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LPKF ProtoLaser U4 User Manual

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ProtoLaser U4
User manual
Order code: 10058054
Version: 1.0

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Summary of Contents for LPKF ProtoLaser U4

  • Page 1 ProtoLaser U4 User manual Order code: 10058054 Version: 1.0...
  • Page 2 Publisher LPKF Laser & Electronics AG Osteriede 7 30827 Garbsen Germany Phone: +49 5131-7095-0 Fax: +49 5131-7095-90 Email: info@lpkf.com Date of issue 2016-05-30 Copyright © 2016 LPKF AG This document and its contents in whole and in parts are subject to copyright.
  • Page 3 Its structure allows trained personnel to perform all tasks. LPKF Laser & Electronics AG (abbreviated to LPKF in the following) reserves the right to make changes in respect to the content of this document. The figures in this document serve as basic understanding and can differ from the actual state of the system.
  • Page 4 Type and source of the hazard! This warning message indicates a hazard of medium risk that can cause death or serious injury if not avoided.  Measure to avoid the hazard. 4/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 5 Indication of a sorted list of steps. The specified order must be observed. Indication of an intermediate result that is followed by further steps or the result. Indication of the result. The sequence is finished. Indication of a single step. V. 1.0 | LPKF Laser & Electronics AG 5/132...
  • Page 6 This note indicates especially useful information. Advanced information This advanced information indicates special knowledge. Registered Trademarks Product and brand names are trademarks of LPKF Laser & Electronics AG, registered ® among others at the US Patent and Trademark Office: LPKF and the company logo, ®...
  • Page 7 Before working with the system/product, this document has to be read carefully. The manufacturer assumes no liability for damage and faults due to non-observance of this document. LPKF Laser & Electronics AG provides a 12-months warranty if the following conditions are met: ...
  • Page 8 General information ProtoLaser U4 8/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 9 4.4 Storage......................63 First startup ......................64 5.1 Safety ......................64 5.2 Requirements of the place of installation ............ 64 5.2.1 Climatic conditions ................ 65 5.2.2 Minimum required space ............... 65 V. 1.0 | LPKF Laser & Electronics AG 9/132...
  • Page 10 7.2.1 Maintenance schedule for the maintenance personnel of the operator ..................104 7.2.2 Maintenance schedule for the LPKF Service ......105 7.3 Maintenance tasks for the maintenance personnel of the operator..105 Troubleshooting ....................122 8.1 Fault display ....................122 8.2 Actions in case of an error ................
  • Page 11  Cutting LTCC In case of doubt contact the LPKF sales department or your local representative to receive more information on alternative materials or processing procedures. Only control the system with the system software that is included in the scope of delivery.
  • Page 12  Always ensure that there is no unintended escape of compressed air.  Defective components that are under pressure when operating the system have to be replaced immediately by sufficiently qualified personnel. 12/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 13 When processing materials, gases or dusts hazardous to health can be produced.  Ensure that the extraction system is switched on and is working properly.  Observe the maintenance intervals of the extraction system.  Check the connection to the system regularly. V. 1.0 | LPKF Laser & Electronics AG 13/132...
  • Page 14 80 °C. The water inside the tissue is vaporized at temperatures above 100 °C. At temperatures above 150 °C the tissue is carbonized. At temperatures above 300 °C the tissue is evaporated. 14/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 15 This plasma is inducing UV light radiation. This UV radiation is hazardous to human eye and skin. This health hazard is particularly high during the welding processes. Table 2: Sources of danger V. 1.0 | LPKF Laser & Electronics AG 15/132...
  • Page 16 Personal protective equipment is to the human eye. There is also a absolutely necessary (laser protective danger of fire and danger to the human glasses and protective screens)! skin. Table 3: Laser classes 16/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 17 Restrict access to the laser area and label the borders (Warning laser beam) Operation mode displays and warning lights on all entrance doors of the laser area Table 5: Structural protective measures V. 1.0 | LPKF Laser & Electronics AG 17/132...
  • Page 18 Immediate medical care in case of any suspected eye injury. Table 6: Organizational protective measures 18/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 19 A laser system that is completely shielded with a protective housing is equivalent  to laser class 1. If the protective housing is removed, the laser class is increased. V. 1.0 | LPKF Laser & Electronics AG 19/132...
