ProtoMat S42 Operating Manual 3.0, English - lpkf.com · Operating Manual 3.0, English ... (The inverted commas are not part of the message.) Symbols and signal words ... 6 Care and

ProtoMat® S42

Operating Manual3.0, English

Arti

cle

num

ber:

xxx_

xxx

Insert cover photo:

Size: 11.5 cm x 9.5 cm

Distance: left: 8.5 cm top: 1.5 cm

Item

num

ber:

1237

47 (1

17 6

53)

ProtoMat® S42

Operating Manual3.0, English

LPKF Laser & Electronics AG Osteriede 7 D-30827 GarbsenGermany

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

ProtoMat® S42

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 originalArticle number: 123747 (117 653)

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 pro-duction 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 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. 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.

Information on this document

Operating Manual 3.0 Rev.: 2.06.2008 3


This document contains important information regarding operation, main-tenance 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. Know-ledge regarding the safety and behaviour in workshops as well as regard-ing the operation of a computer with Windows 2000/XP are required.

Availability

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.

Notations

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 posi-

tions

• 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.)

Symbols and signal words

4 ProtoMat® S42

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).


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.

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-observ-ance 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.


Table of contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Information on this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

List of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Safety information 13

1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.2 Liability information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141.3 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2 What is what? 19

2.1 The circuit board plotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202.3 LPKF dust extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232.4 Accessories and consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.4.1 LPKF accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242.4.2 Tools and consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3 What you should know 27

3.1 Milling/drilling head and traversing table. . . . . . . . . . . . . . . . . . . . . . . . . . . . 273.1.1 Coordinate system and traversing axis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273.1.2 Defined positions of the milling/drilling head. . . . . . . . . . . . . . . . . . . . . . . . . 283.1.3 The pass hole system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293.1.4 Material use and loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.2 The collet chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313.2.1 Tool loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313.2.2 Usable tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.3 The milling depth limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363.4 The dust extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383.5 The vacuum table (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393.6 The VisionSystem (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403.7 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6 ProtoMat® S42

3.8 Automatic mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413.8.1 Production types and phase files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413.8.2 Production phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423.8.3 Data activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4 Manual tasks and settings 47

4.1 Switching on the system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Switching on the LPKF dust extraction (optional) . . . . . . . . . . . . . . . . . . . . 48etting the suction force (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Switching on the circuit board plotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Starting BoardMaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Checking the interfaces (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.2 Switching off the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Quitting BoardMaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Switching off the circuit board plotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Switching off the LPKF dust extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.3 Finding out about BoardMaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544.3.1 The BoardMaster user interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544.3.2 Frequently required functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4.4 Mounting/dismounting of the milling depth limiter base. . . . . . . . . . . . . . . . 58Mounting/dismounting of the plastic base . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4.5 Positioning of the milling/drilling head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Moving the milling/drilling head to a predefined position . . . . . . . . . . . . . . . 59Moving the milling/drilling head step by step in X/Y direction . . . . . . . . . . . 60Moving the milling/drilling head with the mouse. . . . . . . . . . . . . . . . . . . . . . 60

4.6 Material loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614.6.1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614.6.2 Placing and setting up the material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Placing the base material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Defining the working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

4.7 Tool loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634.7.1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634.7.2 Inserting/removing a tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Inserting a tool into the collet chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Removing the tool from the collet chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

4.8 Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Drilling a hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67


4.9 Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Creating a milling track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Setting the milling depth (cylindrical tools) . . . . . . . . . . . . . . . . . . . . . . . . . . 69Setting of the milling width (Universal Cutter and Micro Cutter only) . . . . . . 69

4.10 Setting up a pass hole system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704.10.1 Creating a pass hole system for the traversing table . . . . . . . . . . . . . . . . . 70

Preparing the circuit board plotter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Drilling pass holes in pass hole strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4.10.2 Creating a pass hole system for the vacuum table . . . . . . . . . . . . . . . . . . . 73Preparing the circuit board plotter and the vacuum table . . . . . . . . . . . . . . . 73Drilling pass holes in pass hole strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Drilling pass holes in the sintered plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.10.3 Drilling pass holes in base material or drill underlay . . . . . . . . . . . . . . . . . . 78Drilling pass holes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4.10.4 Inserting the pass hole pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Inserting the pass hole pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

4.11 Setting the VisionSystem (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804.11.1 Setting the image quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Setting brightness and contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Setting the image definition (focusing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4.11.2 Integrating the camera into the coordinate system . . . . . . . . . . . . . . . . . . . 84Setting the camera offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

4.11.3 Calibrating the fiducial recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Setting the fiducial recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Setting the measuring function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Applying the settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Measuring the drillings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

5 Working sequence in the automatic mode 93

5.1 Setting up the production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Selecting a phase file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Creating a new job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Opening an existing job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Importing projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Aligning/copying a project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Saving a job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

8 ProtoMat® S42

5.2 Setting up a production phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Selecting a production phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

5.2.1 Activating data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Activating all data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Activating data areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Activating data segments by index number . . . . . . . . . . . . . . . . . . . . . . . . 101

5.2.2 Deactivating data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Deactivating all data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Deactivating data areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

5.2.3 Selecting tools (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Selecting tools (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

5.3 Starting the production phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Starting a production phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Adjusting milling depth/width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Continuing the production phase (optional) . . . . . . . . . . . . . . . . . . . . . . . . 106Starting the next production phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

5.4 Interrupting/canceling the production. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108Interrupting the production phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108Continuing production at a later time (optional) . . . . . . . . . . . . . . . . . . . . . 108Canceling (discarding) production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

6 Care and maintenance 111

6.1 Maintenance and inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Cleaning the surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Carrying out a visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

6.2 Cleaning the milling depth limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Dismounting the milling depth limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Cleaning and greasing the milling depth limiter . . . . . . . . . . . . . . . . . . . . . 113Mounting the milling depth limiter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

6.3 Cleaning the collet chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114Cleaning the collet chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

6.4 Replacing a fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114Removing the side part of the acoustic cabinet (option) . . . . . . . . . . . . . . 115Replacing fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

6.5 Dust extraction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1176.5.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1176.5.2 Replacing the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Replacing the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118


7 Error messages/malfunctions 119

8 Decommissioning/disposal 121

8.1 Machine parts and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1218.2 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

9 Technical data 123

10 LPKF Service 125

11 EC Declaration of Conformity 127

12 Index 129

For your notes

10 ProtoMat® S42

List of figures


List of figures

Fig. 1: ProtoMat® S42 basic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Fig. 2: Optional components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Fig. 3: Milling/drilling head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Fig. 4: Rear side of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Fig. 5: LPKF dust extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Fig. 7: Coordinate system and axis directions (top view of the traversing table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Fig. 8: Defined positions of the milling/drilling head (top view of the traversing table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Fig. 9: Turning the material around the mirror axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Fig. 10: Collet chuck and tool holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Fig. 11: Setting wheel an plastic base for milling depth . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Fig. 12: Milling width with Universal Cutter and Micro Cutter . . . . . . . . . . . . . . . . . . . . . . . 37

Fig. 13: Dust extraction - operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Fig. 14: Connection settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Fig. 15: BoardMaster user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Fig. 16: Removing the plastic base of the milling depth limiter . . . . . . . . . . . . . . . . . . . . . . 58

Fig. 17: Prompt to insert the tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Fig. 18: Collet chuck and tension lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Fig. 19: BoardMaster message "Drilling a reference hole?" . . . . . . . . . . . . . . . . . . . . . . . . 71

Fig. 20: BoardMaster message "Depth limiter removed" . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Fig. 21: Pass hole strips in the vacuum table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Fig. 22: BoardMaster message "Drilling a reference hole?" . . . . . . . . . . . . . . . . . . . . . . . . 75

Fig. 23: BoardMaster message "Depth limiter has to beremoved“ . . . . . . . . . . . . . . . . . . . 76

Fig. 24: Press-in tool with pass hole pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Fig. 25: Setting the fiducial recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Fig. 26: Setting the image definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Fig. 27: Setting the camera offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Fig. 28: Position the camera above the drilling hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Fig. 29: Drilling in the Camera Image window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Fig. 30: Setting the fiducial recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Fig. 31: Fiducial calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Fig. 32: Calibration not possible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Fig. 33: Calibration successful . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Fig. 34: Measured values in the Camera Image window . . . . . . . . . . . . . . . . . . . . . . . . . . 89

List of figures

12 ProtoMat® S42

Fig. 35: Enter the measured values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Fig. 36: Window Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Fig. 37: Window Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Fig. 38: Enter the actual values of the drilling diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Fig. 39: Measured values in the Camera Image window . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Fig. 40: Placing a project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Fig. 41: Selecting the tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Fig. 42: Tool Exchange window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Fig. 43: Adjusting milling depth/with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Fig. 44: Production phase finished. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Fig. 45: Message when canceling the production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Fig. 46: Dismounting of the milling depth limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Fig. 47: Removing the side part of the acoustic cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Fig. 48: Adjusting the Fuse Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

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 hous-ing 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 Soft-ware BoardMaster Version included in the delivery. If you want to use a different version, please first contact the LPKF Support.

Liability information

14 ProtoMat® S42

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 sys-tem 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, con-tact 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.

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 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.

WARNING

Risk of squeezing!The (unintentional) actuation of the software can lead to move-ments of the circuit board plotter and cause squeezing injuries.Make sure that while handling the circuit board plotter the soft-ware c a n n o t b e actuated unintentionally or by another person.

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.

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.

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!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.

Safety Instructions

16 ProtoMat® S42

WARNING

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/mois-tened cloth. N e v e r blow compressed air through the machine.

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 con-sumables and must not be reused.

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 tra-versing speed. Non-approved tools can cause damage to the col-let 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)

Safety information


• 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 suffi-ciently qualified and authorized personnel only.

• Repairs must be carried out only by qualified LPKF person-nel 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 pre-vention 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 dam-age/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!

General Safety Instructions (Continuation)

(Page 2 of 2)

For your notes

18 ProtoMat® S42

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

1 Rating plate2 Main switch3 Power cable socket4 Fuse holder, voltage setting5 Pass hole strips (right)

6 Traversing table7 Milling/drilling head 8 Warning label! Hot surface9 Lifting magnet10 Internal extraction hose

1

2

3

4

6

1

6

7

8

9

10

5

Options

20 ProtoMat® S42

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

1 Acoustic cabinet2 Camera (VisionSystem)

3 Vacuum table with a sintered plate4 Caution label on cabinet cover:

("Operate only with a closed cover")

1

3

4

2

What is what?


Fig. 3: Milling/drilling head

1 Internal extractionhose2 Spring adjustment3 Lifting magnet4 Warning label:

Hot surfaces5 Heat sink

6 Tension lever7 Setting wheel for milling depth limitation8 Plastic base of the milling depth limiter 9 Tool holding fixture10 Power supply for milling head ligthing

11 Power supply for the optional camera12 Camera data cable13 Camera14 Camera support

1

14

5

2

6

11 107

89

Option VisionSystemBasic equipment

12

13

3

4

Options

22 ProtoMat® S42

Fig. 4: Rear side of the machine

1 Warning label: Hot surface!2 Hub motor3 Suction pipe4 Control unit with data connections (SMCU III)5 Serial ports (Port 1 – Port 4)6 RS232 Connection

7 Indicator Error8 Indicator Online9 Indicator Power10 Ethernet Connection (only for service)

5 6 7 8 94

Basic equipment Option Acoustic Cabinet

13

4

2

What is what?


2.3 LPKF dust extraction

Note: The ProtoMat® S42 can be equipped with another dust extractionsystem. Detailed Information about the dust extraction can be found in the corresponding documents

WARNING


Fig. 5: LPKF dust extrac-tion

1 Extraction hose2 Suction force regulator3 Power supply4 Data cable connection

5 Main switch6 Automatic fuse

1 2

3

4

5

6

Accessories and consumables

24 ProtoMat® S42

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

2.4.1 LPKF accessories

Tab. 1: Accessories

2.4.2 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 manufactur-ers.

Tab. 2: Tool setsi

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.

Designation Function Use

Measuring micro-scope

Measuring and checking the milling tracks and drillings

Quality control through 60-fold magnification and metric scale

Ring set Precise alignment of the spacer rings on the tools

Avoiding repeated milling depth adjustment by using a uniform milling depth for all tools

Designation Contents Use

Tool set Drilling and milling tools, 1/8 " shaft with press-fitted spacer rings

Drilling and milling (see chapter 3.2.2‚ "Usa-ble 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 3.2.2‚ "Usable tools", on page 32.

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

FR4 base material 1.5 mm thick 229 mm × 305 mm (9" 12 ") with/without protective film, 3 mm pass hole drillings

Manufacturing of single-/double-sided printed circuit boards.

Multilayer set Base material, surface lami-nate, prepreg, spacer rings

Multilayer manufacturing processing with LPKF multilayer press MultiPress S.

Drill underlay Drill underlay, DIN A4, 2 mm thick

Drill underlay protects the traversing table from damage during drilling and material penetrating milling.

Sintered plate Sintered plate permeable to air for the vacuum table (ProtoMat S-series)

Working plate/drill underlay for the optional vacuum table.

Cleaning pad Metal-free cleaning pads Removing oxidation residues from the cop-per laminate.

Fig. 6: LPKF Multilayer set (example)

1 Multilayer laminate (depending on the finish-ing with or without protective film)

2 Press pad (grey)3 Prepreg (yellow)

4 Pressboard (blue)5 Base material FR4 18/18 µm6 Sealing rings

1 2 3 4 5 6

For your notes

26 ProtoMat® S42

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 54.

3.1 Milling/drilling head and traversing table

To position the milling/drilling head at any position above the base mate-rial it is moved in x-direction and the traversing table in y-direction. The coordination of both traversing directions is controlled by the BoardMas-ter. In the following this procedure will be denoted as moving the mill-ing/drilling head.Note: The circuit board plotter can be equipped with optionally available vacuum table.

3.1.1 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 tra-versing area on the traversing table and in y-direction on the mirror axis.

Fig. 7: Coordinate system and axis directions (top view of the tra-versing table)

1 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)

2

3

4

1

Milling/drilling head and traversing table

28 ProtoMat® S42

Note: The coordinates Zero point (=Home position) can be configured individu-ally. The internal Zero point of the machine (Null position) is used as a reference coordinate.

3.1.2 Defined positions of the milling/drilling head

Home 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 coordi-nates Zero point. It is used for drilling the left pass hole.

Zero Position 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 mill-ing/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.

Pause Position 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. cre-ate 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.

Fig. 8: Defined positions of the milling/drill-ing head (top view of the tra-versing table)

1 Traversing range2 Traversing table3 Milling/drilling head in Pause position4 Right pass hole pin

5 Mirror axis6 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)

2

4

5

6

1

7

3



3.1.3 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 coordi-nates 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‚ "Set-ting up a pass hole system", on page 70.The pass hole system allows alignment of the base material on the tra-versing 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 multi-layers use the camera based LPKF VisionSystem (option). (see chapter 3.6‚ "The VisionSystem (optional)", on page 40).

Milling/drilling head and traversing table

30 ProtoMat® S42

3.1.4 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 equip-ment 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.



3.2 The collet chuck

The milling/drilling head is equipped with a manually operated quick-change collet chuck for tools with 1/8" shaft. This enables prompt replacement of tools without any additional installation work.

3.2.1 Tool loading

The collet chuck can be opened quickly by means of a tension lever and loaded with a required tool.

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.

Fig. 10: Collet chuck and tool holder

1 Tension lever 2 Plastic base of the mill-ing depth limiter

3 Tool holding fixture (collet chuck)

1

23

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.

The collet chuck

32 ProtoMat® S42

3.2.2 Usable tools

The tools are subdivided into two groups:

• 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.

WARNING


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.

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

Universal Cutter 1/8"

Micro Cutter 1/8"

End Mill (End Mill 1/8")

Fields of application:

Milling of insulation clearances with different widths in cop-per-plated base material. Define the milling width by means of the milling depth adjustment.

Colour: orange

Form: conical

Milling widths: 0.2 mm – 0.5 mm (8 – 20 Mil), variably adjustable via pene-tration depth

0.2 mm - 0.5 mm(8 - 20 Mil)

Copper

Application Fine insulation clearances with 18 µm thickness of copper layer. Define the milling width using the milling depth adjustment

Colour: orange

Form: conical

Milling widths: 0.1 mm – 0.15 mm (4 – 6 Mil), variably adjustable via pene-tration depth

0.1 mm - 0.15 mm(4 - 6 Mil)

Copper

Fields of application: Aluminum engravings, recesses and wide insulation clearances

Colour: violet

Form: cylindrical

Milling widths: d = 0.80 mm (31 mil)d = 1.00 mm (39 mil)d = 2.00 mm (79 mil)d = 3.00 mm (118 mil)

0.8 - 3.0 mm(31 - 118 Mil)

Copper

08 - 3.0 mm(31 - 118 Mil)

Aluminum

The collet chuck

34 ProtoMat® S42

RF End Mill (End Mill (RF) 1/8")

Penetrative tools

End Mill Long (End Mill long 1/8")

)

Contour Router (Contour Router)

Fields of application: Smallest insulation clearances in RF materials.

Colour: blue

Form: cylindrical

Milling widths: d = 0.25 mm (10 Mil)d = 0.40 mm (16 Mil)

0.15 mm - 0.4 mm(6 - 16 Mil)

Copper

Fields of appli-cation:

Contour milling, material cutouts and depaneling in alumi-num and soft RF and microwave materials.

Colour: light green

Form: cylindrical

Milling widths: d = 1.00 mm (39 mil)d = 2.00 mm (79 mil)

1 - 2 mm(39 - 79 Mil)

Aluminum

1 - 2 mm(39 - 79 Mil)

Dielectric


Contour milling, Material cutouts, Depaneling, Drillings >2.4 mm/> 3.0 mm.

Colour: yellow

Form: cylindrical

Milling widths: d = 1.0 mm (39 Mil)d = 2.0 mm (79 Mil)

1 - 2 mm(39 - 79 Mil)

Copper



Drill (Spiral Drill)


High penetration drillings.

Colour: green

Form: cylindrical

Available diam-eters:

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)

min. 0.2 mm(8 Mil)

Copper

max. 3.0 mm(118 Mil)

The milling depth limiter

36 ProtoMat® S42

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.

Setting of the milling depth

The penetration depth of the tools depends on the tool length and mate-rial 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 turn-ing 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 pen-etration depth of the tool. The presetting to a defined value is not possible.

Setting of the milling width

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.

Fig. 11: Setting wheel an plastic base for milling depth

1 Setting wheel for milling depth limitation 2 Plastic base

1 2



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 Cut-ter should mill a 0.2 mm (8 mil) wide milling track. However, the test mill-ing 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:

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.

Fig. 12: Milling width with Universal Cutter and Micro Cutter

1 Milling depth is not suffi-cient, 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

3 421

c

d

e

Universal Cutter: 4 µmMicro Cutter: 2.3 µm

Tip: Use the LPKF measuring microscope for precise checking of the milling width.

The dust extraction

38 ProtoMat® S42

3.4 The dust extraction

The dusts and gases emerging from material processing with the ProtoMat® S42 can cause danger to your health. Always operate the cir-cuit 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.

WARNING


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 con-sumables 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 con-sumables and must not be reused.



Using the Automatic Mode 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 spin-dle motor does not have to be switched on.

Continuous Setting of the Suction Force

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 vac-uum 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.

The VisionSystem (optional)

40 ProtoMat® S42

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 BoardMas-ter 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 process-ing.

Fiducial Recognition The VisionSystem functions on the basis of defined fiducials that are rec-ognised 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.

Calibration Fiducial recognition must be calibrated if the BoardMaster does not rec-ognize the fiducials or if used drill diameter differs from the provided one. Depending on the material to be processed it may be necessary to read-just 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 posi-tion must be aligned precisely. This procedure is normally required only for installation or repositioning of the camera (see chapter 4.11.2‚ "Inte-grating the camera into the coordinate system", on page 84).



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 exe-cuted 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.

3.8.1 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

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 type Phase file

Single-/double-sided printed circuit boards (galvanic through-hole plating)

1-2layer.phs (<standard>)

Single-/double-sided printed circuit boards (galvanic through-hole plating with LPKF ProConduct)

1-2layer + proconduct.phs

4-layered multilayer (galvanic through-hole plating)

4-layer.phs

4-layered multilayer (galvanic through-hole plating with LPKF ProConduct)

4-layer + proconduct.phs

Solder stop foils soldermask.phs

Solder paste stencils stencilmilling.phs

Automatic mode

42 ProtoMat® S42

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.

3.8.2 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. MarkingDrills2. MillingBottom 31. DrillingPlated3. ReadTop 32. Info! ProConduct4. MillingTop 33. Read_Bottom5. DrillingUnplated 34. MillingBottom6. Info! Apply foil to PCB 35. ReadTop7. Read_Bottom 36. MillingTop8. MarkingDrills 37. DrillingUnplated9. DrillingPlated 38. CuttingInside10. Info! ProConduct 39. CuttingOutside11. Read_Top12. CuttingInside13. CuttingOutside

(Page 1 of 2)



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_Fiducials14. MillingLayer3 40. MillingLayer315. Read_Layer2 41. Read_Layer216. MillingLayer2 42. MillingLayer217. Drilling_Fiducials 43. PrepareBottom18. MillingBottom 44. PrepareTop19. Drilling_Fiducials 45. Info! MultiPress work20. MillingTop 46. ReadTop21. Info! MultiPress work 47. MarkingDrills22. Info! Apply foil to PCB 48. DrillingPlated23. Read_Bottom 49. Info! Galvanic plating24. MarkingDrills 50. ReadBottom25. DrillingPlated 51. MillingBottom26. Info! ProConduct 52. Read_Top27. Read_Top 53. MillingTop28. DrillingUnplated 54. DrillingUnplated29. CuttingInside 55. CuttingInside30. CuttingOutside 56. CuttingOutside

Solder stop foils Solder paste templates

Through-hole plating – –

Required phase file soldermask.phs stencilmilling.phs

Production phases 1. CuttingSoldStopTop 1. CuttingSoldStopTop2. CuttingSoldStopBottom 2. CuttingSoldStopBottom

(Page 2 of 2)

Automatic mode

44 ProtoMat® S42

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 proc-essed consecutively time saving:

Tab. 6: Work steps in the production phases

Production phase Work steps Processed material side

MarkingDrills Centre-punching the drillingsDrilling fiducials

Bottom

Read_Top Reading in fiducials (only with VisionSystem)

Top

Read_Bottom Reading in fiducials (only with VisionSystem)

Bottom

DrillingPlated Drilling holes for the through-hole plat-ing

Bottom

DrillingUnplated Drilling mounting holes (not for through-hole plating)

Top

MillingTop Milling Top

MillingBottom Milling Bottom

Info! Galvanic Plating Galvanic through-hole plating (external with galvanic station)

All layers

Info! ProConduct Through-hole plating with the LPKF ProConduct System

All layers

Info! MultiPress_work Pressing the layers with the external Multilayer press

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)



3.8.3 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.

Read_Layer2Read_Layer3Read_Layer4

Reading in fiducials (only with VisionSystem)

Top/bottom

Prepare_TopPrepare_Bottom

Preparing outer layers for pressing, exemption for fiducial drillings(only with galvanically through-hole plated multilayers)

Top/bottom


(Page 2 of 2)

For your notes

46 ProtoMat® S42

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.

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, familiar-ise yourself with the relevant information on setting 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.

Switching on the system

48 ProtoMat® S42

I. Switching on the LPKF dust extraction (optional)

The LPKF dust extraction can be used in the automatic or in the contin-uous 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.

1. Set the main switch of the LPKF dust extraction to the desired posi-tion.

Tab. 7: Operating modes of the LPKF dust extraction:

[ ] The set operation mode will be used.

WARNING

Health hazard!Fine dusts and gases hazardous to your health can emerge dur-ing material processing.Make sure that the dust extraction for material processing is switched on (continuous or automatic operating mode).

Fig. 13: Dust extraction - operating modes

1 Continuous operating mode 2 Off 3 Automatic mode

Setting Operating mode Operation

ON Continuous operat-ing 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.

1 2 3



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 plot-ter (if necessary, inside of the acoustic cabinet).

[ ] The lighting of the milling/drilling head is on.

Switching on the system

50 ProtoMat® S42

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 „Check-

ing 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 win-dow Connect... appears . If required, change the connection settings.

Fig. 14: Connection set-tings



1. Make sure that the circuit board plotter is on and that the mill-ing/drilling head lighting is on.

2. Make sure that the following values are entered and check the set-tings in the Windows system control (see Installation Instructions).

3. Click on Connect....

As soon as the connection to the circuit board plotter has been estab-lished, 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.

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 con-nected and which was defined in the Windows system control.

Baud rate: 38400

Switching off the system

52 ProtoMat® S42

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 refer-ence point?" appears.

2. Click on Yes.The milling/drilling head and the working table will move to the Zero posi-tion.

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.



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 plot-ter.If your ProtoMat® S42 is equipped with another dust extraction, famil-iarise 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.

Finding out about BoardMaster

54 ProtoMat® S42

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.

4.3.1 The BoardMaster user interface

Fig. 15: BoardMaster user interface

1 Title bar2 Main menu3 Function bar

4 Mouse pointer5 Current position of the milling/drilling head6 Mirror axis

7 Mouse pointer coordinate8 Status bar9 Camera Image Application window (only

with the VisionSystem option)

123

5

6

78

9

4



Title bar The title bar shows the program name, the circuit board plotter used as well as the name of any loaded or newly created job.

Main menu The menu bar lists all available menus.

Function bar The function bar shows the functions used for manual control of the cir-cuit board plotter and for starting automatic machining processes.

Current position of the milling/drilling head

The blue cross hair shows the current position of the milling/drilling head.

Mirror axis Mirror axis of the working area. The base material should be positioned at the centre of the mirror axis.

Mouse pointer coordinate The current X and Y coordinate of the mouse pointer referenced to the HOME position.

Status bar The status bar informs you about the functions of buttons, displays or areas on which the cursor is currently located.

Camera Image application window (optional)

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.

Finding out about BoardMaster

56 ProtoMat® S42

4.3.2 Frequently required functions

The frequently required functions can be called up in the function bar.

Designation Function, note

Tool selection Selecting the tool (manual operation) In the automatic operating mode the tool required for the current job is indicated.

Phase selection Selecting the production phaseThe phases required for the selected production type are displayed in the order of processing. The current phase is preselected.

Speed Setting the motor speed (1/min) for the selected tool (the default setting depends on the tool)

Milling speed Setting the feed rate during milling for the selected tool (the default setting depends on the tool)

Phase configuration Opening the Phases window. Configuring the phases (phase sequence, colour display of the data)

Motor on / off Switching the milling/drilling spindle on/off

Lift/lower the milling/drilling head

Lifting/lowering the head

Switching the extraction system On/Off

Switching on/off the extraction system (The LPKF dust extraction must be set to automaticoperating mode)

Move with the mouse 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 posi-tion



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.

Move to +y Move to x-Move to x+Move to y-

Moving the milling/drilling head horizontallyEntering the increment in mm into the input box

Start/Stop Starting/stopping the current production phase

Adding lines Selecting all elements (lines) segments con-nected 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 produc-tion 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.

Designation Function, note

Mounting/dismounting of the milling depth limiter base

58 ProtoMat® S42

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. Dis-mount/replace the plastic base only for special work such as drilling the pass holes, cleaning and maintenance.

Mounting/dismounting of the plastic base

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.

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.

[ ]

Fig. 16: Removing the plas-tic base of the mill-ing depth limiter

1 Pressing the plastic base together 2 Pulling the plastic base downwards

1

2

1



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 follow-ing, 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:

[ ] The milling/drilling head and the traversing table are moved automatically to the selected position.H

Move to Pause

Pause positionThe 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 BoardMas-ter, definition of the coordinate sys-tem, insertion/removal of the tool.

Positioning of the milling/drilling head

60 ProtoMat® S42

Moving the milling/drilling head step by step in X/Y direction

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.

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 travers-ing 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 work-ing 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.

Move to x- The milling/drilling head moves to the left.Move tox+ The milling/drilling head moves to the right.Move to y+ The working table moves forwards.Move to y- The working table moves backwards.

y+

y-

x+x-



4.6 Material loading

4.6.1 Safety Instructions

The circuit board plotter may only be loaded in the Pause position to avoid material damage.

4.6.2 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 4.10.3‚ "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.

WARNING


Material loading

62 ProtoMat® S42

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 com-pletely 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 com-pletely above the base material.



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 BoardMas-ter 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.

4.7.1 Safety Instructions

WARNING

Risk of squeezing!The (unintentional) actuation of the software can lead to move-ments of the circuit board plotter and cause squeezing injuries.Make sure that while handling the circuit board plotter the soft-ware c a n n o t b e actuated unintentionally or by another person.

WARNING


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 tra-versing speed. Non-approved tools can cause damage to the col-let chuck and/or clutch.Use only original LPKF tools.

Tool loading

64 ProtoMat® S42

4.7.2 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

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.

2. Make sure that the motor is off and the milling/drilling spindle does not rotate anymore.

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.

Fig. 17: Prompt to insert the tool



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.

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.

Fig. 18: Collet chuck and tension lever

1 Tool holding fixture (collet chuck) 2 Tension lever

1 2

Drilling

66 ProtoMat® S42

Removing the tool from the collet chuck

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

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 auto-matic operating mode and starts automatically when drilling.

WARNING


WARNING

Health hazard!Material processing can cause formation of dusts and gases haz-ardous 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 com-pressed air through it.



Drilling a hole

1. Select the required drill from the tool selection list and insert it into the collet chuck. (see chapter 4.7.1‚ "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

Please note that the working results of milling depend on the penetration depth of the tool. Not removing enough material between the later con-ductor tracks can cause malfunctions of the printed circuit board. The milling width of the conical milling cutters Universal Cutter and Micro Cut-ter depends on the penetration depth.

WARNING

Health hazard!Material processing can cause formation of dusts and gases haz-ardous 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.

Milling

68 ProtoMat® S42

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 chap-ter 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 4.7.1‚ "Safety Instruc-tions", 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.



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.

+_

+_

Setting up a pass hole system

70 ProtoMat® S42

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 hole-pins 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 15.8.2‚ "Creating a pass hole system for the vacuum table”, on page 62)".

4.10.1 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. 2.95 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.



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.

6. Click on Yes.

Fig. 19: BoardMaster mes-sage "Drilling a ref-erence hole?"


72 ProtoMat® S42

7. Is the 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.


12. If necessary, drill new pass holes in the drill underlay. (see chapter 15.8.3‚ "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 mill-ing depth limiter(s. page 58).

Fig. 20: BoardMaster mes-sage "Depth limit-er removed"



4.10.2 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. 2.95 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.


74 ProtoMat® S42

4. Make sure that the red pass hole strips are inserted into the vac-uum 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.

Fig. 21: Pass hole strips in the vacuum table

1 Pass hole strips in the vacuum table

1



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.

6. Click on Yes.

Fig. 22: BoardMaster mes-sage "Drilling a ref-erence hole?"


76 ProtoMat® S42

The message "Depth limiter has to be removed“ appears.

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.


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.

Fig. 23: BoardMaster mes-sage "Depth limit-er has to bere-moved“



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).


78 ProtoMat® S42

4.10.3 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


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.



12. Click on the Lower head button to drill the pass hole.


[ ] 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.

4.10.4 Inserting the pass hole pins

Inserting the pass hole pins

Use only the pass hole pins provided for your machine equipment:

1. Insert a pass hole pin with the rounded end into the press-in tool (the chamfered end must protrude).

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.

Equipment Pass hole pinsBasic equipment 3 mm × 8 mmVacuum table 3 mm × 10 mm

Fig. 24: Press-in tool with pass hole pin

For your notes

80 ProtoMat® S42

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 under-lay/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.

4.11 Setting the VisionSystem (Option)

Depending on the material to be processed (brightness, contrast, mate-rial thickness), ambient conditions and quality of the passer marks (fidu-cials) the VisionSystem must be set up individually.

4.11.1 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 arbi-trary 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.



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.

2. Move the controls for brightness and contrast so that the material is displayed as bright as possible and the drillings - as dark as possi-ble.Brightness and contrast are set optimally.

3. To close the Setting window: Click on OK.

[ ] Brightness and contrast are optimally set.

Fig. 25: Setting the fiducial recognition

Setting the VisionSystem (Option)

82 ProtoMat® S42

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 tra-versing 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.



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 moni-

tor is sharply focused.

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.

Fig. 26: Setting the image definition

1 Camera2 Camera support

3 Clamping screws

1

2 3


84 ProtoMat® S42

4.11.2 Integrating the camera into the coordinate system

The fiducials recognised by the camera can be used for aligning the coor-dinate system only if the camera is integrated precisely into the coordi-nate 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.

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.

Fig. 27: Setting the camera offset



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 cam-era image are positioned exactly in the centre of the drilling. For exact positioning decrease the step size to 0.005 mm.

8. In the main menu click on Configuration > Heads... .

9. 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.

Fig. 28: Position the cam-era above the drill-ing hole


86 ProtoMat® S42

4.11.3 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 Cam-era Image window



3. Click on Setting.The Setting window is opened.

4. Click on Calibrate camera.

5. The Calibration window is opened.

Fig. 30: Setting the fiducial recognition

Fig. 31: Fiducial calibration


88 ProtoMat® S42

6. Enter the value 1.5 into the Diameter input box.

7. Click on Calibrate.

8. If the message "Calibration not possible!" appears:

– Click on OK.

– Check/correct the camera focus and image brightness and repeat the calibration.

9. When the calibration has been completed successfully, the mes-sage "Calibration complete!" appears.

10. Click on OK, to confirm the message.

11. Click on OK, to close the Setting window.

[ ] The fiducial recognition is completed.

Fig. 32: Calibration not pos-sible

Fig. 33: Calibration suc-cessful



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 diame-ter (DXY) are displayed in the camera image.

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.

Fig. 34: Measured values in the Camera Image window


90 ProtoMat® S42

7. Click on Accept.

Note: The colour difference between the drilling and the surrounding ma-terial 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. 35: Enter the meas-ured values

Fig. 36: Window Calibration



9. In the diameter input box enter the actual drilling diameter in mm (here: 1.5)

– Click on OK. The message "Calibration complete ! " appears.

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. 37: Window Calibration

Fig. 38: Enter the actual values of the drill-ing diameter


92 ProtoMat® S42

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.

[ ] If the DXY value corresponds to the actual drilling diameter in mm (here: 1.5 mm), then the fiducial recognition is completed.

Fig. 39: Measured values in the Camera Image window

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 travers-ing/vacuum table and the work area has been set up in BoardMaster. (see chapter 4.6.2‚ "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 pro-duction 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.

Setting up the production

94 ProtoMat® S42

Tab. 8: Phase files required for production type

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 produc-tion 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.

Required phase file Production type

1-2layer.phs (<standard>) Single-/double-sided printed circuit boards (galvanic through-hole plating)

1-2layer + procon-duct.phs

Single-/double-sided printed circuit boards (galvanic through-hole plating with LPKF ProConduct)

4-layer.phs 4-layered multilayer (galvanic through-hole plating)

4-layer + proconduct.phs 4-layered multilayer (galvanic through-hole plating with LPKF ProConduct)

6-layer.phs 6-layered multilayer

soldermask.phs Solder stop foils

stencilmilling.phs Solder paste stencils



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.

Setting up the production

96 ProtoMat® S42

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, down-sized or discharged from the job.

Note to the sample files • Tutor.LMD contains all informations for the production of a double-sided 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.



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 dis-tance between the project and the edges of the base material is at least 12 mm.

[ ] 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.

Fig. 40: Placing a project

Setting up a production phase

98 ProtoMat® S42

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....


– 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 man-ually. BoardMaster assists you and gives information on the required manual operating steps (see chapter 3.8.2‚ "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 exter-nal devices. Production phases marked with Read ... can only be carried out with installed VisionSystem (option).



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 sev-eral tools to be used in this production phase.

5.2.1 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.


100 ProtoMat® S42

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 ar-eas.

[ ] The selected data area and segments are activated for production.



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.


102 ProtoMat® S42

5.2.2 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.



5.2.3 Selecting tools (optional)

Normally, all tools required within a production phase are used in succes-sion (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.

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.

Fig. 41: Selecting the tools

Starting the production phase

104 ProtoMat® S42

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.

2. If there is already a tool in the collet chuck, remove it using a tweez-ers.

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.

Fig. 42: Tool Exchange window

WARNING




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 adjust-menst, 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?

Starting the production phase

106 ProtoMat® S42

3. If necessary: – Adjust the milling width/depth with the setting wheel for milling

depth limitation

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. 43: Adjusting milling depth/with

1 Setting wheel for milling width/depth

1

Fig. 44: Production phase finished.



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 produc-tion 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 exter-nal 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 traver-sing/vacuum table.

3. Activate the desired data (see chapter 5.2.1‚ "Activating data", on page 99).

4. Click on Start, insert the tool prompted in the Tool Exchange win-dow and activate the desired action (s. page 104)

[ ] The processing of the activated data starts. If necessary, you must adjust the milling width/depth

Interrupting/canceling the production

108 ProtoMat® S42

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 al-ready 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).



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.

– 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.

Fig. 45: Message when canceling the pro-duction

For your notes

110 ProtoMat® S42

Care and maintenance


6. Care and maintenance

Check the components listed here regularly for damage and wear.

6.1 Maintenance and inspection

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 mois-

tened 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.

WARNING

Health hazard due to fine dust!The processing of materials can cause formation of dusts hazard-ous 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 milling depth limiter

112 ProtoMat® S42

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 „Remov-ing 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).

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.

Fig. 46: Dismounting of the milling depth limiter

1 Pulling out the extraction hose2 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.

12 32a



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 „Mount-

ing/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.

Cleaning the collet chuck

114 ProtoMat® S42

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.

Cleaning the collet chuck

1. Make sure that there are no tools in the collet chuck (see „Remov-ing 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.

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.



Removing the side part of the acoustic cabinet (option)

1. Remove the eight screws on the right side part of the acoustic cab-inet.

2. Pull the side part laterally.

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.

Fig. 47: Removing the side part of the acoustic cabinet

Replacing a fuse

116 ProtoMat® S42

Replacing fuses

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.

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.

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.

Fig. 48: Adjusting the Fuse Holder

1 Adjusting for 220 V – 240 V 2 Adjusting for 110 V – 120 V



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.

6.5.1 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 con-sumables 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.

Dust extraction

118 ProtoMat® S42

6.5.2 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.

[ ]

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

Possible cause Indications

Solution

"Switch on the machine!"is displayed when starting Board-Master.

Circuit board plotter without power supply.Lighting at milling/drilling head is off.

Connect the circuit board plotter to the power supply.Make sure that the main switch is in position I.Click on OK.

"Switch on the machine!"is repeatedly displayed when start-ing BoardMaster although the cir-cuit board plotter is switched on and can only be skipped by Can-cel. BoardMaster starts but the circuit board plotter cannot be activated

Circuit board plotter is not con-nected to the computer.

Check the machine communica-tion: Select Configuration > Interface... and activate the Inter-face entry.Make sure that the circuit board plotter is connected to the pro-vided interface of the computer. Check the interface configura-tions in the Windows system con-trol (see Installation Instructions).

The milling head lighting is off. The circuit board plotter is switched off.

Switch the main switch to position I.

No power supply Make sure that the circuit board plotter is connected to the power supply.

Defective fuse 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 Switch the selector switch of the dust extraction to the position ON or select the automatic operating mode.

Defective fuse Press RESET key at the dust extraction switch-off

No data communication Check the wiring of the circuit board plotter.

For your notes

120 ProtoMat® S42

Decommissioning/disposal


8. Decommissioning/disposal

8.1 Machine parts and components

Observe the legal requirements and country-specific and local regula-tions for disposal of waste electrical/electronic equipment or contact the LPKF Service.

8.2 Consumables

Observe the legal requirements and country-specific and local regula-tions for disposal of consumables.

For your notes

122 ProtoMat® S42

Technical data


9. Technical data

ProtoMat® S42

Operating voltage (can be set manually)

220 – 240 V; 50 Hz – 60 Hz (factory setting)

110 V – 120 V; 50 Hz – 60 Hz

Power consumption 200 W

Weight 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° – 25° C (59° F – 77° F)

Admissible humidity Max. 60%

Airborne noise at the workstation 71dB (A) (excluding dust extraction)

Milling/drilling spindleSpeed range

3-phase motorMax. 42,000 U/Min.,software-controlled

Traverse speed Max. 50 mm/s (1.97"/s)

Drilling performance Max. 90 strokes/min.

Tool change Manually, quick clamping system

Tool holder 3.175 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) 1 µm (0.04 Mil)

Repetitive accuracy +/- 5 µm (0.2 Mil)

Precision of the pass hole system +/- 20 µm (0.8 Mil)

Smallest drilling diameter 0.2 µm (8 Mil)

For your notes

124 ProtoMat® S42

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)

North / Central America

China

Phone +49 (0) 5131-7095-0

Fax +49 (0) 5131-7095-90

E-Mail [email protected]@lpkf.de

LPKF webpage www.lpkf.dewww.lpkf.com

Phone +1 (503) 454-4219

Fax +1 (503) 682-7151

E-mail [email protected]@lpkfusa.com

LPKF webpage www.lpkfusa.com

Phone Hotline service

+86-13920308369 (Distribution)+86-13032289111 (Service)

Fax +86-2223006965

E-mail [email protected]

LPKF webpage [email protected]

For your notes

126 ProtoMat® S42

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

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 produc-tions are in compliance with the following EC directives and EN stand-ards:

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 specifica-tions for machinery manufacturers

• EN 60204-1:1997 Safety of machinery - Electrical equipment of machines - Part 1: Gen-eral requirements

LPKF Laser & Electronics AGOsterriede 7D-30827 GarbsenGermany


128 ProtoMat® S42

• EN 61000-6-1-4:2001 Electromagnetic compatibility (EMC)

• EN 55022:1994 A2 Information technology equipment - Radio disturbance characteris-tics - Limits and methods of measurement Amendment A2:1997

Further EU directives applied

• EMC directive 89/336/EEC• Low Voltage Directive 2006 /95/ EEC

Town: GarbsenDate: 2. June 2008

Bernd Hackmann(Board chairman)

Index

129 ProtoMat® S42

12. Index

Numeric1-2layer.phs () 42, 944-layer.phs 944layer.phs 436-layer.phs 94

AAcoustic cabinet

Removing the Side Part 115Activating Data 99All- 57All+ 57Aluminum 34Axis directions 27

BBase material

placing 61Basic equipment 19Baud rate 51BoardMaster 54

starting 50Version 13

CCalibrating fiducial

recognition 86Camera

adjusting 80Power supply 21

Camera Image 55Camera offset 84, 86Care 111centre-punching 44Checking the Interfaces 50Cleaning 111Cleaning the milling depth

limiter 112Conical tool 37Connecting 50Connection for illumination 21Connection settings 50Contour milling 34Contour Router 34Contours 44Coordinates system 27CuttingInside 44

DData Activation 45Declaration of Conformity 127Defined Positions 28Depaneling 34Disclaimer 14Dismounting of the brush head 58Dismounting of the plastic base 58Drill 35Drilling 66DrillingPlated 44DrillingUnplated 44Dust extraction 22, 23

at the milling/drilling head 21Operating mode 48

EEC Declaration of Conformity 127End Mill 33End Mill (RF) 34End Mill long 34End mill long 34Entering the decimal places 57Error messages 119EU directives 128

FFunction Bar 55Function bar 54, 55Fuse holder 116

GGalvanic 42General Safety Instructions 16

HHeat sink 21Home 56, 59Home Position 28Home position 27, 28

IInfo! Apply foil to PCB 44Info! Galvanic Plating 44Info! MultiPress_work 44Info! ProConduct 44Inner cutouts 44Interface type 51

Index


JJob

setting up 96

LLines

select all 57Loading 61LPKF Proconduct 42LPKF ProConduct System 44

MMain menu 54, 55Main switch 52, 115Maintenance 111Malfunctions 119Manufacturer 127MarkingDrills 44Material

cutouts 34height 63turning 29

Material cutouts 34Menu bar 55Micro Cutter 33

Milling width 37Microwave materials 34Milling depth limiter 21

Mounting the base 58Milling speed 56Milling/drilling head 21, 27

lift/lower 56moving gradually 60moving with the mouse 60positioning 59

MillingBottom 44MillingTop 44Mirror Axis 55Mirror axis 28, 54Mode

automatic 41Mounting the brush head 58Mounting the plastic base 58Mouse pointer 55Moving 57Multilayer

LPKF Multilayer set 25Multilayer press 44

NNotations 3

OOpening a job 95Outer layers 45

PPass Hole System 29Pass holes

drilling in pass hole strips 71Pause 56, 59Pause Position 28Penetrative tools 32, 34Phase configuration 56Phase file

selecting 93Phase files 41Phase selection 56Point/comma 57Position of the Milling/Drilling Head 55Prepare_Bottom 45Prepare_Top 45Pressing 44Printed circuit boards

4-layered 43one/two layered 42

ProConduct 44Production

canceling 109interrupting 108

Production phaseWork steps 44

Production phases 44Production type

defining 93Production types 41Project

aligning/allocating 97copying 57copying/moving 97importing 95, 96moving 57

Protective foil 44

RRead_Bottom 44Read_Layer 45Read_Top 44Reading in fiducials 44Replacing the Fuse 114RF materials 34

SSafety Instructions 15

Index

131 ProtoMat® S42

Seller 127Setting up/selecting a job 94Solder paste stencils 43Solder stop foils 43soldermask.phs 43, 94Spacer rings 32Speed 56Speed controller 49Speed range 123Spiral Drill 35Spring adjustment 21Standards 127Start/Stop 57Status Bar 55Status bar 55stencilmilling.phs 43, 94Suction force 49Surface tools 32, 33Switching on 47

Circuit board plotter 49LPKF dust extraction 48

TTechnical Data 123

Through-hole plating 44Title Bar 55Title bar 54, 55Tool diameter 32Tool selection 56Trademark 4Traversing axis 27Traversing table 27

UUniversal Cutter 33

Milling width 37Use

Designated 13Inadmissible 14

VVisual inspection 111

ZZero 56, 59Zero Position 28

For your notes

132 ProtoMat® S42

ProtoMat® S42

Installation Instructions3.0, English

Arti

cle

num

ber:

xxx_

xxx

Insert cover photo:



Item

num

ber:

123

747

(117

653

)

ProtoMat® S42

Installation Instructions3.0, English

LPKF Laser & Electronics AG Osteriede 7 D-30827 GarbsenGermany

Phone ++ 49 - (0) 51 31 - 70 95 - 0 Fax ++ 49 - (0) 51 31 - 70 95 - 90E-mail [email protected] page http://www.lpkf.de

ProtoMat® S42

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 originalItem number: 123 747 (117 653)

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 produc-tion 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 deliv-ery can be used to import and prepare different CAD data formats for the working process.




This document contains important information regarding operation, main-tenance 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. Know-ledge regarding the safety and behaviour in workshops as well as regard-ing the operation of a computer with Windows 2000/XP are required.

Availability

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.

Notations

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 posi-

tions

• 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.)


4 ProtoMat® S42

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).


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.

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-observ-ance 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.

Table of contents

Installation Instructions 3.0 Rev.: 2.06.2008 5

Table of contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Information on this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

List of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Safety information 9

1.1 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.2 Liability information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.3 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 What is what? 13

2.1 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.2 Required accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.3 Optional components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.4 Machine overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.5 LPKF dust extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3 Installation 19

3.1 Checking/adjusting the operating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Adjusting the operating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.2 Mounting the acoustic cabinet (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.3 Setting up the circuit board plotter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Removing the shipping braces and base material . . . . . . . . . . . . . . . . . . . . 21Mounting the plastic base of the milling depth limiter . . . . . . . . . . . . . . . . . . 22Mounting the mains cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.4 Installing the dust extraction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Connecting the LPKF dust extraction to the circuit board plotter . . . . . . . . . 23Setting the operating mode (LPKF dust extraction) . . . . . . . . . . . . . . . . . . . 26Setting the suction force (LPKF dust extraction). . . . . . . . . . . . . . . . . . . . . . 27

Table of contents

6 ProtoMat® S42

3.5 Setting up the Computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Installing the USB serial converter (optional) . . . . . . . . . . . . . . . . . . . . . . . . 28Configuring the COM Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.6 Installing the LPKF software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Starting the software installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.7 Completing installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Connecting the data cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Connecting the power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.8 First putting into operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Checking the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Switching on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Checking the Interfaces (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Testing the machine communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4 Malfunctions and problem solutions 37

5 Technical data 39

6 LPKF Service 41

7 EC Declaration of Conformity 43

8 Index 45

List of figures


List of figures

Fig. 1: ProtoMat® S42 basic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Fig. 2: Milling/drilling head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Fig. 3: Rear side of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Fig. 4: LPKF dust extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fig. 5: Adjusting the fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Fig. 6: Removing the shipping braces and the base material . . . . . . . . . . . . . . . . . . . . . . 21

Fig. 7: Mounting the plastic base of the milling depth limiter . . . . . . . . . . . . . . . . . . . . . . . 22

Fig. 8: Screwing connecting piece on the extraction hose . . . . . . . . . . . . . . . . . . . . . . . . 23

Fig. 9: Connecting the extraction hose to the suction pipe of the circuit board plotter . . . 24

Fig. 10: Connecting the extraction hose to the suction pipe of the acoustic cabinet (optional) 24

Fig. 11: Connections on the dust extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Fig. 12: Connections for the dust extraction on the circuit board plotter . . . . . . . . . . . . . . 25

Fig. 13: LPKF dust extraction – Setting the operating mode . . . . . . . . . . . . . . . . . . . . . . . 26

Fig. 14: Device Manager window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Fig. 15: Connection settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Fig. 16: Advanced settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Fig. 17: Connecting the data cable to the circuit board plotter . . . . . . . . . . . . . . . . . . . . . . 32

Fig. 18: BoardMaster user Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Fig. 19: Input window Connect... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

For your notes

8 ProtoMat® S42

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 hous-ing 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 Soft-ware BoardMaster Version included in the delivery. If you want to use a different version, please first contact the LPKF Support.

Liability information

10 ProtoMat® S42

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 sys-tem 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, con-tact 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.

Safety information


1.3 Safety Instructions

WARNING


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)

Safety Instructions

12 ProtoMat® S42

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

• Have the machine operated, serviced and repaired by suffi-ciently qualified and authorized personnel only.

• Repairs must be carried out only by qualified LPKF person-nel 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 pre-vention 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 dam-age/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!

General Safety Instructions (Fortsetzung)

(Page 2 of 2)

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 indi-vidual components.

2.1 Scope of delivery

Circuit board plotter: ProtoMat® S42

Cable: 230 V Mains voltage cable (type F plug)115 V Mains voltage cable (US standard)Data cable for RS-232 connections

USB serial converter: Incl. Installation CD

Base material: FR4, 229 mm × 305 mm (9" × 12")

Drill underlay: 229 mm × 305 mm (9" × 12")

Accessories: TORX wrench: T10, T202 Pass hole strips5 Pass hole pins (3 mm × 8 mm)Press-in tool for pass hole pins4 Safety fuses2 Pass hole drill Spiral Drill 2.95 mmAdhesive crêpe tape (removable without leaving resi-due)Cleaning brush

CD ROM: BoardMaster ... & CircuitCAM ...Configuration Files

User documentation: ProtoMat® S42 Installation Instructions (this document)ProtoMat® S42 Operating InstructionsProtoMat® S42 Tutor Data Training instructions BoardMaster ManualCircuitCam Manual

Required accessories

14 ProtoMat® S42

2.2 Required accessories

For the operation of the ProtoMat® S42 you need the following accesso-ries:

• 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 magni-fication 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 measur-ing function and broken drill detector

Vacuum table Workpieces are fixed flatly on the working surface

Only with the dust extraction, prevents deflection of the material when processing thin material

Measuring micro-scope

Measuring and checking the milling tracks and drillings

Quality control through 60-fold magnification and metric scale

What is what?


2.4 Machine overview

Fig. 1: ProtoMat® S42 basic equipment

1 Rating plate2 Main switch3 Power cable socket4 Fuse holder, voltage setting5 Pass hole strips (right)

6 Traversing table7 Milling/drilling head 8 Warning label! Hot surface9 Lifting magnet10 Internal extraction hose

1

2

3

4

5

6

1

5

6

7

8

9

10

Machine overview

16 ProtoMat® S42

Fig. 2: Milling/drilling head

1 Internal extraction hose2 Spring adjustment3 Lifting magnet4 Warning label! Hot surfaces.5 Heat sink6 Tension lever

7 Plastic base of the milling depth limiter 8 Tool holding fixture9 Power supply for the lighting of the milling/drilling

head10 Setting wheel for the milling depth limiter11 Power supply for the optional camera

1

3

4

5

2

6

79

10

11

What is what?


Fig. 3: Rear side of the machine

1 Warning label! Hot surfaces.2 Hub motor3 Extraction hose connection4 Control unit with data connections (SMCU III)5 Serial ports (Port 1 – Port 4)

6 RS 232 Connection7 Indicator Error8 Indicator Online9 Indicator Power10 Ethernet connection (only for LPKF Service)

13

5 6 7 8 9

4

Basic equipment

10

Option acoustic cabinet

2

LPKF dust extraction

18 ProtoMat® S42

2.5 LPKF dust extraction

Note: The ProtoMat® S42 can be equipped with another dust extractionsystem. Detailed Information about the dust extraction can be found in the corresponding documents

WARNING


Fig. 4: LPKF dust extrac-tion

1 Extraction hose2 Suction force regulator3 Power supply4 Data cable connection

5 Main switch6 Automatic fuse

1 2

3

4

5

6

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 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

Procedure 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 opera-tion. 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

Mounting the acoustic cabinet (optional)

20 ProtoMat® S42

Note: If the circuit board plotter has already been mounted into the acoustic cab-inet, 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

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 deliv-ered 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.

WARNING


Installation


3.3 Setting up the circuit board plotter

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.

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.

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.

Fig. 6: Removing the ship-ping braces and the base material

1 Cardboard strips with adhesive tape

2 Foam underlay 3 Base material

2

3

1

Setting up the circuit board plotter

22 ProtoMat® S42

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.

– Rotate the plastic base until the opening faces the front.[ ] Mounting the plasticbase of the milling depth limiter is completed.

Fig. 7: Mounting the plas-tic base of the mill-ing depth limiter

1 Milling depth limiter 2 Plastic base

1

2

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 doc-uments.

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 connect-ing piece on the ex-traction hose

Installing the dust extraction

24 ProtoMat® S42

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 ex-traction hose to the suction pipe of the circuit board plotter

1 Closing plu 2 Extraction hose with connecting piece

1 2

Fig. 10: Connecting the ex-traction hose to the suction pipe of the acoustic cabinet (optional)

1 Closing plu 2 Extraction hose with connecting piece

1 2

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.

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.

[ ] The LPKF dust extraction is connected to the ProtoMat® S42.

Fig. 11: Connections on the dust extraction

Fig. 12: Connections for the dust extraction on the circuit board plotter

1 Port 3 2 Port 4

1 2

Installing the dust extraction

26 ProtoMat® S42

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 control-led 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 posi-tion. Use one of the following settings:

[ ] The desired operating mode is set.

Setting Operating mode OperationON Continuous oper-

ationPermanent 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 automati-cally together with the mill-ing/drilling motor, manual switching On/Off using the BoardMaster is possible.

Fig. 13: LPKF dust extrac-tion – Setting the operating mode

1 Continuous operation 2 Off 3 Automatic mode

1 2 3

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 operat-ing system WindowsXP/2000 (not included in the scope of delivery).

System requirements:

For the following work steps you need a computer that is ready for opera-tion.

Processor min. 1.5 GHzRAM: min. 256 MB (512 MB recommended)Hard disk capacity: min. 100 MBCD-ROM drive: min. 16-fold Unused serial (COM) port or USB portFor VisionSystem (optional): additional USB 2.0 port

Setting up the Computer

28 ProtoMat® S42

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 com-puter.

[ ] 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

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 1or: – Prolific USB-to-Serial-Comm Port (COM3)

in case of connection to a USB port by means of the USB-converter.

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: 38400

Data bits: 8

Parity: none

Stop bits: 1

Flow control: Hardware

Fig. 15: Connection settings

Setting up the Computer

30 ProtoMat® S42

6. Click on Advanced....

The window Advanced Settings for ... is opened.

7. Make sure that following settings are applied:

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.

Fig. 16: Advanced settings

Use FIFO buffer activated

Receiving buffer: (8)

Transmission buffer: (6)

COM port number: COM port to which your ProtoMat® S42 is connected.

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 LMD-format). 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/acti-vation of this software in the respective manuals.

Completing installation

32 ProtoMat® S42

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.

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 con-nected.

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).

Fig. 17: Connecting the data cable to the circuit board plotter

1 RS 232 Port 2 Mini Gender Changer (optional)

12

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 cir-

cuit 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 cre-ate 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).

First putting into operation

34 ProtoMat® S42

III. Checking the Interfaces (optional)

If the circuit board plotter is not recognised automatically, the input win-dow Connect... appears. If necessary, you have to change the connec-tion settings.

Fig. 18: BoardMaster user Interface

1 Title bar 2 Main Menu 3 Function Bar

123

Fig. 19: Input window Con-nect...

Installation


1. Make sure that the circuit board plotter is on and that the mill-ing/drilling head lighting is on.

2. Make sure that the following values are entered and check the set-tings of the Windows system control (see "Configuring the COM Port" on page 28)

3. Click on Connect....

[ ] As soon as the connection to the circuit board plotter has been estab-lished, 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 > Con-nect...).

Control unit: SMCU 3Machine: ProtoMat S42Interface 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: 38400

First putting into operation

36 ProtoMat® S42

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 posi-tion.

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 posi-tion.

[ ] The test is completed.

Note: In case of problems please read Chapter 4‚ "Malfunctions and prob-lem solutions", on page 37.

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

Possible cause Troubleshooting

Circuit board plotter can-not be switched on. (The milling head light-ing does not light up after switching on the main switch)

No power supply. Make sure that the circuit board plotter is con-nected to the power supply (milling head light-ing is on).

Incorrect setting of the operat-ing voltage.

Adjust the operating voltage to the value of the power supply (see "Checking/adjusting the operating voltage" on page 19)

Connect ... window opens after starting BoardMaster.

Circuit board plotter has no power supply.Lighting of the milling/drilling head is off.

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....

The connection settings do not correspond to the installation.

Ensure that connection settings correspond to your installation.Check the COM port settings in the in the Windows system control (see Kapitel ‚ „Confi-guring the COM Port”, on page 28).

Dust extraction does not start

No power supply Connect the dust extraction to the power sup-ply.

Dust extraction is switched off Set the switch for operating mode selection of the dust extraction to the position ON or select the automatic mode.

The dust extraction fuse was blown

Press RESET button on the dust extraction-switch-off

No data communication Check the wiring of the circuit board plotter.

For your notes

38 ProtoMat® S42

Technical data


5. Technical data

ProtoMat® S42

Operating voltage (can be set manually)

220 – 240 V; 50 Hz – 60 Hz (factory setting)

110 V – 120 V; 50 Hz – 60 Hz

Power consumption 200 W

Weight 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 71dB (A) (excluding dust extraction)

Milling/drilling spindleSpeed range

3-phases motorMax. 42,000 U/Min.,software-controlled

Traverse speed Max. 50 mm/s (1.97"/s)

Drilling performance Max. 90 strokes/min.

Tool change Manually, quick clamping system

Tool holder 3.175 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) 1 µm (0.04 Mil)

Repetitive accuracy +/- 5 µm (0.2 Mil)

Precision of the pass hole system +/- 20 µm (0.8 Mil)

Smallest drilling diameter 0.2 µm (8 Mil)

For your notes

40 ProtoMat® S42

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)

North / Central America

China

Phone +49 (0) 5131-7095-0

Fax +49 (0) 5131-7095-90

E-mail [email protected]@lpkf.de

LPKF webpage www.lpkf.dewww.lpkf.com

Phone +1 (503) 454-4219

Fax +1 (503) 682-7151

E-mail [email protected]@lpkfusa.com

LPKF webpage www.lpkfusa.com

Phone Hotline service

+86-13920308369 (Distribution)+86-13032289111 (Service)

Fax +86-2223006965

E-mail [email protected] webpage [email protected]

For your notes

42 ProtoMat® S42



7. EC Declaration of Conformity

Declaration of Conformity in accordance with Machinery Directive 98/37/EC, Appendix II A

The manufacturer/seller

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 produc-tions are in compliance with the following EC directives and EN stand-ards:

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 specifica-tions for machinery manufacturers

• EN 60204-1:1997 Safety of machinery - Electrical equipment of machines - Part 1: Gen-eral requirements

LPKF Laser & Electronics AGOsterriede 7D-30827 GarbsenGermany


44 ProtoMat® S42

• EN 61000-6-1-4:2001 Electromagnetic compatibility (EMC)

• EN 55022:1994 A2 Information technology equipment - Radio disturbance characteris-tics - Limits and methods of measurement Amendment A2:1997

Further EU directives applied

• EMC directive 89/336/EEC• Low Voltage Directive 2006 /95/ EEC

Town: GarbsenDate: 2. June 2008

Bernd Hackmann(Board chairman)

Index


8. Index

AAdjusting the Operating Voltage 20

BBasic equipment 15BoardMaster 34

Version 9

CCamera 19COM port number 30Computer

Configuration of Communication Port 28Set-up 27System Requirements 27

Connecting piece for extraction hose 23Connection for illumination 16Connection settings 29

DDeclaration of Conformity 43Disclaimer 10Drill underlay 21Dust Extraction

Connections 25Installation 23Operating mode 26

Dust extraction 18

EEC Declaration of Conformity 43EU directives 44

FFIFO buffer 30First Putting into Operation 33Function Bar 34Fuse holder 19

GGeneral Safety Instructions 11

HHardboard 21Heat sink 16

IInstallation 19Installing the Software 31

MMachine Overview 15Main Menu 34Main switch 23Manufacturer 43Milling depth limiter 16

NNotations 3

PPorts of Dust Extraction System 25Putting the machine into operation 33

RReceiving buffer 30RS 232 port 32

SSafety Instructions 11Scope of delivery 13Seller 43Setting the Suction Force 27Speed controller 27Speed range 39Spring adjustment 16Standards 43

TTechnical Data 39Title Bar 34Trademark 4Transmission buffer 30

UUse

Designated 9Inadmissible 10

VVacuum table 19VisionSystem 19

For your notes

46 ProtoMat® S42

ProtoMat® S42Tutor data

Tutorial2.0, English

Arti

cle

num

ber:

xxx_

xxx

Insert cover photo:



Item

num

ber:

123

747

(117

653

)

LPKF Laser & Electronics AGOsteriede 7D-30827 GarbsenGermanyPhone ++ 49 - 51 31 - 70 95 - 0 Fax ++ 49 - 51 31 - 70 95 - 90E-mail [email protected] page http://www.lpkf.de

About this manual

2 ProtoMat® S42 Tutor data

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 gal-vanically 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 previ-ously drilled LPKF base materials are used.

System overview

1 Main switch (if necessary, inside of the acoustic cabinet)

2 Setting wheel for the milling depth limitation

3 Collet chuck lever

1 2 3

Preparation

Tutorial 2.0 Rev.: 2.06.2008 3

Preparation

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.


3. Place the base material along with the drill underlay on the travers-ing 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.

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.

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.

The working area is displayed in the BoardMaster window in dark grey.

Fig. 1: Setup working area (dark-grey)

Processing the layout data by means of CircuitCAM

Tutorial 2.0 Rev.: 2.06.2008 5


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... .

2. 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)

1 File list2 Register card Graphic

3 Register card Format4 Resolution Digits m.n:

2

1

3

4



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.

– 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 resolu-tion (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)

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.

Fig. 3: Selecting a layout file

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


Tutorial 2.0 Rev.: 2.06.2008 7

II. Generating contours and ligaments

1. Click on the top left corner of the contour line.

The contour line is highlighted by marks.

2. Click on the Contour Routing button.

The Contour Routing window is opened.

Fig. 4: Marking contour line

Fig. 5: Settings for contour milling



3. Select the following settings:

4. Click on Run. [ ] The contour is displayed as a line 2 mm in width.

Outside

Source Current Selection

Destination layer: CuttingOutside

Used tool List LpkfCuttingTools

Tool ContourRouter 2.0 mm (79 mil)

Breakout 4 corners

Width 1 mm

Fig. 6: Contour with liga-ments


Tutorial 2.0 Rev.: 2.06.2008 9

III. Inserting further ligaments (optional)

1. Click on a corner of the contour line highlighted in yellow.

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 con-ductor tracks. Isolation areas are used to define areas in which the cop-per 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 iso-lation area (rub out).

3. If desired, define further isolation areas.

Fig. 7: Positioning a liga-ment



[ ] 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.

Note: By now, you can still define further isolation areas (→ Defining isola-tion areas (optional)), and recalculate the isolation.

Fig. 8: Defined isolation areas (rub out)

Fig. 9: Calculated isolation


Tutorial 2.0 Rev.: 2.06.2008 11

VI. Exporting data as project

The export will automatically produce a *.cam and a *.LMD file. The lat-ter 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.


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.

4. Click on OK.

[ ] The data will be exported as a project.

You can exit CircuitCAM now.

Fig. 10: LMD-file exported

Production


Production

If BoardMaster is opened while the LMD file is being exported from Cir-cuitCAM, 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.

Production

Tutorial 2.0 Rev.: 2.06.2008 13

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.

Production


2. Press the tension lever downwards, with the help of the tweezers insert the needed tool with the shaft upwards into the collet chuck to the stop and then release the tension lever.

The tool is fixed in the collet chuck by the spring force.

Fig. 11: Prompt to insert the tool

WARNING


Fig. 12: Collet chuck and tension lever

1 Tool holding fixture (collet chuck) 2 Tension lever

1 2

Production

Tutorial 2.0 Rev.: 2.06.2008 15

3. Select the desired action:– If you want to start the production immediately:

Activate the item Continue after tool exchange.– If you want to set the milling depth/width for the tool first:

Activate the item Stop after tool exchanges for adjustment.

4. Click on OK in the Tool Exchange window.

[ ] After you have activated the item Stop after tool exchanges for adjustment, you can now either set the milling depth/width (optional) or immediately start the production by clicking on Start.

V. Setting the milling width (optional)

1. To create a test milling track:– Position the milling/drilling head over the unused area of the

base material.

– 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 by about 10 mm in the desired direction.

– Click on the Motor off button.

– Click on the Move to Pause button.

2. Check the milling width/depth:– For Universal Cutter/Micro Cutter:

Does the milling width in the copper laminate have the desired value (e. g. 200 µm for the Universal Cutter 0.2 (8 mil)?

– For cylindrically cut milling cutters with fixed milling width: Was the copper completely removed from the milling track?

Production


3. If required: – Correct the milling width/depth at the setting wheel of the milling

depth limiter.

Note: For each step the milling depth changes by approx. 2 µm, the milling width of the Universal Cutter by approx. 4 µm, of theMicro Cutter by ap-prox. 2.3 µm.

– Mill another test track and check the milling width/depth again.

[ ] Once the desired milling width/depth has been set, the production phase can be continued.

VI. Starting/continuing the production phase

1. Click on Start.

[ ] The current production phase will be started. Once all activated production phase data have been produced, the message "End of the phase!" appears.

Fig. 13: Setting the Milling Width

1 Setting wheel of the milling depth limiter

1

Fig. 14: Production phase completed.

Production

Tutorial 2.0 Rev.: 2.06.2008 17

2. Click on OK.

[ ] Now the next production phase can be started.

VII. Starting the next production phase

In the phase selection list the production phase selected last is always preselected.1. Select the next production phase in the phase selection list.

Note: The production phases designated Info! ... must be produced using exter-nal devices. The production phases designated Read_... are only required when the system is equipped with the VisionSystem (optional).

2. If required: Rotate the material around the mirror axis until the side to be proc-essed faces upwards and fix it on the traversing table/vacuum table .

Tab. 2: Production phases for tutor files (double-sided circuit board with galvanic through-hole plating)


1. MarkingDrills Centre-punching the drillingsDrilling fiducials

Bottom

2. DrillingPlated Drilling holes for the through-hole plat-ing

Bottom

3. Info! Galvanic Plating Galvanic through-hole plating (with through-hole plating station)

On both sides

4. Read_Bottom (only with VisionSys-tem)

Reading in fiducials Bottom

5. DrillingUnplated Drilling mounting holes (not for through-hole plating)

Top

6. MillingBottom Milling Bottom

7. Read_Top (only with VisionSys-tem)

Reading in fiducials Top

8. MillingTop Milling Top

9. CuttingInside Milling inner cutouts Top

10. CuttingOutside Milling contours Top

Production


3. Activate the desired files (see S. 13).4. Click on Start and insert the required tool.

[ ] The production of the activated data starts. It may still be necessary to set the milling width/depth.

Interrupting and saving the production

You can interrupt production at any time and continue at a later time or cancel it.1. Click once on Stop and wait until the data already sent to the circuit

board plotter have been produced.Note: Clicking on Stop several times will continue production, possibly with further data.

2. To save the current production status: – Save the job under a new name.

If possible, select a name containing the current processing status, for example Tutor_DrillingPlated.job.

[ ] The job will be saved with the current processing status and can be opened and continued at a later time.

Production

Tutorial 2.0 Rev.: 2.06.2008 19

Canceling production (optional)

1. To cancel the production: 2. Click on File > Exit to quit BoardMaster.

or: Open another job.

3. When the message "Save the job in file ..." appears.

– 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 canceled.

Fig. 15: Message when cancelling produc-tion

LPKF Laser & Electronics AGOsteriede 7D-30827 GarbsenGermanyPhone ++ 49 - (0) 51 31 - 70 95 - 0 Fax ++ 49 - (0) 51 31 - 70 95 - 90E-mail [email protected] page http://www.lpkf.de

ProtoMat® S42 Tutor data Tutorial 2.0

Copyright© 2008 LPKF AG Any distribution or copying of this document or parts of this document in any form and use of its contents require the written permission of the LPKF AG. Subject to modification.Translation of the german originalItem No.: 123 747 (117 653)

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