LPKF ProtoMat S42 User manual

Manual ProtoMat S42
English, version 2.0
LPKF Laser & Electronics AG
Osteriede 7
D-30827 Garbsen
Telephone : ++ 49 - 51 31 - 70 95 - 0
Telefax : ++ 49 - 51 31 - 70 95 - 90
eMail : [e-mail]
Homepage : http: //www.lpkf.de

2 Version 2.0 Rev.: 24.4.06 ProtoMat S42
Copyright (C) 2006 LPKF AG
No part of this document may be reproduced or transmitted or used for
any purpose without the express written permission of LPKF. The
information contained in this document is subject to change without prior
notification. LPKF assumes no liability for the use of this document. In
particular for damage resulting from information, which is present, not
present or erroneous.
Trademarks: HP-GL is a trademark of the Hewlett-Packard Corp.
All other trademarks are the property of the specific proprietor.
Item number: 117653

ProtoMat S42 Version 2.0 Rev.: 24.4.06 3
Notes on this Manual
The information contained in this document is subject to change without
previous notice. No part of this document may be reproduced or
transmitted for any purposes in any form without express written
permission of LPKF AG. All efforts were made to ensure that this
document is as accurate as possible and that the information contained
therein is complete. Nevertheless, LPKF AG cannot assume any liability
for its use or for any violations of patent or other rights held by third
parties resulting there from.
The operator of the machine is responsible for ensuring that the
following points are observed. Ensure that
• the machine is used only for its intended purpose.
• the machine is operated only in a perfect functional condition and
particularly that the safety equipment is checked regularly for
proper function.
• required personal protective equipment for the operating,
maintenance and repair personnel is available and used.
• the operating instructions are always kept at the location where
the machine is operated and are in a legible and complete
condition.
• only sufficiently qualified and authorized personnel operate,
service and repair the machine.
• this personnel is trained regularly on all questions regarding labor
safety and environmental protection as well as is familiar with the
operating instructions and particularly the safety precautions
contained therein.
• all safety and warning information attached to the machine is not
removed and remains legible.

4 Version 2.0 Rev.: 24.4.06 ProtoMat S42
I. Outline
This Manual is subdivided into the following chapters:
1. Introduction
2. Intended use
3. Safety notes
4. Scope of delivery
5. Layout of machine
6. Bringing into service
7. BoardMaster User Surface
8. Introduction to the Basic Functions
9. BoardMaster Functions
10.Menu Bar
11.Operating procedures
12.Practical tips
13.Other BoardMaster Functions
14.Special Applications
15.Appendix
16.Options
17.Technical Data
18.Declaration of conformity (German)
19.Declaration of conformity
20.Index
II. Conventions used in this manual
Bold text is used to emphasize important information.
Illustrations are numbered. Example: Fig. 5
› Prompts for actions are identified with an arrow.
Italic sections are used to indicate the reactions consequent on an
action.
Word printed in italics mark proper names.
Key inscriptions and menu terms are printed in BOLD CAPITALS.

ProtoMat S42 Version 2.0 Rev.: 24.4.06 5
III. Notes on the symbols used
Danger! This symbol is used to highlight danger to life or health.
Caution! This symbol is used to identify hazards which may cause
damage.
Note! This symbol is used for notes intended to help you avoid faults in
operation or to help you improve your procedures.
Machine greenhorn:
This symbol indicates important tips and information for those not
already familiar with LPKF milling technology.
IV. Terminology
Copper laminate : Special extremely thin base material used for
pressing multilayers.
Base material : Circuit board material coated with copper foil
Solder resist foil : Special foil with cutouts for solder connections
on a circuit board.
BoardMaster : Machine control software.
CircuitCAM : Software for data processing
V. Target Group
This manual is intended for personnel who already possess basic
knowledge of production of circuit boards for the electronic sector.
VI. Intended Use
The machine described in this manual is intended exclusively for
milling and drilling standard commercial circuit board materials in
the electronic industry. Any other type of use of the machine is
expressly prohibited.

