LPKF ProtoMat 93s User manual

ProtoMat 93s
(June 95)
Manual
English version
LPKF Laser & Electronics AG
All rights reserved
PM93s-E(.DOC)
LPKF Laser & Electronics AG
Osteriede 7
30827 Garbsen / Germany
Tel.: ++49-5131-7095-0
Fax: ++49-5131-7095-90

LPKF ProtoMat 93s Manual
2
LPKF ProtoMat is a registered trademark of LPKF Laser & Electronics AG.
MS-DOS and Windows are registered trademarks of Microsoft Corporation.
HP-GL is registered trademark of the Hewlett Packard Corporation.
All other trademarks registered for the corresponding owners.

LPKF ProtoMat 93s Manual
3
1 Introduction......................................................................................................5
1.1 Characteristics of the LPKF ProtoMat 93s.........................................5
2 General Information.........................................................................................6
2.1 Scope of supply.................................................................................6
2.2 Optional accessories .........................................................................6
2.3 Safety precautions.............................................................................7
2.4 Air-borne sound.................................................................................7
2.5 Installation..........................................................................................8
2.6 Machine orientation ...........................................................................10
2.7 LPKF ProtoMat 93s displays and connections ..................................11
2.8 Use of BoardMaster...........................................................................13
3 Setup...............................................................................................................13
3.1 Before switching on ...........................................................................13
3.2 Turning the system on.......................................................................13
3.3 Switch-on instructions for high-speed spindles..................................14
3.4 After switching on ..............................................................................15
3.5 Function test with BoardMaster .........................................................15
3.6 HOME-Position and two-pin system..................................................16
3.7 Programming the HOME position in BoardMaster.............................17
3.8 Making a new two-pin system............................................................18
3.9 Checking and correcting the HOME position.....................................20
4 The LPKF ProtoMat 93s operating displays....................................................20
5 Computer-controlled functions of the LPKF ProtoMat 93s..............................21
5.1 Connection to a PC............................................................................21
5.2 The LPKF ProtoMat 93s Commands.................................................22
5.2.1 Command structure..............................................................22
5.2.2 HP-GL standard commands.................................................22
5.2.3 Special commands...............................................................24
5.2.4 Special command for the high-speed spindle ......................28
5.2.5 Direct commands.................................................................28
5.3 Producing a PCB with BoardMaster ..................................................29
6 Tools and accessories.....................................................................................31
6.1 Tools..................................................................................................31
6.2 Pen holder (optional) .........................................................................32
6.3 Materials used for machining.............................................................33
7 Milling and drilling with the LPKF ProtoMat 93s..............................................34
7.1 Securing the PCB on the machine bed..............................................34
7.2 The mechanical working depth limiter................................................35
7.3 Functional elements on the mill/drill head..........................................37
7.4 Drilling................................................................................................39
7.5 Isolation milling..................................................................................39
7.6 Contour milling in PCB material.........................................................41
7.7 Milling wide isolation channels...........................................................42
7.8 Front plate engraving.........................................................................42
7.9 Milling layout films..............................................................................43
7.9.1 Correction agents.................................................................43
7.9.2 Coloring milled films.............................................................44
7.9.3 Coating removal...................................................................44
7.10 Basis material..................................................................................45

LPKF ProtoMat 93s Manual
4
7.11 Cleaning the PCB ............................................................................46
7.12 Practical tips ....................................................................................47
8 Appendix .........................................................................................................49
8.1 Maintenance......................................................................................49
8.2 Serial port SERIAL 1..........................................................................50
8.3 Serial port SERIAL 2..........................................................................51
8.4 Motor connection...............................................................................52
8.5 Mill head connection..........................................................................52
8.6 EPROMs............................................................................................52
8.7 Fuses, commuting the device voltage................................................53
8.8 Inventory of available tools ................................................................56
8.9 Spare parts for the LPKF ProtoMat 93s.............................................58
8.10 Concluding remarks.........................................................................59
9 Index................................................................................................................60
10 Declaration of conformity for LPKF ProtoMat 93s.........................................62

LPKF ProtoMat 93s Manual
5
1 Introduction
The LPKF ProtoMat 93s mill/drill unit is a circuit board plotter which can be used
to produce prototype PCBs and gravure films, and for engraving aluminum or
plastic.
Familiarity with the BoardMaster driver program of the LPKF ProtoMat 93s is
essential for operation of the machine. Operation of the LPKF ProtoMat 93s with
the LPKF93s.EXE machine driver is described in the LPKF ProtoMat 93s Driver
Manual. The LPKF ProtoMat 93s is controlled from the serial port of a PC.
In order to make any guarantee claims, if necessary, it is absolutely vital to follow
the instructions of this manual before putting the machine into operation. For
machines exported to other countries of the European Community the guarantee
conditions of the corresponding country apply.
1.1 Characteristics of the LPKF ProtoMat 93s
Voltage: 200-240V (or 100-120V)
Power consumption 200VA
Speed of high-speed spindle max. Approximately 60000/min
Weight ca. 40kg (88 Pounds)
Drilling performance: max. 60 strokes/min
Resolution (smallest step): 0.0079375mm (0.0003125 Inch)
Operating data:
Humidity: 60% max.
Temperature: 15-250C (59o-77o)

LPKF ProtoMat 93s Manual
6
2 General Information
2.1 Scope of supply
1. 1 LPKF ProtoMat 93s machine unit with integrated electronics
2. 1 null modem cable (LPKF ProtoMat 93s control unit-computer), AT-Adapter
9/25-pol
3. 1 set of accessories (Drafting Tape, Allen wrenches, alignment pins, tweezers,
brush, 7 mm wrench, 2 red two-pin strips)
4. 1 power cable
5. This manual
2.2 Optional accessories
The following accessories can be supplied for the LPKF ProtoMat 93s:
1. Vacuum system with fine filter (2 micron or better). The fine filter is essential
when handling materials containing glass fiber such as for FR4 base material.
2. Machine table
3. Noise and dust guard hood
4. Pen holder
5. Solder and plated through hole dispenser unit LPKF DispoMat

LPKF ProtoMat 93s Manual
7
2.3 Safety precautions
• In order to be able to guarantee the safe operation of the system the user
must have read this manual and especially the safety precautions printed
in bold types!
• Never reach into the machine while it is running!
• Remember that the machine changes speed automatically during the
process!
• Only change the tool when the mill/drill motor is not spinning!
• Insert the tool into the clamping device as far as it will go!
• Never operate the control PC simultaneously when working with the
device!
• Operator with longer hair must wear a hair net!
• If you modify the equipment yourself, the equipment's safety can no
longer be guaranteed and no guarantee claims can be accepted!
• Please take note that some materials may produce cancerogenous dust or
hazardous gases. Ask your supplier of the materials.
• Always work with the vacuum device!
• When using chemicals please take note of the safety notes on the
containers or separate security sheets delivered with them!
• Keep the workplace tidy.
2.4 Air-borne sound
The continuous sound level at the work place during operation is 71 dB (A).
This value does not include the vacuum unit.

LPKF ProtoMat 93s Manual
8
2.5 Installation
1. Unpack the LPKF ProtoMat 93s carefully (for detaching the security screws
see drawing on the next page). Then loosen the transport safety devices.
These devices are marked red and are located:
Locking of the X-axis - wood panel above the X motor (safety device 2)
Locking of the Y-axis - directly at the head to the left (safety device 3)
Locking of the Z-axis - Phillips screw ( safety device 4)
2. Important! The equipment must stand on a flat and firm base in order to
work properly!
3. Set up the circuit board plotter so that the connecting cables to the electronic
unit can move freely.
4. Connect the LPKF ProtoMat 93s to the computer with the null modem cable
supplied with the system (COM1 or COM2).
5. Connect the LPKF ProtoMat 93s control unit power cord.
6. Fit the Vacuum to the adapter (suitable for stay tube no. 111124 of a Nilfisk
industrial vacuum unit).

LPKF ProtoMat 93s Manual
9
1 324
Transport safety devices of the LPKF ProtoMat 93s
Description of the transport safety devices
1. Safety device 1 Attaching the machine safely to the transport support
2. Safety device 2 Securing the X-axis
3. Safety device 3 Securing the Y-axis
4. Safety device 4 Securing the mill/drill head
Keep all transport safety device and mount them accordingly if the machine is to
be shipped.

LPKF ProtoMat 93s Manual
10
2.6 Machine orientation
+ x
+ y
1
2
3
4
5
LPKF ProtoMat 93s: the x-axis is the longer direction of movement
CAUTION! Keep fingers and any other items out the area of movement!
Description of the main machine positions:
1. PAUSE position. The machine will move to this point to load or turn the
material to be machined.
2. HOME position. This is the relative 0.0 position and MUST lie on the machine
mirror (X) axis (two-pin system) and serves as the reference X=0,Y=0 position
for the machine driver (BoardMaster and LPKF ProtoMat 93s).
3. Two-pin slide with hole for alignment pin.
4. Reference pin for front two-pin strip.
5. Tool change position (absolute zero position). The tool is changed here.

LPKF ProtoMat 93s Manual
11
2.7 LPKF ProtoMat 93s displays and connections
Front LPKF ProtoMat 93s
11
POWER LPKF ProtoMat 93s
1
3
42
Description of the front panel:
1. Operating display of the integrated machine control SMCU
2. X motor
3. High-speed spindle motor
4. Working depth limiter

LPKF ProtoMat 93s Manual
12
IO
10 11
12
12345 67
8
9
12
8
13
Rear view of LPKF ProtoMat 93s
Description of the rear panel:
1. Vacuum connection
2. Output Serial interface (9-pole) for controlling optional equipment
3. Input Serial interface (25-pole) for connection to PC serial port
4. X motor connection
5. Y motor connection
6. Mill/Drill head connection
7. On/Off switch, power cord connector and fuses
8. X motor
9. Y motor
10. High-speed spindle motor
11. Y Axis solenoid
12. Working depth limiter
13. Spindle motor connection

LPKF ProtoMat 93s Manual
13
2.8 Use of BoardMaster
Data required to drive the plotters are generated in CircuitCAM and are stored in
files with HP-GL format or as LPKF binary files (LMD format). BoardMaster is
used for reading the files, decoding plot commands and modifying them for the
specific LPKF System being driven. The drivers use the HP-GL or LMD data and
add important, machine specific functions such as scaling, motor control, etc. The
LPKF ProtoMat 93s circuit board plotters respond to HP-GL commands. The
drivers provide additional capability such as step and repeat, move, rotate, etc.
All LPKF circuit board plotters are driven via an asynchronous interface (RS232C).
In the case of the LPKF ProtoMat 93s, it is operated at 9600 baud, 1 stop bit, 8
data bits, no parity and hardware handshake. The serial interface of the computer
must be configured using the DOS MODE commands in the case of the DOS
driver and using the Windows Main/Control Panel/Port setup facility in the case of
BoardMaster.
3 Setup
3.1 Before switching on
Be sure the voltage set at the machine corresponds with the line voltage: If not,
continue at chapter 8.7 Electrical Fuses, Setting the device voltage.
Before switching on, all items are to be removed from the machine and its range
of movement. Pilot pins must not project from the base material.
CAUTION! Never reach into the machine while it is running!
3.2 Turning the system on
The following switching on order is useful, but not essential:
1. Computer
2. LPKF ProtoMat 93s
3. Start the BoardMaster program

LPKF ProtoMat 93s Manual
14
If for some reason it should be necessary to switch the machine off and on again,
then change to the Machine/Settings window of the BoardMaster program and
click on OK. Thus all necessary initialization parameters like speed ranges, dwell
times positions and so on are again transmitted to the machine.
3.3 Switch-on instructions for high-speed spindles
A tool must always be placed in the shaft of the high-speed spindle when the
machine is switched on. The collet must always be closed and the knob of the
high-speed spindle must be in its top position, otherwise the spindle is blocked
and the motor driver can be overloaded.
Caution: The spindle can be damaged if it operated without a tool inserted!
123
4
5
ABC
Operating the collet of he high-speed spindle
A) Knob in normal position, spindle is running freely. Push the knob (1) down until
it is engaged in order to open or close the collet. Hold the head up to avoid
damaging the tool in the collet. . If necessary, turn the knob slightly to the right
or to the left (2) when pushing it down.
B) Caution: in this position collet and spindle are blocked and the drive electronics
may be damaged if the motor is turned on. In order to open the collet, turn the
knob counter-clockwise (3). To close, turn the knob clockwise (4). Do not turn
the knob too tightly.
C) Bring knob back to normal position (top) (5). The spindle can now run free
again.

LPKF ProtoMat 93s Manual
15
During set-up take note that the bearings of the high-speed spindle have to be run
in first after a longer period of standstill (several months) or after transport. During
initial set-up the spindle should run at 10 000 rpm for several hours.
Normal warm-up of 3 to 10 minutes (at 20 000 rpm) of the spindle is automatically
controlled by BoardMaster. The duration of this warm-up depends on the length of
time the system has been off. During warm-up no speeds exceeding 20,000 rpm
will be allowed. Programmed speed above 20,000RPM will be allowed after the
warm-up time.
3.4 After switching on
When it has been switched on, the equipment moves to limit switches -X and -Y,
and the system then halts in the tool change position. It is then able to accept
commands from the machine drivers. If the equipment does not move when it has
been switched on, check the following:
1. Is the POWER LED on (is on only after successful initialization) ?
2. Are all cables properly inserted ?
3. If necessary, check the fuses at the input power connection!
3.5 Function test with BoardMaster
CAUTION! Make sure that nothing is in the machine operating area when the
first functional test is taking place!
First check that the baud rate for the serial interface used is set to 9600 baud, 8
data bits, 1 stop bit, no parity bit and hardware handshake. Also check that
Channel and the correct interface have been selected in BoardMaster under
Machine Connect... Consult the BoardMaster Manual if you need help.
Now using BoardMaster:
1. turn on the motor (first the motor will turn at a maximum of 20,000 rpm)
2. raise/lower the head
3. switch off the motor
4. move the head manually using the cursor keys on the BoardMaster function
bar.
5. If the equipment does not move, check the interface configuration, the
connecting cable as well as the PC interface.

LPKF ProtoMat 93s Manual
16
3.6 HOME-Position and two-pin system
The HOME position must be on the machine's X axis (two-pin system) to
guarantee alignment of a double sided board. The data for the bottom side of a
PCB is mirrored around the X axis and therefore the board must also be rotated
around the X axis to maintain registration. Inaccuracies in the HOME position
result in a displacement during machining of double-sided boards after the
rotation.
Note:
The two-pin system is parallel only for the current position of the two-pin strips.
The front two-pin slide must be placed against the pin in the groove ( reference ).
If base material of different sizes is used, an additional hole must be drilled in the
strip of the back for every format. To do this, move from the home position in
direction of the rear strip, displace it to the desired position and drill an additional
hole by hand, using the 3 mm drill. The position of the new holes should recorded
or marked at the plotter. This will help when drilling the reference hole in various
size material.

LPKF ProtoMat 93s Manual
17
3.7 Programming the HOME position in BoardMaster
The home position needs to be programmed on new equipment and when the
system has been moved.
The HOME position of the LPKF ProtoMat 93s must be precisely on the mirror (X)
axis (the two-pin system with the red plastic slides) for machining double-sided
PCBs. To do this, proceed as follows:
1. Start BoardMaster
2. Click
Machine in the menu bar.
3. Now select Settings..
4. Activate
Unlock so that you can make entries in this window.
5. Check that
SMCU is selected. If there is no cross in the relevant box, the box
must be clicked.
6. Now
Initialize must be clicked. The equipment travels to all four end positions,
and then stops in the ZERO position (at the front, to the right). The movement
range thus determined is displayed under Size and stored when the Machine
Settings..dialog box is left. For more detailed information see the BoardMaster
Manual.
7. A two-pin system has already been set up at the factory. The HOME position x
and y coordinates is delivered with the machine on the enclosed paper (see
sticker of the driver diskette). They should now be entered under Home in
BoardMaster.
8. If the coordinates are not known, the two-pin system must be drilled again. To
do this, see the section entitled “Making a new two-pin system“.
9. When the
Machine Settings.. dialog box is closed and BoardMaster left, the
new values are saved in a .INI file which is read each time BoardMaster is
called and each time Machine Settings.. called.

LPKF ProtoMat 93s Manual
18
12 345 6
Front stripe of the two-pin system
1. reference pin, may be covered by two-pin stripe (5)
2. front alignment pin
3. HOME position, min. 10 mm distance to the alignment pin
4. mirror axis
5. two-pin stripe
6. two-pin groove
3.8 Making a new two-pin system
The alignment holes in the red two-pin strip become larger over time due to use
and top to bottom alignment will suffer. You must then drill new holes in the slides.
If after a certain time there are too many holes in the slides, the two-pin strips
must be changed.
CAUTION! Take note that sharp tools are involved and that they may be hot.
In order not to hurt yourself because of chips always work with the vacuum
system switched on!

LPKF ProtoMat 93s Manual
19
To make a new two-pin system, proceed as follows:
1. First press both two-pin strips into the machine groove, with the front two-pin
strip pushed against the reference pin to the front of the groove. The distance
between the two two-pin strips should be about the size of the base material in
the X axis.
2. Fit a drill measuring 3 mm in diameter (better 2.95 mm) so that the distance
between the base plate and the drill point is about 0.5 mm. This is the only
time a tool is not inserted into the collet as far as it will go.
3. Adjust the working depth limiter to the top using the knurled screw, in order to
increase the drill stroke.
4. Move the mill/drill head to HOME and then to the front two-pin strip. Then
manually drill a hole about 4 mm deep in the approximate center by pressing
down the drill head. Afterwards, do not move the mill/drill head position in the Y
axis.
5. Move the mill/drill head an exact, known distance (25 mm or 1 inch for
example) the +X direction and define this position as the new HOME position
(Set Home). Knowing this dimension is important because you need to know
the exact distance between the pins to prepare material later.
6. Move in the X axis a known amount to the second, rear two-pin strip and drill a
hole about 4 mm deep there too. Remember the distance between the two
holes because this will be the dimension you need when drilling holes in the
backing material and the copper clad. By no means move in the Y-direction.
7. Now position the drill tool in the drill chuck as far as it will go.
8. Move the mill/drill head to the side. Insert two alignment pins in the holes now
made in the two-pin strip. Check that the pins are firmly inserted as any play
affects alignment accuracy.
9. Mark old holes with a felt pen so they cannot be confused with the new ones.
10.Position the previously drilled base material and drilling base over the
alignment pins. The holes in the base material and the copper clad should
have been drilled using the system and at the same distance apart as the
alignment pins so the plastic strips do not have to be moved.
11.Now fix the base material thus positioned with adhesive tape on all four sides.

LPKF ProtoMat 93s Manual
20
3.9 Checking and correcting the HOME position
1. Make alignment holes in double-sided base material.
2. Fix the material and the drilling base (2 mm) on the base plate with the help of
the alignment pins (see too the section on fixing the PCB on the machine bed).
3. Drill a hole at the HOME position with a 0.7 mm drill.
4. Move the mill/drill head to the PAUSE position.
5. Turn the PCB material around the X axis.
6. Move to the HOME position, move to the tool change position and insert a
universal milling cutter. When the tool has been changed, the mill/drill head
automatically returns to the HOME position.
7. Mill a channel over the hole manually in the X direction, without moving in the
Y direction.
8. Check visually that the milled channel passes precisely through the center
point of the hole.
9. If the milled line does not run exactly through the center point, the HOME
position must be corrected by half the difference. This can be done directly by
changing the home position in Machine Settings.. dialog box.
10. After making a correction, the movement should be repeated as a check.
4 The LPKF ProtoMat 93s operating displays
POWER (green): control operating display. This only comes on when the
system has been initialized (limit switch reached).