Short tutorial, Prepare PCB in BE111 Introduction 
Pak K. Chan Jan 2009.  (with Nghia T Nguyen's contribution)

The LPKF proto milling/drilling (PCB) machine + software is located
in BE111. I suggest making one side PCB only due to alignment.

Exercises:
----------
  You must study 
  three Exercises 1,2,3 in the LPKF CircuitCAM manual
  that guide you through all the glorious details of
  using this milling system.
  

Software:
---------
  1. Produce artwork using any layout tool (e.g. Orcad) that is Gerber capable.
  2. Use software CircuitCAM to convert Gerber format to LMD format
     (see CircuitCam section below)
  3. Use BoardMaster v4.0 to control the LPKF ProtMat 60 Milling table/machine.

Clean and degrease the surface of the substrate (your copper PCB)
-----------------------------------------------------------------

Bits and tools
--------------
  There are three kinds of bits.
      a. milling/routing bit  (rip up copper)
      b. drilling holes
      c. routing the outline of your board, i.e. cut out your board. 

CircuitCam (From Circuit to Cam)
----------
  Use this program to convert Gerber format to LMD format.
  This is also the place where the bits/tools information
  and your artwork (Gerber) information is consolidated into LMD layers.

  Problem:
     Your Gerber file may need a lot of drill sizes and Dcodes,
     but you only have a few tools/bits for the LPKF milling machine.

  Solution:
     The CircuitCam program solves this problem for you by changing
     the drill sizes.

  In CircuitCam, select the layer (e.g. Cutting Outside Layer)
  that you would like to export as LMD ``visible and selectable'',
  select the appropriate tool (e.g. router bit) and its size (e.g. 2mm)
  to realize your layer (it must correspond to the tools/bits that you have).
  

Initial BoardMaster Setup
--------------------------
  1. Start the program BoardMaster.
  2. GoTo tab.
       a. GoTo->Pause moves the head to a position that you can move
          the substrate.
       b. GoTo->Exchange moves the head to a position that you can change
          the bit.

ProtoMat hardware setup.
------------------------
  Drill two reference mounting holes (MH) into the PCB (your substrate).
  To make new mounting holes, I suggest:

  1. transfer the placement of existing holes to a new sheet
     by tapping the substrate with a small drill bit or sharpie
  2. pre-drill the mounting holes with a smaller drill bit
     than 2.95mm
  3. Use LPKF supplied 2.95mm drill bit (or size 32 drill bit)
     to complete the holes.

  The next step is to insert a bit into the milling machine.
  In BoardMaster program, use GoTo->Exchange to move the head to
  a position that you can change the bit.
  Use Fig 5. of LPKF ProtoMat M60 manual as reference,
  as in diagram (a) of Fig 5. you need to PUSH PUSH the knob down until
  it is engaged in order to open or close the collet.
  You have to look from below the head to locate the collet.
  Loosen the collet by turning counter-clockwise
  (but not too loose, or it will fall out).
  Insert the appropriate tool/bit in the collet.
  Tighten the collet by turning clockwise.

  ***************************************************************
  You need clearance between the substrate and the tool/bit.
  Adjust the height of the tool/bit carefully such that when the
  head moves/travels, the tool/bit won't run into any obstacles.
  ***************************************************************
  Use tape to tape down the board on the sides.
  ***************************************************************
  Save your bits, every little bit counts :) 
  
BoardMaster Setup
-----------------
  1. Start the program BoardMaster, if it is not running.

  2. Select Configure->material tab, setup
        a. the board size, e.g. 4x4 inches
        b. upper right corner  e.g. (4,4)
        c. lower left  corner e.g (0,0)
     a "grey area" will show up.

     A better way is manually move the head to a location of
     your substrate. Then set low corner in Configure->material
     to determine the lower corner of your board. Similarly, define
     the high corner. You need to study page 43 of the BoardMaster manual
     to learn how to do this.

  3. File->Import the artwork which is in LMD format. You should
     see an image of the artwork. If the artwork is a drill layer,
     you should only see Xs.

  4.  Find a little icon that looks like a book or a window!
      The icon is for moving artwork.
      Move the artwork into the "grey area" that was defined earlier.

  5. Select the production phase (e.g. Milling Top).
     Assume you have the appropriate tool/bit inserted, drill for drill layer,
     small mill for traces, large mill for contour cutout, etc.

  6. Select Start and you are ready to go. It may take a few minutes
     for the motors to warm up and before the head starts moving.
     When it does, the vacuum machine will turn on and you will hear it !

     ......

  7. If you have studied Contour Routing in the CircuitCAM Manual
     Exercise 3,
     you should have a layer that allows you to mill/cut out your board.