Bungard CCD User manual

Contents Page
Security Information
Declaration of Conformity
0. Introduction 1
I. Control unit and mechanics 1
1. Control unit
1.1 Power supply
1.2 Cable connections
1.3 Components
1.4 Back plane
1.5 Trouble shooting 2
1.6 Exchange of hardware components
1.7 Operating conditions
2. Mechanics unit
2.1 Set up
2.1.1Compressed air conn. (ATC) 3
2.2 Mounting the spindle
2.3 Vacuum cleaner
2.4 Tool receptacles (ATC)
2.5 Tool change (MTC)
2.6 Maintenance 4
2.7 Changing belts
2.7.1 XAxis
2.7.2 YAxis
Contents Page
II. Software 5
0.1 Original disk
0.2 Hard- and Software requirements
0.3 File formats
1. Installation
2. Conventions 6
2.1 Keyboard
2.2 Mouse 7
2.3 Numbers
3. Quick-Start
3.1 Starting the software
3.2 Main Menu 8
3.3 Loading
3.4 Drilling
3.5 Interruption 9
3.6 Ready
4. Dialogues and Menues
4.1 Start-up dialogue
4.2 Main menu 10
4.2.1 Edit fields
4.2.1.1 Scale
4.2.1.2 Offset
4.2.1.3 Clipping 11
4.2.1.4 Drill/Route from to
4.2.1.5 Board thickness
4.2.1.6 Base sheet thickn. 12
4.2.2 Info fields
4.2.3 Buttons
4.3 Load
4.4 Start 13
4.4.1 Tool change
4.4.1.1 Automatic
4.4.1.2 Manual
4.4.1.3 Spindle control
4.4.2 Execution
4.5 Offset 14
4.5.1 Teach-In 15
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BUNGARD CCD Manual

Contents Page
4.6 Tools 15
4.6.1 Info fields
4.6.2 Drilling only
4.6.2.1 +mm
4.6.2.2 Feed
4.6.2.3 1/min
4.6.3 Routing only
4.6.3.1 Depth
4.6.3.2 Iterations
4.6.3.3 Speed XY 17
4.6.2.4 Speed Z
4.6.2.5 1/min
4.6.2.5 Cross relations
4.7 Configuration
4.7.1 File 18
4.7.2 Coordinates
4.7.3 Sorting (Drilling only)
4.7.4 Speed
4.7.5 Ramp
4.7.6 Stroke
4.7.7 Correct. Factors 19
4.7.8 Chord angle (Routing only)
4.7.9 Spindle
4.7.10 (ATC) AutoChg
4.7.11 Configuration files 20
4.8 Panelize
4.9 Quit 21
4.10 Manual spindle operation
5. Errors
5.1 Errors in files
5.2 Other errors
6. Fixing the boards
6.1 Mechanic aids
6.1.1 Clamp fixing
6.1.2 Span fixing 22
6.2 Drilling
6.2.1 Bare boards
6.2.2 Presensitized base mat.
6.2.3 Etched PCBs
6.3 Routing
7. Error messages 23
8. Relation of speed settings 24
Appendix
Bungard Elektronik GmbH&Co.KG ·Rilke Str. 1·D-51570 Windeck
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BUNGARD CCD Manual

BUNGARD CCD /Security Information
With respect to the European Community Edict 89/392/EWG (Machines) the following
infor-
mation is given as asupplement to the manual:
0. Application
The BUNGARD CCD machines are manufactured by Bungard Elektronik, Rilke Straße
1,
51570 Windeck, Germany and are brought into circulation in European countries via local dis-
tributors or agents.
The machines are determined for drilling and milling (routing) printed circuit boards and for
milling (routing) and engraving aluminium plates. Aspecial application is dosing of pastes or
liquids onto panel-shape workpieces. Any other type of application is permissive only with our
consent.
The machines are not determined to be connected or combined with other machines. However,
they need to be connected to and be controlled by acompatible computer. The driver software
is supplied with the machines and is relevant for security.
The machines may only be operated by qualified operators. Children and animals must be kept
off!
1. Emergency Stop Facilities
The ESCape button on the computer stops the spindle and the stepper motors. This is indicated
by ared and yellow message on the screen. The main switch on the rear of the control unit
cuts
the machine from mains supply.
2. Protection against contact with moving parts
There is atransparent, pivoting cover mounted to machines with manual tool change to prevent
incidental contact to the moving tool. It is not possible to entirely envelop the tool. This cover
cannot be mounted to machines wit hautomatic tool change. The following danger remains:
WARNING: Do not touch the tool when the spindle is operational. Prior to any tool
change
action, wait until the spindle has come to acomplete stop. Close the cover entirely after
any
intervention to the tool.
Under normal operating conditions and with the given workpiece materials, there is no special
danger from parts beeing propelled off the machine. However, special operating conditions or
heavy workpieces may require that the machine is encapsulated. Aprotection cover is available
as an option.
3. Noise
With the HF-spindle running at full speed and the vacuum cleaner on, the noise pressure level
at 1m distance is 86 db(A). Operators have to wear ear protection.
4. Dust
It is necessary that the standard vacuum cleaner ore, if special operating conditions occur, a
better one, are always beeing used during operation on printed circuit boards. The vacuum
cleaner must be OFF during and after use of alcohol or other inflammable or explosive liquids
(i. e. used for cooling when milling aluminium). Special operating conditions may require
that
an extraction unit with higher rating be installed.
5. Documentation
Our distributor /reseller in your country is encouraged and in charge of translating the
German
and /or English manual coming with the machine into your native language.
Bungard Elektronik GmbH&Co.KG ·Rilke Str. 1·D-51570 Windeck
Tel [phone] ·Fax 6175 ·[email protected]

EG-Konformitätserklärung
Declaration of conformity
Déclaration de conformitée
Wir (Name des Anbieters)
We (Suppliers Name)
Nous (Nom du Fournisseur) Bungard Elektronik
Anschrift Rilke Straße 1
Address D-51570 Windeck
Adresse
erklären in alleiniger Verantwortung, daß die Produkte
declare under sole responsibility, that the products
déclarons sous notre seule responsibilitée, que les produits
Bezeichnung /Typ
Name /type
Nom /type
mit den Anforderungen der Normen EN 50 081-1, EN 50082-1
fullfil the requirements of the standards EN 55014, EN 55015
satisfaitent aus exigences des normes EN 60204 Teil /Part 1
und den wesentl. Schutzzielen der
and the basic requirements of Richtl. /Directive 89/392 Anh. /App. I
et des exigences de base de la
übereinstimmen und damit den Bestimmungen der folgenden EG-Richtlinien entsprechen:
and therefore correspond to the regulations of the folowing EU-Directives:
et, ainsi, correspondent aux règlements des Directives du Conseil:
89/336/EWG, 89/392/EWG, 73/23/EWG
Windeck, 01.04.96 Dietmar Bungard
Ort und Datum der Ausstellung Name und Unterschrift des Befugten
Place and Date of Issue Name and signature of authorized person
Lieu et date d´établissement Nom et signature de la personne autorisée
Diese Erklärung entspricht EN 45 014
This declaration corresponds to EN 45 014
Cette déclaration correspond àEN 45 014
Entwicklergerät HA 205
Belichtungsgerät HELLAS
Ätzmaschinen JET 34d, DL500
Ätzmaschine Splash, Splash Center
Laminator RLM 419p, RLM 426p
Rollverzinner RT 12R
Bürstmaschine RBM 300, 400, 402
Multilayerpresse RMP210
Tauchbeschichter RDC 10, 12
Bohr- und Fräsmaschine BUNGARD CCD
Durchkontaktierungsanlage COMPACTA
Abwasserreinigungsanlage IONEX

0. Introduction
This manual describes how to operate the CNC drilling machine BUNGARD CCD in both
versions with and without automatic tool change and explains how to use the driver software.
To distinguish between Automatic and Manual Tool Change, the appropriate sections of
the
manual are marked (ATC) and (MTC).
Prior to running the machine, please read carefully both the information on hardware set-up
and
chapter II.3, Quick-Start.
To run the machine, you need an external computer. The hard- and software requirements
are
described in chapter II.0. We hope that you enjoy using the BUNGARD CCD. Please let us
know if we can be of any supplementary technical assistance.
I. Control Unit and mechanics
1. Control unit
1.1 Power supply
The machine must be connected to a230 V50 Hz outlet. It may only be set under current if
the
control unit cover is closed with all cards inserted correctly.
Attention! You must disconnect the machine from the main supply and wait until DC voltages
are low prior to opening the rack or to pulling cards off from the rack. We will
deny
any liability if alterations to any mechanical, electric or electronic components of
the machine are made.
1.2 Cable connections
The control unit is linked to the computer's serial port COM2: by use of astandard RS
232
cable. Insert the male cable connector into the 9pin Sub-D connector located on the interface
module. The connection between the mechanics and the control unit is done
uninterchangeably
by use of one cable with a25 pin Sub-D connector and two cables with 15 pole Sub-D Connec-
tors. The HF spindle is connected to the socket located near of the Zaxis motor.
1.3 Components
The control unit is built from the following modules:
wPower supply for the HF generator and the stepping motors
w3phase HF generator with brake for one 125 Wspindle
wSerial interface linking the control unit to the computer. The interface also controls the refe-
rence switches and generates the stepper motor pulses for the amplifiers.
w2Connector modules with a) one 25 pole and b) two 15 pole Sub-D connectors linking me-
chanics and control unit.
w3power amplifiers driving the stepping motors
All functions of the machine are controlled by the driver software. This applies also to
turning
the spindle on and off and to setting the spindle speed. The control unit front panel only shows
some status LEDs with the following meanings:
HOME X, HOME Y, HOME Z: These LEDs give avisual control on the state of the reference
switches. They are all lit after asuccessful reference run.
ENABLE: The motors are under current (enabled) This LED lights when the machine is
wor-
king. It is controlled by the driver software. When the motors stand still and the LED is on,
the
axes´ position is locked. This is the case e. g. during tool change. There may appear a
slight
hissing sound when the motors stand still and the LED is on. This is not amalfunction.
TOOL: On machines with automatic tool change this LED corresponds to the drill break detec-
tor and turns on and back off if adrill was found to be OK.
The remaining LEDs are indicators for the presence of the different DC voltages.
1.4 Back plane
On the back of the control unit there are an AC inlet with the primary fuse holder, the
main
switch and asecondary fuse holder each for the spindle and the stepping motors .
Bungard Elektronik GmbH&Co.KG ·Rilke Str. 1·D-51570 Windeck
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BUNGARD CCD Manual Page 1

To exchange the primary fuse, you must pull of the small rectangular plastic piece located
in
the middle between the main switch and the AC inlet. There are two fuses in this fuse
holder,
but only the right one is actually used.
Important: In the case that afuse has blown, always replace with one of the same
currant
specification and characteristics. If afuse blows repeatedly, it is likely that acomponent
is
defective. In such case, please do not try to repair on your own but call us for service. We will
then supply the appropriate module for exchange.
1.5 Trouble shooting
Problem: DC supply LEDs are not lit
Check: Is the power cord plugged in correctly? Has the primary fuse blown?
Problem: Spindle does nut run
Check: If all connections are well fit it is likely that the fuse has blown. This can also be a
hint that the automatic overload detection is not working correctly.
Problem: Stepping motors do not run or the computer mouse is locked
Check: RS232 cable and connectors. If the mouse hangs it is likely that COM1: and
COM2:
were interchanged.
Check: Wiring between control unit and mechanics. Push and release the reference switches
of all three axis and check if the corresponding LED on the interface card turns on
and off. Check if the ENABLE LED turns on at the beginning of adrill action.
Problem: Stepper motors run irregularily or block and make high-pitch noises
Check: It is likely that the computer is too slow for the actually set motor speed or
Windows is active in the background. Reduce maximum speed settings (See section
Configuration for details) Start the computer in pure DOS or MS-DOS mode.
1.6 Exchange of hardware components
Prior to any manipulation to the control unit, check that the machine has been disconnected
from the main supply.
Loosen the four screws located on the respective front panel and pull the PCB out of the rack.
Use an antistatic or at least an isolated panel to deposit the PCB on. Insert the new card into
the
rack. Take care that it fits well into the gliding guides on the top and the bottom of the rack.
Fasten the four screws, close the unit's cover if necessary and reconnect to the main supply.
On the right half of the front panel, there are three PCBs mounted behind abigger front
panel.
These contain the power amplifiers for the three axis. They must always remain in their positi-
on. Running the machine with one or more of these PCBs missing or inserted into awrong rack
position may destroy the machine!
There are no user serviceable parts on the PCBs. The potentiometers on the PCBs are factory
set. Do not Change!
The only adaptation that you may make is the setting of another baud rate on the interface
card.
If necessary, pull the card and set all threee jumpers to the desired position. The
corresponding
baud rate is marked on the PCB. The preset position is 38400 bd.
1.7 Operating conditions
The machine may only be operative under normal temperature and humidity conditions, especi-
ally only in absence of corrosive or inflammable vapours. At temperatures lower than 10 °C or
higher than 30 °C, there may occur the following problems: The spindle might not start
running
at low temperatures. The stepping motors might run hot or step losses may occur at more than
30 °C in the surrounding air.
2. Mechanics Unit
2.1 Set up
Put the machine onto astable, even table and adjust the machine's 4feet by turning them.
A
stable desk and aproper setting are important to prevent vibrations etc.
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BUNGARD CCD Manual Page 2

Connect the one 25 pole and two 15 pole cables coming from the control unit. They cannot be
interchanged. The red and blue outlets are reserved for later extensions and are actually not
beeing used.
The Cinch socket takes the cable of the included vacuum cleaner switch box. This box is desi-
gned for astandard 230 Vsupply and amaximum power of 500 W. This box may also power
i.
e. aliquid pump for cooling when routing aluminium.
2.1.1 (ATC) Compressed air connection
The machine requires compressed air of at least 5bar to open and close the spindle chuck.
A
compressor is not included with the machine. At the left rear of the machine there is an
air
valve. Connect the spiral air hose´s free end to that valve. The other end of the hose has a
standard connector for compressed air outlets.
Use the short piece of air hose coming with the spindle to connect it to the fitting on top of
the
Y-axis slider.
2.2 Mounting the spindle
Release the holder clamp by a90 degree left turn of the lever on its right side. Carefully drop
the spindle into the clamp and push it downwards so that the distance flange lies firmly on
the
holder's top. Turn the spindle in adirection that permits to fix the cable in the small black
clamp on top of the Z-axis block. The cable and the connector housing must not be bent by
and
must not interfere with the Z-axis' movement. Fix the plug to the connector box located to
the
right of the Zstepping motor and tighten the plug screw. Turn the lever to close the holder
clamp until the spindle is well tightened.
Important: The distance flange determines the spindle elevation over the table. It is mounted
to the spindle at the factory in away that adrill (with ring) is 0.5 mm over the machine table
when the Zaxis is completely down. You should not change this setting. Otherwise the Zaxis
mecanical position will be different from the one assumed by the driver software. Damag to
the
machine table may then result. See the "Z Axis Definition" in the Appendix.
Only tools with ring should be used. The distance from the top edge of the ring to the tool
tip is 21 mm. The spindle distance flange was factory set with respect to that 21 mm active
tool length.
(ATC): There must be the "test pin" or at least adrill bit in the chuck when the spindle is not
in use. Else, damage to the chuck may occur.
2.3 Vacuum cleaner
The machine comes with asmall bench top vacuum cleaner. After connecting it to the switch
box, put it on the table at the rear of the machine and fix the hose to the exhaust valve which
is
at the left front (MTC) or at the rear (ATC) of the Yaxis. Take care that the hose can freely
follow the machine´s movement.
The swarf removal may appear to be somewhat poor. This is due to the fact that the
shavings
are leaving the drill bit at high speed, but not necessarily in the direction of the valve.
2.4 (ATC) Tool receptacles
On the front end of the machine there is abar with 16 tool receptacles. They are numbered
from 0to 16. Number 0always takes the test pin. The drill and router bits go into the
remaining
15 round pieces. These can move vertically and also have asmall rubber ring inside which
keeps the bit ring in position. The positions of the receptacles are known to the software by
entries to the configuration file.
In front of the tool position No. 0there is the drill break detector. The driver software operates
the machine in away that after each drill was used it is checked in this sensor. The LED on top
of it lights up when the drill is found to be good.
2.5 (MTC) Tool change
To open the spindle chuck, press down the knob on top of the spindle and turn it left. Remove
the tool and insert anew one. Press and turn right the knob to close the chuck. To gain better
access to the tool, You may lift the spindle but it is not recommended to pull it off entirely.
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BUNGARD CCD Manual Page 3

2.6 Maintenance
It is important that you regularly remove all dust and shavings from the machine. To clean
and
lubricate the steel shafts, especially those below the aluminium profile on the X-axis, use a
cloth and some acid free machine oil. On each end of the linear bearing housings, there
are
lubricating felt strippers. Regularly apply some oil to them.
The shafts on the Z-axis do not need special lubrication but must also be kept clean.
Note:The machine must not be used in corrosive or inflammable atmospheres. If it will not be
used for alonger period or prior to transporting it, all steel shafts should be well lubricated.
The drive belts must also be kept clean from dust and shaving but must not not be lubricated.
The belts are subjected to wear. If they show damages like lateral fray-out or damaged teeth
they should be replaced.
2.7 Changing the belts
2.7.1 X-axis
Loosen the two screws of the span brace and remove it. Also remove the block with the rever-
sing roller at the end of the X-axis. Move the Y-axis beam to the middle of the X-axis.
Remove the small plate that fixes the belt to the carrier. The two ends of the belt come free.
Use some adhesive tape to fix the new belt to the old one. The teeth must be aligned on
one
side. Pull the old belt out of the gear housing. The new belt will follow the old one. Remove
the adhesive tape. Remount the reversing roller, but do not tighten the screw. Keep the new belt
on its front end and pull the inner half of it around the reversing roller so that both ends come
to lie in front of the linear bearing carrier.
Cut a3.5 cm long stripe from the old belt. Use this stripe to connect both ends of the belt in a
way that their teeth grip into the gaps of the small stripe. If necessary, cut the new belt on
one
end. The edges should lie face to face on the stripe.
Pull the Y-axis beam back or forth so that the assembly of belt ends and stripe are in position
on the beam. Carefully mount the aluminium cover plate and tighten the screws so far that
the
belt ends can not fall off the carrier. Check if the inner and outer half of the belt are well
aligned. To adjust, move the belt ends under the cover plate. Fix the cover plate by well tighte-
ning the two screws. Fix the block with the reversing roller. If the belt is too loose, you
will
have to disassemble, cut one tooth and remount as described above.
Finally, remount the span bracket and adjust the belt stress. With the Y-Axis beam in the
midd-
le of the X-axis range, it should be possible to press the part of the belt to the left or the
right
of the beam for about 3mm in the direction of the machine table.
2.7.2 Y-axis
Remove the three screws holding the Z-axis stepping motor. Take the motor off from the gear
housing and carefully lay it aside. (Be careful not to damage the cable) Change the belt in
the
same way as explained for the X-axis and then remount the stepping motor. Prior to
tightening
the 3screws, adjust the gap of the gear wheels to aminimum by moving the motor back or
forth.
Note: The reversing rollers can be moved on their axis. Use the blade of ascrewdriver to lift or
lower their position until the belt runs in the middle of the rollers.
After changing the belts it is likely that the machine needs recalibration. See chapter 4.7.7 for a
description of how to determine the Xand Ycorrection factors.
Bungard Elektronik GmbH&Co.KG ·Rilke Str. 1·D-51570 Windeck
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BUNGARD CCD Manual Page 4

II. Software
0.1. Original disk
1Floppy disk 31/2" with the following files:
DRILLPRO.EXE and ROUTEPRO.EXE Driver software for drilling and routing
DRILLPRO.DCF and ROUTEPRO.RCF Configuration file for drilling and routing
DRILLPRO.DTD Drill Tool Data file
ROUTEPRO.RTD Rout Tool Data file
Sample drill and rout files (Subdirectory \SAMPLES)
0.2 Hard- and Software requirements
PC/AT compatible computer, 80x86 CPU, recommended clock speed min. 12 MHz (IBM PS/2
models not supported!)
Free RAM >300 kB
min. 1Disk drive 31/2"
Monochrome or colour monitor with Hercules, CGA, EGA or VGA card
1free serial port RS 232
MS-DOS 3.2 or newer or compatible operating system
0.3 File formats
The driver software for drilling and routing interprets the data files coming from your CAD
package and transforms the commands and coordinates into step information. This is sent to
the
interface card via RS 232
The routing driver accepts the following subset of HP/GL command words with their corre-
sponding parameters: SC, IP, PA, PR, PU, PD, AA, AR, CI, SP. Each command sequence must
be terminated with ";". It is allowed to group several commands in one line. Circles and arcs
are
drawn as achain of vectors with adjustable chord angle.
The drill data must be in standard ASCII drill file format, also known as "Excellon" or "Sieb
&
Meyer" format. Leading zero suppression is allowed, trailing zeros must be present. The driver
replaces missing X- or Y-coordinates by the last valid value. The range of numbers
is
0...999999. The start label "%" must be present. The data section of the file starts after
this
label, preceeding lines are taken as comments. Data blocks must be seperated by
<CR><LF>.
Examples:
%
T01
X1000Y1000
X400
Y10000
%
T15
X0Y0
X100 Y1000
Drill data are often measured in 1/1000 "(say 1mil or 1thou) or 1/10 000 ". HP/GL assumes
0.025 mm as one step. The unit can be set in the configuration menu.
1. Installation
Copy your original disk to another one or to any subdirectory on any partition of your
hard
disk. The configuration files, the tool definition files and the programmes must always be on
the
same drive and in the same subdirectory.
Connect the machine's control unit to the serial port COM2: on your computer. If COM2:
is
used by another device, you may use anormal ASCII editor to change the setting in DRILL-
PRO.CFG and ROUTEPRO.CFG to install for COM2, 3, or 4.. (See chapter 4.7,
Configuration,
for details). The machine comes with astandard cable with 9pin sub-D connectors. If your
computer has a25 pole sub-D connector, please use a1:1 25 on 9pole adaptor.
Bungard Elektronik GmbH&Co.KG ·Rilke Str. 1·D-51570 Windeck
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BUNGARD CCD Manual Page 5

2. Conventions
In the following, both drivers for drilling and routing will be described simultaneously.
There
are only little differences in using them. These will be described separately where necessary.
(You may of course only have one of both programs operating at atime but if you use
the
taskswitcher in DOSSHELL of MS DOS 5.0 or 6.0 or the one that comes with DR DOS 6or
Novell DOS, you may comfortably switch back and forth between the two drivers)
The driver software has agraphics user interface. The software has atree-like structure.
Starting
from the main menu, it branches to submenus and dialogues and returns to the main menu.
The different elements of the user interface show different colours on computers with
graphic
adaptors. In the black and white modes, they can be distinguished by different intensities and/or
highlighted command characters. (The screen on your monitor may look different from
the
hardcopies shown in this manual.)
Messages, warnings or prompts to choose from alternatives are shown in so called dialogue
boxes. To enter numerals, there are so called EDIT fields. The program operation is controlled
by so called buttons. These can be activated either from the keyboard or with amouse.
2.1 Keyboard
To enter or change numerals in EDIT fields, you may use the keys 0... 9, +, -, the decimal
point, the cursor, TAB, BACKSPACE and DELETE keys. If you press other than the above,
no
action is taken and abeep sound comes up. The decimal point and the +and -keys are operati-
ve only in certain EDIT fields.
Missing digits of numbers are padded with zeros from the left. Empty edit fields, wrong entries
or else are beeing rejected as soon as you try to leave adialogue. In such case, an "Input
Error"
box comes up close to the appropriate edit field.
To skip between the edit fields and the buttons, you may either use the TAB and SHIFT TAB,
the cursor up and down keys or the mouse. TAB or Cursor down move to the next, SHIFT
TAB
or cursor up move to the previous field. Pressing the appropriate keys for several times, you can
move all through the edit fields and buttons in aclosed loop.
Within the selected edit field you will see acursor. Aselected button shows in high intensity.
The RETURN or ENTER key or the space bar activate this button, the program will
perform
the appropriate action.
The buttons may also be activated directly by pressing the ALT key, holding it down
and
pressing the key corresponding to the emphasized letter of the button. For example, in the
main
menu an entry of ALT+Qwill Quit the program, ALT+Swill Start processing.
If no edit field is selected or if there are no edit fields in the dialogue, you may also just press
the appropriate letter without the ALT key. Example: Ofor OK, Afor Abort.
There are also dialogue boxes with so called radio buttons. These allow to choose one of
several alternatives. Like the station pushbuttons on aradio, there is always one key chosen
and
the others inactive. The active choice is marked by a(*) symbol, the others only by (). You
may use the cursor left and right buttons to select achoice. It is also possible to select aradio
button by the respective highlighted character.
To choose afile from the directory, there is afile selector box:
Within this box, use the TAB and SHIFT TAB keys to move the cursor from the input line to
the file list and vice versa.
You may change subdirectories by selecting their name or the ..\ entry at the end of the file list
and pressing the OK button.
To load files from another drive, move the cursor to the input line, enter the drive name and a
wildcard extension (i. e. E:*.*) and press ALT+O. To quit the file selector without action, press
ALT+C (Cancel).
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BUNGARD CCD Manual Page 6

2.2 Mouse
If there is amouse installed to your computer, selecting buttons or edit fields turns to be much
easier:
Click an edit field once to position the cursor
Click abutton once to activate acommand
Double click afile name or click once on the file name and once on the OK button to choose
a
file from the file selector.
Click the CANCEL button once to leave the file selector without action.
2.3 Numbers
All entries to numeric edit fields exept for those for the Xand Yoffset are unsigned numbers.
All speed settings are integers. The measuring unit, i. e. "10 mil" or "mm /min" is indicated
above or besides the edit field.
3. Quick Start
The following chapter shall give you afirst introduction to using the machine and the software.
Please follow all the steps from loading adrill file to doing afirst test run of the machine.
More
detailed information on all possible menu selections follows in later chapters. There are
some
sample drill files in the SAMPLES subdirectory on your original disk. For this test run we
assume that you use one of them together with the original menue settings.
3.1 Starting the software Load the file DRILLPRO.EXE
from the DOS prompt. After a
short loading time, the
entry
dialogue comes up. Quit by
pressing ALT+O for OK or just
RETURN. You may also positi-
on the mouse cursor into
the
button field and click once with
the left mouse button.
The software will then initialize,
open the serial interface and ca-
librate the speed for driving
the
stepper motors. Except for alitt-
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le delay, you will normally not recognize this initial set-up. Only if an error message comes
up,
please continue reading chapter 4.7.8 to find out how to configure the serial interface.
3.2 Main Menu
The program now shows the main menu. As long as no drill file has been loaded into memory,
the start button is inactive. So please load adrill file: Press ALT+L. The file selector comes
up.
Read chapter 2for information on how to select afile.
3.3 Loading
While reading the file from disk, aprogram message "Reading drill file, please wait"
appears.
If, by any reason, errors occur when reading the file, the program issues warnings. These
are
described later under the topic "Errors in files".
After asuccessful load, atool table appears on the screen. This will also be explained later
on.
(ATC): For now, only the number of drill bits used by that data file is of interest. Place
the
necessary tools into the receptacles 1to 15. (The tool change position No. 0is reserved for
the
test pin that is in the spindle when it is not used.) Leave this dialogue without alteration.
3.4 Drilling
The main menu appears again (pict. on p. 14). For this first run, you need not put aboard or a
base sheet onto the machine table. Anyway, set the entry for the base sheet thickness to 10
mm.
The START button is now available. "Push" it. The three axes will move to their home positi-
on and will then run again back and forth at slow speed to exactly find the reference switch
position.
The machine is now in adefined starting position. It starts execution of the drill file.
(ATC): The tool change cycle is like follows: The test pin is moved to the drill brake detector
and then is put into tool change position No 0. The Zaxis is lift with the chuck open. The
X
and Yaxes move on aU-shape path from position 0to 1. The Zaxis takes the drill bit,
the
chuck closes and the Zaxis lifts agian.
The spindle is turned on and accelerates to the preset rotation speed. The machine seeks
the
initial drill position. As we set the base sheet thickness to 10 mm, the holes will be drilled "in
the air".
On the screen, the X- and Y-coordinates for each move are shown as well as the numbers of
holes ready and in total. In the first line of this box there will be ashort status information like
"Drilling...", "Moving...", "Spindle Start", "Spindle Stop", "Tool Change" or else.
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(ATC): If there are more than one tool used in the drill file, the spindle will stop and the tool
change sequence will be repeated. After use, each tool is checked in the drill break detector.
3.5 Interruption
You can at any time stop the machine by pressing the ESC key. Keep it pressed for ashort
time
until amessage like "Interrupted... Zaxis lift, Spindle Stop" appears. After the spindle stop,
the
following dialogue appears:
You may then choose to stop (ABORT) or
to go on (CONT.) If you choose to conti-
nue, the machine restarts from the last po-
sition. (When interrupted during adrill ac-
tion, you will be asked if the last hole
shall
be drilled again).
If you have chosen to abort, the
machine
will for security reasonsr emain in the ac-
tual position.
(ATC): Adialogue comes up that allows you to open the chuck and replace the drill bit by
the
test pin from tool pos. 0. (If you miss to do so, the drill will at the next restart go into position
0
and will most certainly break because the test pin is still in. that position.)
Back to the main menu, the sequence number related to the last pair of coordinates will appear
in the DRILL FROM edit field.
3.6 Ready
(ATC): After having drilled all holes, the last drill is returned into its receptacle and the test pi
n
is picked up.
The machine will then return to the zero position (reference run) and you find yourself back in
the main menu.
If you followed this instruction up to here, the machine has done afirst test run. We hope that
it
was successful. You may now try and test on your own the one or other choice from the
menus.
Damage to the machine is nearly impossible. You may anyhow want to do your first experi-
ences without board and base sheet. (ATC): It is only important that there are always drill bits
in the currently used tool change positions. The following chapter gives more detailled
informa-
tion on the options and choices that software offers.
4. Dialogues and Menues
4.1 Start-up dialogue This box always appears after
starting the driver. It shows a
copyright information and also
informs you on the
maximum
quantity of holes/vectors possi-
ble with the actual free
memory
size. The maximum is 16000. If
there is less memory free (i. e.
TSR programs in the back-
ground), you will find areduced
capacity.
Only if there is space for less
than 3000 vectors, or if awrong
DOS version was installed on
your computer, or if yout com-
puter is not AT-compatible,
the
program will not show this dia-
logue but will give ashort mes-
sage at the DOS prompt.
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4.2 Main Menu
The main menu is the "pivot" for all other program action. It allows to set all necessary
parame-
ters and offers different buttons for program control.
4.2.1 Edit fields
The edit fields are arranged in abox. The column titles indicate their function. The rows titled
X: and Y: relate the first three columns to the both main axes. The two fields titled from:
and
to: define the vector/hole where to start and to end processing. The last two fields in the box
define the thickness of the board and of the base sheet.
4.2.1.1 Scale
You may here chose ascaling factor separately for the X- and Y-axis. This is to reduce or
enlarge the image size or to adapt to other than the predefined coordinate units.
Unit: -
Default: 1.0000
Minimum: 0.0000
Maximum: 9.9999
Limits: High values may produce coordinates out of the possible ranges. See 4.2.1.3,
clipping.
4.2.1.2 Offset
Enter an offset from the Xand Yzero position to move the image zero point in positive or
negative direction from the machine zero position. Useful for shifting drilling /routing data or
to adapt data to shifted board origins.
Unit: mm
Default: Depending on the mechanical set-up of the machine bed.
Minimum X:-495.00
Y:-325.00
Maximum X:+495.00
Y:+325.00
Limits: High values may produce coordinates out of the table range. See 4.2.1.3, clipping.
The decimal digits are rounded to multiples of 1mil during drilling /routing.
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4.2.1.3 Clipping
Clipping restricts the range of valid coordinates. The machine's zero position and the
clipping
coordinates define the actual working area.
The settings in these fields are independent from the offset settings. Holes or vectors out of
this
area will not be processed.
The maximum values correspond to the maximum possible working area of the machine so
that,
under normal conditions, the main axes will not touch the mechanical limits of the machine.
Unit: mm
Default X: 495.00
Y: 325.00
Minimum X: 000.00
Y: 000.00
Maximum X: 495.00
Y: 325.00
Limits: Decimal rounding like for Offset.
The clipping and offset settings are evaluated during the drilling /routing process. If there
are
values out of the predefined range, the program reacts as follows:
DRILLING: The holes out of range will be skipped.
ROUTING: All vectors which lie partially or entirely outside the clipping rectangle, as well
as
the first and last vector leading out and back into the clipping area, will be ignored. The router
will be lift. Processing continues with the next valid vector. The dialogue that shows the pro-
gress in work indicates "Clipped..." instead of "Drilling ..." or "Routing..."
4.2.1.4 Drill /Route FROM: TO:
You may define the first and the last hole /vector to be processed. The order is given by
the
(sorted) drill file or the route file.
Invalid values in the FROM: or TO: field will be replaced by 1or will cause the "Input
error"
dialogue to come up.
After acomplete processing of all coordinates the previously chosen FROM: value reappears. If
execution was interrupted, the next following hole number appears in the FROM field.
You may use the FROM and TO settings for example to drill only those holes related to
one
certain tool. Another possibility is to redrill asingle hole after occurrence of adrill damage.
Values:
FROM: Minimum: 0001
Maximum: No. of holes or 16000
Default: 1
TO: Minimum: FROM value or 0001
Maximum: No. of holes or 16000
Default: No. of holes or 1
4.2.1.5 Board thickness
Choose the thickness of the board to be drilled. This input is necessary for the program to
determine the Z-axis movement.
Unit: mm
Default: 1.5
Minimum: 0.0
Maximum: depending on the total Zstroke length
Limits: An invalid entry will be rejected as soon as you try to leave the main menue. You
may alter the configuration file in order to change the default value.
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4.2.1.6 Base sheet thickness
Set the thickness of the base sheet. This input is important for the correct calculation of
the
Z-axis movement.
Unit: mm
Default: 2.0
Minimum: 0.5
Maximum: depending on the total Zstroke length
Limits: An invalid entry will be rejected as soon as you try to leave the main menue. You
may alter the configuration file in order to change the default value. The minimum
value cannot be reduced. It is necessary to give asecurity gap between drill bit
and
machine bed.
4.2.2 Info fields
To the right of the edit fields in the main menu, there are the following information displayed:
TOTAL: nnnn
DONE: nnnn
FILE: UNNAMED.???
The field TOTAL: shows the total amount of holes/vectors. DONE: gives you the quantity of
already processed holes/vectors, counted from the last start of execution.
After program start, the field FILE: is empty. After loading afile, the file name will be shown
here. The default settings for the file type may be altered in the configuration menue.
Beneath the DRILL FROM..TO entries, the screen shows the maximum and minimum coordina-
tes read from adrill /route file. This display is meant as ahelp to determine the coordinates
measuring unit and the position of the drill data related to the machine´s zero position. The first
line shows the Xminimum value on the left and the maximum on the right. The second
line
does the same for the Ydirection. Both, Xand Ymax. and min. values are independent. So
the
vector with the max. Xposition can at the same time be the one with the min. or any else
Y
position and vice versa. These positions are also NOT related to the drill location on the board
and also do not allow any assumption on the position of the board on the machine bed.
4.2.3 Buttons
The main menue contains the buttons LOAD, START, OFFSET, TOOLS, CONFIG.,
PANEL.
(Panelization, drilling only) and QUIT. The parts of the program related to these buttons
may
contain other sub-menues. The operating sequence for these will be described here below.
4.3 LOAD
Shortcut: ALT+L
Action: Shows the file selector to load anew drill /route file. (See chapter 2for details) If you
leave the file selector with ALT+C (cancel), the data in memory (if any) remain unchanged.
While loading the file, the program displays "Reading Drill file, please wait" or "Reading route
file, please wait" respectively. In the case that there are wrong coordinates or tools in the file,
alerts will appear. These will be described later. See chapter "Errors in files".
DRILLING only: According to what was chosen in the configuration, the drill positions
are
beeing sorted in serpentines. Amessage comes up for some seconds.
ROUTING: HP/GL vector coordinates cannot be sorted.
Next comes adialogue showing atool table. This will be described in the TOOLS
chapter.
Back to the main menu, the entry to the edit field TO: and the info fields TOTAL and FILE
are
preset.
If errors occurred when loading, the start button remains inactive. In this case, you should either
read another file or quit the program and check the drill file for errors.
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4.4 START
Shortcut: ALT+S
Press this button to start execution. All three axes will be initialized by areference run. In
DRILLING mode, the machine then goes to the location of the first hole. You will be prompted
as follows:
4.4.1 Tool change
4.4.1.1 Automatic
The tool change sequence is like follows: After the initial reference run, the test pin is checked
in the drill break detector and is returned to tool change position 0. The spindle is lift with
the
chuck open. The Xand Yaxes move in Ushape from the old to the new tool position. The
Z
axis goes down to take the drill bit and the chuck closes. The spindle moves up again, starts
and
accelerates to the preset rotation speed. The machine goes to the first hole to be drilled. After
drilling all holes assigned to that tool, the spindle stops. The sequence will be repeated for all
subsequent tools with the last used tool instead of the test pin beeing checked in the drill break
detector.
If adrill break occured, that tool is not returned into its receptacle but will be dropped in
front
of it. At the end of the drill job, the test pin is picked up and areference run follows.
4.4.1.2 Manual
ADialogue showing the actual tool parameters appears. Insert the tool as described under
2.5
and confirm by the READY button or stop with the ABORT button.
4.4.1.3 Spindle control
The spindle is turned on and off automatically. During the acceleration and brake action
the
software respects adelay time. This time is given in seconds per 10 000 rpm and can be set in
the configuration menue.
4.4.2 Execution
The coordinates read from the file will be transformed into steps according to the settings for
scaling, offset and clipping that you made in the main menu. The actual coordinates and
the
number of holes in total and already done will be shown on the screen.
You can at any time stop the machine by
pressing
the ESC key. Keep it pressed for ashort time
until
amessage like "Interrupted... Zaxis lift,
Spindle
Stop" appears. After the spindle stop, the following
dialogue appears:
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You may then choose to stop (ABORT) or to go on (CONT.) If you choose to continue,
the
machine restarts from the last position. (When interrupted during adrill action, you will be
asked if the last hole shall be drilled again).
If you have chosen to abort, the machine will for security reasons remain in the actual
position.
Back to the main menu, the sequence number related to the last pair of coordinates will appear
in the DRILL FROM edit field.
Remark: the time needed to recognize the ESC key may be longer at a) slow computers and /or
b) high drill speeds. In this case, it may be necessary to keep the ESC key pressed alittle
bit
longer.
The HF generator has aspindle overload protection. If overload occurs, the machine will
also
stop automatically and an alert box similar to the above comes on the screen. Spindle overload
is asevere exeption so that this box does not allow to continue.
During normal execution, the tool change sequence is beeing repeated for each new tool. After
all vectors have been processed aready message appears and you are returned to the
main
menu.
It is possible to drill one file for several times and with different settings for scaling, offset,
clipping etc. The actual drilling /routing coordinates will be recalculated for each run.
4.5 Offset
This command permits you to manually set an offset position. This is useful if you need to
install aboard zero position different from the machine zero.
First after pressing this button, areference run follows. If there was apositive entry to the
X
and Yoffset fields in the main menu, you will be asked whether or not you want to start offset
teaching at that position. If you decide to have the old offset deleted, the entries in the
main
menu edit fields will be reset to zero. So will they be, if at least one of the entries was negative.
Otherwise, the machine will now move to the old offset position.
In the right upper corner the following screen shows the actual Xand Yoffset position.
The
four buttons in the middle are labelled by "back", "forw.", "right", "left". They relate to
the
appropriate directions of the two main axes. Apart from mouse clicking the buttons, you
may
either use the S,D,E,X keys or the 4,6,2,8 keys on the numeric keypad to have the
machine
move. The Zaxis is controlled either by the Rand Ckey or the 9and 3keys on the
numeric
keypad.
The distance for each movement is set by achoice from the radio buttons in the left lower
corner of the screen. Possible values are 1, 10, 100 or 1000 mil.
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Limitation: Moving the machine repeatedly for short distances may lead to acertain loss of
accuracy. It is recommended to do acoarse approach with long moves first and small correc-
tions later.
The main menu scaling factor is not taken into account for offset teaching. The clipping
limits
will be respected.
Pushing the OK button will leave the dialogue. The values for the manually set offset position
will be copied to the corresponding edit fields in the main menu and will be rounded to
mm.
(The step width for offset teaching is based on multiples of mil because stepping in mm would
give an additional loss of precision.)
4.5.1 Teach-In (Drilling only)
The dot-coloured elements of the above screen hardcopy appear only if you entered
the
TEACH-IN mode by pressing the TEACH button once. This mode is useful if you have to
register the position of holes from artworks that were not made on aCAD. (Camera and
moni-
tor are optionally available.)
The edit fields named T, Xand Yare used to indicate and to alter the tool code and the X
and
Ycoordinates for each registration position. To go to ateach-in position, use the S,D,E,X
and
the Rand Ckeys as explained. Then press the TEACH button once and continue with the next
hole. The -POS button moves back to the last position, the +POS to the next (Of course, you
cannot step back before the first or step forth beyond the last position) The coordinates shown
in the Xand Yedit fields can be overwritten manually. The same applies for the Tool code.
Press the MOD button to make the machine go to amanually changed position.
When you leave the Offset Teach menu, you will be prompted if the teached coordinates shall
be written to disk. The teach-in option generates standard drill files which can be loaded back
into DrillPro.
4.6 Tools
This button corresponds to the dialogue which also appears after loading afile. It contains
information on the working parameters of up to 15 tools. The tools are distinguished by name,
witch actually is atwo digit numeric code. The same code may appear in afile more than once,
but of course would occupy one of the 15 possible positions in the drill rack. If there are
more
than 15 tools in afile, an error message comes up. The drill rack´s empty positions have a"- -"
entry in the name column.
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