ProtoMat S62. Operating Manual 7.1, English. Artikelnummer: xxx_xxx. Titelfoto einfügen: Größe: 11,5 cm x 9,5 cm. Abstand: oben: 1,5 cm links: 8,5 cm

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1 Artikelnummer: xxx_xxx Article number: Titelfoto einfügen: Größe: 11,5 cm x 9,5 cm Abstand: oben: 1,5 cm links: 8,5 cm ProtoMat S62 Operating Manual 7.1, English

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3 ProtoMat S62 Operating Manual 7.1, English LPKF Laser & Electronics AG Osteriede 7 D Garbsen Germany Phone (0) Fax (0) lpkf@lpkf.de Homepage

4 ProtoMat S62 Introduction The LPKF ProtoMat S62 is a latest generation compact circuit board plotter. 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 62,000 rpm) ensures the production of accurate structures on different base and housing materials. Thanks to the integrated Z-axis control, the ProtoMat S62 is ideal for 2.5 dimensional work. Accordingly, for example, front plates for electronic housings can be produced and previously populated SMD circuit boards reworked. By means of the optional camera system also double-sided materials, for example for multi-layer and RF applications, can be processed precisely. Flexible and rigid/flexible workpieces can be fixed flat on the working surface thanks to the optional vacuum table. The ProtoMat S62 is controlled via the easy-to-use LPKF BoardMaster software. The LPKF CircuitCAM software included in the delivery can be used to import all common CAD data formats and make them ready for the working process. Copyright 2008 LPKF AG Any distribution or copying of this manual or parts of this manual in any form and use of its contents require the written permission of the LPKF AG. Subject to modifications. Translation of the german original Article number:

5 Information about this document Information about this document This manual contains important information regarding operation, care and maintenance of the LPKF circuit board plotter ProtoMat S62. The manual is directed at persons with basic knowledge in the installation and operation of software-controlled machines. Knowledge regarding the safety and behavior in workshops as well as regarding the operation of a computer with Windows 2000/XP are required. Availability When working at or with the ProtoMat S62, this document must be available in complete and legible condition. It must be within easy reach near the machine for all the persons entrusted with 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. Symbols and signal words WARNING Danger to life or health. This symbol indicates a dangerous situation in which in case of non-observance of the information there is a risk to life or health. Informations to avoid the danger are given. CAUTION Risk of material damage. This symbol indicates a situation which in case of non-observance of the information can result in material damage. Informations to avoid the risks are given. Tip: The hand indicates tips for easier handling, material use and/or further processing. An arrow points to a different location in this document or to another document specified by name. Operating Manual 7.1 Rev.:

6 Brand names Bold print The following detailed information is shown in bold print: Switches, operating elements, labeled connections for example power switches. Software elements: Menu entries, for example File > Open... Input boxes, selection boxes and lists, for example Tool Selection List Buttons; for example: Cancel Windows, dialog boxes, for example input windows Tool Positions Numberings in images Numbers in bold print in figures identify numberings (1) or dimensions (50 mm). Numbers in bold print appearing inside parentheses (1) identify the number in the figure described. Italic print Indented headers The following information is shown in italics: Proper names and brand names, for example Windows (LPKF proper names are not shown in italics.) Software messages, for example "The file will be started..." (The inverted commas are not part of the message.) Indented headings prompt you to carry out an action. Example: I. Carrying 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 a special 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. Brand names The LPKF Logo, LPKF ProtoMat, BoardMaster and LPKF ProConduct are registered trademarks of LPKF Laser & Electronics AG. Windows is a brand name of the Microsoft AG. All other brandnames belong to the respective owner. 4 ProtoMat S62

7 Table of contents Table of contents Introduction Information about this document List of figures For your safety Designated use Safety instructions What is what? Circuit board plotter with acoustic cabinet Milling/drilling head Traversing table and tool magazine Connecting elements and rating plates LPKF dust extraction What you should know The milling/drilling head Defined positions Milling depth/width limitation The traversing table The pass hole system Material fastening The tool magazine Usable tools Surface tools Penetrative tools The 2.5 D function Manual operation Automatic operation Production types and phase files Production phases Data selection Operating Manual 7.1 Rev.:

8 Table of contents 4 Manual tasks and settings Switching on the system Switching on the LPKF dust extraction (optional) Setting the suction force (optional) Switching on the circuit board plotter Starting BoardMaster Checking the connection settings (if necessary) Switching off the system Quitting BoardMaster Switching off the circuit board plotter Switching off the LPKF dust extraction Finding out about BoardMaster The user interface Frequently used functions Positioning the milling/drilling head Moving the milling/drilling head to a predefined position Moving the milling/drilling head step by step in the X/Y direction Moving the milling/drilling head with the mouse Moving the milling/drilling head vertically Mounting/Dismounting the milling depth limiter base Dismounting the plastic base/brush head Mounting the plastic base/brush head Loading Loading and setting up the base material Loading base material Defining the work area Defining the material height and z values Setting up tools Opening the tool magazine dialogue box Assigning tool positions Inserting tools Inserting tools Selecting a tool for processing Picking up/setting down a tool Setting the focus (VisionSystem only) Setting the focus to the saved value Adjusting the focus position ProtoMat S62

9 Table of contents 4.9 Drilling Drilling a hole Milling Creating a milling track Adjusting the milling depth (cylindrical tools) Adjusting the milling width (Universal Cutter and Micro Cutter only) Creating a pass hole system (basic equipment) Preparing the circuit board plotter Drilling pass holes into pass hole strips Drilling pass holes into the drilling underlay Creating a pass hole system for the vacuum table Preparing the circuit board plotter and vacuum table Drilling pass holes into pass hole strips Setting parameters for drilling pass holes Setting the machine parameters for drilling pass hole strips Drilling pass holes into pass hole strips Drilling pass holes into the sinter plate Adjusting machine parameters Drilling pass holes into the sinter plate Inserting pass hole pins Inserting pass hole pins Working sequence in automatic mode Preparation Defining the production type Selecting a phase file Setting up a job Creating a new job Opening an existing job Aligning/Distributing projects Saving a job Setting up the tools Opening the Tool Positions input window Configuring tools in the tool magazine Inserting tools Operating Manual 7.1 Rev.:

10 Table of contents 5.5 Selecting/Setting up a production phase Selecting the production phase Selecting tools (optional) Selecting tools Activating data Activating all data Activating areas of data elements Activating data segments by index number Deactivating all data Deactivating data areas Setting up 2.5 D processing (optional) Setting up contour milling with 2.5 D mode Activating the 2.5 D mode for a phase Setting the moving-free height Setting up surface milling with 2.5 D mode Starting production Starting a production phase Milling contours in 2.5 D mode (optional) Adjusting the milling depth/width Stopping the production phase Interrupting the production phase Ending production Saving the production status Aborting production Care and maintenance Caring/inspecting Cleaning the surfaces Carrying out a visual inspection ProtoMat S62

11 Table of contents 6.2 Maintaining milling depth limiter and collet chuck Removing and cleaning the milling depth limiter Removing the milling depth limiter Cleaning the milling depth limiter Removing and cleaning the collet chuck Opening the collet chuck Removing the collet chuck Cleaning the collet chuck and the collet chuck holder Mounting the collet chuck and the milling depth limiter Screwing in the collet chuck Mounting the milling depth limiter Replacing fuses Removing the side wall of the acoustic cabinet Replacing the fuses Mounting the side wall of the acoustic cabinet Configuring the tool holder position Configuring the tool holder position (without camera) Defining the milling/drilling head offset Activating the service functions Testing the tool holder position Correcting the tool holder position Determining the tool holder position with VisionSystem Setting the camera offset Preparing the tool magazine for determining the position Calling the service functions Reading in the position data Adjusting the camera (only with VisionSystem) Setting the camera offset Calibrating fiducial recognition Preparing the fiducial recognition Determining the fiducial diameter Changing the dust extraction filter Operating Manual 7.1 Rev.:

12 Table of contents 7 Error messages/malfunctions Decommissioning, transport, disposal Decommissioning Switching the ProtoMat S62 off Disconnect the connecting cables Transport Fitting transport braces Disposal Machine parts and components Consumables Technical data LPKF Service EC Declaration of Conformity Index ProtoMat S62

13 List of figures List of figures Fig. 1: ProtoMat S62 basic equipment Fig. 2: Optional components Fig. 3: Milling/drilling head (front view) Fig. 4: Traversing table with tool magazine Fig. 5: Vacuum table (optional) Fig. 6: Main switch with mains connection Fig. 7: Dust extraction and data connections Fig. 8: Control unit with data connections Fig. 9: LPKF dust extraction Fig. 10: Defined positions of the milling/drilling head Fig. 11: Setting wheel for milling depth limiter Fig. 12: Milling width with Universal Cutter and Micro Cutter Fig. 13: Pass hole system Fig. 14: Turning the material through the mirror axis Fig. 15: Tool positions Fig. 16: 2,5 D processing (application examples)) Fig. 17: Dust extraction - operating modes Fig. 18: Dialog box Tool status Fig. 19: Input window Connect Fig. 20: BoardMaster user interface Fig. 21: Removing the plastic base from the milling depth limiter Fig. 22: Fitting the plastic base on the milling depth limiter Fig. 23: Defining the material size and position Fig. 24: Tool positions input window Fig. 25: Assigning tool positions Fig. 26: Defined tool positions Fig. 27: Adjusting the focus position Fig. 28: Selecting pass hole drills for pass hole strips Fig. 29: BoardMaster message "Drill pass hole?" Fig. 30: BoardMaster message "Depth limiter removed" Fig. 31: Selecting pass hole drills for base material/drilling underlay Fig. 32: Pass hole strips in the vacuum table Fig. 33: Setting parameters for drilling pass holes Fig. 34: Selecting pass hole drills for pass hole strips Operating Manual 7.1 Rev.:

14 List of figures Fig. 35: BoardMaster message "Drill pass hole?" Fig. 36: BoardMaster message "Depth limiter removed" Fig. 37: Machine parameters Fig. 38: Selecting pass hole drills for pass hole strips Fig. 39: Press-in tool with pass hole pin Fig. 40: Positioning a project Fig. 41: Tool Positions input window Fig. 42: Assigning tool positions Fig. 43: Defined tool positions Fig. 44: Selecting tools Fig. 45: Activating the 2.5 D mode in the phases dialogue box Fig. 46: Setting the moving-free height Fig. 47: 2.5 D mode: Configuring Fig. 48: Adjusting the milling width Fig. 49: Message when aborting production Fig. 50: Collet chuck tools Fig. 51: Dismantling the milling depth limiter Fig. 52: Dismantling the milling depth limiter Fig. 53: Setting the milling/drilling head offset Fig. 54: Tool with collet chuck wrench Fig. 55: Unscrewing the collet chuck Fig. 56: Cleaning the collet chuck holder Fig. 57: Cleaning the collet chuck holder Fig. 58: Removing the side wall of the acoustic cabinet Fig. 59: Orientation of the fuse holder Fig. 60: Setting the milling/drilling head offset Fig. 61: Setting the milling/drilling head offset Fig. 62: Tool Box with service functions Fig. 63: Setting the milling/drilling head offset Fig. 64: Positioning the camera image above the bore Fig. 65: Setting the milling/drilling head offset Fig. 66: Measuring insert for determining the position with VisionSystem Fig. 67: Setting the milling/drilling head offset Fig. 68: Tool magazine with service functions Fig. 69: Setting the camera offset Fig. 70: Positioning the camera above the bore ProtoMat S62

15 List of figures Fig. 71: Bore in the camera image window Fig. 72: Setting fiducial recognition Fig. 73: Fiducial calibration Fig. 74: Calibration not possible Fig. 75: Calibration successful Fig. 76: Measured values in the camera image Fig. 77: Fiducial settings Fig. 78: Calibration settings Fig. 79: Calibration complete Fig. 80: Fiducial settings Fig. 81: Measured values in the camera image Operating Manual 7.1 Rev.:

16 For your notes 14 ProtoMat S62

17 For your safety 1. For your safety In this chapter you will find information concerning proper use, liability and safety in connection with the operation of the ProtoMat S62. If, after reading this manual, a situation should arise in which you are not sure how to use or service the ProtoMat S62, you should contact LPKF Support or consult a person skilled in the art. 1.1 Designated use The ProtoMat S62 has been designed for the production of electric circuit boards with up to six layers and the processing of a variety of sign and housing materials. The ProtoMat S62 can be used to: Mill and drill single-sided and double-sided printed circuit boards Mill and drill multi-layer materials Mill SMD solder paste stencils Mill solder stop foils Engrave housing plates and signs Mill cut-outs and contours Drill through flat materials The ProtoMat S62 is able to process the following materials: GFK/CFK base material PTFE/ceramic composite base material Wood Non-ferrous metals Aluminium acc. to DIN EN 573: EN AW-6012) Brass acc. to DIN EN 1412: CW603N Plastics Polyoxymethylenes ABS copolymers The ProtoMat S62 may only be used for the applications and materials cited in this document. The circuit board plotter may only be used together with the version of the LPKF Software BoardMaster included in the scope of delivery. If you want to use a different BoardMaster version, please contact the LPKF Support first. Operating Manual 7.1 Rev.:

18 Designated use Operation of the circuit board plotter is only permitted subject to sufficient dust extraction provision, which must include fine dust filtering. We recommend the use of the LPKF dust extraction with integrated HEPA filter. If you want to use a different system for dust extraction, you should contact LPKF Service first. Improper use The ProtoMat S62 must not be used for processing highly combustible materials, sealed containers, hollow pieces, textiles or foodstuffs. The processing of parts of the body (e.g. finger nails) is not permitted. If you are not sure about the use of the materials to be processed, you should contact LPKF Support. Liability for function and damage The ProtoMat S62 has been designed and built in accordance with the state of the art and acknowledged safety engineering guidelines. Nevertheless, its use may constitute a risk to the life and limb of the user or of third parties, or cause damage to the machine and to other equipment or 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 an unsuitable environment Installation and operation by insufficiently informed or unauthorised persons Non-compliance with legal safety requirements Non-observance of technical information Installation carried out incorrectly Insufficient supply facilities Missing, faulty or insufficient maintenance Unauthorised technical modifications Use of non-original spare parts and those not specifically designed for this machine/device Use of non-approved workpieces and/or materials 16 ProtoMat S62

19 For your safety 1.2 Safety instructions WARNING WARNING WARNING WARNING CAUTION Risk of death by electric shock! 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 NEVER be bridged. Risk of injury caused by pointed/sharp tools! Improper use can cause cuts and stab injuries. Handle tools carefully and keep them in the tool box when not in use. Risk of injury! When opened, the cover of the acoustic cabinet can drop down due to impact shocks 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 as a result of vibrations or the influence of third parties. Dusts and gases are hazardous to your health! The processing of the materials can give rise to dusts and gases hazardous to your health. Ensure that the dust extraction is switched on when processing materials. Extract the dust and material residues or remove them with a brush or moistened cloth; do NOT blow compressed air through. Material damage due to incorrect tool positioning! The milling/drilling head, spindle and the tool can become damaged if the tool positions indicated in BoardMaster do not correspond to the actual fitting of the circuit board plotter. Ensure that the settings in the Tool Status window corresponds to the actual fitting of the circuit board plotter. General safety instructions Read the installation instructions/operating manual before operating the machine. In case of uncertainties ask a person qualified in the art or contact LPKF Support. Use the machine only in accordance with its proper use. Never operate the machine in environments subject to fire or explosion hazards. Operate the machine only in a suitable environment. (Page 1 of 3) Operating Manual 7.1 Rev.:

20 Safety instructions General safety instructions (Continuation) Protect the machine against direct sunlight, humidity and flying sparks. Operate the machine only with accessories approved by LPKF and use only original LPKF tools. Use the machine only in perfect condition. Prior to each use, perform a visual inspection. Look out in particular for damaged cables and hoses. Make sure that the safety devices are in perfect working order. It is prohibited to ignore and bridge safety devices or to render them inoperable. Make sure that there is no risk of stumbling caused by cables and hoses. Have the machine operated, serviced and repaired by sufficiently qualified and authorised personnel only. Repairs must only be carried out by qualified LPKF personnel or following consultation with LPKF Support. Keep children away from the work area. Do not eat, drink or smoke in the workshop/work area. Observe the general and legal regulations for accident prevention and environmental protection. You must wear the prescribed protective equipment at all times when operating, servicing and repairing the machine. When handling the circuit board plotter, make sure that the machine cannot start (unintentionally) or be operated by third parties, for example via the computer. Unplug the machine from the mains prior to commencing any maintenance work. Regular care and maintenance are essential. (Page 2 of 3) 18 ProtoMat S62

21 For your safety General safety instructions (Continuation) If evidence of damage or malfunctions is found, the device must be brought to a standstill immediately. Have any malfunctions rectified immediately. If the damage cannot be put right, the machine must be taken out of operation and secured against being switched on. Extract the dust and material residues in the machine or remove them with a brush. Do NOT blow compressed air through! (Page 3 of 3) Operating Manual 7.1 Rev.:

22 For your notes 20 ProtoMat S62

23 What is what? 2. What is what? In this chapter you get to know the components and operating elements of the ProtoMat S62. Before installing the machine or putting it into operation, first familiarise yourself with the individual components. 2.1 Circuit board plotter with acoustic cabinet Fig. 1: ProtoMat S62 basic equipment Acoustic cabinet 2 Milling/drilling head 3 Tool magazine 4 Traversing table (with base material) 5 Main switch (in the acoustic cabinet) Operating Manual 7.1 Rev.:

24 Circuit board plotter with acoustic cabinet Optional components Fig. 2: Optional components StatusLight 2 Camera (VisionSystem) 3 Vacuum table 22 ProtoMat S62

25 What is what? 2.2 Milling/drilling head Fig. 3: Milling/drilling head (front view) Equipment with camera (VisionSystem) Basic equipment Spring adjustment Heat sink Lighting connection Tool holder Operating Manual Plastic base of the milling depth limiter, alternatively: brush head (accessories) Milling depth limiter Setting wheel for milling depth limitation Power supply for the camera Hose for dust extraction Data connection for the camera Camera Power supply cable for the camera Rev.:

26 Traversing table and tool magazine 2.3 Traversing table and tool magazine Fig. 4: Traversing table with tool magazine Tool magazine 2 Tool position 10 3 Pass hole strip with pass hole pin 4 Pass hole strip with pass hole pin 5 Tool position 1 Fig. 5: Vacuum table (optional) Extraction hoses 2 Sintered plate, permeable to air 3 Vacuum table 4 Traversing table 24 ProtoMat S62

27 What is what? 2.4 Connecting elements and rating plates Fig. 6: Main switch with mains connection Acoustic cabinet with right side panel removed 2 Rating plate 3 Fuse holder 4 Mains connection 5 Main switch 6 Acoustic cabinet cover Operating Manual 7.1 Rev.:

28 Connecting elements and rating plates Fig. 7: Dust extraction and data connections Acoustic cabinet (rear view) Dust extraction 3 4 Rating plate Control unit with data connections Fig. 8: Control unit with data connections Not used StatusLight status signals (option) Port 3 (dust extraction) Port 4 (dust extraction) RS 232 RS USB (for service purposes only) Data transfer indicator Motor status indicator (y-axis) Motor status indicator (x-axis) Power indicator (5 V electronic and motor voltage) ProtoMat S62

29 What is what? 2.5 LPKF dust extraction Note: The ProtoMat S62 can be equipped with another type of dust extraction. The relevant documentation contains information about function, operation and maintenance. Fig. 9: LPKF dust extraction Extraction force controller 2 Power supply 3 Data cable 4 Main switch in automatic mode 5 Main switch (OFF) 6 Main switch in continuous mode Operating Manual 7.1 Rev.:

30 For your notes 28 ProtoMat S62

31 What you should know 3. What you should know In this chapter you get to know the functions and operating elements of the ProtoMat S62. Prior to commencing operation, you must first familiarise yourself with the most important elements of the BoardMaster and its various operating modes. 3.1 The milling/drilling head The milling/drilling head can be moved horizontally in the X direction only. The traversing table must be moved in the Y direction to position the milling/drilling head in any position above the base material. The coordination of both traversing directions is controlled by BoardMaster. In the following, this procedure will be denoted as moving the milling/drilling head Defined positions Fig. 10: Defined positions of the milling/drilling head Tool magazine (position 1) 2 Milling/drilling head in home position 3 Milling/drilling head in zero position 4 Milling/drilling head in pause position 5 Right pass hole pin 6 Mirror axis Operating Manual 7.1 Rev.:

32 The milling/drilling head Pause position Home position Zero position In the pause position, the milling/drilling head is on the right and the traversing table is at the front. Use the pause position to load the circuit board plotter. The home position serves as the BoardMaster reference point and lies exactly on the mirror axis of the traversing table. The milling/drilling head is positioned exactly above the left pass hole pin; the traversing table is in the central area. The zero position corresponds to the zero point of the X/Y co-ordinate system and is positioned at the front left on the traversing table. In the zero position, the milling/drilling head is located on the left edge of the traversing range and the traversing table is at the back Milling depth/width limitation The milling depth limiter is located directly on the milling/drilling head. The penetration depth of the surface tools can be set with the setting wheel in order to regulate material removal. Fig. 11: Setting wheel for milling depth limiter 1 1 Setting wheel for milling depth limiter 30 ProtoMat S62

33 What you should know When using the conical tools Universal Cutter and Micro Cutter, you must set the milling width to the desired size with the milling depth limiter. Enlarge the milling depth for cutting wider milling tracks, reduce the milling depth for narrow milling tracks. Fig. 12: Milling width with Universal Cutter and Micro Cutter c d e 1 Milling depth not sufficient, no isolation 2 Milling depth too shallow, milling track too narrow 3 Milling depth too deep, milling track too wide 4 Milling depth perfect, 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 Always check the milling width at the lower edge of the (copper) laminate to ensure the required electrical isolation between the conductor tracks. Tip: Use the LPKF measuring microscope to check the milling width exactly. Operating Manual 7.1 Rev.:

34 The traversing table 3.2 The traversing table The traversing table can be moved in the Y direction to position the milling/drilling head in any position above the work area. BoardMaster coordinates the traversing motions. Fig. 13: Pass hole system Pass hole strip (red) 2 Pass hole pin 3 Traversing table Note: The circuit board plotter can be equipped with the optionally available vacuum table. 32 ProtoMat S62

35 What you should know The pass hole system The ProtoMat S62 is delivered from the factory with a pass hole system for base material in standard size 9" x 12". It comprises two pass hole pins mounted in exchangeable plastic strips. The plastic strips can be used more than once and moved individually in the X direction. Accordingly, multiple pass hole positions can be set up for different base material sizes. The pass hole pins mounted on the traversing table are positioned exactly on the mirror axis of the co-ordinate system. If the base material is turned through this (longitudinal) axis to process the second side, the production data is automatically executed precisely to fit on the base material. Fig. 14: Turning the material through the mirror axis Material fastening The material must lie flat on the drilling underlay to ensure the desired material removal rate across all areas when milling. Fasten it at the edges using adhesive tape which will not leave any traces of residue when removed. Tip: For flexible materials use the optional vacuum table to fasten the material in a perfectly flat position. Operating Manual 7.1 Rev.:

36 The tool magazine 3.3 The tool magazine The tool magazine is located on the traversing table and can be loaded with up to 10 tools. The tool holder (positions) are numbered from left to right. Fig. 15: Tool positions Tool position 1 2 Tool position 10 Loading The tools must be inserted into the tool holder as far as they will go with the tip pointing downwards and according to the tool position indicated in BoardMaster. This facilitates (semi-)automatic taking up and putting down. 3.4 Usable tools The ProtoMat S62 has been designed exclusively for the use of LPKF drilling and milling tools manufactured specifically and equipped with spacer rings. If other tools are used, we cannot guarantee that the circuit board plotter will function without errors, nor can we be held liable for working results. The tools are subdivided into two main groups: Surface tools with 36 mm (1.42") total length (Cutters and End Mills) Penetrative tools with a total length of 38 mm (Spiral Drills, Contour Routers and End Mills long). The numbers on the spacer rings indicate the tool diameter. 34 ProtoMat S62

37 What you should know Surface tools Universal Cutter 1/8" mm (8-20 mil) Copper Application: Colour: Shape: Milling widths: Milling insulation clearances of varying widths in copper-plated base material. Use the milling depth setting to define the milling width. Orange Conical 0.2 mm 0.5 mm (8 mil 20 mil), variably adjustable via penetration depth Micro Cutter 1/8" mm (4-6 mil) Copper Application Fine insulation clearances with copper layer 18 µm thick. Use the milling depth setting to define the milling width. Colour: Orange Shape: Conical Milling widths: 0.1 mm 0.15 mm (4 mil 6 mil), variably adjustable via penetration depth Operating Manual 7.1 Rev.:

38 Usable tools End Mill (End Mill 1/8") mm (31-118mil) mm (31-118mil) Copper Aluminium Application: Colour: Shape: Milling widths: Aluminium engraving, recesses and wide insulation clearances Purple Cylindrical d = 0.80 mm (31 mil) d = 1.00 mm (39 mil) d = 2.00 mm (79 mil) d = 3.00 mm (118 mil) RF end mill (End Mill (RF) 1/8") mm (6-16 mil) Copper Application: Colour: Shape: Milling widths: Smallest insulation clearances in RF materials. Blue Cylindrical d = 0.15 mm (6 mil) d = 0.25 mm (10 mil) d = 0.4 mm (16 mil) 36 ProtoMat S62

39 What you should know Penetrative tools End mill long (End Mill long 1/8") ) 1-2mm (39-79 mil) 1-2mm (39-79 mil) Application: Colour: Shape: Milling widths: Aluminium Dielectric Contour milling, material cut-outs and depanelisation in aluminium and soft RF and microwave materials. Light green Cylindrical d = 1.00 mm (39 mil) d = 2.00 mm (79 mil) Contour router (Contour Router) 1-2mm (39-79 mil) Application: Colour: Shape: Milling widths: Copper Contour milling, material cut-outs, depanelisation, bores >2.4 mm/> 3.0 mm. Yellow Cylindrical d = 1.0 mm (39 mil) d = 2.0 mm (79 mil) Operating Manual 7.1 Rev.:

40 Usable tools Drill (Spiral Drill) min. 0.2 mm (8 mil) max. 3.0 mm (118 mil) Copper Application: Colour: Shape: Available diameters: Bores penetrating the material. Green Cylindrical 0.20 mm (8 mil) 1.40 mm (55 mil) 0.30 mm (12 mil) 1.50 mm (59 mil) 0.40 mm (16 mil) 1.60 mm (63 mil) 0.50 mm (20 mil) 1.70 mm (67 mil) 0.60 mm (24 mil) 1.80 mm (71 mil) 0.70 mm (28 mil) 1.90 mm (75 mil) 0.80 mm (31 mil) 2.00 mm (79 mil) 0.85 mm (33 mil) 2.10 mm (83 mil) 0.90 mm (35 mil) 2.20 mm (87 mil) 1.00 mm (39 mil) 2.30 mm (91 mil) 1.10 mm (43 mil) 2.40 mm (94 mil) 1.20 mm (47 mil) 2.95 mm (116 mil) 1.30 mm (51 mil) 3.00 mm (118 mil) 38 ProtoMat S62

41 What you should know 3.5 The 2.5 D function With its software-controlled 2.5 D function, the ProtoMat S62 is perfect for milling contours and cut-outs in thickwalled housing materials that make high material removals necessary. The material is removed in several cycles to protect the tool. You can also mill stepped crevices, for example component pockets for SMD loading, with the 2.5 D function. Fig. 16: 2,5 D processing (application examples)) a b 1 Deep milling in multiple cycles a - Milling cycle, b - Material 2 Contour milling in multiple cycles 3 Stage milling in two cycles 4 Multi-stage milling with different tool diameters Required accessories Usable tools You will need the vacuum table (which can be purchased as an accessory) to guarantee an exactly flat position when performing 2.5 D surface milling. Contour/cut-out milling can also be performed with the basic equipment in 2.5 D mode. For optimum dust extraction, the milling depth limiter base must be replaced with the LPKF brush head (which is available as an accessory) when processing in 2.5 D mode (see chapter "Dismounting the plastic base/brush head", on page 62). It is only possible to use the End Mill long 1/8" and the Contour Router in 2.5 D processing. The End Mill (RF) 1/8" is not suitable for the 2.5 D function. Operating Manual 7.1 Rev.:

42 Manual operation Use For tool-friendly material removal/contour milling, the 2.5 D function should be used with the following materials/milling depths: Tab. 1: 2.5 D processing, milling depth and materials Material GFK (FR4)/CFK base material PTFE/ceramic composite base material Wood Non-ferrous metals (aluminium, brass) Plastics (polyoxymethylenes, ABS copolymers Milling depth >2mm >0.25mm 3.6 Manual operation The manual operation is used primarily for creating individual bores and structures, for post-processing printed circuit boards manufactured automatically and for special applications. Manual operation supplements the automatic functions and can be executed at any time. 40 ProtoMat S62

43 What you should know 3.7 Automatic operation In automatic mode, the CAD data prepared with CircuitCAM is used for production. These *.LMD files contain information regarding layout, structure and use of the required tools. Tip: Use the tutorial files prepared by LPKF to familiarise yourself with the automatic operation and to produce a double-sided sample circuit board. Detailed information about the tutor data can be found in the tutorial ProtoMat S62 Tutor data Production types and phase files The following production types can be produced using the phase files included in the scope of delivery: Tab. 2: Production types and phase files Production type Single-sided/double-sided printed circuit boards (galvanic through-hole plating) Single-sided/double-sided printed circuit boards (galvanic through-hole plating with LPKF ProConduct) 4-layer multi-layer (galvanic through-hole plating) 4-layer multi-layer (galvanic through-hole plating with LPKF ProConduct) 6-layer multi-layer Solder stop foils Solder paste stencils Phase file 1-2layer.phs (<default>) 1-2layer + proconduct.phs 4-layer.phs 4-layer + proconduct.phs 6-layer.phs soldermask.phs stencilmilling.phs As the ProtoMat S62 is factory-set to produce single-sided/double-sided printed circuit boards followed by galvanic through-hole plating, it is not necessary to select a phase file for this production type. Phase file 1-2layer.phs (<default>) is used. Operating Manual 7.1 Rev.:

44 Automatic operation Automatic production takes place phase-by-phase, whereby each production phase must be started manually. The production phases should always be carried out one after the other in the order specified. Individual production phases can be skipped and/or executed at a later time. Note, however, that some work steps are based on previous production phases which cannot be executed afterwards. You can create additional phase files for your individual applications and/or reconfigure existing ones. Please see the BoardMaster manual for information Production phases The following production phases are contained in the phase files: Tab. 3: Production phases 1/2-layer printed circuit boards Plating LPKF ProConduct Galvanic Required phase file 1-2layer + proconduct.phs 1-2layer.phs (<default>) Production phases (Page 1 of 3) 42 ProtoMat S62

45 What you should know 4-layer printed circuit boards Plating LPKF ProConduct Galvanic Required phase file 4layer + proconduct.phs 4layer.phs Production phases (Page 2 of 3) Operating Manual 7.1 Rev.:

46 Automatic operation Solder stop foils Solder paste templates Required phase file soldermask.phs stencilmilling.phs Production phases 6-layer printed circuit boards Plating Required phase file Galvanic 6layer.phs Production phases (Page 3 of 3) Work steps in the production phases BoardMaster assists you in selecting the next production phase and provides information about the manual operating steps required for production, for example for turning the base material or pressing the individual layers externally before continuing processing with the ProtoMat S62. A production phase must always be selected and started manually. It can be stopped at any time and resumed later. Accordingly, you can check quality, correct the milling depth/width or change tools during production. The production phases comprise the following work steps that are processed efficiently one after the other: 44 ProtoMat S62

47 For your notes Tab. 4: Work steps in production phases Production phase Work steps Processed material side MarkingDrills Read_Top Read_Bottom Centre-punching bores Drilling pass holes Reading in pass holes (only with VisionSystem) Reading in pass holes (only with VisionSystem) Bottom Top Bottom DrillingPlated Drilling holes for plating Bottom DrillingUnplated Drilling mounting holes (not for plating) Top MillingTop Milling Top MillingBottom Milling Bottom Info! Galvanic plating Info! ProConduct Info! MultiPress_work galvanic through-hole plating (external with galvanic station) Plating with the LPKF ProConduct system Pressing multiple layers with external multi-layer press All layers All layers All layers Info! Apply foil to PCB Protective foil ProConduct Top and bottom CuttingInside Milling internal cut-outs Top CuttingOutside Milling contours Top Read_Layer2 Read_Layer3 Read_Layer4 Prepare_Top Prepare_Bottom Reading in pass holes (only with VisionSystem) Preparing outer layers for pressing, drilling pass hole exemptions (only with galvanically plated multi-layers) Top/bottom Top/bottom 45 ProtoMat S62

48 Automatic operation Data selection Production only ever runs with the data you have activated. You can use the selection functions to activate all data or select and activate subsections, individual lines or even individual segments of a line. It is also possible to restrict the selection to one or more tools within a production phase. Thus, for example, you can start by drilling only holes with a selected diameter or cutting milling tracks with a certain width. The data must be selected and reactivated for each production phase. If no data is activated, BoardMaster considers the selected production phase at the start as completed and no processing will be executed. 46 ProtoMat S62

49 Manual tasks and settings 4. Manual tasks and settings This chapter contains essential information about manual operation of the ProtoMat S62. You will find detailed information about the automatic control and operation of the LPKF BoardMaster software in the BoardMaster manual. Observe the safety instructions and follow the guidances step by step in order to achieve the desired result. Y WARNING Risk of injury! When opened, the cover of the acoustic cabinet can drop down due to impact shocks 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 as a result of vibrations or the influence of third parties. 4.1 Switching on the system To avoid unnecessary error messages you always should switch on the system in the specified order. In the following we assume that the computer is switched on and the operating system has been started. Note: If your ProtoMat S62 is equipped with different dust extraction, familiarise yourself with the relevant information on setting options. Operating Manual 7.1 Rev.:

50 Switching on the system I. Switching on the LPKF dust extraction (optional) WARNING Health hazard! Fine dusts and gases hazardous to your health can emerge during material processing. Make sure that the dust extraction for material processing is switched on (continuous or automatic operating mode). 1. Switch the main switch of the LPKF dust extraction to the desired position. Fig. 17: Dust extraction - operating modes Continuous operating mode 2 Off 3 Automatic mode Tab. 5: Operating modes of the LPKF dust extraction: Setting Operating mode Operation ON Continuous operating mode Continuous extraction, Switching On/Off using the BoardMaster is not possible OFF Off No extraction, Switching On/Off using the BoardMaster is not possible Connection to LPKF ProtoMat Automatic mode The extraction starts automatically with the milling/drilling motor, manual switching On/Off using the BoardMaster is possible. [ ] The set operation mode will be used. 48 ProtoMat S62

51 Manual tasks and settings II. Setting the suction force (optional) 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 S62 to the position I. Note: The main switch is located on the right side of the circuit board plotter (if necessary, inside of the acoustic cabinet). The lighting of the milling/drilling head is on. 3. Close the the acoustic cabinet cover. Note: With opened cover the data communication to the computer is interrupted and the circuit board plotter can not be controlled by BoardMaster. [ ] The circuit board plotter is switched on. Operating Manual 7.1 Rev.:

52 Switching on the system IV. Starting BoardMaster 1. Double click on the BoardMaster symbol on the desktop. Make sure that you start the current BoardMaster version. or: Click on Start > Programs > LPKF Laser & Electronics > BoardMaster... Note: Make sure to start the BoardMaster version delivered with the ProtoMat S62 circuit board plotter. 2. If the window Connect... appears: Ensure the correct connection settings (see "Checking the connection settings (if necessary)" on page 51). CAUTION Machine damage caused by wrong operation. The milling/drilling head, tool magazine and tools can collide and become damaged if a wrong position is given. Make sure that the tool positions activated in the dialog window correspond to those specified in the circuit board plotter. Fig. 18: Dialog box Tool status 3. If there is already a tool in the circuit board plotter: Enter the corresponding position in the box Where is the tool?. Enter the number of any free tool position in the field Enter the free tool position:. 50 ProtoMat S62

53 Manual tasks and settings 4. If there is no tool in the circuit board plotter: Deactivate all entries. Enter the value 0 in the field Enter the free tool position:. 5. Click on OK. [ ] The ProtoMat S62 is ready for operation. V. Checking the connection settings (if necessary) If the circuit board plotter is not recognised automatically, the input window Connect... appears. If necessary, you have to change the connection settings. Fig. 19: Input window Connect Make sure that the circuit board plotter is switched on and that the milling/drilling head lighting is on. Operating Manual 7.1 Rev.:

54 Switching off the system 2. Make sure that the following values are entered: Control: SMCU 2 Machine: ProtoMat S62 Interface type: RS-232 (USB is only intended for service purposes) COM Port: COM port to which the circuit board plotter is connected and which was defined in the Windows system control. Baud rate: Check the settings of the Windows system control (see ProtoMat S62 Installation Manual) 4. Click on Connect... As soon as the connection to the circuit board plotter can be established, the BoardMaster user interface appears. 5. If the Connect... window opens repeatedly: Check the settings in the Windows system configuration (see "Configuring the COM port" on page 29) Note: If you click on Cancel BoardMaster will be opened, but the circuit board plotter cannot be activated. [ ] The BoardMaster user interface will be opened (see figure 20 on page 54). 4.2 Switching off the system To switch off the ProtoMat S62, quit the BoardMaster first and then switch off the circuit board plotter and the computer. I. Quitting BoardMaster 1. Click on File > Exit. The message "Do you want to move the milling/drilling head to the reference point?" appears. 52 ProtoMat S62

55 Manual tasks and settings 2. Click on Yes. The milling/drilling head and the working table will move to the Zero position. Note: If you click on No, the Zero position must be reinitialized at the next start, which is time-consuming. [ ] Now you can switch off the circuit board plotter and, if necessary, the dust extraction. II. Switching off the circuit board plotter 1. Switch the main switch on the circuit board plotter (in the acoustic cabinet) to the position 0. The lighting of the milling/drilling head goes out. [ ] Now you can switch off the dust extraction and shut down the computer. III. Switching off the LPKF dust extraction The LPKF dust extraction must be switched off manually only if it is used in continuous operating mode. During the automatic operating mode it is switched off automatically together with the circuit board plotter. If your ProtoMat S62 is equipped with another dust extraction, familiarise yourself with the relevant operation information. 1. Set the main switch of the LPKF dust extraction to the position OFF (centre position). or: Set the main switch of the LPKF dust extraction to the position Connection to LPKF ProtoMat, to use the dust extraction after the next start ProtoMat S62 in the automatic operating mode. [ ] The LPKF dust extraction is switched off. Operating Manual 7.1 Rev.:

56 Finding out about BoardMaster 4.3 Finding out about BoardMaster The ProtoMat S62 is controlled by means of the LPKF Software BoardMaster. In the following the user interface and the most important selection and control elements will be explained The user interface Fig. 20: BoardMaster user interface Title bar 2 Main menu 3 Function bar 4 Tool holder/magazine 5 Current position of the milling/drilling head 6 Mirror axis 7 Mouse pointer co-ordinates 8 Status bar 9 Mouse pointer 10 Camera image application window (VisionSystem option only) 54 ProtoMat S62

57 Manual tasks and settings Title bar Main menu Function bar Tool holder/magazine Current position of the milling/drilling head Mirror axis Mouse pointer co-ordinates Status bar Camera image application window (optional) The title bar shows the program name, the circuit board plotter used as well as the name of any loaded or newly created job. The menu bar lists all available menus. The function bar shows the functions used for manual control of the circuit board plotter and for starting automatic machining processes. The tool magazine indicates the individual tool holders. If the tools have been defined in the tool holders, each tool type is indicated in colour. The blue cross-hair shows the current position of the milling/drilling head. Mirror axis of the work area. The base material should be positioned in the centre of the mirror axis. The current X and Y co-ordinates of the mouse pointer referenced to the HOME position. The status bar provides information about the functions of buttons, displays or areas where the cursor is currently located. The Camera image application window will only appear if the VisionSystem has been installed. The window displays the area monitored by the camera. Please note that this area does not correspond to the current position of the milling/drilling spindle. Note: Detailed information about the functions of the individual operating elements can be found in the BoardMaster manual. Operating Manual 7.1 Rev.:

58 Finding out about BoardMaster Frequently used functions Frequently used functions can be called from the function bar. Designation Tool selection list Function, note Picking up/setting down the desired tool Only the tools set up in the tool magazine dialogue box (Tool positions window) are displayed. Phase selection list Select the production phase The phases required for the selected production type are displayed in the order of processing. The current phase is preselected. Rotation speed Set the motor speed for the selected tool (the default setting depends on the tool). Milling speed Phase configuration Toolbox dialog Set the feed rate for the selected tool when milling (the default setting depends on the tool). Open the Phases window. Configure the phases (phase sequence, data display colours, 2.5 D mode). Open the Tool positions window. Define the tool positions in the tool magazine. Motor on Lift head Vacuum on/off Motor off Lower head Starts the milling/drilling spindle. Stops the milling/drilling spindle. Lifts the milling/drilling head. Lowers the milling/drilling head. Switches the dust extraction on/off. Move by mouse Move the milling/drilling head with the mouse. Move to pause Move the milling/drilling head to the pause position. Move to home Move the milling/drilling head to the home position. 56 ProtoMat S62

59 Manual tasks and settings Designation Move to zero Function, note Move the milling/drilling head to the zero position. Move to y+ Move to x- Move to x+ Move to y- Move to z+ Move to z- Move the milling/drilling head horizontally. Enter the increment in mm in the input box. Move the milling/drilling head vertically. Enter the increment in mm in the input box. Start/Stop Start/stop the current production phase. Add lines Add all (line) segments connected with the selection area. Add segments Add all (line) segments within the selection area. + Activate selected elements for production. - Deactivate selected elements All+ Activate all elements for the current production phase All- Cancel the activation of all elements Operating Manual 7.1 Rev.:

60 Positioning the milling/drilling head Designation Move project Function, note Move a project on the work area with the mouse. Copy project SetFocus Focus Use 2.5 D Copy a project and position the copy on the work area with the mouse. Save the vertical position of the milling/drilling head as the focus position. Move the milling/drilling head vertically to the saved focus position. A check mark appears to indicate that 2.5 D mode has been activated (as a status display only; the mode must be activated in the Phases window). When entering numerical values, decimal places must be separated by a point (not a comma). 4.4 Positioning the milling/drilling head The milling/drilling head can be positioned at will above the traversing table. Thereby also the traversing table will be moved. The co-ordination of both traversing directions is controlled by BoardMaster. In the following, this procedure will be denoted as "moving the milling/drilling head". 58 ProtoMat S62

61 Manual tasks and settings Moving the milling/drilling head to a predefined position To load the circuit board plotter, create a pass hole system or set up the co-ordinate system, the milling/drilling head can be moved to defined positions above the traversing table. 1. Click on one of the following buttons to move the milling/drilling head to a predefined position. The following positions are possible: Move to pause Pause position: The milling/drilling head moves to the right, the traversing table moves forward. Use: Loading the circuit board plotter Move to home Home position: The milling/drilling head moves to the mirror axis above the left pass hole pin; the traversing table moves to the central area. Use: Creating a pass hole system. Move to zero Zero position: The milling/drilling head moves to the left, the traversing table moves backwards. Use: Reference point in BoardMaster, definition of co-ordinate system [ ] The milling/drilling head and the traversing table are moved automatically to the selected position. Operating Manual 7.1 Rev.:

62 Positioning the milling/drilling head Moving the milling/drilling head step by step in the X/Y direction x- y+ y- x+ 1. Enter the desired increment in mm in the input box between the arrow buttons (Move to x/y). 2. Click on the button for the desired direction. The milling/drilling head or the traversing table is moved by the entered value in the following direction. Move to x- Move to x+ Move to y+ Move to y- The milling/drilling head moves to the left. The milling/drilling head moves to the right. The work table moves forwards. The work table moves backwards. Note: If the message "Outside the adjustment range" appears, the desired value is too large. Click on Yes to move the milling/drilling head to the edge of the traversing range. [] Moving the milling/drilling head with the mouse 1. Click on the Move by mouse button. 2. In the work area, click on the desired position for the milling/drilling head. [] The milling/drilling head moves to the desired position. or: Press and hold down the left mouse button and drag the milling/drilling head across the traversing range. The milling/drilling head will follow the movements of the mouse. Note: You need to reactivate the Move by mouse button every time you wish to move the milling/drilling head with the mouse. 60 ProtoMat S62

63 Manual tasks and settings Moving the milling/drilling head vertically 1. Enter the desired increment in mm in the input box between the buttons Move to z+/z-. 2. Click on the button for the desired direction. Note: If the message "Outside the adjustment range" appears, the desired value is too large. Click on Yes to lift or lower the milling/drilling head up to the maximum value. [ ] The milling/drilling head will be lifted/lowered by the desired value. Operating Manual 7.1 Rev.:

64 Mounting/Dismounting the milling depth limiter base 4.5 Mounting/Dismounting the milling depth limiter base In order to ensure that milling will always be performed at the exact working depth, you need to mount the milling depth limiter's plastic base included in the scope of delivery or the brush head which is available to purchase as an accessory. You should only dismount/replace the base/brush head for special tasks such as drilling pass holes, cleaning and maintenance. Dismounting the plastic base/brush head Fig. 21: Removing the plastic base from the milling depth limiter 1. If it is not already there, move the milling/drilling head to the zero position for easier access to the base/brush head. 2. Carefully squeeze the plastic base/brush head and pull it down and out of the milling/drilling head Squeeze the plastic base/brush head 2 Pull the plastic base/brush head down and out [ ] The plastic base/brush head is dismounted. 62 ProtoMat S62

65 Manual tasks and settings Mounting the plastic base/brush head 1. Take a firm hold of the milling/drilling head at the top to prevent it lifting in the following and push the plastic base/brush head into the milling depth limiter from below. Fig. 22: Fitting the plastic base on the milling depth limiter Milling depth limiter 2 Plastic base 2. Rotate the base until the opening is oriented to the front. [ ] The plastic base/brush head is smounted. Operating Manual 7.1 Rev.:

66 Loading 4.6 Loading To avoid material damage, the circuit board plotter must only be loaded in the pause position. WARNING Health hazard! The swarf and dust generated during material processing can cause eye injuries and allergies. Extract the swarf and dust or remove them with a brush or moistened cloth. N EVER blow compressed air through the acoustic cabinet Loading and setting up the base material The circuit board plotter has been designed for the use of base materials with pass holes. We recommend the use of pre-drilled base materials at all times. If your base material has no pass holes, you must drill them first (see chapter "Drilling pass holes into the drilling underlay", on page 80). Loading base material 1. Click on the Move to pause button in order to load the traversing table. 2. Remove any material swarf from the traversing table with a soft brush or a moistened cloth. 3. Set the drilling underlay down on the traversing table so that the pass hole pins slot into the pass holes. 4. Set the base material down on the drilling underlay with the side to be processed facing up so that the pass hole pins slot into the pass holes. 5. Make sure that the pass hole pins do not protrude out of the base material. 6. Using a non-residue adhesive tape, stick the edges of the base material to the drilling underlay. [ ] Now you can set up the work area. 64 ProtoMat S62

67 Manual tasks and settings Setting up the work area To get optimum use of the base material, you first need to define the work area. Thereby the milling depth limiter's plastic base must be located entirely above the base material. Accordingly, when setting up the work area, you must make sure that the milling/drilling head is positioned over the base material with at least 12 mm clearance to the edges of the material to be processed. Make absolutely sure to set the co-ordinates in the order specified (starting with the front left-hand corner - then the rear right-hand corner). Defining the work area 1. Click on the Move by mouse button. 2. Drag the mouse pointer with the left mouse button pressed to the front left-hand corner of the desired work area. The milling/drilling head will move immediately and can be positioned directly with the mouse. Note: If you release the mouse button before completing the positioning task, you will need to click on the Move by mouse button again before resuming. 3. Make sure that the milling/drilling head is in the correct position with the milling depth limiter's plastic base located entirely above the base material. The pass hole pins must not be located in the work area. 4. In the BoardMaster menu bar, click on Configuration > Material > Set Low Corner. The co-ordinates for the front left-hand corner of the work area are read in. 5. Click on the Move by mouse button. 6. Drag the mouse pointer with the left mouse button pressed to the rear right-hand corner of the desired work area. The milling/drilling head will be positioned following the movement of the mouse. 7. Make sure that the milling/drilling head is in the correct position with the milling depth limiter's plastic base located entirely above the base material. 8. In the BoardMaster menu bar, click on Configuration > Material > Set High Corner. The co-ordinates for the rear right-hand corner are read in and the base material is displayed in dark grey in BoardMaster. Operating Manual 7.1 Rev.:

68 Loading Defining the material height and z values BoardMaster is factory-set with the following z values: Material thickness: drilling underlay: Moving free height: 1.60 mm 2 mm 2 mm If you wish to use a thinner/thicker material or a different drilling underlay, you will need to modify the values accordingly. The moving-free height defines the distance between milling/drilling head and material. Defining the material height and z values 1. In the BoardMaster menu bar, click on Configuration > Material > Size... The Define material size and position window is opened. Fig. 23: Defining the material size and position The x and y values show the co-ordinates you have defined and the size of the work area. 2. Enter the thickness of the material to be processed in mm in the Material thickness [mm] input box. 3. Enter the thickness of the drilling underlay used in mm in the Underlay [mm] input box. 4. Click on OK. [ ] The work area is readily set up. 66 ProtoMat S62

69 Manual tasks and settings Setting up tools Before you load the tool magazine, you need to define a unique position for each tool in it. I. Opening the tool magazine dialogue box 1. Click on the button for the Toolbox dialog. 2. Click on Yes to move the milling/drilling head to the pause position. The Tool Positions input window opens. Fig. 24: Tool positions input window 1 2 _ 1 Position in the tool magazine 2 Tool selection lists The tool magazine can hold up to ten tools. The positions specified on the left of the input window under Pos. correspond to the arrangement of the tool holders from left (position 1) to right (position 10) in the tool magazine. Operating Manual 7.1 Rev.:

70 Loading You can select one tool in each of the tool selection lists under Tool (2). Each selection list contains all available tools. Note: The most recently selected tools always appear as the default selections. If you have already loaded a job, the required tools will be marked * or + in the selection lists. II. Assigning tool positions 1. In the selction list Tool for Pos. 1 select one of the required tools (e.g. the Universal Cutter 0.2 mm marking) for centre-punching the drill holes). Fig. 25: Assigning tool positions 2. If you want to use a new or unused tool: Activate the checkbox in the New column. 3. Select the other tools you need from the following selection lists. Once you have assigned a tool position for each of the required tools, the input window could look like this: 68 ProtoMat S62

71 Manual tasks and settings Fig. 26: Defined tool positions Note: The order of the tool positions can be selected at will. During operation, the tools are taken out of the correct tool holder automatically. [ ] Once set up, the tools are displayed in the tool selection list on the function bar. Operating Manual 7.1 Rev.:

72 Selecting a tool for processing Inserting tools WARNING Risk of injury! The tools to be used are very sharp edged and can cause cuts and stab injuries. Handle tools carefully and keep them in the toolbox when not in use. CAUTION Material damage due to incorrect loading! If you insert the tools into other positions than those defined by BoardMaster, the milling/drilling head and spindle and the tools can become damaged. Insert the tools only into the tool holder (positions) defined in BoardMaster. Inserting tools 1. With the tip pointing downwards, push the desired tools as far as they will go into the tool holders defined in the Tool positions window (Pos.). Note: Position 1 is on the left-hand side of the tool magazine, position 10 is on the right. 2. Close the acoustic cabinet cover. 3. Click on OK. 4.7 Selecting a tool for processing To create a bore or milling track, you need to have set up the desired tool and inserted it into the correct position in the tool magazine. The tools currently set up are displayed in the tool selection list. The number in front of the tool name corresponds to the position in the tool magazine. 70 ProtoMat S62

73 Manual tasks and settings Picking up/setting down a tool 1. Select the desired tool in the tool selection list. If there is still a tool in the milling/drilling head, it will be set down first. The desired tool is then taken up and the milling/drilling head pauses above the tool holder. 2. To set down a tool loaded in the milling/drilling head without taking up a new one: Select the QuickLoad entry in the tool selection list. [] The tool is set down in the defined tool holder. 4.8 Setting the focus (VisionSystem only) The focus is determined by the height position of the milling/drilling head. This z value can be saved as a focus position. If the milling/drilling head has moved vertically in the interim period, you can quickly reset the focus position and accordingly the focus to the original value. Setting the focus to the saved value 1. On the function bar, click on Focus. 2. If the camera image is not focussed, reset the focus position (see "Adjusting the focus position"). [] Operating Manual 7.1 Rev.:

74 Setting the focus (VisionSystem only) Adjusting the focus position To set the focus position, the material to be used must be loaded. 1. Move the milling/drilling head so that the camera is positioned above an as high-contrast area as possible, e.g. a bore, or at the edge of a milling. You might need to place a thin printed sheet of paper on the material to be processed to serve as a contrast background. 2. Use the arrow buttons (Move to z+/z-) to move the milling/drilling head vertically and focus the camera image. For fine-tuning, enter a value of 0.05 or less in the input box between the arrow buttons. The camera image is focussed. 3. On the function bar, click on SetFocus. The "Set current focus position?" window appears. Fig. 27: Adjusting the focus position 4. Click on Yes. [ ] The vertical position of the milling/drilling head is saved as the focus position. 72 ProtoMat S62

75 Manual tasks and settings 4.9 Drilling WARNING Health hazard! The processing of the materials can give rise to dusts and gases hazardous to your health. You must switch on the dust extraction before processing materials of any type. Extract the dust and material residues or remove them with a brush or moistened cloth; DO NOT blow them out. For manual processing, the desired tool must be set up in BoardMaster (Tool Positions window) and loaded in the corresponding tool holder (see chapter "Setting up tools", on page 67). The available tools can be used to drill round holes up to 3 mm in diameter. You will need to use the Contour Router milling tool (suitable for use for diameters 2.4 mm or larger) if you wish to drill larger holes/slots (see "Milling" on page 61). Drilling a hole 1. Select the desired drill in the tool selection list. 2. Move the milling/drilling head above the desired drilling position with the mouse or the Move to x/y buttons. 3. Click on the Motor on button. The milling/drilling spindle and the dust extraction (automatic mode only) werden gestartet. 4. Click on the Lower head button. Once the hole has been drilled, the milling/drilling head will be lifted automatically. Operating Manual 7.1 Rev.:

76 Milling 5. Move the milling/drilling head as necessary to drill more holes with the same drill. or: Click on the Motor off button. [ ] The milling/drilling spindle and the dust extraction (automatic mode only) are switched off Milling WARNING Health hazard! The processing of the materials can give rise to dusts and gases hazardous to your health. You must switch on the dust extraction before processing materials. Extract the dust and material residues or remove them with a brush or moistened cloth; do NOT blow compressed air through. Please note that milling results are dependent upon tool penetration depth. Insufficient material removal between the later conductor tracks can cause the circuit board to malfunction. In the case of the Universal Cutter and Micro Cutter conical mills, milling width is determined by penetration depth. Always carry out a test milling on the base material to be used and check the milling depth with a microscope to confirm sufficient material removal. In order to ensure the desired milling width when using the Universal Cutter or Micro Cutter mills, you should check this with a measuring microscope. Correct the milling depth if necessary before continuing work (see chapter "Adjusting the milling depth/width", on page 76). 74 ProtoMat S62

77 Manual tasks and settings Creating a milling track 1. Select the desired mill in the tool selection list. The mill is taken out of the tool magazine and the milling/drilling head pauses above the tool holder. 2. Move the milling/drilling head with the mouse or the Move to x/y buttons to the starting point of the desired milling track. 3. Click on the Motor on button. The milling/drilling spindle and the dust extraction (automatic mode only) will be started. 4. Click on the Lower head button. The milling/drilling head is lowered onto the base material. 5. Move the milling/drilling head with the mouse or the Move to x/y buttons in the desired direction and distance. The milling track is created. 6. Click on the Lift head button. The milling/drilling head is lifted slightly. 7. If necessary create further milling tracks as with the same tool. or: Click on the Motor off button. [ ] The milling/drilling head is lifted slightly; the spindle and dust extraction (automatic mode only) are switched off. Operating Manual 7.1 Rev.:

78 Milling Adjusting the milling depth/width By means ofthe milling/drilling depth limiter the surface removal can be set exactly to the desired rate. For conical formed mills (Universal Cutter, Micro Cutter), the milling width has to be set using the milling depth limiter. Adjusting the milling depth (cylindrical tools) + _ 1. Turn the adjusting wheel on the milling/drilling head to the left to increase the milling depth. 2. Turn the adjusting wheel on the milling/drilling head to the right to reduce the milling depth. Note: The milling depth can be set in increments of 2 µm. 3. Perform a milling test run. 4. Check the result with a magnifying glass. 5. Repeat the process until sufficient material is removed. [ ] The milling depth has been set correctly. Adjusting the milling width (Universal Cutter and Micro Cutter only) + 1. Turn the adjusting wheel on the milling/drilling head to the left to mill a wider track. 2. Turn the adjusting wheel on the milling/drilling head to the right to mill a narrower track. Note: On the Universal Cutter, the milling width can be set in 4 µm increments; on the Micro Cutter it can be set in 2.3 µm increments. 3. Perform a milling test run and check the width with a measuring microscope. 4. Repeat the process until the milling track has the desired width. [ ] The milling width corresponds to the desired setting. 76 ProtoMat S62

79 Manual tasks and settings 4.11 Creating a pass hole system (basic equipment) The ProtoMat S62 traversing table is factory-set with a pass hole system for standard material sizes (9" x 12"). If, after a period of time, the pass hole pins are not seated free of play anymore, you will need to create a new pass hole system. You will also need to do this if you wish to process materials of smaller dimensions. Required tool and accessories To create the pass hole system in the traversing table, you will need the following tool and accessories: Spiral Drill Ref mm for pass holes in the plastic strips on the traversing table. Spiral Drill.3.0 mm: for pass holes in the drilling underlay and in the base material Pass hole pins 3 mm x 8 mm Press-in tool for pass hole pins Combined collet for removing existing pass hole pins You must remember that the procedures for drilling pass holes in the traversing table (see "Preparation" on page 65) differ from those for the vacuum table (see "Creating a pass hole system (vacuum table)" on page 69). Conditions The following information assumes that the Spiral Drill Ref 2.95 mm and Spiral Drill.3.0 mm tools have been set up in BoardMaster and loaded in the tool magazine accordingly. (see chapter "Setting up tools", on page 67) To drill pass holes into the plastic strips on the traversing table, proceed as follows: I. Preparing the circuit board plotter 1. Dismount the plastic base/brush head from the milling depth limiter (see "Dismounting the plastic base/brush head" on page 62). 2. Click on the Move to pause button in order to move the traversing table to the loading position. Operating Manual 7.1 Rev.:

80 Creating a pass hole system (basic equipment) 3. Preparing the traversing table: Remove the drilling underlay from the traversing table. Pull the pass hole pins out of the red plastic strips using a collet. Move the plastic strips in the guide groove so that the new pass holes can be positioned as appropriate for the size of your material. If no more pass holes will fit in the plastic strips: Lift the strips out of the guide groove and insert a new pair. Note: The pass holes should be positioned at least 5 mm from the edge of the base material. Now you can drill the pass holes. II. Drilling pass holes into pass hole strips Fig. 28: Selecting pass hole drills for pass hole strips 1. In the tool selection list select the Spiral Drill Ref 2.95 mm entry. 2. Click on the Move to home button. 3. Click on the Motor on button. 4. Click on the Lower head button. A prompt asking if you wish to drill a pass hole will appear. Fig. 29: BoardMaster message "Drill pass hole?" 5. Click on Yes. 78 ProtoMat S62

81 Manual tasks and settings Fig. 30: BoardMaster message "Depth limiter removed" 6. Check that the plastic base has been removed from the milling depth limiter and click on Yes. The pass hole will be drilled. 7. Using the arrow keys, move the milling/drilling head in the X direction so that it is located in the desired position above the right-hand pass hole strip. Take care not to move the milling/drilling head in the Y direction, otherweise the pass hole will not be positioned exactly on the mirror axis. 8. Make a note of the x value. Note: LPKF base materials have a pass hole clearance of 295 mm. 9. Click on the Lower head button to drill the pass hole. 10. Click on the Motor off button. 11. If nesssescary drill new pass holes into the drill underlay (see "Drilling pass holes into the drilling underlay"). [ ] Now you can insert the pass hole pins into the pass hole strips and remount the plastic base on the milling depth limiter. Operating Manual 7.1 Rev.:

82 Creating a pass hole system (basic equipment) Drilling pass holes into the drilling underlay Fig. 31: Selecting pass hole drills for base material/drilling underlay To drill pass holes into the drilling underlay, the Spiral Drill 3.0 mm must be set up and positioned accordingly in the tool magazine. 1. Mount the plastic base on the milling depth limiter (see "Mounting the plastic base/brush head" on page 63). 2. Click on the Move to pause button. 3. Pull any existing pass hole pins out of the plastic strips in the traversing table using flat nose pliers. 4. Place the base material/drilling underlay in the Y direction as centrally as possible on the traversing tables mirror axis. 5. On the function bar, click on the tool selection list and select the entry 2. Spiral Drill 3.0 mm. 6. Click on the Move to home button. 7. Click on the Motor on button. 8. Click on the Lower head button. The pass hole is drilled. 9. Use the Move to x+ button to move the milling/drilling head to the desired position. Take care not to move the milling/drilling head in the Y direction. 10. Make a note of the x value. 80 ProtoMat S62

83 Manual tasks and settings 11. Click on the Lower head button to drill the pass hole. 12. Click on the Motor off button. [ ] To complete the pass hole system, you simply need to insert the pass hole pins (see chapter 4.13 "Inserting pass hole pins", on page 88) and mount the plastic base on the milling depth limiter(see "Mounting the plastic base/brush head") Creating a pass hole system for the vacuum table The scope of delivery of the vacuum table does not include a pass hole system. To create the pass hole system, you will need the following tool and accessories: Required tool and accessories Spiral Drill Ref mm To drill the pass holes into the plastic strips and the vacuum table's sinter plate Spiral Drill.3.0 mm: To drill the pass holes into the base material (optional) Pass hole pins 3 mm x 10 mm Press-in tool for pass hole pins The following information assumes that the Spiral Drill Ref 2.95 mm and Spiral Drill.3.0 mmtools have been set up in BoardMaster and loaded in the tool magazine accordingly (see chapter "Setting up tools", on page 67). Operating Manual 7.1 Rev.:

84 Creating a pass hole system for the vacuum table Preparing the circuit board plotter and vacuum table Before you can drill the pass holes, you need to prepare the circuit board plotter: 1. Carefully squeeze the milling depth limiter's plastic base and pull it down and out of the milling/drilling head. If it is not already there, move the milling/drilling head to the zero position for easier access to the base. 2. Click on the Move to pause button in order to move the traversing table to the loading position. 3. Remove the sinter plate from the vacuum table. 4. Check that the red pass hole strips are in place in the vacuum table. Fig. 32: Pass hole strips in the vacuum table 1 1 Pass hole strips in the vacuum table 5. If you are replacing an existing pass hole system: Use a collet to pull the pass hole pins out of the red plastic strips. Move the plastic strips in the guide groove so that the new pass holes can be positioned as appropriate for the size of your material. If no more pass holes will fit in the plastic strips: Lift the strips out of the guide groove and insert a new pair. [] Note: The pass holes should be positioned at least 5 mm from the edge of the base material. 82 ProtoMat S62

85 Manual tasks and settings Drilling pass holes into pass hole strips I. Setting parameters for drilling pass holes 1. Select the Spiral Drill Ref mm drill from the Tool selection list. 2. Click on the Tool Lbrary button. The Mill/Drill Tool Edit window is opens. Fig. 33: Setting parameters for drilling pass holes 3. Make sure that in the fr4-60.tol selection list the Spiral Drill 2.95 mm pass hole drill is selected. 4. In the Optimal speed field, set the value for Z-Speed [mm/s] to Click on OK. [ ] Next you need to set the machine parameters. Operating Manual 7.1 Rev.:

86 Creating a pass hole system for the vacuum table II. Setting the machine parameters for drilling pass hole strips 1. In the main menu, click on Configuration > Settings.... The Machine settings window opens. 2. Click on Unlock. 3. Enter the value 11 in the Vacuum table height [mm] input box. 4. Click on OK. [ ] Now you can drill the pass holes. III. Drilling pass holes into pass hole strips Fig. 34: Selecting pass hole drills for pass hole strips 1. On the function bar, click on the tool selection list and select the entry 2. Spiral Drill Ref 2.95 mm. 2. On the menu bar, click on the Move to home button. The milling/drilling head moves to the HOME position. 3. On the function bar, click on the Motor on button. The milling/drilling spindle and the dust extraction start up. 4. If the dust extraction does not start, click on the Vacuum on/off button on the function bar. 5. On the function bar, click on the Lower head button. The prompt Drilling a reference hole? appears. 84 ProtoMat S62

87 Manual tasks and settings Fig. 35: BoardMaster message "Drill pass hole?" 6. Click on Yes. A prompt asking if the depth limiter has been removed appears. Fig. 36: BoardMaster message "Depth limiter removed" 7. Check that the plastic base has been removed from the milling depth limiter and click on Yes. The pass hole will be drilled. 8. Move the milling/drilling head using the Move to x+ button, so that it is located in the desired position above the right-hand pass hole strip. Take care not to move the milling/drilling head in the Y direction, otherwise the pass hole will not be positioned exactly on the mirror axis. 9. Make a note of the x value used. 10. On the function bar, click on the Lower head button. 11. Confirm the prompts with Yes. The pass hole will be drilled. 12. On the function bar, click on the Motor off button. 13. On the menu bar, click on the Move to pause button. 14. Remove dust and swarf with a brush. 15. Place the sinter plate on the vacuum table. [ ] Now you can drill the pass holes into the sinter plate. Operating Manual 7.1 Rev.:

88 For your notes Drilling pass holes into the sinter plate Before drilling pass holes into the sinter plate, the machine parameters have to be adjusted. I. Adjusting machine parameters 1. Put the the sinter plate on to the vaccum table. 2. On the menu bar, select Configuration > Settings.... The Machine settings window opens. Fig. 37: Machine parameters 3. Click on Unlock to allow the settings to be changed. 4. In the Vacuumtable height [mm] input box enter the value Click on OK. [] 86 ProtoMat S62

89 Manual tasks and settings II. Drilling pass holes into the sinter plate 1. On the function bar, click on the tool selection list and select the entry 2. Spiral Drill Ref 2.95 mm. Fig. 38: Selecting pass hole drills for pass hole strips 2. On the function bar, click on the Move to home button. 3. On the function bar, click on the Motor on button. The milling/drilling spindle and the dust extraction start up. 4. On the function bar, click on the Lower head button. 5. Confirm both prompts with Yes. The pass hole is drilled and the milling/drilling head is lifted automatically. 6. Using the Move to x+ button, move the milling/drilling head so that it is located in the desired position above the right-hand pass hole strip. Take care not to move the milling/drilling head in the Y direction (if you do this the pass hole will not be positioned in the centre of the mirror axis). 7. On the function bar, click on the Lower head button. 8. Confirm the prompts with Yes. The pass hole is drilled and the milling/drilling head is lifted automatically. 9. On the function bar, click on the Motor off button. Operating Manual 7.1 Rev.:

90 Inserting pass hole pins 10. If the dust extraction does not shut down automatically, click on the Vacuum off button on the function bar. 11. On the menu bar, click on the Move to pause button. The milling/drilling head moves to the pause position. 12. Remove any swarf with a brush. 13. Remove the sinter plate from the vacuum table. [ ] To complete the pass hole system, you simply need to insert the pass hole pins (see "Inserting pass hole pins") and mount the plastic base on the milling depth limiter(see "Mounting the plastic base/brush head" on page 63) Inserting pass hole pins Only use pass hole pins designed for your equipment configuration. Equipment Basic equipment: Vacuum table Pass hole pins 3 mm x 8 mm 3 mm x 10 mm Note: For inserting the pass hole pins into the vacuum table, the sinter plate has to be taken off. 88 ProtoMat S62

91 Manual tasks and settings Inserting pass hole pins 1. Insert a pass hole pin with the rounded end into the press-in tool (the bevelled end must stick out). Fig. 39: Press-in tool with pass hole pin 2. With the press-in tool press the pass hole pin as far as it will go into the desired bore of the pass hole strip. 3. Check the pass hole pin for a snug fit in the pass hole strip. 4. Repeat the procedure to fit the pass hole pin in the second pass hole strip. 5. Set the drilling underlay/sinter plate down on the traversing table/vacuum table so that the pass hole pins slot into the bores. 6. Check that the pass hole pins do not protrude from the drilling underlay/sinter plate any further than the thickness of the base material. You might need to press the pass hole pins further into the pass hole strip. 7. Mount the plastic base on the milling depth limiter before resuming work with the circuit board plotter (s. page 63). [] Operating Manual 7.1 Rev.:

92 Inserting pass hole pins 90 ProtoMat S62

93 Working sequence in automatic mode 5. Working sequence in automatic mode This chapter explains the fundamental working sequence for the semi-automatic production of single-layer and multi-layer printed circuit boards. It can vary depending on the production type and equipment of your ProtoMat S62 and your individual requirements. If you are working with the LPKF circuit board plotter for the first time, we recommend that you start by practising the procedures described with the example files included in the delivery. Knowledge of how to operate the circuit board plotter manually and the most important Board- Master functions is assumed (see chapter 4 "Manual tasks and settings", on page 47). 5.1 Preparation The following information assumes that the ProtoMat S62 is switched on, the material to be processed is fixed on the traversing/vacuum table and the work area has been set up in BoardMaster. (see chapter "Loading and setting up the base material", on page 64). 5.2 Defining the production type The ProtoMat S62 is factory-set for the production of single-sided or double-sided printed circuit boards with galvanic through-hole plating. The phase file 1-2layer.phs (<default>) is used for such applications. To create a different production type, you will need to select the corresponding phase file. Selecting a phase file 1. Click on File > New and select the phase file provided for the production type (see table 6). Operating Manual 7.1 Rev.:

94 Setting up a job Tab. 6: Production types and phase files Production type Single-sided/double-sided printed circuit boards (galvanic through-hole plating) Single-sided/double-sided printed circuit boards (galvanic through-hole plating with LPKF ProConduct) 4-layer multi-layer (galvanic through-hole plating) 4-layer multi-layer (galvanic through-hole plating with LPKF ProConduct) 6-layer multi-layer Solder stop foils Solder paste stencils Phase file 1-2layer.phs (<default>) 1-2layer + proconduct.phs 4-layer.phs 4-layer + proconduct.phs 6-layer.phs soldermask.phs stencilmilling.phs [ ] The required production phases are displayed in the phase selection (see Tab. 3 "Production phases" on page 40). 5.3 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. Note: The items listed below correspond to the standard production of a singlesided or double-sided printed circuit board with galvanic through-hole plating (1-2layer.phs). To set up a new job, you first need to import a project (LMD file). However, you can also open an existing job and add further projects to it. Information about the example files You can use the Tutor.LMD project to produce a double-sided practice printed circuit board. Fiducial.LMD contains information for drilling a fiducial (only needed if you are using the VisionSystem). 92 ProtoMat S62

95 Working sequence in automatic mode Creating a new job 1. Click on File > Import > LMD/LPR... The Import Project window will appear. 2. Select a project (*.LMD file). 3. Click on Open. The selected project will be placed in the centre of the work area. 4. Import other projects if you need them, for example fiducial bores for automatic fiducial recognition (only with the optional VisionSystem). The imported projects can be moved and copied on the work area. Opening an existing job If already a job is open, you first have to decide whether you wish to save any changes under a different name (see "Saving a job" on page 95). Once you have called the File > Open... menu item, an already opened job can only be overwritten or the changes discarded. 1. Click on File > Open... The Open window is displayed. 2. Double-click on the required *.job file. Select for example Tutor.job to open the production example included in the delivery. [ ] The projects contained in the job can be moved, copied or deleted on the work area. Operating Manual 7.1 Rev.:

96 Setting up a job Aligning/Distributing projects To make optimum use of the base material, you can align, distribute and duplicate projects individually. 1. On the function bar, click on the Move instance button to move a project on the work area. or: On the function bar, click on the Copy instance button to copy a project and move the copy on the work area. 2. Drag the project to be moved with the left mouse button pressed to the desired position on the work area. Make sure that the distance between the project and the edges of the base material is at least 12 mm. Fig. 40: Positioning a project 12 mm 12 mm [ ] The project will be positioned where the mouse button is released. Note: It is also possible to align a project exactly on reference points, rotate and scale it and define it as a multiple panel. To do this, use the Edit > Placement... menu item. 94 ProtoMat S62

97 Working sequence in automatic mode Saving a job If you have have set up an already existing job, you can save it under a different name or the current version can be overwritten. 1. To save the job under a new name: Click on File > Save as... The Save as window will open. 2. Enter a meaningful name for the job in the File name box. 3. Click on Save. [ ] The job will be saved under the desired name. 4. 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. 5.4 Setting up the tools BoardMaster assists you in setting up the tools by displaying the tools required for production in the Tool Positions window. Before loading the tool magazine, make sure that the milling/drilling head is in the pause position. Note: The entries listed below correspond to the standard production of a singlesided or double-sided printed circuit board with galvanic through-hole plating (1-2layer.phs). Operating Manual 7.1 Rev.:

98 Setting up the tools I. Opening the Tool Positions input window 1. Click on the Toolbox dialog button. 2. Click on Yes to move the milling/drilling head to the pause position. The Tool Positions input window opens. Fig. 41: Tool Positions input window Position in the tool magazine 2 Tool selection lists 3 Service life of the tools required for the current phase 4 Tools required for the duration of production The tool magazine can hold up to 10 tools. The positions specified on the left of the dialogue box under Pos. correspond to the arrangement of the tool holders from left (position 1) to right (position 10) in the tool magazine. You can select one tool for each of the corresponding positions in the tool magazine in the tool selection lists under Tool. Each selection list contains all available tools. 96 ProtoMat S62

99 Working sequence in automatic mode The tools required for the job are displayed in the Wanted for current job (phase) box. The preceding numbers designate the tools required for the current phase (displayed on the function bar). The numerical value indicates the service life required for the job in mm (milling cutter) or the number of bores (drill). II. Configuring tools in the tool magazine 1. Select one of the required tools for each position (Pos.) from the Tool selection list. Fig. 42: Assigning tool positions Note: The tools required for the currently selected production phase are marked with an *; the tools required for other production phases are marked with a +. Once you have assigned a tool position to each of the required tools, the input window could look like this: Fig. 43: Defined tool positions Operating Manual 7.1 Rev.:

100 Setting up the tools Note: The order of the tool positions can be selected at will. During operation, the tools are taken out of the correct tool holder automatically. 2. To adjust the manual milling depth setting after each tool change during a production phase: Activate the Stop at tool exchange checkbox. [ ] Initially, keep the window open to insert the tools into the tool magazine according to your settings. III. Inserting tools WARNING Risk of injury! The tools to be used are very sharp edged and can cause cuts and stab injuries. Handle tools carefully and keep them in the toolbox when not in use. CAUTION Material damage due to incorrect loading! If you insert the tools into other positions than those defined by BoardMaster, the milling/drilling head and spindle and the tools can become damaged. Insert the tools only into the tool holder (positions) defined by BoardMaster. 1. With the tip pointing downwards, push the required tools as far as they will go into the tool holders (positions) defined in the Tool Positions window. Note: Position 1 is on the left-hand side of the tool magazine, position 10 is on the right. 2. Close the acoustic cabinet cover. 3. Click on OK. [ ] The tools defined in the Tool Positions input window are displayed in the tool selection list on the function bar. 98 ProtoMat S62

101 Working sequence in automatic mode 5.5 Selecting/Setting up a production phase Each production phase has to be selected and, if necessary, set up manually. BoardMaster assists you in selecting the next production phase and provides information on required manual operating steps. We recommend absolute compliance with the specified order, since some productions phase follow on one from the other while sonme previous phases may not be processed later on. In the phase selection always the current/most recently completed production phase of the job is selected by default. When a production phase with the activated data/selected tools is completed, the next production phase must be selected first. Selecting the production phase 1. Click on the phase selection list on the function bar. 2. Select the desired production phase. [ ] The selected production phase will be loaded Selecting tools (optional) Normally, all tools required within a production phase are used in succession (default setting). This avoids time-consuming tool changes. You can also limit a production phase to the use of one or more tools, for example to rework areas where not enough material has been removed or to drill only holes with selected diameter. Operating Manual 7.1 Rev.:

102 Selecting/Setting up a production phase Selecting tools 1. Click on Edit > Tool Selection... The Select Tools window will be opened. Fig. 44: Selecting tools 2. In the Sel. column, click on the check box to activate or deactivate a tool. Once activated, a tool is identified by a check mark in the check box. 3. Click on OK. The production phase will be executed with the activated tools only. 100 ProtoMat S62

103 Working sequence in automatic mode Activating data During a production phase, only activated data elements will be produced. You can activate data elements in the following ways: All data Areas of data elements including all associated segments With the data segments located in the selection area only Data segments by index number Note: BoardMaster assists you in selecting and activating/deactivating the desired data by colour-coding it. Activating all data 1. Click on All+ to activate all data. [ ] All data is highlighted in colour and is activated for production. Activating areas of data elements 1. To activate data elements within an area including all associated segments: Click on the Add lines button. Draw up the desired area with the left mouse button pressed. Click on the + button. All data segments within the selected area and all associated segments are activated. 2. To activate all data segments within an area only: Click on the Add segments button. Draw up the desired area with the left mouse button pressed. Click on the + button. All data segments within the selected area are activated. Note: Repeat one of the procedures to activate further data ranges. Operating Manual 7.1 Rev.:

104 Selecting/Setting up a production phase Activating data segments by index number 1. To activate one individual data segment: Enter the number of the desired data segment into the Segment number input field. Click on the [] button. Click on the + button. The selected data segment is activated for production. 2. To activate a range of sequential data segments: Enter the number of the first data segment into the Segment number input field. Click on the [] button. Select the number of the last data segment using the arrow buttons. Click on the + button. [ ] The selected range of data segments is activated for production. Deactivating data Deactivating all data 1. Click on All-. [ ] No more data is activated. Deactivating data areas 1. To deactivate all data segments within an area including all associated segments: Click on the Add lines button. With the left mouse button pressed draw up the area to be deactivated. 102 ProtoMat S62

105 Working sequence in automatic mode Click on the - button. All data segments inside the selected area including all associated segements are deactivated. 2. To deactivate the data segments within an area only: Click on the Add segments button. With the left mouse button pressed draw up the area to be deactivated. Click on the - button. [ ] All segments in the selected area are deactivated. 5.6 Setting up 2.5 D processing (optional) Conditions: The plastic base of the milling depth limiter is replaced with the LPKF brush head, which is available as an accessory (see chapter 4.5 "Mounting/Dismounting the milling depth limiter base", on page 62). For surface processing the vacuum table (option) must be installed. The option Stop for depth adjustment in the Tool Positions window is activated. Consider the different approaches of 2.5 D-processing according to the working aim and equipment of the circuit board plotter. Operating Manual 7.1 Rev.:

106 Setting up 2.5 D processing (optional) Setting up contour milling with 2.5 D mode I. Activating the 2.5 D mode for a phase 1. On the function bar, click on the Phase configuration button. The Phases window appears. Fig. 45: Activating the 2.5 D mode in the phases dialogue box 2. Select the desired production phase, for example MillingBottom, from the selection list. Note: The currently active phase is NOT preselected. The selected phase is displayed above the selection list. 3. Activate the Use 2.5 D mode checkbox. 4. Click on OK. [ ] The selected production phase will be processed using the 2.5 D modus. 104 ProtoMat S62

107 Working sequence in automatic mode II. Setting the moving-free height 1. In the main menu, click on Configuration > Material > Size... The Define material size and position window opens. Fig. 46: Setting the movingfree height 2. In the Free drive level [mm]: input box, enter a slightly higher value than the material thickness. 3. Move the milling/drilling head manually as close as possible to the contour to be milled. 4. Make sure that the lowered milling/drilling head just touches the material surface. [ ] As soon as the production phase starts, the 2.5 D mode window will be opened Setting up surface milling with 2.5 D mode To process surfaces in 2.5 D mode, you need the vacuum table. For detailed information about the specific workflow, please contact the LPKF Support. Operating Manual 7.1 Rev.:

108 Starting production 5.7 Starting production In the Phase selection list (on the function bar), always the current (most recently processed) production phase is displayed. If a production phase is finished (all activated data has been executed), you first have to select the next production phase and must activate the desired data. Note: If no data has been activated for processing, BoardMaster will consider the production phase to be finished and the message "End of the phase!" appears. Starting a production phase 1. Make sure that the required production phase is displayed in the phase selection list. 2. Click on Start. The required tool is picked up and production commences. You might need to set 2.5 D mode and the milling depth/width. 106 ProtoMat S62

109 Working sequence in automatic mode Milling contours in 2.5 D mode (optional) If you have activated 2.5 D mode, the 2.5 D mode window will be opened after the start of the production phase. Fig. 47: 2.5 D mode: Configuring 1. Activate the Through cutting checkbox. 2. In the Complete pnetration depth field, enter the material thickness value mm. (Example: Material thickness = 1.8 mm, total penetration depth = 2.3 mm 3. In the Z axis feed per run field, enter the required milling depth in mm per milling run. Remember the maximum permissible milling depths for the different materials (see table Tab. 1: 2.5 D processing, milling depth and materials on page 40) The number of milling runs is displayed in the Number of runs box. 4. Click on Start. [ ] The production will be started. If the "Stop for depth adjustment" message appears, you can adjust the milling depth/width. Operating Manual 7.1 Rev.:

110 Starting production Adjusting the milling depth/width If you activated the Stop after change option when setting up the tools, the "Stop for depth adjustment?" message will appear after a milling tool has been picked up. 1. In order to adjust the milling depth on the basis of a sample milling: Click on Yes. Note: If you click on No, the production will continue with the current depth adjustment. 2. Using the current tool, create a milling track approximately 10 mm in length on a section of the base material you do not need (see chapter "Creating a milling track", on page 75). 3. Check the milling track with a measuring microscope: Is the copper completely milled out? For conical cut mills (Universal Cutter, Micro Cutter): Does the milling width match the value displayed in BoardMaster? 4. To correct the milling depth/width: Turn the adjusting wheel on the milling/drilling head to the left to mill deeper/wider. Turn the adjusting wheel on the milling drilling head to the right to remove less material/mill a narrower track. Note: The milling width will change per raster step by approximately 4 µm (Universal Cutter) or approximately 2.3 µm (Micro Cutter). Fig. 48: Adjusting the milling width 1 1 Setting wheel for milling depth limiter Create a further test track to check the new milling depth/width. 5. Click on Start. [ ] The production will be continued 108 ProtoMat S62

111 Working sequence in automatic mode Stopping the production phase A production phase can be interrupted at any time and resumed subsequently. Production based on data already sent to the circuit board plotter will be completed. Interrupting the production phase 1. Click on Stop once. If the production phase is not interrupted immediately, wait until all data already sent has been processed. If you click on Stop again, the production phase will be resumed immediately and more data will be sent to the circuit board plotter. The production phase is interrupted, no more data is sent to the circuit board plotter. Once the circuit board plotter has processed the data already sent to it, you can execute manual operating steps, for example reworking of individual lines. 2. To continue the production phase: Click on Start. The production phase continues with the activated data. 3. To end the production phase: Select another production phase from the phase selection list. [] 5.8 Ending production Production can be brought to an end at any time. You can save the current processing status and resume production subsequently or abort production. Saving the production status 1. If the plotter is still working: Click on Stop. No more data is transmitted to the circuit board plotter. Production based on data already sent will be completed. Operating Manual 7.1 Rev.:

112 Ending production 2. Save the job under a new name (see "Saving a job" on page 83). If at all possible, choose a name reflecting the current production status, e.g. MyJobDrillingBottom.job. [ ] The job can be saved with the current processing status and then opened and resumed subsequently. Aborting production 1. Click on File > Exit to exit BoardMaster. or: Open another job. 2. If the message "Save the job to the file..." appears. Fig. 49: Message when aborting production Click on No. Note: If you click on Yes, this job will be saved with the current production status (in the currently active phase) and opened with the status of the most recently processed production phase when resumed. [ ] The production is aborted. 110 ProtoMat S62

113 Care and maintenance 6. Care and maintenance The ProtoMat S62 requires little care and is extremly maintenance-free. In order to ensure safe and reliable operation of the ProtoMat S62, implicitly observe the information about caring and ensure that the necessary maintenance work is carried out at within the listed intervals. 6.1 Caring/inspecting WARNING Health hazard due to particulate matter! The processing of materials can give rise to dusts hazardous to your health. Extract the dust and material residues or remove them with a brush or moistened cloth; DO NOT blow it out. Cleaning the surfaces 1. If required, clean the housing surfaces using a dry, antistatic cloth. 2. Remove dust and material residues with a soft brush or a moistened cloth. [] Carrying out a visual inspection 1. Prior to every use, carry out a visual inspection to check the ProtoMat S62 and all connecting cables for damage. 2. If you notice damage, have it made good by a professional prior to next use. If necessary, contact the LPKF Support. Make sure that the ProtoMat S62 can not be used until the damage has been repaired. Operating Manual 7.1 Rev.:

114 Maintaining milling depth limiter and collet chuck 6.2 Maintaining milling depth limiter and collet chuck The milling depth limiter and collet chuck must be cleaned at regular intervals after 100 operating hours and whenever necessary. These components need to be removed for cleaning. Required tools and materials: Torx wrench: T10 and T20 Any drill or milling tool with a mm (1/8") shaft Collet chuck tools Collet chuck wrench Collet chuck brush Fig. 50: Collet chuck tools 1 Collet chuck wrench 2 Collet chuck brush Brush Tip: The inside of the collet chuck can be cleaned at any time without having to be removed. To do this, insert the collet chuck brush into the opened collet chuck and push/turn the brush repeatedly to remove the dust particles. (To open the collet chuck see "Opening the collet chuck" on page 114) Removing and cleaning the milling depth limiter I. Removing the milling depth limiter 1. If there is a tool in the collet chuck: Select QuickLoad from the the tool selection list. The tool will be set down in the tool magazine. 112 ProtoMat S62

115 Care and maintenance 2. Move the milling/drilling head to the zero position. 3. Move the milling/drilling head 150 mm to the right. 4. Pull the extraction hose off the milling/drilling head (1). 5. Disconnect the plug for the head lighting (2). Fig. 51: Dismantling the milling depth limiter Pull off the extraction hose 2 Disconnect plug for head lighting 6. On the milling depth limiter, unscrew the torx screws (3)(4) in the aluminium holding blocks and remove the holding blocks. Fig. 52: Dismantling the milling depth limiter Unscrew the T10 torx screw and remove the holding block. 4 Unscrew the T20 torx screw and remove the holding block. 5 Pull the milling depth limiter down and out Pull the milling depth limiter down and out of the milling/drilling head. [ ] Now you can clean the milling depth limiter (s. page 114) and remove the collet chuck. Operating Manual 7.1 Rev.:

116 Maintaining milling depth limiter and collet chuck II. Cleaning the milling depth limiter 1. Carefully squeeze the plastic base and pull it out of the milling depth limiter. 2. Unscrew the setting wheel from the milling depth limiter. 3. Clean all parts with a brush or a lint-free cloth. 4. Grease the thread with a thin layer of graphite grease. 5. Screw the setting wheel back onto the thread. [] Removing and cleaning the collet chuck Conditions In order to dismount the collet chuck, the milling depth limiter must be removed (s. page 112). I. Opening the collet chuck 1. Close the acoustic cabinet cover. 2. Move the milling/drilling head 20 mm downwards. 3. Click on Configuration > Toolbox... The Tool box window is opened. 4. Click on Service. The Enter service password window is opened. 114 ProtoMat S62

117 Care and maintenance Fig. 53: Setting the milling/drilling head offset 5. Enter bmaster as the service password. 6. Click on OK. The service functions can be selected. In the Main/Aux. clamp box, click on Open. The collet chuck is opened. [ ] Now you can remove the collet chuck. Operating Manual 7.1 Rev.:

118 Maintaining milling depth limiter and collet chuck II. Removing the collet chuck WARNING Risk of injury caused by pointed/sharp edged tools! The tool required for unsrewing the collet chuck can cause cuts and stab injuries. Handle the tool carefully. 1. Place the collet chuck wrench on a tool shaft. 2. Insert the tool into the collet chuck so that the wrench clasps the collet chuck. Fig. 54: Tool with collet chuck wrench Note: The tool is needed to protect the collet chuck against damage when unscrewing. 3. Turn the collet chuck wrench to the left to unscrew the collet chuck from the milling/drilling head an pull the collet chuck downwards out of the milling/drilling head. Fig. 55: Unscrewing the collet chuck [] 116 ProtoMat S62

119 Care and maintenance III. Cleaning the collet chuck and the collet chuck holder 1. Insert the collet chuck brush into the collet chuck and push/turn the brush repeatedly to remove the dust particles. Fig. 56: Cleaning the collet chuck holder 2. Clean the exterior of the collet chuck with a brush. 3. Insert the collet chuck brush into the collet chuck holder on the milling/drilling head and push/turn the brush repeatedly to remove the dust particles. Do NOT use any cleaning agents.the collet chuck holder must NOT be degreased. Fig. 57: Cleaning the collet chuck holder [ ] The cleaning of the collet chuck and collet chuck holder is done. Operating Manual 7.1 Rev.:

120 Maintaining milling depth limiter and collet chuck Mounting the collet chuck and the milling depth limiter Always screw in the collet chuck before mounting the milling depth limiter. I. Screwing in the collet chuck WARNING Risk of injury caused by pointed/sharp edged tools! The tool required for unsrewing the collet chuck can cause cuts and stab injuries. Handle the tool carefully. 1. Using the collet chuck wrench on a tool, screw the collet chuck into the milling/drilling head as far as it will go. 2. Remove the tool and the collet chuck wrench from the milling/drilling head. [] II. Mounting the milling depth limiter 1. Insert the milling depth limiter into the milling/drilling head from below. Make sure that the holding block engages in the groove on the milling depth limiter and that the setting wheel is positioned flat on the upper aluminium block. 2. Secure the milling depth limiter with the aluminium holding blocks. Left-hand holding block: Right-hand holding block: T10 torx screw T20 torx screw 3. Connect the extraction hose onto the milling depth limiter. 4. Connect the plug for the milling head lighting with the pins to the right. 5. Press the plastic base onto the milling depth limiter and move the opening to face the front. 6. Close the acoustic cabinet cover. 7. In the Toolbox window, click on OK. The collet chuck closes and the milling/drilling head moves to the zero position. [ ] Maintenance of the milling depth limiter and the collet chuck is complete. 118 ProtoMat S62

121 Care and maintenance 6.3 Replacing fuses The circuit board plotter is protected by two T4L 250 V fuses. To replace the fuses, you first need to remove the side wall of the acoustic cabinet. I. Removing the side wall of the acoustic cabinet 1. Remove the eight screws from the right side wall of the acoustic cabinet. 2. Pull the side wall to the side and out of the acoustic cabinet. Fig. 58: Removing the side wall of the acoustic cabinet The main switch and the mains cable are freely accessible. 3. Pull the mains cable out of the connecting socket. [] Operating Manual 7.1 Rev.:

122 Replacing fuses II. Replacing the fuses WARNING Risk of death! Missing or insufficient electrical fuse protection can result in fatal electric shocks and/or fire. Use only fuses of type T4L 250 V. Fuse holders must NEVER be bridged. The fuse holder is located under the mains connecting socket. 1. Lever the fuse holder out of the fuse compartment using a flat screwdriver. 2. Replace defective fuses with units of equivalent values. 3. Position the fuse holder so that the required operating voltage is legible upright and push it all the way back into the fuse compartment. Fig. 59: Orientation of the fuse holder 1 Orientation for 220 V 240 V 2 Orientation for 110 V 120 V The arrow behind the set operating voltage points down towards the white stripe (see Fig. 49 on page 104). 4. Plug the mains cable into the mains terminal on the circuit board plotter. 5. Switch the main switch to position O. [ ] Now you can mount the side wall of the acoustic cabinet. 120 ProtoMat S62

123 Care and maintenance III. Mounting the side wall of the acoustic cabinet 1. Slip on the side wall of the acoustic cabinet from the side. 2. Fix the side wall in place with the eight TORX screws. [] 6.4 Configuring the tool holder position If the tool is not picked up/set down correctly, the tool holder position must be determined and reintegrated into the co-ordinate system. This procedure can be completed with or without a camera depending on the equipment Configuring the tool holder position (without camera) To configure the tool holder without VisionSystem, the tool magazine must first be loaded, the milling/drilling head offset must be defined and the service functions must be called. I. Defining the milling/drilling head offset 1. Make sure that there is no tool in the collet chuck of the milling/drilling head. 2. Load the tool holder to be checked with a tool. 3. Click on Configuration > Heads... The Heads window is opened. Operating Manual 7.1 Rev.:

124 Configuring the tool holder position Fig. 60: Setting the milling/drilling head offset 4. Make sure that for both X and Y a 0 is entered into the input boxes. 5. Click on OK. The offset is set correctly. II. Activating the service functions Click on Configuration > Toolbox... The Tool Box window is opened. 1. Click on Service. The Enter service password dialogue box is opened. 122 ProtoMat S62

125 Care and maintenance Fig. 61: Setting the milling/drilling head offset 2. Enter bmaster as the service password. Click on OK. The service functions can be executed now. Fig. 62: Tool Box with service functions Operating Manual 7.1 Rev.:

126 Configuring the tool holder position III. Testing the tool holder position 1. In the Main/Aux. Clamp field, click on Open. The collet chuck opens. 2. In the Pos. column of the tool list, click on the tool position to be checked. 3. Click on Check. The milling/drilling head moves to the selected tool position. 4. IOn the function bar, enter the value 35 into the Move to Z input box. 5. Click on Move to z-. 6. If the message "Infeed to the movement limit?" appears: Click on Yes. The milling/drilling head is lowered. 7. Click on Move to z+ to lift the milling/drilling head. The position is correct and the test can be completed if the milling/drilling head is lifted and lowered without tool contact. [ ] The tool holder position must be corrected if the milling/drilling head collides with the tool when it is lowered, or if it takes the tool out of the tool holder when it is lifted (s. page 125). 124 ProtoMat S62

127 Care and maintenance IV. Correcting the tool holder position 1. Click on Move to z+ to lift the milling/drilling head. 2. Use the Move to x/y buttons with 0.1 mm steps to correct the position of the milling/drilling head above the tool magazine. Click on Move to z-. 3. Correct the X/Y position until the milling/drilling head can be lowered without colliding with the tool. 4. Use the same procedure to make sure that the the milling/drilling head does not take the tool out of the tool holder when it is lifted. [ ] Once the milling/drilling head can be lowered and lifted without colliding with the tool, the position data can be applied 5. In the Tool Box window, click on Accept. The co-ordinates determined are applied to the changing position. 6. Repeat the test and correction functions as necessary for all tool positions. 7. Click on OK to close the Tool magazine window. 8. Exit BoardMaster and restart the program to apply the values saved in the INI file. [ ] The configuration of the tool changing positions is complete. Operating Manual 7.1 Rev.:

128 Configuring the tool holder position Determining the tool holder position with VisionSystem To configure the tool changing positions with the optional VisionSystem, proceed as follows: I. Setting the camera offset 1. Select a 0.8 mm drill and drill a hole in an unused area of the base material. 2. Click on Configuration > Heads... The Heads window is opened. Fig. 63: Setting the milling/drilling head offset 3. Select the Camera item in the selection list. 4. Click on Origin. The reference point button will be deactivated. 5. Click on OK. The offset is set correctly. 126 ProtoMat S62

129 Care and maintenance 6. Click on Move to > Camera >> Head in the main menu. The camera is positioned above the bore. 7. Enter the value (mm) in the Move to X/Y input box for the increment and position the milling/drilling head with the arrow keys so that the cross-hairs of the camera image are positioned exactly in the centre of the bore. Fig. 64: Positioning the camera image above the bore Click on Configuration > Heads... The Heads window is opened. Operating Manual 7.1 Rev.:

130 Configuring the tool holder position 8. Click on Head to apply the new position. The new co-ordinates are displayed in the Offset [mm] field. Fig. 65: Setting the milling/drilling head offset 9. Click on OK. [ ] The camera offset is set correctly. II. Preparing the tool magazine for determining the position 1. Click on Move to pause. 2. Remove all tools from the tool magazine. 3. Press the measuring insert included in the VisionSystem scope of delivery into the tool holder position to be checked. Fig. 66: Measuring insert for determining the position with VisionSystem 1 1 Measuring insert (here in tool position 1) 4. Close the cover. [ ] The tool magazine is prepared for determining the position with VisionSystem. 128 ProtoMat S62

131 Care and maintenance III. Calling the service functions 1. Click on Configuration > Toolbox... The tool magazine window is opened. 2. Click on Service. The Enter service password dialogue box is opened. Fig. 67: Setting the milling/drilling head offset 3. Enter bmaster as the service password. 4. Click on OK. The position data can now be read in. Operating Manual 7.1 Rev.:

132 Configuring the tool holder position Fig. 68: Tool magazine with service functions IV. Reading in the position data 1. In the Pos. column, click on the tool position to be read in. 2. Click on Check. The milling/drilling head moves to the selected tool position. 3. Position the milling/drilling head so that the cross-hairs of the camera are aligned in the centre of the measuring insert. 130 ProtoMat S62

133 Care and maintenance 4. In the tool magazine window, click on Accept. The co-ordinates determined are applied to the changing position. 5. Repeat the test and correction functions as necessary for all tool positions. 6. Click on OK to close the Tool magazine window. 7. Move the milling/drilling head to the pause position. 8. Remove the measuring insert from the tool magazine. 9. Exit BoardMaster and restart the program to apply the values saved in the INI file. [ ] The configuration of the tool changing positions is complete. 6.5 Adjusting the camera (only with VisionSystem) If the camera image on the monitor is not focussed, you will need to reset the focus (see chapter 3.6 "Setting the focus (VisionSystem only)" on page 59). The camera offset between the milling/drilling position and the centre of the camera image must be recalculated if the positioning of the milling/drilling head with the camera produces incorrect results. Automatic fiducial recognition is factory-set for bores 1.5 mm in diameter. The fiducial recognition must be calibrated if BoardMaster does not recognize the fiducials or if a different drill diameter needs to be used. Operating Manual 7.1 Rev.:

134 Adjusting the camera (only with VisionSystem) Setting the camera offset 1. Drill a 0.8 mm hole into an unused area of the base material. Take care not to move the milling/drilling head further, since the current position serves as the reference point. 2. Click on Configuration > Heads... in the main menu. The Heads window is opened. Fig. 69: Setting the camera offset 3. In the Head selection list select Camera. 4. Click on Origin. The reference point button will be deactivated. 5. Click on OK. 6. Click on Move to > Camera >> Head in the main menu. 132 ProtoMat S62

135 Care and maintenance 7. Move the head with the arrow keys until the cross-hairs of the camera image are exactly in the centre of the bore. Reduce the increment to mm for more precise positioning. Fig. 70: Positioning the camera above the bore 8. In the main menu, click on Configuration > Heads In the Head selection list select Camera. 10. Click on Head to apply the new position. The current offset values in X/Y direction are displayed in the Offset field. 11. Click on OK. [ ] The camera offset setting is completed. Operating Manual 7.1 Rev.:

136 Adjusting the camera (only with VisionSystem) Calibrating fiducial recognition Fiducial recognition is factory-set for bores 1.5 mm in diameter. The settings must be recalibrated if the fiducials are not clearly recognised. I. Preparing the fiducial recognition 1. Drill a hole into an unused area of the material to be used with the Spiral Drill 1.5 mm. 2. Click on Move to > Camera>>Head in the main menu. The camera is positioned above the bore and the bore is visible in the Camera image window. Fig. 71: Bore in the camera image window 3. Click on Setting. The Setting window is opened. 134 ProtoMat S62

137 Care and maintenance Fig. 72: Setting fiducial recognition 4. Click on Calibrate camera. 5. The Calibration window is opened. Fig. 73: Fiducial calibration 6. Enter the value 1.5 into the Diameter input box. 7. Click on Calibrate. Operating Manual 7.1 Rev.:

138 Adjusting the camera (only with VisionSystem) 8. If the message "Calibration not possible!" appears: Fig. 74: Calibration not possible Click on OK. Check/correct the camera focus and the image brightness and repeat the calibration. 9. Once the calibration has been completed successfully, the message "Calibration successful!" appears. Fig. 75: Calibration successful 10. Click on OK. 11. Click on OK to close the Calibration window. 12..Click on OK to close the Setting window. [ ] Now you can determine the fiducial diameter. 136 ProtoMat S62

139 Care and maintenance Determining the fiducial diameter The measuring function in the Camera image window can be used to ascertain which value is being measured by BoardMaster at the selected fiducial. 1. To use the measuring function, click on the left edge of the bore with the left mouse button. The first small cross appears. 2. Click on the right edge of the bore with the left mouse button. The values for the X direction, the Y direction and the direct connection (DXY) appear. 3. To receive a clear image, press the right mouse button. Fig. 76: Measured values in the camera image 4. Remember the value (in the example 0.801) and click on Setting. The Setting window is opened. Operating Manual 7.1 Rev.:

140 Adjusting the camera (only with VisionSystem) 5. In the Fiducial diameter input box enter the measured value of the bore. Fig. 77: Fiducial settings The value in the Minimal diamer [mm] input box must be smaller than the fiducial diameter by 0.1 mm. 6. Click on Accept. 7. It can be the case that the colour difference or contrast between the bore and the surrounding material is not large enough (the bore is not dark enough, the material is too bright). If so, enter the value 70 (instead of 90%) in the Minimum quality [%] input box. 8. Click on Calibrate camera. The Calibration window is opened 9. In the Diameter input box enter the actual fiducial diameter in mm (here: 1.5 mm) Fig. 78: Calibration settings 10. Click on OK. 138 ProtoMat S62

141 Care and maintenance The message Calibration complete! should appear. Fig. 79: Calibration complete 11. Click on OK. 12. In the Setting window, click on OK to save the settings. 13. In the Camera Image window, click on Setting, to open the Setting window again. 14. Enter the actual value of the diameter in the Fiducial diameter: input box (here: 1.5 mm) 15. In the Minimal diameter [mm] input put, enter the value 1.4 (1.3 might also be necessary). Fig. 80: Fiducial settings 16. Click on Accept to confirm the entries. 17. Click on OK to close the Setting window. Operating Manual 7.1 Rev.:

142 For your notes [ ] If you now measure the drilled fiducial again, BoardMaster should display the correct value of 1.5. Fig. 81: Measured values in the camera image [] The fiducial recognition set-up is complete. 6.6 Changing the dust extraction filter The dust extraction filter must be changed regularly. You will find detailed information about changing the filter in the documentation of the dust extraction. 140 ProtoMat S62

143 Error messages/malfunctions 7. Error messages/malfunctions This chapter provides information about possible malfunctions and error messages. You should follow the instructions for troubleshooting in the order specified; they provide you with the quickest route to a possible solution. Error message Fault description The Connect... window is displayed when starting BoardMaster. The Connect... window is displayed repeatedly. The milling head lighting is off. Possible cause Notes Circuit board plotter without power supply. Lamp at milling/drilling head is off. Connection settings do not correspond to the installation Circuit board plotter is switched off. No power supply Defective fuse Remedy Connect the circuit board plotter to the power supply. Make sure that the main switch is in the position I. Click on Connect... Check connection settings (see "Checking the connection settings (if neccessary)" on page 36). Check communication settings in the Windows system control (see "Configuring the communication port" on page 29). Switch the main switch to the position I. Make sure that the circuit board plotter is connected to the power supply. Replace the fuse (see "Care and maintenance"). Dust extraction does not start. No power supply Connect the dust extraction to the power supply. Dust extraction is switched off. Defective fuse No data communication. Switch the operation mode switch on the dust extraction to ON or select automatic mode. Press the RESET button on the dust extraction. Check the wiring to the circuit board plotter. (Page 1 of 2) Operating Manual 7.1 Rev.:

144 Error messages/malfunctions Error message Fault description The milling/drilling head interlocks with the tool during a tool change. The tool is not being picked up/set down. Possible cause Notes The tool has not been inserted correctly. The tool is loose in the tool holder. The position of the tool holder is not exact enough. Soiled collet chuck. Soiled tool holder. Remedy Press the tool as far as it will go into the tool holder. Read the position of the tool holder in again (see "Care and maintenance"). Clean the collet chuck (see "Care and maintenance"). Clean the tool holder with a brush or exhaust it with a vacuum cleaner. "E 706 (from ErrorList)" Milling/drilling head moved into the limit switch Click on OK. Restart BoardMaster. (Page 2 of 2) 142 ProtoMat S62

145 Decommissioning, transport, disposal 8. Decommissioning, transport, disposal This chapter contains important information about safe decommissioning and environmentallyfriendly disposal of the ProtoMat S Decommissioning I. Switching the ProtoMat S62 off. 1. Click on File > Exit and follow the on-screen instructions. BoardMaster shuts down. 2. Switch the main switch on the circuit board plotter (in the acoustic cabinet) to position 0. The lighting on the milling/drilling head goes out. 3. Shut down the computer. [ ] You can now disconnect the connecting cable. II. Disconnect the connecting cables. 1. Pull the mains connecting cable plug out of the socket. 2. Remove the data cable. 3. Unscrew the dust extraction hose screw from the hose connector on the acoustic cabinet and remove the dust extraction hose. [ ] The ProtoMat S62 has been taken out of operation. Operating Manual 7.1 Rev.: