LPKF ProtoMat M60 User manual

Manual ProtoMat M60
English, version 1.0
LPKF Laser & Electronics AG
Osteriede 7
D-30827 Garbsen
Telefon : ++ 49 - 51 31 - 70 95 - 0
Telefax : ++ 49 - 51 31 - 70 95 - 90
eMail : [e-mail]
Homepage : http: //www.lpkf.de

2 ProtoMat M60
Copyright (c) 2000 LPKF AG
Distribution or reproduction of this manual and use of its content
permitted only with the written approval of LPKF AG. Right to make
modifications reserved. No liability is accepted for the content. In
particular, we accept no liability for damage caused by information given,
information absent, or erroneous information.
Trademarks: HP-GL is a registered trademark of the Hewlett Packard
Corporation. All other trademarks are registered by their owners.

ProtoMat M60 3
Information on this manual
The information contained in this document may be modified without
prior notification. No part of this document may be reproduced or
transmitted for any purpose or in any form by any means, electronic or
mechanical, by photocopy, by recording or by information storage and
information retrieval systems without the express written permission of
LPKF.
We have taken great trouble to ensure the accuracy and completeness
of the information in this document. However, LPKF accepts no liability
for the use of the document, including breach of copyright or other
infringement against third parties which may arise from this.
It is the duty of the system owner to care for and plan these measures as
well as to control their execution. The owner especially has to ensure
that
• the system is only used as directed
• the system is only operated in perfect and functional
condition. Especially the function of the safty appliances
has to be checked regularly
• the necessary personal protectiv equipment for the
operating, maintaining and repairing personnel is available
and being used
• the operating manual is kept legible and complete at the
place of operation
• only sufficiently qualified and authorized personnel
operates, maintains and repairs the system
• this personnel is regularly instructed in matters of work
safety and environmental protection and is informed on the
operation manuel and especially the safety instructions
• all safety and warning notes or signs stay on the system and
are legible

4 ProtoMat M60
Using this manual
I. Orientation
This manual is divided into the following chapters:
1. Safty notes
2. Introduction
3. General Information
4. Setup
5. Operating displays
6. Computer-controlled functions
7. Tools and accessories
8. Milling and drilling
9. Appendix
10.Declaration of conformity
11.Index
II. Conventions used in this manual
Bold text is used to emphasise important information.
Illustrations are numbered. Example: Fig. 5
› Prompts for actions are identified with an arrow.
Italic sections are used to indicate the reactions consequent on an
action.
Words printed in italics mark proper names
Key inscriptions and menu terms are printed in BOLD CAPITALS.
III. Notes on the symbols used
Danger! This symbol is used to highlight danger to life or health.
Caution! This symbol is used to identify hazards which may cause
damage.
Note: This symbol is used for notes intended to help you avoid faults in
operation or to help you improve your procedures.

ProtoMat M60 5
III. Legend
Copper laminate: special, very thin base material used only for
laminating multilayer boards
Base material : Circuit board material coated with copper foil
Solder foil : special foil for cutting aperatures for the connections to
be soldered
BoardMaster : Machine control software
CurcuitCAM : Software for data preparation
IV. Target Group
This manual is written for people with basic knowledge in PCB
production.

6 ProtoMat M60
Table of contents
1.0 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.0 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Characteristics of the ProtoMat M60 . . . . . . . . . . .10
3.0 General Information . . . . . . . . . . . . . . . . . . 11
3.1 Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Optional accessories . . . . . . . . . . . . . . . . . . . . . . .11
3.3 Air-borne sound . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.0 Computer-controlled functions . . . . . . . . . 13
4.1 Connection to a PC . . . . . . . . . . . . . . . . . . . . . . . .13
4.2 Machine orientation . . . . . . . . . . . . . . . . . . . . . . . .14
4.3 Displays and connections. . . . . . . . . . . . . . . . . . . .15
4.4 Use of BoardMaster . . . . . . . . . . . . . . . . . . . . . . . .16
5.0 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.1 Before switching on . . . . . . . . . . . . . . . . . . . . . . . .17
5.2 Turning the system on . . . . . . . . . . . . . . . . . . . . . .17
5.3 Switch-on instructions for high-speedcycle spindles17
5.4 Changing a tool . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.5 After switching on . . . . . . . . . . . . . . . . . . . . . . . . . .19
5.6 Function test with BoardMaster . . . . . . . . . . . . . . .19

ProtoMat M60 7
5.7 HOME-Position and two-pin system. . . . . . . . . . . .20
5.8 Programming the HOME position. . . . . . . . . . . . . .20
5.9 Checking and correcting the HOME position . . . . .21
5.10 Making a new two-pin system . . . . . . . . . . . . . . .22
5.11 Producing a PCB with BoardMaster . . . . . . . . . . .23
6.0 Tools and accessories . . . . . . . . . . . . . . . 25
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.2 Materials used for machining . . . . . . . . . . . . . . . . .26
7.0 Milling and drilling . . . . . . . . . . . . . . . . . . . 28
7.1 Securing the PCB on the machine bed . . . . . . . . .28
7.2 The mechanical working depth limiter . . . . . . . . . .29
7.3 Functional elements on the mill/drill head . . . . . . .30
7.4 Drilling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
7.5 Isolation milling . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
7.6 Contour milling in PCB material . . . . . . . . . . . . . . .33
7.7 Milling wide isolation channels . . . . . . . . . . . . . . . .34
7.8 Front plate engraving . . . . . . . . . . . . . . . . . . . . . . .34
7.9 Milling layout films . . . . . . . . . . . . . . . . . . . . . . . . .35
7.9.1 Correction agents . . . . . . . . . . . . . . . . . . . . . . . . 36
7.9.2 Coloring milled films. . . . . . . . . . . . . . . . . . . . . . . 36
7.9.3 Coating removal. . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.10 Milling of solder mask foils . . . . . . . . . . . . . . . . . .37
7.11 Drilling with the micrometer screw . . . . . . . . . . . .37

8 ProtoMat M60
7.12 Cleaning the PCB37
7.13 Practical tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
8.0 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.1 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
8.2 Lubricating the carriage guide wipers. . . . . . . . . . .42
8.2.1 Carriage guide wipers of the X-axis . . . . . . . . . . . 42
8.2.2 Oiling the rear wipers . . . . . . . . . . . . . . . . . . . . . . 43
8.2.3 Oiling the front wipers. . . . . . . . . . . . . . . . . . . . . . 43
8.3 Serial port SERIAL 1 . . . . . . . . . . . . . . . . . . . . . . .43
8.4 Serial port SERIAL 2 . . . . . . . . . . . . . . . . . . . . . . .44
8.5 Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . .44
8.6 Mill head connection. . . . . . . . . . . . . . . . . . . . . . . .45
8.7 EPROMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
8.8 Fuses, commuting the device voltage . . . . . . . . . .45
8.9 The LPKF ProtoMat M60 Commands . . . . . . . . . .48
8.9.1 Command structure . . . . . . . . . . . . . . . . . . . . . . . 48
8.9.2 HP-GL standard commands. . . . . . . . . . . . . . . . . 49
8.9.3 Special commands . . . . . . . . . . . . . . . . . . . . . . . . 50
8.9.4 Special command for the high-speedcycle spindle52
8.9.5 Direct commands . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.10 Inventory of available tools. . . . . . . . . . . . . . . . . .53
8.11 Concluding remarks . . . . . . . . . . . . . . . . . . . . . . .54
8.12 Declaration of conformity . . . . . . . . . . . . . . . . . . .55
8.13 Konformitätserklärung . . . . . . . . . . . . . . . . . . . . .56
9.0 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Safety notes
ProtoMat M60 9
1.0 Safety notes
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.

Introduction
10 ProtoMat M60
2.0 Introduction
The LPKF ProtoMat M60 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
M60 is essential for operation of the machine. Operation of the LPKF
ProtoMat M60 is described in the LPKF BoardMaster Manual. The
exclusive operating interface for the LPKF ProtoMat M60 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.
2.1 Characteristics of the ProtoMat M60
Voltage 200-240V (or 100-120V)
Power consumption 200VA
Speed of high-speedcycle
spindle max.
60000/min
Weight ca. 25 kg
Drilling performance max. 60 strokes/min
Resolution (smallest step) 0.0079375mm
Operating data:
Humidity 60% max.
Temperature: 15-25°C

General Information
ProtoMat M60 11
3.0 General Information
3.1 Scope of supply
• 1 LPKF ProtoMat M60 machine unit with integrated electronics
• 1 null modem cable (LPKF ProtoMat M60 control unit-computer),
AT- Adapter 9/25-pol
• 1 set of accessories (Drafting Tape, Allen wrenches, alignment
pins, tweezers, brush, 7 mm wrench, 2 red two-pin strips, 2
alignment drill 2,95 mm)
• 1 power cable
• Inserting tool for alignment pins
• This manual
3.2 Optional accessories
The following accessories can be supplied for the LPKF ProtoMat M60:
• Vacuum system with fine filter. The fine filter is essential in
particular when handling materials containing glass fiber, such as
for FR4 base material.
• Noise and dust guard hood
• LPKF AutoSwitch.
Automatic switch for the vacuum cleaner. With this option can
over the mill/drill spindle, the vacuum cleaner switch on and off.
• LPKF AutoContac
Integrated through-hole plating using a dispenser and a special
conductive paste capable of being soldered
• Integrated milling head lighting
3.3 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.

General Information
12 ProtoMat M60
3.4 Installation
› Unpack the LPKF ProtoMat M60 carefully (for detaching the security
screws see Fig. 1 on page 12). Then loosen the transport safety
devices. These devices are marked red and are located:
• Locking of the X-axis - 2 aluminium elbow joints (safety device 2)
• Locking of the Y-axis - directly at the head to the left (safety
device 3)
• Locking of the Z-axis - Allen screw (safety device 4)
Note: The equipment must stand on a flat and firm base in order to
work properly!
› Set up the circuit board plotter so that the connecting cables to the
electronic unit can move freely.
› Connect the LPKF ProtoMat M60 to the computer with the null
modem cable supplied with the system (COM1 or COM2).
› Plug the LPKF ProtoMat M60 control unit into the electricity supply
› Fit the Vacuum to the adapter (suitable for stay tube no. 111124 of a
Nilfisk industrial vacuum unit).
fig. 1: Transport safety devices of
the LPKF ProtoMat M60
Note: Keep all transport safety device and packing and mount them
accordingly if the machine is to be shipped.
1- Attaching the machine safely to the transport support
2- Securing the X-axis
3- Securing the Y-axis
4- Securing the mill/drill head
4

Computer-controlled functions
ProtoMat M60 13
4.0 Computer-controlled functions
4.1 Connection to a PC
The LPKF ProtoMat M60 has two serial interfaces. The first (SERIAL 1)
is the INPUT to the system and is used for connection to the controlling
computer (PC). The second interface (SERIAL 2) is an OUTPUT and is
provided for future applications.
The LPKF ProtoMat M60 control unit's SERIAL 1 is connected to a serial
interface on the computer with the RS232 cable supplied.
The RS232 cable (null modem) for the LPKF ProtoMat M60 circuit board
plotter is wired as follows:
The cable shield ground is connected only on the PC side (port).
The following parameters must be observed:
If the DOS driver is used the PC's serial interface is initialized with the
DOS command Mode Com1:96,N,8,1. If BoardMaster is used, the port
must be initialized under Windows using Main/Control Panel/Ports.
Baudrate 9600
Parity None
Datenbit 8
Stopbit 1
Hardwarehand-
shake
FIFO-Buffer off

Computer-controlled functions
14 ProtoMat M60
4.2 Machine orientation
Description of the main machine positions:
fig. 2: LPKF ProtoMat M60: the x-
axis is the longer direction of
movement
Danger! Keep fingers and any other items out reaching into the
area of movement!
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 programm BoardMaster.
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.

Computer-controlled functions
ProtoMat M60 15
4.3 Displays and connections
Description of the front panel:
fig. 3: Front LPKF ProtoMat M60
1- Operating display of the integrated machine control SMCU
2- X motor
3- High-speedcycle spindle motor
4- Working depth limiter

Computer-controlled functions
16 ProtoMat M60
Description of the rear panel:
fig. 4: Rear view of LPKF ProtoMat
M60
4.4 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 M60
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 M60, it is operated at 9600
baud, 1 stop bit, 8 data bits, no parity and hardware handshake. The
configuration of the computer’s serial interface has to be accordingly set
within the system control of Windows. The FIFO-buffer has to be
switched off.
1- Vacuum connection 8- X motor
2- Output Serial interface (9-pole) for controlling optional
equipment
9- Y motor
3- Input Serial interface (25-pole) for connection to
PC serial port
10- High-speedcycle spindle motor
4- X motor connection 11- Solenoid
5- Y motor connection 12- Working depth limiter
6- Mill/Drill head connection 13- Connection of high-cycle
spindle
7- On/Off switch, power cord connector and fuses

Setup
ProtoMat M60 17
5.0 Setup
5.1 Before switching on
Caution! Be sure the voltage set at the machine corresponds with
the line voltage: If not, continue at „Fuses, commuting the device
voltage“ on page 45.
Before switching on, all items are to be removed from the machine and
its range of movement. Alignment pins are not allowed to jut out from the
base material. Alignment pins serves to fix, and by the twirl of the base-
material as reference point of the brush mirror.
Danger! Never reach into the machine while it is running!
5.2 Turning the system on
The following switching on order is useful, but not essential:
1. Computer
2. LPKF ProtoMat M60
3. Start the BoardMaster program
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. Through all necessary
initialization parameters like speed ranges, dwell times positions and so
on are again transmitted to the machine.
5.3 Switch-on instructions for high-speedcycle
spindles
A tool must always be placed in the shaft of the high-speedcycle spindle
when the machine is switched on. The collet must always be closed and
the knob of the high-speedcycle spindle must be in itsist top position,
otherwise the spindle is blocked and the motor driver can be overloaded.
Caution! The Danger of spindle can be damaged if it operated
without a tool inserted!
Danger! Do not operate with the tool clamp before the spindle is
standing absolutely still!

Setup
18 ProtoMat M60
fig. 5: Operating the collet of the
high-speedcycle 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. Tight so
that a tool that might be inserted will not be damaged. 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. Spindles of some manufacturers are jumping back
into the normal position by themselves.
Caution! Only operate the spindel with the vacuum cleaner
switched on.
Note: During set-up take note that the bearings of the high-
speedcycle 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 20,000 rpm will be allowed after the warm-up time.
5.4 Changing a tool
For changing a tool there is to be considered, that the tool after the
opening is introduced up to the plot in the tool clamp, before the tool
clamp is closed again. Befor handling the tool clamp you must read
chapters „Switch-on instructions for high-speedcycle spindles“ on
page 17.

Setup
ProtoMat M60 19
5.5 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!
5.6 Function test with BoardMaster
Danger! Make sure that nothing is no other persons are in the
machine operating area when the first functional test is taking
place!
First check that the serial interface used is set to 9600 baud, 8 data
bits, 1 stop bit, no parity bit and hardware handshake and FiFO-
buffer off. 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:
› The correct tool must be declared (clicked on) in the window TOOL-
ASSIGNMENT
› Before the motor can be switched on, the milling head has to be
moved out of the tool-change position a few inches using the cursor
key.
› turn on the motor, to click of (first the motor will turn at a
maximum of 20,000 rpm, warm up phase)
› raise/lower the head, to click of
› switch off the motor, to click of
› move the head manually using the cursor keys on the BoardMaster
function bar.
If the equipment does not move, check the interface configuration, the
connecting cable as well as the PC interface.

Setup
20 ProtoMat M60
5.7 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 2,95 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.
5.8 Programming the HOME position
The home position needs to be programmed on new equipment and
when the system has been moved.
The HOME position of the LPKF ProtoMat M60 must be precisely on the
mirror (X) axis (the two-pin system with the red plastic slides) for
machining double-sided base-material. To do this, proceed as follows:
› Start BoardMaster
› Click CONFIGURATION in the menu bar.
› Now select SETTINGS..
› Activate UNLOCK so that you can make entries in this window.
› Make sure that SMCU is selected.
› Now INITIALIZE must be clicked.
The equipment travels to all four end positions, and then stops in the
ZERO position (tool change position). 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.
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 driver diskette). They should now be entered under
Home in BoardMaster.
If the coordinates are not known, the two-pin system must be drilled
again. To do this, see the section „Making a new two-pin system“ on
page 22.
Click OK to close the MACHINE SETTINGS dialog box and quit
BoardMaster. The new values are saved in an .INI file wich is read each
time BoardMaster is called.