Layout

Power Supply

Nate Moehring

Perspective

OrCAD Capture
OrCAD Layout Gerber Files LPKF CircuitCAM LPKF BoardMaker Pro

Complete Schematic
Only libraries from the Capture\PSPICE folder
can be simulated. To find the fuses, switches, and potentiometers, add the discrete library from the Capture folder. Document electrolytic capacitor orientation. Regulator package TO-220, Regulator library in Capture folder.

Complete Schematic

Export to Layout
Click on project
browser With Schematic selected in the browser, select Tools >> Create Netlist from the Menu bar.

Export to Layout
In Layout tab, check Run ECO to Layout

Export to Layout
Start Layout File >> New, select Default.tch (new
project with default attributes) Then open the netlist file <projectname>.mnl created by the Capture export we just did. Save as Layout project <projectname>.max

Selecting footprints

Axial/.300LX.100W/.031 lead diameter

Selecting footprints

Professional version has more detail

Selecting footprints
Pots will be mounted on the box, not on the
board, so footprint selection is not important. I prefer VRES >> VRES13. We are using regulators with the standard form factor of TO-220, mounted vertically. Professional version has TO-220 library. Vertical
mount is TO-220AB If using student version, any 3 leg footprint with proper dimensions will work, such as using a VRES footprint.

Selecting footprints
Switch, fuse, and LED are mounted on the box,
so footprint is not important. Other regulators are same form factors, but different pin outs! Double check their traces. Modify selections for large capacitors. Create footprint for transformer.

Position components on board

Double check space needed by components
(especially heatsinks). Double check all pin outs. Add vias for input, transformer, and output power connections.

Mounting Holes?
Plan where you would like to position the
PCB and transformer in the project box to determine if it is possible to drill a whole through the PCB at design time (in Layout) so it will easily and securely attach to the box. Do this using a large via or custom footprint. (screws will need to be provided by the student)

Tool Tutorial
Every operation has a
different tool in Layout. Each tool has different modes. To remove a track, select the tool component from the toolbar or menu. You must then place the tool into the Select, Add, or Delete mode from the menu or by right clicking.

Tool Tutorial
You must use the
Component tool to move, add, or delete components. Use the Measure tool to find the dimensions of your board or a component. Must use the <tooltype> tool to move, add, or delete <tooltype>.

Creating a new footprint

Open the library manager Create
New Footprint

Use Pin tool

to add, delete, and move pin connections. Use text tool to add, delete, and move text labels.

Connection Points
Using component tool, select a via to use as
an empty whole to connect items off of the board (ie, transformer, fuse, etc) Once placed, must use via tool to move and delete. (Can also use via tool to create, but then it tries to associate the via to a net.)

Capacitor Footprint
2200uF, 50V, electrolytic, radial (cylindrical):
16mmx31mm (from datasheet) (lead spacing/lead diameter?) 1inch = 1000mils 1mil/.001inch * 1inch/2.54cm * 1cm/10mm = 39.37mils/mm Xmm = .0254mm * Y mils Ymils = Xmm/.0254mm

Capacitor Footprint

Cylinder/Diameter/Lead Spacing/Lead Diameter

Disable Unused Layers

Were constructing a single layer board, but
CircuitCAM must have top and bottom layers in project. Disable layers for Gerber export in Options >> Post Process Settings >> Uncheck Enable for Post Processing for all layers except .top and .bot, device as Extended Gerber. Disable all routing layers except Bottom for trace routing in Tool >> Layer >> Select from Spreadsheet >> Select Unused Routing (Drill layer must be enabled)

Global Spacing (for Routing)

Increasing Pad width

Tool >> Padstack >> Select From Spreadsheet Change Bottom and Drill Width for each
components unique pin style. Make sure to not make pads and holes so big that they overlap! Diameter of AWG18 wire is 40mils. Recommend 32mils of copper around whole. Typical padstack size: 72mils

Potential Padstack sizes

Component Power cord Transformer TO-220 Regulators Capacitors Pots, LED, fuse, switch, 18AWG wires Bottom 200 150 74 74 74 Drill 120 50 42 40 42

1/4W Resistors D0-41 Diodes

66 74

34 42

These sizes are not guaranteed. It is up to the student to determine the best size holes and pads for their project. It is better to err on the size of too large rather than too small.

Changing trace width

(as shared by Nicholas Ange)

Tool >> Net

>> Select From Spreadsheet Double click on the Width column header Set all values to desired width

AutoRoute Board/DRC
Make sure overall board size is <= 8in2 Options >> Global Spacing
Because were going to use thick traces (for higher
current), and because this is a simple board and space is not a concern, were going to space everything by 32 mils.

Auto >> Autoroute board/DRC

Changing trace width

(post-autoroute method)

Tool >> Track >> Select Tool Place cursor over desired trace, but do not click!
Push w on the keyboard. Select Net, and set width to 32 mils. Trace width calculator:
http://www.geocities.com/CapeCanaveral/Lab/9643/TraceWidth.htm

Improving Traces
As a general rule:
Use the Track tool to make changes to an entire net. Use the Track Segment tool to modify just a single
stretch of a trace.
To draw a new trace, you must first use the Connection Tool
to connect from here to there, then click on the connection line using the track or track segment tool to draw the trace. Track tool will do a little more work for you when drawing new traces.

Avoid:
90o angles in your traces. Unnecessarily complex (unintelligent) traces Keep digital and analog traces separated.

Adding a Border
Tool >> Obstacle >> New Draw a shape outlining your board (typically a
box). Select the obstacle >> right click >> Properties Change the obstacle type to Free Track on Bottom layer. CircuitCAM will use this to determine where to cut out the board from the rest of the copper. (contour routing)

Adding Text
Write your name on the board using the text tool.

Final Product

Gerber Preferences

Final Gerber Export

(as recommended by LPKF)

Copy ORCAD2CCAM.PPS to your project

directory. Options >> Post Process Settings Right Click >> Load Post Processing Setup Load ORCAD2CCAM.PPS Right Click >> Run Batch to generate necessary gerber files.

Final Gerber Export

(as recommended by Sara Barnard)

Double check Gerber Settings. Setup top and bottom layers for export in Post
Processor Settings, with device as Extended Gerber. Auto >> Run Post Processor Email to me <projectname>.top, <projectname>.bot, and thruhole.tap in <yourname>.zip by 11:59pm Thursday.