6 Version 2.0 Rev.: 24.4.06 ProtoMat S42
Contents
1.0 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . 11
2.0 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . 13
3.0 Safety Notes . . . . . . . . . . . . . . . . . . . . . . . . 14
4.0 Scope of Delivery . . . . . . . . . . . . . . . . . . . . 16
4.1 Accessories (available as option) . . . . . . . . . . . . .16
5.0 Layout of Machine . . . . . . . . . . . . . . . . . . . 17
5.1 Initial Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.2 Orientation Axis / Positions . . . . . . . . . . . . . . . . . .20
5.3 Machine Components and Connections . . . . . . . .21
5.4 Serial Interface(s) / USB Connection . . . . . . . . . . .22
5.5 Functional Units . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.5.1 The Machining Head . . . . . . . . . . . . . . . . . . . . . . 25
5.5.1.1 Machining Spindle with Collet . . . . . . . . . . . . . . . . . 26
5.5.2 Working Depth Limiter . . . . . . . . . . . . . . . . . . . . . 28
6.0 Bringing into Service . . . . . . . . . . . . . . . . . 29
6.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
6.1.1 System Prerequisites . . . . . . . . . . . . . . . . . . . . . . 29
6.1.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1.3 Directories Generated During Installation . . . . . . 31
6.2 Installation of the USB / RS232 Adapter . . . . . . . .31
6.3 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

ProtoMat S42 Version 2.0 Rev.: 24.4.06 7
6.3.1 HOME Position and Reference Hole System . . . 32
6.4 Switching On the Circuit Board Plotter. . . . . . . . . .33
6.4.1 Starting BoardMaster. . . . . . . . . . . . . . . . . . . . . . 34
6.4.2 Wait Message . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.5 Switching Off the Circuit Board Plotter. . . . . . . . . .36
7.0 BoardMaster User Surface . . . . . . . . . . . . 37
7.1 Function Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
7.2 Brief Summary of Function Bar . . . . . . . . . . . . . . .39
7.2.1 Status information . . . . . . . . . . . . . . . . . . . . . . . . 40
8.0 Introduction to the Basic Functions . . . . 41
8.1 Creating a New Reference Hole System . . . . . . . .41
8.2 Putting on base material. . . . . . . . . . . . . . . . . . . . .42
8.3 Working with Production Data and Phases . . . . . .43
9.0 BoardMaster Functions. . . . . . . . . . . . . . . 49
9.1 Changeable Settings . . . . . . . . . . . . . . . . . . . . . . .49
9.2 Positioning Functions . . . . . . . . . . . . . . . . . . . . . . .49
9.3 Control Functions for Manual Control. . . . . . . . . . .50
9.4 Selection functions . . . . . . . . . . . . . . . . . . . . . . . . .51
9.5 Control Functions for Production Phase. . . . . . . . .52
10.0 The Menu Bar . . . . . . . . . . . . . . . . . . . . . . 53
10.1 Go To Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
10.2 CONFIGURATION Menu . . . . . . . . . . . . . . . . . . .54

