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Drill File Missing Holes Because Generates into Multiple Files

alintz

Six layer board has 5 hole sizes. Drill chart generates correctly. NC Drill file only shows largest 3 holes. ncdrill.log shows that 3 seperate drill files files were sequentially generated all with the same name, so only the last one is viewable.  I can see one previous backup with only the T02 size hole.

PCB Editor 17.2

Here is the ncdrill.log:

(---------------------------------------------------------------------)
(                                                                     )
(    NC DRILL Log                                                     )
(                                                                     )
(    Drawing          : PC150-1 R1.brd                                )
(    Software Version : 17.2S031                                      )
(    Date/Time        : Sat May 23 05:23:11 2020                      )
(                                                                     )
(---------------------------------------------------------------------)
 Processing NC Parameters file 'nc_param.txt' ...
 NC PARAMETERS
 -------------
 FORMAT           3.4
 MACHINE-OFFSET        x:0.00000    y:0.00000   (mm)
 FEEDRATE        1
 COORDINATES        ABSOLUTE
 OUTPUT-UNITS        METRIC
 TOOL-ORDER        INCREASING
 REPEAT-CODES        YES
 SUPPRESS-LEAD-ZEROES    YES
 SUPPRESS-TRAIL-ZEROES    NO
 SUPPRESS-EQUAL        NO
 TOOL-SELECT        YES
 HEADER            none
 LEADER            12
 CODE            ASCII
 SEPARATE        NO
 SEPARATE-ROUTING    NO
 OPTIMIZE_DRILLING    YES
 ENHANCED_EXCELLON    YES
 SCALE            1.000000

 WARNING(SPMHMF-368): Cannot find NC Drill tool file 'nc_tools.txt'
 WARNING(SPMHMF-369): ... will auto-generate tool file 'nc_tools_auto.txt'.

     Auto-generating tool file 'nc_tools_auto.txt' ...
           Size  Plating  Tool        + Tolerance  - Tolerance
          0.320  P        T01            0.000000     0.000000
          0.800  P        T02            0.000000     0.000000
          1.070  P        T03            0.000000     0.000000
          3.000  P        T04            0.000000     0.000000
         10.100  N        T05            0.000000     0.000000

Drill files being output to directory 'R:/Projects/CIRAS-4/PLC/PC150-1 R1,R1' ...
     'PC150-1 R1-1-6.drl' created for holes connecting TOP and BOTTOM
     ----------------------------------------------------------------
     Tool  Num     Size      +/- Tolerance     Plating   Quantity
     T01    1.   0.3200    0.0000/  0.0000      PLATED        124
     ---- Total holes:                                        124
     ---- Total head travel:              1.57 feet (0.48 meters)

     'PC150-1 R1-1-6.drl' created for holes connecting TOP and BOTTOM
     ----------------------------------------------------------------
     Tool  Num     Size      +/- Tolerance     Plating   Quantity
     T02    1.   0.8000    0.0000/  0.0000      PLATED         12
     ---- Total holes:                                         12
     ---- Total head travel:              0.25 feet (0.08 meters)

     'PC150-1 R1-1-6.drl' created for holes connecting TOP and BOTTOM
     ----------------------------------------------------------------
     Tool  Num     Size      +/- Tolerance     Plating   Quantity

     T03    1.   1.0700    0.0000/  0.0000      PLATED         18
     T04    2.   3.0000    0.0000/  0.0000      PLATED          4
     T05    3.  10.1000    0.0000/  0.0000  NON_PLATED          1
     ---- Total holes:                                         23
     ---- Total head travel:              1.26 feet (0.38 meters)

Here is the drill file that is generated showing 5 hole sizes in the initial list, but coordinates only for T03, T04 and T05:

M48
METRIC,TZ
T01C.32
T02C.8
T03C1.07
T04C3.
T05C10.1
;LEADER: 12
;HEADER:
;CODE  : ASCII
;FILE  : PC150-1 R1-1-6.drl for board R:/Projects/CIRAS-4/PLC/PC150-1 R1,R1/#Taaaaac01668.tmp ... layers TOP and BOTTOM
;T03 Holesize 1. = 1.070000 Tolerance = +0.000000/-0.000000 PLATED MM Quantity = 18
;T04 Holesize 2. = 3.000000 Tolerance = +0.000000/-0.000000 PLATED MM Quantity = 4
;T05 Holesize 3. = 10.100000 Tolerance = +0.000000/-0.000000 NON_PLATED MM Quantity = 1
%
G90
T03
X269600Y45000
X295000Y45000
X40000Y196900
R03Y25400
X490000Y348000
R05Y25400
X440000Y540000
R03X-25400
X142700Y530000
X117300Y530000
T04
X35000Y35000
X485000Y35000
X485000Y535000
X35000Y535000
T05
X150000Y285000
M30

  • alintz

    I fixed the problem, but I don't know why.

    In PCB Editor, I replaced the padstack for TO2 (0.8 mm) with another known good padstack, and the problem still occurred. So, I replaced the 0.8 mm holes back to the original padstack, and the problem went away. Now a single drill file is produced with all 5 hole sized properly numerated.

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