Manual

BoardMaster 5.1
A
r
t
i
k
e
l
n
u
m
m
e
r
:
1
1
4
1
6
7
Manual BoardMaster 5.1

English, Version 1.0
LPKF Laser & Electronics AG
Osteriede 7
D-30827 Garbsen (Germany)
Telephone : ++ 49 - 51 31 - 70 95 - 0
Telefax : ++ 49 - 51 31 - 70 95 - 90
eMail : lpkf@[Link]
Homepage: http: //[Link].d


2 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
2008 LPKF Laser & Electronics AG.
LPKF Laser & Electronics AG reserves all rights to modify specifications
and other product information without notification. Systems and products
offered by LPKF Laser & Electronics AG and its affiliates are protected
by domestic and foreign patents either already granted or applied for.
Specification of product names is used exclusively for identification pur-
poses, whereby they may be trade names or registered trademarks of
the specific companies. The LPKF logo and designation ProtoMat are
registered trademarks of LPKF Laser & Electronics AG.
Order No. 114 167
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 3
Preface
This Manual introduces you to operation of BoardMaster 5.1 for Win-
dows
TM
. LPKF BoardMaster is a program for automatic control of HP-
GL-compatible LPKF circuit board plotters.
LPKF BoardMaster is capable of reading in, displaying and processing
production data in LMD format (generated in LPKF CircuitCAM) as well
as production data generated in HP-GL format
BoardMaster takes over complete control of the circuit board plotter. The
WYSIWYG (What You See Is What You Get) display for the data to be
processed, manual control of the circuit board plotter on the Windows
surface as well as the present tool library with all required information
ensures virtually complete automation of circuit board prototype produc-
tion.
This Manual describes the way from LMD/HP-GL circuit board data gen-
erated by CircuitCAM or other programs, over job preparation right up to
completion of the circuit board prototypes with the circuit board plotter.
The Manual introduces the basic control possibilities of BoardMaster
step by step, allowing you to quickly complete your first circuit board in a
simple manner.


4 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
Notes on this manual
Basic use of the Windows surface is not covered in this Manual. If you
are not familiar with use of the various Windows objects, please first
refer to your Windows documentation.
I. Manual outline
This Manual is divided up into the following chapters:
1. Safety Instructions
2. Installation
3. Operating interface
4. Production process
5. Troubleshooting
6. Appendix

II. Conventions used in this manual
Bold text is used to emphasize important information.
Illustrations are numbered continuously - Example: Fig. 5.
Italic sections are used to indicate reactions resulting from an action.
Words printed in italics indicate proper names.
Key inscriptions and menu terms are printed in BOLD CAPITALS.
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 5
III. Notes on the symbols used
Danger!
This symbol is used to warn of danger to life or health..
Attention!
This symbol is used to identify hazards which may cause damage.

Note:
This symbol is used for notes intended to help you to avoid malfunctions
in operation or help you to improve your procedures

IV. Legend
CircuitCAM : Software used for data preparation
BoardMaster : Software used for machine controlling
shearing winkel : In the ideal case the angle between X aund Y-
axis is 90 degrees. This results in a shearing
angle of 0 degrees. The shearing angle is the rela-
tion of the two axes with respect to each other.


6 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 7
Content
1 Safety precautions ........................................................... 9
2) Installation .....................................................................10
2.1 System prerequisites .............................................. 10
2.2 Scope of delivery .................................................... 10
2.3 Installation .............................................................. 11
2.4 Start BoardMaster .................................................. 14
2.4.1 Startup the program .....................................14
3 Operation interface ....................................................... 16
3.1 Menu bar ................................................................ 18
3.1.1 File menu .................................................... 18
3.1.1.1Import data ..............................................19
3.1.2 Edit menu ................................................... 20
3.1.2.1Placement menu .................................... 21
3.1.2.2Reload material menu ............................. 23
3.1.2.3Drill break control .................................... 24
3.1.2.4Teach-In .................................................. 25
3.1.2.5Tool assigment ....................................... 28
3.1.3 View menu .................................................. 29
3.1.4 Configuration menu ..................................... 30
3.1.4.1Material ................................................... 31
3.1.4.2Machine settings ....................................33
3.1.4.3Tool library .............................................. 36
3.1.4.4Heads .....................................................39
3.1.4.5Vacuum system ......................................40
3.1.4.6Connect .................................................. 40
3.1.4.7Tool box .................................................. 42
3.1.4.8Phases .................................................... 44
3.1.4.9Define the tool change position .............. 46
3.1.4.10Fiducials ................................................ 46
3.1.5 Go to menu .................................................. 47
3.1.6 Help menu ................................................... 49
3.2 Function bar ........................................................... 50
3.2.1 Status information ....................................... 52
3.2.2 Changeable parameter ............................... 53
3.2.3 Positioning functions .........................................54
3.2.4 Manual control functions ...................................55
3.2.5 Selection funktions ............................................ 56
3.2.6 Production phase control function ....................58
4 Production process .......................................................59
4.1 Prepare start BoardMaster .....................................59
4.1.1Start BoardMaster ..........................................59
4.1.1.1Tool status ...............................................61
4.1.1.2Check interface .......................................62
4.1.2Insert base material ........................................64
4.1.3Import Production data ...................................64
4.1.4Select first production phase .......................... 66
4.1.5Select second production phase .................... 68
4.1.6Select third production phase ......................... 69
4.1.7Select production phase four .......................... 69
4.2 Tool change ............................................................71
4.2.1Manual tool change ........................................ 71
4.2.2Automatical tool change ................................. 72
4.3 Switch off ................................................................ 73
4.4 Home position and reference hole system ............. 74
4.5 Camera functions ................................................... 75
4.6 2.5-D-Mode ............................................................76
4.7 Camera image fiducial detection ............................77


8 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
5 Troubleshooting .............................................................79
5.1 Circuit board plotter initialisation ............................ 79
6 Appendix ..................................................................... 81
6.1 From Pen Plotter to Circuit Board Plotter .............. 81
6.2 Index ......................................................................82
Safety precautions
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 9
1 Safety precautions
Always observe the following points for your own safety. The use of
BoardMaster alone represents only a minor hazard potential.
Ensure that your computer is properly connected to the line
power and to the circuit board plotter!
Ensure that no one is present in the hazard area of the circuit
board plotter during data transfer between BoardMaster and
the circuit board plotter!
Ensure that no one can enter the hazard area of the circuit
board plotter and come into contact with the tools during
operating phases controlled by BoardMaster!
Ensure that it is not possible for unauthorized persons to
operate BoardMaster when working with the circuit board
plotter, for example during manual tool change or alignment of
the base material!
In the event of an emergency, shut off the circuit board plotter
and PC connected to the circuit board plotter immediately!
Always observe the safety precautions specified in the manual
for the circuit board plotter!
Also observe other safety precautions in this manual!

Installation
10 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
2 Installation
2.1 System prerequisites
The minimum system prerequisites for installation of BoardMaster are:
Pentium Processor with 700 MHz or faster
128 MB RAM (main memory), 256 MB recommended
XGA grafics card, screen resolution 1024 x 768 pixel recommended
Operation System: Microsoft Windows 2000/XP
min. 4x-speed CD ROM drive
RS232 or USB interface depending on the LPKF ProtoMat type
BoardMaster requires approx. 16 MB of free hard disk capacity for instal-
lation.
2.2 Scope of delivery
The BoardMaster scope of delivery includes:
1 x CD ROM with BoardMaster programm
1 x BoardMaster manual
Installation
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 11
2.3 Installation
Insert the BoardMaster ... & CircuitCAM ... CD into the CD-Drive and
wait until the welcome Window Rapid Prototyping PCB will be ope-
nend. Depending on the computer this can last up to one or two
minutes.
If the welcome window Rapid Prototyping PCB is not opened auto-
matically: Start the [Link] file on the CD.
The window BoardMaster 5.1 InstallShield Wizard will be opened:
Select the radio button Install an new version of this product.
Click on NEXT.
Note: For updating an existing software version select the radio
button Update selected product shown in the list below. Define
the path to the programm folder and click on NEXT.
Fig. 1: Installation window

Installation
12 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
Select the desired language (English or German).
Note: The selected language is just for the installation process.
The language used for the software to be installed must be
select later.
Click on NEXT.
The following window will be shown:
Click on NEXT.
Fig. 2: Language selection
Fig. 3: Start of installation
Installation
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 13
The following window will be shown:
Select the language for the BoardMaster 5.1 operating interface.
Click on the radio button for the choosen language, for example
English.
Click on NEXT.
The following window will be schown:
Click on NEXT.
Note: The Install Wizard use a defined destination folder for instal-
lation. Click button CHANGE to change the destination folder.
Fig. 4: Program language
selection
Fig. 5: Installation folder
selection

Installation
14 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
The following window will be shown:

Click on Install.
[ ] The BoardMaster installation will be finished automatically.
2.4 Start BoardMaster
After installation of BoardMaster, the Start menu contains a new program
group LPKF Laser & Electronics, as well as a new linkage on your Win-
dows desktop.
For error-free operation with your circuit board plotter, it is absolutely
necessary to observe the switch-on sequence specified below:
Switch on the circuit board plotter.
Wait until the green operating indicator on front or on the
data-LED on the back panel of the circuit board plotter
lights up.
Start BoardMaster.
Otherwise, the communication accomplished even when BoardMaster is
starting, cannot be performed.
2.4.1 Startup the program
Double-click on the BoardMaster icon on the desktop.
Or click on Start > Programme > LPKF Laser & Electronics AG>
BoardMaster ... .
The BoardMaster startup window will be opened.
Fig. 6: Installation process
Installation
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 15
Fig 7: Startup screen
This startup screen may be visible for up to 8 seconds, which is
related to the communication between the PC and the machine, it
does not represent an error. After that, the program start is
automatically continued.
In case of appearing the Connection... windows:
Check the operating state of the circuit board plotter and con-
nection cable between PC and circuit borad plotter.
Check the connection settings ( see chapter [Link] Connect
on page 40)
In case of appearing the Tool status windows:
Select the tool position and click on OK.
Fig 8: Startup screen
[ ] The BoardMaster operation interface will be opened.

Operation interface
16 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
3 Operation interface
The figure shows the BoardMaster operation interface:
Fig 9: BoardMaster window
The BoardMaster operation interface is separate in several areas:
The title bar indicates the program name with the declaration of the
circuit board plotter type as well as the name of an loaded or new
created job.
The menu bar indicates the available menu functions.
The function bar contains several bottons, displays and functions
to control the circuit board plotter and to modify a job.
The workspace indicates graphically the topview on the circuit
board plotter.
This area is itself divided up into the actual motion range
of the circuit board plotter (displayed in dark gray) and the
area of the base material used (displayed in green) with
the circuit board data to be processed. Only in this area
2
3
4
5
1
6
7
1- title bar 5- available workspace
2- menu bar 6- blue crosslines indicates the actual position of the drill / mill head
3- function bar 7- camera window (optional, ProtoMat with camera system)
4- tool change position (optional, only ProtoMat S62/S100)
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 17
you can lower the head, therefore all data must be
placed in this area.
You can adapt the graphic display of the working area to
your specific requirements with the functions in the VIEW
menu.
The display scroll bars are located on the right of and below the
working area and serve for moving the visible section into the
working area.
The current mouse cursor position is indicated at the left next to
the horizontal scroll bar.
The status bar below the horizontal scroll bar provides information
on buttons, displays or areas where the mouse cursor is presently
located.
The tool changing position (for S62/S100) represents the stations
1-10 of the tool magazine.

Operation interface
18 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
3.1 Menu bar
The foloowing figure indicates the BoardMaster menu bar:
Fig 10: Menu bar
3.1.1 File menu
The functions of the FILE menu are used for file organisation and to
close the BoardMaster program.
Fig 11: File menu
1 3 4 5 6 2
1- File menu 4- Configuration menu
2- Edit menu 5- Go to menu
3- View menu 6- Help menu
NEW Use this submenu to create a new job file for a
BoardMaster application.
OPEN Use this submenu to open an existing job file-
for the a BoardMaster application.
SAVE Use this submenu to save a BoardMaster job
file. The file name will be the same as dis-
played in the title bar.
SAVE AS Use this submenu to save a BoardMaster job
file under a new file name.
IMPORT Use this submenu to import production data or
project files into the BoardMaster program.
ACTUAL Use this submenu point to refresh the actual
job file.
EXIT Use this submenu point to close the BoardMa-
ster program.
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 19
[Link] Import data
Use the menu IMPORT to load production data or BoardMaster projects:
Fig 12: Import menu
Note: Version 3.x LMD files can also be imported. However, it is
necessary to reassign the tools Assigning Tools on page 85 and the
production phases, because these names are not identical and
BoardMaster cannot find the old names.
After importing LMD files, data is positioned immediately in the middle of
the working area for the circuit board plotter. Moreover, the production
data and the required tools are automatically assigned to the data: If it is
not possible for BoardMaster to assign one or more tools, the following
message appears:
Fig 13: Import message
In this case, it is necessary to assign the tools manually in the tool assi-
gnment dialog box or to complete the tool library before importing the
data again.
After exporting the files, all tools required are listed in the CircuitCAM
report window.
LMD/LPR... Select this entry to import LMD files (CircuitCAM
production data) or LPR files (BoardMaster HP-
GL projects) into BoardMaster.
HP-GL into In this submenu, select the entry:
New LPR to import the HP-GL files into
BoardMaster and assign them
to a new project.
STANDARD to import HP-GL files into
BoardMaster and assign
them to a standard project.

Operation interface
20 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
3.1.2 Edit menu
All function of the EDIT menu are used to overwork the process file.
Fig 14: Edit menu
PLACEMENT Select submenu PLACEMENT to place new
project on the basic material.
RELOAD Select submenu RELOAD to overwork already
manufactured circuit boards.
CHECK DRILLL Select submenu CHECK DRILL to monitor the
tool during the production process.
TEACH-IN Select TEACH-IN to edit a production process
step by step in BoardMaster.
TOOL SELECTION not supported
TOOL ASSIGMENT Select submenu TOOL ASSIGMENT to assign
the tool to every project seperately.
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 21
[Link] Placement menu
After you have imported or generated the required projects, you can
place them in the BoardMaster working area. Imported projects are auto-
matically positioned in the center of the working area or the predefined
base material.
Click on EDIT>PLACEMENT to open the following submenu:
Fig 15: Placement menu
Place a project:
Click on ADD and select a project from the list.
or:
Select a project from the list of the left side of the window to change
the placement.
Edit the text field SCALE to get the required scaling for the project.
Standard scale value is 1, indicating scale 1:1.
For application such as front plate and plate engraving other scales can
be defined.
Enter the desired position for the project in the working area in the
text field X and Y under ORIGIN. These values refer to the HOME
position for the circuit board plotter and the data origin.
If the exact position of the data in the coordinate system are not known,
enter the value 0 and 0 here and position the project in the working area
with the aid of the function bar or computer mouse.
Select the appropriate offset for the project in the working area under
ROTATION.
To complete more than one prototype for a project, define the num-
ber of multiple boards under COUNT. Enter the number of boards in
the X direction in the first text field and the number of boards in the Y
direction in the second text field.

Operation interface
22 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
Enter the interval of the boards under DISPLACEMENT. Enter the
displacement of the boards in the X direction in the first text field and
the displacement of the boards in the Y direction in the second text
field.
The displacement of the boards in relation to one another must corre-
spond to at least the length and width of the circuit boards, because
otherwise, the boards would overlap.
Multiple boards can also be created with the function bar.
Place a project in the base material center:
Select the corresponding project in the list field.
Click on CENTER to position the selected project in the center of the
base material.
Add further project for placing:
Click on ADD.
Select a project form the list for placing on the base base material
additional.
Fig 16: Dialog box select project
Click on OK to close the dialog box.
Delete a placed project
Select the project with must be removed from the list.
Click on CANCEL to remove the placed project from the base material.
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 23
[Link] Reload material menu
The function RELOAD MATRIAL serves for reloading a circuit board
which has already been completed and cut, in order to drill additional
holes, engrave text or separate the conductors for coding.
The prerequisites for using the reload function include a circuit board
requiring reprocessing and the circuit board data as LMD file with at
least two identifiable points (holes, reference marks, vectors), which can
be assigned to the corresponding points on the circuit board.
The main purpose of the reload feature is to position the data so that it
coincides with the circuit board to be processed. For this purpose, two
identifiable points in the data (reference points) are assigned to the cor-
responding points on the circuit board to be processed.
When RELOAD MATERIAL is selected, the floating dialog box is ope-
ned:
Fig 17: Dialog box reload material
Reload material
If not already accomplished, open the RELOAD MATERIAL dialog
box. Click on the radio button for [Link] and select the first refe-
rence point on the data (center point of solder eye or hole, corner
point).
Click on to bring CENTER or EDGE mark to the requi-
red position.
Move the machining head with tool installed or the cross hairs on the
camera (LPKF CircuitView Option) as exactly as possible to the
appropriate point on the circuit board. For this purpose, use the
motion keys on the function strip:

Click on the READ button to import the point.
Only drill hole selection
Only pad selection

Operation interface
24 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
Actived radio button 2. PIONT and repeat the above desribed proce-
dure for the second reference point (3. POINT and 4. POINT).
Mark the check box ENABLE.
Close the dialog box RELOAD MATERIAL by clicking OK. A data
reload will be activated.
Mark all data to be transmited to the circuit board plotter. Th data will
be recalculated acc. to the position on the printed circuit board after
clicking START button.
To avoid the data adjustment of further jobs deactived the check box
SETTINGS. Click on OK to leave the function and close the dialog box.
[Link] Drill break control
Click on EDIT>BROKEN DRILL TOOL DETECTION to open the follo-
wing dialog box:
Fig 18: Dialog box Check drill
If you activated the check box CHECK FOR BROKEN TOOL the follo-
wing check functions are available:
Drill control before
each tool change
Click this check box to activate the broken drill
tool detection before every tool change.
Drill control after
drilling process
Click this check box to activate the broken drill
tool detection after a number of drills, defined
in the input field below.
Confirm without
measuring
Click this check box to drill a test hole automa-
tically via BoardMaster. BoardMaster compare
the hole dimension with the default parameter.
If the hole dimension miss the default parame-
ter BoardMaster generates a error message
and the tool must be changed.
Confirm measuring Click this check box to drill a test hole. The
user must check the hole dimension and must
confirm the correct hole dimension.
Check for brocken
tool
Click this check box to activate the broken tool
check.
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 25
Select the required function for broken tool check and click on OK.
Note: The functions described above are only for ProtoMat types
with camera option.
[Link] Teach-In
The BoardMaster program offer the possibility of programming drilling
and milling data from a template (film or circuit board) with the aid of a
Teach-In process. For this purpose, fasten the template to the circuit
board plotter and move to the individual positions to be programmed
with the aid of the camera image in LPKF CircuitView (option). The HP-
GL file completed in this manner can be read into BoardMaster after pro-
gramming and output to the circuit board plotter.
Click on EDIT>TEACH-IN to open the following dialog box:
Fig 19: Dialog box Teach-In
.
STEP [MM] The values entered under X and Y [mm] indi-
cates the distance moved when the motion
buttons (+X, -X, +Y and -Y) are pressed once.
To program the drill holes in an IC enter a
value of 2.54 mm here. This corresponds to a
pad interval of 1/10".
HEAD The command for lifting or lowering the head
can be programmed by clicking one of the two
radio buttons (UP, DOWN). The head remains
in the selected position until the other radio
button is activated.
This function is not used to create a drilling file,
but only for programming milling or contour
data.
RECORD MOVE-
MENTS
All movement command are stored in the sel-
ected file when this check box is activated.
+X, -X, +Y, -Y
Buttons
These buttons serve for moving to a desired
position. If one of these buttons is clicked, the
machining head moves in the selected direc-
tion by the value entered under STEP.

Operation interface
26 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
Fasten the template (film or circuit board) on the circuit board plotter
as parallel as possible to the axis.
Click on EDIT>TEACH-IN to open the dialog box.
Click the SAVE button to create a file in which the data is to be
stored. Enter a name for the file.
After you have entered the corresponding name, the TEACH-IN dialog
box reappears.
Switch on the option RECORD MOVEMENTS, before starting the
reading operation.
The file to be created is an HPGL file meaning that it is also written
according to the steam for an HPGL file.
First enter the desired pin number under PIN and then click the PEN
(SP) button.
Then move with the aid of the motion keys (+X, -X, +Y, -Y) to the
hole positions to be read in and press the DRILL (PD;PU) button.
After reading in all of the required holes, the data is stored automati-
cally, you can exit the TEACH-IN dialog box by pressing the EXIT
button.
PEN The pin number entered in this editing field is
written to the selected file as the SELECT PEN
command. This allows all drilling data even
with different diameters to be combined in one
drilling file. Example: Pin 1 for 0.7 mm, pin 2 for
0.9 mm and so on.
EXIT Clicking this button discontinues the Teach-In
process and closes the recorded drilling or mil-
ling file.
CREATE FILE By clicking this button BoardMaster requests
entry of the name of a file in which the data to
be programmed are to be stored. Here, it is
possible to either create a new file or to write
over a file already present.
APPEND FILE Click this button to select a drilling or milling file
which already exists to which the additional
drilling or milling data are to be appended. The
new data are appended at the end of the selec-
ted file.
PEN [SP] The pin or tool number selected under PEN is
added to the drilling or milling file as the SEL-
ECT PEN (SP) command when this button is
clicked. It serves for differentiation of the indivi-
dual drill diameters.
PLOT [PA] Click this button to move the head (when
RECORD MOVEMENT is switched off) at
angles not equal to 90.
DRILL [PD;PU;] Click this button to program a hole at a position
moved to previously. This causes the com-
mand sequence PEN down, PEN up to be writ-
ten into the file. This command chain
corresponds to a drilling command for the cir-
cuit board plotter.
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 27
The recorded coordinates are then available in the HPGL file created
previously.
Now select IMPORT>HPGL TO>NEW LPR... in the file menu, select
the HP-GL file just created and enter a name for the new LPR pro-
ject.
To produce something with this newly created file using BoardMaster
and the machine, open the EDIT PROJECT dialog box to assign all
required product phases and tools to the HP-GL file.
Moreover, set the unit corresponding to the machine resolution (e.g.
0.0079375) in the EDIT PROJECT dialog box (this value is also given in
the settings SETTINGS dialog box in the CONFIGURATION menu).
Note: Please do not forget to reset the unit back to the original
value after completion of this operation.

Operation interface
28 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
[Link] Tool assigment
Every BoardMaster job consist of one or more projects. A project is
general definded as a printed circuit board imported as LMD file or HP
GL project.
Click on EDIT>TOOL ASSIGMENT to open the following dialog box:
Abbildung 20: Dialog box tool
assigment
Generally the production data will be imported via the file menu. Projects
like LMD data from CircuitCAM or HP GL files can also added via this
dialog box.
The LMD files generated during export in CircuitCAM contain the pro-
duction data for the entire circuit board. The LMD files imported into
BoardMaster are listed in the project list. The CircuitCAM layers with
their production phases (phase) are listed in the field Phase file/Layer.
Each of these entries contains one or more pieces of tool information
(pins) with the assigned tools from the BoardMaster tool library (tool).
If automatic tool assignment was not possible (see above), it is neces-
sary to edit the tools manual:
Select a LAYER without tool assigment from the list.
Open the Pin list field and check whether a tool is assigned to each
PEN.
If not, select the tool to be used here from the Tool list field.
Repeat this assigment process until all tools are correct assigned.
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 29
3.1.3 View menu
To adapt the graphic display of the BoardMaster working area to the
specific requirements of the user the functions in the VIEW menu can be
used:
Fig 21: View menu
ZOOM AREA Select submenu ZOOM AREA to display a fre-
ely selectable cutout of the working area to fill
the screen.
For this purpose, press the left-mouse button
and hold down while moving the mouse to
define the desired area. You can also select
this function by clicking on the function
bar.
ZOOM IN X1.5 Select submenu ZOOM IN X1.5 to increase the
graphic display by a factor of 1.5.
ZOOM OUT /1.5 Select submenu ZOOM OUT /1.5 to decrease
the graphic display by a factor of 1.5.
MACHINE Select submenu MACHINE to display the
entire working surface of the circuit board plot-
ter in the working area.
MATERIAL Select submenu MATERIAL to display the
entire base material surface in the working
area.
ALL PROJECTS Select submenu ALL PROJECTS to display all
positioned projects as large as possible in the
working area.
PREVIOUS Select submenu PREVIOUS to return to the
previous screen display.
BOTH SITES Select submenu BOTH SITES to change back
and forth between simultaneous display of
both sides of the circuit board and display of
only one side of the circuit board.

Operation interface
30 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
3.1.4 Configuration menu
All configuration settings with are used for BoardMaster or the connec-
ted circuit board plotter are grouped under this menu point:
Fig 22: Configuration menu
REAL TOOLS Select submenu REAL TOOLS switch display
of the milled lines in the actual width ON and
OFF. The actual width of the milled lines is defi-
ned in the tool library.
DEFAULT FONT Select submenu DEFAULT FONT to change
back and forth between the Windows system
font and the font set under CHANGE FONT for
display of the text.
CHANGE FONT Select submenu CHANGE FONT to select the
font to be displayed when the DEFAULT FONT
is deactivated.
COM REPORT Select submenu COM REPORT to save the
interface communication between computer
and circuit board plotter (ProtoMat) in a log file.
CAMERA Select submenu CAMERA to activate the
camera (optional).
MATERIAL Select submenu MATERIAL to edit the mate-
rial dimension.
SETTINGS Select submenu SETTINGS to change or edit
general process parameter.
TOOL LIBRARY Select submenu TOOL LIBARAY to edit the
tool library.
HEADS Select submenu HEADS to open the head dia-
log box.
VACUUM SYSTEM Select submenu VACUUM SYSTEM to open
the exhausting dialog box.
CONNECT Select submenu CONNECT to open the inter-
face dialog box.
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 31
[Link] Material
By preparation of a new job first of all the size of the base material must
be defined. It is necessary because BordMaster must display the actual
work space inside the work area to support the optimal placing of the cir-
cuit board data.
Click on CONFIGURATION>MATERIAL to open the following submenu
selection:
Fig 23: submenu selection material
This submenu provides two options to define the material size:
use SET LOW CORNER/HIGH CORNER to edit the material size
via moving the drill/mill head and reading the coordinates.
use dialog box SIZE to edit the material size manual.
Size definition via moving drill/mill head:
Precise determination of the base material size can be accomplished
with the circuit board plotter connected with the functions SET LOW
CORNER and SET HIGH CORNER in the submenu MATERIAL in the
menu CONFIGURATION.
Danger! The following instructions starts the circuit board plotter.
Ensure that no one can enter the motion range of the circuit board
plotter. Danger of pinching and crushing!
Also observe the safety precautions in the circuit board plotter
manual!
TOOL BOX Select submenu TOOL BOX to open the WZ
magazin dialog box.
PHASES Select submenu PHASE to open the phase
dialog box.
DEFINE
EXCHANGE POSI-
TION (ProtoMat S42
only)
Select submenu DEFINE EXCHANGE POSI-
TION to open the position read dialog box.
FIDUCAL SET-
TINGS
Select submeu FIDUCAL to open the fiducal
dialog box.

Operation interface
32 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
Move the drill/mill head of the circuit board plotter with the arrow
keys to the front right corner (X/Y-Min) on the cir-
cuit board material.
Click on CONFIGURATION>MATERIAL>SET LOW CORNER.
Move the drill/mill head of the circuit board plotter with the arrow
keys to the rear left corner (X/Y-Max) on the cir-
cuit board material.
Click on CONFIGURATION>MATERIAL>SET HIGH CORNER.
After the base material size has been defined, it is displayed in dark gray
in the BoardMaster working area.
Note: Always observe the specified sequence for setting the coordinates
(first front right corner, then rear left corner)!
When defining the material size, observe attachment strips and the size
of the working depth limitation as well as the position of the reference
hole pins.
When a new job is defined; the already defined material size is deleted.
Manual input of the material size:
Note: This possibility for defining the size should only be used for
preparing a job when the circuit board is not connected, because
precise entry in consideration of the positioning on the circuit
board plotter and the position of the reference holes in the base
material is not possible.
Click on CONFIGURATION>MATERIAL>SIZE to open the following dia-
log box:
Fig 24: Dialog box material size
Note: The dialog box is splitted in two parts. The upper part is iden-
tically for all ProtoMat types and is use for the input of the base
dependent on ProtoMat type
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 33
material size. The lower part is depending on the actual ProtoMat
type and is used for the input of informations like material thick-
ness or free moving high. For more detail information take a look
into the respective machine manual.
The size of the base material can be defined by manually entering the
corresponding values in the text fields. The size calculated from the
values in the upper text fields is displayed in the text field SIZE.
After exiting this dialog box by clicking OK, the base material area is dis-
played in dark gray in the working area.
Always observe that the minimum values (possibly negative sign) are
entered under X-MIN / Y-MIN and the maximum values under LOW
CORNER.
[Link] Machine settings
Click on CONFIGURATION>SETTINGS to open the following submenu:
Fig 25: Submenu machine settings

Operation interface
34 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
NAME The drill/mill plotter type will be displayed in
this text field, the same type name as indicated
on the BoardMaster title bar. This indication is
use for information only and has no relevance
for the operation process.
NUMBER OF TOOL
POSITIONS
The number in this text field indicates the num-
ber of tool change positions. The number
varieds depending on the drill/mill plotter type:
ProtoMat 95s always 30, ProtoLaser always
23, LPKF Automill always 7, ProtoMat S62/
S100 10.
UNIT Click on one of the two options to have the
length, diameter coordinates and so on dis-
played either in inch or metrically.
SEND Click on this button to send the command in
the entry field to the left of the button to the cir-
cuit board plotter.
For this function it is not necessary to click first
on the button UNLOCK. For the command
syntax please read the manual of the circuit
board plotter.
ROTATION [1/min] The number in this text field indicates the maxi-
mum speed of rotation of the spindle of the cir-
cuit board plotter.
MOVING [mm/s] The number in this text field indicates the maxi-
mum speed of movement of the circuit board
plotter when the machining head is lifted.
RESOLUTION [mm] The numbers in these two fields define the
distance which the circuit board plotter moves
in X or Y direction at one step of the stepping
motor. Do not change these values under any
circumstances as otherwise the correct scaling
of the output cannot be guaranteed.
CORRECTION
[mm]
This value (in millimeters) compensates the
installation position of the sensor with respect
to the tool measurement. This value is part of
the ProtoMat S60 factory settings and it is
stored in the ini-file.
Write to COM-
[Link]
Click this check box to the log data into the
[Link] file.
MILLING DEPTH
SENSOR
This function activates the measurement of the
surface milling tools (only ProtoMat H100).
CORRECTIONS Compensates for a shearing angle that
developed subsequently between the axes.
This setting may only be made under the
instructions of the Support Department of the
LPKF AG
FLIP CORRECTION Failures cause by turning around of the cicuit
board will be equalized with this function.
Change this adjustment under the instruction
of LPKF support devision only.
SMCU 3 CONTROL Controller type SMCU III for ProtoMat S42 (up
manufacturing year 2008).
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 35
Note: The type of control should not be changed as otherwise the
correct data transfer with the corresponding syntax is no longer
possible.

To prevent a change by mistake of the parameters listed in the dia-
log field MACHINE SETTINGS if you want to make a deliberate
modification you have to click on the button UNLOCK (password
protected) to enable the editing of a parameter.
During installation, the machine parameters of the circuit board plotter
are read from the initialisation disk that is supplied together with the plot-
ter. Thus all important values like machine size and the position of the
HOME position (data origin on the axis of reflection) are already pro-
grammed at the factory. The circuit board plotter is immediately ready for
operation.
All important information like HOME position and area of travel must be
sent from BoardMaster to the control of the circuit board plotter.
Note: In case the individual INI-file is lost it may be necessary to newly
initilise the circuit board plotter.
If the plotter parameters must be set anew or corrected, please follow
the instructions in chapter Initialization of Circuit Board Plotter on page
104.
A chain of commands in plotter syntax can be entered in the text field
START LINE. The commands are stored in the initialisation file when
BoardMaster is closed and are sent to the circuit board plotter when
BoardMaster is started.
All inputs in the dialog field MACHINE SETTINGS are transferred to the
plotter when OK is clicked to leave the program and they are stored in
the initialisation file when BoardMaster is closed. Thus they are available
at each new start of the program.
SMCU 2 CONTROL Controller type SMCU II for ProtoMat H100,
ProtoMat X60 (up manufacturing year 2004),
ProtoMat H60, ProtoMat S62.
SMCU 1 CONTROL Controller type SMCU I for LPKF 91s,
LPKF92s, ProtoMat 91s, 91s/VS, 92s*,93s and
ProtoMat 95s also ProtoMat C20, C30*, C60,
C100/HF, M30*, M60 and X60.
BoardMaster is capable to operate two types of
control. Selection of the control type is done in
the field CONTROL and is preset for the circuit
board plotter selected in the setup.

Operation interface
36 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
[Link] Tool library
The BoardMaster program provides tool libraries containing tools availa-
ble from LPKF with all specific tool settings. The tool library files are
available in three versions: *.TOL for drilling and milling tools, *.DIS for
dispensing needles and *.VAC for evacuation needles (only with LPKF
AutoContac). All lists can be changed and stored for later use.
Click on CONFIGURATION>TOOL LIBRARY to get access to the
several tool libraries:
Fig 26: Tool library submenu
The tool library contains the definitions of all necessary tools inclusive
their characteristical features for the circuit board plotter operation. To
add tool or change existing tools the following parameter description
must be observed.
Click on CONFIGURATION>TOOL LIBRARY>MILL/DRILL to open
the following dialog box:
Fig 27: Mill/Drill tool edit menu
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 37
NAME LIST This list field contains the name of the tool. The
selection of the name should provide informa-
tion on the type of tool to facilitate later selec-
tion in other program sections. After selecting a
tool in the list field, you can display its settings
and change them if required. The names sel-
ected here must coincide with those in Circuit-
CAM. This name allows automatic tool
assignment when importing LMD files.
DIAMETER [mm] The number in this text field indicates the dia-
meter of the tool. This value allows automatic
tool assignment when importing LMD files and
the display of the actual diameter in the gra-
phic working area.
HEAD DOWN TIME The number in this text field indicates the time
interval in seconds between the command
Lower head and the command Raise head
for the drilling tool.
DRILL/MILL The tool can be defined as a milling or drilling
tool by clicking one of these two options.
DESCRIPTION An additional description of the tool can be
entered in this text field. However, this specifi-
cation has no significance for the production
sequence.
LIFE CYCLE [mm
or no. of holes]
The number in the text field MAXIMUM speci-
fies the maximum cutting path or maximum
number of holes for the tool. In the text field
PRESENT; the cutting path already cut or the
current number of holes for the tool is indica-
ted.
The tool change procedure can be started by
clicking REPLACE and after replacing the old
tool, the specification in the text field
PRESENT is reset to 0.
OPTIMAL SPEED The speed in the text field rotation defines the
optimum rpm for the machining spindle. The
number in the text field MILLING defines the
optimum feed rate for milling tools.
MILLING INFEED
[mm]
Value in millimeters for milling depth (engra-
ving tools L=36mm) and infeed (cutting mills
L=38mm). All milling tools that only machine
the surface of the material or engrave it pene-
trate into the material with this value, after the
zero position was detected by the depth sensor
prior to that. Cutting mills are not detected by
the depth sensor. Then the value only indicates
the further infeed.
WORKING MODE Here parameter sets or profiles can be assi-
gned to each tool. There are the profiles
THROUGHPUT, BALANCED, QUALITY.
Parameters speed, acceleration and dwell
times can be stored for each of the three axes,
they apply to lower head (drilling) and head
down(milling). These profiles are stored in an
MCH-file and are preset for the various wor-
king mode profiles.

Operation interface
38 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
Note: The speed is used automatically only for circuit board plot-
ters with variable spindle speed. For all other circuit board plotters
with variable motor speed, the optimal speed must be set by hand
on the control. The optimal speed to be set is, however, indicated
by BoardMaster upon tool change.
All changes in the tool library can be stored in a tool file (*.TOL) and
loaded again later. The file to be loaded when BoardMaster is star-
ted can be defined in the machine file *.MCH with the command
#[Link] also applies for production phases, the dispen-
ser and vacuum tools.
By clicking on SAVE all changes of the tool file (*.TOL) will be saved.
Click on LOAD to reload this data file later on.
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 39
[Link] Heads
Select CONFIGURATION>HEADS to open this dialog box:
Fig 28: Dialog box Heads
The tool heads are listed on the left side and the corresponding offsets
are in the X/Y text fields on the right side ofthe window:
HEAD The milling/drilling head serves as a reference
for all other options mounted on the head. Its
offset should therefore always be set to X = 0
and Y = 0.
OFFSET [mm] The distance between a light dot or camera
option mounted on the machining head and the
machining head is defined here. This can be
used for precise positioning for reloading cir-
cuit boards already completed.
A detailed description of how these offsets are
calculated is given in the following chapter.
AUTO (ProtoMat
S62/S100 only)
This function is used to calibrate the camera
offset automatically. The calibration process
needs a inserted tool and a base material fixed
on the object table.

Operation interface
40 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
[Link] Vacuum system
Select CONFIGURATION>VACUUM SYSTEM to open this dialog box:
Fig 29: Dialog box vacuum system
Use the submenu VACUUM SYSTEM to call up the status of the
vacuum system. The operation hours will be reported.
[Link] Connect
Select CONFIGURATION>CONNECT to open this dialog box:
Fig 30: Dailog box connect
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 41
The editable parameter of the serial interface for the several Circuit
Board Plotter types are listed in the table below:
Note: Using the ProtoMat S62 or S42 the FIFO buffer must be
actived (see table above)!
CONTROL Inserted automatically
MACHINE Selectable machine configurations:
H100 2003-:
Protomat H100 Manufacture Year 2003
H100 2004-:
ProtoMat H100 Manufacture Year 2004
H60
ProtoMat H60
S-Serie (Firmware 2.7.9)
ProtoMat S62/S100
ProtoMat S42
SMCU_2AX:
ProtoMat 91s, 91s/VS, 92s, 93s, C20, C30,
C30s, C40, C60, C100/HF, M30s, M60,
M100, L60, X60
SMCU_2AX Toolchange:
ProtoMat 95s, 95s/II
SMCU3AX:
ProtoMat D100, M60/3D
X60:
ProtoMat X60/II
X60 III:
ProtoMat X60 / III
FIRMWARE Display of the particular firmware version.
INTERFACE TYPE Used communication ports of the control PC.
Selectable interfaces RS 232 or USB (USB
only for ProtoMat types with LPKF
[Link] controller - Firmware update pos-
sible)
COM PORT Selection of the computer interface with is con-
nected to machine
BAUD RATE 9600, 38400 or 57600 depending on the con-
nected ProtoMat type.
CONNECT To establish the connection to the machine
click the CONNECT button.
Circuit Board Plotter
type
Baud
Rate Data Bit Stop Bit Parity Protocol FIFO
LPKF 91s / 92s
ProtoMat 91s, 91s/VS,
92s*, 93s und 95s*
ProtoMat C20, C30*,
C40, C60, C100/HF,
M30*, M60 und X60
9600 8 1 non Hard-
ware
No
ProtoMat H100, H60,
S62/S100
57600 8 1 non Hard-
ware
Yes
ProtoMat S42 38400 8 1 non Hard-
ware
Yes

Operation interface
42 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
Set this parameter via Windows system control:
Windows 2000/XP: System - Hardware - Device manager
(Login: Admin!!!)
Check the connection between the computer and the circuit board plot-
ter if BoardMaster get no access to the circuit board plotter after the star-
tup of the program.
Also compere the serial interface parameter of the Windows system con-
trol with the listed parameter in the table above.
Note: The main reason for a faulty communication are not correct
protocol settings for the serial interface. Take care that Hardware
handshake and not XON/XOFF is used for protocol.
[Link] Tool box
Note: The ProtoMat S42 do not support this function.
Fig 31: Dailog box connect
Pos. 1 to 10 List of tools.
Head Click on the radio button UP to lift the head for
5 mm. Click on the radio button DOWN to drop
the head for 5 mm.
Main/Aux. Clamp Click on the radio button OPEN to open the
main clamp or aux. clamp (H100). Click on the
radio button CLOSE to close the main clamp
or aux. clamp (H100).
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 43
Tool position Click on the button CHECK to check a selec-
ted tool position. Click on the button INTERPO-
LATE to calculate the tool positions 2 to 9
automatically, when tool position 1 and 10 are
already known. Click on the button APPLY
CURRENT POSITION to accept the manual
correction of the tool position.
Check tool position Click the check box 1 to 10 to define the tool
positions for the check procedure.
Start/Stop Click on the button START to start the check
procedure for the selected tool positions. Click
on the button STOP to finish the check proce-
dure. The value in field RUNS define the num-
ber of check procedure repeats.
Service Click on the button SERVICE (password pro-
tected) to change the parameters and settings.
OK Click on the button OK to save the settings.
Cancel Click on the button CANCEL to leave the menu
without taking over the actual settings.

Operation interface
44 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
[Link] Phases
All data to be transferred to the circuit board plotter by BoardMaster
must be assigned to a certain production phase. These production pha-
ses define a work sequence which does not require any manipulations
by the user. An example of such a manipulation would be through con-
tacting the circuit board or turning the base material. The only exception
here is manual tool change. This assignment is prepared in CircuitCAM
and is accomplished automatically in BoardMaster.
Some production phases are already defined in the initialization file.
However, you can adapt these production phases to your specific requi-
rements at any time. The names of the production phases must coincide
in CircuitCAM and BoardMaster.
Click on CONFIGURATION>PHASES to open the dialog box:
Fig 32: Dialog box phases
All standard defined production phases are listed in the list field. After
selecting a production phase, you can view its settings and change them
if required.
Two settings are required for each production phase:
The color with which the data assigned to this production phase is to
be displayed. This setting serves for differentiation of the various
production phases on the working area.
Definition of the circuit board side (visible = component side or
reversed = soldering side) for the production phase. Mark the
indicator box REVERSE SIDE for all production phases for
processing the bottom of the circuit board. All other production
phases for which the indicator box REVERSE SIDE is not marked,
are defined for processing the top.
Generating a new prduction phase:
Inside production phase listmark the production phase where the
new production phase will be inserted above or below.
Edit name of the production phase into the text field.
To insert the production phase on the relevant position click on INS
ABOVE or INS BELOW.
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 45
By clicking SAVE all changes within the menu PHASES will be saved in
a phase defintion file (*.PHS) and can be loaded by clicking the
LOAD button.
Note: On one-sided material, the option REVERSE SIDE should
be activated for the phase CUTTING OUTSIDE! This eliminates
the necessity of turning the base material.
Intention of the phase files:
[Link] Production of a 1 or 2 layer printed circuit
board.
[Link] Production of a 4 layer (Multilayer) printed cir-
cuit board (sequential build-up method).
[Link] Production of a 6 layer (Multilayer) printed cir-
cuit board (registration pin method).
[Link] Production of a 8 layer (Multilayer) printed cir-
cuit board (registration pin method).
[Link] Cutting of solder foil system EasySolder

Operation interface
46 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
[Link] Define the tool change position
This function must be used by machines without tool change bank. Click
on CONFIGURATION>DEFINE CHANGE POSITION to open the follo-
wing sub menu:
Fig 33: Position read
[Link] Fiducials
Click on CONFIGURATION>FIDUCIALS to open the following sub
menu:
Fig 34: Fiducial settings
UNLOCK Click on the UNLOCK button to read in a new
tool position..
READ After the machine is moved to the relevant
position this position can be saved by clicking
the READ button.
CANCEL Click the CANCEL button to leave this menu.
Recognition Indicator [%]
1 Immediately
recognized if hig-
her than
Edit a value to define the acceptance of the
camera analysis (default: 98)
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 47
3.1.5 Go to menu
Danger:When an entry in the menu GO TO is selected, the connec-
ted circuit board plotter starts moving! The hazard of pinching and
crushing exists!
For this reason, ensure that no one can enter the motion range of
the circuit board plotter during the operating phases!
This menu provided functions for moving the drill/mill head to definded
positions:
2 Try on next spiral
position if lower
than
Edit a value to define the point where the
camera analysis will not detect a object as an
fiducial (default: 40)
3 Move to center if
improvement is
higher than
Edit a value up to this point the divergency of
the fiducial detection will be ignored (default:
4).
4 Spiral search area
size [mm]
Edit a value to define the dimension of search
area (default: 5).
5 Show fiducials for
a period of [s]
Edit a value to define the display time for
detected fiducials.
6 Max. stretch
threshold [%]
Edit a value to define the maximum divergency
between reality area and the fiducial detection
area (default: 0.1).
OK Click on the button OK for taking over the set-
tings.
DEFAULT Click on the DEFAULT button to reload the fac-
tory settings.
CLEAR FID. Click on CLEAR FID. to delete the number of
required fiducials.
CANCEL Click on the CANCEL button to leave the
menu. All settings will not taking over.
Calibration
Damping time [ms] Edit a value to define the measuring delay time
(default: 0).
Axis play security X
[mm]
This function is not supported. The value must
be 0.
Axis play security y
[mm]
This function is not supported. The value must
be 0.
Alignment
Required no. of
fiducials
Click on radio button 2, 3 or 4 to define the
number of searched fiducials.
Confirm fiducials
after recognition
Click on the check box to get a confirm mes-
sage after every check procedure.
Settings... Click on the button SETTINGS... to change the
camera contrast, brightness and so on.

Operation interface
48 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
Fig 35: Go to menu (S42)
Fig 36: Go to menu (S62/S100/
H100)
HOME Select HOME to move the the drill/mill head to
the HOME position (data origin).
PAUSE Select PAUSE to move the drill/mill head to the
PAUSE position (standard Xmax/Ymax).
EXCHANGE (Proto-
Mat S42 only)
Select EXCHANGE to move the drill/mill head
to the exchange position (standard Xmin/
Ymin).
EXCHANGE (user-
defined, ProtoMat
S42 only)
Select EXCHANGE (user-defined) to move the
drill/mill head to the user-defined exchange
position.
ZERO POSITION
(ProtoMat S62/S100
only)
Select ZERO POSITION to move the drill/mill
head to the tool change position (default:
Xmax/Ymax).
CAMERA >> HEAD
(optional)
Select CAMERA>>HEAD to move the camera
to the actual position of the drill/mill head.
HEAD >> CAMERA
(optinal)
Select HEAD>>CAMERA to move the drill/mill
head to the preset (original) position.
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 49
3.1.6 Help menu
Click on menu HELP to get the actual program information:
Fig 37: Program information
Click on OK to close the menu.

Operation interface
50 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
3.2 Function bar
The function bar in BoardMaster includes functions for positioning and
copying projects on the base material as well as for control of the
connected circuit board plotter. Moreover, the function bar provides
important status information on the machining process.
This short summary contains a list of all features in the function bar. The
individual features and meanings are explained briefly. Each function
includes a reference to the corresponding page in the manual containing
a detailed explanation when present. The hot keys for the function are
also listed following the page number.
Fig 38: Function bar
Fig 39: Job information
1
2
3
4
5
6
1- Job informations 4- Marking functions
2- Tool and control functions 5- Process control functions
3- Mill control functions 6- File functions
1
2 3 4 5
6
7
8 9
1- Display or selection of the active job phase 6- Display: Drilling process time (in s) or feed motion (in mm/s)
2- no function 7- Display: Speed drill spindle (unit: 1/min)
3- no function 8- Display. Impact depth of the tool (in mm) - only H100
4- Display: Quantity drill hols or length mill line (in mm) 9- Display or selection of the active phase
5- Connect LPKF-Online-Shop
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 51
Fig 40: Tool and control functions
Fig 41: Milling functions
Fig 42: Marking functions
1
2
3
4 5 6
7
8
9
10 11
1- Display: Configuration Phase 7- Drive drill/mill head to coordinates zero point
2- Display: Configuration Active Tool Library 8- Drive drill/mill head to HOME position
3- Dialog box: Tool Position 9- Drive drill/mill head to PAUSE position
4- Switching ON/OFF vacuum/exhausting 10- positioning of the XY table with the computer mouse
5- Switching ON/OFF milling spindle 11- ?
6- Display interface
1 2 3
4
5
6
1- Camera function: adjust fokus - optional 4- Display: vector index
2- Camera function: fix fokus - optinal 5- Manual movement drill/mill head Z axis
3- Camera function: stop fokus - optional 6- Manual movement drill/mill head X/Y axis
4 5
6
7
8 9 10 11
1
2
3
1-Select area - lines crossing the area 7- Marking data of all production phases
2- Move project 8- Erase selected data from mark
3- Activate/deactivate marked lines 9- Add selected data to mark
4- ? 10- Select area - lines inside the area
5- Display: Quantity marked lines 11- Duplicate project
6- Undo marking data

Operation interface
52 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
3.2.1 Status information
Fig 43: Status information
1
2 3 4
5
1 INTERFACE This display provides information on the
interface set for transferring the control
data. Here NULL means that the data is
not sent to an interface. When the mouse
is moved over this display field, the values
set for the interface are indicated in the
status bar.
2 Actual mill/drill
head position
Display of the actual drill/mill head position
with all three axis: X/Y/Z.
3 Vector quantity Display the number of finished project vec-
tors.
4 2.5D MODE The thickness of the material is divided
into various processing layers. The num-
ber of layers depends on the depth with
which the tool penetrates the material. The
penetration depth must be individually
adapted to each tool. The settings that are
made can be stored in the hob. When the
option is enabled with a checkmark, then
the following dialog appears.
5 Duration estima-
tion
Display of the estimated duration time in
hours:minutes with is calculated for the
activated production phases. Single selec-
tions will not included in the time calcula-
tion.
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 53
3.2.2 Changeable parameter
The display fields indicated here can be edited and thereby adapted to
your requirements.
Fig 44: Changeable parameter
1 2 3
4
1 Tool This list field shows the tool used for the
current production phase.
2 Current production
phase
The current production phase is indicated
in this list field.
3 Step size for
manual control
This text field allows definition of the step
width by which the drill/mill head is moved
each time one of the six Arrow buttons
(outlined with dotted line in figure above) is
clicked. The text field can be marked and
the value can be increased or decreased
in defined steps with the + or - button.
4 Vector index This text field allows you to define the vec-
tor index. An index is counted with each
line segment or arc segment. Here, it is
possible to define the vector index at
which processing is to be started, for
example.