  • Page 20 The operator has to ensure that the maintenance intervals stated in this document are observed.  The operator has to check all safety devices for proper function and completeness on a regular basis. 20/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 21 The maintenance personnel has been trained for the special field where he/she works and knows the relevant standards and regulations. Service personnel Service personnel are persons who are authorized by the manufacturer LPKF for servicing the system/product. These tasks may only be performed by the LPKF Service.
  • Page 22 The protective glasses with side shields serve for eye protection in case of flying debris and liquid splashes. Respirator mask Respirator masks protect against hazards from harmful substances in gases, vapors, and particles. 22/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 23 Warning against artificial optical radiation! Use your personal protective equipment to avoid damage to health. The label is applied at the following position(s):  on the system rear next to the main switch V. 1.0 | LPKF Laser & Electronics AG 23/132...
  • Page 24 In order to avoid serious injuries to your skin or your eyes always comply with the safety instructions while operating the lasers. The label is applied at the following position(s):  on the front of the processing head 24/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 25 (e.g. compressed air, extraction system) is still connected and can cause injuries.  Disconnect the supply of all external components immediately.  Before working with pressurized components, ensure that these are completely depressurized and de-energized. V. 1.0 | LPKF Laser & Electronics AG 25/132...
  • Page 26 The emergency stop button (3) is located at the front of the system. Pushing this button immediately switches off the laser and stops the motorized axis. This stop is only intended for an emergency. 26/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 27 Maximum service life of safety-relevant components Component Service life in years Safety relay cover monitoring Laser safety shutter Safety control unit (emergency stop button) Magnet switch of cover Table 8: Service life V. 1.0 | LPKF Laser & Electronics AG 27/132...
  • Page 28 2. Disconnect the supply of all external components. 3. Secure the main switch with a padlock. Fig. 3: Securing against restart 4. Keep the key safe.  The system has been secured against restart. 28/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 29 They have to be disposed of by a waste management company. Coolant additive Glysantin Has to be disposed of according to local regulations, e.g. at a suitable disposal site or a suitable incineration plant. V. 1.0 | LPKF Laser & Electronics AG 29/132...
  • Page 30 Weight (with packaging) Load capacity Data Value Unit Min. distributed load kN/m² Min. point load on an area of 0.00196 m² 0.835 Pneumatic data Data Value Unit Pressure Flow rate Nl/min 30/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 31 µm (mil) Emissions Data Value Unit Sound pressure level LpA (EN ISO 3744) < 70 dB (A) Sound power level LwA (EN ISO 3744) < 70 dB (A) EMC emission class – V. 1.0 | LPKF Laser & Electronics AG 31/132...
  • Page 32 1 x Logbook Data medium Documentation The data medium contains the following:  Brochure ProtoLaser U4  User manual ProtoLaser U4  Basic reference ProtoLaser U4  Product catalog Rapid Prototyping 32/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 33 Table 9: Starter kit ProtoLaser Wear parts The following wear parts are excluded from the warranty:  Sinter plate  Gas spring of the cover  Felt of the extraction hood V. 1.0 | LPKF Laser & Electronics AG 33/132...
  • Page 34 The type label is located at the housing of the system. For information on identifying the system and the relevant equipment, specify the system model and the serial number on the type label when you contact the LPKF Service. Fig. 4:...
  • Page 35 Total view Fig. 5: System overview with open cover Cover Button ACK Processing unit On/Off switch x/y table Emergency stop button Maintenance door Housing 10 Maintenance cover in processing area Leveling foot V. 1.0 | LPKF Laser & Electronics AG 35/132...
  • Page 36 Beam conditioner The beam conditioner expands, deflects and focuses the laser beam. Fig. 6: Beam conditioner Mirror Pilot laser Laser safety lock F-theta lens Camera Scanner unit Camera lens 36/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 37 Due to the spatial distance between the two mirrors and additional effects of the lens, the real scan field is a combination of cushion distortion and barrel distortion (see following figure). V. 1.0 | LPKF Laser & Electronics AG 37/132...
  • Page 38 The system has been calibrated ex works. However, if calibration errors should occur, contact the LPKF service. The contact details are in the first pages of this manual in the information on customer service.
  • Page 39 The felt of the extraction hood rests on the material which creates a defined airflow. Fig. 12: Extraction hood Connector for extraction hose Compressed-air connector for compressed air nozzles Felt V. 1.0 | LPKF Laser & Electronics AG 39/132...
