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.

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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

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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

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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

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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