Manual ProtoMat 95s/II English, version 1.0 LPKF Laser & Electronics AG Osteriede 7 D-30827 Garbsen Telefon : ++ 49 - 51 31 - 70 95 - 0 Telefax : ++ 49 - 51 31 - 70 95 - 90 eMail : lpkf@lpkf.de Homepage : http: //www.lpkf.
Copyright (c) 2000 LPKF AG Distribution or reproduction of this manual and use of its content permitted only with the written approval of LPKF AG. Right to make modifications reserved. No liability is accepted for the content. In particular, we accept no liability for damage caused by information given, information absent, or erroneous information. Trademarks: HP-GL is a registered trademark of the Hewlett Packard Corporation. All other trademarks are registered by their owners.
Information on this manual The information contained in this document may be modified without prior notification. No part of this document may be reproduced or transmitted for any purpose or in any form by any means, electronic or mechanical, by photocopy, by recording or by information storage and information retrieval systems without the express written permission of LPKF. We have taken great trouble to ensure the accuracy and completeness of the information in this document.
I. Orientation This manual is divided into the following chapters: 1. Safety regulations 2. Introduction 3. General information 4. Computer-controlled functions 5. Setup 6. Tools, material and accessories 7. Stages in milling and drilling 8. Practical tips 9. Appendix 10.LPKF ProtoMat 95s/II commands 11.Declaration of confirmity 12.Index II. Conventions used in this manual Bold text is used to emphasise important information. Illustrations are numbered. Example: Fig.
III. Legend Copper laminate: special, very thin base material used only for laminating multilayer boards Base material : carrier material of thr main board, coated with a copper foil Solder foil : special foil for cutting aperatures for the connections to be soldered BoardMaster : Machine control software CurcuitCAM : Software for data preparation IV. Target Group This manuel is written for people with basic knowledge in PCB production.
Table of contents 1.0 Safety regulations. . . . . . . . . . . . . . . . . . . . 10 2.0 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . 11 2.1 Ratings for the LPKF ProtoMat 95s/II. . . . . . . . . . . 11 3.0 General information . . . . . . . . . . . . . . . . . . 12 3.1 Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . .12 3.2 Optional accessories . . . . . . . . . . . . . . . . . . . . . . .12 3.3 Air-borne sound . . . . . . . . . . . . . . . . . . . . . . . . . . .12 3.
5.3 Preparing the tools . . . . . . . . . . . . . . . . . . . . . . . . .28 5.3.1 The spacer ring press . . . . . . . . . . . . . . . . . . . . . 28 5.3.2 Functions in BoardMaster . . . . . . . . . . . . . . . . . . 29 5.3.2.1 The Tool Magazine I/O Status dialogue box . . . . . . . 29 5.3.2.2 The Tool Box dialogue box . . . . . . . . . . . . . . . . . . . . 29 5.3.2.3 The Tool Position dialogue box. . . . . . . . . . . . . . . . . 31 5.3.3 Preparing the tool magazine . . . . . . . . . . . . . . . . 32 5.
7.6 Contour milling in circuit base material. . . . . . . . . .54 7.7 Milling wide isolation channels and rubouts . . . . . .54 7.8 Front plate engraving . . . . . . . . . . . . . . . . . . . . . . .55 7.9 Milling solder-stop sheets. . . . . . . . . . . . . . . . . . . .55 7.10 Milling layout films . . . . . . . . . . . . . . . . . . . . . . . .56 7.10.1 Staining milled films . . . . . . . . . . . . . . . . . . . . . . 57 7.10.2 Removing the coating. . . . . . . . . . . . . . . . . . . . . 57 7.
.10 Removing the electronics unit . . . . . . . . . . . . . . .75 10.0 LPKF ProtoMat 95s/II commands . . . . . . 78 10.1 Command structure . . . . . . . . . . . . . . . . . . . . . . .78 10.1.1 10.1.2 10.1.3 10.1.4 HP-GL standard commands . . . . . . . . . . . . . . . 78 Special commands. . . . . . . . . . . . . . . . . . . . . . . 80 Special command for the high-speedcycle spindle82 Direct commands . . . . . . . . . . . . . . . . . . . . . . . . 82 10.2 Table of available tools . . . . . . . . . . . .
Safety regulations 1.0 Safety regulations Caution! The user must have read this manual, paying particular attention to the safety instructions printed in bold, to ensure safe working with this system. • It is a general requirement for your safety that you operate the LPKF ProtoMat 95s/II circuit board plotter in accordance with the regulations. This entails milling and drilling permitted materials only. • Under no circumstances may the limit switches on the hood be overridden.
Introduction 2.0 Introduction The LPKF ProtoMat 95s/II circuit board plotter is a system for creating circuit board prototypes and engraving films as well as for engraving aluminium or plastic. Each tool change required is made automatically. The LPKF ProtoMat 95s/II circuit board plotter is expressly not designed for machining wood. Unlike other machines in the LPKF ProtoMat family, the LPKF ProtoMat 95s/II may only be operated under the hood supplied for safety reasons.
General information 3.0 General information 3.1 Scope of supply 1. One LPKF ProtoMat 95s/II machine unit with integrated electronic circuitry 2. One null modem cable (LPKF ProtoMat 95s/II control unit computer) 3. One set of accessories (adhesive tape, various Allen keys, 5 alignment pins, tweezers, brush, 7 mm box spanner, two red registration hole strips, syringe containing oil) 4. One mains cable 5. Spacer ring press 6. Pre-assembled hood for the LPKF ProtoMat 95s/II 7. This manual 8.
General information 3.4 Troubleshooting The LPKF ProtoMat 95s/II circuit board plotter incorporates high-quality state-of-the-art technology resulting in a machine capable of delivering trouble-free performance. However, should any malfunction should present itself, please first check that you have carried out all the instructions as specified in this manual. The cause of the malfunction may be something minor.
General information 3.6 Initialization The following initialization procedures have been carried out on the ProtoMat 95s/II by LPKF at the factory so that the positions of the plotter head and auxiliary clamp have been defined and preset (see „Functions in BoardMaster“ on page 29.). 1. 2. 3. 4.
Computer-controlled functions 4.0 Computer-controlled functions 4.1 Connection to a PC The LPKF ProtoMat 95s/II has two serial ports.The first (25-pin) is used for connection to the controlling computer (PC). The second port (9-pin) is reserved for future applications. The 25-pin port on the LPKF ProtoMat 95s/II control unit is connected to one of the computer's serial ports using the null modem cable supplied.
Computer-controlled functions 4.2 Reprogramming the machine data You will have to re-enter the PAUSE or HOME position data in the machine settings if the PC operating system crashes and the head no longer moves to these positions. Proceed as follows: fig. 2: fig. 3: › Click UNLOCK. This activates the SET HOME and INITIALIZE push button. › Click on INITIALIZE. The device moves to all four end positions. The device then comes to a halt in the zero position (at the front right).
Computer-controlled functions › Now enter the values noted down for the HOME position in the HOME box. These values are determined as described in the section „Checking and correcting the HOME position“ on page 35. The coordinates for the Pause position correspond to the values in the Size box. You can enter any coordinates here. › Click OK to quit this box. › BoardMaster must be shut down and restarted. The new values are saved when the MACHINE SETTINGS... dialogue box is closed and you quit BoardMaster.
Computer-controlled functions 4.3 Machine orientation Description of the main machine positions: fig. 4: LPKF ProtoMat 95s/II: the xaxis has the longer traverse path 1 +x 6 2 3 4 ....................................... 7b +y 7a 5 7 1- PAUSE position. The plotter head travels to this point to load or turn the material to be machined. 2- HOME position. This is located on the machine's axis of symmetry (registration hole system) and acts as the reference position for LPKF BoardMaster.
Computer-controlled functions 4.4 Displays and connections Description of the front view: fig.
Computer-controlled functions Description of the rear panel: fig.
Computer-controlled functions fig. 7: Side view of the LPKF ProtoMat 95s/II 1 2 7 3 4 5 8 1- Plotter head 2- Hood limit switch connection 3- 6 bar port for connecting the hood compressed air distributor 4- Port for connecting the pneumatic system unit 6 5- Pneumatic system unit 6- Vacuum connection 7- X-axis motor 8- Compressed air inlet (6 mm) from the DispoMat (LPKF AutoContac, optional) 4.5 The hood and pneumatic port The LPKF ProtoMat 95s/II is normally supplied with the hood preassembled.
Computer-controlled functions fig.