8 Version 2.0 Rev.: 24.4.06 ProtoMat S42
10.2.1 Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10.2.2 Machine Settings . . . . . . . . . . . . . . . . . . . . . . . . 56
10.2.3 Tool Parameter. . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.2.4 Heads Dialog Box. . . . . . . . . . . . . . . . . . . . . . . . 60
10.2.5 Adjust Camera Offset . . . . . . . . . . . . . . . . . . . . . 61
10.2.6 Phase... - Production Phases. . . . . . . . . . . . . . . 62
10.2.7 Defining the Base Material Size . . . . . . . . . . . . . 64
10.3 File Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
10.4 Edit Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
10.4.1 Assigning Tools . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.4.2 Placing Projects . . . . . . . . . . . . . . . . . . . . . . . . . 70
10.4.3 Select Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10.5 Reload Dialog Box . . . . . . . . . . . . . . . . . . . . . . . .72
10.6 View Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
10.7 Selecting Production Phase . . . . . . . . . . . . . . . . .75
11.0 Operating Procedures . . . . . . . . . . . . . . . 76
11.1 Fastening the Base Material. . . . . . . . . . . . . . . . .76
11.2 The tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
11.3 Drilling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
11.4 Insulation Milling . . . . . . . . . . . . . . . . . . . . . . . . . .78
11.5 Contour Milling in Circuit Board Material . . . . . . .79
11.6 Milling Wide Insulation Channels . . . . . . . . . . . . .80
11.7 Cleaning Circuit Boards . . . . . . . . . . . . . . . . . . . .81
12.0 Practical Tips . . . . . . . . . . . . . . . . . . . . . . 82
13.0 Other BoardMaster Functions . . . . . . . . . 84

ProtoMat S42 Version 2.0 Rev.: 24.4.06 9
13.1 Learning Fiducial (Option) . . . . . . . . . . . . . . . . . .84
13.2 Setting fiducials . . . . . . . . . . . . . . . . . . . . . . . . . .88
13.2.1 Measuring function (with camera system) . . . . . 91
13.2.2 Adjusting Milling Depth . . . . . . . . . . . . . . . . . . . 92
13.2.3 Drilling Reference Holes in Base Material . . . . . 93
14.0 Special Applications . . . . . . . . . . . . . . . . 95
14.1 Front Panel Engraving . . . . . . . . . . . . . . . . . . . . .95
14.2 Milling Polyimide Films . . . . . . . . . . . . . . . . . . . . .95
15.0 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . 97
15.1 Switching over the device voltage . . . . . . . . . . . .97
15.2 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
15.2.1 X Axis, Y-Axis and Z Axis . . . . . . . . . . . . . . . . . 99
15.2.2 Maintenance on Working Depth Limiter . . . . . 101
15.2.3 Maintenance instruction for Machining Head . 103
15.3 The Teach-In Dialog Box . . . . . . . . . . . . . . . . . .104
16.0 Options . . . . . . . . . . . . . . . . . . . . . . . . . . 107
16.1 Installing the camera . . . . . . . . . . . . . . . . . . . . .107
16.2 Mounting the Vacuum Table . . . . . . . . . . . . . . . .109
16.2.1 Machines without housing . . . . . . . . . . . . . . . . 110
16.2.2 Machine with housing . . . . . . . . . . . . . . . . . . . 114
16.3 Spring setting at the machining head . . . . . . . . . 116
17.0 Technical Data . . . . . . . . . . . . . . . . . . . . 118
18.0 Declaration of Conformity (German) . . 119