  • Page 40 Extraction system LMD 508 with prefilter unit  Compressor MONSUN Fast R For more information contact the LPKF sales department or your local representative. Extraction system The extraction system TEKA LMD 508 is used as a standard accessory. For a detailed description of the extraction system refer to the supplied manufacturer's manual.
  • Page 41 13 Cover or Harting socket or 9-pin D-sub socket Control panel 14 Mains cable with mains plug Antenna of the ControlUnit 2 15 Exhaust muffler with exhaust fitting Fan door 16 Intake fitting V. 1.0 | LPKF Laser & Electronics AG 41/132...
  • Page 42  Defective components that are under pressure when operating the system have to be replaced immediately by sufficiently qualified personnel. Fig. 14: Compressor If you are using other accessories, refer to the manufacturer’s manual for more information. 42/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 43 USB 2.0 socket, type B, for connecting the 8 mm (0.315") outer tube diameter) for system to the PC connecting to the compressed-air supply Socket, for connecting the mains cable Network connector V. 1.0 | LPKF Laser & Electronics AG 43/132...
  • Page 44  Turning the control lever The vacuum in the extraction hood is reduced and on the towards the vertical position x/y table it is increased. 44/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 45 Power meter connector Fig. 19: USB port (power meter connector) This port is used by the LPKF Service for connecting the power meter, if necessary. 3.6.3 Pin assignment The system is equipped with a male 9-pole sub-D connector that provides remote control of the external extraction system.
  • Page 46 The emergency stop button has been pushed. The handle (2) is used for opening and closing the cover. The adjustment lever (3) with toggle function is used for height adjustment of the leveling foot and locking it. 46/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 47 Pushing the emergency stop button (6) immediately switches off the laser and stops the motorized axes. This stop is only intended for an emergency. Table 12: Displays and control elements at the system front V. 1.0 | LPKF Laser & Electronics AG 47/132...
  • Page 48 The temperature display of the chiller shows the current temperature of the coolant. The fill level indicator of the chiller shows the current fill level. Table 13: Displays and control elements behind maintenance door 48/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 49 4.0 bar (0.4 megapascal [MPa]). The control lever (2) of the extraction manifold controls the vacuum in the extraction hood and on the x/y table. Table 14: Displays and control elements in processing area V. 1.0 | LPKF Laser & Electronics AG 49/132...
  • Page 50 SERVICE KEY switches off the service mode. Table 15: Displays and control elements at the rear of the system 50/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 51 Dual Core 2.6 GHz 8 GB Memory requirements 2 GB Graphics board With 1 GB dedicated memory (non-shared memory) LPKF discourages the use of the following graphics boards because they cause problems:  Intel 82945G Screen resolution 1680 x 1050 pixels...
  • Page 52 Fig. 24: Desktop icon CircuitPro PL CircuitPro PL is started and the following user interface is displayed:  Fig. 25: User interface CircuitPro PL  The system software has been started. 52/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 53 Service mode The service mode may only be activated by the LPKF Service because switching from laser class 1 to laser class 4 constitutes a hazard. The signal light is lit orange. Switching between the modes of operation...
  • Page 54  Dispose of the packaging material environmentally friendly.  Observe the local disposal regulations and hire a specialized company for the disposal, if necessary. The system may only be shipped in the original packaging of LPKF. Contact the LPKF Service if you need the packaging. 54/132...
  • Page 55 1. Remove the screws from the lid. 2. Lift off the lid. Fig. 27: Lifting off the lid 3. Remove the edge protectors. 4. Remove the screws from the front of the packaging. V. 1.0 | LPKF Laser & Electronics AG 55/132...
  • Page 56 Transport and storage ProtoLaser U4 5. Remove the front. Fig. 28: Packaging without front 6. Remove the screws from the side and rear panels. 56/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 57 8. Cautiously remove the foils and the edge protectors. The transport ramps are on the inside of the front panel. 9. Remove the screws of the transport ramps. Fig. 30: Transport ramps V. 1.0 | LPKF Laser & Electronics AG 57/132...
  • Page 58 14. Push all rocker switches (1) to the right to lower the leveling feet and thus lift the system. 15. Adjust all leveling feet using the adjustment levers (2) until the system is lifted off the transport supports. 58/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 59 20. Push the adjustment levers (2) (see figure 33) back into their resting positions. 21. Cautiously roll the system from the box floor via the transport ramps.  The system has been unpacked. V. 1.0 | LPKF Laser & Electronics AG 59/132...
  • Page 60 ProtoLaser U4 Transporting the system Before transporting a system, the LPKF Service has to be contacted. The only exception is the transport over short distances (see the following chapter). Ensure that the following prerequisites are fulfilled before performing the described...
  • Page 61 4. Level the system (see chapter 4.3.2). 5. Secure the system at the place of destination with the locks of the leveling feet.  The system has been moved over a short distance. V. 1.0 | LPKF Laser & Electronics AG 61/132...
  • Page 62 9. Perform one of the following steps:  Push the rocker switch to the right to lower the leveling foot.  Push the rocker switch to the left to raise the leveling foot. 62/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 63 When putting the system out of operation and into storage over a longer period, ensure that the storage room is clean, almost dust-free, and has a sufficient loadbearing capacity. V. 1.0 | LPKF Laser & Electronics AG 63/132...
  • Page 64 This chapter contains important information on first startup of the system. Safety Observe the following safety instructions for the first startup of the system: LPKF recommends to have the LPKF Service perform the first startup. For further information on an optional training contract or installation contract, contact the LPKF Service.
  • Page 65 Do not block this area because it is a working space for operation and maintenance. Fig. 38: Minimum required space Screen, keyboard, and mouse Prefilter unit (recommended position) Extraction system System V. 1.0 | LPKF Laser & Electronics AG 65/132...
  • Page 66 The system should be installed on a vibration-damped floor.  LPKF will gladly advise you on suitable damping measures such as active and passive vibration-dampers or vibration-damping mats. LPKF assumes no liability for inaccuracies and/or damage due to inadequate vibration damping.
  • Page 67 50/60 Power rating ~1.4 Leakage current ~2.15 Pneumatic data Data Value Unit Pressure Flow rate Nl/min Compressed-air purity acc. to ISO 8573-1:2010-04 Data Value Unit Solid particles Class Water Class Class V. 1.0 | LPKF Laser & Electronics AG 67/132...
  • Page 68 Preparations Before the system is installed, you have to consider and ensure the following:  A suitable extraction system has to be provided. LPKF recommends the use of the LMD 508 extraction system. This is optionally available at LPKF. ...
  • Page 69 Hex key 5 mm connected.  Removing the transport locks of the chiller 1. Pull on the lower left edge of the maintenance door to open it. Fig. 41: Opening the maintenance door V. 1.0 | LPKF Laser & Electronics AG 69/132...
  • Page 70 3. Pull out the chiller until the transport brackets protrude from the base frame. 4. Remove the screws (5, 11, 6, 9) that fasten the transport brackets to the chiller. 5. Remove the transport brackets (2, 10). 70/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 71 The transport locks of the chiller have been removed. Store the transport brackets in a dry place in immediate vicinity of the system. Reinstall the transport brackets for securing the chiller every time the system has to be transported. V. 1.0 | LPKF Laser & Electronics AG 71/132...
  • Page 72 4. Repeat steps 2 and 3 on the left side of the x axis. 5. Cover the mounting hole with the bellows.  The transport locks of the x/y table have been removed. 72/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 73  Pouring in the coolant 1. Pull on the lower left edge of the maintenance door to open it. Fig. 46: Opening the maintenance door V. 1.0 | LPKF Laser & Electronics AG 73/132...
  • Page 74 6. Screw the cap back onto the filler neck. 7. Close the maintenance door. 8. Store unused coolant according to the information in the safety data sheet.  The coolant has been poured in. 74/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 75 3. Repeat steps 1 and 2 with the second keyhole of the rear cover. 4. Tilt the rear cover slightly forward and disconnect the grounding cable. Fig. 49: Grounding cable 5. Lift the rear cover upwards. V. 1.0 | LPKF Laser & Electronics AG 75/132...
  • Page 76 6. Pry out the line filter using a flat-bladed screwdriver. 7. Turn the line filter by 180° and reinsert it. 8. Reassemble the mentioned components in reverse order.  The local mains voltage setting of the chiller has been changed. 76/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 77 Connect the stack light with the system and install it subsequently. Material  Connecting the stack light 1. Connect the cable of the system with the connector of the stack light: Fig. 51: Connecting the cable V. 1.0 | LPKF Laser & Electronics AG 77/132...
  • Page 78 The markings of the stack light and of the socket must match up. Fig. 52: Stack light markings 3. Fasten the stack light by turning it clockwise. Fig. 53: Turning the stack light  The stack light has been connected. 78/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 79 ProtoLaser U4 First startup 5.4.2 Connecting the extraction system The extraction system is an optional accessory that can be ordered from LPKF. The following shows the required steps for connecting the TEKA-LMD 508 and the prefilter unit: Material  Connecting the extraction system 1.
  • Page 80 5. Connect the air outlet nozzle with your exhaust system. Fig. 58: Air outlet nozzle 6. Connect the extraction system to the mains power supply. Fig. 59: Wall socket  The extraction system has been connected. 80/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 81 ProtoLaser U4 First startup LPKF recommends to set the rotation speed of the extraction system to 70%. Adjust the stop delay of the extraction system according to your needs. For further information refer to the user manual of the extraction system.
  • Page 82 1. Connect the network cable to the system. Fig. 61: Connecting the network cable 2. Connect the network cable to your network. Fig. 62: Network connector  The network cable has been connected. 82/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 83 The screen is connected to the system via a USB cable. The keyboard and mouse are connected to the screen via a USB cable. Material  Connecting the screen, keyboard, and mouse 1. Connect the DisplayPort cable to the system. Fig. 63: DisplayPort connector V. 1.0 | LPKF Laser & Electronics AG 83/132...
  • Page 84 4. Connect the USB cable to the screen. Fig. 66: USB port at bottom of screen 5. Connect the USB cable of the keyboard and the mouse to the screen. Fig. 67: USB port at bottom of screen 84/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 85 Fig. 68: Connector for mains cable at bottom of screen 7. Plug the mains cable into the wall socket. Fig. 69: Mains cable  The screen, keyboard, and mouse are connected. V. 1.0 | LPKF Laser & Electronics AG 85/132...
  • Page 86 1. Connect the mains cable to the system. Fig. 70: Connector for mains cable 2. Plug the mains cable into the wall socket. Fig. 71: Wall socket  The mains cable has been connected. 86/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 87 1. Turn the main switch at the rear of the system to position I ON. Fig. 72: Main switch set to I ON  The mains power supply of the system is switched on. V. 1.0 | LPKF Laser & Electronics AG 87/132...
  • Page 88 Health hazard by gases or dusts! Processing materials with laser beams can produce gases or dusts hazardous to health.  Only process materials that are approved by LPKF.  Always ensure that the extraction system is switched on and working properly. NOTICE...
  • Page 89  Power supply Operate the system connected to an overcurrent protection device (230 V / 16 A / 110 V).  Check if the safety devices described on page 25 function properly. V. 1.0 | LPKF Laser & Electronics AG 89/132...
  • Page 90 2. Double-click on the desktop icon of CircuitPro PL 3.0. Fig. 73: Desktop icon CircuitPro PL The following dialog is displayed:  Fig. 74: Dialog New document 3. Select the template PLU4_doublesided_NoTHP.cp2d. 4. Click on [Load template]. 90/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 91 The following dialog is displayed:  Fig. 78: Dialog Checking signal lights 8. If all lamps of the stack light are lit, click on [Yes].  The system has been switched on. V. 1.0 | LPKF Laser & Electronics AG 91/132...
  • Page 92 1. Click on File> Import or on The following dialog is displayed:  Fig. 79: Dialog Import 2. Navigate to the folder C:\Users\User name\Documents\LPKF Laser & Electronics\LPKF CircuitPro PL 3.0\Example Data\UseCase_DoubleSidedPCB and select the files Tutor.BOA, Tutor.BOT, Tutor.DRL and Tutor.TOP. 3. Click on [Open].
  • Page 93 4. In the column Layer/Template select the layer DrillPlated. 5. Click on [OK]. The CAM view changes as follows:  Fig. 81: Imported data in the CAM view  The data have been imported. V. 1.0 | LPKF Laser & Electronics AG 93/132...
  • Page 94 The scan fields and toolpaths are computed automatically with default settings and  the following message is displayed: Fig. 84: Message Computation results 3. Click on [Close].  The toolpaths have been computed. 94/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 95 4. Click on [Save]. 5. In the pane Workflow setup right-click in the Toolpaths section on Top Layer. The context menu is displayed.  6. Click on the menu item Configure… V. 1.0 | LPKF Laser & Electronics AG 95/132...
