LPKF ProtoMat S62 User manual

ProtoMat®S62
Operating Manual
7.1, English
Artikelnummer: xxx_xxx
Titelfoto einfügen:
Größe: 11,5 cm x 9,5 cm
Abstand: links: 8,5 cm
oben: 1,5 cm
Article number: 121 882

ProtoMat®S62
Operating Manual
7.1, English
LPKF Laser & Electronics AG
Osteriede 7
D-30827 Garbsen
Germany
Phone ++ 49 - (0) 51 31 - 70 95 - 0
Fax ++ 49 - (0) 51 31 - 70 95 - 90
E-Mail [email protected]
Homepage http://www.lpkf.de

ProtoMat®S62
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: 121 882
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 produc-
tion 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 pre-
cisely. Flexible and rigid/flexible workpieces can be fixed flat on the work-
ing 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.

Information about this document
Operating Manual 7.1 Rev.: 18.06.2008 3
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
→An arrow points to a different location in this document or to another
document specified by name.
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-observ-
ance 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.

Brand names
4ProtoMat®S62
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 dimen-
sions (50 mm).
– Numbers in bold print appearing inside parentheses (1) identify the
number in the figure described.
Italic print 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 headers 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.

Table of contents
Operating Manual 7.1 Rev.: 18.06.2008 5
Table of contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Information about this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
List of figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1 For your safety 15
1.1 Designated use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 What is what? 21
2.1 Circuit board plotter with acoustic cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Milling/drilling head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3 Traversing table and tool magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.4 Connecting elements and rating plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.5 LPKF dust extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3 What you should know 29
3.1 The milling/drilling head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1.1 Defined positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1.2 Milling depth/width limitation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2 The traversing table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.2.1 The pass hole system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.2.2 Material fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3 The tool magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4 Usable tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4.1 Surface tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.4.2 Penetrative tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.5 The 2.5 D function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.6 Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.7 Automatic operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.7.1 Production types and phase files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.7.2 Production phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.7.3 Data selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Table of contents
6ProtoMat®S62
4 Manual tasks and settings 47
4.1 Switching on the system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Switching on the LPKF dust extraction (optional) . . . . . . . . . . . . . . . . . . . . 48
Setting the suction force (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Switching on the circuit board plotter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Starting BoardMaster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Checking the connection settings (if necessary) . . . . . . . . . . . . . . . . . . . . . 51
4.2 Switching off the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Quitting BoardMaster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Switching off the circuit board plotter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Switching off the LPKF dust extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.3 Finding out about BoardMaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
4.3.1 The user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.3.2 Frequently used functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.4 Positioning the milling/drilling head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Moving the milling/drilling head to a predefined position . . . . . . . . . . . . . . . 59
Moving the milling/drilling head step by step in the X/Y direction . . . . . . . . 60
Moving the milling/drilling head with the mouse. . . . . . . . . . . . . . . . . . . . . . 60
Moving the milling/drilling head vertically. . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.5 Mounting/Dismounting the milling depth limiter base. . . . . . . . . . . . . . . . . .62
Dismounting the plastic base/brush head . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Mounting the plastic base/brush head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.6 Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
4.6.1 Loading and setting up the base material . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Loading base material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Defining the work area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Defining the material height and z values . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.6.2 Setting up tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Opening the tool magazine dialogue box. . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Assigning tool positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.6.3 Inserting tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Inserting tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.7 Selecting a tool for processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Picking up/Setting down a tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.8 Setting the focus (VisionSystem only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Setting the focus to the saved value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Adjusting the focus position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Table of contents
Operating Manual 7.1 Rev.: 18.06.2008 7
4.9 Drilling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Drilling a hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.10 Milling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Creating a milling track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Adjusting the milling depth (cylindrical tools) . . . . . . . . . . . . . . . . . . . . . . . . 76
Adjusting the milling width (Universal Cutter and Micro Cutter only) . . . . . . 76
4.11 Creating a pass hole system (basic equipment) . . . . . . . . . . . . . . . . . . . . . 77
Preparing the circuit board plotter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Drilling pass holes into pass hole strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Drilling pass holes into the drilling underlay . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.12 Creating a pass hole system for the vacuum table. . . . . . . . . . . . . . . . . . . 81
Preparing the circuit board plotter and vacuum table . . . . . . . . . . . . . . . . . . 82
4.12.1 Drilling pass holes into pass hole strips . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Setting parameters for drilling pass holes. . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Setting the machine parameters for drilling pass hole strips . . . . . . . . . . . . 84
Drilling pass holes into pass hole strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.12.2 Drilling pass holes into the sinter plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Adjusting machine parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Drilling pass holes into the sinter plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.13 Inserting pass hole pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Inserting pass hole pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5 Working sequence in automatic mode 91
5.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.2 Defining the production type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Selecting a phase file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.3 Setting up a job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Creating a new job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Opening an existing job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Aligning/Distributing projects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Saving a job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.4 Setting up the tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Opening the Tool Positions input window. . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Configuring tools in the tool magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Inserting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Table of contents
8ProtoMat®S62
5.5 Selecting/Setting up a production phase . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Selecting the production phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.5.1 Selecting tools (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Selecting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.5.2 Activating data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Activating all data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Activating areas of data elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Activating data segments by index number . . . . . . . . . . . . . . . . . . . . . . . . 102
Deactivating all data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Deactivating data areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.6 Setting up 2.5 D processing (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
5.6.1 Setting up contour milling with 2.5 D mode . . . . . . . . . . . . . . . . . . . . . . . . 104
Activating the 2.5 D mode for a phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Setting the moving-free height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.6.2 Setting up surface milling with 2.5 D mode . . . . . . . . . . . . . . . . . . . . . . . . 105
5.7 Starting production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Starting a production phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Milling contours in 2.5 D mode (optional). . . . . . . . . . . . . . . . . . . . . . . . . . 107
Adjusting the milling depth/width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.7.1 Stopping the production phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Interrupting the production phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.8 Ending production. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Saving the production status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Aborting production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6 Care and maintenance 111
6.1 Caring/inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Cleaning the surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Carrying out a visual inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111