ProtoMat S42. Operating Manual 3.0, English. Article number: xxx_xxx. Insert cover photo: Size: 11.5 cm x 9.5 cm. Distance: top: 1.5 cm left: 8.

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1 Article number: xxx_xxx Item number: ( ) Insert cover photo: Size: 11.5 cm x 9.5 cm Distance: top: 1.5 cm left: 8.5 cm ProtoMat S42 Operating Manual 3.0, English

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3 ProtoMat S42 Operating Manual 3.0, English LPKF Laser & Electronics AG Osteriede 7 D Garbsen Germany Phone (0) Fax (0) lpkf@lpkf.de Home page

4 ProtoMat S42 Introduction The LPKF ProtoMat S42 is a compact circuit board plotter of the newest generation. It is suitable especially for the rapid and safe production of circuit board prototypes in electronic labs and development departments. The high number of revolutions (up to 42,000 rpm) guarantees the production of accurate structures on different base and housing materials. By means of the optional camera system double-sided materials can also be processed, e. g. for multilayer and RF applications. Flexible and rigidflexible workpieces can be fixed flatly on the working surface by means of the optional vacuum table. The ProtoMat S42 is controlled via the easy-to-use LPKF BoardMaster software. You can use the LPKF CircuitCAM Lite software included in the scope of delivery to import different CAD data formats and process them to production data. Copyright 2008 LPKF AG Any distribution or copying of this manual or parts of this manual in any form and use of its contents require the written permission of the LPKF AG. Subject to modifications. Translation of the german original Article number: ( )

5 Information on this document Information on this document Availability Notations This document contains important information regarding operation, maintenance and care of the LPKF ProtoMat S42 circuit board plotter and accessories. The manual is directed at persons with basic knowledge in the installation and operation of software-controlled machines. Knowledge regarding the safety and behaviour in workshops as well as regarding the operation of a computer with Windows 2000/XP are required. When working at or with the ProtoMat S42, this document must be available in complete and legible condition. It must be within an easy reach near the machine for all the persons authorised to work on the machine. As the machine owner, you have to make sure that the machine is only operated by persons who have read and understood this manual or have been informed about its contents. Different notations enable better orientation in this document. Bold print The following detailed information is shown in bold print: Switches, operating elements, labeled connections for example power switches. Software elements: Menu items, e. g. File > Open... Input boxes, selection boxes and lists, e. g. Tool Selection List Buttons and functional symbols; e. g. Cancel Windows, dialogue boxes, for example input window Tool positions Numbers in bold print written in parentheses (1) identify the number in the figure described. Italic print The following information is printed in italics: Proper names and trademarks, e. g. Windows (LPKF proper names are not printed in italics) Software messages, for example "Starting the file..." (The inverted commas are not part of the message.) Operating Manual 3.0 Rev.:

6 Symbols and signal words Actions to be carried out Indented headings prompt you to carry out an action. Example: Carry out an action If the heading is preceded by a roman numeral (e. g. I), then you have to carry out further actions to achieve the work objective. 1. A numbered indented sentence prompts you to carry out one step of an action. 2. Always carry out the steps of an action in the numbered order. [ ] Square brackets indicate that no further steps need to be carried out for this action. If further actions are required to achieve the work objective, they will be indicated. Figures Numbers in bold print in figures identify numberings (1) or dimensions (50 mm). Symbols and signal words WARNING Danger to life or health! This symbol indicates a dangerous situation in which, in case of non-observance of the information, there is a risk to life or health. Measures required to avoid danger are indicated. CAUTION Risk of material damage! This symbol indicates a situation which, in case of non-observance of the information, can result in material damage. Measures required to avoid danger are indicated. Tip: The hand indicates hints for easier operation, use of material and/or its further processing. Registered trademarks and brand names The LPKF Logo, LPKF ProtoMat, BoardMaster and LPKF ProConduct are registered trademarks of LPKF Laser & Electronics AG. Microsoft and Windows are trademarks or registered trademarks of the Microsoft Corporation in the USA and/or other countries. All other trademarks belong to their respective owners. 4 ProtoMat S42

7 Table of contents Introduction Information on this document List of figures Safety information Designated use Liability information Safety Instructions What is what? The circuit board plotter Options LPKF dust extraction Accessories and consumables LPKF accessories Tools and consumables What you should know Milling/drilling head and traversing table Coordinate system and traversing axis Defined positions of the milling/drilling head The pass hole system Material use and loading The collet chuck Tool loading Usable tools The milling depth limiter The dust extraction The vacuum table (optional) The VisionSystem (optional) Manual operation Operating Manual 3.0 Rev.:

8 3.8 Automatic mode Production types and phase files Production phases Data activation Manual tasks and settings Switching on the system Switching on the LPKF dust extraction (optional) etting the suction force (optional) Switching on the circuit board plotter Starting BoardMaster Checking the interfaces (optional) Switching off the system Quitting BoardMaster Switching off the circuit board plotter Switching off the LPKF dust extraction Finding out about BoardMaster The BoardMaster user interface Frequently required functions Mounting/dismounting of the milling depth limiter base Mounting/dismounting of the plastic base Positioning of the milling/drilling head Moving the milling/drilling head to a predefined position Moving the milling/drilling head step by step in X/Y direction Moving the milling/drilling head with the mouse Material loading Safety Instructions Placing and setting up the material Placing the base material Defining the working area Tool loading Safety Instructions Inserting/removing a tool Inserting a tool into the collet chuck Removing the tool from the collet chuck Drilling Drilling a hole ProtoMat S42

9 4.9 Milling Creating a milling track Setting the milling depth (cylindrical tools) Setting of the milling width (Universal Cutter and Micro Cutter only) Setting up a pass hole system Creating a pass hole system for the traversing table Preparing the circuit board plotter Drilling pass holes in pass hole strips Creating a pass hole system for the vacuum table Preparing the circuit board plotter and the vacuum table Drilling pass holes in pass hole strips Drilling pass holes in the sintered plate Drilling pass holes in base material or drill underlay Drilling pass holes Inserting the pass hole pins Inserting the pass hole pins Setting the VisionSystem (Option) Setting the image quality Setting brightness and contrast Setting the image definition (focusing) Integrating the camera into the coordinate system Setting the camera offset Calibrating the fiducial recognition Setting the fiducial recognition Setting the measuring function Applying the settings Measuring the drillings Working sequence in the automatic mode Setting up the production Selecting a phase file Creating a new job Opening an existing job Importing projects Aligning/copying a project Saving a job Operating Manual 3.0 Rev.:

10 5.2 Setting up a production phase Selecting a production phase Activating data Activating all data Activating data areas Activating data segments by index number Deactivating data Deactivating all data Deactivating data areas Selecting tools (optional) Selecting tools (optional) Starting the production phase Starting a production phase Adjusting milling depth/width Continuing the production phase (optional) Starting the next production phase Interrupting/canceling the production Interrupting the production phase Continuing production at a later time (optional) Canceling (discarding) production Care and maintenance Maintenance and inspection Cleaning the surfaces Carrying out a visual inspection Cleaning the milling depth limiter Dismounting the milling depth limiter Cleaning and greasing the milling depth limiter Mounting the milling depth limiter Cleaning the collet chuck Cleaning the collet chuck Replacing a fuse Removing the side part of the acoustic cabinet (option) Replacing fuses Dust extraction Safety instructions Replacing the filter Replacing the filter ProtoMat S42

11 7 Error messages/malfunctions Decommissioning/disposal Machine parts and components Consumables Technical data LPKF Service EC Declaration of Conformity Index 129 Operating Manual 3.0 Rev.:

12 For your notes 10 ProtoMat S42

13 List of figures List of figures Fig. 1: ProtoMat S42 basic equipment Fig. 2: Optional components Fig. 3: Milling/drilling head Fig. 4: Rear side of the machine Fig. 5: LPKF dust extraction Fig. 7: Coordinate system and axis directions (top view of the traversing table) Fig. 8: Defined positions of the milling/drilling head (top view of the traversing table) Fig. 9: Turning the material around the mirror axis Fig. 10: Collet chuck and tool holder Fig. 11: Setting wheel an plastic base for milling depth Fig. 12: Milling width with Universal Cutter and Micro Cutter Fig. 13: Dust extraction - operating modes Fig. 14: Connection settings Fig. 15: BoardMaster user interface Fig. 16: Removing the plastic base of the milling depth limiter Fig. 17: Prompt to insert the tool Fig. 18: Collet chuck and tension lever Fig. 19: BoardMaster message "Drilling a reference hole?" Fig. 20: BoardMaster message "Depth limiter removed" Fig. 21: Pass hole strips in the vacuum table Fig. 22: BoardMaster message "Drilling a reference hole?" Fig. 23: BoardMaster message "Depth limiter has to beremoved Fig. 24: Press-in tool with pass hole pin Fig. 25: Setting the fiducial recognition Fig. 26: Setting the image definition Fig. 27: Setting the camera offset Fig. 28: Position the camera above the drilling hole Fig. 29: Drilling in the Camera Image window Fig. 30: Setting the fiducial recognition Fig. 31: Fiducial calibration Fig. 32: Calibration not possible Fig. 33: Calibration successful Fig. 34: Measured values in the Camera Image window Operating Manual 3.0 Rev.:

14 List of figures Fig. 35: Enter the measured values Fig. 36: Window Calibration Fig. 37: Window Calibration Fig. 38: Enter the actual values of the drilling diameter Fig. 39: Measured values in the Camera Image window Fig. 40: Placing a project Fig. 41: Selecting the tools Fig. 42: Tool Exchange window Fig. 43: Adjusting milling depth/with Fig. 44: Production phase finished Fig. 45: Message when canceling the production Fig. 46: Dismounting of the milling depth limiter Fig. 47: Removing the side part of the acoustic cabinet Fig. 48: Adjusting the Fuse Holder ProtoMat S42

15 Safety information 1. Safety information In this chapter you can find information concerning the designated use, liability and safety when using the ProtoMat S42. If, after reading this manual, a situation should arise in which you are not sure how to use or service the ProtoMat S42, please contact the LPKF Support or consult a person skilled in the art. 1.1 Designated use The ProtoMat S42 is designed for manufacturing of electric circuit boards with up to six layers and the processing of different sign and housing materials. The following operations can be carried out: Milling and drilling of single-sided and double-sided base materials Milling and drilling of multilayer materials Milling SMD solder paste stencils Milling solder stop foils Engraving housing plates and signs Milling cutouts and contours Approved materials: GRP/CRP base material PTFE/ceramic composite base material Wood Non-ferrous metals Brass acc. to DIN EN 1412: CW603N Plastics Polyoxymethylene ABS copolymers The ProtoMat S42 may only be used for mentioned in this document operations and materials to be processed. The circuit board plotter may only be used together with the LPKF Software BoardMaster Version included in the delivery. If you want to use a different version, please first contact the LPKF Support. Operating Manual 3.0 Rev.:

16 Liability information The circuit board plotter may only be operated with a sufficient dust extraction including fine dust filter. We recommend to use the LPKF dust extraction with an integrated HEPA filter. If you want to use another system for dust extraction, please first contact the LPKF Service. Inadmissible Use The ProtoMat S42 may not be used for processing highly inflammable materials, closed containers, hollow pieces, textiles and food. The processing of body parts (e. g. finger nails) is not allowed. If you are not sure about the use of the materials to be processed, contact the LPKF Support. 1.2 Liability information The ProtoMat S42 has been developed and built in accordance with state-of-the-art standards and recognised safety rules. Nevertheless, improper handling/use may constitute a risk to life and limb of the user or of third parties, or cause damage to the machine and to other material property. Disclaimer The manufacturer/seller cannot be held liable for damage caused by the following actions/conditions: Improper handling, including any use not mentioned in this manual. Use in unsuitable environment Installation and operation by insufficiently informed or unauthorized persons Non-observance of the legal safety regulations Non-observance of the technical information Incorrect installation Insufficient supply facilities Missing or insufficient maintenance Unauthorized technical modifications Use of workpieces/materials and spare parts that are not specifically approved by LPKF for this machine/this device. 14 ProtoMat S42

17 Safety information 1.3 Safety Instructions WARNING WARNING WARNING WARNING WARNING WARNING WARNING Risk of death by electric shock! Missing or insufficient electrical fuse protection can result in fatal electric shocks and/or fire. Use only safety fuses of type T4L 250 V. Fuse holders must n e v e r be bridged. Risk of injury! The opened cover of the acoustic cabinet can drop down due to impact effect or vibrations. This can result in limbs being broken or crushed. When opening the cover of the acoustic cabinet make sure that it engages in the uppermost position and cannot drop down because of vibrations or other persons actions. Risk of squeezing! The (unintentional) actuation of the software can lead to movements of the circuit board plotter and cause squeezing injuries. Make sure that while handling the circuit board plotter the software c a n n o t b e actuated unintentionally or by another person. Risk of burns! The tool and the collet chuck can be very hot after use and cause burns. When inserting/removing the tools into/from the tool magazine always use the tweezers. Risk of injury! The tools used are very sharp-edged and can cause cuts and stab injuries. Treat the tools carefully and keep them in the tool box when not in use. Health hazard! Material processing can cause formation of fine dusts and gases hazardous for your health. Make sure that the dust extraction is equipped with HEPA filters and is switched on during material processing. Health hazard! The dust plugging the filter can damage the respiratory organs and is potentially carcinogenic. Replace the filter according to its service life. N e v e r try to clean the filters, they are consumables and must not be reused. Operating Manual 3.0 Rev.:

18 Safety Instructions WARNING CAUTION CAUTION CAUTION Health hazard! The chips and dusts emerging from processing of the material can be carcinogenic and cause eye injuries and allergies. Extract the chips and dusts or remove them with a brush/moistened cloth. N e v e r blow compressed air through the machine. Danger of machine damage! The dust extraction can be damaged because of operation with clogged filters. Replace the filters depending on their service life. Filters are consumables and must not be reused. Machine damage due to improper operation! The actuation of the tension lever while the motor is running can cause damage of the collet chuck clutch. Actuate the tension lever only when the motor is at the standstill. Danger due to non-approved tools! The circuit board plotter works with very high rotating and traversing speed. Non-approved tools can cause damage to the collet chuck and/or clutch. Use only original LPKF tools. General Safety Instructions Read the Installation/Operation instructions before using the machine. In case of uncertainties ask a person qualified in the art or contact the LPKF Support. Use the machine only in accordance with its designated use. Never operate the machine in environments subject to fire or explosion hazards. Operate the machine only in suitable environment. Protect the machine against direct sunlight, humidity and flying sparks. Operate the machine only with accessories approved by LPKF and original LPKF tools. Use the machine only in perfect condition. Prior to each use, perform a visual inspection. Pay attention to damaged cables and hoses in particular. (Page 1 of 2) 16 ProtoMat S42

19 Safety information General Safety Instructions (Continuation) Make sure that the safety devices are in perfect working order. It is prohibited to bridge safety devices or to make them inoperable. Make sure that there is no risk of stumbling caused by cables and hoses. Have the machine operated, serviced and repaired by sufficiently qualified and authorized personnel only. Repairs must be carried out only by qualified LPKF personnel or after having consulted the LPKF Support. Keep children away from the work area. Do not eat, drink or smoke in the workshop/working area. Observe the general and legal regulations for accident prevention and environmental protection. Operate, service and repair the machine only when wearing the prescribed protective equipment. When handling the circuit board plotter, make sure that the machine cannot start (unintentionally) or is operated by a third person, for example at the computer. Prior to any maintenance work pull the mains plug. Maintenance work must be carried out regularly. Rectify any damages or malfunctions immediatly. If damage/malfunctions cannot be rectified, shut down the system and assure it against putting in operation. Extract dust/material residues from the machine or remove with a brush. Do n o t blow compressed air through it! (Page 2 of 2) Operating Manual 3.0 Rev.:

20 For your notes 18 ProtoMat S42

21 What is what? 2. What is what? In this chapter you get to know the components and operating elements of the ProtoMat S42. Before putting the machine into operation, familiarise yourself with the individual components. 2.1 The circuit board plotter Fig. 1: ProtoMat S42 basic equipment Rating plate 2 Main switch 3 Power cable socket 4 Fuse holder, voltage setting 5 Pass hole strips (right) 6 Traversing table 7 Milling/drilling head 8 Warning label! Hot surface 9 Lifting magnet 10 Internal extraction hose Operating Manual 3.0 Rev.:

22 Options 2.2 Options WARNING Risk of injury! The opened cover of the acoustic cabinet can drop down due to an impact effect. This can result in limbs being broken or crushed. Make sure that the cover engages in the uppermost position and does not drop down due to vibrations or impacts. Fig. 2: Optional components Acoustic cabinet 2 Camera (VisionSystem) 3 Vacuum table with a sintered plate 4 Caution label on cabinet cover: ("Operate only with a closed cover") 20 ProtoMat S42

23 What is what? Fig. 3: Milling/drilling head Basic equipment Option VisionSystem Internal extractionhose 2 Spring adjustment 3 Lifting magnet 4 Warning label: Hot surfaces 5 Heat sink 6 Tension lever 7 Setting wheel for milling depth limitation 8 Plastic base of the milling depth limiter 9 Tool holding fixture 10 Power supply for milling head ligthing 11 Power supply for the optional camera 12 Camera data cable 13 Camera 14 Camera support Operating Manual 3.0 Rev.:

24 Options Fig. 4: Rear side of the machine Basic equipment Option Acoustic Cabinet Warning label: Hot surface! 2 Hub motor 3 Suction pipe 4 Control unit with data connections (SMCU III) 5 Serial ports (Port 1 Port 4) 6 RS232 Connection 7 Indicator Error 8 Indicator Online 9 Indicator Power 10 Ethernet Connection (only for service) 22 ProtoMat S42

25 What is what? 2.3 LPKF dust extraction WARNING Health hazard! Material processing can cause formation of fine dusts and gases hazardous for your health. Make sure that the dust extraction is equipped with HEPA filters and is switched on during material processing. Note: The ProtoMat S42 can be equipped with another dust extractionsystem. Detailed Information about the dust extraction can be found in the corresponding documents Fig. 5: LPKF dust extraction Extraction hose 2 Suction force regulator 3 Power supply 4 Data cable connection 5 Main switch 6 Automatic fuse Operating Manual 3.0 Rev.:

26 Accessories and consumables 2.4 Accessories and consumables Following LPKF accessories are available for the ProtoMat S42 (not included in the scope of delivery). Detailed information on installation and use of these components can be found in the corresponding documents LPKF accessories Tab. 1: Accessories Designation Function Use Measuring microscope Ring set Measuring and checking the milling tracks and drillings Precise alignment of the spacer rings on the tools Quality control through 60-fold magnification and metric scale Avoiding repeated milling depth adjustment by using a uniform milling depth for all tools Tools and consumables For perfect and safe operation of the ProtoMat S42 we recommend to use only LPKF original tools. LPKF cannot be held liable for machine and consequential damages that result from use of tools by other manufacturers. Tab. 2: Tool setsi Designation Contents Use Tool set Drilling and milling tools, 1/8 " shaft with press-fitted spacer rings Drilling and milling (see chapter "Usable tools", on page 32). HF- and Microwave tool set Milling tools specifically required for handling HF- and microwave applications, 1/8 shaft with press-fitted spacer rings Drilling and milling. For detailed description of individual tools see chapter "Usable tools", on page 32. Note: The scope of delivery includes the pass hole drill Spiral Drill 2.95 mm and Spiral Drill 3.0 mm. The contents of the tool sets can differ depending on the land of delivery. 24 ProtoMat S42

27 What is what? Consumables (not included in the scope of delivery) For safe and perfect operation of the ProtoMat S42 we recommend you to use LPKF original consumables. They are available in multilayer sets or as separate parts for different applications. Tab. 3: Consumables (not included in the scope of delivery) Designation Contents Use Copper laminated FR4 base material Multilayer set Drill underlay Sintered plate FR4 base material 1.5 mm thick 229 mm 305 mm (9" 12 ") with/without protective film, 3 mm pass hole drillings Base material, surface laminate, prepreg, spacer rings Drill underlay, DIN A4, 2 mm thick Sintered plate permeable to air for the vacuum table (ProtoMat S-series) Manufacturing of single-/double-sided printed circuit boards. Multilayer manufacturing processing with LPKF multilayer press MultiPress S. Drill underlay protects the traversing table from damage during drilling and material penetrating milling. Working plate/drill underlay for the optional vacuum table. Cleaning pad Metal-free cleaning pads Removing oxidation residues from the copper laminate. Fig. 6: LPKF Multilayer set (example) Multilayer laminate (depending on the finishing with or without protective film) 2 Press pad (grey) 3 Prepreg (yellow) 4 Pressboard (blue) 5 Base material FR4 18/18 µm 6 Sealing rings Operating Manual 3.0 Rev.:

28 For your notes 26 ProtoMat S42

29 What you should know 3. What you should know In this chapter you get to know the functions and operating elements of the ProtoMat S42. You can find an overview of frequently used BoardMaster elements in chapter 4.3 "Finding out about BoardMaster", on page Milling/drilling head and traversing table To position the milling/drilling head at any position above the base material it is moved in x-direction and the traversing table in y-direction. The coordination of both traversing directions is controlled by the BoardMaster. In the following this procedure will be denoted as moving the milling/drilling head. Note: The circuit board plotter can be equipped with optionally available vacuum table Coordinate system and traversing axis The coordinates Zero point (= Home position) has been preset ex works. It is located in the x-direction 10 mm away from the left edge of the traversing area on the traversing table and in y-direction on the mirror axis. Fig. 7: Coordinate system and axis directions (top view of the traversing table) Traversing range of the circuit board plotter 2 Traversing table 3 Mirror axis 4 Coordinates Zero point (Home position, x = 0 mm, y = 0 mm) Operating Manual 3.0 Rev.:

30 Milling/drilling head and traversing table Note: The coordinates Zero point (=Home position) can be configured individually. The internal Zero point of the machine (Null position) is used as a reference coordinate Defined positions of the milling/drilling head Fig. 8: Defined positions of the milling/drilling head (top view of the traversing table) Traversing range 2 Traversing table 3 Milling/drilling head in Pause position 4 Right pass hole pin 5 Mirror axis 6 Milling/drilling head in the Zero position (= internal Zero point of the machine) 7 Milling/drilling head in Home position (= coordinates Zero point and the left pass hole pin) Home Position Zero Position Pause Position In the Home position the milling/drilling head is located on the left side and the traversing table in the medium range. The Home position lies exactly on the mirror axis of the traversing table and defines the coordinates Zero point. It is used for drilling the left pass hole. In the Zero position you can load the milling/drilling head with a tool and carry out maintenance work on it, e. g. clean the collet chuck. The milling/drilling head is positioned at the left edge of the traversing area and the traversing table is at the back. Note: The Zero position defines the initial point of the traversing area and is required for initialising the internal coordinates system of the machine. In the Pause position you can load the traversing table with the material to be processed and carry out maintenance work on the table, e. g. create a new pass hole system. The milling/drilling head is positioned at the right edge of the traversing area and the traversing table is at the front. 28 ProtoMat S42

31 What you should know The pass hole system The pass hole system is required to align the materials to be processed on both sides exactly fitting. It lies exactly on the mirror axis of the coordinates system and consists of two pass hole pins that are mounted on the traversing table by means of the red plastic strip. The circuit board plotter has been ex factory equipped with a pass hole system for base material in the standard format (9" 12"). The plastic strips with the pass hole pins can be moved inside of the guide groove, this allows the use of smaller base material or other pass hole distances. You can find information on drilling the pass holes in chapter 4.10 "Setting up a pass hole system", on page 70. The pass hole system allows alignment of the base material on the traversing table after finishing the first side in such a way that the rear side can be drilled/milled exactly fitting to the first side. For that purpose you just have to rotate it around the mirror (longitudinal) axis and place the pass holes onto the pass hole pins. The production data for the second side is automatically correctly aligned to the base material. Fig. 9: Turning the material around the mirror axis Tip: For manufacturing double-sided printed circuit boards and multilayers use the camera based LPKF VisionSystem (option). (see chapter 3.6 "The VisionSystem (optional)", on page 40). Operating Manual 3.0 Rev.:

32 Milling/drilling head and traversing table Material use and loading For production of your circuit board prototypes using the ProtoMat S42 we recommend you to use the LPKF base materials or LPKF Multilayer sets (see chapter 2.4 "Accessories and consumables", on page 24). Material loading To prevent damage of the traversing table during drilling always place and fix the material for the ProtoMat S42 without the vacuum table together with a drill underlay. First align it with the help of the pass hole system and use only completely removable adhesive tape for fixing. For the ProtoMat S42 with a vacuum table you must place the material to be processed directly on the sintered plate of the vacuum table and fix it with an adhesive tape. The drill underlay included in the basic equipment must not be placed under the material. Note: The sintered plate of the vacuum table is a consumable. Tip: Use the optional vacuum table for flexible materials to fasten the material in a perfect flat position. 30 ProtoMat S42

33 What you should know 3.2 The collet chuck CAUTION Machine damage due to improper operation! The actuation of the collet chuck while the motor is running can cause damage of the collet chuck clutch. Actuate the tension lever only if the motor is at the standstill. The milling/drilling head is equipped with a manually operated quickchange collet chuck for tools with 1/8" shaft. This enables prompt replacement of tools without any additional installation work. Fig. 10: Collet chuck and tool holder Tension lever 2 Plastic base of the milling depth limiter 2 3 Tool holding fixture (collet chuck) Tool loading The collet chuck can be opened quickly by means of a tension lever and loaded with a required tool. WARNING Risk of burns! The tool and the collet chuck can be very hot after use and cause burns. When inserting/removing the tools into/from the tool magazine always use the tweezers. Operating Manual 3.0 Rev.:

34 The collet chuck Usable tools WARNING Risk of injury! The tools used are very sharp-edged and can cause cuts and stab injuries. Treat the tools carefully and keep them in the tool box when not in use. CAUTION Danger due to unauthorised tools! The circuit board plotter works with a very high rotating and traverse speed. The use of unauthorised tools can cause damage to the collet chuck and/or clutch. Use only original LPKF tools. The tools are subdivided into two groups: Group Titles: Total length Surface tools Cutter 36 mm (1.42") End Mills Tools of high penetration depth Spiral Drills 38 mm (1.49") Contour Router End Mills Surface tools (36 mm (1.42") total length) Cutter and End Mills Penetrative tools with 38 mm total length (Spiral Drills, Contour Router and End Mills long). The figures given on the spacer rings indicate the tool diameter. 32 ProtoMat S42

35 What you should know Surface tools Universal Cutter 1/8" 0.2 mm mm (8-20 Mil) Copper Fields of application: Colour: Form: Milling widths: Milling of insulation clearances with different widths in copper-plated base material. Define the milling width by means of the milling depth adjustment. orange conical 0.2 mm 0.5 mm (8 20 Mil), variably adjustable via penetration depth Micro Cutter 1/8" 0.1 mm mm (4-6 Mil) Copper Application Colour: Form: Milling widths: Fine insulation clearances with 18 µm thickness of copper layer. Define the milling width using the milling depth adjustment orange conical 0.1 mm 0.15 mm (4 6 Mil), variably adjustable via penetration depth End Mill (End Mill 1/8") mm (31-118Mil) mm (31-118Mil) Copper Aluminum Fields of application: Colour: Form: Milling widths: Aluminum engravings, recesses and wide insulation clearances violet cylindrical d = 0.80 mm (31 mil) d = 1.00 mm (39 mil) d = 2.00 mm (79 mil) d = 3.00 mm (118 mil) Operating Manual 3.0 Rev.:

36 The collet chuck RF End Mill (End Mill (RF) 1/8") 0.15 mm mm (6-16 Mil) Copper Fields of application: Colour: Form: Milling widths: Smallest insulation clearances in RF materials. blue cylindrical d = 0.25 mm (10 Mil) d = 0.40 mm (16 Mil) Penetrative tools End Mill Long (End Mill long 1/8") ) 1-2mm (39-79 Mil) 1-2mm (39-79 Mil) Aluminum Dielectric Fields of application: Colour: Form: Milling widths: Contour milling, material cutouts and depaneling in aluminum and soft RF and microwave materials. light green cylindrical d = 1.00 mm (39 mil) d = 2.00 mm (79 mil) Contour Router (Contour Router) 1-2mm (39-79 Mil) Copper Fields of application: Colour: Form: Milling widths: Contour milling, Material cutouts, Depaneling, Drillings >2.4 mm/> 3.0 mm. yellow cylindrical d = 1.0 mm (39 Mil) d = 2.0 mm (79 Mil) 34 ProtoMat S42

37 What you should know Drill (Spiral Drill) min. 0.2 mm (8 Mil) max. 3.0 mm (118 Mil) Copper Fields of application: Colour: Form: Available diameters: High penetration drillings. green cylindrical 0.20 mm (8 Mil) 0.30 mm (12 Mil) 0.40 mm (16 Mil) 0.50 mm (20 Mil) 0.60 mm (24 Mil) 0.70 mm (28 Mil) 0.80 mm (31 Mil) 0.85 mm (33 Mil) 0.90 mm (35 Mil) 1.00 mm (39 Mil) 1.10 mm (43 Mil) 1.20 mm (47 Mil) 1.30 mm (51 Mil) 1.40 mm (55 Mil) 1.50 mm (59 Mil) 1.60 mm (63 Mil) 1.70 mm (67 Mil) 1.80 mm (71 Mil) 1.90 mm (75 Mil) 2.00 mm (79 Mil) 2.10 mm (83 Mil) 2.20 mm (87 Mil) 2.30 mm (91 Mil) 2.40 mm (94 Mil) 2.95 mm (116 Mil) 3.00 mm (118 Mil) Operating Manual 3.0 Rev.:

38 The milling depth limiter 3.3 The milling depth limiter For drilling/milling the milling/drilling head is lowered so far that the plastic part rests on the material. The former serves as a milling depth limiter and ensures that the tools penetrate the material up to the desired depth. Fig. 11: Setting wheel an plastic base for milling depth Setting wheel for milling depth limitation 2 Plastic base Setting of the milling depth Setting of the milling width The penetration depth of the tools depends on the tool length and material tolerances. It can be varied by means of the milling depth limiter in 2-µm steps. In this case it is necessary to mount the plastic base. By turning the wheel you can change the distance between the collet chuck and the plastic base and, thus, set the penetration depth of the tool. Note: To set the milling depth to a desired value you must first create the milling track which serves as a basis for checking and, if necessary, correcting the penetration depth of the tool. The presetting to a defined value is not possible. The milling width of cylindrically cut milling tools matches exactly the value printed on the spacer ring of the tool. The milling width of the conically shaped tools Universal Cutter and Micro Cutter depends on the penetration depth and must be set to the desired size using the milling depth limiter. It is essential to know: The deeper the tool penetrates the material, the wider is the milling track. 36 ProtoMat S42

39 What you should know Fig. 12: Milling width with Universal Cutter and Micro Cutter c d e 1 Milling depth is not sufficient, no isolation 2 Milling depth is too small, milling track too narrow 3 Milling depth is too large Milling track too wide 4 Milling depth is optimal Milling width equal to nominal width a - Nominal width, B - Milling width, c - Conical tool (Universal Cutter, Micro Cutter), d - (Cu-) Laminate, e - Carrier material Note: Always check the milling width at the lower edge of the (copper-) laminate to guarantee the desired electrical isolation between the conductor tracks. Example You are using the Universal Cutter 0.2 mm [8mil], i. e. the Universal Cutter should mill a 0.2 mm (8 mil) wide milling track. However, the test milling is only 0.15 mm (6 mil) wide. To create a deeper and, thus, wider milling track turn the wheel at the milling/drilling head to the left. For each step the milling depth is increased by the following values depending on the tool: Universal Cutter: 4 µm Micro Cutter: 2.3 µm To mill the milling track with the Universal Cutter 0.05 mm wider, turn the wheel 12 or 13 steps to the left. Note: Different values are produced at different cutting angles of cutting conical tools. Tip: Use the LPKF measuring microscope for precise checking of the milling width. Operating Manual 3.0 Rev.:

40 The dust extraction 3.4 The dust extraction WARNING Health hazard! Material processing can cause formation of fine dusts and gases hazardous for your health. Make sure that the dust extraction is equipped with HEPA filters and is switched on during material processing. WARNING Health hazard! Used filters can reduce the dust extraction power in such a way that it will set free dusts and gases hazardous for your health. Replace the filters depending on their service life. Filters are consumables and must not be reused. CAUTION Danger of machine damage! The dust extraction can be damaged because of operation with clogged filters. Replace the filters depending on their service life. Filters are consumables and must not be reused. The dusts and gases emerging from material processing with the ProtoMat S42 can cause danger to your health. Always operate the circuit board plotter with dust extraction. The following information refers to the LPKF dust extraction. The dust extraction can be used in the automatic or in the continuous operating mode. If your ProtoMat S42 is equipped with another dust extraction, familiarise yourself with the relevant information on setting options. The LPKF dust extraction is equipped with a HEPA absolute filter and extracts in a reliable way chips, dust and gases emerging during material processing. Note: For machines with a vacuum table (optional) the dust extraction is also required for producing the needed vacuum. 38 ProtoMat S42

41 What you should know Using the Automatic Mode Continuous Setting of the Suction Force We recommend to use the automatic mode, in order to achieve the optimum service life of the filters and to keep the noise emissions low. The LPKF dust extraction starts each milling/drilling procedure automatically and switches off again shortly after it. The run-on time of the LPKF dust extraction can be set in the BoardMaster. If the LPKF dust extraction is switched to automatic operation mode, it can be started anytime manually by means of the BoardMaster. The spindle motor does not have to be switched on. The suction force must be set depending on the equipment of your ProtoMat S42 and the material to be processed. Note that when using the vacuum table maximum suction force must be set in order to ensure sufficient and constant contact pressure. 3.5 The vacuum table (optional) The surface of the vacuum table consists of a sintered plate permeable to air which, at the same time, serves as a working surface. The workpiece is fixed flatly over the whole surface by vacuum, created by the dust extraction so that it cannot deflect anymore. This makes the vacuum table particularly suitable for processing flexible materials (e. g. solder stopfoils) and rigid-flexible substrates (e. g. polyimide in connection with FR4 base material). Processing of rigid materials is also possible without restrictions. To enable fixing of the processed material by vacuum created by the vacuum table it has to be placed directly on the sintered plate. The sintered plate serves as a drill underlay for material penetrating processing and has to be replaced with a new one, if necessary. Make sure that there is sufficient suction pressure during dust extraction so that the material to be processed is fixed flatly on the sintered plate (see chapter "Switching on the LPKF dust extraction (optional)", on page 48). Tip: Both sides of the sintered plate can be used. The ridges on the sintered plate occuring during high penetration processing can be removed manually by means of abrasive paper. Operating Manual 3.0 Rev.:

42 The VisionSystem (optional) 3.6 The VisionSystem (optional) The VisionSystem helps to reference the material to be processed in the coordinates system much faster and preciser compared to the pass hole system. It consists of a camera mounted on the milling/drilling head with integrated lighting and camera software implemented into the BoardMaster including broken drill detector and direct measuring function. The camera image is constantly displayed on the screen. This enables optimal control of the milling and drilling quality already during processing. Fiducial Recognition Calibration The VisionSystem functions on the basis of defined fiducials that are recognised by the camera as reference points. Fiducial recognition is preset ex factory for drillings with a diameter of 1.5 mm and can be modified in the BoardMaster. Fiducial recognition must be calibrated if the BoardMaster does not recognize the fiducials or if used drill diameter differs from the provided one. Depending on the material to be processed it may be necessary to readjust the image quality (see chapter 4.11 "Setting the VisionSystem (Option)", on page 80). You can change the following settings: Brightness and contrast (using BoardMaster) Image definition (manually, on the camera/using vertical realignment) Image rotation (manually using realignment) Since the camera image cannot be adjusted exactly to the tool position, the horizontal distance between the camera and the milling/drilling position must be aligned precisely. This procedure is normally required only for installation or repositioning of the camera (see chapter "Integrating the camera into the coordinate system", on page 84). 40 ProtoMat S42

43 What you should know 3.7 Manual operation The manual mode is mainly used for creating individual drillings and structures, for post-processing automatically manufactured printed circuit boards and for maintenance and adjustment work, e. g. for creating a pass hole system or testing the milling width of individual tools. The manual mode supplements the automatic functions and can be executed anytime. 3.8 Automatic mode During the automatic mode the production is carried out using the CAD data prepared by means of CircuitCAM. The data are saved as *.LMD files and contain information regarding layout, structure and use of the required tools. The automatic production is carried out stage by stage on the basis of selected data areas. The required tool must be inserted manually and the production stages/phase stages must be started using the BoardMaster. Tip: Use the enclosed tutorial files to produce a double-sided printed circuit board with galvanic through-hole plating to familiarise yourself with the automatic mode Production types and phase files The following production types can be created using the phase files added at the factory: Tab. 4: Production types and phase files Production type Single-/double-sided printed circuit boards (galvanic through-hole plating) Single-/double-sided printed circuit boards (galvanic through-hole plating with LPKF ProConduct) 4-layered multilayer (galvanic through-hole plating) 4-layered multilayer (galvanic through-hole plating with LPKF ProConduct) Solder stop foils Solder paste stencils Phase file 1-2layer.phs (<standard>) 1-2layer + proconduct.phs 4-layer.phs 4-layer + proconduct.phs soldermask.phs stencilmilling.phs Operating Manual 3.0 Rev.:

44 Automatic mode The ProtoMat S42 is ex factory preset to produce single-/double-sided printed circuit boards which is followed by galvanic through-hole plating, so that it is not necessary to select a phase file for this production type. Hereby, the phase file 1-2layer.phs (<standard>) is used. The production phases should always be carried out consecutively in the specified order. You can also skip individual production phases and/or carry them out at a later time. Please note, however, that some work steps are based on previous production phases and, therefore, cannot be carried out later. You can create further phase files for your individual applications and/or reconfigure the existing ones. You can find information on this process in the BoardMaster manual Production phases The following production phases are contained in the phase files: Tab. 5: Production phases One/two layered printed circuit boards Through-hole plating LPKF Proconduct Galvanic Required phase file 1-2layer + proconduct.phs 1-2layer.phs (<standard>) Production phases 1. MarkingDrills 1. MarkingDrills 2. MillingBottom 31. DrillingPlated 3. ReadTop 32. Info! ProConduct 4. MillingTop 33. Read_Bottom 5. DrillingUnplated 34. MillingBottom 6. Info! Apply foil to PCB 35. ReadTop 7. Read_Bottom 36. MillingTop 8. MarkingDrills 37. DrillingUnplated 9. DrillingPlated 38. CuttingInside 10. Info! ProConduct 39. CuttingOutside 11. Read_Top 12. CuttingInside 13. CuttingOutside (Page 1 of 2) 42 ProtoMat S42

