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

Table of contents
Operating Manual 7.1 Rev.: 18.06.2008 9
6.2 Maintaining milling depth limiter and collet chuck. . . . . . . . . . . . . . . . . . . 112
6.2.1 Removing and cleaning the milling depth limiter. . . . . . . . . . . . . . . . . . . . . 112
Removing the milling depth limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Cleaning the milling depth limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.2.2 Removing and cleaning the collet chuck. . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Opening the collet chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Removing the collet chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Cleaning the collet chuck and the collet chuck holder . . . . . . . . . . . . . . . . 117
6.2.3 Mounting the collet chuck and the milling depth limiter. . . . . . . . . . . . . . . . 118
Screwing in the collet chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Mounting the milling depth limiter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.3 Replacing fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Removing the side wall of the acoustic cabinet . . . . . . . . . . . . . . . . . . . . . 119
Replacing the fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Mounting the side wall of the acoustic cabinet . . . . . . . . . . . . . . . . . . . . . . 121
6.4 Configuring the tool holder position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.4.1 Configuring the tool holder position (without camera). . . . . . . . . . . . . . . . . 121
Defining the milling/drilling head offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Activating the service functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Testing the tool holder position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Correcting the tool holder position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.4.2 Determining the tool holder position with VisionSystem. . . . . . . . . . . . . . . 126
Setting the camera offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Preparing the tool magazine for determining the position. . . . . . . . . . . . . . 128
Calling the service functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Reading in the position data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.5 Adjusting the camera (only with VisionSystem) . . . . . . . . . . . . . . . . . . . . . 131
Setting the camera offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.5.1 Calibrating fiducial recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Preparing the fiducial recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Determining the fiducial diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.6 Changing the dust extraction filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Table of contents
10 ProtoMat®S62
7 Error messages/Malfunctions 141
8 Decommissioning, transport, disposal 143
8.1 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Switching the ProtoMat®S62 off.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Disconnect the connecting cables.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
8.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
Fitting transport braces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
8.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
8.3.1 Machine parts and components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
8.3.2 Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
9 Technical data 145
10 LPKF Service 147
11 EC Declaration of Conformity 149
12 Index 151

List of figures
Operating Manual 7.1 Rev.: 18.06.2008 11
List of figures
Fig. 1: ProtoMat®S62 basic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fig. 2: Optional components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fig. 3: Milling/drilling head (front view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fig. 4: Traversing table with tool magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fig. 5: Vacuum table (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fig. 6: Main switch with mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fig. 7: Dust extraction and data connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fig. 8: Control unit with data connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fig. 9: LPKF dust extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fig. 10: Defined positions of the milling/drilling head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fig. 11: Setting wheel for milling depth limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fig. 12: Milling width with Universal Cutter and Micro Cutter . . . . . . . . . . . . . . . . . . . . . . . 31
Fig. 13: Pass hole system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fig. 14: Turning the material through the mirror axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fig. 15: Tool positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fig. 16: 2,5 D processing (application examples)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Fig. 17: Dust extraction - operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fig. 18: Dialog box Tool status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Fig. 19: Input window Connect... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Fig. 20: BoardMaster user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fig. 21: Removing the plastic base from the milling depth limiter . . . . . . . . . . . . . . . . . . . . 62
Fig. 22: Fitting the plastic base on the milling depth limiter . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fig. 23: Defining the material size and position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fig. 24: Tool positions input window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fig. 25: Assigning tool positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Fig. 26: Defined tool positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fig. 27: Adjusting the focus position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Fig. 28: Selecting pass hole drills for pass hole strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Fig. 29: BoardMaster message "Drill pass hole?" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Fig. 30: BoardMaster message "Depth limiter removed" . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Fig. 31: Selecting pass hole drills for base material/drilling underlay . . . . . . . . . . . . . . . . . 80
Fig. 32: Pass hole strips in the vacuum table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Fig. 33: Setting parameters for drilling pass holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Fig. 34: Selecting pass hole drills for pass hole strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

