• Training is carried out by LPKF or by persons authorized by LPKF.

• All service operations must be agreed with LPKF.

• Keep children away from the described workspace.

• Eating, drinking or smoking in the workspace is not allo-wed.

(Page 1 of 2)

Safety notes

20 ProtoLaser S

• Make sure to comply with the generalities and rules for accident prevention and environment protection.

• Operation, maintenance and repair is only permitted with prescribed protective equipment.

• Check performance of the emergency stop switch regu-larly.

• The system must never be operated by more than one person.

• Disconnect the system from the mains during all mainte-nance work on the system.

• Maintenance and service operations must be done regu-larly.

• Whenever damage or malfunctions occur, shut down the system immediately. Delete failures immediately. If it is not possible to correct the failures, switch off the system and assure it against starting up.

General safety notes (continued)

(Page 2 of 2)

Safety notes


Conventional usage

The ProtoLaser S is used for structuring ultra fine circuit paths in copper materials, for abrasion-resistant marking and for engraving. The system must be used only in combination with the applications described in this manual and the LPKF Software CircuitMaster.

Incorrect usage

Do not use the ProtoLaser S for the machining of easy flammable mate-rial like paper, plastic and so on.Contact LPKF service if you are in doubt about the usage of the process material.It is not allowed to operate the system without the standard cover and housing parts. Do not control the laser system with another or modified software.

Safety notes

22 ProtoLaser S

Liability

The ProtoLaser S has been developed and built in accordance with the state-of-art standards and recognised safety rules. Nevertheless, the usage may constitute a risk to life or physical condition of the user, or third parties, or cause damage to the machine and to other material property.

disclaimer The manufacturer cannot be held liable for damage caused by the follo-wing conditions:

• Improper handling, including any usage not mentioned in this manual.

• Use in unsuitable environments.• Installation and operation by insufficiently informed or unauthorised

persons.• Non-observance of the legal safety requirements.• Non-observance of the technical information of this manual.• Installation carried out incorrectly.• Missing, faulty or insufficient maintenance.• Unauthorised technical modifications.• Use of non-original spare parts and those not specifically designed

for this machine.• Use of non-approved work pieces and materials.

Safety notes


Laser protection instructions

C a u t i o n : T h i s c h a p t e r s h o u l d b e r e a d c a r e f u l l y b y a l l u s e r s b e f o r e o p e r a t i n g t h e l a s e r s y s t e m a n d t h e s a f e t y p r e c a u t i o n s g i v e n m u s t b e o b s e r v e d !

Content of the laser protection instruction

1. Laser radiation and its protection classes2. Laser radiation and its hazards3. Effect of laser radiation on biological tissue4. Effect of laser radiation on the human eye5. Other hazard possibilities and side effects6. Safety regulations and operating instructions7. Laser area behaviour8. Safety precautions and equipment9. Use of body protection equipment10. Check of constructional and operative safety equipment11. Accident behavior


24 ProtoLaser S

Laser radiation safety classes

The individual laser safety classes are described here to explain the meaning of the individual hazards.

class 1: The accessible laser radiation is not dangerous

class 1M: The accessible laser radiation is in the spectrum of 302.5 to 4,000 nm. The accessible laser radiation is not hazardous for the eye provided the radiation cross section is not reduced by optical instruments (magnifying glasses, lenses, telescopes).

class 2: The accessible laser radiation is only in the visible spectrum (400 to 700 nm). Short-term exposure (up to 0.25 s) is not hazardous for the human eye.

class 2M: The accessible laser radiation is in the visible spectrum of 400 to 700 nm. Short term exposure to radiation (of up to 0.25 s) is not hazardous for the human eye, provided the cross section is not diminished by optical instru-ments (magnifying glasses, lenses, telescopes).

class 3A: The accessible laser radiation is hazardous for the human eye when the radiation cross section is reduced by optical instruments. If this is not the case, the emitted laser radiation in the visible spectrum does not pose a hazard when the exposure time is short (up to 0.25 s) nor does it pose a hazard in other spectral ranges even with long exposure times.

class 3R: The accessible laser radiation is in the spectrum of 302.5 to 10,600 nm and is hazardous for the human eye. The power or energy is a maximum of five times the limit value of the permissible radiation of class 2 in the spectrum of 400 to 700 nm.

class 3B: The accessible laser radiation is hazardous for the human eye and in cer-tain cases also for the skin.

class 4: The accessible radiation is extremely hazardous for the human eye and hazardous for the skin. Even diffuse reflected radiation may be danger-ous. The laser radiation can pose a fire or explosion hazard.

Safety notes


Hazards of laser radiation

Laser radiation presents two basic hazard potentials.

Primary hazards: The primary hazards of laser radiation result from the laser beam itself. The hazards are:

1. direct laser radiation2. indirect laser radiation (diffused radiation from beam)3. reflections of the laser radiation in the room

Details regarding the effects of this radiation on the human body will be given later.

Secondary hazards: The secondary hazards of laser radiation can be subdivided into direct and indirect hazards:

Direct hazards: Indirect hazards:

High voltage (of System) Hazardous substances (from material processing)

High frequency Fire hazard (through effects of heat)

Dispersion/ pump radiation (of laser bulbs)

Ignition of explosive substances

Optical system (from exploding)

Chemical substances (with gas lasers)


26 ProtoLaser S

Effect of laser radiation on biological tissue

The interaction between laser radiation and biological tissue varies highly. It ranges from skin mutating processes resulting from long radia-tion periods at low radiation density up to so-called photo disruptive effects. These lead to an extremely rapid increase of the temperature in the eye resulting in shock waves. This results in injury to the retina.

t: Radiation duration in secondsP: Laser Power in WE: Intensity in Watt/cm²

Possible injury depending on radiation wavelength

Type of damage

Photochemical: Thermic: Photomechanic:

t =10...1,000 s, CW t = 1 ms...1 s, quasi CW t = 10 ps...10 µs

P < 100 mW P< 20...100 W

E < 50 mW/cm² E < 50...100 W/cm² E > 106 W/cm²

Spectral range Eye Skin

Ultraviolet C (180 nm - 280 nm)

Sunburn

Ultraviolet B (280 nm - 315 nm)

Inflammation of cornea Accelerates ageing of skinIncreased pigmentation

Ultraviolet A (315 nm - 400 nm)

Cataract Browning

Visible light (400 nm - 780 nm)

Photochemical and thermal injuries to retina

Photosensitive reactionsBurning

Infrared A (780 nm - 1400 nm)

Burning of retina

Infrared B (1.4 µm - 3.0 µm)

Watery bulges, burning of cornea

Burnings

Infrared C (3.0 µm - 1 mm)

Burning of cornea alone

Safety notes


Effect of Laser radiation on human eye

The degree of transmission (energy absorbed) by the eye depending on the wavelength is an important figure in determining the maximum per-missible radiation values. It is obvious that the radiation in the visible range can reach the retina completely; the transmission factor is nearly one.

Moreover, the laser radiation is focused differently in the eye depending on the wavelength (see following illustration).

Fig. 2: Wavelength de-pendent transmis-sion of eye

Fig. 3: Effect of laser radi-ation on human eye


28 ProtoLaser S

Possible photochemical injury to eye:

• Inflammation of the cornea• Conjunctivits• Cataract• Blindness

Possible thermal injury to eye:

• Inflammation of the cornea• Cataract• Separation of the retina• Blindness

Fig. 4: The human eye

1 Iris2 Lens3 Cornea4 Pupil5 Ciliary body6 Retina

7 Yellow spot8 Blind Spot9 Optic nerves10 Sclera11 Vascular choroid

123

4

5

6

7

8

9

10

11

Safety notes


Other Possible Hazards

Optical systems: The materials or coatings can release hazardous particles and gases such as resonates and selenides in the event of breakage, overheating or other destructive effects..

Positioning laser: A positioning laser is usually a compact laser diode or HeNe laser classi-fied in class 2. The natural lid-closing reaction generally provides satis-factory protection for the eye. It is generally not hazardous for the skin

Laser gas: With excimer lasers, the toxic and corrosive halogenes chlorine and fluo-rine represent a considerable danger. Observe all rules regarding storage and use of toxic substances. Provide for good ventilation of the working area. It is mandatory to chain gas bottles if stored upright.