Operation interface
54 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
3.2.3 Positioning functions
Move projekt
Activate this button to move a project in the operating area. Position the
cursor on the project to be moved, press the left mouse key and drag the
project to the desired position with the mouse key depressed.
The project appears as a dark area while it is being moved.

Duplicate project
Activate this button to duplicate a project and position the copy in the
operating area. Position the cursor on the project to be duplicated, press
the left mouse key and drag the copy of the project to the desired
position with the mouse key depressed.
The copy of the project is represented as a dark area during duplication.
Note: Each time a project is moved or duplicated it is necessary to
reactivate the corresponding button.
Click a project with the right mouse key to open the PLACEMENT
dialog box and display the settings for this project.
In this dialog box you can correct the reference point values for
positioning projects on the same X and Y coordinates (align). If the
control key is pressed and held down, while clicking and holding
down the left mouse key on the project, the project is moved only in
the X or in the Y direction.
You can also use the PLACEMENT dialog box for rotating a project
(after positioning with the mouse) by changing the setting
ROTATION.
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 55
3.2.4 Manual control functions
Danger! After activating one of the following buttons on the
function bar, the connected circuit board plotter is put into motion!
Ensure that no one can move into the hazard area of the plotter
during the operating phases controlled by BoardMaster!
Manual control
The head can be moved in the directions +X, +Y, -X and -Y with the aid
of the arrow keys. Pressing one of the arrow keys once, moves the head
by the value entered on the function bar in the entry field STEP FOR
MANUAL CONTROL in the selected direction (See "Changeable Set-
tings" on page 24). Motion in the X and Y direction can also be accom-
plished by holding down the Ctrl key on your keyboard and pressing the
arrow keys on the keyboard. The Z-axis can be moved with the keyboard
by pressing the Ctrl key and actuating the Page or Page key.
Move using the computer mouse
Click this buttons to move the drill/mill head to the position in the opera-
ting area which you click with the left mouse button. If you continue to
hold down the left mouse button, you can move the mouse and the head
follows the motion of the mouse after it has reached the mouse starting
position. This function allows the head to be moved to any desired loca-
tion very quickly for defining the material size. To control the XY table
with the mouse motion again it is first necessary to activate the button
again.

Home position
Click this button to move the drill/mill head to the HOME position. This
position is principally moved to in order to check the existing reference
hole system or to produce a new one.
Zero point
Click this button to move the drill/mill head to the zero point of the X-Y
coordinate system. This position is generally moved to before switching
the circuit board plotter off
Vacuum
Click this button to switch the vacuum system ON or OFF. Please note
that the vacuum system cannot be switched OFF when the drill/mill
spindle is running.
Drill/mill spindle ON/OFF
Click this button to switch the drill/mill spindle ON or OFF.
Pause position
Click this button to move the drill/mill head to the Pause Position. This
position is used when material is to be exchanged or when material is to
be turned round.

Operation interface
56 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
3.2.5 Selection functions
Before selecting, you must have activated all phases to be assigned
data and which you want to process. Detailed information on activation is
given in the chapter Phases. Data must be selected before it can be
sent to the plotter for processing. Only data in the activated phases can
be selected.
The following buttons are available on the function bar for selecting the
data:
Mark all
Click this button to mark all data for the enabled production phases. The
data marked are displayed in a lighter color on the monitor.
Cancel mark all
Click this button to cancel all marking of the data.
Select area
Click this button to select a data area. For this purpose, press the left
mouse key and hold it down while dragging the mouse over the desired
area.
This function also selects lines crossing the area. The selected data are
displayed in white on the monitor.
Select area (only inside)
Click this button to mark a data area. For this purpose, press the left
mouse key and hold it down while dragging the mouse over the desired
area.
This function marks lines crossing the marked area only up to their first
support coordinate outside of this area. The marked data is indicated in
white on the monitor.
Note: It is necessary to reactivate the corresponding button each
time an area is selected.
Mark selected data
Click this button to add selected data to the marking.
Cancel selected data
Activate this button to delete selected data from the current marking.
Selected lines
Increase or decrease the number in the window with the small arrow
buttons to the right. Each number stands for a certain vector (section of
line). The entire job is processed vector for vector in the sequence of this
numbering. It is possible to select a certain vector or a number of vectors
for subsequent marking. For this purpose, it is necessary to select the
number of the corresponding line with the aid of the right arrow button.
Then, it is necessary to activate the function Selected lines by clicking
. You can then increase or decrease the number with the arrow
buttons to select each selected vector and display it in white on the
monitor. These selected lines can be marked by clicking or added to
a marking. If vectors already marked are selected in this manner, they
can be unmarked by clicking .
This function can be deactivated by clicking .
Operation interface
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 57
Furthermore this function allows to select a project to start with a deter-
mined vector index value. Enter the vector value from which the project
is to be processed. Confirm the function with and then the vector
value is increased using the keyboard entry (for example by adding a
number, e.g. 564 becomes 5640). The subsequent routes are then rep-
resented in white and can be added to the selection by pushing the
button.

Operation interface
58 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
3.2.6 Production phase control function
Danger! After activating one of the following buttons on the
function bar, the connected circuit board plotter is put into motion!
Ensure that no one can move into the hazard area of plotter and
come into contact with the tools during the operating phases
controlled by BoardMaster!
Start
Click this button to transfer the marked data for the enabled production
phase to the plotter over the serial interface.
Stop
Activate this button to discontinue data transfer to the plotter after star-
ting.
Attention: After clicking the stop button, the plotter does not stop
immediately; first, it continues to process the data in the buffer!
The click on the stop button only interrupts transmission of data to
the plotter!
Production process
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 59
4 Production process
This chapter describes the principle procedure to produce a prototype of
an double-sided, not through connected circuit board with BoardMaster
step by step.
You will learn to work with BoardMaster and the circuit board plotter
shortly if you adhere the following instructions.
4.1 Preparing BoardMaster start
For error-free operation with your circuit board plotter, it is absolutely
necessary to observe the switch-on sequence specified below:
Switch on the circuit board plotter.
Wait until the green operating indicator on the front panel or
the data LED on the back panel of the circuit board plotter
light up.
Start BoardMaster.
Otherwise the communication between computer and circuit board plot-
ter can not be implemented after the BoardMaster program starts.
4.1.1 Start BoardMaster
Double-click on the BoardMaster on the desktop.
Or click on Start>Program>LPKF Laser & Electronics AG>
BoardMaster ... .
The BoardMaster startup window will be opened:
Fig 45: Startup screen
This image may be visible for up to 8 seconds, which is related to
the communication between the PC and the machine, it does not
represent an error. After this time period, the program start is
automatically continued.

Production process
60 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
If the message CONNECT.. will be opened:
Check the power switch of the ciruit board plotter - position I
(ON). Check the data connection cable between computer and
circuit board plotter - interface plugs and cable are correct
installed.
Check the connection settings (see chapter [Link] Connect
on page 40).
The BoardMaster operation interface will be opened.
BoardMaster is waiting of corresponding message of the drill/mill head
(the continuing movement of the drill/mill head).
As soon as the plotter sends the requested reply to the computer, the
program is continued normally.
Production process
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 61
[Link] Tool status
Note: The following informations refer to the BoardMaster
application with ProtoMat 95s, 95s/II and S62!
Using a ProtoMat 95s, 95s/II, H100 S62 or S100 the dialog box TOOL
STATUS will be opened after starting BoardMaster.
Fig 46: Tool status
Caution:It is absolutely necessary to establish where a tool is
located at switch on. Then, the free tool position can be entered in
the tool box. Note: Position 1 = Tool 1 all the way to the left, Posi-
tion 30 = Tool 30 is therefore all the way to the right in the tool box
After starting BoardMaster for the first time, the TOOL STATUS dialog
box appears as illustrated above. The actual status, meaning where a
tool is located and which position is free in the plotter tool box for this
tool, must be defined by the user. Each time the program is restarted,
the tool status present the last time the program was closed is displayed.
This can then be confirmed simply by pressing OK.
If the status displayed does not coincide with the actual status, it is
necessary for the user to correct the status.
Then, the program asks whether the tool is to be put back in the tool box
upon exiting BoardMaster.

Production process
62 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
[Link] Check interface
If the circuit board plotter are not detected automatically the dialog box
CONNECT will be opened. In this case the connection settings must
be changed.
Make sure that the circuit board plotter is switch on. Check the con-
trol light on the drill/mill head - the light must lit on.
Make sure that the needed settings of the Circuit Board Plotter are
inserted and check the system settings of Windows (see installation
instruction).
Click on CONNECT.
The following window will be shown:
Fig 47: Dialog box Connection
Production process
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 63
When the communication between computer and circuit board plotter has
been successfull established the BoardMaster operation interface will be
opened.
Note: By clicking CANCEL the BoardMaster operation interface will be
opened but the circuit board plotter can not be controlled via software. To
change the connection settings click on CONFIGURATION>INTER-
FACE and use the CONNECT dialog box to establish a connection to the
circuit board plotter.
[ ] The BoardMaster operation interface will be opened.
Fig 48: Dialog box Connection

Production process
64 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
4.1.2 Insert base material
Click on GO TO>PAUSE to move the drill/mill head to PAUSE posi-
tion.
We recommend using the base material already present on the circuit
board plotter. The first base material board is already mounted for preci-
sely this reason to make introduction easier for you. Drilling and posi-
tioning material of other sizes is not described here.
Fasten the base material with adhesive tape on all four sides (we
recommend Tesakrepp 5250).
Further steps for all ProtoMat types:
In order to process data created with CircuitCAM or similar software, it is
first necessary to import them into BoardMaster.
View base material:
The work area of the base material must be visible on the monitor.
Define the the displayed sector via BoardMaster. This definition has no
influence on the production process.

Fix material size view:
Define the base material size.
4.1.3 Import production data
The Working Instructions for BoardMaster indicating the method for
processing the base material are contained in the production data. They
are generated by CircuitCAM or a similar program and must first be
imported:
You can import the LMD production data (e.g. [Link]) generated
by the CircuitCAM software or the HP-GL project files already generated
by BoardMaster. At this point, we will now import a file in LMD format
([Link]).
Import the file [Link] by clicking the entry LMD or LPR...in the
submenu IMPORT in the menu FILE and select a file (e.g.
[Link]). This file can be found in the directory C:\Program
files\LPKF50\Data\.
Tool allocation:
A tool must be assigned to each production phase so that BoardMaster
knows which tool to use for each individual program phase (milling cut-
ters, drills of different sizes, engraving, etc.). As a rule, BoardMaster
accomplishes this itself, as is the case when importing [Link]. Howe-
ver, if you are processing an HPGL file, this will have to be accom-
plished manually. In this case, please read the next Chapter Assigning
Tools on page 85 before continuing here.
If you are working with an HP-GL file, assign the appropriate tools/
phases to the imported production data for projects (EDIT>TOOL
Production process
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 65
ASSIGNMENT). Otherwise, simply continue on to the next proces-
sing step.
Place production data:
You now have the possibility of positioning the imported production data
as desired on the base material to define how they are to be machined
later.
Position the imported production data or projects by selecting the
entry PLACEMENT... in the menu EDIT or click the button on
the function bar. You can then move the image of the production
data with the mouse and position it by holding down the left mouse
key..
Save Job
Click on FILE>SAVE AS to save the job under a customized name
after all projects are placed.

Production process
66 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
4.1.4 Select first production phase
Each production phase such as Milling bottom must be selected sepa-
rately and prepared for processing (assignment of correct tool, etc.).
Start with the first production phase:
Select the production phase Milling bottom from the function list in
the list box PRODUCTION PHASE (see figure below).
Fig 49: List production phase
Milling Bottom
Mark data:
Theoretically, it is possible to process only certain sections of this pro-
duction phase by correspondingly selecting the data. For this reason, it
is always necessary to first select the desired areas to be processed.
Since the entire production phase is to be processed here, we select all
data for this phase:
Click on to mark all data.
Danger!Activating one of the following buttons on the function bar,
sets the connected circuit board plotter in motion! The danger of
pinching and crushing exists!
Ensure that no one can enter the hazard area of the circuit board
plotter during the operating phases controlled by BoardMaster or
come into contact with the tools!
Starting milling operation for selected production phase:
Click on to transmit the mark data to the circuit board plotter
via the serial interface.
If you use a machine without automatic tool change, the machine first
moves to the tool change position if not already positioned there and
the following message appears:
1
Production process
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 67
Fig 50: Tool change
This message always appears when a tool is to be changed. If you use a
ProtoMat S62/S100/H100 then skip the following steps.
Now install the first tool required in the machining head (see machine
manual).
Click Stop for change after tool transfer and then click OK to close
the message box.
Now set the cutting depths if you are operating the circuit board plot-
ter for the first time.
Switch on the vacuum!
Click on again.
The production phase Milling bottom is run. Then the following
message appears:
Fig 51: End phase
Click on OK.

Production process
68 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
4.1.5 Select second production phase
Select the production phase Drilling Plated on the function bar in the
list box PRODUCTION PHASE (see figure below).
Fig 52: List production phase
Drilling Plated
Mark data:
Click on to mark all data.

Danger! Activating one of the following buttons on the function bar,
sets the connected circuit board plotter in motion! The danger of
pinching and crushing exists!
Ensure that no one can enter the hazard area of the circuit board
plotter during the operating phases controlled by BoardMaster or
come into contact with the tools!
Starting drilling operation for selected production phase:
Click on from the function bar to send the selected data for the
current production phase to the circuit board plotter via the serial
port.
The message Tool Change appears.
Now install the required tool.
Click Stop for change after tool transfer and then OK to close the
message box.
Adjust the drilling depth.
If necessary, click Continue after tool transfer and then click OK.
Switch on the vacuum!
Click on again.
The production phase is completed.
Continue to comply with the subsequent drill requests by installing the
tool (drill) as requested and then click OK until the production phase is
completely processed.
1
Production process
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 69
Turning base material:
After drilling and milling the bottom, move the head to the Pause
position (menu bar GO TO-PAUSE) and turn the base material
around the X axis and fasten it again with adhesive tape.
4.1.6 Select third production phase
Select the production phase Milling top on the function bar in the list
box PRODUCTION PHASE.
Fig 53: List production phase
Milling tool
Mark data:
Click on to mark all data.


Danger!Activating one of the following buttons on the function bar,
sets the connected circuit board plotter in motion! The danger of
pinching and crushing exists!
Ensure that no one can enter the hazard area of the circuit board
plotter during the operating phases controlled by BoardMaster or
come into contact with the tools!
Starting milling operation for selected production phase:
Switch on the vacuum!
Click on on the function bar.
The selected data for the current production phase are transferred to
the circuit board plotter via the serial port.
The operations for changing tools and setting the milling/drilling depth
are repeated. Proceed as described for the first production phases.
4.1.7 Select fourth production phase
Note: In this production phase, the circuit board is cut out of the
base material. During this operation, pay attention to the cutting
depth of the milling tool used here. (!)In this particular case(!)
adjust the milling depth visually! If required, in the same manner as
1

Production process
70 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
adjusting the drilling depth. Here, it is important that the cutter cut
through the entire thickness of the base material without cutting
deeply into the drilling subsurface!
Select the production phase CUTTING OUTSIDE on the function bar
in the list box PRODUCTION PHASE.
Mark data:
Click on the ALL+ button to mark all data.
Danger!Activating one of the following buttons on the function bar,
sets the connected circuit board plotter in motion! The danger of
pinching and crushing exists!
Ensure that no one can enter the hazard area of the circuit board
plotter during the operating phases controlled by BoardMaster or
come into contact with the tools!
Starting milling operation for selected production phase:
Switch on the vacuum!
Click on the START/STOP button of the function bar.
The selected data of the actual production phase will be transmitted to
the circuit board plotter via the serial interface.
The operations for changing tools and setting the milling/drilling depth
are repeated. Proceed as described for the first production phases.
Note: Observe that it is always necessary to switch the auto motor
function back on before proceeding after any adjustment of the
drilling or milling depth!
When the production phase Cutting outside has been completed,
move the circuit board plotter to the PAUSE position.
The double-sided circuit board is now finished. It can be broken out of
the base material carefully. If you want to process the data for other pro-
duction phases (dispensing, milling inner layers of a multiple layer board,
etc.), follow the instructions above in the same manner for these phases.
For this purpose, read the corresponding chapter in the manual.
Production process
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 71
4.2 Tool change
4.2.1 Manual tool change
The list TOOLS inside the function bar is listing all tools of the tool
library. On top of the list are the tools with will be used during the actual
production phase, marked with *:
Fig 54: Tool list
If no production phase is selected the first production phase of the pro-
duction phase list is active.
When processing a production phase, the user are always requested to
install the tool to be used next when a tool change is required.
If a different tool is selected from the list, the machining head moves to
the tool change position. Simultaneously the message appears on the
screen that the present tool is to be replaced with the tool just selected.
Danger:This instruction starts the circuit board plotter. Danger of
pinching and crushing! Also observe safety precautions for chan-
ging tools in the circuit board plotter manual!
After changing the tool, and confirming the change by clicking OK, pro-
cessing can be continued with the next control commands.

Production process
72 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
4.2.2 Automatical tool change
The following dialog box can only be called up when machines with auto-
matic tool changing unit are used. (example ProtoMat 95s, H100 and so
on). If you now open the TOOL list field on the function bar, only the
thirty or seven tool positions with their corresponding tool assignment
are displayed instead of a list of all tools as for circuit board plotters with
manual tool change.
Fig 55: Tool position
Note: When the program is started for the first time, the tool
<UNKNOWN> is assigned to each tool position, i.e. no tool entered.
This is intended to cause the user to check the tools in the circuit
board plotter magazines and assign the corresponding positions in
the TOOL POSITIONS dialog box.
It is absolutely necessary to ensure that the tools in the tool box
coincide exactly with those assigned in BoardMaster in order to
prevent using the wrong tools and therefore malfunctions.

Open the TOOL POSITIONS dialog box by clicking the TOOL list field
with the right-mouse button.

A tool can be assigned to the tool positions 1 to 30 by selecting the tool
required for the production phase from the appropriate list field.
If a tool position is not assigned to a required tool, this dialog box is ope-
ned automatically when the production phase is started. It is possible to
continue only after all tools have been assigned a position!
Production process
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 73
The tools required for the selected production phase are listed in the list
field WANTED FOR CURRENT JOB (PHASE).
The option SELECT indicates the tool momentarily located in the machi-
ning head.
The CURRENT life cycle and the MAXIMUM life cycle are indicated fol-
lowing each tool.
It is necessary for the NEW check box to be switched on when a used
tool is replaced by a new tool in the tool box. The current life cycle is
then reset to 0.
When exiting BoardMaster, the tool assignment in BoardMaster are
stored under the name extension *.TLS and automatically reloaded each
time BoardMaster is started.
4.3 Switch off
When switching off the circuit board plotter, first quit BoardMaster before
switching off the machine. In the opposite sequence, recurring error
messages are possible, which can be cancelled only by repeatedly
actuating the Yes button. (Error message: Do you really want to cancel
the current process...)
Before BoardMaster is actually switched off, a menu is displayed asking
where the machining head is to be displaced to:
Fig 56: Go to reference point menu
Click on YES to move the drill/mill head to the reference point,
respectively move to zero position.

Production process
74 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
4.4 Home position and reference hole system
The HOME position is a reference point programmed in the software.
BoardMaster use this point as a reference position for orientation on the
machine base plate. The circuit board plotter can be controlled correctly
by BoardMaster only when this point is adjusted correctly. The HOME
position must be located on the reflection axis (reference hole system) of
the machine for production of circuit boards coated on both sides. The
base material is turned around this reflection axis. Inaccuracies in the
HOME position lead to an offset in processing the base material after
turning.
Note: The HOME position is set at the factory and its position for a
ProtoMat S62 is different from the position of the rest of the Proto-
Mat types.
Note: The parallelism of the reference hole system is ensured only
for the current position of the reference hole strips. The front
reference hole strip must be pushed against the reference pin in
the reference hole groove (referenced). If you use base material of
different sizes later, it will be necessary to drill an additional
reference hole in the !rear! reference hole strip for each format. The
position of the pusher for the various holes should be noted or
marked on the circuit board plotter. This ensures parallelism for the
various formats and eliminates the possibility of mix-ups.
It is only necessary to reprogram the HOME position in exceptional
cases (offset on double-sided circuit boards) or possibly after transport
of the machine or loss of the individual .INI file.
Fig 57: Reference hole ProtoMat S-
series

1- HOME position
2- Reference hole notch
3- PAUSE position
1
2 3
Production process
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 75
Abbildung 58: Reference hole
system other ProtoMat
types
4.5 Camera functions
Note: Only for ProtoMat S62/100 with camera option.
Set Focus
Use the arrow keys to move the dril/mill head with camera until the
image is focussed. Then press this key to have the current Z value
stored in the INI file as focus position.
Focus
Click this button to have the camera moved back to the focus position
when it the camera or drill/mill head is currently in a different position.
Stop
Click this button stops ongoing reading processes of the camera, e.g.
when fiducials are being read in.
1- Reference pin 4- axis of reflection
2- Front pilot pin 5- reference strip
3- HOME position, (distance depending on
machine types)
6- Reference hole notch

Production process
76 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
4.6 2.5D mode
By activating the 2.5-D-Mode checkbox in the function bar the following
dialog box will be opened:
Fig 59: 2.5-D-Mode dialog box
In 2.5-D-Mode the working depth limiter is of no use, instead you should
mount a brush. If the dialog is terminated with escape then the whole
process is cancelled. By clicking OK the following dialog box will be ope-
ned:
Fig 60: 2.5-D-Mode
The material thickness is divided into various processing layers. The
number of layers depends on the depth with which the tool penetrates
the material. The penetration depth must be individually adapted to each
tool. The settings that are made can be stored in the job.
Production process
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 77
4.7 Camera image fiducial detection
Note: Only for ProtoMat S62/100 with camera option.
Fig 61: Camera view
Note: This image can only be seen when the phase for fiducial
recognition is selected.
When the camera is successfully calibrated, a live image like the figure
above can be seen.
Freeze image
The image is frozen and the menu item LIVE becomes visible, so that it
is possible to switch between the two modes.
Live image
The image is again represented in real time and the menu item
FREEZE becomes visible. Thus it is possible to switch between the two
modes.
Find
When the menu item FIND is activated, a standard fiducial is searched in
the image area. The result is shown in a message as quality and stance
to the image center.
Settings
After activation of this menu item the following dialog is opened:

Production process
78 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
Fig 62: Camera settings
Fiducial setting
Changing the settings for fiducial detection.
Standard
Use default settings.
Transfer
Use actual edit settings.
Camera calibration
Camera adjustment with selected values.
Brightness
Adjust the camera brightness.
Contrast
Adjust the camera contrast.
Image information
Display of the actual camera settings.
Overlay settings
Changing the colour, switch ON/OFF the crosslines and changing the
dimensions of the substitute circles.
Note: A detailed describtion of the camera calibration will be find in
the machine manual (ProtoMat S62 or ProtoMat S100).
Troubleshooting
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 79
5 Troubleshooting
We refere to the particular machine manuals, for example user manual
ProtoMat S62, to get detailed troubleshooting information.
The following informations are notes and tips and the first steps for trou-
bleshooting when the system run out of function.
5.1 Circuit board plotter initialisation
Danger! The following instructions starts the circuit board plotter
motor!
Take care that no person be in the process area of the circuit board
plotter-Risk of crush!
Adhere the safety instruction of the machine manual!
Click on CONFIGURATION>SETTINGS.
Click on UNLOCK (password protected) to change the machine
parameter.
Click on INITIALIZE to start the initialisation process.
During the initialization process, the machining head moves to the limit
switches in all four directions of motion, thereby transmitting the values
measured to BoardMaster. These values are displayed in the text fields
ZERO POINT (Xmin/Ymin, always 0/0) and SIZE (Xmax/Ymax). These
entries cannot be edited, they can only be reset by initializing.
The values in the text field PAUSE are identical to the values in the text
field SIZE. However, they can be edited to move the Pause position to
any desired position.
Note: The values in the text field HOME (data origin) are set to
Xmin and Ymax/2 as default. The HOME values determined in this
manner are not the exact values leading to coincidence of the top
and bottom during production of double-sided circuit boards. For
this purpose, it is necessary for the HOME position to be located
precisely on the plotter reflection axis.
To reset the HOME position precisely on the circuit board plotter reflec-
tion axis, it is necessary to drill new reference holes. For this purpose,
first remove the base material and drilling panel as well as the reference
hole pins. If no more space is present on the old reference hole strips,
use new strips.

Troubleshooting
80 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
Then follow the following instructions:
After the circuit board plotter has come to a stop at the tool change
position after initialization, select Spiral Drill Ref. 2.95 from the Tool
list and clamp it in so that an interval of 0.5 mm is present between
the base plate and tip of the drill (a 0.5 mm thick plate can be placed
beneath as an aid).
The machine moves to the tool change position and the message
Continue after tool change appears.
After inserting the tool acknowledge the message with OK.
Move the machining head to the HOME position defined by initializa-
tion by clicking Go to in the menu and then HOME position.
Move the machining head in the positive X direction with the arrow
keys (not in Y direction under any circumstances) approx. 15 mm.
Move the machining head with the arrow keys to the middle of the
front reference hole strip (this time X and Y axes). For this purpose,
set the increment to 0.05 mm.
Move in the positive X direction to find a free point on the reference
hole strip (if necessary, change increment setting).
Click on to switch on the motor of the drill/mill head. Click on
to drill a hole. Wait until the drill/mill head has lowered com-
pletely into the material and click on again to lift the drill/mill
head.
Click on to switch off the motor of the drill/mill head.
Move the drill/mill head 30 mm in the positive X direction from the
new reference hole (not in Y direction under any circumstance),
because the HOME position should always be 30 mm away from the
reference hole.
Go to CONFIGURATION>SETTINGS on the menu bar. Click on
UNLOCK and then SETHOME. The data for the current machining
head position are read in as the new HOME position and can be
saved by clicking the OK button.
Move the drill/mill head along the X axis to the rear reference hole
strip and then drill the rear hole as described above by performing
the concrete steps for drilling a hole (do not change anything in the
menu Configuration again).
We recommend noting the values for the HOME position to prevent
having to setup the circuit board plotter again if they are changed by
mistake. However, after a new initialization run, it is always necessary to
readjust the HOME position.
Appendix
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 81
6 Appendix
6.1 From pen plotter to circuit board plotter
Conventional pen plotters, such as are used for printout of large gra-
phics and drawings, have a paper transport for moving the paper back
and forth along one axis (X axis). The print head containing various pins
of different sizes and colors, can be moved along the second axis (Y
axis). The print head can therefore be moved to any position on the
paper. The print head is then lowered while the head/paper is moving so
that the plotter can draw. It must be possible for the plotter to change the
pins in order to draw lines of different thicknesses and colors.
The circuit board plotter operates according to the same principle with a
few differences:
The base material, here the copper-coated circuit board material, is
not transported; it is held tightly on a machine base plate.
Instead of drawing, milling and drilling operations are accomplished.
Some terms used in the BoardMaster software may be irritating
because they are taken over from the old pen plotter technology.
For this reason, we have listed the basic terms in a comparative list for
better understanding:
Pen Plotter Circuit Board Plotter
Pen (thick, thin, black, red) Tools (drill, milling cutter, ...)
Drawing paper as processing
material
Circuit board base material as
processing material
Pen change (thick, thin, ...) Tool change (universal cutter,
end mills,...)

Appendix
82 Stand: 10.12.08 Version 1.0 BoardMaster 5.1
6.2 Index
A Attention 5, 58, 69
B Base material 9, 16, 21 - 22, 29, 31 - 33, 39,
44 - 45, 50, 64 - 65, 69 - 70, 74,
79, 81
C Camera 16, 23, 25, 30, 39, 46 - 48, 51,
75, 77, 78
Check interface 62
CircuitCAM 3, 5, 11, 19, 28, 37, 44, 64
Configuration 18, 27, 30 - 33, 36, 39 - 41, 44
46, 51, 63, 79, 80
Connection 14, 41 - 42, 60, 62, 63
Control function 50, 51, 55, 58
D Danger 5, 31, 47, 55, 58, 66, 68 - 71,
79
F Fiducials 46 - 47, 75
Font 30
Function bar 16, 21, 22, 29, 50, 55, 56, 58,
65, 66, 68, 69, 70, 71, 72, 76
H Head down time 37
HP-GL 3, 19, 27, 64
L Light dot 39
Lines 16, 30, 51, 56, 78, 81
LMD 3, 19, 23, 28, 37, 64
LPR 19, 27, 64
M Manual control 3, 53, 55
Menu bar 16, 18, 69, 80
mill/drill head position 52
Motion range 16, 31, 47
N Note 4, 5, 19, 25, 27, 32, 35, 38, 41,
42, 45, 54, 55, 56, 60, 61, 69,
70, 72, 74, 75, 77, 78, 79
O Offset 21, 39, 74
Optimal speed 37, 38
P Parameter 24, 30, 35, 36, 37, 41, 42, 43,
53, 79
Pause position 48, 51, 55, 64, 69, 70, 74, 79
Phases 38, 44, 45, 47, 51, 52, 55, 56,
58, 64, 66, 68, 69, 70
Placement 20, 21, 22, 54, 65
Positioning functions 54
Processor 10
R RAM 10
S Status information 50, 52
T TEACH-IN 20, 25, 26
Title bar 16, 18, 34
V Vacuum 30, 38, 40, 51, 55, 67, 68,
69, 70
Appendix
BoardMaster 5.1 Stand: 10.12.08 Version 1.0 83
W Windows 3, 4, 10, 14, 30, 42, 62
Z Zoom area 29