MEGAELECTRONICSLIMITED.

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PhotoplotterFP8000/8000XL
Instructionmanual
Note:Anyinquiriesrelatedtophotoplotterhardwareorsoftwareshouldbeaddressedtoan
authorizeddistributor.Photoplottersoftwareissubjecttocopyright.Alltheinformationenclosed
hereissubjecttochangeduetoconstantinnovationoftheproduct.Dateofthelastchangeinthis
document:June17,2011.

1.Briefdescription:
Photoplotter FP8000/8000 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.
PhotoplotteriscontrolledbysoftwareinstalledonPCattachedviaitsUSBport(PCisnotapartof
the photoplotter supply). An external, universal power unit is used tosupply needed power(100
240VAC/36VDC1.66A).
The photoplotter software allows to read input files, to set output resolution and type of image
(negative,mirror,etc.)drawnonthefilm.WhenworkingwithGerberfiles,itispossibletocheckand
modifyusedapertures(Dcodes)andmakesimplefilmpanelisationforGerberdataandassociated
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
photoplottersoftwareforyourconvenience(otherwiseitmaybedownloadedfromPentalogixweb
page:http://www.pentalogix.com/Download/download.html).
Photoplotter is driven by program Run_photo_USB, which reads in hiresolution bitmap files FPF,
(photoplotter proprietary file format) and BMP. From this reason, if you work with Gerber or
Postscriptfiles,thesefilesmustbeconvertedintooneofthesebitmapfilesformatfirst.Gerberfiles
are converted by program Gerb2bitmap, which is a part of the photoplotter software, while
Postscriptfilesareconvertedbyanexternalprogram,suppliedasanoption.ConverterofGerber
files has also builtin converter of aperture files to convert various aperture format into one
standardformat(Lavenirformatisusedasastandardapertureformat).Aperturefileconversionis
needed only when working with standard Gerber format RS274D. There is no need to convert
aperture file when working with extended Gerber format RS274X, as this type of file already
containsinformationonusedapertures.
Varioustypesoffilmsmaybeusedforthisphotoplotter,butallofthemmustbesensitivetolight
wavelengthof670nm(redlight).Thinfilms(0.1mm)usedbyimagesettingmachinesaswellas
standard photoplotter films (0.18 mm) can be used, although 0.1mm films are recommended for
thismodelofthephotoplotter.Films0.1mmcomeeitherinrollsofvariouswidthandlength,orin
precutsheetsofseveralsizes.Filminrolliseasytotapeonasmalldruminphotoplotter,asfilm
tendstobendautomatically.Thereareseveralmanufacturersofsuitablefilms,likeKodak,Horsell,
Fuji,Agfa,TyponGraphicSystems,etc.,whilefilmshavevariousnameslikeEZR4,RD4,TRLR+.As
filmlightsensitivitydifferswithvariousfilms,severaltestplotsmaybeneededtofindsuitablelight
intensity.Filmshavetobewetprocessed(developedandstabilised)likeanyotherfilmsafterlighted
inphotoplotter.Filmmanufacturersrecommendandusuallysupplychemicalstobeusedfortheir
filmsprocessing.

Thepowerswitchislocatedontheleftsideoftheplotter.
Onthebacksideoftheplotterthefollowingitemscanbefound:powersupplyconnector(label:Input36V
2A)computerUSBcableconnector(label:USB)Labelwithserialnumberoftheplotter(SN)
Onthefrontorleftsideoftheplotterthefollowingitemsarelocated:Yellow(orRed)LEDindicatingplotting
operation(label:Laser)GreenLEDindicatingpoweron(label:Power)

2.Technicalparameters:
Maximumfilmsize:FP8000:360mmx360mm/14"x14"FP8000XL:380mmx450mm/15"x17,5"
Maximumphotoplottingarea:FP8000:340mmx320mm

FP8000XL:360mmx420mmPlotresolution:(508,1016,1355,1625,2032,2710,4064,8192)x8600dpi,
Plottingspeed:approximately13mmoffilmwidth/minutefor1016dpiUsedlight:Laserdiode670nm
(red)Readsinimageformats:Gerber(RS274D,RS274X),hiresBMP,Postscript(option)Readsinaperture
files:directlyCAM350,GCCAM,IsoCAM,Lavenir,otherformatslikePads,Eagle,OrCAD,Protel,PCADreads
throughbuiltinconverter.Photoplotteroverallsize:FP8000:LxWxH(700x340x210)

FP8000XL:LxWxH(700x370x230)Photoplotterweight:FP8000:approx.25kg(55lbs)FP8000
XL:approx.26.5kg(58lbs)Power:anexternalpowersupplyunit100240VAC/36VDC2.78A
Reversed(negative)&mirrorplotting,filmanddrillpanelisation,Dcodeediting,outputpreview&print,
interactiveorcoordinatesimagepositioningonfilm,glue/unglueimagelocation,automaticpositioningof
associatedimagesondifferentlayers.

PhotoplottersoftwareissuppliedonCDwithinstallationprogram.
RequiresPentiumcomputerwithatleastWindows2000andUSBport,100MBHDspaceminimumfor
softwareandoutputfiles.Thecomputerspeedhasinfluenceonplottingtime.Plottingfilesmaybequite
large,inrangeoftensofMB,soextraspaceonharddiskmayberequired.

Warranty1(one)yearonparts.
ThereisnoexpressedwarrantyonfunctionalityofenclosedsoftwarewhatsoeverexceptwarrantyonCD
media.

Notes:
1)Outputresolution

Thelowestresolution(508&1016dpi)paynotbesuitableforfineresults.

1355and1625dpiresolutionissuitableformostplottingapplication

Use2032or2710dpiforplottingfinelines(butittakeslongertimetoplot)

2)
Plotsize:althoughplotterallowstoplottomaximumspecifiedsize.Beaware,thatfilmswideacross
thewholedrummaybedifficulttofixproperly,whichmayresultinhigherinaccuracyintheright
partofthefilm.Thisisduetotechnicsusedtofixfilmtothedrumsurfacebystickytape.Tofixwide
filmproperlyrequiressomeexperience.Ifyouencounterproblemwithinaccuracyonwidefilms,
enterdeviationvaluesintocorrectiontablefortherightsideofthedrum,whichwillcorrectit,
providedfilmsarealwaysfixedtothedruminthesamemanner.

ImportMasterGerber
PaneliseSelectedBoard
DeleteSelectedBoard
Preview
ExportGerbertoBitmap
PrintPreview
View&EditApertureTable
ImportApertures
ImportAssociatedGerber

Howtopreparephotoplotter:
3.1Photoplottersoftwareinstallation
ConnectphotoplotterwithPCviaUSBcablesuppliedwiththephotoplotter.USBconnectorislocatedonthe
backsideofthephotoplotter.Thephotoplotterdoesnotneedtobepoweredatthismoment.
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
pointtodirectoryInstall\Drivers\locatedoninstallationCDandconfirm.
AfterhardwareinstallationyoucaninstallphotoplottersoftwaregotodirectoryInstalloninstallationCD
suppliedwiththephotoplotterandexecuteSETUP.exe.
Softwarestartstoinstallonconnectedcomputer.

3.2Powerthephotoplotter
Connectsuppliedpowersupplyunitwiththephotoplotterconnectorislocatedonthebackside.Switch
poweron(leftsideofthephotoplotter).ThegreenLEDlabelledPowerwillcomeon.Red(oryellow)LED
labelledLaserwillflashfourtimesatthismoment.
Whenphotoplotteristurnedon,thelaserlightheadwillmovebacktothelefttocontactamicroswitchand
thenwillmovebacktotherighttoitsinitialposition.Attachedcomputercannotinitiatecommunicationwith
photoplotter before light head makes the above described move. This initialization runs automatically,
withoutrunningphotoplottersoftware.

AUTO/MANUALswitch:PositionofAUTO/MANUALswitchhasimpactagainstlaserheadbehaviour.AUTO
laserheadmovestoitsstartingposition(leftsideofthedrum)MANUALlaserheadmoves1cmtotheright
only
Beforefirstdataplotting,checktheAUTO/MANUALswitchandsetittoAUTOposition.Whenyoustartthe
plotter,laserheadwillmovetoitsstartingposition(leftside),afterthatyoucanstartdataplotting(laser
headwillmovefromlefttorightsideduringtheplotting).Whentheplottingisfinishedandtheswitchwill
beinAUTOposition,laserheadwillmovebacktoitsstartingpositionandplotterwillbereadyagainfor
plotting.WhentheplottingisfinishedandtheswitchwillbeinMANUALposition,laserheadwillmove1cm
totherightonlyandplotterwillbereadyagainforplotting.

AUTOmodeissuitableforsingledataplottinginthewholefilmwidth.MANUALmodeissuitablewhenyou
wanttoplot2(ormore)datasidebyside(indrumaxisdirection).Afterfirstdataplottinglaserheadmoves
littletotherightonly(1cm)andnextplottingstartsfromthisposition.

Ifyouturnpoweronafterfilmisloaded,itmayhappenthatlaserlightbeamflashesshortlyonthefilmat
themomentwhenpoweristurnedonandelectroniccircuitryisreset.Thismayresultinverysmallspoton
thefilm.

3.3Placeandtapefilm
Liftthephotoplotterlid,soyouhaveaccesstotheoutersurfaceofthedrum.Rotatedrumbyhand(inany
direction)topointwhitearrowlocatedontheleftsideofthedrumtowhitearrowlocatedontheleftsideof
drumholder.Thisistheoutgoingpositionofthedrumforphotoplotting.Thelefttopcornerofphoto
plottedareaisthenapproximately20mmfromtheleftedgeofthedrumonthehorizontallinemarkedby
whitearrow.Placefilmonthedrumwithitstopedgeapproximately20mmbehindthewhitemarkonthe
drum,holditfirmbyhandandfixittothedrumbymeansofamaskingtapealongthetopedge.Rotate
drumbyonehandtobeabletofixfilmsbottomedge,butmakesurefilmistightondrumsurface.Afterfilm
isfixedtoitspositiononthedrum,rotatedrumbackto1stinitialposition(bothwhitearrowspointtoeach
other).Closethelid.

NOTES:
Itisamatterofpracticetofixfilmproperlyonthedrumsurface.

Filmsusedinthisphotoplotteraresensitivetolightof670nm(redlight).Whenworkingwithfilm
(loading,unloading,)uselightdarkgreenlight.Itisrecommendedtousedimlightinroomduring
photoplotting.Makesuretherearenoothersourcesoflightthatmayexposefilm,forexamplelight
comingfrommonitorscreen,whenloadingandunloadingfilm.Thefilmmanufacturercanrecommend
propertypeofdarkroomsafelightifneeded.

Transparentfilmsmustbemountedwithemulsionsideonthedrumsurface.(Filminrollsusedforimage
settingmachineshasemulsionsideoninnersideandthereforeitiseasytoputitonphotoplotterdrum
properly).Emulsionsideofthefilmhaslightgreycolour,comparewithdarkcolouroftheotherside.

However,filmsmadeforlaserphotoplotters,likeDuPontfilms,whichhaveaspecialantireflection
coatingontheothersideofthefilm,cannotbeplottedwithemulsionsidepointedtowardsdrumsurface.
Inthiscaseemulsionsidemustbeonoutersurface,whilesourceoflaserlightmayneedtoberefocused.
Fromthisreason,usetransparentfilms,otherwiselaserlightfocusmustbeadjustedcontactyour
photoplottersupplierfordetails.

3.4Runphotoplotter
Before you start plotting, make sure that drum is in its initial position (white arrow on the left side of the
drumshouldbealignedwithwhitearrowonthetopoftheleftholderofthedrum).Afteryoupreparedyour
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
plottingisinprogress.WhenphotoplottingisfinishedorinterruptedbySTOPcommand,drumautomatically
stops, laser head moves back to its outgoing position and LED labelled Laser stops light. Time needed for
photoplottingofgivenimageisdisplayedoncomputerindialogwindowofcontrolsoftware.

Donotstartplottingagainbeforethelaserlightheadreachescompletelyitsinitialposition(theleftsideof
thescrew)!

Note:Becausevariousfilmsusedforphotoplottingaredifferentlysensitivetolight,itispossibletoadjust
intensityoflaserlightasneededinphotoplottersoftware,alsoinrespecttoselectedresolution.Thissetting
mayalsobeneededtoadjusttimeaftertimetoreflectthestatusofchemicalsusedforfilmwetprocessing.
Openthelid(darkgreenlight!!!)andremovefilm.Processfilmimmediately.
Note:Afterremovingfilmfromdrumsurface,itmaybenecessarytocleanthedrumsurfacetoremovesticky
areas caused by sticky tape. Use soft cloth and common liquid cleaner. Do not spray. Drum surface under
filmmustbekeptcleananddry.
ATTENTION!Duringphotoplottingisfilm(drum)lightedbylaserlightthatisharmfultohumaneye.Donot
openphotoplotterlidduringphotoplotting,norduringtestingwithoutfilm.

4.PHOTOPLOTTERSOFTWARE

4.1BriefDescription

PhotoplottersoftwarecomesononeCDtogetherwithViewMateprogramforviewingGerberfilesandwith
abriefmanualinPDFformat.ItmustbeinstalledonPCunderwithWindows98orhigher.
CDcontains5directoriesInstall,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 FP8000
underProgramFiles)withtwoprograms(Gerb2bitmapandRun_Photo_USB.
Gerb2bitmap.exereadsinGerberfiles.ItallowstoviewGerberdataastheyappearonthefilm,editDcodes,
do film penalization, and converts Gerber file into photoplotter bitmap file (.FPF), which can be read into
plottercontrolprogram(Run_photo_USB)tobeusedforphotoplotting.Itcanalsoconvertvariousformats
ofaperturefilesintoLavenirsformat,whichisusedbythisplotter.

Run_photo_USB.exe controls photoplotting. 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.
LatestphotoplottersoftwareislocatedinUpdatedirectory.Please,copythefilesintophotoplotterdirectory
(defaultFP8000underProgramFiles).

ManualdirectorycontainsthismanualandAdobeAcrobatReaderprogram.

UtildirectorycontainsprogramMM2INCH.EXE(mmtomilsconverter).

ViewmatedirectorycontainsprogramViewMate.ThisprogramismadebyPentaLogix(Lavenir)andisafree
ofchargeadditiontothephotoplottersoftware.ItallowstoviewGerberfilesandtoconvertaperturefiles
madeinvariousPCBlayoutsystemsintoonecommonfileformat(Lavenirsformatofaperturefile,extension
.env). Installation of this program is done by executing ViewMate Setup in directory ViewMate on CD.
ViewMatecanbeexpandedtofullGerbereditorViewMastercontactphotoplottersupplierorPentaLogix
directly(http://www.pentalogix.com).

4.2Detailedprogramsdescription:
ProgramGerb2Bitmap
ThisprogramreadsinGerberfilesandconvertsitintohiresolutionbitmapfileinproprietaryformat(FPF),
whichcanbethenreadintoplottercontrolprogram(Run_photo_USB.exe)tobeusedforphotoplotting.It
allowstoviewGerberimageasitappearsonthefilm,editDcodes,panelisefilmandassociateddrill.Italso
has a builtin converter of aperture files made in various CAD software (Eagle, Pads, OrCad, Protel, PCAD,
etc.)

Thelargegreyareaonthescreenrepresentsplottingareaofthephotoplotter.Thetopleftcornerofgrey
fieldareahas0,0plottingcoordinateswithincreasingYcoordinategoingverticallydownandincreasingX
coordinate running horizontally to the right. The coordinates of the cursor located in the plotting area are
displayedattheleftbottomcornerinunitssetinPreferenceDataFormat.Thesizeoftheplottingareacan
besetasuserwishesinPreferencePlottingAreaSize.Althoughusercansetanysizeoftheplottingarea,it
make sense to set only usable plotting area. The maximum size in drum axis can be 360 mm, in drum
circumferenceaxisisthemaximum320mmforplotterswithdrumdiameteraround110mmor450mmfor
plotterswithdrumdiameterof150mm.Thereason,whythesizeofplottingareaisnotfixedisthefactthe
user may wish to set size of the area to the size of the film he uses, which may be different from the
maximumplottingsize.

Pleasenote,thatplottedimageisinplottingarearotatedby270degree(or90degree)andmirroredfrom
someprogrammingreasons.Itmeans,XaxisofthegreyplottingarearepresentsYaxisofthefilmloadedin
photoplotter(drumcircumference),whileYaxisofthegreyplottingarearepresentsXaxisofthefilmloaded
inphotoplotter(drumaxis).AtthesametimetheimageismirroredovertheYaxisoftheplottingarea.This
hasnoimpactonproperphotoplotting,astheoverallsizeoftheplottedimageisthesame.

Toavoidconfusionwithplotrotationonthefilm,thisistherule:horizontallineoftheplottedimagewillbe
verticalinplotter.

Command JobImport Master Gerber or the first left icon loads main Gerber file(s), while JobImport
AssociatedGerberorGbriconloadsGerberfilesassociatedwiththemasterfile.ThemasterGerberfile(s)
canbelocatedanywhereinsidetheplottingarea,usuallyonlayer(film)number1(default),whileassociated
GerberfilesareautomaticallypositionedunderMasterGerberondifferent,specifiedlayers(films).IfMaster
GerberfileisforexampletopsideroutingofthePCB,thenAssociatedGerberfilesareforexamplesilkscreen,
soldermaskorbottomsideroutingofthesameboardtheywillbeinsamelocationastheMasterimage,
butondifferentlayers(films),evenwhenpenalizationisdone.SeveralMasterGerberfiles(sameordifferent)
canbeloadedonone,samelayer(film).AssociatedGerberfilesareloadedintoselectedlayer,whichcanbe
selectedintoprightwindow

ActiveLayer.
Note:ThemeaningMasterGerberandAssociatedGerbermakessenseonlyincaseofseveralartworks
(likeTopsiderouting,Bottomsiderouting,Silkscreen,Soldermask,etc.)fromthesameboardwillbephoto
plotted, while one of them (Master) will be
panelised the other ones (Associated) must be
thenbepanelisedtooandbepositionedexactlytothesamelocationastheMasterimage.Iffilmsarenot
panelised,thaneveryGerberfilecanbeconsideredasMasterGerber,asitcanbepositionedanywherein
plottingareawithoutconsideringanotherGerberfiles.

If standard Gerber file is loaded (RS274D), then data format ofGerber file has to be set in dialog window
usingcommandPreferenceDataFormat.ThisdataformatdoesnotneedtobesetfortheextendedGerber
file(RS274X),asthisinformationisdirectlyinitsGerberfile.AfterreadingGerberfile,asmallportionofthe
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
movedtoanylocationinsidetheplottingareaby
left mouse button (click on red rectangle, hold
button down, drag to a new location, release
button).Asplotterstartstoplotattopleftcorner
and continues to the right, it makes sense to
place this red rectangle to the top left corner of
plottingarea.

After positioning red rectangle inside plotting

area,correspondingaperturefilemustbeloaded
in case of standard Gerber format (RS274D).
Extended Gerber format (RS274X) contains
information on used apertures and therefore
does not require to load aperture file. If you are
notsurewhichformatisloaded,seetheaperture
table (Preference Aperture Table) an Icon if
table is empty, without information on used
D/codes, than aperturefilehastobeloaded.

Aperturefilescanhavevariousformats,dependingonsoftwarewhereitwascreated.Thisprogramuses
Lavenirsformatasastandard.BesideLavenirsformat(.env)canthisprogramreaddirectlyseveralother
formatslikeCAM350,IsoCAM,GCCAMotherformatsmustbeconvertedtooneofthem.Theprogramhas
builtinDOSapertureconvertermadebyLavenir,whichallowstoconvertmostofthecommonaperturefile
formatsintoLavenirsformatinaneasyway.

Beforeloadingaperturefile,makesureitwillbeloadedonthesamelayerascorrespondingGerberfile
useActiveLayertosetactivelayer.
UseJobImportAperturesorApticontoactivatethisaperturesconverter.Adialogwindowappears
whereitispossibletochooseaperturetypeofloadedaperturefilesandtodefinetheloadedaperturefile.If
loadedfilehasformatofLavenir,CAM350,GCCAMorIsoCAM,thenitcanbeloadeddirectly,justchoose
thisaperturetype.Ifloadedtypeisnotlistedunderaperturetype,useotheraperturesitwillbringupthe
apertureconverter
automatically.

Note: Similar, new Windows

version of this converter is in
ViewMate program that one
can be also used to convert
aperture files to Lavenirs
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
wascreated.The
conversion will start by clicking
onStartorF4.ExitconverterbyusingESCkeyboardbutton.Whenconvertercloses,confirmOKonasmall
dialogwindow.ThenameofloadedaperturefilewillbedisplayedinthefieldAPERTUREforparticularlayer,
besidenameofcorrespondingGerberfileunderGERBER.

Please note, that selected aperture file will appear in this converter always under name of APERT.TXT,
whileconvertedfilewillhaveassignednameofAPERT.ENV.Thisisdoneonpurposetoavoidproblemswith
longernamesofaperturefiles.ProgramwillalwaysrenameselectedaperturefileasAPERT.TXT,convertitas
APERT.ENVandafterthisconversionisconfirmedbyOKinasmalldialogwindow,itrenameconvertedfile
backtotheoriginalonewithextension.env.

Tocheckand/ormodifyloadedaperturetableforselected(active)layerusePreferenceApertureTableor
anicon.
It is possible to define custom aperture table directly in Aperture Table (Preference Aperture Table),
withoutanyconversion.Inaperturetableselectshapes(Round,.)andtypesizesofselectedDcodes,then
save under any name. Program will create an aperture file in Lavenirs format (.env), which can be then
loadedthroughJobImportAperturesasaApertureTypeselectLavenir).

This method is used when there is a problem with aperture file conversion, or user does not have any
aperturefilegeneratedbyPCBdesignsoftware,etc.
Pleasenote,thatloadedaperturefileisalwaystiedtoloadedandactiveassociatedGerberfile.IfGerber
fileisdeleted(EditDeleteBoardoricon),theaperturefileisalsodeleted.

Aclickonredrectangleinworkingareawithrightmousebuttonbringsasmallmenu:
SetActiveallowstosetthisimage(board)activeonlyactiveboardcanbemoved,deleted,..Moveto
allowstomovethisimagetodesiredlocationbytypinginanewabsolutecoordinatesLockallowstogluethis
imagetoitscurrentlocationitcanbemanipulatedanymoreUnlockungluesthisimageitisfreetobe
manipulatedwithAddGerberonactivelayerallowstoloadGerberfileassociatedwiththisoneondifferent
layerAddApertureonactivelayerallowstoloadaperturefileforGerberfileassociatedwiththisoneon
selectedlayer

UseJobPrevieworanicontopreviewresultofGerbertobitmapconversionforselectedlayer.Itis
possibletomakeholes(openings)inotherwisefilledpadstomakemanualdrillingeasyspecifyHoleSize
inPads.Assomepads,forexampleSMDdonothaveanyholes,specifyDcodeswithoutholesforthese
pads.Similarly,toviewcreatedtechnologicalareadefinedunderPreferenceTech.Area,clickonTech.Area.

UseJobExportPhotoplotterBitmaptoexportconvertedGerberimagetohiresbitmapfileinphotoplotter
proprietaryformat(FPF).AsinPreview,itispossibletomakeholes(openings)inotherwisefilledpadsto
makemanualdrillingeasyspecifyHoleSizeinPads.Assomepads,forexampleSMDdonothaveany
holes,specifyDcodeswithoutholesforthesepads.Similarly,toexportcreatedtechnologicalarea(robber
bend)definedunderPreferenceTech.Area,clickonTech.Area.

Itispossibletoenterusernotesthatwillbeattachedtothefile(forexampleprojectidentification,)this
infotextwillbealsodisplayedinRun_plotterprogramwhensearchingforparticularimagefile.

UseJob500dpiBitmaptogenerateBMPfile(namedClip.bmp)forcheckingpurposeyoucandisplayitin
anybmpviewer(ifnothingmore,thanPaintBrushinWindowswilldothat).

Gerb2bitmapCOMMANDSOVERVIEW:
Icons (from left):

ImportMasterGerber
PaneliseSelectionBoard
DeleteSelectedBoard
Preview
ExportGerbertoBitmap
PrintPreview
ViewandEditApertureTable
ImportApertures

JOB
JobNewstartsanewplottingprojectdefaultsituationwhenstartingthisprogram.
JobOpenopensprojectfilepreviouslysavedbycommand
JobSaveorSaveas.JobSave/Saveassavesthecurrentplottingprojectasitisinthisprogramunderits
ownfileformat(.wpr).Thisallowstoexitprogramandreturnbackwithoutlosinganyworkpreviouslydone
withloadingGerberandaperturefiles,penalization,etc.,.
JobCloseclearstheplottingareaandloadeddatatoallowtostartanotherproject
JobPrint(oranicon)canprintpreviewimageforchecking
JobExportPhotoplotterBitmap(oranicon)convertsloadedGerberdataintohiresolutionbitmapfilefor
selectedplottinglayer,withspecifiedoutputresolutionandsavesitunderspecifiedname.Usernote
attachedtothefilemaybehereentered.(Exportname).AfterexecutingOKprogramcalculatesnewraster
dataanddisplaysitforchecking.Pleasenotethatthisoperationmaytakesometime,bepatient.
JobPreview(oranicon)allowspreviewingimage(s)asitlooklikeontheplotforselectedlayer.
JobImportMasterGerberloadsmain(independent)Gerberfile(s)
JobImportAssociatedGerberloadsGerberfile(s)associatedwiththeMasterfile(soldermask,etc)on
selectedlayer(film)
JobImportAperturesloadsaperturefileforselectedlayer(film)
JobExitendstheprogram

EDIT:
EditInsertMarkallowstoinsertasmallGerberimagetothefilmseePreferenceMark
EditCopytoClipboard
EditDeleteBoard(oranicon)deletesselectedboardimage(s)andassociatedGerberandaperturefile.Edit
LockAllBoardsgluesimagestotheirlocationinplottingareatopreventanyshiftormove.
EditUnlockAllBoardsungluesallimages,sotheymaybemovedinsideplottingareaasneeded.Edit
RelativemoveofLockedBoardsallowstomovegluedimagesrelativelytotheircurrentpositioninXandY
coordinates.Pleasenote,thatYcoordinatehasreversepolarity(positivevaluemovesimageverticallydown).

TOOLS:
ToolsPaneliseBoardsallowstodosimplefilmpanelisation.ThenumberofcopiesinXandYdirectionand
spacingbetweenimages(edgetoedge)canbesetinopeneddialogwindow.
Newcopiedimagesappearsasgreenrectangles.Greencolourmeansthatthisimageisnotactive(cannotbe
moved,deleted,).Tosetanygreenrectanglesasactive,clickrightmousebuttononitanduse
SetActivecommand.Note,thatonlyoneactiveimage(board)atthesametimewillbeinsideplottingarea.

ToolsPanelizeDrillpanelisesdrillforpenalizedfilm(only).TheoriginalExcellondrillfile(.drl)hastobe
selected,aswellasanew(panelised)drillfilenamehastobespecified.IfoffsetbetweenpanelisedGerber
dataandpaneliseddrilldataisrequired,thenthiscanbealsospecified.AfterexecutingOK,program
calculatesnewdrilldataforpanelisedfilmitmaytakesometime,pleasebepatient.Onceitisdone,it
displayspanelisedfilmincludingdrillmarksofnewpaneliseddrilldata.ToolsViewTextFileallowstoviewa
textfile(forexampleapertureorGerberfile)ToolsConvertApertureallowstoconvertselectedaperturefile

PREFERENCE:
PreferenceMemorySettingallowstospecifycomputermemorysizeusedforcalculations.Recommended
size=RAMmemory20MB.Themorememoryavailable,thefastercalculationofbitmap.
PreferencePlottingAreaSizeallowsoperatortosetmax.Sizeofdisplayedplottingarea
PreferenceDataFormatallowsoperatortosetformatofloadedGerberfile
PreferenceApertureTableoriconallowstoviewandeditD/codesofloadedaperturefile
PreferenceUnitsallowstosetunitsofmeasurement
PreferenceMarkallowstospecifynamesandfilepathforvariousMarksmallGerberimagesused
automaticallyonallplottinglayers.TheycanbeinsertedtotheboardimagebyEditInsertMark.
PreferenceColoursallowstodefineplottinglayernamesandtheircolours.

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

AnexampleofTech.Areatherobberstrip

Program Run_Photo_USB

This program controls connected photoplotter. Reads in bitmap files in FPF (proprietary
photoplotterformat)andstandardBMPformat,allowstocalibratephotoplotter,presetvaluesfor
intensity of laser light and to set output parameters for plotting (plot resolution, negative and/or
mirrorplotting).
FileOpen
(or F3) command allows to read in input file generated previously in Gerb2bitmap program (FPF
format)orWindowsBMPformat(seepictureonthenextpage).
FPF file can be previewed before loading and its image size, resolution and user notes created in
Gerb2Bitmapisdisplayed.
Pleasenote,thatimagesizeisextendedby10mmoneachside.

In case of BMP file, its image cannot be viewed here. Its resolution MUST be entered in dialog window
(InputResolution).Ifinputresolutionvalueisenteredwrong,thefinalplotwillhavewrongdimensions.

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,butplottingwillbeOKisdisplayed.

Please note, that loaded image does not need to appear correctly in both axis, usually it is compressed in
verticaldirectiontosavespaceonthescreen.Youcandragbottomsideofthedialogwindowtomakeimage
lookright,butkeepinmind,thatthisimageisheredisplayedonlyforyourinformation.

Whenimageisdisplayed,useToolsRunphotoplotterorbutton

Anewdialogboxappears,whereitispossibletosetplotoutputresolution,reversed(Negative)andmirrored
(Mirror)plotting.Timeneededforplottingisshownautomatically.ClickonPlotwillstarttheplotter.
Thehigheroutputresolution,thelongerplottingtime.

SetupSetupTable
opens dialog window for plotter setup here it is possible to define adjusted drum diameter, measured
inaccuracyvaluesinbothscrewaxisanddrumrotation(circumference)directionsaswellasplotangleerror
usedforanautomaticcorrection.Thissetupisuniqueforeachphotoplotterandthatiswhysetupfile(.phs)
issuppliedwitheachphotoplotter.UseSetupImportfile(.phs)toloadthisdataintosetuptable.Usermay
modifythissettinginsetuptableifneededandsaveitasanewfile(.phs)usingSave,aswellasexportitby
SetupExport.

DrumDiameterisarealdrumdiameterplusapproximately(0.8xfilmthickness).Asitisanexactdrum
diameter,itisimportanttoknowthepropervaluewhenthisvalueisgreater,theplottedlinelengthin
drumcircumferencedirectionisshorterandviceversa.Itmaybenecessarytomodifythisvaluealittlebit,to
reflectdifferentplottingconditionsattheusersite(temperature,humidity,film).

AngleErrorrepresentsalinearinaccuracybetweentherightangleplotandthereal(nonrightangle)ploton
aline360mmlongalongdrumaxis.Thisisonehalfofverticaldistancebetweencorrespondinghorizontal
linesofthetwofilms,measured360mmfromtheleft0position,whileoneofthefilmsisflippedupside
down.

ScrewErrorrepresentsalinearinaccuracyofascrewinitsaxisdirectionfor300mmdistance.

DrumLinearityismeasuredinaccuracyforevery10mmindrumrotationdirection.Ifmeasureddistanceis
longerforgivendistancefromthebeginning(forexamplemeasureddistanceis120.09mmfrom120mm
distance),thenthispositivedifferenceisentered(0.09).
Ifmeasureddistanceisshorterforgivendistance(forexamplemeasureddistance119.92for120mm
distance),thennegativedifferenceisentered(0.08).Softwarewillthenautomaticallycompensatefor
entereddifferences.

ScrewLinearityismeasuredinaccuracyforevery20mminscrewaxisdirection.).Softwarewillthen
automaticallycompensateforentereddifferences.

ToolsGenerateTestGrid
Generatestestplotfileinshapeof10mmlinegridofspecifieddimensions(drumcircumferenceanddrum
axisdirection)anddefinedlinethickness.Thisplotfilewillbeautomaticallyplottedwithresolution1016dpi.

Testplotcanbeusedasacheckplot,whereplotteraccuracymaybemeasuredanyinaccuraciesindrum
circumferenceordrumaxisdirectionmaybeenteredintosetuptableforrelateddistance.
PlotsizedependsonvalueswritteninfilesDrumaxisandDrumcircumference.

ThegridlinesareplottedwiththicknessspecifiedinfieldLinewidth.IfIncludesetuptableischecked,then
setuptablewillbeautomaticallyincludedatthebottomoftheplot.

IfserialnumberofthephotoplotteriswritteninfieldS/N,thenthisinfowillbealsoincludedontheplot.

ClickonOKtocontinuesoftwarewillautomaticallygeneratetestplotfile,whichcanbenowplottedasany
otherplotfile.

ContinueaswithanyotherplotfileuseRunphotoplotter(ToolsRunPhotoplotterorbutton)

Tools Plot Light Bar

Will plot several small images in one row, where
every image is plotted with different intensity of
light according to preset parameters.
Light intensity starts with value entered in field
Initial light on the first image.
Light intensity automatically increases with
every next image by value entered in filed
Increment.
Number of images is set by value in field
Number.

ClickonbuttonOKstartsplot.

Light
Allowstopresetvaluesforintensityoflaserlightrelatedtoused
film sensitivity and output resolution. For films with higher light
sensitivitythevaluesarelower.

Valuesgoalsodownforhigherresolution,regardlessofthefilm,
aslesslightisneededwithfinerimage.

HowtoworkwithprogramRun_photo_USB:

UseFileOpen(oruseF3)toreadinaninputfile,eitherFPForBMP.
IfyouselectFPFbitmap,imagewillbepreviewedasyoubrowseacrossalistofFPFfileingivendirectory.
Alsoinformationonitsresolutionisdisplayed,aswellasoverallimagesize(+10mmoneachside)anduser
notesattachedtothatimage.

Information on FPF file resolution, image size and user notes is incorporated into FPF file automatically in
Gerb2bitmap program. The input resolution value of selected FPF image will be automatically entered into
thisprogram,sothereisnoneedtodothatmanually(seefurther).

IfyouloadBMPfile,imageitselfaswellasinformationisnotdisplayed.ItisnecessarytoenterBMPimage
resolutioninfieldInputresolution.

Afteryouselectfileforplotting,clickOK.Thefileisdisplayedasitwillbeplottedonfilm.Becausebitmap
filescanbequitealargefiles,ittakessometimetoreadthemintobedisplayedbepatient.Iftheinputfile
isbiggerthanapproximately14MB,fileisnotdisplayedtosavetimeneededfordisplay.

Click on Run photoplotter button to get a new dialog window where you set output resolution (Output
Resolution).CheckNegativetoplotreverse(negative)imageand/orMirrortoplotmirroredimage.Youcan
changeintensityoflaserlight(Light)ifneeded,otherwisethisvalueispresetindialogwindowunderLight
command.Timeneededforgivenfileandsetresolutionisalsoindicated(Plottingtime).Note,thatforthe
higherresolutionthelongertimeisneeded.

ClickonPlotbuttontostartphotoplotting.Ittakesawhileforplotterdrumtoreachneededspeedtorotate
beforeitstartstoplot.Theremainingplottingtimeisindicatedintopleftcornerofthedialogwindow.

ProgramViewMate
ThisprogramcanbeusedtoviewGerberfilesbeforeplottingthem.IfGerberfileisinextendedformat(RS
274X),itcanbeloadeddirectlybycommandFILEIMPORTGERBER.IfGerberfileisinstandardformat(RS
274D),thenassociatedaperturefilemustbeconvertedintoLavenirsformatfirst.Aperturefileconversionis
madeinthefollowingway:

Use command FILEIMPORTAPERTURES to select given aperture file. To check that ViewMate will
automaticallyrecognizeformatofthisaperturefile,usebuttonGUESSTYPEinthedialogwindowanameof
thePCBlayoutsystemwhereaperturefilewasgeneratedwillappear.ClickonOPENtoreadinthataperture
file. Command FILEEXPORTAPERTURES saves read aperture file under the same (or different) name with
Lavenirsextension(.env).Thisnew,convertedaperturefilecanalsobeusedinprogramGerber2bmp(File
Importapertures)loaditafterassociatedGerberfileisloadedintoGerb2bmp.Afterconvertingaperture
fileGerberfilecanbeloadedtobedisplayedforcheckingpurposes.

5.Brief,stepbystepguideforphotoplottersoftware:
5.1 LoadGerberfile(s)intoGerb2bitmapprogram.IfyouloadGerberfileinstandardformat(RS274D),it
may be necessary to set parameters (units, data format, colours, .). To load Gerber data use Job
ImportMasterGerberoranicon.LoadedGerberdatawillappearasaredrectangleinrighttopcorner
moveittotopleftcornerofthegrey(plotting)areabymouse(leftbutton).Atthesamemomentthe
nameofloadedGerberfilewillappearinthetablefieldunderGERBERforlayerNo.1(plottinglayer).

Asanexample,youcanloadGerberfilesuppliedwiththissoftware(directorySAMPLES).FileRs274x1.gbr
andRs274x2.gbrareGerberfilesinextendedformat(RS274X)andthereforethereisnoneedtoconvert
their aperture files. File Rs274_1.gbr and Rs274_2.gbr are Gerber files in standard format (RS274D) and
therefore their corresponding aperture files (Rs274_1.whl and Rs274_2.whl) must be converted into
Lavenirsformat(.env)beforeloadingthemintoplotterprogram.Convertedaperturefilesarealsoincluded
(rs274_1.envandrs274_2.env)foranycase.

5.2Loadcorrespondingaperturefile,butonlyiftheloadedGerberfilewasstandardGerberfile(RS274D).
UseJobImportAperturesoraniconAPT.MakesurethatthisisdoneforthesamelayerasloadedGerber
data (select layer under Active Layer). Loaded aperture file and its Dcodes can be viewed and edited in
PreferenceApertureTable,oruseanicon.

5.2bLoadassociatedGerberfile(s)(ifany)byJobImportAssociatedGerberoruseGBRicononselected
layer (film) set layer(s) in Active Layer. Corresponding images will be automatically placed in the same
location on the film as the Master Gerber image. When Master image is moved or panelised, all related
imagesarealsomovedorpanelised.IfMasterimageisdeleted,allrelatedimages(files)arealsodeleted.

5.2c Load aperture file(s) for associated Gerber images. Make sure that aperture files are loaded on the
samelayers(activelayer)

5.2d If you need to panelise film (to place several copies of the same image on one film), use Tools
Panelise Board, where you set number of copies and their mutual spacing. Then you need to panelise
correspondingdrillfilebyToolsPaneliseDrill.

5.2eIfyouneedarobberstriparoundtheimage,usePreferencesTech.Areatocreateit

5.2ePreviewresultsofplacementofloadedGerberfile(s)forselectedlayerbyJobPrevieworuseanicon.
Note: Command Delete deletes loaded image(s), Gerber files and associated aperture files). In case of
panelizationtheimageisdeletedonebyone.

5.3ExportloadedGerberfile(s)tohiresolutionbitmapfilebyJobExportPhotoplotterBitmap.Specifythe
exportfilename(ExportName).Settheexportfileoutputresolution.Theoutputresolutioncanbeset
in several preset values 1016, 1350 and 2032, or in any value (Other..). Unless you have a specific
reason,werecommendtousepresetvalues.Theexportedfileisdisplayedforcheckingpurpose.

Selected output resolution has nothing to do with plotting resolution, as program Run_Photo_USB will
read in this export file resolution, but plot with output resolution, which will be set in Run_photo_USB
program. It may be an advantage to keep both resolutions the same, but in any case, the plotting
resolutionwillalwaysberecalculatedfromthisexportfileresolution.

5.4 Loadbitmapfile(.fpf)generatedinprogramGerb2bmpintoprogramRun_photo_USBbycommand
FileOpen.Selectedfileisshowninpreviewwindow,displaystheoverallimagedimension(notethat
displayedimagedimensionis10mmlargeronallsides)andanyusernotecreatedwhenbitmapfilewas
createdinGerb2Bitmapprogram.ItisalsopossibletoloadhiresBMPfilebyselectingthisBMPtypeof
fileinsteadofPhotoplotterBitmap(FPF),butwithoutpreview,usernotesandoverallimagedimensions
donotforgettospecifyBMPresolutioninInputresolutionfield.
Loadedfilewillbedisplayed,unlessthefileisbiggerthan14MB.Note,thatimageaxisXwillbecome
axisYonthefilmonphotoplotterdrum,whileimageaxisYwillbethehorizontalaxisofthefilmin
photoplotter.ClickonbuttonRunphotoplotterandspecifydesiredresolutionoftheplot.Ifneeded,you
canspecifyNegativeor/andMirroredimagetobeplotted.ClickonPlotbuttonstartsplotting.

Whenphotoplotterstartstorun,itneedssometimetospeedupthedrumrotation.Afterdrumreacheshis
workingrevolution,itrotates30timestomakesure,therotationisstabilized.Afterthatplotterstartstoplot
andindicatestimeleftforplotting.ThefrontpanellightlabelledLaserlightstoindicateplottinginprogress.
Whenplottingisfinishedorinterrupted(STOPbutton),laserheadwillreturntotheinitialpositionanddrum
willstop.Donotstartplottingagain,unlesslaserheadhasreturnedtoitsinitialposition.

6.Howtomaketestfilms
Occasionally,itisneededtomaketestfilms,justtofindoutproperworkingconditionslikelightintensityor
plotaccuracy.

Tomaketestfilmtofindoutproperlightintensity
Usestripoffilm,approx.100mmwideand300mmlongandtapeittothedrum(longersideover
drum).
UsecommandToolsPlotLightBar,whereyousetparameterslikeinitiallightintensity,automatic
lightintensityincrementandnumberoftestimages.ClickOKandplotwillstart.Asaresulttherewill
beanumberofsmallimagesautomaticallygeneratedbysoftwarewhichwereplottedwithlight
intensitystartingfromtheinitialoneandincreasingwitheveryimage.Nowitiseasytocompare
imagesanddefinethebestone,whereblackareaiscompletelyblack,butverythinlinesarestill
cleanandsharp,withoutgreysurroundings(overexposed).Makeonemoretestifnecessary.Enter
valueoflightintensityofthebestimageforgivenoutputresolutionintolighttableunderLight.

Tomaketestfilmtocheckplotaccuracy:

UseSetupGenerateTestGridPlotfeature.Thiswillgeneraterasterplotinshapeof10mmlinegrid
ofspecifieddimensions(drumcircumferenceandaxisdirection)anddefinedlinethickness.Specify,if
youwanttoincludeparametersfromSetupTable(theywillbeplottedinsmallsizeatthebottomof
thefilm).Plottwotestfilmstheyshouldbesamewhenyoumountthemtogether.Rotateoneof
them90degrees,fliponeofthemhorizontallyorvertically,theyshouldbesame.

Whattodoifplotisnotaccurate:

a) ifoveralldimensionindrumcircumferencedirectioniswronglinearly(alloralmostallgridsinthis
directionarelittlebitsmallerorbigger),changeDrumDiameterinRun_photo_USBprogramunder
SetupSetupTable.Ifdimensionissmaller,decreasediametervalue,ifdimensionisbigger,increase
drumdiameter.Toestimatecorrectdrumdiameterusethefollowingformula:multiplycurrentdrum
diameterwithratioofmeasureddistanceon300mmand300(oranyotherdistance).Forexample,
measureddistanceindrumcircumferenceon300mmgridis300.1,whilecurrentdrumdiameteris
157.45.Newdrumdiameterwillbe300.1/300multipliedby157.45=157.50Pleasenotethatthisdrum
diameterisnotrealdrumdiameter,butlittlebitbigger,dependingonfilmsize.
b) Ifoveralldimensionindrumaxisdirectioniswronglinearly,changeScrewErrorvalueinSetupTable.
Thevaluerepresentsanerrorindimensionfor300mmmeasuredfrom0indrumaxisdirection.For
examplevalue0.05meansthatoveralldimensionis0.05mmshorterfor300mm(measureddimension
for300mmis299.95).
c) Ifthereareerrorsonlyincertainareasalongthedrumcircumferencedirection,entermeasured
differencesinDrumLinearitytableforeveryparticulargridwhereerrorappears.
d) Ifthereareerrorsonlyincertainareasalongthedrumaxis(screw)direction,entermeasured
differencesinScrewLinearitytableforeveryparticulargridwhereerrorappears.
e) Iflinesdrawnhorizontally(indrumaxisdirection)arenotperpendiculartolinesinverticaldirection
(drumcircumferencedirection),measurethedifferencebetweenidealhorizontallineanddrawn
horizontallineat300mmdistancefrom0andenterthisvalueasAngleError.

7. PhotoplotterMaintenance
Therearenoserviceablepartsinsidephotoplotter.Keepdrumcleanandprotectinnerspaceoftheplotter
from falling objects. Keep the lid closed at all times except loading and unloading film. Use basic cleaning
chemicalsandsoftclothtocleandrumsurfacefromstickyareasleftbehindbymaskingtape.

Note: If you need to open the plotter, remove all screws and carefully lift the upper part of the case just
abovetheplotterandmoveitbackwardstherearewiresbetweenthisuppercaseandthebottompartof
theplotter.

Photoplottershouldbekeptindryplaceatroomtemperature(around20degreesCelsius).

Note:Donotrotatedrumbyhandfast,asattachedsteppermotorgeneratesthenpowerthatcandamage
photoplotterelectroniccircuitry.

MAIN SWITCH
POWER 24V / 2.5A DC
DRUM MOTOR
SCREW MOTOR

LASER (PANEL LED)

SCREW
MICROSWITCH LASER
(LASER HEAD)

PHOTOPLOTTER 8000 DPI

PCB TERMINALS -CABLE BLOCK DIAGRAM

FP8000 & FP8000XL Photoplotter Insts(0611)

BACK VIEW
Product Serial Number
Main Switch

TOP VIEW (WITH LID OPEN)

Auto/ Manual Switch

Power
Laser

Main Switch

MegaElectronicsLtd.,
MegaHouse,GripIndustrialEstate,Linton,Cambridge,UnitedKingdom.CB214XN
Telephone:+44(0)1223893900
Fax:+44(0)1223893894
Email:sales@megauk.com

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