45 What you should know 4-layered printed circuit boards Through-hole plating LPKF Proconduct Galvanic Required phase file 4layer + proconduct.phs 4layer.phs Production phases 1. Drilling_Fiducials 1. Drilling_Fiducials 14. MillingLayer3 40. MillingLayer3 15. Read_Layer2 41. Read_Layer2 16. MillingLayer2 42. MillingLayer2 17. Drilling_Fiducials 43. PrepareBottom 18. MillingBottom 44. PrepareTop 19. Drilling_Fiducials 45. Info! MultiPress work 20. MillingTop 46. ReadTop 21. Info! MultiPress work 47. MarkingDrills 22. Info! Apply foil to PCB 48. DrillingPlated 23. Read_Bottom 49. Info! Galvanic plating 24. MarkingDrills 50. ReadBottom 25. DrillingPlated 51. MillingBottom 26. Info! ProConduct 52. Read_Top 27. Read_Top 53. MillingTop 28. DrillingUnplated 54. DrillingUnplated 29. CuttingInside 55. CuttingInside 30. CuttingOutside 56. CuttingOutside Solder stop foils Solder paste templates Through-hole plating Required phase file soldermask.phs stencilmilling.phs Production phases 1. CuttingSoldStopTop 1. CuttingSoldStopTop 2. CuttingSoldStopBottom 2. CuttingSoldStopBottom (Page 2 of 2) Operating Manual 3.0 Rev.:

46 Automatic mode Work steps in the production phases BoardMaster assists you in selecting the next production phase and gives information on the operating steps required for production, e. g. for the tool change, for turning around the base material or for pressing externally individual multilayers before continuing to process with the ProtoMat S42. A production phase must always be selected and started manually, it can be interrupted anytime and continued at a later time. This allows you to check the quality and correct the milling depths/widths or to change tools during production. The production phases contain the following work steps that are processed consecutively time saving: Tab. 6: Work steps in the production phases Production phase Work steps Processed material side MarkingDrills Read_Top Read_Bottom DrillingPlated DrillingUnplated Centre-punching the drillings Drilling fiducials Reading in fiducials (only with VisionSystem) Reading in fiducials (only with VisionSystem) Drilling holes for the through-hole plating Drilling mounting holes (not for through-hole plating) Bottom Top Bottom Bottom Top MillingTop Milling Top MillingBottom Milling Bottom Info! Galvanic Plating Info! ProConduct Info! MultiPress_work Galvanic through-hole plating (external with galvanic station) Through-hole plating with the LPKF ProConduct System Pressing the layers with the external Multilayer press All layers All layers All layers Info! Apply foil to PCB Protective foil ProConduct Top and bottom CuttingInside Milling inner cutouts Top CuttingOutside Milling contours Top (Page 1 of 2) 44 ProtoMat S42

47 What you should know Production phase Work steps Processed material side Read_Layer2 Read_Layer3 Read_Layer4 Prepare_Top Prepare_Bottom (Page 2 of 2) Reading in fiducials (only with VisionSystem) Preparing outer layers for pressing, exemption for fiducial drillings (only with galvanically through-hole plated multilayers) Top/bottom Top/bottom Data activation During a production phase only activated data areas are processed. The following selection options are available: Activate all data Activate selected data areas Activate selected data areas including all data segments that follow them Activate individual data segments or segment areas. If data areas have to be activated, they should be first selected with the mouse and then activated. You can activate several data areas one after another and/or select already activated data areas and exclude them from processing (deactivate). Individual segments or segment areas can be selected in the segment index. Data activation phase by phase The data must be selected and activated again for each production phase. If no data is activated, the BoardMaster considers the selected production phase at the production start as completed and no processing will be executed. Note: BoardMaster assists you in selecting and activating/deactivating the desired data by highlighting them in colour. Operating Manual 3.0 Rev.:

48 For your notes 46 ProtoMat S42

49 Manual tasks and settings 4. Manual tasks and settings This chapter contains basic information on the manual operation of the ProtoMat S42. Detailed information on the automatic control and operation of the LPKF Software BoardMaster can be found in the BoardMaster manual. Observe the safety instructions and follow the instructions step by step to obtain the desired result. WARNING Risk of injury! The opened cover of the acoustic cabinet can drop down due to an impact effect. This can result in limbs being broken or crushed. Make sure that the cover engages in the uppermost position. 4.1 Switching on the system Make sure to switch the ProtoMat S42 on and off always in the specified order. In the following we assume that the computer is switched on and the operating system has been started. Always switch on the individual components of the ProtoMat S42 in the order described here to ensure safe data transmission. Note: If your ProtoMat S42 is equipped with different dust extraction, familiarise yourself with the relevant information on setting options. Operating Manual 3.0 Rev.:

50 Switching on the system I. Switching on the LPKF dust extraction (optional) The LPKF dust extraction can be used in the automatic or in the continuous operating mode. We recommend to use the automatic operating mode, in order to achieve the optimum service life of the filters and to keep the noise emissions at the working place low. WARNING Health hazard! Fine dusts and gases hazardous to your health can emerge during material processing. Make sure that the dust extraction for material processing is switched on (continuous or automatic operating mode). 1. Set the main switch of the LPKF dust extraction to the desired position. Fig. 13: Dust extraction - operating modes Continuous operating mode 2 Off 3 Automatic mode Tab. 7: Operating modes of the LPKF dust extraction: Setting Operating mode Operation ON Continuous operating mode Continuous extraction, Switching On/Off using the BoardMaster is not possible OFF Off No extraction, Switching On/Off using the BoardMaster is not possible Connection to LPKF ProtoMat Automatic mode The extraction starts automatically with the milling/drilling motor, manual switching On/Off using the BoardMaster is possible. [ ] The set operation mode will be used. 48 ProtoMat S42

51 Manual tasks and settings II. etting the suction force (optional) The suction force of the LPKF dust extraction can be set continuously. 1. Turn the Speed controller to select the desired suction force. For the optimum operation with low noise pollution we recommend the following settings: Basic equipment (w i t h o u t vacuum table): Turn the Speed controller to the medium range. For operation w i t h vacuum table (optional): Turn the Speed controller to the position Max. [ ] The dust extraction is ready for operation. III. Switching on the circuit board plotter 1. Make sure that there are no objects on the traversing/vacuum table of the circuit board plotter. 2. Switch the main switch of the ProtoMat S42 to the position I. Note: The main switch is located on the right side of the circuit board plotter (if necessary, inside of the acoustic cabinet). [ ] The lighting of the milling/drilling head is on. Operating Manual 3.0 Rev.:

52 Switching on the system IV. Starting BoardMaster 1. Double-click the BoardMaster icon on the desktop. or: Click on Start > Programs > LPKF Laser & Electronics AG> BoardMaster.... Note: Make sure to start the BoardMaster version delivered with the ProtoMat S42 circuit board plotter. 2. If the window Connect... appears: Make sure that the connection settings are correct (see Checking the interfaces (optional) ). [ ] The BoardMaster user interface is opened. V. Checking the interfaces (optional) If the circuit board plotter is not recognised automatically, the input window Connect... appears. If required, change the connection settings. Fig. 14: Connection settings 50 ProtoMat S42

53 Manual tasks and settings 1. Make sure that the circuit board plotter is on and that the milling/drilling head lighting is on. 2. Make sure that the following values are entered and check the settings in the Windows system control (see Installation Instructions). Control unit: SMCU 3 Machine: ProtoMat S42 Interface type: RS-232 (USB is not intended for service purposes) COM port number: COM port to which the circuit board plotter is connected and which was defined in the Windows system control. Baud rate: Click on Connect... As soon as the connection to the circuit board plotter has been established, the BoardMaster user interface appears. Note: If you click on Cancel the BoardMaster will be started but the circuit board plotter cannot be activated. You can open the input window Connect... anytime from the main menu (Configuration > Interface...) to change the connection settings. [ ] The BoardMaster user interface is opened. Operating Manual 3.0 Rev.:

54 Switching off the system 4.2 Switching off the system To switch off the ProtoMat S42, quit the BoardMaster first and then switch off the circuit board plotter and the computer. I. Quitting BoardMaster 1. Click on File > Exit. The message "Do you want to move the milling/drilling head to the reference point?" appears. 2. Click on Yes. The milling/drilling head and the working table will move to the Zero position. Note: If you click on No, the Zero position must be reinitialized at the next start, which is time-consuming. [ ] Now you can switch off the circuit board plotter and, if necessary, the dust extraction. II. Switching off the circuit board plotter 1. Switch the main switch on the circuit board plotter (in the acoustic cabinet) to the position 0. The lighting of the milling/drilling head goes out. [ ] Now you can switch off the dust extraction and shut down the computer. 52 ProtoMat S42

55 Manual tasks and settings III. Switching off the LPKF dust extraction The LPKF dust extraction must be switched off manually only if it is used in continuous operating mode. During the automatic operating mode it is switched off automatically together with the circuit board plotter. If your ProtoMat S42 is equipped with another dust extraction, familiarise yourself with the relevant operation information. 1. Set the main switch of the LPKF dust extraction to the position OFF (centre position). or: Set the main switch of the LPKF dust extraction to the position Connection to LPKF ProtoMat, to use the dust extraction after the next start ProtoMat S42 in the automatic operating mode. [ ] The LPKF dust extraction is switched off. Operating Manual 3.0 Rev.:

56 Finding out about BoardMaster 4.3 Finding out about BoardMaster The ProtoMat S42 is controlled by means of the LPKF Software Board- Master. Here you can find the description of the user interface and most important selection and control elements The BoardMaster user interface Fig. 15: BoardMaster user interface Title bar 2 Main menu 3 Function bar 4 Mouse pointer 5 Current position of the milling/drilling head 6 Mirror axis 7 Mouse pointer coordinate 8 Status bar 9 Camera Image Application window (only with the VisionSystem option) 54 ProtoMat S42

57 Manual tasks and settings Title bar Main menu Function bar Current position of the milling/drilling head Mirror axis Mouse pointer coordinate Status bar Camera Image application window (optional) The title bar shows the program name, the circuit board plotter used as well as the name of any loaded or newly created job. The menu bar lists all available menus. The function bar shows the functions used for manual control of the circuit board plotter and for starting automatic machining processes. The blue cross hair shows the current position of the milling/drilling head. Mirror axis of the working area. The base material should be positioned at the centre of the mirror axis. The current X and Y coordinate of the mouse pointer referenced to the HOME position. The status bar informs you about the functions of buttons, displays or areas on which the cursor is currently located. The application window Camera Image is only displayed if the VisionSystem is installed. The window shows the area monitored by the camera. Note that this area does not correspond to the current position of the milling/drilling spindle. Note: Detailed information on functions of individual operating elements can be found in the BoardMaster manual. Operating Manual 3.0 Rev.:

58 Finding out about BoardMaster Frequently required functions The frequently required functions can be called up in the function bar. Designation Tool selection Function, note Selecting the tool (manual operation) In the automatic operating mode the tool required for the current job is indicated. Phase selection Selecting the production phase The phases required for the selected production type are displayed in the order of processing. The current phase is preselected. Speed Milling speed Phase configuration Motor on / off Setting the motor speed (1/min) for the selected tool (the default setting depends on the tool) Setting the feed rate during milling for the selected tool (the default setting depends on the tool) Opening the Phases window. Configuring the phases (phase sequence, colour display of the data) Switching the milling/drilling spindle on/off Lift/lower the milling/drilling head Lifting/lowering the head Switching the extraction system On/Off Move with the mouse Switching on/off the extraction system (The LPKF dust extraction must be set to automaticoperating mode) Positioning the milling/drilling head with the mouse Move to Pause Moving the milling/drilling head to the Pause position Move to Home Moving the milling /drilling head to the Home position Move to Zero Moving the milling/drilling head to the Zero position 56 ProtoMat S42

59 Manual tasks and settings Designation Move to +y Move to x- Move to x+ Move to y- Function, note Moving the milling/drilling head horizontally Entering the increment in mm into the input box Start/Stop Starting/stopping the current production phase Adding lines Selecting all elements (lines) segments connected to the selection area. Adding segments Selecting all (lines) segments within the selection area. + Activating selected elements for the production - Deactivating the selected elements All+ Activating all the elements for the current production phase. (The preselection is not required) All- Cancelling the activation of all elements. (The preselection is not required) Moving a project Moving a project with the mouse in the working area. Copying a project Copying a project and positioning the copy with the mouse on the work area. Value Inputs When entering numeric values, the decimal places must be separated by a point (not comma). Information on further functions can be found in the BoardMaster manual. Operating Manual 3.0 Rev.:

60 Mounting/dismounting of the milling depth limiter base 4.4 Mounting/dismounting of the milling depth limiter base The plastic base of the milling depth limiter must be always mounted to guarantee the exact working depth when executing milling work. Dismount/replace the plastic base only for special work such as drilling the pass holes, cleaning and maintenance. Mounting/dismounting of the plastic base Fig. 16: Removing the plastic base of the milling depth limiter 1. Move the milling/drilling head to the Zero position. 2. To dismount the plastic base: Slightly press the plastic base together and pull it downwards out of the milling/drilling head Pressing the plastic base together 2 Pulling the plastic base downwards 3. To mount the plastic base: Insert the plastic base slightly pressed together all the way from below into the milling depth limiter. Rotate the plastic base until the opening is faces forwards. [ ] 58 ProtoMat S42

61 Manual tasks and settings 4.5 Positioning of the milling/drilling head The milling/drilling head can be positioned above the traversing table as desired. Hereby, the working table is also moved. The coordination of both traversing directions is controlled by the BoardMaster. In the following, we will refer to this procedure merely as "moving the milling/drilling head". Moving the milling/drilling head to a predefined position 1. Click on one of the following buttons to move the milling/drilling head to a predefined position. The following positions are possible: Move to Pause Pause position The milling/drilling head moves to the right, the traversing table to the front. Use: Loading the traversing table/vacuum table, checking the milling depth/width. Move to Home Home position: The milling/drilling head moves on the mirror axis over the left pass hole pin, the traversing table to the centre. Use: Create the pass hole system. Move to Zero Zero position: The milling/drilling head moves to the left, the traversing table to the rear. Use: The reference point in the BoardMaster, definition of the coordinate system, insertion/removal of the tool. [ ] The milling/drilling head and the traversing table are moved automatically to the selected position.h Operating Manual 3.0 Rev.:

62 Positioning of the milling/drilling head Moving the milling/drilling head step by step in X/Y direction x- y+ y- x+ 1. Enter the desired increment in mm into the input box between the arrow keys (Move to x/y). 2. Click on the button for the desired direction. Move to x- Move tox+ Move to y+ Move to y- The milling/drilling head moves to the left. The milling/drilling head moves to the right. The working table moves forwards. The working table moves backwards. Note: If the message "Outside the adjustment range" appears, the desired increment is too large. Click on Yes to move the milling/drilling head up to the edge of the traversing area. [ ] The milling/drilling head or the traversing table are moved in the following direction by the entered value. Moving the milling/drilling head with the mouse 1. Click on the button Move with mouse. 2. Drag the mouse pointer with the left mouse button pressed to the front, left corner of the desired working area. Hereby, the milling/drilling head is immediately moved and can be positioned directly with the mouse. or: Click on the desired position of the circuit board plotter in the working area. [ ] The milling/drilling head moves to the desired position. Note: The Move with mouse button must be reactivated each time to move the milling/drilling head with the mouse. 60 ProtoMat S42

63 Manual tasks and settings 4.6 Material loading Safety Instructions WARNING Health hazard! Material processing can cause formation of fine dusts and gases hazardous for your health. Make sure that the dust extraction is equipped with HEPA filters and is switched on during material processing. The circuit board plotter may only be loaded in the Pause position to avoid material damage Placing and setting up the material The circuit board plotter is designed to use base material with pass holes. Basically we recommend to use pre-drilled base material. If your base material does not have any pass holes, these must be drilled first (see chapter "Drilling pass holes in base material or drill underlay", on page 78). I. Placing the base material 1. Click on the button Move to Pause. 2. If necessary, remove any material chips on the traversing table with a soft brush or moistened cloth. 3. If not already done: Place the drill underlay on the traversing table so that the pass hole pins engage in the pass holes. 4. Place the base material on the drill underlay with the side to be processed facing upwards so that the pass hole pins engage in the pass holes. 5. Make sure that the pass hole pins do not protrude from the base material. 6. Glue the edges of the base material on the drill underlay with a completely removable adhesive tape. [ ] The base material is fixed on the traversing table. Now you can define the working area. Operating Manual 3.0 Rev.:

64 Material loading II. Defining the working area To place the circuit board data optimally on the base material, you must first define the working area. When defining the working area, make sure that the milling/drilling head is positioned at a distance of at least 12 mm to the edges of the material to be processed. Make sure to observe the specified order for setting the coordinates (first front, left corner - then rear, right corner)! 1. Click on the Move with mouse button. 2. Drag the mouse pointer with the left mouse button pressed to the front, left corner of the desired working area. Hereby, the milling/drilling head is immediately moved and can be positioned directly with the mouse. Note: If you release the mouse button in the meantime, the Move with mouse button has to be pressed again. 3. Make sure that the milling/drilling head is positioned at the desired position and with the plastic base of the milling depth limiter completely above the base material. The pass hole pins may not be positioned in the working area. 4. n the BoardMaster menu bar click on Configuration > Material > Set > X,Y Min. The coordinates for the front left corner of the working area are being read in. 5. Click on the Move with mouse button. 6. Move the mouse pointer with the left mouse button pressed to the rear, right corner of the desired working area. The milling/drilling head is positioned according to the mouse movement. 7. Make sure that the milling/drilling head is positioned at the desired position and with the plastic base of the milling depth limiter completely above the base material. 62 ProtoMat S42

65 Manual tasks and settings 8. In the BoardMaster menu bar click on Configuration > Material > Set > X,Y Max. The coordinates for the rear, right corner are being read in, the BoardMaster displays the base material in dark-grey. Note: By means of the menu item Configuration > Material > Size... you can determine and edit the exact coordinates. [ ] The definition of the working area is completed. 4.7 Tool loading The ProtoMat S42 is equipped with a quick-change collet chuck which enables tool change without any mounting work Safety Instructions WARNING Risk of squeezing! The (unintentional) actuation of the software can lead to movements of the circuit board plotter and cause squeezing injuries. Make sure that while handling the circuit board plotter the software c a n n o t b e actuated unintentionally or by another person. WARNING Risk of injury! The tools used are very sharp-edged and can cause cuts and stab injuries. Treat the tools carefully and keep them in the tool box when not in use. CAUTION Machine damage due to improper operation! The actuation of the tension lever while the motor is running can cause damage of the collet chuck clutch. Actuate the tension lever only when the motor is at the standstill. CAUTION Danger due to non-approved tools! The circuit board plotter works with very high rotating and traversing speed. Non-approved tools can cause damage to the collet chuck and/or clutch. Use only original LPKF tools. Operating Manual 3.0 Rev.:

66 Tool loading Inserting/removing a tool Before replacing the tool in the collet chuck you have to select it in the BoardMaster. Inserting a tool into the collet chuck WARNING Risk of burns! The tool and the collet chuck can be very hot after use and cause burns. Always remove/insert the tool by means of tweezers. 1. Select the desired tool from the tool selection list. The milling/drilling head is moved to the Zero position. The Tool Exchange window appears. Leave the window opened. Fig. 17: Prompt to insert the tool 2. Make sure that the motor is off and the milling/drilling spindle does not rotate anymore. 64 ProtoMat S42

67 Manual tasks and settings 3. If there is already a tool in the collet chuck: Hold the tool with the tweezers, press the tension lever and pull out the tool downwards. Fig. 18: Collet chuck and tension lever Tool holding fixture (collet chuck) 2 Tension lever 4. Press the tension lever downwards, insert the tool with the shaft upwards into the collet chuck to the stop using the tweezers and then release the tension lever. The tool is fixed in the collet chuck by the spring force. 5. In the Tool Exchange window click on OK. [ ] The required tool is in the collet chuck and BoardMaster uses respective tool parameters. Now you can start/continue the processing. Operating Manual 3.0 Rev.:

68 Drilling Removing the tool from the collet chuck WARNING Risk of burns! The tool and the collet chuck can be very hot after use and cause burns. Always remove/insert the tool by means of tweezers. 1. Click on the Move to Zero button. The traversing table moves backwards. 2. Make sure that the motor is off and the milling/drilling spindle does not rotate anymore. 3. Hold the tool with the tweezers, press the tension lever and pull out the tool downwards. [ ] 4.8 Drilling WARNING Health hazard! Material processing can cause formation of dusts and gases hazardous to your health. Process any type of material only with the dust extraction switched on. Extract the dust and material residues or remove them with a brush or with a moistened cloth, do n o t blow compressed air through it. The available tools allow you to drill round holes with a diameter up to 3 mm. Larger holes/long holes must be cut out with the milling tool Contour Router (usable from a diameter of 2.4 mm)(see "Milling" on page 17). Note: In the following we assume that the dust extraction is used in the automatic operating mode and starts automatically when drilling. 66 ProtoMat S42

69 Manual tasks and settings Drilling a hole 1. Select the required drill from the tool selection list and insert it into the collet chuck. (see chapter "Safety Instructions", on page 63). 2. Move the milling/drilling head with the mouse or the Move to x/y button to the desired drilling position. 3. Click on the Motor on button. Drilling spindle and dust extraction will be started. 4. Click on the Lower head button. After drilling the hole, the milling/drilling head is automatically lifted. 5. If necessary, move the milling/drilling head for drilling further holes with the same drill. or: 6. Click on the Motor off button. [ ] Drilling spindle and dust extraction are switched off. 4.9 Milling WARNING Health hazard! Material processing can cause formation of dusts and gases hazardous to your health. Process the material only with the dust extraction switched on. Extract the dust and material residues or remove them with a brush or with a moistened cloth, do n o t blow compressed air through it. Please note that the working results of milling depend on the penetration depth of the tool. Not removing enough material between the later conductor tracks can cause malfunctions of the printed circuit board. The milling width of the conical milling cutters Universal Cutter and Micro Cutter depends on the penetration depth. Operating Manual 3.0 Rev.:

70 Milling Always execute a test milling on the used base material and check the milling depth with a microscope to control if enough material has been removed. Check the milling depth with a microscope to guarantee the desired milling depth when using the milling cutters Universal Cutter or Micro Cutter. If necessary, correct the milling depth before continuing work (see chapter 3.6, "Setting the milling depth/width", on page 40) Note: When using the conical milling cutters (Universal Cutter, Micro Cutter), the milling width must be set with the milling depth limiter. Creating a milling track 1. Select the required milling cutter from the tool selection list and insert it into the collet chuck. (see chapter "Safety Instructions", on page 63). 2. Move the milling/drilling head with the mouse or the Move to x/y button to the starting point of the desired milling track. 3. Click on the Motor on button. Spindle and dust extraction (only in automatic mode) will be started. 4. Click on the Lower head. The milling/drilling head is lowered to the base material. 5. Move the milling/drilling head with the mouse or the Move to x/y button in the desired direction and distance. The milling track is being created. 6. Click on the Lift head button. The milling/drilling head is lifted. 7. If necessary, cut further milling tracks with the same tool. 8. Click on the Motor off button, after you have created the desired milling track. [ ] The milling/drilling head is slightly lifted, the spindle and dust extraction are switched off. 68 ProtoMat S42

71 Manual tasks and settings Setting the milling depth (cylindrical tools) + _ 1. Turn the setting wheel on the milling/drilling head to the left for deeper milling. 2. Turn the setting wheel on the milling/drilling head to the right for less deep milling. Note: The milling depth can be set in steps of 2 µm. 3. Mill a test track. 4. Check the result with a magnifying glass. 5. Repeat the procedure until enough material is removed. [ ] The setting of the milling depth is completed. Setting of the milling width (Universal Cutter and Micro Cutter only) + _ 1. Turn the setting wheel on the milling/drilling head to the left to cut a wider milling track. 2. Turn the setting wheel on the milling/drilling head to the right to cut a narrower milling track. Note: The milling width of the Universal Cutter can be set in steps of 4 µm and the width of the Micro Cutter in steps of 2.3 µm. 3. Mill a test track and check the width with a measuring microscope. 4. Repeat the procedure until the milling track corresponds to the desired width. [ ] The milling width corresponds to the desired setting. Operating Manual 3.0 Rev.:

72 Setting up a pass hole system 4.10 Setting up a pass hole system The traversing table of the ProtoMat S42 is equipped ex factory with a pass hole system for standard material sizes (9" 12"). If the pass holepins are not seated any more free of play in the fiducials after some time, a new pass hole system has to be created. This also applies to the processing of smaller materials. Observe different procedure for drilling of the pass holes in the traversing table and in the vacuum table (see chapter "Creating a pass hole system for the vacuum table, on page 62)" Creating a pass hole system for the traversing table Required tools and accessories The following tools and accessories are necessary to create a pass hole system: Spiral Drill Ref mm Pass holes in the plastic strips of the traversing table. Spiral Drill 3.0mm: Pass holes in the drill underlay and base material. Pass hole pins 3 mm 8 mm Press-in tool for pass hole pins. Cut-pliers for removing existing pass hole pins I. Preparing the circuit board plotter 1. Dismount the plastic base of the milling depth limiter (see chapter 3.3, "Mounting/dismounting the base of the milling depth limiter", on page 6) 2. Click on the Move to Pause button to move the traversing table into the loading position. 3. Preparing the traversing table: Remove the drill underlay from the traversing table. Pull the pass hole pins out of the red plastic strip with pliers. Move the plastic strips in the guide groove so that the new pass holes can be positioned according to the desired material size. 70 ProtoMat S42

73 Manual tasks and settings 4. If no further pass holes fit into the plastic strips: Lever the plastic strips with a screwdriver from the guide groove. Insert a new pair of plastic strips into the guide groove so that the pass holes can be positioned at least 5 mm away from the edge of the base material. [ ] The circuit board plotter is ready for drilling the pass holes in the vacuum table. Now you can drill the pass holes in the pass hole strips. II. Drilling pass holes in pass hole strips 1. In the tool selection list select the entry Spiral Drill Ref 2.95 mm. 2. Insert the drillspiral Drill Ref 2.95 mm with the help of the tweezers into the collet chuck. 3. Click on the Move to Home button. 4. Click on the Motor on button. 5. Click on the Lower head button. The inquiry, asking if a pass hole shall be drilled, appears. Fig. 19: BoardMaster message "Drilling a reference hole?" 6. Click on Yes. Operating Manual 3.0 Rev.:

74 Setting up a pass hole system 7. Is the depth limiter removed? Fig. 20: BoardMaster message "Depth limiter removed" 8. Make sure that the plastic base of the milling depth limiter has been removed and click on Yes. The pass hole is being drilled. 9. Move the milling/drilling head with the Move to x+/x- button so that it is placed at the desired position above the right pass hole strip. Make sure that the milling/drilling head is not moved in Y direction, otherwise the pass hole is not positioned at the centre of the mirror axis. Write down the x value. Note: The LPKF base materials have a pass hole spacing of 295 mm. 10. Click on the Lower head button to drill the pass hole. 11. Click on the Motor off button. 12. If necessary, drill new pass holes in the drill underlay. (see chapter "Drilling pass holes in base material or drill underlay", on page 69) [ ] To complete the pass hole system you have to insert the pass hole pins into the pass hole strips(s. page 79) and mount the plastic base of the milling depth limiter(s. page 58). 72 ProtoMat S42

75 Manual tasks and settings Creating a pass hole system for the vacuum table The vacuum table is delivered ex factory without pass hole system. Required tools and accessories The following tools and accessories are necessary for creating a pass hole system: Spiral Drill Ref mm For drilling pass holes in the plastic strips and the sintered plate of the vacuum table Spiral Drill 3.0mm: For drilling pass holes in the base material (optional). Pass hole pins 3 mm 10 mm Press-in tool for pass hole pins. I. Preparing the circuit board plotter and the vacuum table To drill the pass holes you have to prepare the circuit board plotter first: 1. Slightly press the plastic base of the milling depth limiter together and pull it out of the milling/drilling head downwards. If necessary, move the milling/drilling head to the Zero position for grabbing the base better. 2. Click on the Move to Pause button to move the traversing table into the loading position. 3. Remove the sintered plate from the vacuum table. Operating Manual 3.0 Rev.:

76 Setting up a pass hole system 4. Make sure that the red pass hole strips are inserted into the vacuum table. Fig. 21: Pass hole strips in the vacuum table 1 1 Pass hole strips in the vacuum table 5. If an existing pass hole system has to be replaced: Pull the pass hole pins out of the red plastic strips with pliers. Move the plastic strips in the guide groove so that the new pass holes can be positioned according to the material size. 6. If no further pass holes fit into the plastic strips: Lever the plastic strips with a screwdriver from the guide groove. Insert a new pair of plastic strips into the guide groove so that the pass holes can be positioned at least 5 mm away from the edge of the base material [ ] The circuit board plotter and the vacuum table are ready for drilling the pass holes. Now you can set the machine parameters for drillings in the pass hole strips. 74 ProtoMat S42

77 Manual tasks and settings II. Drilling pass holes in pass hole strips 1. In from the tool selection list select the entry Spiral Drill Ref 2.95 mm. 2. With the help of the tweezers, insert the drill Spiral Drill Ref 2.95 mm into the collet chuck. 3. Click on the Move to Home button. The milling/drilling head is moved to the HOME position. 4. Click on the Motor on button. Milling/drilling spindle and dust extraction are started. 5. Click on the Lower head button. The message "Drilling a reference hole?" appears. Fig. 22: BoardMaster message "Drilling a reference hole?" 6. Click on Yes. Operating Manual 3.0 Rev.:

78 Setting up a pass hole system The message "Depth limiter has to be removed appears. Fig. 23: BoardMaster message "Depth limiter has to beremoved 7. Make sure that the plastic base of the milling depth limiter has been removed and click on Yes. The pass hole is being drilled. 8. Move the milling/drilling head with the Move to x- button so that it is placed at the desired position above the right pass hole strip. Make sure that the milling/drilling head is not moved in Y direction, otherwise the pass hole is not positioned at the centre of the mirror axis. 9. Write down the X value used. 10. Click on the Lower head button. 11. Confirm the inquiries with Yes. The pass hole is being drilled. 12. Click on the Motor off button. 13. Click on the Move to Pause button. [ ] The drilling of the pass holes in the pass hole strips is completed. Now you can drill the pass holes in the sintered plate. 76 ProtoMat S42

79 Manual tasks and settings III. Drilling pass holes in the sintered plate 1. Make sure that there are no pass hole pins in the pass hole strips. 2. Remove the dust and chips from the vacuum table with a brush. 3. Place the sintered plate on the vacuum table. 4. If not already done: In from the tool selection list select the entry Spiral Drill Ref 2.95 mm. With the help of the tweezers, insert the drillspiral Drill Ref 2.95 mm into the collet chuck. 5. Click on the Move to Home button in the menu bar. 6. Click on the Motor on button in the function bar. The milling/drilling spindle and dust extraction have been started. 7. Click on the Lower head button in the function bar. 8. Confirm both inquiries with Yes. The pass hole is drilled and the milling/drilling head is lifted automatically. 9. Move the milling/drilling head with the Move to x- button so that it is placed at the desired position above the right pass hole strip. Make sure that the milling/drilling head is not moved in Y direction, otherwise the pass hole is not positioned on the mirror axis. 10. Click on the Lower head button in the function bar. 11. Confirm both inquiries with Yes. The pass hole is drilled and the milling/drilling head is lifted automatically. 12. Click on the Motor off button in the function bar. [ ] The pass holes in the sintered plate have been drilled. To complete the creation of the pass hole system you have to insert the pass hole pins (s. page 79). Operating Manual 3.0 Rev.:

80 Setting up a pass hole system Drilling pass holes in base material or drill underlay The procedure for drilling the pass holes in the base material and in the drill underlay is identical. Drilling pass holes 1. Click on the Move to Pause button. 2. Pull any pass hole pins that may still be present out of the sintered plate using flat pliers. 3. Place the base material/ the drill underlay on the mirror axis of the sintered plate in the Y direction as closely to the centre as possible. 4. Make sure that the plastic base is mounted. 5. IIn the function bar click on the tool selection list and select the entry 2. Spiral Drill 3.0 mm. 6. Insert the drill Spiral Drill 3.0 mm with the help of the tweezers into the collet chuck. 7. Click on the Move to Home button. 8. Click on the Motor on button. 9. Click on the Lower head button. The pass hole is being drilled. 10. Move the milling/drilling head with the Move to x+ button to the desired position. Make sure not to move the milling/drilling head in Y direction. 11. Write down the x value. 78 ProtoMat S42

81 Manual tasks and settings 12. Click on the Lower head button to drill the pass hole. 13. Click on the Motor off button. [ ] The pass holes in the base material or in the drill underlay are drilled. To complete the creation of the pass hole system you have to insert the pass hole pins Inserting the pass hole pins Inserting the pass hole pins Use only the pass hole pins provided for your machine equipment: Equipment Basic equipment Vacuum table Pass hole pins 3 mm 8 mm 3 mm 10 mm 1. Insert a pass hole pin with the rounded end into the press-in tool (the chamfered end must protrude). Fig. 24: Press-in tool with pass hole pin 2. Press the pass hole pin all the way into the desired drilling of the pass hole strip using the press-in tool. 3. Make sure that the pass hole pin is seated firmly in the pass hole strip. Operating Manual 3.0 Rev.:

82 For your notes 4. Position the drill underlay/sintered plate on the traversing-/vacuum table so that the pass hole pins engage in the drillings. 5. Make sure that the pass hole pins protrude from the drill underlay/sintered plate only as much as the base material is thick. If necessary, press the pass hole pins deeper into the pass hole strips. [ ] The pass hole system is created. Remember to mount the plastic base of the milling depth limiter before continuing work Setting the VisionSystem (Option) Depending on the material to be processed (brightness, contrast, material thickness), ambient conditions and quality of the passer marks (fiducials) the VisionSystem must be set up individually Setting the image quality Faults in the fiducial recognition may occur due to different image quality. Brightness, contrast, ambient lighting and focusing can influence the image quality so that the fiducials available cannot be recognised or arbitrary contours (e. g. chips, material discolouration) can be recognised by the software as fiducials. To ensure automatic fiducial recognition following conditions have to be provided: Brightness and contrast The material in the image area is displayed very brightly, ideally white. The drillings are displayed very darkly, ideally black Image definition: The contours are distinguished very clearly from each other. 80 ProtoMat S42

83 Manual tasks and settings Setting brightness and contrast Always set the brightness and contrast for the currently processed material. 1. In the Camera image window click on the Setting menu. The Setting window is opened. Fig. 25: Setting the fiducial recognition 2. Move the controls for brightness and contrast so that the material is displayed as bright as possible and the drillings - as dark as possible. Brightness and contrast are set optimally. 3. To close the Setting window: Click on OK. [ ] Brightness and contrast are optimally set. Operating Manual 3.0 Rev.:

84 Setting the VisionSystem (Option) Setting the image definition (focusing) The image definition depends on the vertical position of the camera. The focusing is preset for 1.8 mm thick base material and can be aligned directly at the lens of the camera when the blurriness is insignificant. If you are using thinner/thicker material and the focusing of the lens does not give good results, you must readjust the camera vertically. 1. Place a test workpiece of the material to be processed on the traversing table as close to the centre as possible and fix it with an adhesive tape. 2. Mill with the Universal Cutter two vertically intersecting milling tracks in the material min. 10 mm long as close to the centre as possible (see "Setting the milling track" on page 57). 3. Move the milling/drilling head so that the camera image displays the intersection of the milling tracks. 82 ProtoMat S42

85 Manual tasks and settings 4. If the camera image is not focused: Hold the camera (1) with one hand. Loosen the locking screws (3) of the camera support so that the camera can be easily height-adjusted. Move the camera up or down till the camera image on the monitor is sharply focused. Fig. 26: Setting the image definition Camera 2 Camera support 3 Clamping screws 5. If the camera image is distorted: Turn the camera so that the camera image is exactly aligned 6. Screw the clamping screws (3) tightly. [ ] The setting of the image definition is completed. Operating Manual 3.0 Rev.:

86 Setting the VisionSystem (Option) Integrating the camera into the coordinate system The fiducials recognised by the camera can be used for aligning the coordinate system only if the camera is integrated precisely into the coordinate system. The camera offset must be determined again if the positioning of the milling/drilling head using the camera gives incorrect results. Setting the camera offset 1. Drill a 0.8 mm hole into an unused area of the base material. Make sure not to move the milling/drilling head anymore, since the current position serves as a reference point. 2. In the main menu click on Configuration > Heads... The Heads window is opened. Fig. 27: Setting the camera offset 3. Select the Camera item in the Head selection list. 4. Click on Origin. The reference point button will be deactivated. 5. Click on OK. 84 ProtoMat S42

87 Manual tasks and settings 6. In the main menu click on Go to > Camera >> Head. 7. Move the head with arrow keys so that the cross hairs of the camera image are positioned exactly in the centre of the drilling. For exact positioning decrease the step size to mm. Fig. 28: Position the camera above the drilling hole 8. In the main menu click on Configuration > Heads IIn the Head selection list select the Camera item. 10. Click on Head to apply the new position. The current offset values in x/y direction are displayed in the Offset box. 11. Click on OK. [ ] The camera offset setting is completed. Operating Manual 3.0 Rev.:

88 Setting the VisionSystem (Option) Calibrating the fiducial recognition The automatic fiducial recognition is preset ex factory for drillings with a diameter of 1.5 mm. You have to carry out following operations if the BoardMaster does not recognize the fiducials or if another drill diameter is used: Setting the fiducial recognition Setting the measuring function Applying the settings Measuring the drillings I. Setting the fiducial recognition In the following, fiducial recognition for the drillings is calibrated with 1.5 mm diameter. 1. Drill a hole into an unused area of the used base material with the Spiral Drill 1.5 mm. 2. In the main menu click on Go to > Camera >> Head. The camera will be positioned above the drilling and the drilling is visible in the Camera Image window. Fig. 29: Drilling in the Camera Image window 86 ProtoMat S42

89 Manual tasks and settings 3. Click on Setting. The Setting window is opened. Fig. 30: Setting the fiducial recognition 4. Click on Calibrate camera. 5. The Calibration window is opened. Fig. 31: Fiducial calibration Operating Manual 3.0 Rev.:

90 Setting the VisionSystem (Option) 6. Enter the value 1.5 into the Diameter input box. 7. Click on Calibrate. 8. If the message "Calibration not possible!" appears: Fig. 32: Calibration not possible Click on OK. Check/correct the camera focus and image brightness and repeat the calibration. 9. When the calibration has been completed successfully, the message "Calibration complete!" appears. Fig. 33: Calibration successful 10. Click on OK, to confirm the message. 11. Click on OK, to close the Setting window. [ ] The fiducial recognition is completed. 88 ProtoMat S42

91 Manual tasks and settings II. Setting the measuring function With the measuring function you can determine if the diameter of the drillings recognized by the VisionSystem corresponds to the actual diameter. 1. In the Camera Image window, click on the left edge of the drilling. A cross marks the starting point of measuring. 2. Click on the opposite edge of the drilling. The measuring distance is indicated. The values for the x direction (DX), y direction(dy), and the drilling diameter (DXY) are displayed in the camera image. Fig. 34: Measured values in the Camera Image window 3. Write down the DXY value (here: 0.801). 4. Click on Setting. The Setting window is opened. 5. Enter the written down value of DXY into the Fiducial diameter input box. 6. In the input box Minimum diameter enter a 0.1 (mm) smaller value. Operating Manual 3.0 Rev.:

92 Setting the VisionSystem (Option) Fig. 35: Enter the measured values 7. Click on Accept. Note: The colour difference between the drilling and the surrounding material can be not large enough (the drilling is not dark enough, material is too bright). In this case, the value 70 (instead of 90%) can be entered into the input box Minimal quality [%]. 8. Click on Calibrate camera. The Calibration window is opened. Fig. 36: Window Calibration 90 ProtoMat S42

93 Manual tasks and settings 9. In the diameter input box enter the actual drilling diameter in mm (here: 1.5) Click on OK. The message "Calibration complete! " appears. Fig. 37: Window Calibration 10. Click on OK. [ ] The measuring function is set. Now you have to apply the settings. III. Applying the settings 1. In the Setting window click on OK to apply the newly set values. 2. Click on Setting, to open the Setting window again. 3. Enter into the input box Fiducial diameter the actual value of drilling diameter in mm (here: 1.5). 4. Enter into the input box Minimum diameter [mm] a value 0.1 mm smaller (here: 1.4). Fig. 38: Enter the actual values of the drilling diameter Operating Manual 3.0 Rev.:

94 Setting the VisionSystem (Option) 5. Click on Accept. 6. Click on OK. [ ] The settings are applied by the software. To check the settings you should measure the drillings again. IV. Measuring the drillings 1. In the Camera Image window, click on the left edge of the drilling. A cross marks the starting point of measuring. 2. Click on the opposite edge of the drilling. The measuring length and the values for the X direction (DX), Y direction (DY), and the drilling diameter (DXY) are indicated in the camera image. Fig. 39: Measured values in the Camera Image window [ ] If the DXY value corresponds to the actual drilling diameter in mm (here: 1.5 mm), then the fiducial recognition is completed. 92 ProtoMat S42

95 Working sequence in the automatic mode 5. Working sequence in the automatic mode This chapter explains the fundamental working sequence for the semi-automatic production of single- and multi-layered printed circuit boards. It can differ depending on the production type and equipment of your ProtoMat S42 and your individual requirements. If you are working with the LPKF circuit board plotter for the first time, we recommend to practice at first the described procedures with the example files included in the delivery. Knowledge regarding the manual operation of the circuit board plotter and the most important functions of BoardMaster is a prerequisite (see chapter 4 "Manual tasks and settings", on page 47). 5.1 Setting up the production In the following, we assume that the ProtoMat S42 has been switched on, the material to be processed has been fastened on the traversing/vacuum table and the work area has been set up in BoardMaster. (see chapter "Placing and setting up the material", on page 61). Defining the production type The ProtoMat S42 is preset at the factory to the production of single- or double-sided printed circuit boards with galvanic through-hole plating. Hereby, the phase file 1-2layer.phs (<standard>) is used. For creating another production type select the corresponding phase file. Selecting a phase file 1. Click on File > New and select the phase file provided for the production type. (see table Tab. 5: Production phases on page 42) [ ] The required production phases are displayed in the Phase selection list. Now you can open/create and set up a job. Operating Manual 3.0 Rev.:

96 Setting up the production Tab. 8: Phase files required for production type Required phase file 1-2layer.phs (<standard>) 1-2layer + proconduct.phs 4-layer.phs 4-layer + proconduct.phs 6-layer.phs soldermask.phs stencilmilling.phs Production type Single-/double-sided printed circuit boards (galvanic through-hole plating) Single-/double-sided printed circuit boards (galvanic through-hole plating with LPKF ProConduct) 4-layered multilayer (galvanic through-hole plating) 4-layered multilayer (galvanic through-hole plating with LPKF ProConduct) 6-layered multilayer Solder stop foils Solder paste stencils Setting up a job A job contains all data and information required for production. You can open and edit an existing job, or create a new one. Only one job can be opened at a time. If a job is already opened, you have to decide if you want to save the changes made under another name (see "Saving a job"). After calling the menu item File >Open..., an already opened job can only be overwritten or the changes can be discarded. Note: The items displayed in the following correspond to the standard production of a single- or double-sided printed circuit board with galvanic through-hole plating (1-2layer.phs). For creating a new job or changing an existing one, (other) projects can be imported, duplicated, aligned on the traversing range, enlarged/reduced or removed. 94 ProtoMat S42

97 Working sequence in the automatic mode Creating a new job 1. Click on File > Import > LMD / LPR... The Import project window will appear. 2. Select a project (*.LMD file). 3. Click on Open. The selected project will be placed in the center of the work area. 4. Click on File > Save As... The Save as window will be opened. 5. In the File name box, enter a meaningful name for the job. 6. Click on Save. [ ] The job will be saved under the desired name. Now you can set up the job. Opening an existing job 1. Click on File > Open... The Open window is displayed. 2. Double-click on the desired *.job file. Select for example Tutor.job to open the example files included in the scope of delivery. [ ] The projects contained in the job will be displayed on the monitor. Now you can set up/edit the job. Operating Manual 3.0 Rev.:

98 Setting up the production Setting up a job To create a new job oder to change an exisiting one, (further) projects can be imported, duplicated, aligned on the traversing table, enlarged, downsized or discharged from the job. Note to the sample files Tutor.LMD contains all informations for the production of a doublesided circuit board. Fiducial.LMD contains informations for drilling the fiducial holes (only necessary for use of the VisionSystems (option). Importing projects 1. Click on File > Import > LMD / LPR... The Import Project window will be opened. 2. Choose a project (*.LMD -file). 3. Click on Open. The selected project will be placed in the center of the work area. 4. If necessary, import further projects e. g. fiducial drills for the automatic fiducial recognition (for use of the VisionSystem only) [ ] The required project files are inserted in the job. Now you can align, copy and allocate the projects on the working area. 96 ProtoMat S42

99 Working sequence in the automatic mode Aligning/copying a project To make optimum use of the base material, you can align, allocate and duplicate the projects individually. 1. Click on the Move instance button in the function bar to move a project on the work area. or: 2. Click on the Copy instance button in the function bar to copy a project and move the copy on the work area. 3. Drag the project to be moved to the desired position on the work area with the left mouse button pressed. Make sure that the distance between the project and the edges of the base material is at least 12 mm. Fig. 40: Placing a project [ ] The project will be positioned where the mouse button is released. Note: It is also possible to align a project exactly to the reference points, rotate and scale it and define it as a multiple panel. To do so, use the Edit > Placement... menu item. Now you can save the job. Operating Manual 3.0 Rev.:

100 Setting up a production phase Saving a job If you set up an already existing job, you can save under another name or the current version can be overwritten. 1. To save the job under a new name: Click on File > Save as... The Save as window will be opened. Enter a meaningful name for the job into the File name box. Click on Save. The job will be saved under the desired name. 2. To save the job under the current name and discard the previous version: Click on File > Save. [ ] The changed job will be saved under the previous name. Now you can set up the fist production phase. 5.2 Setting up a production phase Each production phase has to be selected and, if necessary, set up manually. BoardMaster assists you and gives information on the required manual operating steps (see chapter "Production phases", on page 42). We recommend to observe the order of the production phases without fail, since some work steps are based on one another and cannot be executed afterwards. In the Phase selection list the current/last processed production phase of the job is always preselected. When a production phase is completed with the activated data/selected tools, the next production phase must be selected first. Note: Production phases marked with Info!... have to be carried out with external devices. Production phases marked with Read... can only be carried out with installed VisionSystem (option). 98 ProtoMat S42

101 Working sequence in the automatic mode Selecting a production phase 1. Choose the desired production phase in the Phase selection (on the function bar). 2. Make sure that the material is loaded side up to be processed according to the production phase. (see table Tab. 6: Work steps in the production phases on page 44). Note: Always turn the material around the mirror axis. [ ] The production phase is choosen. Now you can activate the data to be produced and optionally select several tools to be used in this production phase Activating data During a production phase only the data activated by you are produced. You have the following possibilities of activating data: All data Data areas including all lines associated with the selected area with all segments lying in the selection area Segments with index number Note: BoardMaster supports you with the selection and activation of the desired data, emphasizing these in colour. Keep in mind, that in some production phases are only a few, poor visible data selectable (e. g. the markings in the Marking- Drills production phase). Zoom into the working area on the display if necessary. Operating Manual 3.0 Rev.:

102 Setting up a production phase Activating all data 1. Click on All+. All data are highlighted in color and will be activated. Activating data areas Data areas can be activated including all associated data segments or exclusively with the data segment within the selected area. 1. In order to activate data within an area including all associated lines: Click on the button Selecting complete lines. With the left mouse button pressed, draw up the desired area. Click on the Button +. All lines and segments connected to the selected area are activated. 2. In order to activate exclusively the segments lying within an area: Click on the button Selecting segments. With the left mouse button pressed, draw up the desired area. Click on the Button +. All segments in the selected area are activated. Note: Repeat one of the procedures, in order to activate further data areas. [ ] The selected data area and segments are activated for production. 100 ProtoMat S42

103 Working sequence in the automatic mode Activating data segments by index number 1. In order to activate an individual segment: Enter the index number of the desired segment into the field Segment index. Klicken Sie auf den Button [ ]. Click on the Button +. The selected segment is activated for production. 2. In order to activate several sequential segments: Enter in the field input of the line course index the number of the desired segment. Click on the Button +. Select further segments with the arrow buttons. Click on the Button +. The selected segments are activated for production. Note: Repeat one of the procedures, in order to activate further data. [ ] The selected data area and segments are activated for production. Operating Manual 3.0 Rev.:

104 Setting up a production phase Deactivating data Deactivating all data 1. Click on All-. [ ] No more data are activated. Deactivating data areas 1. In order to deactivate data within an area and all associated lines: Click on the Button Select complete lines. Draw with pressed left mouse button the desired range up. Click on the - button All lines and segments connected to the selected area are activated. 2. In order to deactivate only the segments lying in a range: Click on the Button Select segments. Draw with pressed left mouse button the desired range up. Click on the - button The segments of the selected area are deactivated. [ ] Deactivating of the selected data is finished. Note: Repeat one of the procedures, in order to deactivate further data. 102 ProtoMat S42

105 Working sequence in the automatic mode Selecting tools (optional) Normally, all tools required within a production phase are used in succession (default setting) and BoardMaster prompts you to change the tool. You can deactivate several tools, e. g. to process only miling tracks of the same width or to post-process areas with a determined tool. Selecting tools (optional) 1. Click on Edit > Tool Selection... The Select Tools window will be opened. Tools required to process the entire production phase are preselected. Fig. 41: Selecting the tools 2. In the column Sel. click on the check box to activate or deactivate a tool. The activated tool is marked by a check mark in the check box. 3. Click on OK. [ ] The current production phase will be executed with the activated tools only. Operating Manual 3.0 Rev.:

106 Starting the production phase 5.3 Starting the production phase To avoid malproduction and extensive post-processing, you should check before everey production start, wether the desired data are activated and the requiered tools are selected in BoardMaster. Note: The activated data will be emphasized in colour accordingly your Board- Master settings. I. Starting a production phase 1. Click on Start. The Tool Exchange window will be opened. D o n o t click on OK yet. Otherwise production will be started without tool or with the tool currently in the collet chuck. Fig. 42: Tool Exchange window WARNING Risk of burns! The tool and the collet chuck can be very hot after use and cause burns. Always remove/insert the tool by means of tweezers. 2. If there is already a tool in the collet chuck, remove it using a tweezers. 3. Use a tweezers to insert the required tool with the shaft upwards into the collet chuck to the stop. The tool is fixed in the collet chuck by the spring force. 104 ProtoMat S42

107 Working sequence in the automatic mode 4. In the Tool Exchange window, choose the action to be carried out next: Click on Continue after Tool exchange, if production is to be started immediately. Click on Stop after tool exchange for adjustmenst, to be able to adjust milling depth/width before processing. 5. Click on OK. [ ] The processing will be started. If you have activated the entry Stop after tool exchange for adjustmenst, you can now adjust the milling depth/width (optional) or start processing immediately by clicking on Start. II. Adjusting milling depth/width 1. To mill a sample track: Position the milling/drill head above an area of the material not used for production. Click on the Motor on button. Click on the Lower head button. Move the milling/drilling head with the mouse or with the Move to x/y buttons for about 10 mm into the desired direction. Click on the Motor off button. Click on the Move to Pause button. 2. Check the milling depth/width: For Universal Cutter/Micro Cutter: Does the milling width in the copper laminat match the desired value, e. g. 200 µm when using the Universal Cutter 0.2 (8 mil)? For cylindrically cut mills with fixed mill width: Is the copper on the milling track completely milled off? Operating Manual 3.0 Rev.:

108 Starting the production phase Fig. 43: Adjusting milling depth/with 3. If necessary: Adjust the milling width/depth with the setting wheel for milling depth limitation 1 1 Setting wheel for milling width/depth Note: The milling width changes for about 2 µm per step. The milling depth changes for about 4 µm per step using the Universal Cutter and 2.3 µm per step using the MicroCutter. Mill a further sample track and check the milling width/depth again. [ ] When the desired milling width/depth is set, you can start/continue the the current production phase. III. Continuing the production phase (optional) 1. Click on Start. [ ] The current production phase will be started. Note: After all activated structures have been processed, BoardMAster prompts you End of the phase!. Fig. 44: Production phase finished. 106 ProtoMat S42

109 Working sequence in the automatic mode 2. Click on OK. [ ] Now you can start the next production phase. IV. Starting the next production phase In the Phase selection list (on the function bar) always the current (last processed) production phase is shown. If a production phase is finished (all activated data are processed), first you must select another production phase and activate the desired data (see chapter 5.2 "Setting up a production phase", on page 98) 1. Choose the next production phase in the Phase selection list. Note: Production phases marked with Info!... have to be carried out with external devices. Production phases marked with Read... can only be carried out with installed VisionSystem (option). 2. If necessary: Turn the material around the mirror axis and fix it on the traversing/vacuum table. 3. Activate the desired data (see chapter "Activating data", on page 99). 4. Click on Start, insert the tool prompted in the Tool Exchange window and activate the desired action (s. page 104) [ ] The processing of the activated data starts. If necessary, you must adjust the milling width/depth Operating Manual 3.0 Rev.:

110 Interrupting/canceling the production 5.4 Interrupting/canceling the production You can interrupt the production at any time, e. g. to adjust the milling width/depth, post-process segments or change the tool. I. Interrupting the production phase 1. If the plotter is still working: Click once on Stop to stop processing. Note: If the processing is not interrupted immediately, wait until all data already sent to the circuit board plotter have been produced. Clicking on Stop several times will continue production, possibly with further data. [ ] The production phase is interrupted an can be continued with the currend status immediately or at a later time. II. Continuing production at a later time (optional) To continue the production at a later time, you must save the current production status. 1. Save the job under a new name (see Saving a job on page 98). Choose a name reflecting the production status, e. g. MyJob_MillingTop.job [ ] Production can be continued with the current production status at a later time.(see Opening an existing job on page 95). 108 ProtoMat S42

111 Working sequence in the automatic mode Canceling (discarding) production 1. Click on File > Exit to quit BoardMaster. or: Open another job. 2. When the message "Save the job to the file..." appears. Fig. 45: Message when canceling the production Click on No. Note: If you click on Yes, this job will be saved with the current production status (in the currently active phase) and opened with the status of the production phase processed last when opening it the next time. [ ] The production is cancelled and the current production status discarded. Operating Manual 3.0 Rev.:

112 For your notes 110 ProtoMat S42

113 Care and maintenance 6. Care and maintenance Check the components listed here regularly for damage and wear. 6.1 Maintenance and inspection WARNING Health hazard due to fine dust! The processing of materials can cause formation of dusts hazardous to your health. Extract the dust and material residues or remove them with a brush or with a moistened cloth, do n o t blow compressed air through it. Cleaning the surfaces 1. If required, clean the housing surfaces with a dry, antistatic cloth. 2. Remove dust and material residues with a soft brush or a moistened cloth. [ ] The surfaces are cleaned. Carrying out a visual inspection 1. Check the ProtoMat S42 and all connection cables visually for signs of damage prior to each use. 2. If you detect damage: Make sure that the ProtoMat S42 is not used until the damage has been repaired. Make sure that the ProtoMat S42 is repaired professionally. If necessary, contact the LPKF Support. [ ] If you do not detect any damage, you can put the machine into operation. Operating Manual 3.0 Rev.:

114 Cleaning the milling depth limiter 6.2 Cleaning the milling depth limiter The milling depth limiter has to be cleaned at regular intervals, with daily operation at the latest after three months. I. Dismounting the milling depth limiter 1. Make sure that there are no tools in the collet chuck (see Removing the tool from the collet chuck on page 66). 2. Move the milling/drilling head to the Zero position. 3. Quit the BoardMaster and switch off the circuit board plotter at the main switch. The lighting of the milling/drilling head goes out. 4. Pull out the extraction hose at the milling/drilling head (1). 5. Unscrew the screws of the holding block on the right with a Torx wrench and remove the holding block (2). Fig. 46: Dismounting of the milling depth limiter 1 2 2a 3 1 Pulling out the extraction hose 2 Unscrewing the Torx screw and removing the holding block (2a) 3 Pushing the milling depth limiter laterally downwards and pulling it out to the right. 6. Press the milling depth limiter downwards and pull it out laterally (3). If necessary, turn the setting wheel of the milling depth limiter a bit to the left. 112 ProtoMat S42

115 Care and maintenance 7. Press the plastic base of the milling depth limiter together and pull it out. 8. Unscrew the setting wheel from the milling depth limiter. [ ] Now the milling depth limiter can be cleaned. II. Cleaning and greasing the milling depth limiter 1. Clean all parts with a brush or a non-fluffy cloth. 2. Grease the thread slightly with graphite grease. 3. Screw the setting wheel again onto the thread. [ ] Now the milling depth limiter can be mounted again. III. Mounting the milling depth limiter 1. Slide the milling depth limiter with the setting wheel in the holder laterally from below and push it upwards. 2. Make sure that the holding block on the left engages in the groove of the milling depth limiter and that the setting wheel is positioned flatly on the upper aluminum block. 3. Tighten the holding block on the right with a Torx screw. 4. Place the dust extraction hose on the milling depth limiter. 5. Mount the plastic base of the milling depth limiter (see Mounting/dismounting of the plastic base on page 58). [ ] Please note that the milling depth has to be reset the next time the milling is performed. Operating Manual 3.0 Rev.:

116 Cleaning the collet chuck 6.3 Cleaning the collet chuck Clean the collet chuck if necessary and at regular intervals after 100 operating hours. Clean it together with the milling depth limiter in order to have better access to the collet chuck. CAUTION Collet chuck damage! The collet chuck may be damaged by vacuum and improper cleaning tools. Clean the collet chuck only with a 3 mm pipe brush. Cleaning the collet chuck 1. Make sure that there are no tools in the collet chuck (see Removing the tool from the collet chuck on page 66). 2. Move the milling/drilling head to Zero position. 3. Press the plastic base of the milling depth limiter together and pull it out downwards. 4. Insert the 3 mm pipe brush several times all the way into the collet chuck tool holder and pull it out again. 5. Mount the plastic base of the milling depth limiter. [ ] Cleaning of the collet chuck is completed. 6.4 Replacing a fuse The circuit board plotter is protected by two fuses T4L 250 V. These fuses are in the fuse box at the mains connecting socket. Note: If your circuit board plotter is equipped with an acoustic cabinet, you must remove the side part of the cabinet to replace the fuses. 114 ProtoMat S42

117 Care and maintenance Removing the side part of the acoustic cabinet (option) 1. Remove the eight screws on the right side part of the acoustic cabinet. 2. Pull the side part laterally. Fig. 47: Removing the side part of the acoustic cabinet The main switch and the mains cable are easily accessible. 3. Turn the main switch to O position. 4. Pull the mains cable out of the mains connecting socket. [ ] Now you can replace the fuses. Operating Manual 3.0 Rev.:

118 Replacing a fuse Replacing fuses WARNING Risk of death! Missing or insufficient electrical fuse protection can result in fatal electric shocks and/or fire. Use only fuses of type T4L 250 V. Fuse holders must n e v e r be bridged. The fuse holder is located under the mains connecting socket. 1. Lever the fuse holder out of the fuse compartment by means of a flat screwdriver. 2. Replace the defective fuse with a safety fuse with values T4L 250 V. 3. Adjust the fuse holder in such a way that the required operating voltage is upright legible and push it all the way back into the fuse compartment. Fig. 48: Adjusting the Fuse Holder 1 Adjusting for 220 V 240 V 2 Adjusting for 110 V 120 V The arrow behind the adjusted operating voltage points downwards to the white line. 4. Plug the mains cable into the mains connection of the circuit board plotter. 5. If the circuit board plotter is mounted in the acoustic cabinet: Slide on the side part of the acoustic cabinet laterally and screw it tightly with eight TORX screws. [ ] The fuse holder is adjusted appropriately to the mains voltage. Now the circuit board plotter can be put into operation. 116 ProtoMat S42

119 Care and maintenance 6.5 Dust extraction The following information refers to the LPKF dust extraction. If your ProtoMat S42 is equipped with a different dust extraction, familiarise yourself with the relevant documentation about maintenance and care work required Safety instructions WARNING Health hazard! Material processing can cause formation of fine dusts and gases hazardous to your health. Make sure that the dust extraction is equipped with HEPA filters. WARNING Health hazard! The dust plugging the filter can damage the respiratory organs and is potentially carcinogenic. Replace the filter according to its service life. Never t r y t o c l e a n the filters, they are consumables and must not be reused. CAUTION Danger of machine damage! The dust extraction can be damaged because of operation with clogged filters. Replace the filters according to their service life. Filters are consumables and must not be reused. CAUTION Danger of environmental damage! Used filters can damage the environment. Dispose of the extraction filters according to legal requirements and country specific regulations. Operating Manual 3.0 Rev.:

120 Dust extraction Replacing the filter If the extraction performance decreases noticeably or the BoardMaster prompts you to do so, replace the filters of the dust extraction. Note: If the extraction performance regularly decreases noticeably before the BoardMaster prompts you to replace the filters, the BoardMaster can be set to display the message after a shorter period of time. In this case contact the LPKF Support. Replacing the filter 1. Note the information and follow the instructions in the document "Operation and maintenance manual for LPKF dust extraction of ProtoMat S-series" that are included in the scope of delivery of the dust extraction. [ ] 118 ProtoMat S42

121 Error messages/malfunctions 7. Error messages/malfunctions In this chapter you will find information concerning possible malfunctions and error messages. Please observe the instructions for fault elimination in the specified order to find a solution as soon as possible. Tab. 9: Error messages, causes and solution Error message Fault Description "Switch on the machine!" is displayed when starting Board- Master. "Switch on the machine!" is repeatedly displayed when starting BoardMaster although the circuit board plotter is switched on and can only be skipped by Cancel. BoardMaster starts but the circuit board plotter cannot be activated The milling head lighting is off. Possible cause Indications Circuit board plotter without power supply. Lighting at milling/drilling head is off. Circuit board plotter is not connected to the computer. The circuit board plotter is switched off. No power supply Defective fuse Solution Connect the circuit board plotter to the power supply. Make sure that the main switch is in position I. Click on OK. Check the machine communication: Select Configuration > Interface... and activate the Interface entry. Make sure that the circuit board plotter is connected to the provided interface of the computer. Check the interface configurations in the Windows system control (see Installation Instructions). Switch the main switch to position I. Make sure that the circuit board plotter is connected to the power supply. Replace the fuse (see "Care and Maintenance") dust extraction does not start No power supply Connect the dust extraction to the power supply. dust extraction is switched off Defective fuse No data communication Switch the selector switch of the dust extraction to the position ON or select the automatic operating mode. Press RESET key at the dust extraction switch-off Check the wiring of the circuit board plotter. Operating Manual 3.0 Rev.:

122 For your notes 120 ProtoMat S42

123 Decommissioning/disposal 8. Decommissioning/disposal 8.1 Machine parts and components Observe the legal requirements and country-specific and local regulations for disposal of waste electrical/electronic equipment or contact the LPKF Service. 8.2 Consumables Observe the legal requirements and country-specific and local regulations for disposal of consumables. Operating Manual 3.0 Rev.:

124 For your notes 122 ProtoMat S42

125 Technical data 9. Technical data ProtoMat S42 Operating voltage (can be set manually) Power consumption Weight V; 50 Hz 60 Hz (factory setting) 110 V 120 V; 50 Hz 60 Hz 200 W 43 kg (94.8 lb) Dimensions (W H D) 580 mm 480 mm 760 mm (26.4" 21.3" 29.9" ) Admissible ambient temperature C (59 F 77 F) Admissible humidity Max. 60% Airborne noise at the workstation Milling/drilling spindle Speed range Traverse speed Drilling performance Tool change 71dB (A) (excluding dust extraction) 3-phase motor Max. 42,000 U/Min.,software-controlled Max. 50 mm/s (1.97"/s) Max. 90 strokes/min. Manually, quick clamping system Tool holder mm (1/8") X/Y drive 2-phase stepping motors Z drive system Magnetic drive, 5 mm (0.2") Milling depth adjustment Manually Working area 229 mm 305 mm 5 mm (9" 12" 0.2") Resolution (X/Y) Repetitive accuracy Precision of the pass hole system Smallest drilling diameter 1 µm (0.04 Mil) +/- 5 µm (0.2 Mil) +/- 20 µm (0.8 Mil) 0.2 µm (8 Mil) Operating Manual 3.0 Rev.:

126 For your notes 124 ProtoMat S42

127 LPKF Service 10. LPKF Service Sales and service contact details are listed below. Our expert team would be delighted to assist you. Europe (LPKF head office) Phone +49 (0) Fax +49 (0) LPKF webpage North / Central America Phone +1 (503) Fax +1 (503) LPKF webpage sales@lpkfusa.com support@lpkfusa.com China Phone Hotline service (Distribution) (Service) Fax LPKF webpage sales@lpkf.cn sales@lpkf.cn Operating Manual 3.0 Rev.:

128 For your notes 126 ProtoMat S42

129 EC Declaration of Conformity 11. EC Declaration of Conformity Declaration of Conformity in accordance with Machinery Directive 98/37/EC, Appendix II A The manufacturer/seller LPKF Laser & Electronics AG Osterriede 7 D Garbsen Germany hereby declares that the circuit board plotter ProtoMat S42 conforms to the provisions of the directive(s) identified above - including the modifications effective at the time of this 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 productions are in compliance with the following EC directives and EN standards: Applied harmonized standards EN 292-1:1991 Safety of machinery - Basic terms, general principles for design - Part 1: Basic terminology, methods EN 292-2:1995+A1:1995 Safety of machinery - Basic terms, general principles for design - Part 2: Technical principles and specifications EN 349:1993 Safety of machinery - Minimum gaps to avoid crushing of body parts 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 :1997 Safety of machinery - Electrical equipment of machines - Part 1: General requirements Operating Manual 3.0 Rev.:

130 EC Declaration of Conformity EN :2001 Electromagnetic compatibility (EMC) EN 55022:1994 A2 Information technology equipment - Radio disturbance characteristics - Limits and methods of measurement Amendment A2:1997 Further EU directives applied EMC directive 89/336/EEC Low Voltage Directive 2006 /95/ EEC Town: Garbsen Date: 2. June 2008 Bernd Hackmann (Board chairman) 128 ProtoMat S42

131 Index 12. Index Numeric 1-2layer.phs () 42, 94 4-layer.phs 94 4layer.phs 43 6-layer.phs 94 A Acoustic cabinet Removing the Side Part 115 Activating Data 99 All- 57 All+ 57 Aluminum 34 Axis directions 27 B Base material placing 61 Basic equipment 19 Baud rate 51 BoardMaster 54 starting 50 Version 13 C Calibrating fiducial recognition 86 Camera adjusting 80 Power supply 21 Camera Image 55 Camera offset 84, 86 Care 111 centre-punching 44 Checking the Interfaces 50 Cleaning 111 Cleaning the milling depth limiter 112 Conical tool 37 Connecting 50 Connection for illumination 21 Connection settings 50 Contour milling 34 Contour Router 34 Contours 44 Coordinates system 27 CuttingInside 44 D Data Activation 45 Declaration of Conformity 127 Defined Positions 28 Depaneling 34 Disclaimer 14 Dismounting of the brush head 58 Dismounting of the plastic base 58 Drill 35 Drilling 66 DrillingPlated 44 DrillingUnplated 44 Dust extraction 22, 23 at the milling/drilling head 21 Operating mode 48 E EC Declaration of Conformity 127 End Mill 33 End Mill (RF) 34 End Mill long 34 End mill long 34 Entering the decimal places 57 Error messages 119 EU directives 128 F Function Bar 55 Function bar 54, 55 Fuse holder 116 G Galvanic 42 General Safety Instructions 16 H Heat sink 21 Home 56, 59 Home Position 28 Home position 27, 28 I Info! Apply foil to PCB 44 Info! Galvanic Plating 44 Info! MultiPress_work 44 Info! ProConduct 44 Inner cutouts 44 Interface type ProtoMat S42

132 Index J Job setting up 96 L Lines select all 57 Loading 61 LPKF Proconduct 42 LPKF ProConduct System 44 M Main menu 54, 55 Main switch 52, 115 Maintenance 111 Malfunctions 119 Manufacturer 127 MarkingDrills 44 Material cutouts 34 height 63 turning 29 Material cutouts 34 Menu bar 55 Micro Cutter 33 Milling width 37 Microwave materials 34 Milling depth limiter 21 Mounting the base 58 Milling speed 56 Milling/drilling head 21, 27 lift/lower 56 moving gradually 60 moving with the mouse 60 positioning 59 MillingBottom 44 MillingTop 44 Mirror Axis 55 Mirror axis 28, 54 Mode automatic 41 Mounting the brush head 58 Mounting the plastic base 58 Mouse pointer 55 Moving 57 Multilayer LPKF Multilayer set 25 Multilayer press 44 N Notations 3 O Opening a job 95 Outer layers 45 P Pass Hole System 29 Pass holes drilling in pass hole strips 71 Pause 56, 59 Pause Position 28 Penetrative tools 32, 34 Phase configuration 56 Phase file selecting 93 Phase files 41 Phase selection 56 Point/comma 57 Position of the Milling/Drilling Head 55 Prepare_Bottom 45 Prepare_Top 45 Pressing 44 Printed circuit boards 4-layered 43 one/two layered 42 ProConduct 44 Production canceling 109 interrupting 108 Production phase Work steps 44 Production phases 44 Production type defining 93 Production types 41 Project aligning/allocating 97 copying 57 copying/moving 97 importing 95, 96 moving 57 Protective foil 44 R Read_Bottom 44 Read_Layer 45 Read_Top 44 Reading in fiducials 44 Replacing the Fuse 114 RF materials 34 S Safety Instructions 15 Operating Manual 3.0 Rev.:

133 Index Seller 127 Setting up/selecting a job 94 Solder paste stencils 43 Solder stop foils 43 soldermask.phs 43, 94 Spacer rings 32 Speed 56 Speed controller 49 Speed range 123 Spiral Drill 35 Spring adjustment 21 Standards 127 Start/Stop 57 Status Bar 55 Status bar 55 stencilmilling.phs 43, 94 Suction force 49 Surface tools 32, 33 Switching on 47 Circuit board plotter 49 LPKF dust extraction 48 T Technical Data 123 Through-hole plating 44 Title Bar 55 Title bar 54, 55 Tool diameter 32 Tool selection 56 Trademark 4 Traversing axis 27 Traversing table 27 U Universal Cutter 33 Milling width 37 Use Designated 13 Inadmissible 14 V Visual inspection 111 Z Zero 56, 59 Zero Position ProtoMat S42

134 For your notes 132 ProtoMat S42

135 Article number: xxx_xxx Item number: ( ) Insert cover photo: Size: 11.5 cm x 9.5 cm Distance: top: 1.5 cm left: 8.5 cm ProtoMat S42 Installation Instructions 3.0, English

136

137 ProtoMat S42 Installation Instructions 3.0, English LPKF Laser & Electronics AG Osteriede 7 D Garbsen Germany Phone (0) Fax (0) lpkf@lpkf.de Home page

138 ProtoMat S42 Introduction The LPKF ProtoMat S42 is a compact circuit board plotter of the newest generation. It is suitable especially for the rapid and safe production of circuit board prototypes in electronic labs and development departments. The high number of revolutions (up to rpm) guarantees production of accurate structures on different base and housing materials. By means of the optional camera system double-sided materials can also be processed e. g. for multi-layer and RF applications. Flexible and rigid/flexible workpieces can be fixed flatly on the working surface by means of the optional vacuum table. The ProtoMat S42 is controlled via the easy-to-use LPKF BoardMaster software. The LPKF CircuitCAM software included in the scope of delivery can be used to import and prepare different CAD data formats for the working process. Copyright 2008 LPKF AG Any distribution or copying of this manual or parts of this manual in any form and use of its contents require the written permission of the LPKF AG. Subject to modifications. Translation of the german original Item number: ( )

139 Information on this document Information on this document Availability Notations This document contains important information regarding operation, maintenance and care of the LPKF ProtoMat S42 circuit board plotter and accessories. The manual is directed at persons with basic knowledge in the installation and operation of software-controlled machines. Knowledge regarding the safety and behaviour in workshops as well as regarding the operation of a computer with Windows 2000/XP are required. When working at or with the ProtoMat S42, this document must be available in complete and legible condition. It must be within an easy reach near the machine for all the persons authorised to work on the machine. As the machine owner, you have to make sure that the machine is only operated by persons who have read and understood this manual or have been informed about its contents. Different notations enable better orientation in this document. Bold print The following detailed information is shown in bold print: Switches, operating elements, labeled connections for example power switches. Software elements: Menu items, e. g. File > Open... Input boxes, selection boxes and lists, e. g. Tool Selection List Buttons and functional symbols; e. g. Cancel Windows, dialogue boxes, for example input window Tool positions Numbers in bold print written in parentheses (1) identify the number in the figure described. Italic print The following information is printed in italics: Proper names and trademarks, e. g. Windows (LPKF proper names are not printed in italics) Software messages, for example "Starting the file..." (The inverted commas are not part of the message.) Operating Manual 3.0 Rev.:

140 Symbols and signal words Actions to be carried out Indented headings prompt you to carry out an action. Example: Carry out an action If the heading is preceded by a roman numeral (e. g. I), then you have to carry out further actions to achieve the work objective. 1. A numbered indented sentence prompts you to carry out one step of an action. 2. Always carry out the steps of an action in the numbered order. [ ] Square brackets indicate that no further steps need to be carried out for this action. If further actions are required to achieve the work objective, they will be indicated. Figures Numbers in bold print in figures identify numberings (1) or dimensions (50 mm). Symbols and signal words WARNING Danger to life or health! This symbol indicates a dangerous situation in which, in case of non-observance of the information, there is a risk to life or health. Measures required to avoid danger are indicated. CAUTION Risk of material damage! This symbol indicates a situation which, in case of non-observance of the information, can result in material damage. Measures required to avoid danger are indicated. Tip: The hand indicates hints for easier operation, use of material and/or its further processing. Registered trademarks and brand names The LPKF Logo, LPKF ProtoMat, BoardMaster and LPKF ProConduct are registered trademarks of LPKF Laser & Electronics AG. Microsoft and Windows are trademarks or registered trademarks of the Microsoft Corporation in the USA and/or other countries. All other trademarks belong to their respective owners. 4 ProtoMat S42

141 Table of contents Table of contents Introduction Information on this document Table of contents List of figures Safety information Designated use Liability information Safety Instructions What is what? Scope of delivery Required accessories Optional components Machine overview LPKF dust extraction Installation Checking/adjusting the operating voltage Adjusting the operating voltage Mounting the acoustic cabinet (optional) Setting up the circuit board plotter Removing the shipping braces and base material Mounting the plastic base of the milling depth limiter Mounting the mains cable Installing the dust extraction Connecting the LPKF dust extraction to the circuit board plotter Setting the operating mode (LPKF dust extraction) Setting the suction force (LPKF dust extraction) Installation Instructions 3.0 Rev.:

142 Table of contents 3.5 Setting up the Computer Installing the USB serial converter (optional) Configuring the COM Port Installing the LPKF software Starting the software installation Completing installation Connecting the data cable Connecting the power supply First putting into operation Checking the installation Switching on the machine Checking the Interfaces (optional) Testing the machine communication Malfunctions and problem solutions 37 5 Technical data 39 6 LPKF Service 41 7 EC Declaration of Conformity 43 8 Index 45 6 ProtoMat S42

143 List of figures List of figures Fig. 1: ProtoMat S42 basic equipment Fig. 2: Milling/drilling head Fig. 3: Rear side of the machine Fig. 4: LPKF dust extraction Fig. 5: Adjusting the fuse holder Fig. 6: Removing the shipping braces and the base material Fig. 7: Mounting the plastic base of the milling depth limiter Fig. 8: Screwing connecting piece on the extraction hose Fig. 9: Connecting the extraction hose to the suction pipe of the circuit board plotter Fig. 10: Connecting the extraction hose to the suction pipe of the acoustic cabinet (optional) 24 Fig. 11: Connections on the dust extraction Fig. 12: Connections for the dust extraction on the circuit board plotter Fig. 13: LPKF dust extraction Setting the operating mode Fig. 14: Device Manager window Fig. 15: Connection settings Fig. 16: Advanced settings Fig. 17: Connecting the data cable to the circuit board plotter Fig. 18: BoardMaster user Interface Fig. 19: Input window Connect Installation Instructions 3.0 Rev.:

144 For your notes 8 ProtoMat S42

145 Safety information 1. Safety information In this chapter you can find information concerning the designated use, liability and safety when using ProtoMat S42. If, after reading this manual, a situation should arise in which you are not sure how to use or service ProtoMat S42, please contact the LPKF Support or consult a person skilled in the art. 1.1 Designated use The ProtoMat S42 is designed for manufacturing of electric circuit boards with up to six layers and the processing of different sign and housing materials. The following operations can be carried out: Milling and drilling of single-sided and double-sided base materials Milling and drilling of multilayer materials Milling SMD solder paste stencils Milling solder stop foils Engraving housing plates and signs Milling cutouts and contours Approved materials: GRP/CRP base material PTFE/ceramic composite base material Wood Non-ferrous metals Brass acc. to DIN EN 1412: CW603N Plastics Polyoxymethylene ABS copolymers The ProtoMat S42 may only be used for mentioned in this document operations and materials to be processed. The circuit board plotter may only be used together with the LPKF Software BoardMaster Version included in the delivery. If you want to use a different version, please first contact the LPKF Support. Installation Instructions 3.0 Rev.:

146 Liability information The circuit board plotter may only be operated with a sufficient dust extraction including fine dust filter. We recommend to use the LPKF dust extraction with an integrated HEPA filter. If you want to use another system for dust extraction, please first contact the LPKF Service. Inadmissible Use The ProtoMat S42 may not be used for processing highly inflammable materials, closed containers, hollow pieces, textiles and food. The processing of body parts (e. g. finger nails) is not allowed. If you are not sure about the use of the materials to be processed, contact the LPKF Support. 1.2 Liability information The ProtoMat S42 has been developed and built in accordance with state-of-the-art standards and recognised safety rules. Nevertheless, improper handling/use may constitute a risk to life and limb of the user or of third parties, or cause damage to the machine and to other material property. Disclaimer The manufacturer/seller cannot be held liable for damage caused by the following actions/conditions: Improper handling, including any use not mentioned in this manual. Use in unsuitable environment Installation and operation by insufficiently informed or unauthorized persons Non-observance of the legal safety regulations Non-observance of the technical information Incorrect installation Insufficient supply facilities Missing or insufficient maintenance Unauthorized technical modifications Use of workpieces/materials and spare parts that are not specifically approved by LPKF for this machine/this device. 10 ProtoMat S42

147 Safety information 1.3 Safety Instructions WARNING Risk of death by electric shock! Missing or insufficient electrical fuse protection can result in fatal electric shocks and/or fire. Use only safety fuses of type T4L 250 V. Fuse holders must n e v e r be bridged. WARNING Risk of injury! The open cover of the acoustic cabinet can drop down due to impact effect or vibrations. This can result in limbs being broken or crushed. When opening the cover of the acoustic cabinet make sure that it engages in the uppermost position and cannot drop down because of vibrations or other persons actions. General Safety Instructions Read the Installation/Operation instructions before using the machine. In case of uncertainties ask a person qualified in the art or contact the LPKF Support. Use the machine only in accordance with its designated use. Never operate the machine in environments subject to fire or explosion hazards. Operate the machine only in suitable environment. Protect the machine against direct sunlight, humidity and flying sparks. Operate the machine only with accessories approved by LPKF and original LPKF tools. Use the machine only in perfect condition. Prior to each use, perform a visual inspection. Pay attention to damaged cables and hoses in particular. Make sure that the safety devices are in perfect working order. It is prohibited to bridge safety devices or to make them inoperable. (Page 1 of 2) Installation Instructions 3.0 Rev.:

148 Safety Instructions General Safety Instructions (Fortsetzung) Make sure that there is no risk of stumbling caused by cables and hoses. Have the machine operated, serviced and repaired by sufficiently qualified and authorized personnel only. Repairs must be carried out only by qualified LPKF personnel or after having consulted the LPKF Support. Keep children away from the work area. Do not eat, drink or smoke in the workshop/working area. Observe the general and legal regulations for accident prevention and environmental protection. Operate, service and repair the machine only when wearing the prescribed protective equipment. When handling the circuit board plotter, make sure that the machine cannot start (unintentionally) or is operated by a third person, for example at the computer. Prior to any maintenance work pull the mains plug. Maintenance work must be carried out regularly. Rectify any damages or malfunctions immediatly. If damage/malfunctions cannot be rectified, shut down the system and assure it against putting in operation. Extract dust/material residues from the machine or remove with a brush. Do n o t blow compressed air through it! (Page 2 of 2) 12 ProtoMat S42

149 What is what? 2. What is what? In this chapter you get to know the components and operating elements of the ProtoMat S42. Before installing the machine or putting it into operation, first familiarise yourself with the individual components. 2.1 Scope of delivery Circuit board plotter: ProtoMat S42 Cable: USB serial converter: 230 V Mains voltage cable (type F plug) 115 V Mains voltage cable (US standard) Data cable for RS-232 connections Incl. Installation CD Base material: FR4, 229 mm 305 mm (9" 12") Drill underlay: 229 mm 305 mm (9" 12") Accessories: TORX wrench: T10, T20 2 Pass hole strips 5 Pass hole pins (3 mm 8 mm) Press-in tool for pass hole pins 4 Safety fuses 2 Pass hole drill Spiral Drill 2.95 mm Adhesive crêpe tape (removable without leaving residue) Cleaning brush CD ROM: BoardMaster... & CircuitCAM... Configuration Files User documentation: ProtoMat S42 Installation Instructions (this document) ProtoMat S42 Operating Instructions ProtoMat S42 Tutor Data Training instructions BoardMaster Manual CircuitCam Manual Installation Instructions 3.0 Rev.:

150 Required accessories 2.2 Required accessories For the operation of the ProtoMat S42 you need the following accessories: Computer with Microsoft Windows XP/2000 operating system. dust extraction We recommend the LPKF dust extraction with AutoSwitch function. Tools and consumables We recommend the LPKF accessories set for ProtoMat S42-1/8". Measuring microscope We recommend the LPKF measuring microscope with 60-fold magnification for optimal control of the milling process. 2.3 Optional components The ProtoMat S42 can be optionally equipped with the following LPKF accessories. You can find detailed information on installation and use of these components in the corresponding documents. Tab. 1: Optional Components Designation Function Use Acoustic cabinet Sound protection Reduction of the acoustic emissions at the workplace VisionSystem Optical fiducial recognition Camera based layout alignment, optimum for the Multilayer production, integrated measuring function and broken drill detector Vacuum table Measuring microscope Workpieces are fixed flatly on the working surface Measuring and checking the milling tracks and drillings Only with the dust extraction, prevents deflection of the material when processing thin material Quality control through 60-fold magnification and metric scale 14 ProtoMat S42

151 What is what? 2.4 Machine overview Fig. 1: ProtoMat S42 basic equipment Rating plate 2 Main switch 3 Power cable socket 4 Fuse holder, voltage setting 5 Pass hole strips (right) 6 Traversing table 7 Milling/drilling head 8 Warning label! Hot surface 9 Lifting magnet 10 Internal extraction hose Installation Instructions 3.0 Rev.:

152 Machine overview Fig. 2: Milling/drilling head Internal extraction hose 2 Spring adjustment 3 Lifting magnet 4 Warning label! Hot surfaces. 5 Heat sink 6 Tension lever 7 Plastic base of the milling depth limiter 8 Tool holding fixture 9 Power supply for the lighting of the milling/drilling head 10 Setting wheel for the milling depth limiter 11 Power supply for the optional camera 16 ProtoMat S42

153 What is what? Fig. 3: Rear side of the machine Basic equipment Option acoustic cabinet Warning label! Hot surfaces. 2 Hub motor 3 Extraction hose connection 4 Control unit with data connections (SMCU III) 5 Serial ports (Port 1 Port 4) 6 RS 232 Connection 7 Indicator Error 8 Indicator Online 9 Indicator Power 10 Ethernet connection (only for LPKF Service) Installation Instructions 3.0 Rev.:

154 LPKF dust extraction 2.5 LPKF dust extraction WARNING Health hazard! Material processing can cause formation of fine dusts and gases hazardous for your health. Make sure that the dust extraction is equipped with HEPA filters and is switched on during material processing. Note: The ProtoMat S42 can be equipped with another dust extractionsystem. Detailed Information about the dust extraction can be found in the corresponding documents Fig. 4: LPKF dust extraction Extraction hose 2 Suction force regulator 3 Power supply 4 Data cable connection 5 Main switch 6 Automatic fuse 18 ProtoMat S42

155 Installation 3. Installation This chapter contains information on installation of the basic equipment of your ProtoMat S42 (if necessary, with the acoustic cabinet). Required materials Procedure For the installation of the ProtoMat S42 you need following accessories: dust extraction Computer with Windows XP/2000 operating system. Torx wrench from the accessories kit If necessary, screwdriver (flat, 4 mm) Optional: ProtoMat S42 acoustic cabinet Carry out installation in the order indicated here. The optional components, e. g. the camera basedvisionsystem or the vacuum table, should be installed only after the first putting into operation. You can find the information about this in the respective mounting / installation Instructions. 3.1 Checking/adjusting the operating voltage The circuit board plotter can be set to function with 110 V 120 V AC or 220 V 240 V AC. The operating voltage can be adjusted by means of the fuse holder (under the main switch) and corresponds to the upright value legible at the bottom of the fuse holder. Fig. 5: Adjusting the fuse holder 1 Adjusting for 220 V 240 V 2 Adjusting for 110 V 120 V Installation Instructions 3.0 Rev.:

156 Mounting the acoustic cabinet (optional) Note: If the circuit board plotter has already been mounted into the acoustic cabinet, the right side part of the acoustic cabinet must be dismounted. Information on this can be found in the manual "ProtoMat S42 Operation". Adjusting the operating voltage WARNING Risk of death by electric shock! Missing or insufficient electrical fuse protection can result in fatal electric shocks and/or fire. Use only safety fuses of type T4L 250 V. Fuse holders must n e v e r be bridged. 1. If available: Pull the mains cable out of the circuit board plotter. 2. Lever the fuse holder out of the fuse compartment by means of a flat screwdriver. 3. Adjust the fuse holder in a such way that the required operating voltage is upright legible and push it all the way back into the fuse compartment. The arrow behind the adjusted operating voltage points downwards to the white line. [ ] The desired operating voltage is set. 3.2 Mounting the acoustic cabinet (optional) To find out about mounting of the acoustic cabinet read the manual delivered with the acoustic cabinet. Note: The acoustic cabinet has to be installed together with the circuit board plotter. Subsequent installation of the completely installed circuit board plotter involves an additional work effort. 20 ProtoMat S42

157 Installation 3.3 Setting up the circuit board plotter WARNING Risk of injury! The open cover of the acoustic cabinet can drop down due to impact effect or vibrations. This can result in limbs being broken or crushed. When opening the cover of the acoustic cabinet make sure that it engages in the uppermost position and cannot drop down because of vibrations or other persons actions. I. Removing the shipping braces and base material 1. Remove the following shipping braces: Cardboard strips with adhesive tape Plastic foam under the milling head Lift up the milling/drilling head with one hand to remove the plastic foam underlay. Fig. 6: Removing the shipping braces and the base material Cardboard strips with adhesive tape 2 Foam underlay 3 Base material 2. Remove the base material from the traversing table. Note: The white hardboard serves as a drill underlay and must remain on the traversing table. [ ] There are no shipping braces on the circuit board plotter anymore. Installation Instructions 3.0 Rev.:

158 Setting up the circuit board plotter II. Mounting the plastic base of the milling depth limiter The plastic of the milling depth limiter is included as an accessory. 1. Lift up the milling/drilling head with one hand and push the milling depth limiter from below into the milling/drilling head. 2. Press the plastic base slightly together and insert it from below into the milling depth limiter. Fig. 7: Mounting the plastic base of the milling depth limiter Milling depth limiter 2 Plastic base Rotate the plastic base until the opening faces the front. [ ] Mounting the plasticbase of the milling depth limiter is completed. 22 ProtoMat S42

159 Installation III. Mounting the mains cable The scope of delivery of ProtoMat S42 includes a mains cable with type F plug (230 V AC) and a mains cable with US standard plug (115 V AC). 1. Plug the mains cable suitable for your mains supply into the mains connecting socket of the circuit board plotter. 2. Make sure that the main switch is in the O position. 3. If the ProtoMat S42 is mounted in the acoustic cabinet: Lead the mains cable towards the back out of the acoustic cabinet. [ ] The mains cable is completely mounted. 3.4 Installing the dust extraction For the operation of the ProtoMat S42 we recommend to use the LPKF dust extraction with automatic On/Off switching. If you are going to use another system for dust extraction, contact the LPKF Support first and observe the information on dust extraction contained in the enclosed documents. I. Connecting the LPKF dust extraction to the circuit board plotter 1. Position the dust extraction in such a way that the connecting lines can be laid without bending or chafing them. 2. Screw the connecting piece from the accessory bag of the ProtoMat S42 on the extraction hose (left-hand thread). Fig. 8: Screwing connecting piece on the extraction hose Installation Instructions 3.0 Rev.:

160 Installing the dust extraction 3. Insert the extraction hose with the connecting piece into the suction pipe of the circuit board plotter or of the acoustic cabinet. Fig. 9: Connecting the extraction hose to the suction pipe of the circuit board plotter Closing plu 2 Extraction hose with connecting piece Fig. 10: Connecting the extraction hose to the suction pipe of the acoustic cabinet (optional) Closing plu 2 Extraction hose with connecting piece 24 ProtoMat S42

161 Installation 4. Make sure that the extraction hose is closed with a plug on the side opposite to the extraction hose. 5. Insert the loose end of the extraction hose into the air intake of the dust extraction. 6. Plug the 9-pin plug of the data cable into the data connecting socket of the dust extraction and fasten the plug-in connection. Fig. 11: Connections on the dust extraction 7. Plug the mains cable into the mains connecting socket of the dust extraction. 8. Plug the loose end of the data cable into Port 3 or Port 4 on the rear side of the circuit board plotter and fasten the connection using the screws. Fig. 12: Connections for the dust extraction on the circuit board plotter Port 3 2 Port 4 [ ] The LPKF dust extraction is connected to the ProtoMat S42. Installation Instructions 3.0 Rev.:

162 Installing the dust extraction II. Setting the operating mode (LPKF dust extraction) The LPKF dust extraction can be used in the automatic or in the continuous operating mode. We recommend to use a software controlled operating control system for the automatic mode, in order to guarantee the lowest possible power consumption and safe operation. 1. Set the main switch of the LPKF dust extraction to the desired position. Use one of the following settings: Setting Operating mode Operation ON Continuous operation Permanent extraction, Switching On/Off using the BoardMaster is not possible OFF Off No extraction, Switching On/Off using the BoardMaster is not possible Connection to LPKF ProtoMat Automatic mode The extraction starts automatically together with the milling/drilling motor, manual switching On/Off using the BoardMaster is possible. Fig. 13: LPKF dust extraction Setting the operating mode Continuous operation 2 Off 3 Automatic mode [ ] The desired operating mode is set. 26 ProtoMat S42

163 Installation III. Setting the suction force (LPKF dust extraction) 1. Basic equipment (w i t h o u t vacuum table): Turn the SPEED controller of the dust extraction to the medium range. 2. For operation w i t h vacuum table (optional): Turn the SPEED controller of the dust extraction to the position MAX. [ ] The suction force is set according to the equipment of the machine. 3.5 Setting up the Computer The ProtoMat S42 is controlled by means of a computer with the operating system WindowsXP/2000 (not included in the scope of delivery). System requirements: Processor min. 1.5 GHz RAM: min. 256 MB (512 MB recommended) Hard disk capacity: min. 100 MB CD-ROM drive: min. 16-fold Unused serial (COM) port or USB port For VisionSystem (optional): additional USB 2.0 port For the following work steps you need a computer that is ready for operation. Installation Instructions 3.0 Rev.:

164 Setting up the Computer Configuring the communication port If your computer has an (unused) serial connection, you can connect the ProtoMat S42 directly to it. You just have to configure the COM port (see "Configuring the COM Port"). You can optionally connect the ProtoMat S42 to an unused USB port(see "Installing the USB serial converter (optional)"). To do so you need an enclosed USB serial converter. It simulates a (serial) COM port on your computer Installing the USB serial converter (optional) To install the USB serial converter you have to install the USB driver included in the scope of delivery first: 1. Put the CD USB Serial Converter into the CD drive. 2. Now start the file Setup.exe (CD:\Driver\Setup.exe) 3. Follow the on-screen instructions. After successful installation of the USB driver, you can connect the USB serial converter. 4. Plug the USB serial converter into an unused USB port of the computer. [ ] Installation of the USB serial converter is completed. Configuring the COM Port 1. Click on Start > Settings > System control > System > [Hardware] > Device manager. The Device Manager window is opened. Fig. 14: Device Manager window 28 ProtoMat S42

165 Installation 2. If necessary, click on the + icon in front of the entry Ports (COM and LPT), in order to list the existing COM ports. Note: A question or exclamation mark besides an input indicates a faulty driver installation. In this case you should delete the input and repeat the installation of the driver. 3. Double-click the COM port that you want to connect to the ProtoMat S42, for example: Communication port (COM1) for the serial connection to COM 1 or: Prolific USB-to-Serial-Comm Port (COM3) in case of connection to a USB port by means of the USBconverter. The window Communication Port (Com...) Properties is opened. Note: Write down the number of the selected COM port from the title bar of the window. You will need it at a later time. 4. Click on the tab Connection settings. 5. Select the following settings: Bits per second: Data bits: 8 Parity: none Stop bits: 1 Flow control: Hardware Fig. 15: Connection settings Installation Instructions 3.0 Rev.:

166 Setting up the Computer 6. Click on Advanced... The window Advanced Settings for... is opened. Fig. 16: Advanced settings 7. Make sure that following settings are applied: Use FIFO buffer activated Receiving buffer: (8) Transmission buffer: (6) COM port number: COM port to which your ProtoMat S42 is connected. 8. Click on OK at a time, to close the setting windows. Configuration of the selected communication port is completed. 9. Restart the computer for the selected settings to take effect. [ ] The COM port is configurated according to your specifications. 30 ProtoMat S42

167 Installation 3.6 Installing the LPKF software For operation of the circuit board plotter with the basic equipment you need only the LPKF Software BoardMaster that can be found on the enclosed CD and the INI file for system configuration which can be found on the CD Configuration Files. The on the CD BoardMaster... & CircuitCAM... available LPKF Software CircuitCAM, is only required for preparation and conversion of circuit board layout files into a BoardMaster-readable file format (e. g. the LMDformat). To operate the ProtoMat S42 it is not required to install CircuitCAM on the computer. If you want to practice operating the ProtoMat S42 with the enclosed Tutor files (see ProtoMat S42 Tutor data Tutorial), you have to install CircuitCAM on the computer connected to the circuit board plotter. Starting the software installation 1. Put the CD BoardMaster... & CircuitCAM... into the CD drive. Note: The start of the welcome window may take a few seconds. 2. If the welcome window "Rapid Prototyping PCB" is not displayed automatically: Start the file setup.exe from the CD. The LPKF welcome window is displayed. 3. Follow the on-screen instructions. [ ] The selected software will be installed on the computer. Note: You can find detailed information on installation and registration/activation of this software in the respective manuals. Installation Instructions 3.0 Rev.:

168 Completing installation 3.7 Completing installation Connecting the data cable 1. Connect the included data cable to the RS 232 port on the rear side of the ProtoMat S42. If the RS-232 plug of the data cable does not fit the RS 232 port of the circuit board plotter, use the enclosed Mini Gender Changer as an adapter. Fig. 17: Connecting the data cable to the circuit board plotter RS 232 Port 2 Mini Gender Changer (optional) 2. Connect the serial plug of the data cable to the COM port selected during the setting up of the computer or to the serial port of the USB serial converter. [ ] The data cable between the computer and the circuit board plotter is connected. Connecting the power supply 1. Make sure that the set operating voltage corresponds to available power supply (see "Adjusting the operating voltage" on page 20). 2. Plug in all mains connecting plugs into the earthed sockets. [ ] The power supply is connected. The installation of the ProtoMat S42 is now completed. Now you can put the system into operation (see chapter 3.8 "First putting into operation", on page 33). 32 ProtoMat S42

169 Installation 3.8 First putting into operation To put the ProtoMat S42 into operation for the first time, you have to switch on the machine in the specified order. After having checked the coordinates system you can setup optional components and prepare a pass hole system. I. Checking the installation 1. Make sure that the shipping braces have been removed. 2. Make sure that there are no objects on the working table of the circuit board plotter. 3. Check all the lines and hoses for tight fit. Make sure that cables and hoses are not bent and they do not create any risk of stumbling. [ ] Checking of the installation is now completed. Now you can put the machine into operation. II. Switching on the machine 1. Switch on the computer and wait until the operating system has been started. 2. Switch the main switch of the ProtoMat S42 (on the right side of the circuit board plotter (inside of the acoustic cabinet) to position I. The milling/drilling head lighting is on. 3. Double-click the BoardMaster icon on the desktop. or: Click on Start > Programs > LPKF Laser & Electronics > BoardMaster.... Note: Make sure to start the BoardMaster version delivered with the ProtoMat S42 circuit board plotter. [ ] BoardMaster will be started. Note: If the window Connect... appears, you must check the interfaces (s. page 34). Installation Instructions 3.0 Rev.:

170 First putting into operation Fig. 18: BoardMaster user Interface Title bar 2 Main Menu 3 Function Bar III. Checking the Interfaces (optional) If the circuit board plotter is not recognised automatically, the input window Connect... appears. If necessary, you have to change the connection settings. Fig. 19: Input window Connect ProtoMat S42

171 Installation 1. Make sure that the circuit board plotter is on and that the milling/drilling head lighting is on. 2. Make sure that the following values are entered and check the settings of the Windows system control (see "Configuring the COM Port" on page 28) Control unit: SMCU 3 Machine: ProtoMat S42 Interface type: RS-232 (USB is only intended for service purposes) COM port number: COM port to which the circuit board plotter is connected and which was defined in the Windows system control(see "Configuring the COM Port" on page 28). Baud rate: Click on Connect... [ ] As soon as the connection to the circuit board plotter has been established, the BoardMaster user interface appears. Note: If you click on Cancel BoardMaster will be opened, but the circuit board plotter cannot be activated. The input window Connect... can be opened again at anytime from the Main Menu (Configuration > Connect...). Installation Instructions 3.0 Rev.:

172 First putting into operation IV. Testing the machine communication To guarantee correct data communication between BoardMaster and the circuit board plotter, the machine communication must be tested. 1. Click on the Move to Pause button in the function bar. The milling/drilling head and the working table are moved to the Pause position. 2. Click on the Move to Home button in the function bar. The milling/drilling head and the work table are moved to the Home position. 3. Click on the Move to Zero button in the function bar. The milling/drilling head and the work table are moved to the Zero position. [ ] The test is completed. Note: In case of problems please read Chapter 4 "Malfunctions and problem solutions", on page ProtoMat S42

173 Malfunctions and problem solutions 4. Malfunctions and problem solutions In this chapter you will find information concerning error messages, malfunctions and solutions. Tab. 2: Error and operational faults Error/Function Description Circuit board plotter cannot be switched on. (The milling head lighting does not light up after switching on the main switch) Connect... window opens after starting BoardMaster. Possible cause No power supply. Incorrect setting of the operating voltage. Circuit board plotter has no power supply. Lighting of the milling/drilling head is off. Troubleshooting Make sure that the circuit board plotter is connected to the power supply (milling head lighting is on). Adjust the operating voltage to the value of the power supply (see "Checking/adjusting the operating voltage" on page 19) Connect circuit board plotter to power supply. Ensure that the main switch of the circuit board plotter is in position I. Click on Connect... Connect... window opens repeatedly after clicking on Connect... Dust extraction does not start The connection settings do not correspond to the installation. No power supply Dust extraction is switched off The dust extraction fuse was blown No data communication Ensure that connection settings correspond to your installation. Check the COM port settings in the in the Windows system control (see Kapitel Configuring the COM Port, on page 28). Connect the dust extraction to the power supply. Set the switch for operating mode selection of the dust extraction to the position ON or select the automatic mode. Press RESET button on the dust extractionswitch-off Check the wiring of the circuit board plotter. Installation Instructions 3.0 Rev.:

174 For your notes 38 ProtoMat S42

175 Technical data 5. Technical data ProtoMat S42 Operating voltage (can be set manually) Power consumption Weight V; 50 Hz 60 Hz (factory setting) 110 V 120 V; 50 Hz 60 Hz 200 W 43 kg (94.8 lb) Dimensions (W H D) 580 mm 480 mm 760 mm (26.4" 21.3" 29.9" ) Admissible ambient temperature 15 C to 25 C (59 F to 77 F) Admissible humidity Max. 60% Airborne noise at the workstation Milling/drilling spindle Speed range Traverse speed Drilling performance Tool change 71dB (A) (excluding dust extraction) 3-phases motor Max. 42,000 U/Min.,software-controlled Max. 50 mm/s (1.97"/s) Max. 90 strokes/min. Manually, quick clamping system Tool holder mm (1/8") X/Y drive 2-phase stepping motors Z drive system Magnetic drive, 5 mm (0.2") Milling depth adjustment Manually Working area 229 mm 305 mm 5 mm (9" ") Resolution (X/Y) Repetitive accuracy Precision of the pass hole system Smallest drilling diameter 1 µm (0.04 Mil) +/- 5 µm (0.2 Mil) +/- 20 µm (0.8 Mil) 0.2 µm (8 Mil) Installation Instructions 3.0 Rev.:

176 For your notes 40 ProtoMat S42

177 LPKF Service 6. LPKF Service Here you will find all the information on distribution and service. Our competent employees will be glad to consult you. Europe (LPKF Head office) Phone +49 (0) Fax +49 (0) LPKF webpage North / Central America Phone +1 (503) Fax +1 (503) LPKF webpage sales@lpkfusa.com support@lpkfusa.com China Phone Hotline service (Distribution) (Service) Fax LPKF webpage sales@lpkf.cn sales@lpkf.cn Installation Instructions 3.0 Rev.:

178 For your notes 42 ProtoMat S42

179 EC Declaration of Conformity 7. EC Declaration of Conformity Declaration of Conformity in accordance with Machinery Directive 98/37/EC, Appendix II A The manufacturer/seller LPKF Laser & Electronics AG Osterriede 7 D Garbsen Germany hereby declares that the circuit board plotter ProtoMat S42 conforms to the provisions of the directive(s) identified above - including the modifications effective at the time of this 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 productions are in compliance with the following EC directives and EN standards: Applied harmonized standards EN 292-1:1991 Safety of machinery - Basic terms, general principles for design - Part 1: Basic terminology, methods EN 292-2:1995+A1:1995 Safety of machinery - Basic terms, general principles for design - Part 2: Technical principles and specifications EN 349:1993 Safety of machinery - Minimum gaps to avoid crushing of body parts 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 :1997 Safety of machinery - Electrical equipment of machines - Part 1: General requirements Operating Manual 3.0 Rev.:

180 EC Declaration of Conformity EN :2001 Electromagnetic compatibility (EMC) EN 55022:1994 A2 Information technology equipment - Radio disturbance characteristics - Limits and methods of measurement Amendment A2:1997 Further EU directives applied EMC directive 89/336/EEC Low Voltage Directive 2006 /95/ EEC Town: Garbsen Date: 2. June 2008 Bernd Hackmann (Board chairman) 44 ProtoMat S42

181 Index 8. Index A Adjusting the Operating Voltage 20 B Basic equipment 15 BoardMaster 34 Version 9 C Camera 19 COM port number 30 Computer Configuration of Communication Port 28 Set-up 27 System Requirements 27 Connecting piece for extraction hose 23 Connection for illumination 16 Connection settings 29 D Declaration of Conformity 43 Disclaimer 10 Drill underlay 21 Dust Extraction Connections 25 Installation 23 Operating mode 26 Dust extraction 18 E EC Declaration of Conformity 43 EU directives 44 F FIFO buffer 30 First Putting into Operation 33 Function Bar 34 Fuse holder 19 G General Safety Instructions 11 H Hardboard 21 Heat sink 16 I Installation 19 Installing the Software 31 M Machine Overview 15 Main Menu 34 Main switch 23 Manufacturer 43 Milling depth limiter 16 N Notations 3 P Ports of Dust Extraction System 25 Putting the machine into operation 33 R Receiving buffer 30 RS 232 port 32 S Safety Instructions 11 Scope of delivery 13 Seller 43 Setting the Suction Force 27 Speed controller 27 Speed range 39 Spring adjustment 16 Standards 43 T Technical Data 39 Title Bar 34 Trademark 4 Transmission buffer 30 U Use Designated 9 Inadmissible 10 V Vacuum table 19 VisionSystem 19 Installation Instructions 3.0 Rev.:

182 For your notes 46 ProtoMat S42

183 Article number: xxx_xxx Item number: ( ) Insert cover photo: Size: 11.5 cm x 9.5 cm Distance: top: 1.5 cm left: 8.5 cm ProtoMat S42 Tutor data Tutorial 2.0, English LPKF Laser & Electronics AG Osteriede 7 D Garbsen Germany Phone Fax lpkf@lpkf.de Home page

184 About this manual About this manual This manual allows you to familiarise yourself with the most important functions of the ProtoMat S42 and the LPKF Software CircuitCAM Lite. You will use the Tutor data included in the scope of delivery to produce a double-sided printed circuit board. (The printed circuit board must be galvanically through-hole plated on external devices.) Detailed information on the circuit board plotter and the BoardMaster LPKF software can be found in the operating manual of the ProtoMat S42. In the following we assume that the ex factory basic settings and previously drilled LPKF base materials are used. System overview Main switch (if necessary, inside of the acoustic cabinet) 2 Setting wheel for the milling depth limitation 3 Collet chuck lever 2 ProtoMat S42 Tutor data

185 Preparation Preparation WARNING Danger of persons and material damage! Improper use can cause serious injury and/or material damage. Be sure to read the S42 operating manual and observe the safety instructions contained therein, before starting work. I. Starting the system 1. Switch on the circuit board plotter at the main switch. The lighting of the milling/drilling head is on. 2. Switch the dust extraction to the automatic mode. 3. Switch on the computer. 4. Double-click the BoardMaster icon. or: Click on Start > Programs > LPKF Laser & Electronics > BoardMaster.... [ ] BoardMaster has been started. Now the circuit board plotter can be set up. II. Setting up the circuit board plotter 1. Make sure that there are no objects in the traversing range of the circuit board plotter/traversing table. 2. Click on the Move to Pause button. 3. Place the base material along with the drill underlay on the traversing table or directly on the vacuum table and fix it with adhesive tape. 4. In the BoardMaster main menu, click on File > New and select the production type 1-2layer.phs. [ ] The circuit board plotter is set up. Now you can define the working area. Tutorial 2.0 Rev.:

186 Preparation III. Defining the working area To define the working area, you have to define the front left corner point first and then the back right corner point. Make sure that the milling depth limiter base is completely above the base material and that the pass hole pins are outside of the working area. 1. Click on the Move with mouse Button. 2. Drag the mouse pointer with the left mouse button pressed to the front left corner point of the desired working area. 3. In the main menu, click on Configuration > Material > Set Low Corner. The front left corner point is read in. 4. Click on the Move with mouse Button. 5. Drag the mouse pointer with the left mouse button pressed to the back right corner point of the desired working area. 6. In the main menu, click on Configuration > Material > Set High Corner. The back right corner point is read in. Fig. 1: Setup working area (dark-grey) The working area is displayed in the BoardMaster window in dark grey. 4 ProtoMat S42 Tutor data

187 Processing the layout data by means of CircuitCAM Processing the layout data by means of CircuitCAM The layout data have to be processed to production data in CircuitCAM and must be exported to the LMD-format. I. Importing the layout data to CircuitCAM 1. On the desktop double click on the CircuitCAM symbol. or: Click on Start > Program Files > LPKF Laser & Electronics > CircuitCAM In the Front-To-End tool bar, click on the Import button. 3. In the C:\Program Files\CicuitCAM 6.0\ExampleData\ Prototyping directory select the following files with the Ctrl key depressed: Tutor.boa; Tutor.BOT; Tutor.drd; Tutor.TOP 4. Click on Open. The Import window is opened with the selected files. Fig. 2: Import settings for layout files (Ex.Tutor.boa) File list 2 Register card Graphic 3 Register card Format 4 Resolution Digits m.n: Tutorial 2.0 Rev.:

188 Processing the layout data by means of CircuitCAM 5. In order to assign the desired layer and resolution to a layout file: In the file list, click on the name of the desired tutor file (column File name), to select the file. Fig. 3: Selecting a layout file In the column Layer/Template, click on the dropdown list and select the desired layer. ( Tab. 1: "Layer assignation and resolution (Digits m.n)") On the Format register card, field Digits m.n, click on the desired dropdown list and select the desired value for the resolution (selectable for Tutor.drd only). ( Tab. 1: "Layer assignation and resolution (Digits m.n)") 6. Assign a certain layer to each layout file and, if necessary, change the resolution in the Digits m.n input box. Use the follwing settings: Tab. 1: Layer assignation and resolution (Digits m.n) File name Layer/Template Digits m. n Tutor.BOT BottomLayer 2 4 Tutor.TOP TopLayer 2 4 Tutor.boa BoardOutline 2 4 Tutor.drd DrillPlated 2 3 The settings are instantly displayed on the register card Graphic. 7. Click on OK. [ ] After you have imported all layout files, the data will be displayed in the CircuitCAM graphic window. 6 ProtoMat S42 Tutor data

189 Processing the layout data by means of CircuitCAM II. Generating contours and ligaments 1. Click on the top left corner of the contour line. Fig. 4: Marking contour line The contour line is highlighted by marks. 2. Click on the Contour Routing button. The Contour Routing window is opened. Fig. 5: Settings for contour milling Tutorial 2.0 Rev.:

190 Processing the layout data by means of CircuitCAM 3. Select the following settings: Outside Source Current Selection Destination layer: CuttingOutside Used tool List LpkfCuttingTools Tool ContourRouter 2.0 mm (79 mil) Breakout 4 corners Width 1 mm 4. Click on Run. [ ] The contour is displayed as a line 2 mm in width. Fig. 6: Contour with ligaments 8 ProtoMat S42 Tutor data

191 Processing the layout data by means of CircuitCAM III. Inserting further ligaments (optional) 1. Click on a corner of the contour line highlighted in yellow. Fig. 7: Positioning a ligament The asterisk shows the current ligament position. It can be moved by means of the +/- keys. 2. Move the asterisk by means of the +/- keys (keyboard) to the desired ligament position. Note: Ligaments can only be placed at the corner points and centers of a contour segment. With each key press, the asterisk will jump to the next possible bridge position. 3. Click on the Breakout Tab button. [ ] The contour line will be interrupted at the selected position. IV. Defining isolation areas (optional) In a simple isolation, only isolation lines will be milled around the conductor tracks. Isolation areas are used to define areas in which the copper will be completely removed between conductor tracks. This will only leave conductor tracks and lands. These areas are also referred to as rub out. 1. Click on the Rubout All Layers button. 2. Click and drag the mouse over the layout, in order to define an isolation area (rub out). 3. If desired, define further isolation areas. Tutorial 2.0 Rev.:

192 Processing the layout data by means of CircuitCAM Fig. 8: Defined isolation areas (rub out) [ ] The desired isolation areas are defined. V. Calculating the isolation 1. Click on the Insulate All layers button. [ ] The isolation lines and areas (rub out) will be calculated and displayed. Fig. 9: Calculated isolation Note: By now, you can still define further isolation areas ( Defining isolation areas (optional)), and recalculate the isolation. 10 ProtoMat S42 Tutor data

193 Processing the layout data by means of CircuitCAM VI. Exporting data as project The export will automatically produce a *.cam and a *.LMD file. The latter is used for the production by means of the LPKF circuit board plotter and is referred to as a project. If BoardMaster is open when the export is carried out, the LMD file (project) will be automatically applied. 1. Make sure that BoardMaster is open and material size and position have been set up in accordance with the components fitted to the circuit board plotter. 2. Click on the Export LPKFCircuitBoardPlotter button. The Save as window will be opened. 3. Save the Tutor.cam file with any name in the desired directory. The *.LMD file is exported automatically to the same directory and will be imported in BoardMaster. CircuitCAM prompts the export of the *.LMD file and gives information about the directory used. Fig. 10: LMD-file exported 4. Click on OK. [ ] The data will be exported as a project. You can exit CircuitCAM now. Tutorial 2.0 Rev.:

194 Production Production If BoardMaster is opened while the LMD file is being exported from CircuitCAM, it will be automatically imported as a project. (An LMD file is referred to as a project in BoardMaster.) Projects are managed for production in a job. A job always consists of one or more projects and information on the production type (e. g. single- /multilayered circuit board) and on the current production status. Note: If a job is already opened in BoardMaster, the LMD data will be imported to BoardMaster as an additional project. Prerequisites The following description assumes that the material has already been fixed on the traversing table and the working area has been set up (see "Setting up the circuit board plotter" on page 3). I. Setting up a job 1. If the LMD file was not imported automatically to BoardMaster: Click on File > Import > LMD or LPR... Select the generated *.LMD file and click on OK. Now the job can be set up individually. 2. To move a project on the base material: Click on the Move project button. Drag the project to the desired position in the working area with the mouse button pressed. 3. To copy a project: Click on the Copy project button. Drag the project to the desired position in the working area with the mouse button pressed. A copy of the project will be inserted at the desired position. 4. Click on File > Save/Save as..., to save the job. [ ] Now the first production phase can be set up. 12 ProtoMat S42 Tutor data

195 Production II. Selecting the production phase 1. In the phase selection list, select the production phase 1. MarkingDrills. Note: In this production phase, all the drillings are centre-punched and, if the project contains any fiducials, they are drilled. [ ] Now you can activate the data for the production. III. Activating the data for production 1. To activate all data for production: Click on All+. All data for the production are activated. 2. To activate a data area: Click on the Select Lines or Select Segments button. Pull on the desired data area with the mouse button pressed to open it. Click on the + button. [ ] The selected data for the production are activated. Note: Use the All- or - buttons, to deactivate already activated data or data areas. IV. Starting the production phase 1. Click on Start. The Tool transfer window will be opened. Do n o t click OK yet because otherwise the production will be started without the tool or with the tool which is already in the collet chuck. Tutorial 2.0 Rev.: