Quick Start Guide
Contents
1. ProtoMat S62 Quick Start Guide PR P PR NI re N L A rm L J LS Wa J pan _ UN Laser amp Electronics Thank You Thank you for purchasing an LPKF ProtoMat Circuit Board Plotter ProtoMat circuit board plotters are key elements of any in house production from precision one off prototyping to short run production Ensure years of solid performance by following the setup and installation instructions in this Quick Start Guide carefully and review the more extensive documentation supplied with the ProtoMat when referred ProtoMat Anatomy Hood Spring head and adjustment Milling motor Machining head a P lool magazine Vacuum hose Case Fiducial recognition camera Tool position 10 Working depth limiter Power switch and fuseblock located behind side cover For clear access remove side cover 8 screws Tool position 1 Vacuum table Workpiece Setting options Fuseblock settings lt Machine table under vacuum table 110 115 V 220 240 V Shipping Checklist Verify the following items are included with the S62 or S100 Circuit board plotter and pre assembled hood Data cable 9 pin PC to RJ45 ProtoMat cable Power cable standard power supply cable ProtoMat user manual includes BoardMaster operations CircuitCAM user manual CD ROM with BoardMaster and CircuitCAM software CD ROM with Configuration Files CD2. is normal Click Yes The machine head will lower and if the head is properly aligned the machine head will drop to the bottom without sticking or dislodging the tool Click the Z axis up button and the head should rise back to the original position without sticking or dislodging the tool 6 If the head is not properly adjusted use 0 1 mm increments on the manual X Y controls to adjust the head until step 5 can be completed smoothly without the tool or the head sticking 7 Click the Accept button and repeat steps 3 through 6 for each tool position on the tool magazine 8 Close the tool box dialogue by clicking OK and restart BoardMaster 14 Set Calibrate camera offset The camera offset must be adjusted and calibrated the first time the ProtoMat is used any time the camera is replaced or any time the offset is in question 1 Set up a piece of scrap board material in the working area switch on the ProtoMat and use BoardMaster to manually select a 1 5 mm drill and drill a single hole in the scrap material Do not move the machine head after drilling 2 In BoardMaster select Configuration gt gt Heads select the Camera and click Origin then OK 3 Inthe BoardMaster menu select Go to gt gt Camera gt gt Head and use the manual XY controls to move the head such that the crosshairs are as directly centered on the visible hole as possible For better precision decrease the step width to
3. 0 005 mm Use the Z controls to bring the image into as clear a focus as possible and press the Set Focus button 4 When the crosshairs are as centered as possible in BoardMaster select Configuration gt gt Heads click the Head button and then click OK to lock the new offset 5 In the Camera Image window click Settings to open the Setting window Adjust s the Brightness and Contrast to create a strong contrast between the edges of the hole and the background of the work piece figure 22 Ideally the hole should be black and the work piece light gray F F Camera Image Simit ooe Stil Find Setting OK 1 444 O 0 013 Ip 22 Measuring the actual hole diameter A click here first B click here second C read measured value 6 Measure the diameter of the hole in the Camera Image window accurate diameter and figure 22 Note that this measured value will probably be the crosshairs are properly Famerp naga incorrect centered on the hole SR OR eae 7 Complete the Fiducial settings accordingly figure 23 figure 26 If the camera is still miscalibrated Setting extremely rare or the i QUE s offset still questionable US Ne repeat steps 2 through 12 Sends tsi t s ati 14 Restart BoardMaster 26 Perfectly calibrated 15 Finished The ProtoMat is now ready for use 23 Entering the measured values for example 1 44 mm Note that Minimal qualit
4. Box list figure 20 and click the Service button When prompted for the Service password enter BMASTER 5 Click the Check 1 button use the Z keys in the main interface to focus the image and the XY keys to center the crosshairs directly over the tool position figure 21 Click Accept button when finished 21 The Measure Insert in the camera 6 Repeat steps 3 through 5 for the remaining tool positions 7 Close the Tool Box dialogue by clicking OK and send the machine head to the Pause position 8 Reinstall the tools in the tool magazine and restart BoardMaster If there is no camera installed 1 Turn the ProtoMat on and make sure that there is a tool in every Slot of the tool magazine and that there are no tools In the ProtoMat s collet 2 In BoardMaster select Configuration gt gt Heads choose Camera under the Head drop down box and set both offset values to O and click OK 3 In BoardMaster select Configuration gt gt Toolbox click on tool position 1 and click the Service button When prompted for the Service password enter BMASTER 4 Under Main Aux Clamp select Open click on tool position 1 in the Tool Box list and click the Check button 5 In the main BoardMaster interface enter 35 in the step size window for the Z axis and click the Z axis down button If a dialogue box opens asking to set up a movement border this
5. ROM tutorial Base material connected to machine base plate Accessory set tools drills fuses and depth limiter foot Other References Please review all documentation including printed material and the CD ROM tutorial for more details Online support http www lpkfusa com and http www protomat com and support lpkfusa com Startup Procedure Install CircuitCAM and BoardMaster to the host computer referring to the User Guide where needed for troubleshooting Note that the installation CD has to be Initially located and note all installation directories for future reference 1 Unpack the ProtoMat by removing the cardboard cover the accessory bag pulling out the foam inserts pulling the box sidewalls up and d oving the protective ae arene 5 C 6 Connecting a ProtoMat to a computer 2 Lift the ProtoMat as indicated in 1 Note the printed installation guide Connecting the ProtoMat the User Guide do not use the exhaust tube as a handle and to a host computer varies place it onto a sturdy flat and level surface strong enough to Slightly depending on if the support 55 kg 121 Ibs connection is Via RS 232 3 Remove the shipping braces three interface or a USB port pieces and any stray adhesive or foam 4 Verify that the ProtoMat s fuseblock remove blue side cover for access is USB port installation 1 Install the drivers for the USB to serial correctly set for the operating region s TR TETE
6. before continuing 4 Inthe BoardMaster interface click the Pause button figure 12 and verify that the machine head moves to the Pause position 5 Click the Zero Position button figure 13 and verify the machine head moves into the Zero Position or Tool Exchange position 6 Click the Home button figure 14 and verify that the machine head moves into the Home position 9 Installing vacuum table if included If the vacuum table is not already installed follow the included installation instructions Installing the optional vacuum table is quick and easy Refer to the included video training and the User Manual for more details OS eS 13 Zero Tool Exchange 10 Installing camera if included Installing the optional camera is also easy and only requires an open USB 2 0 port on the host computer Refer to the included video training and the User Manual for more details The basic steps are 1 Install the camera software on the host computer 2 Remove the heatsink plate on the machine head and screw the camera to the machine head 3 Connect the camera power supply cable to the socket on the machine head figure 15 4 Run the camera USB cable up along the exhaust hose using the supplied brackets and out through the back of the ProtoMat Be sure the connection to the camera and the connection to the 15 Camera power cable ho
7. converter according to voltage The fuseblock can be set for the directions included EON MEAC 110 120 volts or 220 240 volts Whichever voltage reads upright with the unit figure is the set voltage figure 2 currently set for 220 240 V If the 2 Connect one end of the USB to serial converter to the USB port value must be changed pry the fuseblock out and reinsert it in of the host computer and the other end to the serial cable of the the correct orientation ProtoMat 3 Switch the host computer on After a minute or so the computer will register a new virtual COM port Continue with the serial port installation instructions below 2 Connecting air supply S100 only If the unit is an S100 connect the air supply 6 bar 100 I min or 87 psi 3 5 cfm to the connector which is located inside the back access slot near the top of the opening figure 3 Serial port installation 1 Connect the ProtoMat to the host computer using the included RS 232 serial cable if it s not already Make sure that the proper COM port is selected in Windows by clicking Start gt gt Control Panel gt gt System gt gt 3 Air supply connection Hardware gt gt Device Manager expand the Ports 3 Con necting dust extraction system setting right click the COM1 port choose Properties and clicking Port Settings and that the port settings match those The dust extraction system keeps the shown in Figure work area cl
8. ean of dust and debris and 2 Click Advanced and make sure the FIFO settings are as is controlled by the ProtoMat shown in Figure 9 1 Mount the dust extraction system near the ProtoMat and connect the exhaust tube to the side of the black dust extraction manifold in the back of the ProtoMat 2 Connect the 9 pin side of the control cable figure 4 to the dust extraction unit and the 25 pin side figure 5 to an open 25 pin connector in the back of the ProtoMat either connector will work 3 Set the dust extraction unit control to auto and connect the unit to main power 9 FIFO settings Windows Assuring a trouble free connection to the host computer is one of the 5 The 25 pin connector most Important first steps Refer to the troubleshooting section of this Either socket will work Quick Start Guide and the troubleshooting section of the User Manual Installing depth limiter for more detail Make absolutely certain all COM settings match and that all cables are securely connected The machine depth limiter must be installed by hand Press the foot upward into the working area of the machine head until it pops into place figure 6 6 Installing the depth limiter 7 Switching the ProtoMat on Caution Do not operate ProtoMat unless the lid is closed securely and all objects includ ing tools hands etc are clear of the working area Overriding the safety mechanism or leavin
9. er supply have not been tripped Verify that the fuse in the ProtoMat is good a quick check with an ohmmeter should reveal nearly O ohms resistance The ProtoMat appears to be on and functioning but completely unresponsive to the host computer Verify that the RS 232 cable is firmly connected to both the ProtoMat and the host computer Verify that the COM port settings in BoardMaster are in sync with the COM port settings in Windows see Connecting a ProtoMat to a computer Reboot the computer and try again BoardMaster reports Error E115 figure 27 Description E715 motor circuit power voltage too low in process smcu dmcO mc 27 Error E115 Verify that the RS 232 cable is firmly connected to both the ProtoMat and the host computer Verify that the COM port settings in BoardMaster are in sync with the COM port settings in Windows see Connecting a ProtoMat to a computer Reboot the computer and try again BoardMaster reports a Voltage too low error Disconnect the ProtoMat from the mains power and verify that the fuseblock is properly oriented for the existing mains voltage supply The proper voltage should be upright on the fuseblock see Unpacking and Installing the ProtoMat The ProtoMat reports a Wrong ID or Can t read from Calib_Result tbl error Board Master 29 Can t read cal table error 28 Wrong ID error Copy the two files from the Configuration Files CD ROM to C Program F
10. ew Application Review Compatibility Grid CircuitCAM Overview BoardMaster Overview Basic 2 Layer Board Building Tutorial Chemical Free Through Hole Plating Tutorial Galvanic Plating Overview Multilayer PCB Overview and Tutorial Professional Solder Mask Tutorial Surface Mount Technology Overview and Tutorial Microwave and RF Application Notes Plastics and Aluminum Engraving Image information QL_LIB version 3 00 08 Size in pixel 540 x 480 Size in mm 4 23 3 17 Contrast Brightness For the latest copy visit http www 1lpkfusa com 25 Entering the corrected values and setting Minimal quality to 90 tar or contact your local distributor 12 Click Accept to set the new values and close the Setting window by clicking OK 13 Using the same technique from step 6 remeasure the drill hole and verify that the Camera Image window now reports the Troubleshooting Guide Although the ProtoMat S62 and S100 are designed for years of trouble free service errors can always occur The vast majority of problems are easily solved within a minute or two of simple troubleshooting Please review the following list of potential problems and their easy solutions The ProtoMat is completely DOA no lights no motion nothing Verify that the unit is plugged completely into an operating socket sometimes adjusting the unit s position can work the plug free Verify that all fuses or breakers in the mains pow
11. g stray parts in the work area can result in damage to the machine or personal injury The basic switch on procedure is 1 Verify that there are no foreign objects in the enclosed working are of the ProtoMat including tools unsecured working material etc Boot the host computer Switch on the ProtoMat Close the ProtoMat hood Start BoardMaster and complete the Tool Status dialog box figure 10 usually the Free tool position is O 6 If this is the first time the ProtoMat has been turned on or if the data connection is in doubt make sure BoardMaster refers to the proper COM port by clicking in BoardMaster s Menu 11 Communication port settings BoardMaster Configuration gt gt Connect and verify that the settings match Window s COM settings figure 11 6 Verify that the ProtoMat machine head moves to the Home position 8 Checking basic functions Checking basic functions normally only has to be done the first time the machine is switched on or if the machine has been moved 1 If this is the first time the ProtoMat is switched on make sure there are no tools in the tool collet and no tools in the tool tray 2 Switch on the ProtoMat following the above procedure 3 Ifthe machine head was not already in the Home position it will automatically seek out the Home position by hunting for limit switches This may take a moment Wait until the head completely stops moving
12. hoose the same tool from the respective drop down box in BoardMaster box should look like Figure 17 Click the OK button and BoardMaster will change the representative colors of the tools on the main interface to accurately reflect the tool types loaded in the magazine Restart Board Master Pos Tool 1 Universal Cutter 0 2 mm marking fo 50000 2 Spiral Drill 0 5 mm 3 Spiral Drill 0 6 mm 4 Spiral Drill 0 7 mm 5 Spiral Drill 0 8 mm in ce Cr ce Cr JC P Cr Ch Er 6 SprlDm 0Smm 2 pe ami F 7 Spiral Drill 1 0 mm 8 Universal Cutter 0 2 mm 8 mi 9 End Mill 1 0 mm 39 mil me DL ie Jc m g se p TT ei 17 Tool positions dialog box showing initial settings for all tools ro Select fom Inn Now Wanted for ouent job phase When all ten tools have been inserted the Tool Positions dialogue 12 Checking the toolbar position After the toolbar is loaded check the toolbar position Goto Help File Edt view Configuration 1 In BoardMaster select the 1 tool Clee B from the Selected Tool drop down box www figure 18 val Dril O S mm 2 As tool is selected monitor the drill head and make sure that the tool is cleanly lifted from the tool bar without scraping or catching and that the tool does not fall from the collet after lifting 3 Repeat steps 1 and 2 for all ten tools Monitor each tool as it s replaced making sure that it is replaced firml
13. iles lpkf xx bmaster xx represents a two character code and if there are already files of that name present overwrite those files If this problem persists contact LPKF Technical support see below The ProtoMat fails to pick up or put away a tool or there is a tool collision e Make sure all tools are properly seated in the sockets e Lubricate all tool tings using a silicon graphite Teflon or other Suitable lubricant e Recalibrate the toolbar see Adjusting the toolbar position above Holes are not drilled centered on solder pads when board is flipped to side 2 If the ProtoMat has a fiducial recognition camera the camera has probably gone slightly out of alignment Recalibrate the camera see Set Calibrate camera offset If the ProtoMat does not have a camera then the set pins have become worn and new set pin holes must be drilled See the User Manual for this procedure There is some problem with the Fiducial Recognition Camera no image faulty image etc Please refer to the installation manual for the Fiducial Recognition Camera to troubleshoot camera errors The ProtoMat reports a Filter full error Verify that the data cable is securely connected to both the ProtoMat and the dust extraction unit If the problem persists replace the filter bag A Extraction system filter is Full 31 Cover open error Additional troubleshooting guides and tips can be found in the User Manual and online a
14. st computer s USB port are solid 5 Adjust the spring setting of the machining head by carefully following the directions in the User Manual and training video 6 Switch the ProtoMat on using the above procedure The computer will discover new hardware twice once for audio once for video and install the camera After this in the BoardMaster menu choose Configuration gt gt Settings Unlock Check the Camera checkbox then click OK gt gt Two additional video windows will open in BoardMaster If the Tool Status dialog box opens verify and complete that information 7 Restart BoardMaster basic tool Starter Package containing a variety of useful tools for drilling milling and routing PCBs in a variety of material that the tool magazine be loaded correctly and that BoardMaster be properly configured 1 Turn the ProtoMat on and in BoardMaster click the It is critical 11 Loading the tool magazine The ProtoMat ships with a Tool position 1 Tool position 10 amin 16 The ten tool positions Opens Toolbox dialogue button If asked about placing the machine head in the Pause position choose Yes 2 The tools should be inserted one at a time into the tool magazine according to figures 16 and 17 Each tool may be labeled in the case but may not individually labeled so be especially careful to not mix tools As each tool is inserted into the magazine c
15. t http www lpkfusa com or http www protomat com and if none of these actions corrects the error contact LPKF at support lpkfusa com or by calling 503 454 4229 Specifications Specification Working area X Y Z 229 x 305 x 38 mm 9 x 2 x 5 Resolution OY Precision of front to back alignment 0 02 mm 0 8 mil 0 02 mm 0 8 mil Tool collet SAS mme 3 175 mm 1 8 pneumatic release collet Travel speed max Max 150 mm second 6 second Dimensions W H D 670x 540x 760MM 670 D40 760 mim 264221520708 264602152200 un Compressed air supply 6 bar 87 psi 100 I min 3 528 cfm Size of tracks and gaps depends on materials and tools 100 um tracks and gaps possible with LPKF MicroCutter on FR4 18 18 um Cu Extras Enhance the operation of the ProtoMat S62 or S100 with these high quality accessories tools and consumables Dust Extraction System Measuring Microscope System Status Light Brush Head Basic Starter Set Multilayer Starter Set Base Material Professional Tooling Check with your local LPKF distributor for these and other accessories to help create the perfect prototyping solution Also check online at http www 1lpkfusa com or call 503 454 4233 or 1 800 345 5753
16. y into the toolbar at the same level as the other tools upright and smoothly without catching or scraping against any part of the ProtoMat Any tool position that exhibits scraping catching dropping or other signs of misalignment must be adjusted see Adjusting the toolbar position 13 Adjusting the toolbar position Adjust the toolbar position only if indicated by a misaligned tool or other calibration error Adjusting the tool position is sometimes necessary due to normal operating fluctuations such as movement temperature changes and humidity changes Drill 1 0 mm Cutter 0 2 0 mm U mm 8 mil i can 18 Selecting tool 1 There are two different procedures depending on if a camera is installed Refer to the Users Manual for more detailed explanations TONER sere in position 1 If there is a camera installed 1 Set the Camera Offset see Set Calibrate camera offset 2 Turn the ProtoMat on send the machine head to the Pause position and remove all tools from the tool magazine 3 Place the brass Measure Insert into tool position 1 figure 19 and close the hood 3000 Spiral Drill 0 6 mm Spiral Drill 0 7 mm Spiral Drill 0 8 mm Spiral Drill 0 9 mm Spiral Drill 1 0 mm Universal Cutter 0 2 mm 8 mil End Mill 1 0 mm 39 mil Contour Router 1 0 mm 39 mil 301 5736 20 Choosing tool 1 4 In BoardMaster select Configuration gt gt Toolbox on tool position 1 inthe Tool g
17. y is set to 70 only for calibration and is normally 90 e Fiducial diameter use the measured value from step 6 e Number of fiducials 1 e Minimal diameter the measured value from step 6 minus 0 1 mm e Minimal quality 90 8 In the Fiducial settings section of the Setting window click the Accept button 9 If the calibration is unsuccessful try lowering the minimal quality the crcl Gieling COK wil fresh to 70 and clicking Accept Pr again Adjusting the Brightness and Contrast to create more contrast may help as well Repeat until the calibration is successful and the Calibration window appears figure 24 10 Complete the Calibration window enter either radius or diameter and the other value will populate automatically and click OK The calibration should be successful if not then repeat step 9 and the alert window 24 Calibration window can be dismissed by clicking OK 1 Additional Tutorials and How to s 11 In the Fiducial settings section of the Setting window enter the proper values accordingly figure 2 For more tutorials tips and how to s see LPKF s latest Fiducial diameter 1 5 Rapid PCB Prototyping catalog featuring an extensive e Number of fiducials 1 technical guide designed to enhance and in house e Minimal diameter 1 4 prototyping laboratory The Technical Guide includes e Minimal quality 90 tutorials and overviews on Setting Base Material Overvi
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