Computer-controlled functions fig. 9: Water trap with pressure reducer 3 6 1 2 4 5 1- 12 bar (max.) compressed air inlet from the compressor 2- 6 bar compressed air outlet to the compressed air distributor 3- Setting adjuster for 6 bar connection 4- Pressure gauge 5- Drain valve 6- Fixing bracket fig.
Computer-controlled functions 4.6 What is LPKF BoardMaster used for? The data required to drive the plotters is generated by postprocessing with LPKF CircuitCAM and is stored in an LPKF binary file (LMD format). BoardMaster now reads these files, decodes the plotter commands and modifies them for the particular machine being driven. This is necessary as although different machines may perform similar operations, they nevertheless use different command sets.
Setup 5.0 Setup 5.1 Before switching on Caution! You must ensure that the voltage set on the machine corresponds with the mains line voltage before switching on. If not, see the section headed Setting the device voltage, electrical fuses. Remove all objects from the plotter and its traverse range before switching on. Pilot pins must not be projecting from the base material. Caution! Carefully close the hood. Never reach into the machine while it is running. Never move the plotter head manually.
Setup The following screen will appear when the program is started: fig. 11: The Tool Status dialogue box Note: You must determine where any tool is located when the machine is switched on. Next the vacant tool position in the tool magazine must be specified: Position 1 Position 30 = tool 1 is positioned extreme right, = tool 30 is therefore positioned extreme left in the tool magazine.
Setup Caution! You must first run in the bearings on the high-frequency spindle when starting up the machine if it has been shut down for a prolonged period (several months)or if the machine has just been shipped. The spindle should be run at 10,000 rpm for several hours the first time the machine is started up. Thereafter the control system automatically specifies that the spindle be warmed up (at 20,000 rpm) for about 3 to 5 minutes whenever the machine is switched on.
Setup 5.3 Preparing the tools 5.3.1 The spacer ring press All tools must be fitted with spacer rings to ensure the precise pick up and set down of tools. The spacer ring press used to force the spacer rings onto the tools comprises the following parts: fig.
Setup 5.3.2 Functions in BoardMaster 5.3.2.1 The Tool Magazine I/O Status dialogue box › Click on CONFIGURATION, STATUS in the BoardMaster menu bar to open the TOOL BOX I/O STATUS dialogue box. fig. 16: The Tool Box I/O Status dialogue box The Tool Box I/O Status dialogue box provides information on the signals set and the data lines connected. • IN is used to check the additional lines connected to the automatic tool change • OUT indicates which lines have been activated by BoardMaster.
Setup fig. 17: The Tool Box dialogue box MAIN CLAMP AT EXCHANGE POSITION defines the position of the plotter headover the transfer station AUXILIARY CLAMP AT EXCHANGE POSITION specifies the position of the auxiliary gripper over the transfer station. Use AUXILIARY CLAMP AT FIRST TOOL POSITION to specify the set position of the auxiliary gripper over the first tool in the tool magazine AUXILIARY CLAMP AT LAST TOOL POSITION indicates the position defined for the gripper over the last tool.
Setup 5.3.2.3 The Tool Position dialogue box Right-clicking on the Tool combo box opens the TOOL POSITION dialogue box. Left-clicking selects the tool for manual changing. Various tools have already been assigned in the screen-shot. Unassigned positions are marked as . fig. 18: The Tool Positions dialogue box with defined tools The LOAD LIST and SAVE list buttons are used to load an existing tool list and to save a newly created or modified tool list.
Setup 5.3.3 Preparing the tool magazine The tools fitted with spacer rings are placed into the tool magazine in the following steps (see „Tools, material and accessories“ on page 44.). Only tools which are 1/8 inch in diameter and 36 mm or 38 mm in length may be used. › Switch on the circuit board plotter. (The x and y-limit switches are activated) › Close the hood. › Start up the BoardMaster program.
Setup Caution! Ensure that the correct tool is inserted in the correct position. The hood must be closed once the tools have been inserted. › Once the hood has been closed, click on TOOL BOX DOWN in the TOOL POSITIONS dialogue box in BoardMaster to lower the tool box. › Continue at point „Preparing the tools“ on page 28 if you have not assigned and inserted all tools in a single step. First save your tool list. 5.