  • Page 96 The context menu is displayed.  18. Click on the menu item Delete. The unused toolpath Drill Unplated is deleted.  19. In the pane Workflow setup right-click in the Toolpaths section on Contour. 96/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 97 1. In the pane Workflow setup right-click in the Production section on Bottom Side (Standard). The following context menu is displayed:  Fig. 90: Context menu 2. Click on the menu item Compute scan fields. V. 1.0 | LPKF Laser & Electronics AG 97/132...
  • Page 98 5. In the pane Workflow setup right-click in the Production section on Top Side (Standard). The following context menu is displayed:  Fig. 93: Context menu 6. Click on the menu item Compute scan fields. 98/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 99 7. Adapt the settings, if necessary. 8. Click on [OK]. The CAM view changes as follows:  Fig. 95: Scan field Bottom Side + Top Side  The scan fields have been computed. V. 1.0 | LPKF Laser & Electronics AG 99/132...
  • Page 100 The production data can be moved using drag & drop or by entering the values in the fields x an y. Click on [Set center] to place the processing data at the center of the base material. 11. Click on [Continue]. 100/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 101  In the Windows user interface, click on Start > Shut down.  Press the On/Off button at the system front briefly. The operating system is shut down.   The system has been switched off. V. 1.0 | LPKF Laser & Electronics AG 101/132...
  • Page 102 2. Open the cover. 3. Remove the sinter plate. 4. Clean the x/y table, if necessary. 5. Insert the new sinter plate. 6. Close the cover.  The sinter plate has been replaced. 102/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 103  Disconnect the external components from the power supply.  Secure the system and the components against unintended restart. For maintenance tasks wear your personal protective equipment (see chapter 1.7). V. 1.0 | LPKF Laser & Electronics AG 103/132...
  • Page 104 Compressor MONSUN Refer to the user manual Maintenance Refer to the user Fast R of the manufacturer. manual of the manufacturer. Table 18: Maintenance schedule for the maintenance personnel of the operator 104/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 105 Maintenance schedule for the LPKF Service NOTICE Property damage by unauthorized use! Unauthorized use can cause damage to the system.  Maintenance and service tasks have to be performed by the LPKF Service. Component/Assembly Interval Task to be performed Remark...
  • Page 106 8. Clean or replace the protection glass if it is dirty or damaged. For further information refer to page 118. 9. Reassemble the mentioned components in reverse order.  The protection glass at the processing head has been checked visually. 106/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 107 6. Check the extraction hood for dirt. 7. Clean the extraction hood if it is dirty. 8. Reassemble the mentioned components in reverse order.  The extraction hood has been checked visually. V. 1.0 | LPKF Laser & Electronics AG 107/132...
  • Page 108 3. Repeat steps 1 and 2 with the second keyhole of the rear cover. 4. Tilt the rear cover slightly forward and disconnect the grounding cable. Fig. 109: Disconnecting the grounding cable 5. Lift the rear cover upwards. 108/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 109 Fig. 111: Pulling out the coolant filter 8. Clean the coolant filter with running water. Fig. 112: Coolant filter 9. Reassemble the mentioned components in reverse order.  The coolant filter has been cleaned. V. 1.0 | LPKF Laser & Electronics AG 109/132...
  • Page 110 1. Pull on the lower left edge of the maintenance door to open it. Fig. 113: Opening the maintenance door Fig. 114: Air filter 2. Remove the six cap nuts of the air filter. 3. Remove the air filter. 110/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 111 Replace the air filter if it is damaged or if the dirt cannot be fully removed. 5. Reassemble the mentioned components in reverse order. 6. Close the maintenance door.  The air filter has been cleaned. V. 1.0 | LPKF Laser & Electronics AG 111/132...
  • Page 112 1. Pull on the lower left edge of the maintenance door to open it. Fig. 116: Opening the maintenance door Fig. 117: Chiller 2. Remove the four screws of the air filter. 3. Remove the air filter. 112/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 113 Replace the air filter if it is damaged or if the dirt cannot be fully removed. 5. Reassemble the mentioned components in reverse order. 6. Close the maintenance door.  The air filter has been cleaned. V. 1.0 | LPKF Laser & Electronics AG 113/132...
  • Page 114 7. Put some lubricating grease (special ball bearing grease Dynalub 510) on a wooden lab spatula. 8. Apply a thin lubricant film to the linear guiding rails using the wooden lab spatula, avoid overdosage. 9. Cover the opening with the bellows. 114/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 115 20. Repeat the steps 4 - 8 on the y axis. 21. Cover the opening with the bellows.  The drive spindles and the linear guides have been cleaned and lubricated. V. 1.0 | LPKF Laser & Electronics AG 115/132...
  • Page 116 Always read the safety data sheets before working with hazardous substances  and chemicals and always observe the instructions given therein. 1. Pull on the lower left edge of the maintenance door to open it. Fig. 121: Opening the maintenance door 116/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 117 9. Use the spout to fill the resulting coolant into the filler neck (1). 10. Fill coolant into the chiller until the fill level indicator (2) indicates a maximum fill level. 11. Screw the cap back onto the filler neck. V. 1.0 | LPKF Laser & Electronics AG 117/132...
  • Page 118 3. Disconnect the compressed-air tube (5) and the extraction hose (3) from the extraction hood (4). 4. Remove the screws (2) of the extraction hood. 5. Pull out the extraction hood towards you. 118/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 119 7. Unscrew the lens clockwise. Fig. 126: Unscrewing the lens 8. Cautiously place the lens onto the lens-cleaning tissue. 9. Unscrew the fastening ring clockwise. Fig. 127: Fastening ring V. 1.0 | LPKF Laser & Electronics AG 119/132...
  • Page 120 12. Sprinkle the protection glass with common isopropyl alcohol. Fig. 130: Sprinkling the protection glass Quickly pull off the moist lens-cleaning tissue so that no film develops on the protection glass. 120/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 121 15. Reassemble the mentioned components in reverse order. 16. Close the maintenance door in the processing area.  The protection glass of the processing head has been cleaned. V. 1.0 | LPKF Laser & Electronics AG 121/132...
  • Page 122 Table 20: Fault monitor Icon Name Description Accept all All errors not yet acknowledged are acknowledged automatically. Clear all All errors already acknowledged are deleted from the list. Table 21: Icons in fault monitor 122/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 123 SENSOR_MODE_POSITION_IP (internal interpolation of an analog encoder signal). The controller has been switched off. Supply voltage of motors too low The controller has been switched off. V. 1.0 | LPKF Laser & Electronics AG 123/132...
  • Page 124 Check the minimum space requirements of the system. Clean the filter of the laser module. Wait for 60 minutes and start the system again. Contact the LPKF Service! LD temp meter fault 124/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 125 Clean the filter of the laser module. Wait for 60 minutes and start the system again. Check the climatic conditions. LD temp. meter over 35° Check the chiller. Restart the system. V. 1.0 | LPKF Laser & Electronics AG 125/132...
  • Page 126 Polygon delay too long Reduce the polygon delay points of polygon vectors Table 23: Processing quality For detailed information on setting the tool parameters invoke the help function by pressing (F1). 126/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 127 Safety NOTICE Environmental hazard by improper disposal of the system! Improper disposal of the system can cause hazards to the environment.  Dispose of the system properly or contact the LPKF Service. Preparations Before disassembling the system:  Switch off the system.
  • Page 128 Chiller ......................74 Fig. 48: Rear cover ....................75 Fig. 49: Grounding cable ..................75 Fig. 50: Line filter of the chiller ................76 Fig. 51: Connecting the cable .................. 77 128/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 129 Fig. 105: Lighting ring ....................106 Fig. 106: Protection glass ..................106 Fig. 107: System with open cover ................107 Fig. 108: Rear cover ....................108 Fig. 109: Disconnecting the grounding cable ............108 V. 1.0 | LPKF Laser & Electronics AG 129/132...
  • Page 130 Table 17: Minimum system configuration CircuitPro PL ..........51 Table 18: Maintenance schedule for the maintenance personnel of the operator ... 104 Table 19: Maintenance schedule for the LPKF Service ........... 105 Table 20: Fault monitor ..................... 122 Table 21: Icons in fault monitor ................122 Table 22: Fault table ....................
  • Page 131 ....14 list of figures ........128 UV radiation ........16 list of tables ........130 load capacity ......33, 68 lubricants .......... 32 wavelength ........14 x/y table ........41, 73 V. 1.0 | LPKF Laser & Electronics AG 131/132...
  • Page 132 Appendix ProtoLaser U4 10.4 EC Declaration of conformity 132/132 LPKF Laser & Electronics AG | V. 1.0...
  • Page 134 & LPKF Laser Electronics AG Osteriede 7 30827 Garbsen Deutschland Telefon +49 5131 7095-0 Telefax +49 5131 7095-90 www.lpkf.com...