List of figures
12 ProtoMat®S62
Fig. 35: BoardMaster message "Drill pass hole?" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Fig. 36: BoardMaster message "Depth limiter removed" . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Fig. 37: Machine parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Fig. 38: Selecting pass hole drills for pass hole strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Fig. 39: Press-in tool with pass hole pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Fig. 40: Positioning a project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Fig. 41: Tool Positions input window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Fig. 42: Assigning tool positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Fig. 43: Defined tool positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Fig. 44: Selecting tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Fig. 45: Activating the 2.5 D mode in the phases dialogue box . . . . . . . . . . . . . . . . . . . . .104
Fig. 46: Setting the moving-free height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Fig. 47: 2.5 D mode: Configuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Fig. 48: Adjusting the milling width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Fig. 49: Message when aborting production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Fig. 50: Collet chuck tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Fig. 51: Dismantling the milling depth limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Fig. 52: Dismantling the milling depth limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Fig. 53: Setting the milling/drilling head offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Fig. 54: Tool with collet chuck wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Fig. 55: Unscrewing the collet chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Fig. 56: Cleaning the collet chuck holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Fig. 57: Cleaning the collet chuck holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Fig. 58: Removing the side wall of the acoustic cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Fig. 59: Orientation of the fuse holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Fig. 60: Setting the milling/drilling head offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Fig. 61: Setting the milling/drilling head offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Fig. 62: Tool Box with service functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Fig. 63: Setting the milling/drilling head offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Fig. 64: Positioning the camera image above the bore . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Fig. 65: Setting the milling/drilling head offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Fig. 66: Measuring insert for determining the position with VisionSystem . . . . . . . . . . . . .128
Fig. 67: Setting the milling/drilling head offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Fig. 68: Tool magazine with service functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Fig. 69: Setting the camera offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Fig. 70: Positioning the camera above the bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133

List of figures
Operating Manual 7.1 Rev.: 18.06.2008 13
Fig. 71: Bore in the camera image window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Fig. 72: Setting fiducial recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Fig. 73: Fiducial calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Fig. 74: Calibration not possible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Fig. 75: Calibration successful . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Fig. 76: Measured values in the camera image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Fig. 77: Fiducial settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Fig. 78: Calibration settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Fig. 79: Calibration complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Fig. 80: Fiducial settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Fig. 81: Measured values in the camera image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

For your notes
14 ProtoMat®S62

For your safety
Operating Manual 7.1 Rev.: 18.06.2008 15
1. For your safety
In this chapter you will find information concerning proper use, liability and safety in connection
with the operation of the ProtoMat®S62.
If, after reading this manual, a situation should arise in which you are not sure how to use or
service the ProtoMat®S62, you should contact LPKF Support or consult a person skilled in the
art.
1.1 Designated use
The ProtoMat®S62 has been designed for the production of electric cir-
cuit boards with up to six layers and the processing of a variety of sign
and housing materials.
The ProtoMat®S62 can be used to:
• Mill and drill single-sided and double-sided printed circuit boards
• Mill and drill multi-layer materials
• Mill SMD solder paste stencils
• Mill solder stop foils
• Engrave housing plates and signs
• Mill cut-outs and contours
• Drill through flat materials
The ProtoMat®S62 is able to process the following materials:
• GFK/CFK base material
• PTFE/ceramic composite base material
• Wood
• Non-ferrous metals
– Aluminium acc. to DIN EN 573: EN AW-6012)
– Brass acc. to DIN EN 1412: CW603N
• Plastics
– Polyoxymethylenes
– ABS copolymers
The ProtoMat®S62 may only be used for the applications and materials
cited in this document.
The circuit board plotter may only be used together with the version of the
LPKF Software BoardMaster included in the scope of delivery. If you
want to use a different BoardMaster version, please contact the LPKF
Support first.

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

For your safety
Operating Manual 7.1 Rev.: 18.06.2008 17
1.2 Safety instructions
WARNING
Risk of death by electric shock!
Missing or insufficient electrical fuse protection can result in fatal
electric shocks and/or fire.
› Use only fuses of type T4L 250 V.
› Fuse holders must NEVER be bridged.
WARNING
Risk of injury caused by pointed/sharp tools!
Improper use can cause cuts and stab injuries.
› Handle tools carefully and keep them in the tool box when not in
use.
WARNING
Risk of injury!
When opened, the cover of the acoustic cabinet can drop down
due to impact shocks or vibrations. This can result in limbs being
broken or crushed.
› When opening the cover of the acoustic cabinet make sure that
it engages in the uppermost position and cannot drop down as
a result of vibrations or the influence of third parties.
WARNING
Dusts and gases are hazardous to your health!
The processing of the materials can give rise to dusts and gases
hazardous to your health.
› Ensure that the dust extraction is switched on when processing
materials. Extract the dust and material residues or remove
them with a brush or moistened cloth; do NOT blow com-
pressed air through.
CAUTION
Material damage due to incorrect tool positioning!
The milling/drilling head, spindle and the tool can become dam-
aged if the tool positions indicated in BoardMaster do not corre-
spond to the actual fitting of the circuit board plotter.
› Ensure that the settings in the Tool Status window corresponds
to the actual fitting of the circuit board plotter.
General safety instructions
› Read the installation instructions/operating manual before
operating the machine. In case of uncertainties ask a person
qualified in the art or contact LPKF Support.
› Use the machine only in accordance with its proper use.
› Never operate the machine in environments subject to fire or
explosion hazards.
› Operate the machine only in a suitable environment.
(Page 1 of 3)

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