LPKF ProtoPlace E4 Standard Operating Procedure

Overview

The '''LPKF ProtoPlace E4''' is a hand-operated device designed to position SMDs accurately onto already prepared printed circuit boards. The '''ProtoPlace E4''' uses vacuum needles on the placement/marking head to assist in accurately picking up, locating and dropping SMDs from either loose component trays or tape feeders onto solder-pasted pads on PCBs. The '''ProtoPlace E4''' is ideal for prototyping the assembly of a printed circuit board, or for small volume assembly in a laboratory.

Figure 1: LPKF Protoplace E4 main parts

The main tool includes the monitor/camera display, placement head, work area, tape feeder lanes, component trays, and vacuum/air system.

Manual placement of surface mounted devices (SMD) should be performed in the ProtoPlace E4 and dispense test approvals should only be done by staff members. It is expected that PCB solder paste will be applied to the printed circuit board (PCB) prior to any use of the ProtoPlace E4, either via stencil printing or by any other form of solder paste dispense process that has been approved.

Tool Parts

Figure 2: Work area and placement head

The main parts of the LPKF ProtoPlace E4 are:

• Monitor / camera display
• Manual placement head
• Vacuum nozzle / needle holder
• PCB work area
• Magnetic PCB holder area
• Tape feeder lanes
• Loose component tray
• Component storage trays
• Foot switch / vacuum control
• Vacuum / air pump and tubing

Figure 3: Vacuum System

The vacuum system allows the placement needle to pick up and release small SMD components. The vacuum function should be tested before placing components on a real PCB.

Accessories

Figure 4: ProtoPlace E4 Placement accessories

The ProtoPlace E4 accessories include:

• Angled placement needles
• Vacuum pickup nozzles
• Component trays
• Tape feeder lanes
• Magnetic PCB holders
• Tweezers or small hand tools for handling parts
• Optional dispensing needle set, if approved by staff for testing

Standard Operating Procedure

Worktable Preparation

1) Ensure that no unwanted debris (including, but not limited to, loose parts, solder paste residue, clipped leads, tape debris, etc.) is present for the ProtoPlace E4 workspace.

2) Ensure clear of PCB workspace.

3) Ensure all connections are made to the monitor, camera, vacuum/air pump, foot switch, and tubing.

4) Prior to powering the system, check that the correct EU-to-US power adapter or staff-approved power connection is in place.

5) Inspect vacuum tubing for damage or other defects. If defective, do not use.

6) Inspect placement needles/nozzles for defects. Do not use.

7) Ensure that only those components and/or accessories necessary for the PCB assembly are on the worktable.

8) Keep ProMask/ProLegend chemicals, wet developing equipment, gloves, rollers, chemical resin packets, etc., away from the ProtoPlace E4 workspace.

9) Use a PCB that already has solder paste applied to the appropriate pads.

10) Place PCB flat onto the work area & secure using magnetic PCB holders.

11) Ensure PCB does not move when lightly touched.

12) Place loose SMD components into the component tray and/or load component tape into the feeder lanes.

13) Arranged so that orientation may be checked before placement of the components.

System startup and vacuum check

1) Activate the display for the camera/monitor.

2) If the Pump or suction pump is not operational, turn-on the Pump or suction pump.

3) Ensure the camera will display correctly on the monitor.

4) Use an appropriate vacuum packaging needle/nozzle based on the size of the component being used.

5) To ensure that the vacuum pickup works correctly, test it using an example component or an unimportant component.

6) Place the component in front of the placement head.

7) Lower the vacuum/ suction package needle until it just touches the component.

8) Activate the vacuum using either the foot-brake switch or vacuum control.

9) Slowly raise the placement head upward.

10) Confirm that the component has maintained its attachment to the needle.

11) Once the component is above the tray, remove the vacuum.

12) Confirm that the component has dropped to a clean finish and is not stuck to the needle.

Note: If you are unable to consistently pick up and drop a component from the vacuum, stop!

PCB and component setup

1) Verify that there is solder paste on every pad where an electronic component will be fitted

2) Safeguard that the board does not move when secured by magnetic holders.

3) Ensure that the pads with solder paste are visible on the monitor.

4) Organise parts to be placed by value/footprint/reference designator before proceeding with placement.

5) Use component trays for loose components.

6) If tape feeders are available, use them for taped components.

7) Minimise the amount of open component values to prevent ambiguity when more than one open value.

8) Confirm orientation of polarized components before picking them up.

9) Confirm pin 1 orientation prior to picking up ICs.

10) Limit use of tweezers to occasions when necessary, there should be no scraping of either PCB pads or solder paste with tweezers.

Component placement

1) Move the placement head above the component tray or tape feeder lane.

2) Lower the vacuum needle until it lightly contacts the component.

3) Activate the vacuum.

4) Slowly lift the component from the tray or feeder.

5) Watch the monitor and confirm that the component is held straight on the needle.

6) Move the placement head above the correct PCB footprint.

7) Use the camera display to align the component with the solder-pasted pads.

8) Lower the component slowly until it touches the solder paste.

9) Release the vacuum.

10) Lift the placement head straight upward.

11) Confirm that the component stayed on the pads and did not shift.

12) If the component is misaligned, gently correct its position with tweezers before continuing.

13) Repeat the placement process for all required SMD components.

14) Change needle/nozzle size if the component is too small, too large, or cannot be held reliably.

15) Do not force the placement head downward onto the PCB.

16) Do not drag components across the solder paste with the needle.

17) Do not place components if the solder paste is dried out, contaminated, or smeared across adjacent pads.

Staff-approved dispensing test

This section of the ProtoPlace E4 is designated for only qualified operators to perform commissioning/testing. Regular users should not dispense solder paste on the ProtoPlace E4 without approval from the staff for this setup. To assist you in conducting a test dispense, please follow these guidelines:

1. Ensure the dispensing accessory is being used by either a qualified operator or under the supervision of a staff member.

2. Ensure that the dispensing needle is clean and properly seated.

3. Use solder paste or test material supplied and approved by staff.

4. Do not use solder paste that is dry, outdated, questionable or has been contaminated.

5. Perform the initial dispense test on a scrap printed circuit board or a test coupon, not on a device belonging to a user.

6. Ensure that the test coupon is flat on the work surface.

7. Position the dispensing needle above the test pad.

8. Dispense the smallest amount of material possible.

9. Inspect the size and shape of the dot created by the dispense of material.

10. If the dot produced is too big, variable, stringy, or blocked, cease operating and notify staff.

11. Following tests, remove the test coupon and clean the work surface area.

12. Dispose of any used solder paste, wipes or contaminated materials in accordance with Nanofab Staff Procedures.

Note: Do not leave solder paste inside a needle or dispensing accessory after use.

Shutdown and cleanup

To ensure that the PCB work area is clean for the next user, follow these procedures:

1. Restore the placement head to its resting position in the safe position.

2. If the vacuum/air pump will not be needed until the next user has finished, please turn it off.

3. Ensure that, if appropriate, to turn off the monitor/camera display.

4. Take the PCB from the work area.

5. Close every component tray and tape the packages shut.

6. Return needles, nozzles, feeders, and any other accessories back to where they belong.

7. Clean up the work area of all loose or open components.

8. Use an appropriate cleanroom wipe to clean the work area if necessary.

9. Do not clean the equipment using compressed air.

10. Dispose of used wipes and contaminated materials and solder paste impacts based on the disposal directions provided by Nanofab staff.

11. Notify Nanofab staff of issues related to broken needles, clogged nozzles, missing accessories, display problems, vacuum problems, or power supply problems.

Troubleshooting

Symptom	Solution
Vacuum does not pick up the component	Check that the pump is on, check the foot switch, check tubing, replace or clean the needle, and use a needle size appropriate for the component.
Component falls before reaching the PCB	Re-test vacuum on a scrap component, check for leaks, use a larger or smaller needle, and confirm the component surface is flat.
Component sticks to the needle after release	Release the vacuum again, lift straight upward, and clean or replace the needle if paste is present.
Component shifts after placement	Secure the PCB with magnetic holders, lower the placement head more gently, and reposition the component with tweezers.
Camera display is blank or unclear	Check monitor power, check video/camera connections, and notify staff if the image does not return.
Placement head does not move smoothly	Stop using the tool, remove obvious loose debris if safe, and notify Nanofab staff.
Dispensing needle clogs during staff-approved test	Stop the dispensing test, remove the clogged needle, and notify staff. Do not force paste through the needle.
Power does not turn on	Confirm that the approved power adapter is connected. If the tool still does not power on, stop and contact Nanofab staff.