Setup 5.6 Functional test using LPKF BoardMaster Caution! Make sure that no other persons are working on the machine while the first functional test is taking place. › First check the configuration of the serial port: 9600 baud , 8 data bits, 1 stop bit, no parity bit, hardware handshake and FIFO off. › Also check that the correct interface has been selected in BoardMaster under CONFIGURATION, CONNECT... . › Consult the BoardMaster manual if you require assistance.
Setup 5.7 HOME position and registration hole system The HOME position must be on the machine's axis of symmetry (registration hole system) to ensure correct alignment of a double-sided base. Double-sided base are rotated about this axis of symmetry. Inaccuracies in the HOME position result in misalignment when doublesided base are rotated during the machining process. The HOME position is contained on the configuration diskette supplied as standard.
Setup Carry out the following steps: › Make registration holes in double-sided base material. › Secure the material and drilling base (2 mm) onto the base plate using the registration hole pins. (see also the section entitled "Securing the board onto the machine bed"). › Start up BoardMaster and select LMD or LPR from the FILE, IMPORT menu. fig. 21: › Now select the file NULL-PKT.LMD and import it by clicking OK. fig.
Setup fig. 23: › Right-click on the project. fig. 24: The PLACEMENT dialogue box opens. Specify the position in the ORIGIN POINT box as x=0, y=0 and confirm by clicking on OK. › Select the DRILLINGPLATED process from the production phase list box. › Click on and enclose the first hole by clicking and dragging with the left mouse button. › Now enable the selected hole for machining by clicking and START. The hole is drilled in the board once the tool has been changed for the specified drill.
Setup › Now select the MILLINGTOP process from the production phase list box. Click on once again and enclose the milling track corresponding to the first hole by clicking and dragging with the left mouse button. fig. 25: › Now enable the milling track for machining by clicking START. and The software again changes automatically the specified tool and mills a circular track. Check the settings, including the milling pass width and the milling depth setting before you start machining.
Setup fig. 26: › The HOME position must be corrected if the milled line does not pass exactly through the centre point. This can be done directly by amending the HOME position in the MACHINE SETTINGS dialogue box (see „Programming the HOME position in LPKF BoardMaster“ on page 39.). The correct value can be calculated using the formula given above. The Y coordinates must always be added to the correction value. › After making a correction, the process should be repeated as a check.
Setup fig. 27: › Click on UNLOCK so that you can make entries in this dialogue box. fig. 28: › If necessary, correct the Home position coordinates by increased or decreasing the value by the value previously measured. › The new values will only be saved once the MACHINE SETTINGS... dialogue box is closed and you quit . 5.10 Making a new registration hole system The registration holes in the red registration hole strip become larger over time due to use and will no longer be as precise as before.
Setup fig.
Setup fig. 30: › Switch on the motor by clicking and (raise/lower head) to drill a hole approximately 4 mm deep. The head may need to be lowered several times to reach the drilling depth. Do not move the position of the plotter head in the y-axis again. › Use the traverse buttons in BoardMaster to move the plotter head approximately 25 mm in the positive X direction and define this position as the new HOME position: Open the MACHINE SETTINGS...
Setup › Mark any old holes with a felt-tip pen so that they cannot be mistaken for the new holes. The drilling base should be drilled to a larger diameter, such as 5-6 mm, to allow for inaccuracies in the registration holes. Position the previously drilled base material and drilling base over the alignment pins. The format of the base material should be selected so that the registration hole strip does not need to be moved more than 10 mm.
Tools, material and accessories 6.0 Tools, material and accessories 6.1 Tools Tools for the LPKF ProtoMat 95s/II have a diameter of 1/8 inch and two different lengths. Tools used to machine the material surface (milling and engraving) are 36 mm long while tools used for drilling or contour milling are 38 mm long. The following tools are available: fig.
Tools, material and accessories 6.2 Materials used for machining In general all base materials supplied by LPKF can be used for machining. You are free to machine all other materials at your own risk. Take into consideration the notes of the manufacturers. However, phenol resins of lesser quality, such as FR 2, can adversely affect the milling quality. Glass fibre reinforced epoxy material (FR 4 or G 10) can be a health hazard due to the milling dust produced (allergies, risk of cancer).
Tools, material and accessories Material supplied by LPKF and suitable for machining: FR3 material: engraving, drilling, milling FR4 material: engraving, drilling, milling Engraving film: engraving The following products have proved particularly successful as materials for RF andmicrowave applications: Rogers: R0®4000 , RT/duroid®, TMM®, Ultralam® Other materials upon request. Danger! Do not allow to the material to overheat - lethal gases may be produced.
Stages in milling and drilling 7.0 Stages in milling and drilling 7.1 Securing the PCB on the machine bed › Make 3.0 mm or 3.05 mm diameter congruent registration holes in the base materialand drilling base in the x-axis.This can also be done with any bench drill. Please note that the diameter decreases during galvanic through-hole plating. Note: The drilling base should be drilled to a larger diameter, such as 5 mm, to allow for inaccuracies in the registration holes.
Stages in milling and drilling Note: Very thin base material may be secured with spray adhesive to ensure perfect flatness It is important that no adhesive tape, drilling or milling swarf is left between the individual layers to ensure that the base material lies absolutely flat. Small particles under the base material have an adverse affect on the uniformity of the milling depth. Caution! Switch on the vacuum system. Bear in mind that the vacuum filter might need be changed. 7.
Stages in milling and drilling fig. 34: LPKF ProtoMat 95s/II working depth limiter 2 1 3 6 4 5 1- Holding plate 2- Knurled nut used to set milling depth 3- Retaining block for working depth limiter 4- Suction nozzle 5- Tool fixture (collet) 6- Compressed air connection Milling depth is set by adjusting the knurled nut (2) on the working depth limiter.
Stages in milling and drilling 7.3 Functional elements on the plotter head fig.
Stages in milling and drilling fig.
Stages in milling and drilling 7.4 Drilling fig. 37: Twist drill Caution! Make sure that the board is secured in position before drilling. Switch on the vacuum system. The boards must be drilled with drills designed specifically for boards. It is important that the head always lowers at a constant speed. This setting may be made with two setting nuts in the pneumatic block on the plotter head. Lowering the head too quickly may result in burring, particularly with holes of small diameter.
Stages in milling and drilling Caution! Check that the board is properly secured before milling. Switch on the vacuum system. Ensure that the (36 mm long) LPKF Universal Cutters being used are sufficiently sharp before you start milling. The milling width is preset in CircuitCAM by selecting the isolation track width and the appropriate tool. The preferred milling width is between 0.2 and 0.4 mm.
Stages in milling and drilling 7.6 Contour milling in circuit base material fig. 40: Contour Cutters The traverse speed must be reduced for contour milling. This may vary from material to material. Use only contour Cutters (38 mm long) designed specifically for this purpose: preferably with a 1 mm or 2 mm diameter. The 1 mm contour Cutter should only be used for internal holes (smaller internal radius). It breaks relatively easily so set the feed rate to the minimum setting.
Stages in milling and drilling 7.8 Front plate engraving fig. 42: Top: Double-edged cutter. Bottom: LPKF Universal Cutter Set the traverse speed as appropriate for the engraving depth and the material when engraving. Use an LPKF Universal Cutter or LPKF double-edged cutter. Caution! Switch on the vacuum system, even when engraving. 7.9 Milling solder-stop sheets › Start up the tool library SOLST-VS.TOL in BoardMaster to load the corresponding tools.
Stages in milling and drilling 7.10 Milling layout films fig. 43: LPKF RF Cutter › Layout filmsmay be machined with LPKF RF Cutters. › Secure the film base (plexiglas or glass sheet) onto the machine bench with Tesa tape. › Lay the film material on the base with the coated (matte) side facing upwards. › Now flatten the film material out firmly on the film support, expelling any air completely. › Now stick down the film on all four sides with a non-stretching transparent adhesive tape to form an air seal.
Stages in milling and drilling 7.10.1 Staining milled films For milled negative films, there is Duroscal (black stain), with which positives can be made. The fully milled engraving film is stained with Duroscal stain by pouring the liquid onto a SAFIR pad and spreading it evenly over the whole film. Excess stain must be wiped off with cellulose wadding. The stained film must be held against the light to check it and to find poorly covered areas so that they can be re-stained.
Stages in milling and drilling 7.11 Tool libraries in BoardMaster BoardMaster can be loaded with a previously created library of various tools as an aid to deciding which tool can be used for which materials. › Select the MILL/DRILL submenu of the CONFIGURATION, TOOL LIBRARY menu in BoardMaster. fig. 44: The MILL/DRILL TOOL EDIT dialogue box opens and you can now LOAD a suitable tool library from the directory selected. The tool library directory is called C:\LPKF30\BMASTER.