10 Version 2.0 Rev.: 24.4.06 ProtoMat S42
19.0 Declaration of Conformity . . . . . . . . . . . 121
20.0 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Introduction
ProtoMat S42 Version 2.0 Rev.: 24.4.06 11
1.0 Introduction
The machine described in this manual is a circuit board plotter suitable
for producing circuit board prototypes and engraved films. It consists
basically of a base plate, an X/Y motion system and a machining head.
This machining head can be moved along both axes with the aid of the
X/Y motion system. The machining head can also be lowered. This
results in two basic processing possibilities. First, a channel can be
milled with a milling cutter in a piece of base material fastened to the
base plate by moving the lower machining head.
Second, a hole can be drilled in the base material by lowering the
machining head when it is standing still and a drill installed.
This circuit board plotter offers very high precision in machining and high
machining speed. Almost completely automatic processing is possible
due to other special functions like the adjustable depth with which the
tool penetrates the base material during drilling, which can be set via the
software. All this helps to minimize the effort required for operation in
small series production. Another special feature is the optionally
available vacuum table which enables the processing of soft and flexible
substrates (special PCB materials).
The machine is controlled and operated almost completely by the
BoardMaster software. Always read this manual carefully before
starting work with the machine. After unpacking, set up your circuit
board plotter on a suitable table (see chapter „Initial Setup“ on
page 17 for a description) and inspect all of the components
described in the following chapters precisely, i.e. familiarize
yourself with the mechanical control possibilities. This will make it
easier when you then start up the machine in combination with the
software with the aid of the quick start instructions or the
BoardMaster chapters.
LPKF BoardMaster 5.0 for WindowsTM is a program for automatic control
of HP-GL-compatible LPKF circuit board plotters.
LPKF BoardMaster is capable of reading in, displaying and processing
production data in LMD format (generated in LPKF CircuitCAM) as well
as production data generated in HP-GL format
BoardMaster takes over complete control of the circuit board plotter. The
WYSIWYG (What You See Is What You Get) display for the data to be
processed, manual control of the circuit board plotter on the Windows
surface as well as the present tool library with all required information
ensures virtually complete automation of circuit board prototype
production.
This Manual shows you the path from LMD/HP-GL circuit board data
generated by CircuitCAM or other programs, over job preparation right
up to completion of the circuit board prototypes with the circuit board
plotter.
The Manual introduces the basic control possibilities of BoardMaster
step by step, allowing you to quickly complete your first circuit board in a
simple manner.
Basic use of the Windows surface is not covered in this manual. If you
are not familiar with the use of the various Windows objects, please first
refer to your Windows documentation.

Introduction
12 Version 2.0 Rev.: 24.4.06 ProtoMat S42
In order to ensure that any possible guarantee claims are honored,
always follow the instructions in this manual before starting up the
machine. Machines exported to other EU countries are subject to the
guarantee terms in that country.
Now we hope you enjoy familiarizing yourself with your circuit board
plotter.

Intended Use
ProtoMat S42 Version 2.0 Rev.: 24.4.06 13
2.0 Intended Use
The machine described in this manual is exclusively designed and
constructed for the machining of commercially approved materials for
the production of printed circuit boards or front plates. This comprises
especially the following working steps:
Machining of all one-sided and double-sided board types in the usual
packing density (FR3, FR4, FR5, G10), flexible substrates, drilling test
adapters, structuring film patterns, producing solder frames for PCB
assembly, SMD fine line technology, contour-milling, engraving of front
panels or labels, depth milling of rigid or flexible boards, depaneling and
reworking of populated and unpopulated boards, machining of housings
and multilayers up to 8 layers in combination with MiniContac III and
MultiPress-II.
Any other use is explicitely forbidden! Danger of damage to
material or personal injury, and any guarantee claims are excluded!

Safety Notes
14 Version 2.0 Rev.: 24.4.06 ProtoMat S42
3.0 Safety Notes
Danger: To ensure safe work with the circuit board plotter, the user
should read this Manual as well as the enclosed documentation
and particularly the safety precautions in bold face print!
• Keep your workplace orderly. Disorder at the workplace
increases the danger of an accident!
• Take surrounding influences into consideration: Do not
subject the electric machine to water or water spray. Do not
use the circuit board plotter in moist or wet surroundings.
Provide for good illumination. Never use the machine in
areas endangered by fire or explosion.
• Keep children away from the working area! Ensure that
children cannot touch the machine or connection line!
• Wear suitable work clothing! Do not wear wide clothing or
jewelry. This can be caught by moving parts!
• Wear a hair net if you have long hair! Otherwise, your hair
can get caught in a rotating tool!
• Care for your machine and the accessories properly and
observe the maintenance instructions! Check the plug and
cable regularly and if damaged have replaced by an
authorized electrician!
• Before any type of maintenance or cleaning work on the
machine, disconnect the power plug!
• Always be attentive! Observe your work and proceed
rationally. Do not use the machine if you are
unconcentrated!
• Always work with the vacuum on! Dusts resulting during
operation of the machine may pose a health hazard and
must therefore be evacuated!
• Check the machine regularly for damage! Ensure that all
parts are installed correctly and that all conditions are
fulfilled for proper operation as intended.
• Use only accessories and add-on equipment specified in the
operating instructions or recommended or prescribed by the
manufacturer! Use of other tools or accessories can cause
damage to the machine or pose an injury hazard for the
user!
• Have the machine repaired by authorized personnel! The
circuit board plotter fulfills all applicable safety regulations.
Repair should be performed only by qualified personnel
using genuine parts, because improper repairs can pose an
injury hazard for the user
• Never reach into the machine while it is running!
• When using a machine with housing: do not open housing
while machine is in operation, danger of injury!
• Caution! Machine changes motion speed automatically
during operation!

Safety Notes
ProtoMat S42 Version 2.0 Rev.: 24.4.06 15
• Change tools only with the machining head spindle stopped!
Injury hazard!
• When changing tools manually, always insert tool into chuck
against stop!
• When performing manipulations on the machine, never
operate the controlling PC simultaneously.
• Never reach into the traversing range of the running
machine! The XY positioning systeem may move very fast.
Fot this reason the handling also of auxiliary tools in the
area of the base plate is strictly prohibited. Shear force may
e.g. cut of fingers
• The safety of the machine can no longer be guaranteed if
modifications are made to the machine by the user and the
guarantee is invalidated!
• Observe that some materials can produce carcinogenic dust
or dangerous gases during processing. Obtain information
from material suppliers.
• Eating, drinking or smoking while working with the circuit
board plotter is prohibited! The danger exists of ingesting
toxic substances through the mouth! Never leave food or
beverages open in the workroom (dust deposit!).
• When using chemicals, please observe the instructions on
the containers or any separate safety data sheets!
• Wear suitable protection gloves during the exchange of
material of the machine base plate. Danger of cutting due to
sharp edges of the metall supports!
• Ensure that your computer is properly connected to the line
power and to the circuit board plotter!
• Ensure that no one is present in the hazard area of the
circuit board plotter during data transfer between
BoardMaster and the circuit board plotter!
• Ensure that no one can enter the hazard area of the circuit
board plotter and come into contact with the tools during
operating phases controlled by BoardMaster!
• Ensure that it is not possible for unauthorized persons to
operate BoardMaster when working with the circuit board
plotter, for example during manual tool change or alignment
of the base material!
• In the event of an emergency, shut off the circuit board
plotter and PC connected to the circuit board plotter
immediately!
• Also observe other safety precautions in this manual!

Scope of Delivery
16 Version 2.0 Rev.: 24.4.06 ProtoMat S42
4.0 Scope of Delivery
• 1 Machine unit LPKF ProtoMat S42 with integrated electronic
circuitry
• 1 Connection cable machine - PC (RS232)
• 1 USB/RS232 adapter
• 1 Set accessories (foot of the working depth limiter, adhesive
tape, various Torx tools, 5 reference hole pins, tweezers, brush, 2
red reference hole strips, 2 reference hole drills 2.95 mm, set of
fuses)
• 1 Power cable
• 1 Piece base material (fixed on machine base plate)
• 1 Manual ProtoMat machine and software BoardMaster
• 1 CD ROM with software program BoardMaster
• 1 Manual software CircuitCAM
4.1 Accessories (available as option)
• 1 Vacuum system with fine mesh filter and integratetd automatic
switch, adjustable exhaust power and automatic filter control. The
vacuum system is switeched on and off via the machining
spindle.
• Danger: The fine filter is required particularly for processing
materials containing fiber glass such as FR4 base material!
Otherwise, the hazard exists of carcinogenic dust particles
escaping!!
• Vision System
Camera-based positioning system for fiducial recognition
• LPKF ProConduct
System for through-plating with paste
• LPKF ProMask
System for application of solder resist
• Vacuum table
System for fixing rigid or flexible materials free from distortion or
warp
• Hood

Layout of Machine
ProtoMat S42 Version 2.0 Rev.: 24.4.06 17
5.0 Layout of Machine
5.1 Initial Setup
› Lift the cover of the cardboard box (1in figure below) and remove
the cardboard below
› Remove the software package and the manuals.
› Pull the styrofoam parts (3) at the side upward out of the box and lift
the cardboard sidewalls (2) .
› Remove the protective foil.
› Put the circuit board plotter on a horizontal support capable of
bearing the load.
Figure 1: Cardboard packing of the
ProtoMat S42
Note: The machine should be positioned on a level and solid
surface to prevent malfunctions and erroneous operation!
› Remove securing device (see 1 in following figure) before switching
on the plotter !!! Also remove any residual glue remaining on the
board.
Caution! Should you switch on the plotter without having removed
the transport securing device first, we will not accept any guarantee
claims for resulting damage!!!
1- Top cover of cardboard machine packing
2- Cardboard sidewalls (or frame)
3-Styrofoam protection at the sides
4- Place for manuals
13
23
4

Layout of Machine
18 Version 2.0 Rev.: 24.4.06 ProtoMat S42
Figure 2:Transport sealings
› After the removal of the transport securing device, the foot of the
working depth limiter (contained in the accessories set supplied with
the delivery) has to be inserted in the working depth limiter
underneath the mill/drill head! To do this, hold the machining head
tight with your other hand and press foot in!
›
Note: If the software BoardMaster should already have been started
when the foot is being inserted and should the machining head not
be held firmly, then an error message appears as the machining
head is moving outside of the movement border.
Figure 3: ProtoMat S42
› Connect the 25 pol socket to the 25-pole connector at the rear of the
ProtoMat. The other side with the 9pole connector can either be con-
nected to the USB port of your PC (to do this, a USB/RS232 adapter
must be used) or directly to the COM port.
1
1- Vacuum hose
2- Machining head
3- Movable table to fix base material
3
1
2
3

Layout of Machine
ProtoMat S42 Version 2.0 Rev.: 24.4.06 19
Note: The machine can only be operated at COM1 to COM32. If a
renumbering of the ports should be required, please read the
Windows-Help file.
› Connect the power cable on the LPKFProtoMat machine to the line
power. To do this, pull the power cable from the backside of the
machine to the front until it reaches the main switch.
Figure 4: Mains connection, main
switch, voltage switch-
over
› Screw the vacuum hose in the connecting piece (counter-clockwise)
and attach this to the adapter, see figure below.
Figure 5: Connection vacuum
system
› Attach the loose vacuum hose over the circuit board plotter to the
appropriate connection on the machining head (position 5 in figure 1
on page 17).
1- Mains connection, main switch and switching the voltage
1
1Exhaust adapter 3Vacuum hose
2Connecting piecet
1
2
3

Layout of Machine
20 Version 2.0 Rev.: 24.4.06 ProtoMat S42
› Connect the control cable for the exhaust system on the rear of the
machine (see figure 5.3 on page 21)
Note: Please save all transport retainers as well as the packaging
for re-use if the machine is transported again.
5.2 Orientation Axis / Positions
The machining head can move along 3 axes. These axes are called the
X, Y and Z axes. Definition of the axes is important for you during
operation so that you always know where the table is moving. In the
BoardMaster software, the motion paths are described exclusively
according to these axis designations.
Figure 6: Orientation axis
1- Pause position:
The machine is moved to this point to install or turn the material to be processed
2- HOME position
3- Zero position:
The macine is moved to this point after switching on (machining head on the left, table to the
front).
X-Axis
Y-Axis
Z-Axis: Lifting/lowering the machining head
1
2
3Z-Axis