UV radiation: When processing metals with laser, invisible UV radiation is released by the resulting metal vapor plasma, which can lead to injury to the eyes and skin. Here, a hazard is posed particularly during welding applications.


30 ProtoLaser S


Safety Precautions / Company Instructions

• Only the persons whose presence is required should be pre-sent in the laser area.

• Laser radiation of classes 2, 2M, 3A, 3B and 4 should reach only as far as required for the specific application.

• Avoid uncontrolled reflected radiation of class 3 or 4 lasers; keep reflecting or glossy objects or surfaces out of the neigh-borhood of the laser wherever possible, remove or cover.

• When switching on a class 3 or 4 laser device, always announce to all those present in the laser area immediately beforehand.

• Injury from laser radiation can only be excluded when uncon-trolled reflected radiation cannot occur during operation and manipulation in the laser beam is prevented.

• Suitable eye protection equipment offers protection against direct, reflected or diffusely scattered laser radiation. Howe-ver, never look directly into the beam even when wearing eye protection.

• The use of suitable eye protection is particularly important for lasers which can radiate different wavelengths.

• Before using any type of eye protection, ensure that it is sui-table for the specific application and does not have any obvious defects.

• Report obvious defects like changes of the protective filters such as cracks, changes in color, changes in the light per-meability as well as faults in the base element immediately to the laser protection representative.

Safety notes


Behaviour in laser area

Intended use Take safety precautions according to the laser class used.

During maintenance/ service/ repair

1. Prevent laser radiation from exiting if possible.2. If necessary, inform people in laser area and take appropriate safety

precautions.3. Shield laser area with curtains or dividing walls and attach appro-

priate warning signs at the entry to laser area.4. Care is also required when working on the electrical and mechanical

parts of the system.

Demonstrations Inform visitors of dangers resulting from the laser. If possible, only dem-onstrate laser systems classified in classes 1 or 2. For higher classes provide appropriate protective equipment for visitors and ensure that it is used

Safety Precautions and Safety Equipment

Organizational measures • Shielding• Install and use a vacuum system• Reduce reflection in operating room • Inform employees• Mark laser area• Observe operating safety and legal regulations

Personal protective equipment

• Wear laser protective goggles• Use respiratory protection• Wear work clothing


32 ProtoLaser S

Operator Protection

Always wear body protection when accident or health hazards cannot be excluded by other means. Particularly in the case of:

• Optical system adjustment work• Service and maintenance work• Use of the laser system other than that intended as well as process-

ing of parts which do not enable appropriate shielding of the laser beam

Constructional and Apparative Protective Equipment

1. Ensure that the constructional and apparative protection devices are in good condition. If not, inform the responsible expert or laser pro-tection specialist to eliminate the defects.

2. If the normal processing is not possible without hazards shut down the laser system.

Behavior in the Event of Accident

1. If there is reason to believe that eye injury has occurred from the laser radiation, the injured person has to consult an eye specialist immediately.

2. Inform the laser protection representative.3. Record the events leading to the accident.

Function description


3. Function description

The LPKF ProtoLaser S system consists of five essential functional units:• Laser source• Cooling unit• Laser beam deflection system with objective• X/Y/Z vacuum table• Camera system

The laser source generates infrared radiation of wavelength 1,064 nm.With this laser source it is possible to cut copper. The speedy structuring process of the system is based on the special scanning head and an opti-mal process routine. Further material processing like drilling and cutting can be done with the optionally available ProtoMat systems (Drill/MIll plotter).

Function of the laser source

The laser source used in this system is a diode-pumped solid-state laser system, which was developed for emitting pulsed laser radiation. The system delivers laser radiation of wavelength 1,064 nm at a power of <20 W in CW. The laser was designed for integration into a complete system. The extremely high laser peak performance of the system at repetition rates of up to 100 kHz allows a much higher machining rate in combina-tion with very low operating costs. In addition to that, the laser has excel-lent beam quality, excellent pulse stability and precise energy control. All these properties make this laser an excellent laser tool.

Function of the optical X/Y laser beam deflection

The X/Y laser beam deflection consists of a laser beam deflection system which is based on a scanner and of a telecentric F-Theta objective. The laser beam is deflected into the desired direction via deflecting mirrors. A more detailed explanation of this lens will follow in a later chapter when the beam path is explained.

Application range

34 ProtoLaser S

Function of the Z-drive

The mechanical Z-axis allows material of a wide range of thicknesses to be machined. The mechanical Z-axis is driven by a stepping motor via a gear, thus achieving an extremely precise positioning accuracy. Com-bined with an optical calibration system, the Z-drive adjusts the laser beam for the optimal focus point.

3.1 Application range

The ProtoLaser S laser system is suitable for structuring:• micro copper circuit paths on circuit board materials, for example

FR 4• RF-substrates• RFIDs on PET foil substrates• RF filters on ceramic substrates

WARNING

Danger to life or health!Any other kind of usage is not allowed in general.Usage of other cutting gases or materials must be agreed with LPKF AG.

Function description


3.2 Technical Data

Tab. 1: Technical data

Technical Data: LPKF ProtoLaser S

Max. layout area (X/Y/Z) 229 x 305 x 10 mm (9“ x 12“ x 0.4“)

Structuring speed Ø 6 cm² / min (1 inch²/min) (Ø based on 18 µm Cu)

Beam diameter in focus 25 µm (1 mil) (Ø based on 18 µm Cu)

Minimum track/gap 50 µm/25 µm (2 mil/1 mil) (depend on material and laser parameters)

Resolution scan field 2 µm (0.08 mil)

Repeatability ± 2 µm ( ± 0.08 mil) (direct repeated movements of the laser beam)

Laser pulse frequency 10 - 100 kHz, continuous wave (CW)

Machine dimensions (W x H x D)- with open working door

875 x 1,430 x 750 mm (34.5“ x 56.3“ x 29.5“)875 x 1,730 x 750 mm (34.5“ x 68.1“ x 29.5“)

Machine weight 260 kg (573 pounds)

Operation environment specifications

Electric supply 110/230 V, 50-60 Hz, 1.4 kW

Compressed air supply 8 bar (116 psi), 160 l/min (3.5 cfm)

Cooling unit water-cooled (intern cooling circuit)

Ambient temperature 22 ± 2 °C (68 °F ± 2 °F)

Required accessories Exhaust unit, air compressor

Transport and storage

36 ProtoLaser S

4. Transport and storage

T h e f o l l o w i n g c h a p t e r d e s c r i b e s t h e t r a n s p o r t c o n d i t i -o n s i n a b r i e f o v e r v i e w.

4.1 Transport notices

• All transport equipments must be selected by taking into account the corresponding total weight.

• The transport vehicle should be equipped with a special spring sys-tem (air-cushioned box trailer). Impacts have to be avoided.

• For transport in special climatic zones or transport by sea, special precautions have to be taken (contact LPKF service).

• The penetration of moisture and dirt during transport must be pre-vented by taking suitable measures.

CAUTION

Damage of the system!The X/Y positioning system can possibly move and so get dama-ged if pc and laser control are not switched off .Before transportation switch off the PC and afterwards the laser control. So it will be ensured that the X/Y positioning system does not move.

CAUTION

System damage!Sensitive and adjusted optical components Inside the laser head can be damaged if the transport information will not be adhered to.Transport the laser head in a horizontal position and take care that the transport is always shockproof, otherwise the error free operation of the laser head can not be warranted.



4.1.1 Transportation lock

The cooling unit located behind the front panel on the front side of the system housing is equipped with a transportation lock. To mount/dis-mount this transportation lock act as follows:

Dismounting the transportation lock

1. Open the front panel of the ProtoLaser S system (see following figure).

2. Use a 3 mm hexagon key to loosen the two screws under the front panel.

CAUTION

Damage of the system!The cooling unit can be damaged if the system will be transported over long distances (for example room to room) without transpor-tation lock.Always install the transportation lock before every transport acti-vity.

Fig. 5: Removing the front panel

Transport notices

38 ProtoLaser S

3. Remove the front panel like shown in the following figures.

The cooling unit and the transportation lock are visible now (see following figure).

Fig. 6: Removing the front panel

3.2.1.



4. Loosen the two screws (2) which connect the transportation lock angle (1) with the system housing (see following figure)

Fig. 7: Screw positions of the transportation lock

1 Transportation lock angle2 Connection between transportation lock angle and system housing

3 Connection between transportation lock angle and cooling unit

4 Cooling unit

1 1

23

4 32

Transport notices

40 ProtoLaser S

Notice: Put the screw with rubber piece aside. You will need this screw for your following steps.

5. Pull out the cooling unit a little bit.6. Loosen the screws that connect the transportation lock angle with

the cooling unit (3, Figure 8).7. Remove both transportation lock angles.

Fig. 8: Screws of the transportation lock

1 Screw with rubber piece 2 Transportation lock angle

1

2

Tip: Store both transportation lock angles nearby. You will need it again for transportation of the ProtoLaser S later.



8. Push the cooling unit approx. 2 cm into the system housing (see following figure).The cooling unit is now able to operate freestanding.

Fig. 9: Pushing the cooling unit into the rack

1 Handholds for pushing or pulling the cooling unit

1

Tip: There is a resistance at the beginning of the bearing. This causes difficulty when you are pushing the cooling unit (see following figure).

Transport notices

42 ProtoLaser S

9. Fix the screw with the rubber piece (4) in front of the cooling units bearing (see figure above).

Note: The remaining three screws of the transportation lock can be fixed into the system housing again.

[ ] The dismounting of the transportation lock is finished now.

To mount the transportation lock act in reverse order.

Fig. 10: Resistance of the bearing

1 Handholds for pushing the cooling unit2 Bearing with resistance

3 Roller bearing4 Screw with rubber piece

1

2

3

4

Installation and start-up


5. Installation and start-up

O n l y a u t h o r i s e d s ta f f i s a l l o w e d t o f u l f i l l t h e a s s e m -b l i n g , m o u n t i n g a n d i n s ta l l a t i o n w o r k o n t h e s y s t e m . T h e l o c a l s a f e t y i n s t r u c t i o n s m u s t b e o b s e r v e d . I f y o u a r e n o t s u r e i n a n y w a y p l e a s e a s k a c o m p e t e n t p e r s o n o r c o n ta c t t h e L P K F S u p p o r t .

General operation details

Operation details

• Danger to life and health if electrical components are handled improperly. Motors are operated with a voltage of 50 V DC.

• All important adjusting places are labeled and sealed. For any kind of self-contained adjusting liability is not assu-med.

• For safety reasons refrain from all kinds of manipulation inside of the system during operation.

• During operation the compressed air must comply with the denoted values.

• Switch off the system completely during maintenance.

• External shock load or rather force attack may change the adjustment of the table and must be avoided.

Checklist for starting up

44 ProtoLaser S

5.1 Checklist for starting up

Tab. 2: Checklist for starting up

Checklist

Pay attention to placement conditions (see chapter 5.2‚ „Position-ing conditions”, on page 45)

Pay attention to general operation details (see chapter ‚ „General oper-ation details”, on page 43)

Check connections see chapter Chapter 1.3‚ „System requirements”, on page 11

Check operability and data connection of: • electrical connections• exhausting• data cable to vacuum

table



5.2 Positioning conditions

When installing the ProtoLaser S system, the following points must be taken into account:

• Check the system for transport damage before starting the assem-bling work.

• Danger signs must inform about the laser operation.• The room must be clean and dust-free. • The ground must be antistatic and must have an adequate sustaina-

blity. The total weight is 260 kg!

Tab. 3: Climatic conditions

Tip: We recommend to use flagstone (bearing force min. 65 kg/cm2)for the basement).

Climatic conditions

temperature 22 °C ± 2 °C (68 °F +/- 4 °F)

periodic change max. 0.5 °C/h

humidity max. 60 %

Positioning conditions

46 ProtoLaser S

Minimum required space

Notice: Do not walk through the areas marked red in the following figure during the operation process. Due to the connection cable the risk of stumbling is high. Do not barricade the marked blue areas because the access to system compon-ents must be possible..

Fig. 11: Minimum required space

1 Exhaust unit2 Pocket filter box

3 ProtoLaser S4 Recommended position for table and PC

1 2 3 4

Tip: The working area around the system must have 600 mm additio-nal space.



Aligning

The ProtoLaser S has four pedestals with rolls and so the system posi-tioning is very easy. After you have determined the final position of your system it has to be aligned horizontally with the four integrated pedestals (see arrows in following figure).

Fig. 12: Pedestal ProtoLaser S

1

2

3

4


48 ProtoLaser S

Aligning the system

1. Pull the ring (see following figure) to pull out the height adjustment lever of the pedestals.

2. Adjust the reversing lever (1) to the right for turning the pedestal downwardsor: Adjust the reversing lever (1) to the left for turning the pedes-tal upwards

3. Pull the height setting lever of pedestals bidirectional until you have reached your desired result.

4. Repeat the steps 1- 3 for the rest of the pedestals until ProtoLaser S is aligned horizontal.

Note: Check the alignment of the system by using a water level.

[ ] Now the system is placed in a horizontal position.

Note: The system is placed stationary now. It can not be moved any more. To move the system you have to turn the pedestals upwards like described in steps 1-3.

Fig. 13: Adjusting lever for height setting

1 Reversing lever for pedestals for upwards or downwards selection

2 Height setting lever (= turn pedestals upwards or downwards)

3 Ring to pull out the height setting lever of pedestals.

1

2

3



Required Connections

Tab. 4: Required Connections

Required connections

electrical interface

230 V/110 V, 50/60 Hz, 1.4 KW

cooling unit

internal cooling circuit, no external cooling required

Compressed-air supply

pressure min. 6 bar (87 psi) / max. 8 bar (116 psi)

compressed air consump-tion

appr. 160 l/min (3,5 cfm)

Tip: If the power supply voltage or transformer output voltage is not stable and does not conform to the values given above use a voltage stabilizer to ensure the output.


50 ProtoLaser S

Local main voltage

Check the adjusted voltage of the cooling unit (110V / 230V) before the ProtoLaser S will be connected to the mains voltage socket. The setting must be according to the local main voltage (see following figure).

Note: Any other power supply units of the system are switched-mode power supplies. They adjust themselves to the local main voltage automatically.

Fig. 14: Switch over volt

1 Adjustment for main voltage

1



5.3 Installation and mounting

Note: LPKF can run the first start-up. For further information about optional training or installation contracts please contact the service division of LPKF.

Please follow these steps to install the ProtoLaser S:1. Install the software and driver.2. Insert the USB PCI Adapter into the PC.3. Connect the exhausting unit (optional).4. Connect compressed air unit.5. Fill the cooling fluid into the cooling unit6. Connect the ProtoLaser S to PC.7. Connect the ProtoLaser S to the mains power supply.

5.3.1 Installing LPKF software and driver

The LPKF software and hardware-drivers have to be installed. You can find the software on the delivered CD CircuitMaster ... & CircuitCAM ..

Starting the software installation

1. Put the CD CircuitMaster ... & CircuitCAM ... into the CD drive.Note: The start of the welcome window may take a few seconds.

2. If the welcome window "Rapid PCB Prototyping" is not displayed automatically: Start the file setup.exe from the CD.

CAUTION

System damage!If a transformer with another pin assignment is used, the system can be destroyed. Only use transformers which have pin assignments like descri-bed in table 1 on page 39.

Installation and mounting

52 ProtoLaser S

The LPKF welcome window is displayed.

3. Select the desired language.4. Click on Install Software.

Now you can select the software to be installed.

Note: Install the hardware-drivers for your ProtoLaser S first.

5. Click on Install Driver.The drivers for the gateway, the laser beam defraction system and pc interface card are installed.

Install the USB camera drivers6. Click on Install USB Driver.

The InstallShield Wizard for the camera is displayed.

7. Follow the installation instructions by clicking on Next.

Fig. 15: Welcome window with language choice



During the installation routine you will get to this point.

8. Click on Install Driver.The following menu window will be shown:

9. Select the desired language.

Fig. 16: Install drivers for camera

Fig. 17: Choose language


54 ProtoLaser S

Follow the installation routine until this menu point is displayed:

10. Select the setup type USB.11. Follow the installation routine until the camera installation is finis-

hed.[ ] The installation of the hardware drivers is finished now.

Installing CircuitMaster

Note: The LPKF software CircuitMaster has been factory configured especially for your ProtoLaser S. To guarantee data communication between ProtoLaser S and CircuitMaster you have to copy the corresponding configuration data after installation.

1. Click on Install CircuitMaster.The InstallShield Wizard for CircuitMaster is opened.

2. Select the language for your CircuitMaster operating interface.3. Click on Next.4. Click Next to accept the folder configuration.

Fig. 18: Select setup type



5. Click on Install.Note: To guarantee data communication between ProtoLaser S and Cir-cuitMaster you have to copy the corresponding configuration data (see„Copying the configuration data“ on page 55) after installation. You can find the required configuration data on the delivered cd Configu-ration Files.

6. Click on Finish after passing through the installation routine.7. Remove the installation CD.[ ] The driver and software installation is finished now.

Copying the configuration data

Note: Make sure that the serial number on the CD Configuration Files is identi-cal to the serial number of the laser system (see labeling on the reverse side of the ProtoLaser S)

1. Put the cd Configuration Files into the drive.2. Start the Windows Explorer.3. Open the folder Calibration_files on your drive. 4. Highlight all existing folders.5. Copy the highlighted folders.6. Paste the folders you have copied into the program folder of Circuit-

Master.Note: The existing data in the folder have to be overwritten.

7. Take the CD Configuration Files out of the drive.

[ ] The installation of CircuitMaster is finished now.


56 ProtoLaser S

Installing CircuitCAM

CircuitCAM is necessary to prepare and convert layout data from circuit board plotter into a file format (for example LMD format) which can be read by CircuitMaster. For the ProtoLaser S operation the installation of CircuitCAM on your PC is not required.If you want to practice work with ProtoLaser S by using the delivered tutor data, you should install CircuitCam on the connected PC.For further information about the CircuitCam installation read the deli-vered CircuitCAM manual.

Installing the PC interface card and USB PCI Adapter

1. Plug-in the PC interface card and the USB PCI Adapter into your PC (Fig. 19 on page 56).

2. Switch-on the system (see Chapter 6.1‚ „Switch-On the system”, on page 77).

3. Start-up the PC.Note: The installation instruction for the USB PCI adapter can be taken from the supplied manual.

Tip: If the hardware-detection-tool does not start automatically, click in the Windows bar on Settings > control panel > Hardware. Allocate the driver of the delivered CD manually.



5.3.2 Connecting the exhausting unit (optional)

We recommend the exhausting unit TEKA LMD 508 (not included in scope of delivery of ProtoLaser S).You can order the exhausting unit which is described in a separate manual.

Connect the exhausting unit as follows

1. Connect the extraction hose of the exhausting unit to ProtoLaser Sand to the exhausting unit (see following figure).

Fig. 19: Connecting the hose of exhausting unit

1 Connection exhausting unit > pocket filter, flange exhausting unit

2 Connection pocket filter > exhau-sting unit, flange pocket filter

3 Connetion pocket filter > Pro-toLaser S, flange pocket filter

4 Connection ProtoLaser S > pocket filter, flange ProtoLa-ser S

5 ProtoLaser S6 Pocket filter unit7 Exhausting unit

1 2 3 4

567


58 ProtoLaser S

2. Connect the cable of the exhausting unit to the ProtoLaser S and to the exhausting unit (see following figure).

Fig. 20: Connecting cable exhausting unit

1 TEKA exhausting unit2 Vacuum control interface TEKA

exhausting system

3 Connecting cable 4 Vacuum control interface ProtoLaser S

1

2

3

4



5.3.3 Connecting the local compressed air system

The hose of the compressed air unit has to be connected to its local com-pressed air system. The following supply is required:

• Quick disconnect coupler NW 7,2 (working pressure 0 - 35 bar)

The compressed air unit has to be connected as follows

1. Connect the hose of the compressed air unit to the reverse side of the ProtoLaser S (see following figure).

2. Put the insertion nozzle of the compressed air hose into the quick disconnect coupler of your local compressed air unit.

[ ] The compressed air unit is connected now.

Fig. 21: Connection com-pressed air unit

1 Insertion nozzle NW 7,22 Compressed air hose

3 Connection compressed air hose of the ProtoLaser S (rear system side)

1 23


60 ProtoLaser S

5.3.4 External compressed-air system (optional)

If there exists no local compressed-air system, then we recommend to order the optional compressed air system described in the following. Note: Take into consideration the dimensions noted in the following table (WxDxH) as the refrigerant type dryer is only suited for wall-fastening.

5.3.5 Cooling fluid

The cooling fluid that is supplied in an external container must be filled into the system before it is first operated.

Filling in the cooling fluid

1. Open the cap of the filler (1) at the cooling unit (see following figure).

Article description Article number

Compressor for compressed-air supply especially for LPKF ProtoLaser, consisting of:

• Compressor 240 l/min (970 x 480 x770 mm)• Refrigerant type dryer 500 l/min

(325 x 262 x 742 mm)• Quick coupling• Male coupling• Locking screw• Reducer• Connecting hose

122 805



2. Fill in the supplied cooling fluid.The filling level display (3) shows the corresponding filling level.

3. Switch on the system.4. Wait some minutes and check the filling level of the cooling system.5. If necessary add cooling fluid.6. Switch off the system. [ ] The cooling fluid is filled.

5.3.6 Connect the PC

When the software is installed on the PC the PC must be connected with the ProtoLaser S. The data transmission based on a USB connection. The "USB CAM" cable and the "USB PLS" cable must be connected to the PC.

Fig. 22: Filler at the cooling unit

1 Filler cooling fluidt2 Drain cooling fluid

3 Filling level display cooling fluid

1 2 3


62 ProtoLaser S

1. Lay the USB PLS cable to the PC.2. Plug the connector of the USB PLS cable into a free USB interface

of the PC main board.3. Lay the USB CAM cable to the PC.4. Plug the connector of the USB CAM cable into the USB interface of

the PCI card.[ ] The ProtoLaser S system is connected to the PC.

5.3.7 Connect the mains power supply

The ProtoLaser S must be connected to the mains power supply.1. Plug the mains power connector into the IEC socket on the rear

side of the ProtoLaser S system.2. Lay the mains power cable to a free earthing contact socket.3. Plug the mains power connector into the earthing contact socket.[ ] The ProtoLaser S system is connected to mains power supply.

Fig. 23: USB connection cables

1 USB CAM connection cable 2 USB PLS connection cable

1

2



5.4 System components

This chapter describes the system components and the operation ele-ments of the ProtoLaser S. First of all make yourself familiar with several components and parts of the system before starting operation.

ProtoLaser S

The functions of the switches are described in the following table:

Fig. 24: Overview ProtoLaser S

1 Signal light2 Cover with laser radiation protec-

tion pane

3 Emergency stop button4 On/Off switch

5 Mains switch (on-off)

2

3

1

4

5

System components

64 ProtoLaser S

Signal light (1) The signal light shows different operating states. These operating states are recorded in a status table (see for example. Fig. 47 on page 88).

• The signal light status is red if there is any system error, for example when during the actual state the referencing of the axis is necessary.

• The signal lamp status is yellow if during an actual work any action caused a reset, for example: The door is open. After you close the door, the status will expire.

• The signal lamp status is green, if the system is ready for operation or if the system is working.

Emergency stop button (3) By pressing the emergency stop button the system will be shut down imme-diately. This shut down is intended for emergency only, because the laser source is not cooled down correctly. The durability will be reduced if the laser source is not cooled down correctly for several times.

Main switch(5) The mains switch on the backside of the system housing is used for swit-ching ON/OFF the mains voltage. The mains switch does not start-up the system!

Power button (4) First switch on the main switch and than press the power button as well to start the system.



Components inside the system

Behind the front cover are the following components:• Cooling unit for the laser source • Power supply for the laser system• SMCU II (axis control X/Y)• DAC module (axis control Z)

Fig. 25: Components in-side the system

1 Cooling unt for the laser source2 Air filter for cooling unit3 Cooling-water discharge 4 Cooling-water intake5 Display diode temperature6 Filling level indication cooling water

7 DAC module (axis control Z)8 SMCU II (axis control X/Y)9 Key switch service10 Air filter for power supply11 Power supply for the laser system

1 2 3 4 5 6

7891011

System components

66 ProtoLaser S

Behind the side panel on the right side you will find the control cabinet.

Fig. 26: Components in-side right hand

1 Protection unit2 Main relay3 Power supply scanning head 12V4 Power supply 5V

5 Power supply 24V6 Power supply 50V7 Power distribution laser system8 Motion system SMCU II & DAC

1 2 3 4 5 6

78



Positioning system

The integrated X/Y/Z table precisely moves the work piece under the laser, positioning the work piece in accordance with the addressable laser fields. An integrated vacuum table holds the work piece flat against the work surface, without the use of pins or clamps.

Fig. 27: Positioning system

1 X-axis2 Y-axis3 Z-axis4 XYZ-table

5 Exhausting flow6 Pneumatic maintenance unit (6 bar)7 Camera and laser pointer

8 Laser head 9 Beam deflexion with objective10 Lighting ring11 Exhausting socket

1 2 3 4 5

67891011

System components

68 ProtoLaser S

Exhausting unit (optional)

The exhausting unit TEKA LMD 508 (not included in scope of delivery of ProtoLaser S), is described in a separately delivered manual.

Fig. 28: Exhausting unit components

1 Exhausting unit TEKA LMD 5082 Pocket filter unit

3 ProtoLaser S

1 2 3



Exhausting unit supplies

Fig. 29: Exhaustion connections

1 Compressed air nozzle 2 Exhaustion socket 3 Exhaustion hose

12

3

System components

70 ProtoLaser S

Exhaustion distributor

By using the exhaustion distributor you can control the vacuum in the exhaustion socket and at the vacuum table.

Turning the knob to the right

The vacuum in the exhaustion socket is redu-ced but at the vacuum table increased.

Turning the knob to the left

The vacuum in the exhaustion socket is increased but at the vacuum table reduced

Fig. 30: Exhaustion distributor

1 Exhaustion distributor

1



Pneumatic maintenance unit

The working pressure can be adjusted by using the pressure controller (1).

Note: The optimal working pressure is 6 bar.

Fig. 31: Pneumatic maintenance unit

1 Pressure controller

1

System components

72 ProtoLaser S

Scanning head

Under the scanning head and behind the cover (2) is the lighting ring (3).This lighting ring must be removed for cleaning the internal objective (see chapter 8.3.3‚ „Optics”, on page 107).

Fig. 32: Scanning head with lighting ring

1 Beam deflection device 2 Cover 3 Lighting ring

1 2

3



Laser beam processing unit

The laser beam processing unit is used for expanding, deflecting and focusing the laser beam.

Fig. 33: Laser beam processing unit

1 Scanning head2 F-Theta objective3 Expansion of laser beam

4 Laser beam mirror unit5 Pilot laser

6 Camera objective7 Camera

1 2 3 4 5

6

7= Laser pointer

= Camera light

= Laser light

System components

74 ProtoLaser S

Beam deflection with telecentric F-Theta objective

The laser beam passes through two 45° deflecting mirrors (5) and enters the scanning head. The laser beam (6) is deflected in the scanning head in the X and Y directions by two galvanometer scanners (3 + 4) driven separately from one another (Dynamic deflection).This setup makes it possible, in conjunction with the telecentric F-Theta lens (2), to deflect the beam which otherwise would be static. This pro-duces a square image field, the so-called scanning field (1).

Fig. 34: Scanning field

1 Scanning field2 Objective3 X galvanometer scanner

4 Y galvanometer scanner5 Passive reflector6 Laser beam

1

2

Z

X

Y

34

5 6



As a result of the rotation of the mirrors attached to the galvanometer scanners, the incident laser beam migrates on the mirror surfaces. This produces a so-called cushion- or barrel-distorted image (see following figure).

As a result of the relative distance of both mirrors in space, the real (actual) image is a combination of cushion distortion and barrel distortion (see following figure).

To allow the microstructuring being carried out offset-free, the scanning head is calibrated such that a square image is formed (see following fig-ure).

Fig. 35: Cushion/Barrel dis-tortion

Fig. 36: Real / actual image

Fig. 37: Square image

System components

76 ProtoLaser S

A f t e r a n y k i n d o f c h a n g i n g o f t h e f o c u s h e i g h t ( f o r e x a m p l e c h a n g i n g t h e o f f s e t o f l a s e r c a m e r a , m a i n t e -n a n c e o r r e pa i r w o r k o f t h e t a b l e o r c h a n g i n g o f t h e s i n t e r e d p l a t e ) t h e s c a n n i n g f i e l d h a s t o b e c a l i b r a t e d a g a i n .Note: The system has been calibrated ex works. Should you encounter calibra-tion errors despite that, please contact the LPKF AG Service Department.

Pilot laser

The function of the pilot laser is to make the zero point of the scanning field visible during a processing pause. It can also be used as a means for data alignment. Once the processing process has been started, the pilot laser is switched off automatically.

Operation


6. Operation

This chapter describes the general system handling of the ProtoLaser S.Observe the safety information and adhere to the instruction step by step to get the required result. Before you start to handle the system the know-ledge about the important CircuitMaster elements and the different opera-tion modes is necessary.

6.1 Switch-On the system

Note: The system has to be run with an overcurrent protection device (230 V / 16 A, 110 V).

Before starting the system the following components must be switched- on or be in operation mode:

• Electrical connection • Exhaust unit

WARNING

Health hazard!The system is working with an automatic exhausting unit. If the exhausting unit is switched off gases or dust hazardous to health can be inhaled by the user.Check the power switch (switch-on) and control the typical intake noise of the exhausting unit before you start the structuring of components.

CAUTION

Damage to property!Items which are located in the work process area can cause damage to property.Make sure that there are no items located in the work process area before you switch on the system!

Switch-On the system

78 ProtoLaser S

Start-up the system in the following order

Note: Make sure that the Emergency Stop button has been unlocked (by turning the red button to the left) and that the hood is closed.

1. Switch-on the mains switch to On (on the backside of the system housing).

After switching on, at first nothing happens since the Emergency Stop relay does not have an automatic start.

2. Press the upper blue start button (on the front side of the system housing).The laser goes into the standby mode and the operating mode displaylights up blue.

3. Start the PC.

Fig. 38: Backside ProtoLaser S

1 main switch

1

Operation


4. Start up CircuitMaster (see chapter 6.2‚ „Handling the software Cir-cuitMaster”, on page 79)The laser system changes to the operation mode.

The system requires about 10 minutes warm-up time for the laser source, to allow the diode temperature to settle at a constant level. The warm-up phase starts automatically during processing of the first job.

6.2 Handling the software CircuitMaster

Starting CircuitMaster

1. Double-click on the CircuitMaster icon on the desktop. CircuitMaster is starting up and the following message will be shown.

The machine moves all axes to the reference point and is ready for oper-ation in a defined position.

[ ] Now you can start the structuring process.

Fig. 39: Moving to refer-ence point

Handling the software CircuitMaster

80 ProtoLaser S

CircuitMaster user interface

The user surface of CircuitMaster is subdivided into several areas:

Tab. 5: Declaration user surface

Fig. 40: User surface

1 title bar2 menu bar3 function bar

4 camera image5 scroll bars6 working area

7 status bar8 current cursor position

1 2 3 4

5678

Operation


Description Function

title bar (1) Shows the name of the program with information about the laser system used and the name of any loaded or newly created job.

menu bar (2) Lists the available menus.

function bar (3) Contains various buttons, displays and functions for controlling the laser system and for modifying a job.

camera image (4) Displays the current camera image.

working area (5) Displays graphically the current view on the Y X table. You can adapt the graphical depiction of the working area to your requirements with the func-tions in the View menu.

scroll bars (6) The scroll bars are located on the right and below the working area and serve to shift the visible sec-tion in the working area.

status bar (7) The status bar below the horizontal scroll bar gives you information about buttons, displays or areas on which the cursor is currently located.

current cursor position (8)

The current cursor position is displayed on the left next to the horizontal scroll bar.


82 ProtoLaser S

Data import

Importing data

1. In the menu File click on Import > LMD/LPR. or: Click on the button (shown beside) in the menu baror: Press CTRL + I on your keyboard.The following dialog window will be shown:

2. Select the data file for import.3. Click on Open.

Fig. 41: Import project data

Operation


The highlighted file will be imported and the following window will be shown:

After the file import open the according tool library. Select the process material.

Select the process material

1. Click on Job>Material>Size.

Fig. 42: Selecting tool li-brary


84 ProtoLaser S

The following menu window will be shown:

For loading the material, the table must be moved to the loading position.

Fig. 43: Define material size and position

X [mm] Material position

Y [mm] Material position

Reversed (check box) Process data for reversed side

Data Size (button) Transfer data

Thickness [mm] Input field for the material thickness.

Free drive level [mm] Set the value in a way that the exhausting cover can move freely over the work piece.

Focus free drive level [mm] This value define the movement of the Z axis (lift up) when the table will be move during the fiducial search process.

Tolerance [mm] This value define the range in plus minus steps relating to the material thickness where the optimal working point will be detected.

Autofocus (check box) The laser system will be automatically bring into focus.

Operation


Loading the material

1. Click the button Load material.The table moves to load position.

2. Open the cover.3. Put the material on the table.

The colour of the status bar changes from green to yellow.

Note: The reason can be displayed if you click on Status (see following figure).

4. Close the cover.The colour of the status bar changes to green again. Now you can con-tinue working.

Fig. 44: status bar


86 ProtoLaser S

Material size

How to determine the material size

1. Click on the button (shown beside) in the menu bar.You can move the table by using your mouse.

2. Move the table in this position that the laser point is at the lower left corner of the material (see following figure).

3. Click in the menu Job>Material on Set low corner.4. Align the table that the laser point is at the top right corner on the

material (see following figure).

Fig. 45: Position of the la-ser point on the material down left

Operation


5. Click in the menu Job>Material auf Set high corner.[ ] The size is then defined

Preparation for structuring

Following system requirements must be set up before structuring:

1. Click with the right mouse button on Layout.

Fig. 46: Position of the la-ser point on the material top right


88 ProtoLaser S

The following dialog will be shown:

2. Click on Center.3. Click on OK.

The layout is positioned now in the middle of the material.

4. Click on the button (shown beside) in the menu bar.5. Highlight the area you want to increase by pressing the left mouse

button (see following figure).

Fig. 47: Positioning dialog

Operation


Fig. 48: Highlighting the area to be increased

1 Highlighted area

1


90 ProtoLaser S

6. Click on the button (shown beside) in the menu bar.Then the dialog Phases with preset values is displayed.

Note: The activated phase is displayed marked with an asterisk (see arrow) and there is a checkmark in the checkbox Enabled.

7. Click on Ok.8. Click on All + button in the menu bar.

The data of all activated production phases are highlighted. They are shown brighter in the display.

9. Click on Start button in the menu bar.[ ] The structuring can start, if no error messages occur (see following chap-

ter).

Fig. 49: Dialog phases

Operation


Note message before structuring

Before the structuring starts note messages can be displayed:

Note message: phases

If some phases are not activated the following message will be shown:

1. Click on Cancel. If necessary allocate a tool (see also CircuitMa-ster manual)

2. Click on Ok.[ ] The structuring starts.

Fig. 50: Starting


92 ProtoLaser S

Message: Warm-up

The system needs approximately 10 minutes for warming-up. The laser source and the temperature of diodes are kept constant. The warm-up phase starts automatically during the first job. The following message is displayed during the warm-up phase:

Note: Only interrupt the warm-up phase by clicking on Stop if the laser is already warmed-up.

Furthermore a message displays the remaining warm-up time:

Fig. 51: Message: warm up

Fig. 52: Display warm-up time

Operation


If you click on the Stop button during the message Waiting for warm-upthe following message is displayed:

Following operations can be completed by clicking on:

After the warm-up time is reached another warm-up phase (19 seconds) starts to stabilise the laser. Afterwards the system is ready for use.N e v e r i n t e r r u p t t h e s e c o n d w a r m - u p p h a s e ( 1 9 s e c o n d s ) o f t h e l a s e r.The focus position is approached and the layout is structured.

Fig. 53: Laser not ready

Stop processing Stops the processSkip warm-up Interrupts the warm-up phaseContinue warm-up Continues the warm-up phase

Adjustment of the laser source

94 ProtoLaser S

6.3 Adjustment of the laser source

6.4 Switching off the system

To switch off the system, proceed as follows:

1. Exit the software CircuitMaster.2. Shut down the PC.3. Push the On/Off button.[ ] The system is switched off now.

CAUTION

The adjustment of the laser source must always be carried out by personnel trained by LPKF only. However, should it become necessary on short notice, suitable instructions are available in individual cases, which are made available after prior consulta-tion by phone.

Troubleshooting


7. Troubleshooting

This chapter describes solutions and controls for possible system pro-blems or error messages. We cannot go into every kind of problem or error. If there are any undescribed problems please contact the LPKF service devision.The error codes generated by motion I/O which can possibly appear are shown in the status dialog of CircuitMaster.The description of the error codes is listed in the error code table (see Table 6 on page 96).

Error code table motion I/O

96 ProtoLaser S

7.1 Error code table motion I/O

Tab. 6: Table error codes/error messages

Error code Error message

0 - 699 Refer to LPKF service division!

700 Exception error

701 Connection lost error

702 Sync lost error

703 Deadline missed error

704 Event lost error

705 Pipe full error

706 Limit switch error

707 Hardware malfunction

708 Abort mode

709 Encoder error

710 Critical I/O event occured (at emergency level)

711 critical CanOpen event occured (at emergency level)

712 A power drive protection interrupt occured during operation. This may be due to over-temperature or over-current.

713 The control deviation abs /reference-control_variable) is too big (greater than ac_max_control_error). Controller has been switched off.

714 The sensor of the axis controller does not yield a valid signal. Currently used in SENSOR_MODE_POSITION_IP (internal interpolation of an analog encoder signal) only. Controller has been switched off.

715 Motor circuit power voltage too low. Examine the safety devices.

716 Lower position range limit reached (softframe error)

717 Upper position range limit reached (softframe error)

718 The axis controller received a motion command, but the con-troller is in state OFF. The motion can't be executed.

719 The detected motor temperature has exceeded the maximum allowed temperature. The motor has been switched off to pre-vent damage due to over temperature

Troubleshooting


7.2 Error code table laser module

The error codes generated by the laser module which can possibly appear are shown in the laser console on the monitor.

The description of the error codes is listed in the error code table (see Table 7 on page 97).

Tab. 7: Error code table laser module

Fig. 54: Laser console


There is 8A-T melting fuse built-in in Main switch on the back side of Laser Power station. Check it if module doesn’t respond at all..

EMS_STOP Safety circuit is active after Head up signal. Check connection

E04Comm with LAS_CTRL_Err

Contact LPKF Service!

E05 LAS_CTRL_Err Contact LPKF Service!

E06X2/X601 sett.fault


E13cooling unit water flow low

• Check if water pipes are not blocked

• Restart the system

• For Clear/Exchange water filter contact Service LPKF

E14cooling unit water temp H/L

• Check environment conditions

• Check if cooling unit has free space on front and back side

• Check filter on cooling unit modules

• Wait 15 min and restart system

E15cooling unit water.level Low

• Check cooling unit

• Check water level in cooling unit

• Fill “water “ in cooling unit


E16Saf.shut op. Err /Cover up


Error code table laser module

98 ProtoLaser S

E17Saf shut cl.Err


E23LD undervoltage


E24Curr.reg.SAF circuit. open


• Contact LPKF Service!

E25Curr reg OTP

• Check that there is free space for air circulation at the back and front side of the modules

• Clean air filter

• Wait 60 minutes and restart the system

E2648V.temp.reg. fault


E27TEMP REG OVC

• Wait for 1h and restart the system

• Clean filter laser power supply

E28TEMP REG OTP


• Check that there is free space for air circulation at the back and front side of the module


• Wait for 1h and restart the system

E30LD temp meter fault


E31Fan 1 fault



E32Fan 2 fault



E34Ctistal 1 Temp Err"


E35Cristal 2 Temp Err"


E41RF R.Power Err


E42 RF F.Power Err


E43RF Overtemp. Err

• Check that there is free space for air circulation at the back and front side of the module



Troubleshooting


E53cooling unit water flow low

• Check if water pipes are not blocked



E54cooling unit water temp H/L


• Check if cooling unit has free space on front and back side

• Check filter on cooling unit modules

• Wait 15 min and restart system

E55cooling unit water level Low

• Check water level in cooling unit

• Fill “water “ in cooling unit


E57Saf.shut.Err/cover up

See Err 16 and 17!

E59Pow.shut.Err(Saf.shut 2 Err)

See Err 18 and 19!

E60LT temp under 7°C

• Environment temperature must be over 10 °C

• Restart system

E61LT temp over 39°C

• Environment temperature must be under 35 °C


• Restart system

E63LD undervoltage

See Err 23

E64Curr_reg SAF circuit open

See Err 24

E65Curr reg OTP

See Err 25

E6648V temp reg fault,

See Err 26

E67TEMP REG OVC

See Err 27

E68TEMP REG OTP

See Err 28

E69Fan 3 fault

See Err 29


Error code table laser module

100 ProtoLaser S

E70LD temp. meter over 35°



• Restart system

E71Fan 1 fault

See Err 31

E72Fan 2 fault

See Err 32

E73LD temp. out to High



• Restart system

E74Crystal 1 Temp Err


E75Crystal 2 Temp Err


E76LD temp.out to Low



• Restart system


Troubleshooting


7.3 Optimization of the processing quality

Tab. 8: Optimization of the processing quality

Problem Possible cause Remedy

Laser beam burns at the starting points Laser - ON - delay too short Laser ON - increase delay

Laser beam burns at the end points Laser -OFF - delay too long Laser OFF - reduce delay

When structuring closed lines there are remaining webs

Starting point Laser - ON - delay too long

Laser ON - reduce delay

Structures are not lasered completely End point Laser - OFF - delay too short

Laser OFF - increase delay

At the structure start an inlet or overshoot is visible

Jump - delay too short Jump - increase delay

Corners of polygons have been rounded off • Polygon - delay too short • Polygon - increase delay

• Mark - speed too high • Mark - reduce speed

Burn-in effects at the endpoints of the polygon vector

Polygon - delay too long Polygon - reduce delay

Maintenance and service

102 ProtoLaser S

8. Maintenance and service

A basic requirement of the smooth functioning of the laser system is a conscientious maintenance and appropriate handling of the unit and the associated supply units.

8.1 Safety measures

.

Each maintenance and each service is entered in the logbook including the date, the operating hours and the activities that were carried out.Also essential to the permanent functioning of the entire system is the control of the additional units, such as the exhausting unit and the com-pressor. In these areas, maintenance should be carried out at regular intervals and documented in accordance with the manufacturer’s instruc-tions.A n y t y p e o f w o r k r e q u i r e s t h e r e l e v a n t s a f e t y r e g u l a -t i o n s t o b e o b s e r v e d .

CAUTION

Machine damage!Unauthorized tampering with the machine will invalidate the manufacturer's warranty.In general, maintenance and service work must be carried out by LPKF-trained technicians.

WARNING

Danger to life!Operating the system during maintenance and service work can cause perilous physical injuries.In general, switch off the complete system and separate from the mains supply for all maintenance and service work.



8.2 Maintenance and service plan

Tab. 9: Maintenance and service plan

Note: Please also observe the maintenance instructions / intervals of the exter-nal components, such as the exhausting unit!

Maintenance items Check Replacement/Maintenance

Exhausting unit (internal)

• Cleaning of the suction bell Visual check

Exhausting system TEKA LMD 508 (optional)

• Change the pocket filter Visual check

• Change the filter set 1,000 h or 12 months

Laser source

• Laser diodes 10,000 h(Replacement by the manufacturer only)

• Laser outcoupling mirror Visual check Every week

• Change the laser emitting window 1,000 h or 12 months (Replacement by maintenance)

Laser modul

• Exhausting the air filter Visual check Replace if necessary

cooling unit

• Exhausting the air filter Visual check Replace if necessary

Mechanical X/Y/Z-axis 1,000 h or 12 months

Service and maintenance by owner

104 ProtoLaser S

8.3 Service and maintenance by owner

All maintenance steps which are described in the following chapters can be accomplished by the owner. For more information about a service contract please contact the LPKF Service.

8.3.1 Extraction system TEKA LMD 508 (optional)

The maintenance work must be done according to the manufacturer spe-cifications described in the manual include in delivery (see TEKA 508 manual).

8.3.2 Exhausting unit

The exhausting unit in the ProtoLaser S has to be dismounted for – cleaning the suction bell after the visual check and– for reaching and cleaning the laser emitting window.

CAUTION

System damage!The exhausting unit can be damaged by using spare parts of third party manufacturers.Use only original spare parts of the supplied exhausting unit (see exhausting unit manual).

Filter Check Change

Prefilter mat regular visual check

By decreasing of the suction capacity or during the replace-ment of the particle filter.

Particle filter Filter pollution: 100 %

By decreasing of the suction capacity.

Activate carbon filter regular visual check

During the replacement of the particle filter or if gases, coming from the clean air side, infiltrate the activate carbon filter.



Dismounting the exhausting unit

1. Remove the hose from the compressed air nozzle.

2. Detract the extraction hose.

Fig. 55: Removing the hose from compressed air nozzle

Fig. 56: Detracting the ex-traction hose


106 ProtoLaser S

3. Remove the panel.

4. Pull the suction bell out to the front.

[ ] The exhausting unit is dismounted now.

The suction bell can be cleaned if polluted with a usual glass cleaner.

Fig. 57: Removing the pan-el

Fig. 58: Pulling out the suc-tion bell



8.3.3 Optics

After the exhausting unit is dismounted you can remove the lighting ring to reach the optics/laser emitting window.

Removing the lighting ring

1. Pull off the lighting ring.

You can clean the optics now as described in the following chapter.

Fig. 59: Remove the light-ing ring


108 ProtoLaser S

Cleaning the laser emitting window

After you have removed the lighting ring (see Figure 59), you can dis-mount the laser emitting window (1) to clean it.Note: We recommend the cleaning of the laser emitting window if you get bad results while structuring or if you have not cleaned the laser emitting window for a long time..

If you switch off the laser pointer and look from below into the laser emit-ting window you have following possibilities for checkup:

Fig. 60: Laser emitting win-dow

1 Laser emitting window

1

Laser pointer is not visible Laser emitting window is cleanLaser pointer is visible on the glass

Laser emitting window must be cleaned



Cleaning the laser emitting window

1. Unscrew the objective from the scanning head.

2. Put the objective carefully on the delivered cleaning tissue.

CAUTION

System damage!The laser emitting window can be damaged when unqualified pro-tection procedures are used during the cleaning process of the optics. Wear protective gloves during the cleaning process.

Tip: Before you start cleaning put your required accessories aside (cleaning tissue for the lens and isopropanol). Keep a cleaning tissue near by you to put the dismounted objective on it.

Fig. 61: Unscrewing the ob-jective

1 Scanning headf 2 Objective

1

2


110 ProtoLaser S

3. Unscrew the mounting ring of the objective.

4. Remove the protection glass.

Fig. 62: Unscrewing the mounting ring

1 Mounting ring

1

Fig. 63: Removing the pro-tection glass

1 Protection glass

1



Note: Do not clean the objective dry because the coating of the protection glass can be scratched.

5. Put the protection glass on a cleaning tissue and cover it with another tissue.Note: While covering the protection glass with a tissue pay attention that a piece of the protection glass is not covered. You will need this uncovered part for touching later (see following figure).

Tip: Cover the lense with a cleaning tissue to avoid pollusion (see fol-lowing figure)

Fig. 64: Covering the lense

Fig. 65: Covering the pro-tection glass


112 ProtoLaser S

6. Give some drops of usual isopropanol on the protection glass.

7. Hold the protection glass at the uncovered part with your fingertips and detract the cleaning tissue with your other hand.

Clean the protection glass accurately and make a visual check if there are streaks or water drops. If necessary, clean the protection glass again with a new cleaning tissue.

Fig. 66:

Tip: Take off the cleaning tissue quickly so that there does not occur a film on the protection glass.

Fig. 67: Detracting the cleaning tissue



Mount the objective in reverse order:– Insert the cleaned protection glass– Screw the mounting ring– Mount the objective into the scanning head

Note: While mounting the objective pay attention that the protection glass does not cant.

Note: While mounting the scanning head pay attention that the objective is not tightened too much.

8.3.4 Air filter laser module/cooling unit

There is an air filter in each case for the laser module and the cooling unit. These two air filters should be cleaned if necessary with an external vacuum cleaner. In case of abrasive wear the air filters should be chan-ged.

Fig. 68: Suction of the air filters

1 Air filter laser module 2 Air filter cooling unit

1

2

Service and maintenance by manufacturer

114 ProtoLaser S

8.3.5 List of exchange parts

The parts which are mentioned in the following list can be changed by the owner. Please use the item numbers in the list to order the parts at LPKF service.

Tab. 10:Exchange parts

8.4 Service and maintenance by manufacturer

8.4.1 Laser source

Item Item number

Suction bell (complete) 124 522

Alternative laser emitting window 122 026

Laser protection glass, acrylglass green for system door

124 523

Compressed air hose, super-Air 10.0 x 2.75 mm (10 m)

110 076

Compressed air maintenance unit 124 519

Air filter cooling unit 124 518

Air filter laser module 124 517

Objective F-Theta with laser emitting window 114 735

CAUTION

System impairment After inappropriate or unauthorised maintenance we can not ensure the error-free system function.All maintenance work must be made by LPKF service personal. Any system changes by the customer will cause the loss of the warranty claim!

Storage


9. Storage

We refer to our service division if you need any information about placing out of operation, machine storage and machine disposal.

Appendix

116 ProtoLaser S

10. Appendix

10.1 List of figur

Fig. 1: Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Fig. 2: Wavelength dependent transmission of eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Fig. 3: Effect of laser radiation on human eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Fig. 4: The human eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Fig. 5: Removing the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Fig. 6: Removing the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Fig. 7: Screw positions of the transportation lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Fig. 8: Screws of the transportation lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Fig. 9: Pushing the cooling unit into the rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Fig. 10: Resistance of the bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Fig. 11: Minimum required space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Fig. 12: Pedestal ProtoLaser S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Fig. 13: Adjusting lever for height setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Fig. 14: Switch over volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Fig. 15: Welcome window with language choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Fig. 16: Install drivers for camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Fig. 17: Choose language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Fig. 18: Select setup type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Fig. 19: Connecting the hose of exhausting unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Fig. 20: Connecting cable exhausting unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Fig. 21: Connection compressed air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Fig. 22: Filler at the cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Fig. 23: USB connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Fig. 24: Overview ProtoLaser S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Fig. 25: Components inside the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Fig. 26: Components inside right hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Fig. 27: Positioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Fig. 28: Exhausting unit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Fig. 29: Exhaustion connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Fig. 30: Exhaustion distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Fig. 31: Pneumatic maintenance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Appendix


Fig. 32: Scanning head with lighting ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Fig. 33: Laser beam processing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Fig. 34: Scanning field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Fig. 35: Cushion/Barrel distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Fig. 36: Real / actual image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Fig. 37: Square image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Fig. 38: Backside ProtoLaser S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Fig. 39: Moving to reference point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Fig. 40: User surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Fig. 41: Import project data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Fig. 42: Selecting tool library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Fig. 43: Define material size and position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Fig. 44: status bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Fig. 45: Position of the laser point on the material down left . . . . . . . . . . . . . . . . . . . . . . . . 86

Fig. 46: Position of the laser point on the material top right . . . . . . . . . . . . . . . . . . . . . . . . 87

Fig. 47: Positioning dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Fig. 48: Highlighting the area to be increased . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Fig. 49: Dialog phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Fig. 50: Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Fig. 51: Message: warm up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Fig. 52: Display warm-up time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Fig. 53: Laser not ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Fig. 54: Laser console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Fig. 55: Removing the hose from compressed air nozzle . . . . . . . . . . . . . . . . . . . . . . . . . 105

Fig. 56: Detracting the extraction hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Fig. 57: Removing the panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Fig. 58: Pulling out the suction bell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Fig. 59: Remove the lighting ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Fig. 60: Laser emitting window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Fig. 61: Unscrewing the objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Fig. 62: Unscrewing the mounting ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Fig. 63: Removing the protection glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Fig. 64: Covering the lense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Fig. 65: Covering the protection glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Fig. 66: 112

Fig. 67: Detracting the cleaning tissue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

List of figur

118 ProtoLaser S

Fig. 68: Suction of the air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Appendix


10.2 List of tables

Tab. 1: Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Tab. 2: Checklist for starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Tab. 3: Climatic conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Tab. 4: Required Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Tab. 5: Declaration user surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Tab. 6: Table error codes/error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Tab. 7: Error code table laser module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Tab. 8: Optimization of the processing quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Tab. 9: Maintenance and service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Tab. 10: Exchange parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Tab. 11: Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Glossary

120 ProtoLaser S

10.3 Glossary

Tab. 11:Glossary

Concept Declaration

CircuitCAM Data preparation software

CircuitMaster Machine control software

Emergency Stop Press switch for Emergency Stop

Logbook Lst of maintenance and service information

Appendix


10.4 Index

Aadjusting places . . . . . . . . . . . . . . . . . . . . . . . . 43Adjustment of the laser source . . . . . . . . . . . . . 94

BBarrel distortion . . . . . . . . . . . . . . . . . . . . . . . . . 75brand identifications . . . . . . . . . . . . . . . . . . . . . . 6

CCompany Instructions . . . . . . . . . . . . . . . . . . . . 30connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Cursor position . . . . . . . . . . . . . . . . . . . . . . . . . 81cutting gases . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

DDanger signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 45disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

EEmergency stop button . . . . . . . . . . . . . . . . . . . 64Event of Accident . . . . . . . . . . . . . . . . . . . . . . . 32exhausting unit . . . . . . . . . . . . . . . . . . . . . . 57, 68eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30eye protection equipment . . . . . . . . . . . . . . . . . 30

GGalvanometer scanner . . . . . . . . . . . . . . . . . . . 74

HHazards of laser radiation . . . . . . . . . . . . . . . . . 25

IInstalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Llaser protective goggles . . . . . . . . . . . . . . . . . . 19Laser source . . . . . . . . . . . . . . . . . . . . . . . 33, 103

Mmachine disposal . . . . . . . . . . . . . . . . . . . . . . 115machine storage . . . . . . . . . . . . . . . . . . . . . . . 115Main switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Ooperation details . . . . . . . . . . . . . . . . . . . . . . . 43Outcoupling mirror . . . . . . . . . . . . . . . . . . . . . 103

PPilot laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76placing out of operation . . . . . . . . . . . . . . . . . 115Power button . . . . . . . . . . . . . . . . . . . . . . . . . . 64Processing speed . . . . . . . . . . . . . . . . . . . . . . 33Protective Equipment . . . . . . . . . . . . . . . . . . . . 32protective filter . . . . . . . . . . . . . . . . . . . . . . . . . 30Pulse stability . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Rreflections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Repetition rate . . . . . . . . . . . . . . . . . . . . . . . . . 33required space . . . . . . . . . . . . . . . . . . . . . . . . . 46

SScanning head . . . . . . . . . . . . . . . . . . . . . . . . . 74Scroll bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . 103shock load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Signal light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Solid-state laser system . . . . . . . . . . . . . . . . . . 33starting the system . . . . . . . . . . . . . . . . . . . . . . 77Status bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Ttransport conditions . . . . . . . . . . . . . . . . . . . . . 36

UUV radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

VVarioscan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

WWavelength. . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Index

122 ProtoLaser S

operation manual protolaser s - north forge technology...

Documents