Mega FP?8000 XL User manual

MEGAELECTRONICSLIMITED.,

MegaHouse,GripIndustrialEstate,Linton,Cambridge,CB214XN

Telephone:+44(0)1223893900Fax:+44(0)1223893894

email:[email protected]web:www.megauk.com



PhotoplotterFP‐8000/8000XL

Instructionmanual

Note:Anyinquiriesrelatedtophotoplotterhardwareorsoftwareshouldbeaddressedtoan

authorizeddistributor.Photoplottersoftwareissubjecttocopyright.Alltheinformationenclosed

hereissubjecttochangeduetoconstantinnovationoftheproduct.Dateofthelastchangeinthis

document:June17,2011.



1.Briefdescription:

Photoplotter FP‐8000/8000 XL is a small,  raster, low cost plotter which draws image on film by

means of laser diode light. Film itself is fixed to the outer surface of rotating drum by means of

masking tape. The source of laser diode light moves step by step along the rotating drum.

Photoplotteriscontrolledbysoftwareinstalledon PCattachedviaitsUSBport(PC isnota  partof

the photoplotter supply). An external, universal power unit is used to supply needed power (100‐

240VAC/36VDC–1.66A).

The photoplotter software allows to read input files, to set output resolution and type of image

(negative,mirror,etc.)drawnonthefilm.WhenworkingwithGerberfiles,itispossibletocheckand

modifyusedapertures(D‐codes)andmakesimplefilmpanelisationforGerberdataandassociated

drill data. Viewing of Gerber files and conversion of various types of aperture files is possible in

freeware program ViewMate (made by Pentalogix, formerly Lavenir), which is attached to the

photoplottersoftwareforyourconvenience(otherwiseitmaybedownloadedfromPentalogixweb

page:http://www.pentalogix.com/Download/download.html).

Photoplotter is driven by program Run_photo_USB, which reads in hi‐resolution bitmap files FPF,

(photoplotter proprietary file format)  and BMP. From this reason, if you work with Gerber or

Postscriptfiles,thesefilesmustbeconvertedintooneofthesebitmapfilesformatfirst.Gerberfiles

are converted by

program Gerb2bitmap, which is a part of the  photoplotter software, while

Postscriptfiles are converted by anexternal program, supplied as an option. Converterof Gerber

files has also built‐in converter of aperture files to convert various aperture format into one

standardformat(Lavenirformatisusedasa

standardapertureformat).Aperturefileconversionis

needed only when working with standard Gerber format RS‐274‐D. There is no need to convert

aperture file when working with extended Gerber format RS‐274‐X, as this type of file already

containsinformationonusedapertures.

Varioustypesof films may be used for this photoplotter,butall ofthem must be sensitive to light

wave length of 670 nm (red light). Thin films (0.1 mm) used by image setting machines as well as

standard photoplotter films (0.18 mm) can be used, although 0.1mm films are recommended for

thismodelofthephotoplotter.Films0.1mmcomeeitherinrollsofvariouswidth andlength,orin

pre‐cut sheets of several sizes. Film in roll is easy to tape on a small drum in photoplotter, as film

tendsto bendautomatically.Thereareseveralmanufacturersofsuitablefilms,like Kodak,Horsell,

Fuji,Agfa,Typon Graphic Systems, etc., whilefilms have variousnameslike EZR4, RD4, TR‐LR+. As

filmlightsensitivity differswithvariousfilms,severaltestplotsmaybeneededtofindsuitablelight

intensity.Filmshavetobewetprocessed(developedandstabilised)likeanyotherfilmsafterlighted

in photoplotter. Film  manufacturers recommend and usually supplychemicals to be used for their

filmsprocessing.

Thepowerswitchislocatedontheleftsideoftheplotter.

Onthebacksideoftheplotterthefollowingitemscanbefound:‐powersupplyconnector(label:Input 36V

2A)‐computerUSBcableconnector(label:USB)‐Labelwithserialnumberoftheplotter(SN………)

Onthefrontor

leftsideoftheplotterthefollowingitemsarelocated:‐Yellow(orRed)LEDindicatingplotting

operation(label:Laser)‐GreenLEDindicatingpoweron(label:Power)



2.Technicalparameters:

Maximumfilmsize:FP8000:360mmx360mm/14"x14"FP8000XL:380mmx450mm/15"x17,5"

Maximumphoto‐plottingarea:FP8000:340mmx320mm



FP8000XL:360mmx420mmPlotresolution:(508,1016,1355,1625,2032,2710,4064,8192)x8600dpi,

Plottingspeed:approximately13mmoffilmwidth/minutefor1016dpiUsedlight:Laserdiode670nm

(red)Readsinimageformats:Gerber(RS274D,RS

274X),hi‐resBMP,Postscript(option)Readsinaperture

files:directlyCAM350,GC‐CAM,IsoCAM,Lavenir,otherformatslikePads,Eagle,OrCAD,Protel,PCADreads

throughbuilt‐inconverter.Photoplotteroverallsize:FP8000:LxWxH(700x340x210)



FP8000XL:LxWxH(700x370x230)Photoplotterweight:FP8000:approx.25kg(55lbs)FP8000

XL:approx.26.5kg(58lbs)Power:anexternalpowersupplyunit100‐240VAC/36VDC–2.78A

Reversed(negative)&mirrorplotting,f ilmanddrillpanelisation,D

‐codeediting,outputpreview&print,

interactiveorcoordinatesimagepositioningonfilm,glue/unglueimagelocation,automaticpositioningof 

associatedimagesondifferentlayers.



PhotoplottersoftwareissuppliedonCDwithinstallationprogram.

RequiresPentiumcomputerwithatleastWindows2000andUSBport,100MBHDspaceminimumfor

softwareandoutputfiles.Thecomputerspeedhasinfluenceonplottingtime.Plottingfilesmaybequite

large,inrangeoftensofMB,so

extraspaceonharddiskmayberequired.



Warranty1(one)yearonparts.

ThereisnoexpressedwarrantyonfunctionalityofenclosedsoftwarewhatsoeverexceptwarrantyonCD

media.



Notes:

1)Outputresolution

 Thelowestresolution(508&1016dpi)paynotbesuitableforfineresults.

 1355and1625dpiresolutionissuitableformostplottingapplication

 Use2032or2710dpiforplottingfinelines(butittakeslongertimetoplot)



2) Plotsize:although

plotterallowstoplottomaximumspecifiedsize.Beaware,thatfilmswideacross

thewholedrummaybedifficulttofixproperly,whichmayresultinhigherinaccuracyintheright

partofthefilm.Thisisduetotechnicsusedtofixfilmtothedrumsurfaceby

stickytape.Tofixwide

filmproperlyrequiressomeexperience.Ifyouencounterproblemwithinaccuracyonwidefilms,

enterdeviationvaluesintocorrectiontablefortherightsideofthedrum,whichwillcorrectit,

providedfilmsarealwaysfixedtothedruminthesamemanner.



 ImportMaster

Gerber

PaneliseSelectedBoard

DeleteSelectedBoard

Preview

ExportGerbertoBitmap

PrintPreview

View&EditApertureTable

ImportApertures

ImportAssociatedGerber

Howtopreparephotoplotter:

3.1Photoplottersoftwareinstallation

ConnectphotoplotterwithPCviaUSBcablesuppliedwiththephotoplotter.USB connectorislocatedonthe

backsideofthephotoplotter.Thephotoplotterdoesnotneedtobepoweredatthismoment.

Computer will detect new connected USB device (photoplotter) and will run new hardware installation

(Windows procedure). Do not

 use an Automatic installation, but select „ Install from list or location“ and

pointtodirectoryInstall\Drivers\locatedoninstallationCDandconfirm.

After hardware installation you can install photoplotter software – go to directory Install on installation CD

suppliedwiththephotoplotterandexecuteSETUP.exe.

Softwarestartsto

installonconnectedcomputer.

3.2Powerthephotoplotter

Connectsuppliedpowersupplyunitwiththephotoplotter–connectorislocatedonthebackside.Switch

poweron(leftsideofthephotoplotter).ThegreenLEDlabelledPowerwillcomeon.Red(oryellow)LED

labelledLaserwillflashfourtimesatthismoment.

Whenphotoplotteristurnedon,

thelaserlightheadwillmovebacktothelefttocontacta micro‐switchand

thenwillmovebacktotherighttoitsinitialposition.Attachedcomputercannotinitiatecommunicationwith

photoplotter before light head makes the above described move. This initialization runs automatically, 

withoutrunningphotoplottersoftware.

AUTO/MANUALswitch:PositionofAUTO/MANUALswitchhasimpactagainstlaserheadbehaviour.AUTO‐

laserheadmovestoitsstartingposition(leftsideofthedrum)MANUAL‐laserheadmoves1cmtotheright

only

Beforefirstdataplotting,checktheAUTO/MANUALswitchandsetittoAUTOposition.Whenyoustartthe

plotter,laserheadwillmovetoitsstartingposition(leftside),afterthatyoucanstartdataplotting (laser

headwillmovefromlefttorightsideduringtheplotting).Whentheplotting

isfinishedandtheswitchwill

beinAUTOposition,laserheadwillmovebacktoitsstartingpositionandplotterwillbereadyagainfor

plotting.WhentheplottingisfinishedandtheswitchwillbeinMANUALposition,laserheadwillmove1cm

totherightonly

andplotterwillbereadyagainforplotting.



AUTOmodeissuitableforsingledataplottinginthewholefilmwidth.MANUALmodeissuitablewhenyou

wanttoplot2(ormore)data‐sidebyside(indrumaxisdirection).Afterfirstdataplottinglaserheadmoves

littletothe

rightonly(1cm)andnextplottingstartsfromthisposition.



Ifyouturnpoweronafterfilmisloaded,itmayhappenthatlaserli ghtbeamflashesshortlyonthefilmat

themomentwhenpoweristurnedonandelectroniccircuitryis reset.Thismayresultinvery

smallspoton

thefilm.



3.3Placeandtapefilm

Liftthephotoplotterlid,soyouhaveaccesstotheoutersurfaceofthedrum.Rotatedrumbyhand(inany

direction)topointwhitea rrowlocatedontheleftsideofthedrumtowhitearrowlocatedontheleftsideof

drumholder.Thisistheoutgoingpositionof

thedrumforphoto‐plotting.Thelefttopcornerofphoto‐

plottedareaisthenapproximately20mmfromtheleftedgeofthedrumonthehorizontallinemarkedby

whitearrow.Placefilmonthedrumwithitstopedgeapproximately20mmbehindthewhitemarkon

the

drum,holditfirmbyhandandfix ittothedrumbymeansofamaskingtapealongthetopedge.Rotate

drumbyonehandtobeabletofixfilm‘sbottomedge,butmakesurefilmistightondrumsurface.Afterfilm

isfixedtoits

positiononthedrum,rotatedrumbackto1stinitialposition(bothwhitearrowspointtoeach

other).Closethelid.



NOTES:

Itisamatterofpracticetofixfilmproperlyonthedrumsurface.



Filmsusedinthisphotoplotteraresensitivetolightof670nm(redlight).Whenworkingwithfilm

(loading,unloading,…)uselightdarkgreenlight.Itisrecommendedtousedimlightinroomduring

photo‐

plotting.Makesuretherearenoothersourcesoflightthatmayexposefilm,forexamplelight

comingfrommonitorscreen,whenloadingandunloadingfilm.Thefilmmanufacturercanrecommend

propertypeofdarkroomsafelightifneeded.



Transparentfilmsmustbemountedwithemulsionsideonthedrum

surface.(Filminrollsusedforimage

settingmachineshasemulsionside oninnersideandthereforeitiseasytoputitonphotoplotterdrum

properly).Emulsionsideofthefilmhaslightgreycolour,comparewithdarkcolouroftheotherside.



However,filmsmadeforlaserphoto

‐plotters,likeDuPontfilms,whichhaveaspecialanti‐reflection

coatingontheothersideofthefilm,cannotbeplottedwithemulsionsidepointedtowardsdrumsurface.

Inthiscaseemulsionsidemustbeonoutersurface,whilesourceoflaserlightmayneedtobere‐focused.

From

thisreason,usetransparent films,otherwiselaserlightfocusmustbeadjusted–contactyour

photoplottersupplierfordetails.

3.4Runphotoplotter

Before you start plotting,  make sure that drum is in its initial position (white arrow on the left side of the

drumshouldbealignedwithwhitearrowonthetopoftheleftholderofthedrum).Afteryoupreparedyour

data for plotting on connected PC using photoplotter software,

 start plotting ‐see further info. The

photoplotter drum starts slowly to rotate. After drum reaches its working speed, it rotates a while before

actual plotting starts. At this moment red (or yellow) LED labelled Laser starts to light as an indicator that

plottingisinprogress.Whenphoto‐plotting

isfinishedorinterr uptedbySTOPcommand,drumautomatically

stops, laser head moves back to its outgoing position and LED labelled Laser stops light. Time needed for

photo‐plottingofgivenimageisdisplayedoncomputerindialogwindowofcontrolsoftware.



Donotstartplotting againbefore thelaser

light headreaches completely its initialposition (the leftside of

thescrew)!



Note: Because various films used for photo‐plotting are differently sensitive to light, it is possible to adjust

intensityoflaserlightasneede dinphotoplottersoftware,alsoinrespecttoselectedresolution.Thissetting

may

alsobeneededtoadjusttimeaftertimetoreflectthestatusofchemicalsusedforfilmwetprocessing.

Openthelid(darkgreenlight!!!)andremovefilm.Processfilmimmediately.

Note:Afterremovingfilmfromdrumsurface,itmaybenecessarytocleanthedrumsurface toremovesticky

areas

 caused by sticky tape. Use soft cloth  and common liquid cleaner. Do not spray. Drum surface under

filmmustbekeptcleananddry.

ATTENTION!Duringphoto‐plottingisfilm(drum)lightedbylaserlightthatisharmfultohumaneye.Donot

openphotoplotterlidduringphoto‐plotting,

norduringtestingwithoutfilm.

4.PHOTOPLOTTERSOFTWARE



4.1BriefDescription



PhotoplottersoftwarecomesononeCDtogetherwithViewMateprogramforviewingGerberfilesandwith

abriefmanualinPDFformat.ItmustbeinstalledonPCunderwithWindows98orhigher.

CDcontains5directories–Install,Manual,Update,Util,Viewmate

Install directory contains photoplotter control software. This program can be installed on computer by

executing its own installation program SETUP.EXE. Installation creates a new directory (default FP‐8000

underProgramFiles)with twoprograms(Gerb2bitmapandRun_Photo_USB.

Gerb2bitmap.exereadsinGerberfiles.ItallowstoviewGerberdataastheyappearonthefilm,editD‐codes,

do film penalization, and converts Gerber file into photoplotter bitmap file (.FPF),  which can be read into

plottercontrol program(Run_photo_USB) tobeused forphoto‐plotting. Itcanalso  convert

variousformats

ofaperturefilesintoLavenir‘sformat,whichisusedbythisplotter.



Run_photo_USB.exe controls photo‐plotting. Reads in bitmap files  like photoplotter FPF, regular BMP and

controls plotting process. It allows to set output resolution as well as to calibrate photoplotter in X and Y

coordinates.

LatestphotoplottersoftwareislocatedinUpdatedirectory.Please,copythefilesintophotoplotterdirectory

(defaultFP‐8000underProgramFiles).



ManualdirectorycontainsthismanualandAdobeAcrobatReaderprogram.



UtildirectorycontainsprogramMM2IN CH.EXE(mmtomilsconverter).



ViewmatedirectorycontainsprogramViewMate.ThisprogramismadebyPentaLogix(Lavenir)andisafree

ofcharge addition tothe photoplotter software. It allows to view Gerber files and to convert aperture files

madeinvariousPCBlayoutsystemsintoonecommonfileformat(Lavenir‘sformatofaperturefile,

extension

.env). Installation of this program is done by executing ViewMate Setup in directory ViewMate on CD.

ViewMatecanbe expanded to fullGerber editor ViewMaster – contactphotoplotter supplier orPentaLogix

directly(http://www.pentalogix.com).

4.2Detailedprogramsdescription:

ProgramGerb2Bitmap

This program reads in Gerberfiles and converts it into hi‐resolution bitmap fileinproprietary format (FPF),

whichcan  be thenread into plottercontrolprogram (Run_photo_USB.exe) tobe usedforphoto‐plotting.It

allowstoviewGerberimageasitappearsonthefilm,editD‐codes,panelisefilm

andassociateddrill.Italso

has a built‐in converter of aperture files made in various CAD software (Eagle, Pads, OrCad, Protel, P‐CAD,

etc.)



Thelargegreyarea onthescreen representsplottingarea of thephotoplotter.Thetopleftcornerof grey

fieldareahas0, 0 plotting coordinateswith increasingYcoordinate going vertically  down and increasingX

coordinate running horizontally to the right. The coordinates of the cursor located in the

 plotting area are

displayedattheleftbottomcornerinunitssetinPreference‐DataFormat.Thesizeoftheplottingareacan

besetasuserwishesinPreference‐PlottingAreaSize.Althoughusercansetanysizeoftheplottingarea,it

make sense to set only usable

 plotting area. The maximum size in drum axis can be 360 mm, in drum

circumferenceaxisis themaximum320mmforplotterswithdrumdiameteraround110mmor450mmfor

plotterswithdrumdiameterof150mm.Thereason,whythesizeofplottin gareaisnotfixed

isthefactthe

user may wish to set size of the area to the size  of the film he uses, which may be different from the

maximumplottingsize.

Pleasenote,thatplottedimageisinplottingarearotatedby270degree(or–90degree)andmirroredfrom

someprogrammingreasons.Itmeans,XaxisofthegreyplottingarearepresentsYaxisofthefilmloadedin

photoplotter(drumcircumference),whileYaxisofthegreyplottingarearepresents

Xaxisofthefilmloaded

inphotoplotter(drumaxis).AtthesametimetheimageismirroredovertheY axisoftheplottingarea.This

hasnoimpactonproperphoto‐plotting,astheoverallsizeoftheplottedimageisthesame.



Toavoidconfusionwithplot

rotationonthefilm,thisistherule:horizontallineoftheplottedimagewillbe

verticalinplotter.



Command Job‐Import Master Gerber or the first left icon loads main Gerber file(s), while Job‐Import

AssociatedGerber or„Gbr“iconloads Gerberfilesassociatedwiththemasterfile.The

masterGerberfile(s ) 

canbelocatedanywhereinsidetheplottingarea,usuallyonlayer(film)number1(default),whileassociated

Gerberfilesareautomaticallypositioned underMasterGerberondifferent,specifiedlayers(films).IfMaster

GerberfileisforexampletopsideroutingofthePCB,thenAssociatedGerberfilesare

forexamplesilkscreen,

soldermaskorbottom side routing of the same board – they will be in same location as the Master image,

butondifferentlayers(films),evenwhenpenalizatio nisdone.SeveralMasterGerberfiles(sameordifferent)

canbeloadedonone,samelayer(film).AssociatedGerber

filesareloadedintoselectedlayer,whichcanbe

selectedintoprightwindow



ActiveLayer.

Note:Themeaning„Master Gerber“and „AssociatedGerber“makessenseonlyincaseofseveralartworks

(likeTopsiderouting,Bottomsiderouting,Silkscreen,Soldermask,etc.)fromthesameboardwillbephoto‐

plotted, while one of them (Master) will be

panelised‐the other ones (Associated) must be

then be

 panelised too and be positioned exactly to the same location as the Master image. If films are not 

panelised,thaneveryGerberfilecanbeconsideredas„MasterGerber“,asitcanbepositionedanywherein

plottingareawithoutconsideringanotherGerberfiles.



If standard Gerber file is loaded  (

RS274‐D), then data format of Gerber file has to be set in dialog window

usingcommandPreference‐DataFormat.ThisdataformatdoesnotneedtobesetfortheextendedGerber

file(RS274‐X),asthisinformationisdirectlyinitsGerberfile.AfterreadingGerberfile,

asmallportionofthe

image will be displayed in top right corner of

plotting field like a red rectangle with its size

equal to given image. This rectangle can be

movedtoanylocationinside theplottingareaby

left mouse button (click on red rectangle, hold 

button down,

drag to a new location, release

button).Asplotterstartstoplotattopleftcorner

and continu es to the right, it makes sense to

place this red rectangle to the top left corner of

plottingarea.



After positioning red rectangle inside plotting

area,correspondingaperturefilemustbeloaded

 case of standard Gerber format (RS‐274D).

Extended Gerber format (RS‐274X) contains

information on used apertures and therefore

does not require to load aperture file. If you are

notsurewhichformatisloaded,seetheaperture

table (Preference – Aperture Table) an Icon – if

table is

 empty, without  information on used

D/codes

, than aperturefilehastobeloaded.

Aperturefilescanhavevariousformats,dependingonsoftwarewhereitwascreated.Thisprogramuses

Lavenir‘sformatasastandard.BesideLavenir‘sformat(.env)canthisprogramreaddirectlyseveralother

formatslikeCAM350,IsoCAM,GC‐CAM–otherformatsmustbeconvertedtooneofthem.Theprogramhas



built‐inDOSapertureconvertermadebyLavenir,whichallowstoconvertmostofthecommonaperturefile

formatsintoLavenir‘sformatinaneasyway.



Beforeloadingaperturefile,makesureitwillbeloadedonthesamelayerascorrespondingGerberfile–

useActiveLayertoset

activelayer.

UseJob–ImportAperturesor„Apt“icontoactivatethisaperturesconverter.Adialogwindowappears

whereitispossibletochooseaperturetypeofloadedaperturefilesandtodefinetheloadedaperturefile.If

loadedfilehasformatofLavenir,CAM350,GC‐CAMor

IsoCAM,thenitcanbeloadeddirectly,justchoose

thisaperturetype.Ifloadedtypeisnotlistedunderaperturetype,useotherapertures–itwillbringupthe

apertureconverter

automatically.

Note: Similar, new Windows

version of this converte r  is in

ViewMate program – that one 

can be also used to convert

aperture files to Lavenir‘s

format.



When DOS aperture converter

starts, program will

automatically fill all needed

information in it. The user can

verify the source of aperture

file by clicking

 on „Guess

Format“ – the converter will

report the name of the

program where aperture file

wascreated.The

conversion will start by clicking

on„Start“orF4.ExitconverterbyusingESCkeyboardbutton.Whenconvertercloses,confirmOKonasmall

dialogwindow.Thenameofloaded

aperturefilewillbedisplaye dinthefieldAPERTUREforparticularlayer,

besidenameofcorrespondingGerberfileunderGERBER.



Please note,  that selected aperture file will appear in this converter always under name of „APERT.TXT“,

whileconvertedfilewillhaveassignednameof„APERT.ENV“.Thisisdoneonpurpose

toavoidproblems with

longernamesofaperturefiles.ProgramwillalwaysrenameselectedaperturefileasAPERT.TXT,convertitas

APERT.ENV andafterthis conversion is confirmed by OK in a small dialog window, it rename converted file

backtotheoriginalonewithextension.env.



Tocheckand/or

modifyloadedaperturetableforselected(active)layerusePreference–ApertureTableor

anicon.

It is possible to define custom aperture table directly in Aperture Table (Preference – Aperture Table),

withoutanyconversion.Inaperturetableselectshapes(Round,….)andtypesizesofselectedD‐codes,then

save under any name. Program will create an aperture file in Lavenir‘s format (.env), which can

 be then

loadedthroughJob‐ImportApertures–asaApertureTypeselectLavenir).

This method is used when there is a problem with aperture file conversion, or user does not have any

aperturefilegeneratedbyPCBdesignsoftware,etc.

Pleasenote,thatloadedaperturefileisalwaystiedtoloadedandactiveassociatedGerberfile.IfGerber

fileisdeleted(Edit–Delete

Boardoricon),theaperturefileisalsodeleted.

Aclickonredrectangleinworkingareawithrightmousebuttonbringsasmallmenu:

SetActiveallowstosetthisimage(board)active–onlyactiveboardcanbemoved,deleted,…..Moveto

allowstomovethisimagetodesiredlocationbytypinginanew

absolutecoordinatesLockallowstoglue this

imagetoitscurrentlocation–itcanbemanipulatedanymoreUnlockungluesthisimage–itisfreetobe

manipulatedwithAddGerberonactivelayerallowstoloadGerberfileassociatedwiththisoneondifferent

layerAddApertureon

activelayerallowstoloadaperturefileforGerberfileassociatedwiththisoneon

selectedlayer



UseJob‐PrevieworanicontopreviewresultofGerbertobitmapconversionforselectedlayer.Itis

possibletomakeholes(openings)inotherwisefilledpadstomakemanualdrillingeasy

–specifyHoleSize

inPads.Assomepads,forexampleSMDdonothaveanyholes,specifyD‐codeswithoutholesforthese

pads.Similarly,toviewcreatedtechnologicalareadefinedunderPreference‐Tech.Area,clickonTech.Area.



UseJob‐ExportPhotoplotterBitmaptoexportconvertedGerberimage

tohi‐resbitmapfileinphotoplotter

proprietaryformat(FPF).AsinPreview,itispossibletomakeholes(openings)inotherwisefilledpadsto

makemanualdrillingeasy–specifyHoleSizeinPads.Assomepads, forexampleSMDdonothaveany

holes,specifyD‐codes

withoutholesforthesepads.Similarly,toexportcreatedtechnologicalarea(robber

bend)definedunderPreference‐Tech.Area,clickonTech.Area.



Itispossibletoenterusernotesthatwillbeattachedtothefile(forexampleprojectidentification,…)–this

infotextwillbealsodisplayedinRun_plotterprogram

whensearchingforparticularimagefile.



UseJob‐500dpiBitmaptogenerateBMPfile(namedClip.bmp)forchecking purpose–youcandisplayitin

anybmpviewer(ifnothingmore,thanPaintBrushinWindowswilldothat).

Gerb2bitmapCOMMANDSOVERVIEW:

Icons (from left):

JOB

Job‐Newstartsanewplottingproject–defaultsituationwhenstartingthisprogram.

Job‐Openopensprojectfilepreviouslysavedbycommand

Job‐SaveorSaveas.Job‐Save/Saveassavesthecurrentplottingprojectasitisinthisprogramunderits

ownfileformat(.wpr).This

allowstoexitprogramandreturnbackwithoutlosinganyworkpreviouslydone

withloadingGerberandaperturefiles,penalization,etc.,….

Job‐Closeclearstheplottingareaandloadeddatatoallowtostartanotherproject

Job‐Print(oranicon)canprintpreviewimageforchecking

Job‐ExportPhotoplotterBitmap

(oranicon)convertsloadedGerberdata intohi‐resolutionbitmapfilefor

selectedplottinglayer,withspecifiedoutputresolutionandsavesitunderspecifiedname.Usernote

attachedtothefilemaybehereentered.(Exportname).AfterexecutingOKprogramcalculatesnewraster

dataanddisplaysitfor

checking.Pleasenotethatthisoperationmaytakesometime,bepatient.

Job‐Preview(oranicon)allowspreviewingimage(s)asitlooklikeontheplotforselectedlayer.

Job‐ImportMasterGerberloadsmain(independent)Gerberfile(s)

Job‐ImportAssociatedGerberloadsGerberfile(s)associatedwiththeMasterfile

(soldermask,etc…)on

selectedlayer(film)

Job‐ImportAperturesloadsaperturefileforselectedlayer(film)

Job‐Exitendstheprogram



EDIT:

Edit‐InsertMarkallowstoinsertasmallGerberimagetothefilm–seePreference‐Mark

Edit‐CopytoClipboard

Edit‐DeleteBoard(oranicon)deletesselectedboardimage(s)andassociatedGerberandaperturefile.Edit‐

LockAllBoardsgluesimagestotheirlocationinplottingareatoprevent

anyshiftormove.

Edit‐UnlockAllBoardsungluesallimages,sotheymaybemovedinsideplottingareaasneeded.Edit‐

RelativemoveofLockedBoardsallowstomovegluedimagesrelativelytotheircurrentpositioninXandY

coordinates.Pleasenote,thatYcoordinatehasreversepolarity

(positivevaluemovesimageverticallydown).



TOOLS:

Tools‐PaneliseBoardsallowstodosimplefilmpanelisation.ThenumberofcopiesinXandYdirectionand

spacingbetweenimages(edgetoedge)canbesetinopeneddialogwindow.

Newcopiedimagesappearsasgreenrectangles.Greencolourmeansthatthis

imageisnotactive(cannotbe

moved,deleted,…).Tosetanygreenrectanglesasactive,clickrightmousebuttononitanduse

SetActivecommand.Note,thatonlyoneactiveimage(board)atthesametimewillbeinsideplottingarea.



ImportMasterGerber

PaneliseSelectionBoard

DeleteSelectedBoard

Preview

ExportGerbertoBitmap

PrintPreview

ViewandEditApertureTable

ImportApertures

Tools‐PanelizeDrillpanelisesdrillforpenalizedfilm(only).TheoriginalExcellondrillfile(.drl)hastobe

selected,aswellasanew(panelised)drillfilenamehastobespecified.IfoffsetbetweenpanelisedGerber

dataandpaneliseddrilldataisrequired,thenthiscanbealsospecified.AfterexecutingOK,

program

calculatesnewdrilldataforpanelisedfilm–it maytakesometime,pleasebepatient.Onceitisdone,it

displayspanelisedfilmincludingdrillmarksofnewpaneliseddrilldata.Tools‐ViewTextFileallowstoviewa

textfile(forexampleapertureorGerberfile)Tools‐Convert

Apertureallowstoconvertselectedaperturefile



PREFERENCE:

Preference–MemorySettingallowstospecifycomputermemorysizeusedforcalculations.Recommended

size=RAMmemory–20MB.Themorememoryavailable,thefastercalculationofbitmap.

Preference‐PlottingAreaSizeallowsoperatortosetmax.Sizeofdisplayedplottingarea

Preference

–DataFormatallowsoperatortosetformatofloadedGerberfile

Preference–ApertureTableoriconallowstoviewandeditD/codesofloadedaperturefile

Preference–Unitsallowstosetunitsofmeasurement

Preference‐MarkallowstospecifynamesandfilepathforvariousMark‐small

Gerberimagesused

automaticallyonallplottinglayers.TheycanbeinsertedtotheboardimagebyEdit‐InsertMark.

Preference‐Coloursallowstodefineplottinglayernamesandtheircolours.

Preference – Tech. Area allows to set parameters for so called robber  strip‐copper strip around board

outlineusedforboardmanufacturingpurposes 



Anexampleof“Tech.Area”–therobberstrip



Program Run_Photo_USB

This program controls connected photoplotter. Reads in bitmap files in FPF (proprietary

photoplotterformat)andstandardBMPformat,allowstocalibratephotoplotter,pre‐setvaluesfor

intensity of laser light and to set output parameters for plotting (plot resolution, negative and/or

mirrorplotting).

File‐Open

(or F3) command allows to read in input file generated previously in Gerb2bitmap program ( FPF

format)orWindowsBMPformat(seepictureonthenextpage).

FPF file can be previewed before loading and its image size, resolution and user notes created in

Gerb2Bitmapisdisplayed.

Pleasenote,thatimagesizeisextendedby10mmoneachside.

In case of BMP file, its image cannot be viewed here. Its resolution MUST be entered in dialog window

(InputResolution).Ifinputresolutionvalueisenteredwrong,thefinalplotwillhavewrongdimensions.

Selected file is loaded into program by OK button. Loading may take some time, depending on file size. If

loaded file size is smaller than 14 MB, than its image is displayed,  otherwise a message „File is too big to

display,butplottingwillbeOK“isdisplayed.

Please note, that loaded image does not need to appear correctly in both axis, usually it is compressed in

verticaldirectiontosavespaceonthescreen.Youcandragbottomsideofthedialogwindowtomakeimage

lookright,butkeepinmind,thatthisimageisheredisplayed

onlyforyourinformation.



Whenimageisdisplayed,useTools‐Runphotoplotterorbutton



Anewdialogboxappears,whereitispo ssibletosetplotoutputreso lution,reversed(Negative)andmirrored

(Mirror)plotting.Timeneededforplottingisshownautomatically.ClickonPlotwillstarttheplotter.

Thehigher

outputresolution,thelongerplottingtime.



Setup‐SetupTable

opens dialog window for plotter setup – here it is possible  to define adjusted drum diameter, measured

inaccuracyvalues inbothscrewaxisanddrumrotation(circumfer ence)dire ctionsaswellasplotangleerror

usedforanautomaticcorrection.Thissetupisuniqueforeachphotoplotterandthatiswhysetup

file(.phs)

issuppliedwitheachphotoplotter.UseSetup‐Importfile(.phs)toloadthisdataintosetuptable.Usermay

modifythissettinginsetuptableifneededandsaveitasanewfile(.phs)usingSave,aswellasexportitby

Setup‐Export.

DrumDiameterisarealdrumdiameterplusapproximately(0.8xfilmthickness).Asitisanexactdrum

diameter,itisimportanttoknowthepropervalue–whenthisvalueisgreater,theplottedlinelengthin

drumcircumferencedirectionisshorterandviceversa.Itmaybenecessary

tomodifythisvaluealittlebit,to

reflectdifferentplottingconditionsattheusersite(temperature,humidity,film).



AngleErrorrepresentsalinearinaccuracybetweentherightangleplotandthereal(non‐rightangle)ploton

aline360mmlongalongdrumaxis.Thisisonehalf

ofverticaldistancebetweencorrespondinghorizontal

linesofthetwofilms,measured360mmfromtheleft0position,whileoneofthefilmsisflippedupsid e 

down.



ScrewErrorrepresentsalinearinaccuracyofascrewinitsaxisdirectionfor300mmdistance.



DrumLinearityismeasuredinaccuracy

forevery10mmindrumrotationdirection.Ifmeasureddistanceis

longerforgivendistancefromthebeginning(forexamplemeasureddistanceis120.09mmfr om120mm

distance),thenthispositivedifferenceisentered(0.09).

Ifmeasureddistanceisshorterforgivendistance(forexamplemeasureddistance119.92for120

mm

distance),thennegativedifferenceisentered(‐0.08).Softwarewillthenautomaticallycompensatefor

entereddifferences.



ScrewLinearityismeasuredinaccuracyforevery20mminscrewaxisdirection.).Softwarewillthen

automaticallycompensateforentere ddifferences.

Tools‐GenerateTestGrid

Generatestestplotfileinshapeof10mmlinegridofspecifieddimensions(drumcircumferenceanddrum

axisdirection)anddefinedlinethickness.Thisplotfilewillbeautomaticallyplottedwithresolution1016dpi.



Testplotcanbeusedasacheckplot, whereplotteraccuracymaybemeasured–

anyinaccuraciesindrum

circumferenceordrumaxisdirectionmaybeenteredintosetuptableforrelateddistance.

PlotsizedependsonvalueswritteninfilesDrumaxisandDrumcircumference.



ThegridlinesareplottedwiththicknessspecifiedinfieldLinewidth.IfIncludesetuptableischecked,

then

setuptablewillbeautomaticallyincludedatthebottomoftheplot.



IfserialnumberofthephotoplotteriswritteninfieldS/N,thenthisinfowillbealsoincludedontheplot.



ClickonOKtocontinue–softwarewillautomaticallygeneratetestplotfile,whichcanbenowplottedasany

otherplotfile.



Continueaswithanyotherplotfile–useRunphotoplotter(Tools–RunPhotoplotterorbutton)

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Mega FP?8000 XL User manual

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