LPKF ProtoMat C30 User manual

Manual ProtoMat C30/C 30-S
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 C30/C30-S
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 C30/C30-S 3
Information on this manuel
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 C30/C30-S
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 C30/C30-S 5
III. Legend
Copper laminate:special, very thin basis material used only for
laminating multilayer boards
Basis material: carrier material of thr main board, coated with a copper
foil
Solder foil: special foil for cutting aperatures for the connections to
be soldered
BoardMaster: Machine control software
CircuitCAM: Software for data preparation
IV. Target Group
This manuel is written for people with basic knowledge in PCB
production.

6 ProtoMat C30/C30-S
Table of contents
1.0 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 LPKF ProtoMat C30 (C30/S) machine ratings . . . .10
2.0 Safty Notes . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.0 General information . . . . . . . . . . . . . . . . . . 12
3.1 Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.2 Optional accessories . . . . . . . . . . . . . . . . . . . . . . .12
3.3 Air-borne sound . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4.0 Computer-controlled functions . . . . . . . . . 14
4.1 Connection to a PC . . . . . . . . . . . . . . . . . . . . . . . .14
4.2 Machine orientation . . . . . . . . . . . . . . . . . . . . . . . .15
4.3 Displays and connections. . . . . . . . . . . . . . . . . . . .16
4.4 Functional elements on the plotter head . . . . . . . .18
5.0 Use of LPKF BoardMaster . . . . . . . . . . . . . 19
6.0 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.1 Switch-on sequence . . . . . . . . . . . . . . . . . . . . . . . .20
6.2 After switching on . . . . . . . . . . . . . . . . . . . . . . . . . .20
7.0 Functional test with LPKF BoardMaster. . 21
7.1 HOME position and registration hole system . . . . .22

ProtoMat C30/C30-S 7
7.2 Checking and correcting the HOME position . . . . .22
7.3 Programing the HOME position in
LPKF BoardMaster . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
7.4 Creating a new registration hole system . . . . . . . .27
8.0 Tutorial on creating a printed circuit board30
8.1 Reprogramming the machine data . . . . . . . . . . . . .32
9.0 Tools, material and accessories. . . . . . . . 34
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
9.2 Materials used for machining . . . . . . . . . . . . . . . . .35
10.0 Procedures for milling and drilling . . . . 37
10.1 Securing the board . . . . . . . . . . . . . . . . . . . . . . . .37
10.2 Operating the working depth limiter . . . . . . . . . . .38
10.3 Changing a tool (C30) . . . . . . . . . . . . . . . . . . . . .39
10.4 Changing a tool (C30/S) . . . . . . . . . . . . . . . . . . . .39
10.5 Drilling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
10.6 Isolation milling . . . . . . . . . . . . . . . . . . . . . . . . . . .40
10.7 Contour milling in base material . . . . . . . . . . . . . .41
10.8 Milling wide isolation channels and rubouts . . . . .42
10.9 Front plate engraving . . . . . . . . . . . . . . . . . . . . . .42
10.10 Milling solder-stop sheets . . . . . . . . . . . . . . . . . .43
10.11 Milling layout films. . . . . . . . . . . . . . . . . . . . . . . .43
10.11.1 Staining milled films . . . . . . . . . . . . . . . . . . . . . 44

8 ProtoMat C30/C30-S
10.11.2 Removing the coating. . . . . . . . . . . . . . . . . . . . 44
11.0 Tool libraries in BoardMaster . . . . . . . . . 46
11.1 Cleaning the board . . . . . . . . . . . . . . . . . . . . . . . .47
12.0 Practical tips . . . . . . . . . . . . . . . . . . . . . . . 48
13.0 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . 50
13.1 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
13.1.1 Working depth limiter . . . . . . . . . . . . . . . . . . . . . 50
13.2 Lubricating the carriage guide wipers. . . . . . . . . .51
13.2.1 Carriage guide wipers of the Y-axis . . . . . . . . . . 52
13.2.2 Carriage guide wipers of the X-axis . . . . . . . . . . 53
13.2.3 Oiling the rear wipers . . . . . . . . . . . . . . . . . . . . . 53
13.2.4 Oiling the front wipers. . . . . . . . . . . . . . . . . . . . . 54
13.3 SerialPort 1 serial connection. . . . . . . . . . . . . . . .54
13.4 SerialPort2 serial connection . . . . . . . . . . . . . . . .55
13.5 Connecting the stepping motors. . . . . . . . . . . . . .55
13.6 Connecting the plotter head . . . . . . . . . . . . . . . . .55
13.7 EPROMs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
13.8 Switching the device voltage,
electrical fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
13.9 Removing the electronics unit . . . . . . . . . . . . . . .57
13.10 The Command set . . . . . . . . . . . . . . . . . . . . . . .59
13.10.1 Command structure . . . . . . . . . . . . . . . . . . . . . 59
13.10.2 HP-GL standard commands. . . . . . . . . . . . . . . 60
13.10.3 Special commands . . . . . . . . . . . . . . . . . . . . . . 61
13.10.4 Special command for the motor controller . . . . 63

ProtoMat C30/C30-S 9
13.10.5 Direct commands. . . . . . . . . . . . . . . . . . . . . . . 63
13.11 Table of available tools . . . . . . . . . . . . . . . . . . . .65
14.0 Concluding remarks . . . . . . . . . . . . . . . . 66
15.0 Konformitätserklärung für LPKF ProtoMat
C30 (C30/S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
15.1 Declaration of conformity . . . . . . . . . . . . . . . . . . .68
16.0 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Introduction
10 ProtoMat C30/C30-S
1.0 Introduction
The LPKF ProtoMat C30 (C30/S) circuit-board plotter is a system for the
production of circuit board prototypes and engraving films, and for
engraving aluminium or plastic.
It is essential that you familiarize yourself with the functions of the LPKF
BoardMaster driver program before using the plotter. You will find a
description of the driver program's functionality in the manual for the
LPKF BoardMaster. The operating interface for the LPKF ProtoMat C30
(C30/S) is a PC.
It is absolutely vital that you read the instructions given in this manual
before putting the machine into operation, otherwise you will invalidate
any warranty claims. The appropriate national warranty provisions apply
for machines exported to other countries of the European Community.
1.1 LPKF ProtoMat C30 (C30/S) machine ratings
Voltage 200-240V (or 100-120V)
Power input 150VA
Speed of plotter spindle DC motor,
5000 - 32,000/min (variable)
Weight approximately 24 kg
Drilling performance 78 lifts/min maximum
Resolution (smallest increment) 7.9375 µm (0.3125 mil)
Operating data:
Humidity 60% max.
Temperature: 15-25°C

Safty Notes
ProtoMat C30/C30-S 11
2.0 Safty 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.

General information
12 ProtoMat C30/C30-S
3.0 General information
3.1 Scope of supply
1. One LPKF ProtoMat C30 (C30/S) machine unit with integrated
electronics
2. One null modem cable (LPKF ProtoMat C30 (C30/S) control unit to
computer), 9/25-pin AT-adapter
3. One set of accessories (adhesive tape, various Allen keys, 5
alignment pins, tweezers, brush, 7 mm box spanner, two red
registration hole strips, syringe containing oil, 2 alignment drill
2,95 mm)
4. One mains cable
5. Inserting tool for alignment pins
6. This manual
3.2 Optional accessories
The following accessories are available for the LPKF ProtoMat C30
(C30/S):
1. Vacuum system with fine mesh filter.
The fine mesh filter is particularly essential when handling materials
containing glass fibre, such as FR4 base material.
2. Noise and dust protective hood
3. LPKF AutoSwitch.
Automatic switch for the vacuum system. This option allows the
vacuum system to be switched on and off by the plotter spindle.
4. ZelSpot.
Illuminates the plotter head.
5. LPKF AutoContac
Integrated through-hole plating using a dispenser and a special
conductive paste capable of being soldered.
3.3 Air-borne sound
There is a continuous sound pressure level of 71 dBA at the workstation
during operation.
This value does not include the vacuum unit.

General information
ProtoMat C30/C30-S 13
3.4 Installation
› Unpack the LPKF ProtoMat C30 (C30/S) carefully. Remove the
securing bolts. (see securing bolt 1 in the drawing)
• Securing device (M5 x 25, 4.5 x 60 screws)
Now loosen the transport securing devices. The transport securing
devices are located:
• To secure the X axis - (securing device 2) angle brackets on each
side of the machine's base plate M4 x 10 screws
• To secure the Y axis - (securing device 3) on the left-hand side of
the plotter head M4 x 40 screws
• To secure the Z axis - (securing device 4) on the plotter head
M4 x 20 screw
Set up the circuit-board plotter so that the cables connecting the
electronics unit are free to move.
› Connect the LPKF ProtoMat C30 (C30/S) to COM1 or COM2 on the
computer using the null modem cable.
› Plug the LPKF ProtoMat C30 (C30/S) control unit into the electricity
supply.
Fit the vacuum system onto the adaptor
(fits pipe no. 111124 on a Nilfisk industrial vacuum system).
fig. 1:
Caution! The machine must stand on a flat and firm base in order to
work correctly and without malfunctions.
Note: Keep all transport securing devices and reattach them
accordingly if the machine is to be shipped again. The packaging
should also be kept and used when the machine is returned for
servicing.
1- To secure themachine to the transportation base (M5 x 25, 4.5 x 60 screws)
2- To secure the X axis (M4 x 10 screws)
3- To secure the Y axis (M4 x 40 screw)
4- To secure the plotter head (M4 x 20 screw)
4
123

Computer-controlled functions
14 ProtoMat C30/C30-S
4.0 Computer-controlled functions
4.1 Connection to a PC
The LPKF ProtoMat C30 (C30/S) has two serial ports. The first (25-pin)
is used for connection to the controlling computer (PC).
The second port (9-pin) is intended for future applications.
The 25-pin interface of the LPKF ProtoMat C30 (C30/S) control unit is
connected to a serial port on the computer with the null modem cable
supplied.
The RS232 (null modem) cable for the LPKF ProtoMat C30 (C30/S)
circuit-board plotter is wired as follows:
The following parameters must be observed:
• Baud rate 9600(default setting, others upon request)
• Parity none
• Data bits 8
• Stop bit 1
• Handshake hardware
• FiFo buffer
enabled no
25-pin socket 25-pin socket
PC (COMx) Circuit-board plotter
(SerialPort1)
1 1
2TXD 3
3RXD 2
45
5 4
77
8GND 20
15,17 24
20 8
24 15,17

Computer-controlled functions
ProtoMat C30/C30-S 15
4.2 Machine orientation
Description of the machine's main positions:
fig. 2: LPKF ProtoMat C30 (C30/S):
The X axis has the greater
travel
Danger! Do not put fingers or any items into the movement range.
1- PAUSE position.
The plotter head travels to this point to load or turn the material to be machined.
2- HOME position.
This is on the plotter's axis of symmetry (registration hole system) and serves as the
reference position for the LPKF BoardMaster
3- Registration hole slide with hole for alignment pin
4- Reference pin for the front registration hole strip. The front registration hole slide butts
against the stop.
5- Tool change position (zero position).
The tool is changed here.
5
+ x
+ y
1
2
3
4

Computer-controlled functions
16 ProtoMat C30/C30-S
4.3 Displays and connections
Description of the front view:
fig. 3: Front view of LPKF ProtoMat
C30 (C30/S)
1- Operating indicator for the integrated SMCU machine controller
2- Motor for the longitudinal axis (X axis)
3- Plotter spindle (DC motor)
4- Lever for opening the tool collet (Only ProtoMat C30/S)
5- Working depth limiter
POWER LPKF ProtoMat C30
1
3
4
2
5

Computer-controlled functions
ProtoMat C30/C30-S 17
Description of the rear:
fig. 4: Rear view of the LPKF
ProtoMat C30 (C30/S)
1- Vacuum system connection 8- X motor
2- Serial port (9-pin) for expansion units 9- Y motor
3- Serial port (25-pin) for connection to PC 10- Plotter spindle (DC motor)
4- X motor connection 11- Solenoid actuator
5- Y motor connection 12- Working depth limiter
6- Connection for plotter head and options 13- DC motor connection
7- On/Off switch with mains connector and fuses
10 11
23 7
9
12
8
1456
13
IO

Computer-controlled functions
18 ProtoMat C30/C30-S
4.4 Functional elements on the plotter head
fig. 5: Front view of plotter head
1- Shock absorber 6- Plotter spindle (DC motor)
2- Lifting magnet 7- Bottom head stop adjustment
(Caution - do not adjust.)
3- Working depth limiter 8- Fixing screw for working depth limiter
4- Motor cover 9- Plotter head base plate
5- Mounting flange for the DC motor 10- Lever for opening the tool collet
(Only ProtoMat C30/S)
4
9
3
1
7
8
10
5
6
2

Use of LPKF BoardMaster
ProtoMat C30/C30-S 19
5.0 Use of LPKF BoardMaster
The data required to drive the plotters is generated by postprocessing
with LPKF CircuitCAM and is stored in a binary LPKF file (LMD format).
BoardMaster now reads these files, decodes the plotter commands and
modifies them for the particular machine being driven.
This is necessary as although different machines may perform similar
operations, they nevertheless use different command sets.
The LPKF ProtoMat C30 (C30/S) circuit-board plotter is HP-GL
compatible, ie the driver generates data in HP-GL format plus some
special commands.
Modifications such as enlargement, rotation and duplication etc can be
made in LPKF BordMaster.
All LPKF circuit-board plotters are controlled through an asynchronous
interface (RS232C).
In the case of the LPKF ProtoMat C30 (C30/S), this is set at
9600 Baud, 1 stop bit, 8 data bits, no parity, hardware handshake
and FIFO off in the Windows control panel.

Setup
20 ProtoMat C30/C30-S
6.0 Setup
Caution! You must ensure that the voltage set on the machine
corresponds with the mains line voltage before switching on. If not,
see the section headed Setting the device voltage, electrical fuses.
Remove all objects from the plotter and its traverse range before
switching on. Pilot pins must not be projecting from the base
material.
Danger! Never reach into the machine while it is being switched on.
Never move the plotter head manually. Doing so could damage the
electronics.
6.1 Switch-on sequence
It is useful, but not essential, to keep to the following switch-on
sequence:
1. Computer
2. LPKF ProtoMat C30 (C30/S)
3. Start up the BoardMaster program
If, for whatever reason, it should be necessary to switch the machine off
and back on, you must switch briefly to the BoardMaster MACHINE
SETTINGS... dialog box and quit this with OK. This will send the
necessary initialization parameters, such as speed ranges, dwell times,
positions and so on to the machine once again.
6.2 After switching on
The equipment moves to the x and y limit switches when the machine is
switched on. The system first halts in the tool change position. It now
waits for commands from BoardMaster. Check the following if the
equipment does not move when it is switched on:
1. Is the POWER LED lit (only lights after successful initialization)?
2. Are all cables correctly inserted?
3. You may need to check the power supply fuses.