JCUT-PCB Engraving Machine

Software and Hardware Instructions

Co.,, Ltd.
Jinan JCUT CNC equipment Co.

Please read the usage manual carefully before usage and keep it for further reference.
 Contents
Chapter 1 Introduction
1.1 Overall Introduction to JCUT-PCB Engraver
1.2 Special Features
1.3 Technical Parameters
Chapter 2 Engraver Hardware & Software Installation
2.1 Hardware Installation
2.2 Software Installation
Chapter 3 Operating Instructions for JCUT-PCB Engraver
3.1 How to Create a Machining File
3.2 COPPERCAM Software
3.3 Instructions for Hardware
Chapter 4 Operating Procedures for PCB Machining
Chapter 5 Special Explanations and Instructions
Chapter 1 Introduction
1.1 Overall Introduction to JCUT-PCB Engraver
JCUT PCB engraver machines single-sided and double-sided PCBs automatically and accurately,
according to PCB files created by PCB design soft wares(e.g. Protel). Users only need to design a
PCB file and generate the relevant machining file. Transferring the machining file to its control
system via USB, the engraver can complete all the work of manufacturing a fine PCB quickly and
automatically, including engraving, drilling and trimming. It realized automatic PCB manufacture
with low cost and high efficiency. With its simple usage and high reliability, this equipment
provides an ideal facility for university laboratories of electronic, electro-mechanics, computer,
control, instruments and meters, and electronic enterprises, scientific research institutions, and the
army.
Function Introduction
PCB engraver is a high-tech product that integrates electro-mechanics, software, and hardware. It
utilizes and transforms the PCB file information of a PCB design software(e.g. PROTEL) into
international G-code and transport them to the engraver. The engraver will then be controlled
automatically to complete the work of engraving, drilling and trimming. Under the computer’s
control, it physically mills off the unwanted copper from a blank copper clad laminate to produce
the designed PCB. It’s highly accurate, time & material saving, and easy to use.
Main Working Principle
1. About Blank PCB Board
A blank PCB board is an insulated board on which conducting copper is clad. The principle of
making PCBs is to mill off the unwanted copper from the blank PCB board. The procedure is like
traditional engraving, and the difference is that traditional engraving is handmade but this is
automatically operating under computer numeric control.
2. Computer Engraving Route
To machine a PCB, the first step is to define the areas that need to be milled off and the route that
the engraving tool is supposed to move along. In this system, with its high-speed calculating ability
utilized, the computer will get the information from a saved PCB file, and program the route. This
process is called computer engraving route.
3. Instruction Transportation
Control software can get the PCB machining information from PCB files, and transform them into
many independent instructions that the engraver can each understand. All these instructions
constitute the machining route. On receiving the instructions, for example when the separation
button is clicked, control software will transport the machining route instructions to the engraver’s
control panel via communication interface. Then the engraver’s CPU will coordinate the three
stepping motors’ speed and directions to operate according to the instructions. When all the work is
done, the control software will send a instruction to halt the engraver.
4. Movement Coordination and Control
In this equipment, three independent straight leading tracks are perpendicularly arranged. The
block on Y axle carries the operation platform backward and forward. The block on X axle carries
Z axle and the main axle motor on Z axle leftward and rightward. Z axle controls the main axle
motor upward and downward. Under the coordination of the engraver’s control system, the three
axles lead the rotating cutting tool to move three-dimensionally toward the workpiece and machine
the workpiece according to user's demand. For example, stop the Z & Y axle movement and set the
tool bit a little lower than the surface of the workpiece, make X-ward movement, the tool bit will
mill a straight X-ward score as wide as the tool bit. Make Y-ward movement while X axle stopped,
you can get a straight Y-ward score. When the X & Y axles are making movement at the same
speed, you can get a 45 degree oblique line. By controlling the moving speed of X & Y axles, you
can get beelines at different angles. By making different combinations of speed and range you get
different 2D shapes. When the tool bit is higher than the surface of the workpiece and the Z axle
movement is rested, by making X-ward and Y-ward movement the cutting tool will be carried to the
given position. Make downward Z axle movement while X & Y axle movement is rested, the main
axle motor will drive the tool bit to drill the board.
Whole appearance (fig. 1)

1.2 Special Features

Support Gerber format PCB file information of PROTEL directly.
Highly automatic procedures of engraving, drilling and trimming.
English operation interface, user-friendly and easy to use.
All the X Y Z axles are equipped with internationally advanced straight leading screw and block
pre-tightening device, which guarantee the tightness of the block.
The entire structure is made of cast iron, entirely milled smooth, with level and steady bearing
surface for the leading tracks.
All the X Y Z axles are equipped with ball bearing leading screws imported from Germany
originally, which guarantee the smooth movement, the high exactitude and the minimum shaking.
1.3 Technical Parameters
Specifications:
Main axle: 1.5kw frequency converter, 800W water-cooling frequency conversion motor
Main axle revolving speed: 24,000r/min (rating)
Driving system: Precise leading screw with three straight leading axles
Controlling software: DSP control system
Interface: PCI interface
Largest working area: 300mm×300mm (3030)/300mm×250mm (3025)
Workpiece type: Single/double sided
Driving mode: X, Y, Z axes stepping motor
Operating speed: 0－8000mm/min
Minimum line width: 6-8mil
Minimum line width and spacing: 6-8 mil
Resetting positioning accuracy: 0.001 mm
Drilling depth: 0～30mm
Drilling diameter: 0.3～2.0mm(increasable)
Drilling speed: 60-100 holes/min
Operation mode: Manual tool change, automatic operation
Software environment: WindowsXp/2000/vista
Computer configuration: CPU P4, RAM 256MB
Operating voltage: AC200V-240V/50Hz
Mean power: 800W

Chapter 2 Hardware & Software Installation

The installation of the engraver includes hardware installation and software installation. Hardware
installation includes the PCI cable connection between the engraver and the computer, the
installation of the PCI cable of the engraver’s control panel, the connection between the main axle
motor and the frequency converter, the installation of the water-cooling system and all the power
lines.
2.1 Hardware Installation
For facility's sake, it’s better to lay the engraver as high as the computer on a work table
horizontally and steadily without wobbling. Connect each end of the PCI cable to the interface of
the engraver’s control panel and the PCI interface of the computer. Then connect the main axle’s
power line to the frequency converter’s output port(make sure not to tangle any part of the
equipment). Then fill the cooling water tank with tap-water, put the mini immersible pump in it and
make sure the inlet port of the pump is outside the tank. Connect one end of the main axle’s cooling
water pipe to the pump, and put the other end into the water though the little hole on the cooling
water tank. The installation of the engraver would be finished when the power lines of the engraver,
the frequency converter and the cooling water system are well connected.
When using it, turn on the water cooling pump first and make sure the cooling water is running
normally. Then turn on the engraver and connect it with the computer. You can turn on the main
axle motor’s frequency converter before operation. The maximum output has been limited to
400Hz(24000rpm) already, and you can just turn the frequency converter’s knob clockwise to the
end.
All the parameters of the machine have been set optimally before leaving factory, and are not
accessible for users. If you do have to adjust the parameter settings, please contact us and we will
adjust them for you. Please do not change the parameter settings without permission.
2.2 Software Installation
Recommended PC configuration:
P4 2.4GHZ or higher
256MB RAM or larger
One available PCI interface or more
Operation system winXP, 2000, VISTA
CD-ROM
Insert the installation CD in your CD-ROM drive, and run COPPERCAM and NCSTUDIO
installation program.
After the installation a shortcut to COPPERCAM will be created on your desktop. And
NCSTUDIO could be used by running it directly.

CHAPTER 3 Engraver Using

It is natural for you to machine a PCB immediately to approve your creation after designing a
circuit file. Please be patient to read this instruction and the operation introduction carefully before
putting it into practice. You will soon be familiar with the equpiment using, whose convenience is
to fascinate you deeply.
3.1 How to create a machining file
After designing and saving a PCB file, how to create a machining file that the equipment can
execute, a file that drive the engraver to machine the PCB we need? Let’s take the attached
“wireless hypersensitive receiver.PCB” for example.
Open the “hypersensitive wireless receiver.PCB” and create a new file “hypersensitive wireless
receiver.DDB”. Otherwise open the DDB file immediately. Then we can see the design file as the
illustration shows below.
 The picture below comes out by clicking “new” option in “File” menu and choose the first option
“CAM output configuration”.

After that click straight “OK” to the picture below.

After selecting the file format of Gerber, click straight “Next” to choose layers as shown in the
following picture
Select the layers of circuit arrangement (caution: bottom layer, top layer and keep out layer must be
included) and click “next” to the picture below.

Select the illustrated mm unit and 4:4 format (saving the exactitude of 4 digits after the decimal
point), click “finish” to generate light printing file “Gerber output1” (CAUTION: *.GBL is bottom
layer file, *.GTL is top layer file.). According to the same procedure, generate PCB NC Drill file
(*.TXT represents NC Drill file).
With the light printing file and NC Drill file generated, we need to unify their coordinates. Drill’s
default coordinate system is not “center plots on”. Right click Gerber output1 file, select properties
and click “advanced” option like the next illustration and remove the “center plots on” check box.
Then click OK.
Options of Protel differs from versions. For the Protel with sp6, through Gerber output1 file →
properties→advanced, select “reference to relative origin” because it is drill’s default coordinate
system.
Finally, right click the folder containing light printing files and drilling files in the left column (like
fig.9). Select “Export” to transfer the saved folder “CAMManager1.cam” to the position user
designates. So the machining file is done.
Other options all apply default settings of Protel (Gerber output1’s properties):
like Gerber file’s suppress leading zero but drill’s suppress trailing zero, which will exert some
influence on software’s extracting information.

If it is a single-layered PCB, we should make the 2.GTL file and 3.TXT file generate G instruction
file based on whose route the cutting tools engraves. If it’s a double-layered PCB, there will be one
more bottom layered file 1.GBL.
Next is the introduction to it.
3.2 SOFTWARE COPPERCAM
3.2.1INSTALLING SOFTWARE COPPERCAM,

Run COPPERCAM on the computer

Enter its main interface
File
Machine
Edit
Display
Parameters
Help
Shortcut toolbar exhibits as the illustration below 1

Shortcut toolbar exhibits as the illustration below 2

Open a one-layered file 1.GTL from COPPERCAM

Opened file exhibits like the next picture:

Please add the type of cutting tool in Tool library in Parameters:

Number of cutting tools where a lot of cutting tools can be added

Names of cutting tools, Engraving tool –cutter used for engraving and separating(flatbottom
dagger), Basic cutter—cutting tools used for cutting profiles(straight knives), Drilling
tool—drilling tools(straight knives with drill bits)
Diameter—diameter of colter arm（generally0.3-2mm);
Profile—profiles of cutting tools including cylindrical，conical（flatbottom dagger）， Angle-20-60
°users are able to select angles of the cutting tools
Click OK to affirm after adding cutting tools. Then add other knives with the same method.
After adding all the knives, click selected tools in Parameters as below:

Select flatbottom dagger used for separating in ENGRAVING TOOL, Depth—cutting depth ，
generally 0.1-0.2mm
Select model of the flatbottom dagger used for milling in HATCHING TOOL and choose carving
depth.
Select straight knife used for cutting profiles in CUTTING TOOL and choose cutting depth.
Select cutting tool used for orientation in CENTERING TOOL(generally 0.4-0.8mm straight knife)
In DRILLING TOOLS Use one single tool for different bore diameters with circular boring; Use
for each drill the closest smaller tool, with circular boring; Use for each drill the closest greater tool,
without circular boring.
If we choose the first option, the drilling procedure will turn out that one cutter machines all drills;
if we choose the second and third options, a proper drilling knife must be selected in SELECTED
TOOLS. However, in actual machining process a few more machining drill files are generated,
which will cause much more work load in that one drilling file attaches to one cutting tool of one
model.
Size of circular boring for all drills depends on practice
Drilling depth of common PCB is 1.6mm and more than 1.6mm would be best, other options have
not to be modified. Then click OK.

Now we could separate the current PCB by choosing the separating function in tool menu as shown
in the following figure. Only if finishing board separation can we start milling or local engraving.
Select Apply to all layers and Use simplified calculation (faster) and then click OK.

Engraving route in the PCB board has formed through the process as the next illustration shows:

Enlarge one part as shown in the following illustration:

Now you can add drilling file to the top-layered PCB board as the following steps show:

Select Drills in FILE, choose 2.GBL file and confirm it so that machining route will form

This software automatically applies dimensions of the cutting tools you should use and click Oks
respectively
It shows as below:

If carving a single-layered PCB, you should export the file. However, if machining a double-
layered PCB, you should handle with the positionings of the top layer and drills before generating

the bottom layer route. Operations show as below: Click the positioning and you can
position it. Put your mouse pointer at the lower left corner of the circuit diagram and click.
Input the numbers of X and Y and then confirm as exhibited in the following picture:

Choose 0 in “Reframe around existing circuitry with a margin of” in Dimensions of FILE, make Z
cutting thickness 1.6mm which is also the depth of PCB and click OK as shown in the next picture:
lower left corner is the carving origin. After finishing carving the first side, the PCB should be
reversed and the positioned origin of the PCB’s second layer is the lower right corner location point,
which is the key to the procedure.
You can check simulation effect in the Display menu. If not proper, please reselect cutting tools.

Then export the files of the first layer and the cutting route. Click , as below:
In DATA, choose ISO G-Code for CNC-Mill Process of Format with other options remaining the

same, click OK. Continue to click , confirm to enter into the next interface:

Sequence (sequence of milling and drilling)

Flip horizontally
Finally save the file as *.PLT so that we can open the file in PCB control system to output carving
The second layer carving:
Shut down COPPERCAM, restart it, open 2.GBL in the same way to generate a route and then add
location bore whose number is the one we have set when machining the first layer.

Click in the menu. Because it’s the second layer, it must be reversed. If you want

complete milling or part milling, please select as shown in the following illustration:

Hatch inside(milling area）： while board (the whole circuit diagram including the area outside
the circuit）， card contour(area of the circuit diagram），
selected zone
Apply to all layers
Link hatches

It shows as the following figure：

Lower left corner is the carving origin, also the location point.

If you want to check the simulation effect, please lick as below:

Then export the cutting route of this PCB layer, save it as *.plt, and finally output the file via the
PCB engraver’s control system.
3.3 Instructions For Hardware
After generating the machining file, we have to adjust the machine to machine the PCB board we
have designed. We have made a complete introduction to the machine installation. Now we
continue to introduce machine usage.

3.3.1 PCB Fixing

As the illustration exhibits, after confirming the installation of the engraver hardware and software,
select a copper-clad whose area a bit lager than your design(the size of the copper-clad should
ensure that it will not hamper the machining operation after installation), make one border of the
copper-clad tightly abut against the end line of bottom platform of the engraver, and press the two
borders tight and flat with uniform forces. Use the fixture pressing the four borders of the copper-
clad in order to tighten them(CAUTION: the borders of the copper-clad must tightly abut against
the borders of the platform and ensure that the borders are plane and smooth so that precise
positioning can be ensured when changing the borders).
3.2.2 Drill Bit Installation
When machining PCB, drills and location bores of double-sided boards require drills. First we
choose drills of one norm(if the size of the bore in the PCB file is unknown, we can select 0.8mm
drills),loosen the screws under main axle motor with a double wrench, and then insert the drill bits
and screw tightly. Installation of the main axle motor bits and cutting tools has automatic
rectification function, with which we are able to automatically prevent the cutting tools installation
from inclination.
3.2 Start Power Sources
Turn on the power of the cooling pump, engraver and main axle frequency converter sequently,
make sure water are flowing normally. After the frequency converter output reach 400Hz, we can
start operating the software to machine PCBs.
CHAPTER 4 Operating Procedures for PCB Machining
In this chapter, we will take a hypersensitive wireless receiver machining (double-sided circuit
board)for example to instruct the engraver operation.
1. As the former chapter shows, we first turn on the power sources of cooling pump, engraver and
main axle frequency converter seqently and make sure water are flowing normally.
2. Open the PCB file “hypersensitive wireless receiver.PCB”, generate a machining file with the
former method and save it to the desktop.
3. In PROTEL, the size of the PCB we have generally measured to be machined is about 80 ×
60mm. Select a larger PCB, fix one border tightly to the end line and ensure that the area on which
knifepoint can move is larger than the size we have measured before.
4. After choosing a drill of one norm, fix it on the main axle motor tightly(like 0.8mm),start the
power source of the main axle frequency converter making the main axle rotate normally at
24000r/min (SEPCIAL TIP: the cutting tools and drill bits equipped are quite sharp. Improper
operation easily results in cutting your finger. Please be very cautious!)
5. Open the software, adjust the coordinates of the three axes in the control area and control the bit
to approximately reach the lower left corner of the board.
6. Because we should finish metallizing the bores before machining a two-sided PCB, in this
instance we finish drilling first. Check the information layer of the bore in the design, click the drill
button after making sure that there is no error. Then there pops up a child dialog box, select drill
bits of proper norms according to the prompt in the child dialog box to add them to the right
column (CAUTION: when choosing drill bits, we can set one of a norm for all bores to avoid
trouble),and input the dimension of the PCB thickness(engraver default is 1.6mm of general norm).
Click OK and it begin machining PCB. Then a prompt asking you whether to change the drill for
0.8mm will pop up, and the engraver starts drilling automatically after you confirming and
installing the drill. When finishing drilling the bores of 0.8mm, the engraver will remind you of
changing it for a drill of 1.0mm, change it and then confirm it. The engraver will finish all the
drillings.
7. After removing the PCB and cleaning it up, we can use fine sandpapers to grind the circuits of
the two side until the circuits are apparent and smooth. In order to prevent PCB from oxidization
and enhance further weldability, we can spread some mineral spirits on it.

Chapter 5 Special Explanations and Instructions

Special Explanations:
1. The dimensions of cutting tools range from 0.1 mm to 0.5 mm with drill bits from 0.6 mm to 1.2
mm. If users need other norms, please call our company for additional purchase.
2. This machine is equipped with a plexiglass bottom plate. Please contact our company after a long
run and we are responsible for the disassembly and replacement. This machine is also equipped
with a larger-sized flat-end milling cutter for remachining the bottom plate. Please keep it well
preserved.
3. This software has set a separation function to machine circuit rapidly so no longer support copper
cladding settings. As to PCB files with copper cladding settings, this software might not possibly
recognize. Please revise or redesign them before applying.
4. The cutting tools and drill bits provided by the equipment are easily consumable and not in the
warranty scope. Please be cautious to prevent them from breaking during usage and keep it safe
when they are not used. If you need to make additional purchase, please contact our company.
Special Instructions:
1. This machine is a piece of industrial equipment with certain operating danger. Please operate
with care and keep it well kept by certain person in order to prevent unnecessary loss..
2. It must be used according strictly to the instructions, and for the indicated purpose. Please
shutdown the electricity source immediately if any accident happens when operating, and wait for a
while before operating it again. Please contact us directly if there's any fatal problem, and do not
disassemble it without permission.
3. The main axle motor maybe hot after long time of operation. Please pause the operation for a
while then and change the cooling water before continuing.
4. Please grease the mechanical parts regularly, like the leading screw, to ensure it’s smooth
movement.

Jinan JCUT CNC equipment Co., Ltd.

Huoju building, suite 1014, Huayuan road No.40, zip code 250100.
Tel:: +86-531-82374813
Tel
Fax:: +86-531-82374653
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