Complete PCB Design

Department of Engineering & Physics University of Central Oklahoma

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Complete

PCB Design Using

NI Multisim, NI Ultiboard,

LPKF CircuitCAM and BoardMaster

Wei Siang Pee


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Introduction

Multisim equips educators, students, and professionals with the tools to analyze circuit

behavior. The intuitive and easy-to-use software platform combines schematic capture and

industry-standard SPICE simulation into a single integrated environment. Multisim abstracts the

complexities and difficulties of traditional syntax-based simulation, so you no longer need to be

an expert in SPICE to simulate and analyze circuits.

Ultiboard provides an easy and intuitive platform to design printed circuit boards

(PCBs). The flexible Ultiboard design environment offers automated functionality for speed and

manual techniques for precise control. With complete integration to NI Multisim, Ultiboard helps

you optimize PCB design. Quickly prototype whether for professional designs or academic

research.

CircuitCAM is a combined Computer Aided Design(CAD) and Computer Aided

Manufacturing (CAM) program. You can use CircuitCAM to import, check and edit circuit

board production data in various CAM formats, and then output them into a LMD format.

CircuitCAM is particularly useful for calculating the insulations channels between the conductor

tracks in circuit board prototype production using LPKF circuit board plotters.

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.

LPKF Protomat S100 is one of LPKF's top-of-the-line rapid circuit board plotters, ideal

for all in-house prototyping applications, including multilayer and RF applications. The S100

features the highest spindle speed possible -- resulting in the precision circuit geometries today's

high-frequency and microwave applications demand -- and a pneumatic working depth limiter,

for the most surface-sensitive substrates.

PCB process & Recommended Experience Level

Multisim

Ultiboard CircuitCAM BoardMaster

Intermediate

level

Novice level Novice level Novice level


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Exercise 1 – Introduction to Multisim

In this exercise, you will design a circuit shown below.


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1. Creating a Custom Component in NI Multisim. LM2937ET_3.3_ND is a custom

component and you will create your custom component in Multisim for Printed Circuit Board

(PCB) layout. Select [Tools]>>[Component Wizard] from the Multisim menu. From this

windows , enter your component information. Select layout only (footprint), and choose

[Next>] when you done.

2. Click [Select a Footprint] to choose a footprint for LM2937ET_3.3_ND component. Choose

[Next>] when done.


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3. Select [ANSI] symbol set, and click [Copy from DB]. Choose LM7805CT’s symbol for

LM2937ET_3.3_ND component. Click [OK] and choose [Next>] when done.


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4. Set pin parameters for your component. Click [next>] when done.

5. Set mapping information between symbol and layout footprint. Click [next>] when done.


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6. Select the simulation model. Click [Finish] when done.


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ERC Rules Check

Remember to exclude green color components before you run the Electrical Rules Check.

1. Double-click on the desired component to display its properties dialog box. Example:

LM2937ET.


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2. Click on the [Pins] tab. Select [exclude] for each of the component’s pins.

3. Click [OK] to close dialog box. Select [Tools] >> [Electrical Rules Check] to display

Electrical Rules check Dialog box and click [OK] to close dialog box again. You will see

ERC results in the Results tab of Spreadsheet View.


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Transferring from Multisim to Ultiboard

1. Select [Transfer] / [Transfer to Ultiboard 10]. A standard Windows Save As dialog box

appears. Specify the name and location of the files to be created and click [Save]. Multisim

creates files that can then be loaded into Ultiboard.

2. Enter the desired parameters and click [OK].


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Caution:

Comparison between

Green color component ?

Ans: Layout only

vs

Blue color component ?

Ans: Layout and Simulation only

vs

Black color component ?

Ans: Virtual component. No Layout and simulation


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How to modify black color components?

1. Remember to edit black color components. Avoid virtual component in the circuit design.

Double-click on the desired component to display its properties dialog box. Example: 1uF.

Click on the [Edit Footprint].


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2. Select the footprint [CAPPR1000 – 2200X2500], and click [Select].

3. You will see Footprint: CAPPR1000-2200x2500 and Manufacturer: IPC-221A/2222 in the

Layout Settings. Click [OK] to close dialog box.


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Exercise 2 - Introduction to Ultiboard

1. The following dialog should appear after select [Transfer] / [Transfer to Ultiboard 10].

Change the width to 30 mils, and the clearance to 30 mils. Click [OK] to close dialog box.

2. Make sure all fields are selected in Import Netlist Action selection and click [OK].


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3. A board outline (a yellow rectangular) is placed on the workplace with the components

(above the board outline) ready to be placed.

4. Accessing layers. Click [Layers] in the design toolbox to display Layers tab. The layer

highlighted in red is the active layer. To active the Board Outline layer, double click the

Board Outline layer in the Design Toolbox.


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5. The Board outline will be highlighted in red:

6. Working with the Board Outline. Right-click the edge of yellow rectangle and select

Properties from the menu. This launch a Rectangular Properties dialog.


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7. Under the rectangular tab, set the Units to mm, the Width to 160 and the Height to 50. Click

OK to close the dialog box and the board outline becomes much smaller.


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8. Select the components and drag them until they are above the board outline.


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9. Ultiboard Configuration. Select [Options] >> [Global Preferences], and then select the

General Settings tab. Make sure it matches below settings.


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10. Select PCB Design tab and make sure you choose Auto trace narrowing and Auto add

teardrop. Click OK to close the dialog box.


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11. Select [Options] >> [PCB Properties], and then go to Copper Layers tab. Change Board

thickness to 59.00 mil. *Refer to LPKF’s PCB board.


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12. Next, go to the Pad/Vias tab, and modify the settings as shown.

How to calculate annular ring?

For example, a 50 mil drill hole (radius of 25 mils) with a relative value of .6 (60%) will

create an annular ring of 15 mils (60% of 25 mils).


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13. Go to Design Rules tab, and the “Use multiple clearances” checkbox must be selected.

Otherwise, only clearance to traces will be operational. Set the “Clearance to Traces”

parameter to 40.000000 mils; “Clearance to Pads”, “Clearances to Vias” and Clearance to”

Copper Areas” parameters to 32.000000 mils. Click OK to close dialog box.


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14. Power and Ground Planes. Select [Place] >> [Powerplane]. Select net 0 for Copper Bottom

Layer. Click [OK] to close the dialog box. The bottom layer fills in red color plane.


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15. The next step of PCB design is layout the components. Place the components inside the

yellow triangle. It takes practice to make perfect PCB boards. The green lines represent

copper trace on the top layer of the board.

3D View

16. Once you are satisfied with your PCB design, remember to save the design.


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Making a PCB using ProtoMat S100

First, you create your circuit design in Multisim and then you import it into Ultiboard for PCB

layout. After you complete the PCB layout, you will use CircuitCam 6.0 to import your

Ultiboard Gerber file to create a production layout file. At last, you use Board Master to run

ProtoMat S100 to fabricate your PCB.

1. Exporting from Ultiboard. Select [File]>> [Export], and then go to select Gerber RS-274X.

After that, Click “Properties”.


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2. You will see Gerber properties dialog box. Transfer Board Outline, Copper Top, Copper

Bottom, and Drill to the Export Layers by using arrow . Click [OK] to close the dialog

box.


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3. Click Export in the Export dialog box. Click [OK] to close Create aperture mapping – Board

Outline dialog box. Choose a save location for your file and click Save.

4. Click [OK] to close Create aperture mapping – Copper Bottom dialog box. Choose a save

location for your file and click Save.


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5. Click [OK] to close Create aperture mapping – Copper Top dialog box. Choose a save

location for your file and click Save.

6. Click [OK] to close Create aperture mapping – Drill-Copper Top-Copper Bottom dialog box.

Choose a save location for your file and click Save.


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Exercise 3 – Introduction to CircuitCAM

1. Importing to Circuit Cam 6.0. Open CircuitCam by double click to the icon on

the desktop. Click on the import button to import a new data file. You need to import

four (Gerber RS-274X form) data files: Board Outline, Copper Top, Copper Bottom, and

Drill. After select the four data files, you will see an import dialogue box.

\


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2. Choose the layer type for each file in the import dialog box. For instance, your board outlines

BoardOutline. Click [OK] to close the dialog box, and your PCB board should appear.

Remove any extra parts that you do not want in your finished PCB.


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3. Contour Routing. Click to contour routing button. This section defines the board

outlines to cut. Use the following settings: Select outside; Source – BoardOutline layer;

CuttingOutside Destination Layer; Used tool – LpkfCutting Tools List , Contour Router

2.0mm (79mil) Tool; Breakout – 4 edges, 1 mm Tab width. Unselect Make dills on layer.


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4. Click [OK] to close the dialog box, and you will see a wide yellow board outlines with four

breakout tabs.

5. Create Insulation. You need to select the insulated all layers button to create space

between traces and the copper on the PCB.

6. Rubout area. A rubout area is a zone in which all the residue copper between the conductor

tracks and the pads is removed from the circuit board. Click Rubout Top layer, and then

use the cursor to create a rectangle around area you desire.

Purple color line is the Rubout

top color.


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7. Remove your Ultiboard Outline. Click a Green check next to the BoardOutline.

8. Save your current file, and name your file. Click Export LPKFCircuitBoardPlotter, and

it will export your file as a LMD file. Click [OK] to close CircuitCam dialog box.


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Exercise 4 – Introduction to BoardMaster

1. BoardMaster will use the LMD file in CircuitCAM to create your PCB by using LPKF

ProtoMat S100 milling machine. Switch on the S100 milling machine. The S100’s switch is

located on the front, right side of the machine.


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2. Open BoardMaster by double click to the BoardMaster 5.0 icon on the desktop.

Click [OK] to the Tool Status dialog box.

3. Click [File] >> [New] and then select 1-2layer.phs.


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4. Placing the copper board. Click the pause button to move S100’s drill head to pause

position, and then you can access the top of the milling machine to place the copper board.

Place the copper board over a white underlay material, and press it firmly onto the set pins.

Place the oval hole over the right pin.

5. Defining the work area. You have to define the front left and then the back right corner

points for the work area.

Front Left. Click on the Move with mouse button. Drag the mouse pointer to the front

left corner point of the desired work area. In the main menu, click [Configuration] >>

[Material] >> [Set Low Corner].

Back Right. Click on the Move with mouse button. Drag the mouse pointer to the

back right corner point of the desired work area. In the main menu, click [Configuration] >>

[Material] >> [Set High Corner].

Pause Position


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6. Reviewing the material size and position. Click [Configuration] >> [Material] >> [Size…].

The material thickness should be 1.6mm and the free drive lever 3mm.


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7. Importing into BoardMaster. Click [File] >> [Import] >> [LMD\LPR…]. Navigate to the

file you exported from CircuitCAM. Select your LMD file and click [Open].

If you want to move the project on the base material, click Shift button. Select and

hold your project and move it to a desired area.

Do not place your project over either of the two set pins.

Do not place your project outside of the boundaries.

8. Saving the current setting in a file. Click Save button.


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9. Placement and Assignment of the tools in the Toolbox. Click Toolbox button and

select [Yes] when asked to send the drill head to the PAUSE position. You will see the Tool

Positions dialog box.

Use the drop down boxes to select the wanted tools for the job. The wanted tools are listed in

the window on the right. Select Stop at tool exchange.


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10. Loading the tool magazine. As each tool has been inserted into the magazine, choose the

same tool from the respective drop-down box in BoardMaster. Make sure each tool is firmly

seated into the socket. Numbering is left to right 1,2,3,4,5,6,7,8,9,10 in the milling machine.


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11. Adjusting the milling depth of the Tool. You will likely have the missing pads and traces

if the milling machine drills too deep or too shallow. You have to verify the milling depth

before start a production run. Select the tool Universal Cutter 0.2mm (8 mil). The milling

machine will automatically retrieve the tool.

12. Click the Move with mouse button and move the drill head to an unused position of the

work surface. Click the Motor button to switch on the motor. Lower the drill head

and trace a 10mm sample line in the -Y direction. Raise the drill head ,

and then click the Motor button to switch off the motor. Click Pause button, it

will move the drill head to pause position.


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13. Examining the sample line by using Microscope with a scale of 0.001 inches. The width

must be exactly 0.2mm (8 mil). You can adjust the milling depth by using knurled wheel if

necessary. When you turn the knurled wheel, you will feel it click. For S100, 6 clicks = 1 mil

(0.0254mm). Adjust the wheel clockwise to lower the drill head, which creates a slightly

wider channel. Adjust the wheel counter clockwise to raise the cutting head and create

narrower channel. Mill a new sample and measure again until the channel is exactly 0.2mm

(8 mil) wide.


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14. Starting production phases.

a. Marking Drills. Click the All+ button to select all of your design and then click

the Start button to begin the marking drills phase. The S100 begins the process and

notifies you when completed.

b. Drilling Plated. Click the All+ button to select all of your design and then click

the Start button to begin the drilling plated phase. The S100 begins the process and


c. Milling Bottom. Click the All+ button to select all of your design and then click

the Start button to begin the Milling Bottom phase. The S100 begins the process

and notifies you when completed.

d. The first side of the PCB is finished after the Milling Bottom phase is completed. Click

Pause button because you need to send the drilling head to Pause position, and

clear the work space. Flip the copper board and reset it against the work space.


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e. Milling Top. Click the All+ button to select all of your design and then click the

Start button to begin the Milling Top phase. The S100 begins the process and


f. Cutting Outside. Cutting Outside is the last production phase and it separates the

working PCB from the working material. Click the All+ button to select all of

your design and then click the Start button to begin the Cutting Outside phase. The

S100 begins the process and notifies you when completed.

g. Click Pause button, it will send the drill head to the pause position.

h. Remove the copper board from the milling machine and close the BoardMaster.

i. Click [OK] when you get the message”Machine’s head will move to reference point

when you press the button!”


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15. Clean up the work area before you leave.

a. Close the Plexiglas doors of the LPKF circuit board plotter box.

b. Clean up any dust, debris, or board scraps.

c. Switch off the milling machine.

d. Log off the PC.

Top PCB


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Bottom PCB

- END -

Complete PCB Design

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