Stages in milling and drilling 7.12 Cleaning the PCB Before components are mounted, the finished PCB must be thoroughly cleaned. This can be done manually or in a board brushing machine. If cleaning by hand, the PCB is placed on a flat support. › Brush the board with a wet board cleaner (such as the LPKF PAD board cleaner) in the preferred direction of the conductor paths.
Stages in milling and drilling › Move to the bottom left corner (-x, -y) of the base material using the traverse buttons in BoardMaster such that the working depth limiter does not quite come into contact with the adhesive tape. › Program this corner in the BoardMaster menu CONFIGURATION, MATERIAL, SET LOW CORNER . › In the same way, move to the top right corner (+x, +y) of the material and program this under CONFIGURATION, MATERIAL, SET HIGH CORNER.
Stages in milling and drilling › The milling depth should now be set. To do this, click on UNIVERSAL CUTTER 0.2 MM in the TOOLS combo box (top left in the screen). The plotter head travels to the zero position. The auxiliary clamp fetches the universal milling cutter from the tool magazine and takes it to the transfer station where it is handed over automatically. › Use the traverse buttons in BoardMaster to move to a vacant point on the base material but without moving across the project.
Practical tips 8.0 Practical tips • Set the milling depth such that engraving is too deep rather than too shallow. Insufficient depth when engraving increases wear on the milling tool. • There are a number of reasons why the milling width (depth) might be uneven. It is important that the machine bed is truly clean. Adhesive tape residue and such like can have a significant adverse affect on the milling depth. Millings between the machine bed, drilling base and board reduce precision.
Practical tips Note: We recommend that you punch-mark small diameter holes before drilling. The MARKINGDRILLS phase in BoardMaster is intended for this purpose and uses a special universal milling cutter, the UNIVERSAL CUTTER 0,2 MM FOR MARKING. • Vitrification of the drilled hole occurs as a result of the base material melting when the drill remains in the hole too long after the hole has been made. These holes then cause problems for through-hole plating. Reduce drilling times as appropriate.
Appendix 9.0 Appendix 9.1 Maintenance Note: Keep spindles clean. In rooms with a high air humidity, wipe down with a lightly oiled cloth from time to time. Keep transport spindles oiled and clean. Do not oil the bearings. 9.1.1 Working depth limiter fig. 46: Dismantle and clean the working depth limiter at regular intervals. To do this, first switch off the machine. Then proceed as follows: › Undo the pneumatic connection.(1) › Remove the plug from the spindle (3).
Appendix › Clean both parts of the working depth limiter using the brush supplied. When clean, the working depth limiter is reassembled in reverse order and the spindle is reinserted into the retaining block. › Always check that the insertion depth of the spindle is correct before starting up. The stop ring must sit on top. The distance between the drill tip and machine base plate must be 0.5 mm when the head is lowered. The machine may not be able to drill through the board if the distance is too great.
Appendix SerialPort1 pinouts: Pin Signal Meaning 2 TXD Transmit data 3 RXD Receive data 4 RTS Request to send 5 CTS Clear to send 7 GND-I Ground (isolated) 8 DCD Data carrier detect 20 DTR Data terminal ready All signals are galvanically decoupled; all contacts not described are not used. 9.3 SerialPort2 serial connection The SerialPort2 data channel is an RS 232-C standard port and can be used for communication between the control unit and another system.
Appendix 9.4 Connecting the stepping motors The stepping motors are connected per axis via a 15-pole SUB-D plug. If a limit switch is actuated, any further axis movement towards the limit switch is immediately blocked. The position of the sockets is described in the section „Displays and connections“ on page 19. Caution! Never confuse the cable for the stepping motor and the plotter head. 9.5 Connecting the plotter head The plotter head is connected to the control unit by a 15-pole socket.
Appendix fig. 48: Three pneumatic hoses will be found on the underside of the front of the machine revealed. The right hose connection lights up green in operation. › Now disconnect the right, illuminated hose connection (see Fig. 49 on page 68). You may now move the tool change magazine up and down by hand. fig. 49: › Open the SERVICE window in the CONFIGURATION \ TOOL MAGAZINE menu.
Appendix fig. 50: › Now click on Service. The following window appears. fig. 51: › Enter BMASTER in the input field. Note: Once the password has been entered, all tool change functions can be operated manually and independently of one another. › Click on CHECK at the top left of the TOOL MAGAZINE window. The machine moves to the check position. › Now click on OPEN in the COLLET WINDOW. The plotter head collet opens. › Insert a universal milling cutter tool in the plotter head collet.
Appendix fig. 52: 1- Tool ring 2- Lower plate of the working depth limiter › Now click on CLOSE in the COLLET window. The plotter head collet closes and grips the tool. › Shift the entire TOOL MAGAZINE window down the screen until you can see the BoardMaster main menu bar. › Enter the value 0.1mm in the step window. Make sure that you enter a decimal point between the zero and the one. fig. 53: › Lift the tool change magazine carefully with both hands (as shown on Fig.
Appendix fig. 54: 1 3 2 1- Auxiliary gripper 2- Changeover-station 3- Plotter head fig. 55: 1 1- Tool change magazine › If necessary, correct the plotter head position using the arrow keys in the main menu bar. › Then repeat the bold printed steps (see above) until the transfer station can be shifted over the tool with no problem. › Click on READ in the POSITION OF PLOTTER HEAD OVER TRANSFER STATION (MM) tool magazine window. The coordinates set for the plotter head are now imported and saved.
Appendix › Click on CHECK in the POSITION FO AUXILIARY GRIPPER OVER TRANSFER STATION (MM) window. The auxiliary gripper moves to the corresponding check position. › Insert the tool into the auxiliary gripper as far as the stop. › Now click on CLOSE in the COLLET window. The collet clamps the tool in the auxiliary gripper. › Now repeat position adjustment as described in the bold printed steps (see above) again until the tool in the auxiliary gripper can be moved to the transfer station without problem.
Appendix 9.7 EPROMs The software for the control unit is in 2 EPROMs. The LPKF ProtoMat 95s/II will have to be partially dismantled if the EPROMs need to be changed (updates). • Proceed as described under „Removing the electronics unit“ on page 75. • Use only PLCC pliers to remove the EPROMs as otherwise the mounting contacts might be damaged. • When inserting new EPROMs, support the PCB from the bottom in order to avoid bending of the board. • Take care that the orientation of the EPROMs is correct. 9.
Appendix BoardMaster switches from automatic tool change to manual change if the “Dispense” or “Vacuum” production phase is selected since it is not possible to change the various dispense and vacuum needles automatically. In addition the operator must attach the brakket to the plotter head. Caution! Revert to the automatic tool change mode for drilling, engraving or milling. The bracket must be removed as otherwise the plotter would be damaged by the automatic tool change. 9.
Appendix 9.10 Removing the electronics unit The control unit must be isolated from the mechanism. › First move the plotter head to the TOOL CHANGE position if the circuit board plotter is still attached. › Now use the traverse buttons to move the crossbar to the centre of the machine base plate. Note: The head must not be in either the tool change or Home position and the limit switches must have been cleared.
Appendix fig.
Appendix The secondary circuits are protected by microfuses (medium slow) as follows: Fuse Type Power circuit F701 3,15 A Power high level F703 5,00 A +24 V at I/O-Interface F704 2,00 A +5V and VREF F705 0,50 A RS 232 C / SER1 The units are reassembled in the opposite order to that described above for disassembly. Caution! Never confuse the cable for the stepping motor and the plotter head. Always check that head and motor cables are connected correctly before switching on.
LPKF ProtoMat 95s/II commands 10.0 LPKF ProtoMat 95s/II commands 10.1 Command structure The SMCU (Signal Processor Control Unit) control unit in the machine interprets the HP-GL commands described below and converts them into defined reactions. The machine has a resolution of approximately 0.005 mm. This differs from the resolution used by standard HP-GL plotters. The use of master commands reduces the output. The syntax: Symbol Meaning {...
LPKF ProtoMat 95s/II commands ER (x,y){;} Edge rectangle relative Draws a rectangle defined by two corner points lying diagonally to each other. The first corner point is determined by the current position and the second by the relative coordinate (x,y). IN {;} Initialize Changes the control unit to the same status as after switching on. This restores all default settings. IW (x0,y0,x1,y1){;} Input window Restricts the working area on the XY axis to a window with the given corner coordinates.
LPKF ProtoMat 95s/II commands 10.1.2 Special commands All special commands begin with the symbol "!" and their syntax is otherwise like that for HP-GL standard commands. !AS (a){;} Acceleration Set Defines a new acceleration constant a=mm/s². The valid value range is 10...50000. !CC {;} Close channel Ends a data transmission introduced with !OC. !CM (n){;} Change mode Switches between the drill (n=0) and mill (n=1) working modes.
LPKF ProtoMat 95s/II commands !RD (a){;} Read port Effects the reading of the input port with the address a=<0..15>. The data is output via the serial interface from the which the command came, as an ASCII figure. !RS (r){;} Resolution set Gives the control unit the step size (r=µm/step) of the machine. The valid value range is 1...32000. !TA (x,y,z){;} Plot three-D absolute Carries out a physical movement from the current position to the absolute coordinate (x,y,z).
LPKF ProtoMat 95s/II commands 10.1.3 Special command for the high-speedcycle spindle Before communicating with the high-speedcycle spindle, send the command for opening the SERIAL2 (!OC;), then the serial interface SERIAL2" must be closed again (!CC;) !RM (r){;} Revolutions Motor, r=0...60. Sets the speed (r)*1000 of the high-speedcycle spindle. 10.1.4 Direct commands Direct commands are special commands which, once they have been interpreted, are carried out via the command buffer.
LPKF ProtoMat 95s/II commands 10.2 Table of available tools Tools marked with an asterisk (*) are available for the LPKF ProtoMat 95s/II. Name Diameter Length in mm 36 mm Universal milling cutter 0.2 - 0.4 * L Micromill 0.1 - 0.2 * L HF cutter 0.25 * L 0.4 * L Contour milling cutters Double-chamfered cutters Drills ProtoMat 95s/II Delivery 38 mm L = in stock 1.0 * L 2.0 * L 3.0 * L 0.8 * L 1.0 * L 2.0 * L 3.0 * L 0.3 * L 0.4 * L 0.5 * L 0.6 * L 0.
LPKF ProtoMat 95s/II commands 84 1.8 * L 1.9 * L 2.0 * L 2.1 * L 2.2 * L 2.3 * L 2.4 * L 2.5 * L 2.6 * L 2.7 * L 2.8 * L 2.9 * L 2.95 * 3.
LPKF ProtoMat 95s/II commands 10.
LPKF ProtoMat 95s/II commands Caution! Be sure to give the machine number (stamped on the machine bed) when ordering replacement parts. 10.4 Concluding remarks As a rule, the machine recommendations 93 / 44 of the European Community, dated June 14, 1993 applies to this manual. Where reference has not been made to the EC Directive in any section, we hereby refer the reader to the relevant paragraphs of the Directive and any claims concerning completeness and liability are excluded.
Declaration of conformity 11.0 Declaration of conformity 1. Manufacturer of the machine designated LPKF ProtoMat 95s/II is company: LPKF Laser & Electronics AG Osteriede 7 D-30827 Garbsen Germany 2. The machine designated as LPKF ProtoMat 95s/II is a circuit board plotter, intended for the creation of circuit boards-prototypes and engraving films, as well as for the engraving of aluminum or plastics. The series number of the machine is 1E....................... (see also the base plate).
Declaration of conformity 11.1 Konformitätserklärung 1. Hersteller der mit LPKF ProtoMat 95s/II bezeichneten Maschine ist die Firma: LPKF Laser & Electronics AG Osteriede 7 D-30827 Garbsen 2. Bei der mit LPKF ProtoMat 95s/II bezeichneten Maschine handelt es sich um einen Fräsbohrplotter, der zum Erstellen von Leiterplattenprototypen und Gravurfilmen, sowie zum Gravieren von Aluminium oder Kunststoff geeignet ist. Die Seriennummer der vorstehenden Maschine ist 1E............(siehe auch Bodenplatte).
Index 12.0 Index A Asynchronous interface ........................................................................................... 24 AutoContac bracket .................................................................................................... 73 Auxiliary gripper ......................................................................................... 18, 30, 49, 50 B Baud rate ...................................................................................................................
Index L Layout film .......................................................................................................................55 Limit switch ......................................................................................................................33 Line voltage .....................................................................................................................25 M Machine bed .......................................................................................
Index SerialPort2 ...................................................................................................................... 65 SMCU ................................................................................................................................ 77 Solder-stop sheet ........................................................................................................ 54 Spacer ring ................................................................................................
