Panasonic KXF-493C User manual

Operating Instructions
Model No. KXF-493C
Thank you for purchasing CM120, the multi-functional chip mounter.
Before placing the machine in service, be sure to read the instruction manual for
proper usage.
After that, store it carefully and it if necessary.
493C-E-MMAB-0009
Multi-functional Chip Mounter CM120
Maintenance Manual(1/2)

Page 3
“Use of this machine:
This machine is designed and constructed to be used for placing
electric and electronic components on PCB.
This machine shall be used for this purpose only.
It shall not be used for any other purpose.”
“Operation of this machine:
This machine shall be operated by professional, specially trained operators.
It shall not be operated by non-professional, not specially trained operators.
Regarding the training course, please contact Panasonic Factory Solutions Co., Ltd. or PFSE.”
Machine was manufactured by: Panasonic Factory Solutions Co., Ltd.
441-13, Nagahasu, Tateishi-machi, Tosu-city, Saga, Japan
Phone number :81-942-84-2644
Fax number :81-942-84-2636
For Service and Supply of Spares in Europe
you may contact Panasonic Europe:
Continental Europe
PFSE
Panasonic Factory Solutions Europe
Winsbergring 15
22525 Hamburg Germany
Phone number : 0049-(0)40-85386-321
Fax number : 0049-(0)40-85386-332
United Kingdom
PFSE
Panasonic Factory Solutions Europe
Panasonic House, Willoughby Road
Bracknell, Berks. RG12 8 FP
Phone number : 0044-(0)1344-853267
Fax number : 0044-(0)1344-425970
Year: 2005
493C-E-MMA00-B01-03
M11E
DO NOT ALLOW ANY PERSON WHO HAS NOT RECEIVED SPECIAL TRAINING
TO OPERATE THE MACHINE.
The machine may be operated improperly and injure you.
Either carry out training by yourself, or consult the manufacturer.
WARNING

Page 4
SPECIFICATIONS
493C-E-MMA00-B01-01
∗1: Data is created by PT. This machine can correct only some of data.
∗2: The power consumption depends upon the power supply voltage and frequency.
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Page 5
This manual is for the installation of Multi-functional Chip Mounter
CM120-MU.
Installation manual (Only for CE standard version)
The assembly of each unit is individually indicated by an exploded
view of the parts. Use this for ordering parts or confirming the assem-
bly of the units.
Parts List
This manual is for the machine operators, and describes the operating
procedure, precautions and information which is necessary for safe
and effective operation.
ORGANIZATION OF MANUALS
6 manuals (Nonstandard version: 5 copies) are attached to this machine. They are classified into 5
types (Nonstandard version: 4 types). Use each manual according to the working purpose and person
in charge.
The production data of the line including this machine are programmed on PT. Refer to the instruction
manuals accompanied with PT.
Operating manual (for operators)
This manual is for the machine engineers, and describes operation
method and teaching of boards and parts.
Operating manual (for engineers)
This manual is for machine maintenance, and describes the daily
checks, adjustment and replacement of consumable parts.
Troubleshooting is also included.
Maintenance manual (1/2, 2/2)
This machine’s manuals
This manual
493C-E-MMA00-B01-00

Page 6 493C-E-MMA00-B01-00
= MEMO =

Page 7
1
2
3
4
5
493C-E-MMA00-A02-28
SAFETY PRECAUTIONS
REGULAR MAINTENANCE
MACHINE PARAMETER AND MACHINE PARAMETER TEACHING
SOLUTIONS FOR ERROR
UPDATING
DISCARDING THE PRODUCTS
APPENDIX
Maintenance Manual
Maintenance Manual

Page 8
SAFETY PRECAUTIONS................................................................ 13
Chapter 1 REGULAR MAINTENANCE
1-1 Outline of Maintenance .............................................................................. 1-2
1-1-1 Checking the Operating Period, Contents and History Information ....................1-2
1-1-2 Maintenance Mode..............................................................................................1-5
1-1-3 Regular Check Items for Period..........................................................................1-6
1-1-4 Regular Check Items for Each Unit.....................................................................1-9
1-2 Lubricating................................................................................................ 1-13
1-2-1 Setting the Cartridge .........................................................................................1-13
1-2-2 Using the Grease Gun ......................................................................................1-14
1-2-3 Greasing Point ..................................................................................................1-15
1-3 Check Every 24 Hours (Every Day) ......................................................... 1-17
1-3-1 Checking the MR Unit (before Operation).........................................................1-17
1-3-2 Cleaning the Feeder Setting Face (before Operation)......................................1-18
1-3-3 Cleaning the NG Chip Ejecting Box and Empty Tape Box (after Operation).....1-19
1-3-4 Cleaning the Empty Tape Duct..........................................................................1-20
1-4 Check Every 140 Hours (Every Week)..................................................... 1-21
1-4-1 Cleaning the Color Touch Panel (Front Side)....................................................1-21
1-4-2 Cleaning the Line Camera (Front Side) ............................................................1-22
1-4-3 Cleaning the Color Touch Panel (Rear Side) ....................................................1-23
1-4-4 Cleaning the Load Cell Unit (Rear Side)...........................................................1-23
1-4-5 Checking the Movement of Safety Area Sensor (Front Side) : General safety specification .. 1-24
1-4-6 Cleaning the Transfer Head and Nozzle (Front Side) .......................................1-25
1-4-7 Checking the Movement of Safety Area Sensor (Rear Side) : General safety specification... 1-48
1-4-8 Cleaning the Nozzle Stocker and Nozzle (Rear Side) ......................................1-48
1-4-9 Cleaning the Board Holder ................................................................................... 1-52
1-5 Check Every 560 Hours (Every Month).................................................... 1-54
1-5-1 Checking the Exhaust Cleaner (before Operation) ...........................................1-54
1-5-2 Transfer Head : Cleaning the Large Reflector ..................................................1-55
1-5-3 Checking the Board Transfer Belts and Rollers ................................................1-57
1-5-4 Lubricating the Board Holder and Board Conveyor ..........................................1-60
1-5-5 Lubricating the Board Holder ............................................................................1-64
1-5-6 Lubricating the X-Y Unit and Head Unit (Rear Side).........................................1-66
1-5-7 Lubricating DT10F-3 (optional) : General safety specification ..........................1-71
1-5-8 Lubricating DT20F-20U (optional).....................................................................1-72
1-6 Check Every 3000 Hours (Once per Half a Year)..................................... 1-74
1-6-1 Lubricating the Linear Encoder .........................................................................1-74
1-7 Consumable Parts to be Changed Every 3000 Hours (Once per Half a Year) ..... 1-77
1-7-1 Changing the Board Transfer Belts and Rollers................................................1-77
1-8 Consumable Parts to be Changed Every 6000 Hours (Once a Year) ...... 1-80
1-8-1 Procedures for Replacing Consumables Used on the Vacuum Pump..............1-80
493C-E-MMA00-A02-02

Page 9
1-9 Replacing the Consumable Parts............................................................. 1-83
1-9-1 Replacing the Battery........................................................................................1-83
1-9-2 Replacing Color Touch Panel Back Light ..........................................................1-85
Chapter 2Machine Parameter and
Machine Parameter Teaching
2-1 Machine Parameter .................................................................................... 2-2
2-1-1 XY Plane Calibration ...........................................................................................2-3
2-1-2 Origin Offset ........................................................................................................2-3
2-1-3 Status Indicator ...................................................................................................2-4
2-1-4 Head....................................................................................................................2-4
2-1-5 Load Relation......................................................................................................2-5
2-1-6 Tray Feeder.........................................................................................................2-5
2-1-7 Nozzle Stocker....................................................................................................2-6
2-1-8 Heat Calibration Mark .........................................................................................2-6
2-1-9 PCB Stage ..........................................................................................................2-7
2-1-10 PCB Positioning ..................................................................................................2-7
2-1-11 Lead Checker......................................................................................................2-8
2-1-12 Chip Eject............................................................................................................2-8
2-1-13 Recognition .........................................................................................................2-9
2-1-14 Camera ...............................................................................................................2-9
2-1-15 Network.............................................................................................................2-10
2-1-16 Feeder Base......................................................................................................2-12
2-1-17 Feeder Timer.....................................................................................................2-12
2-1-18 Action Parameter Configuration........................................................................2-13
2-1-19 Option Configuration .........................................................................................2-13
2-2 Procedures of Machine Parameter Teaching ........................................... 2-14
2-2-1 Head Camera....................................................................................................2-16
2-2-2 XY Plane Calibration .........................................................................................2-22
2-2-3 Load Cell Calibration.........................................................................................2-27
2-2-4 Head Z Origin....................................................................................................2-30
2-2-5 Mounting Force .................................................................................................2-33
2-2-6 Head Stroke End...............................................................................................2-36
2-2-7 Magnification of Line Camera (Pixel Rate) .......................................................2-39
2-2-8 Theta of Line Camera and Head.......................................................................2-42
2-2-9 Monitor Camera ................................................................................................2-46
2-2-10 Head Position....................................................................................................2-50
2-2-11 Line Camera Position........................................................................................2-53
2-2-12 Nozzle Stocker..................................................................................................2-56
2-2-13 Feeder Base......................................................................................................2-60
493C-E-MMA00-A02-04

Page 10
Chapter 3 SOLUTIONS FOR ERROR
3-1 Error Messages .......................................................................................... 3-2
3-1-1 Errors in Using the Floppy Disk...........................................................................3-2
3-1-2 Errors during PT Network....................................................................................3-2
3-1-3 Errors during the Self-diagnosis..........................................................................3-3
3-1-4 Immediate Stop Error ..........................................................................................3-5
3-1-5 Emergency Stop Error ........................................................................................3-8
3-1-6 Axis Error of Emergency Stop...........................................................................3-10
3-2 Check and Solutions ................................................................................ 3-12
3-2-1 Disk is Write Protect..........................................................................................3-12
3-2-2 Format Error......................................................................................................3-12
3-2-3 Emergency Switch On ......................................................................................3-13
3-2-4 Servo Switch Off ...............................................................................................3-13
3-2-5 Air Pressure Drop..............................................................................................3-14
3-2-6 Production End Signal ON ................................................................................3-14
3-2-7 CPU Box Over Heat
Driver Box 1 Over Heat
Driver Box 2 Over Heat
Power Box 1 Over Heat ....................................................................................3-15
3-2-8 Z-and SL-axis Brake Open Error ......................................................................3-16
3-2-9 Vacuum Pump 1 Thermal Error
Vacuum Pump 2 Thermal Error
Vacuum Pump 3 Thermal Error.........................................................................3-17
3-2-10 Disconnection I/O fiber lines # 1 to 5 ................................................................3-18
3-2-11 Area Sensor Detect (Operator-side Front)
Area Sensor Detect (Operator-side Rear)
Area Sensor Detect (Antioperator-side Front)
Area Sensor Detect (Antioperator-side Rear) ...................................................3-19
3-2-12 Chip Eject Conveyor Full Stop ..........................................................................3-20
3-2-13 Tape Float Stop .................................................................................................3-20
3-2-14 DT10F (#2 and 3) Cover Open .........................................................................3-21
3-2-15 DT20F (# 2 and 3) Magazine Exchange Door Open ........................................3-21
3-2-16 DT20F(#2 and 3) Supply Door Open ................................................................3-22
3-2-17 DT20F(#2 and 3) Brake Open Error .................................................................3-22
3-2-18 PCB Recognition Error......................................................................................3-23
3-2-19 Chip Pickup Error ..............................................................................................3-24
3-2-20 Mount Position Recognition Error .....................................................................3-24
3-2-21 Recog Communication Error.............................................................................3-25
3-2-22 Disconnection Optical Ring ...............................................................................3-25
3-2-23 RS485 Communication Error ............................................................................3-26
3-2-24 Feedback Error .................................................................................................3-27
3-2-25 Overrun Error ....................................................................................................3-28
3-2-26 Driver Error........................................................................................................3-29
3-2-27 Interlock Error....................................................................................................3-35
3-2-28 Disconnection Fiber Line...................................................................................3-35
493C-E-MMA00-A02-00

Page 11
3-3 Load Arrangement.................................................................................... 3-36
3-3-1 Load Arrangement of Main Body ......................................................................3-36
3-3-2 DT20F-20U Load Arrangement.........................................................................3-38
3-3-3 DT10F-3 Load Arrangement .............................................................................3-39
3-4 Load List................................................................................................... 3-40
3-4-1 Load List of Main Body .....................................................................................3-40
3-4-2 DT20F-20U Load List........................................................................................3-44
3-4-3 DT10F-3 Load List ............................................................................................3-46
3-5 The input and Output Check of Machine.................................................. 3-47
3-5-1 The Input Check after Error...............................................................................3-47
3-5-2 The Output Check after Error............................................................................3-48
Chapter 4 UPDATING
4-1 Updating the Recognition Device ............................................................... 4-2
4-1-1 Updating Procedure ............................................................................................4-2
4-1-2 Error Massages Updating ...................................................................................4-3
4-2 Updating the System .................................................................................. 4-4
4-2-1 Installing the System (Ver. 2.20 or Later) ............................................................4-4
4-2-2 Installing the Screen Transfer System ...............................................................4-4
4-2-3 Installing the System Disk...................................................................................4-5
Chapter 5 DISCARDING THE PRODUCTS
5-1 Discarding the Air Spring............................................................................ 5-2
INDEX
ROUTINE CHECK LIST
Appendix A I/O MAP
493C-E-MMA00-A02-04

Page 12 493C-E-MMA00-A02-02
Appendix BLOAD CONNECTION DIAGRAM
B-1 WIRING DIAGRAM (CE standard version)
B-2 LOAD WIRING DIAGRAM (CE standard version)
B-3 WIRING DIAGRAM (Nonstandard version)
B-4 LOAD WIRING DIAGRAM (Nonstandard version)
B-5 WIRING DIAGRAM (Common)
B-6 LOAD WIRING DIAGRAM (Common)
Appendix CCONTROL BOX
C-1 CPU BOX
C-2 POWER BOX
C-3 DRIVER BOX1
C-4 DRIVER BOX2 (CE standard version)
C-5 PUMP UNIT
C-6 400V TRANS BOX (CE standard version)
Appendix DSETUP DIAGRAM
Appendix EWHOLE CONNECTION DIAGRAM
(CM120, DT20)
Appendix FDIRECT TRAY FEEDER
(DT20F-20U)
F-1 TRAY UNIT
F-2 LOAD WIRING DIAGRAM
F-3 LOAD WIRING DIAGRAM (Supplying part)
F-4 SETUP DIAGRAM
Appendix GAIR CIRCUIT DIAGRAM

Page 13
SAFETY PRECAUTIONS
Be sure to observe
The precautions that must be observed in order to prevent injury to the user or another
person, or damage to property, are as follows.
The degree of danger or injury resulting from incorrect use due to the failure to read an
indication is classified and described as follows.
The matters should be observed are classified and described according to the symbols
shown below.
(The followings are only some examples of the symbolic indications.)
This indication refers to a situation which is considered that
there is imminent danger of death or serious injury.
This indication refers to a situation which is considered that
there is a possibility of death or serious injury.
This indication refers to a situation which is considered that
there is a possibility of only injury or physical damage.
These symbols indicate matters to which attention must be paid.
These symbols indicate an action that must not be carried out.
DANGER
WARNING
CAUTION
These symbols indicate an action that must be carried out.
493C-E-MMA00-A03-02

Page 14
SAFETY PRECAUTIONS
Be sure to observe
WARNING
493C-E-MMA00-A03-00
Follow the warning indication.
This is a label for ensuring the safe machine use. If you do not observe it, there is a risk of human
injury or damage to property.
The following warning labels are pasted on this machine. Follow the instructions on each label. If a label has
come off, put a new one on a proper position. To order a label from the manufacturer, refer to PARTS LIST.
Label part No.
Front view of warning label indicated positions (CE standard version)
M32E
0 1 J Q B
feeder tables will have
serious injury.
∗Electrical
power
indication.f
0 1 K 1 B
DANGER
DO NOT OPEN
THE COVER
WHEN
OPERATING
You will have serious
injury if you touch the
active part inside.
0 1 P 9 B
WARNING
DO NOT DISABLE
SAFETY SENSOR
You will have serious
injury by active part
if you disable safety
sensor.
493C-003P00.tiff
0 1 N C B
WARNING
ELECTRIC
SHOCK
You will have serious
electric shock if you
touch electric active
part inside.
0 1 J X A
DANGER
DO NOT TOUCH
ACTIVE PART
WHEN
OPERATING
You will have serious
injury if you touch the
active part.
0 1 N M B
WARNING
WORKER
OPERATING
IN THE BACK
Make sure that no
worker is in the back
when machine
starting.

Page 15
SAFETY PRECAUTIONS
Be sure to observe
Front view of warning label indicated positions (Nonstandard version)
493C-AA00tiff
WARNING
0 1 P 9 B
WARNING
DO NOT DISABLE
SAFETY SENSOR
You will have serious
injury by active part
if you disable safety
sensor.
0 1 J X A
DANGER
DO NOT TOUCH
ACTIVE PART
WHEN
OPERATING
You will have serious
injury if you touch the
active part.
0 1 N M B
WARNING
WORKER
OPERATING
IN THE BACK
Make sure that no
worker is in the back
when machine
starting.
0 1 K 1 B
DANGER
DO NOT OPEN
THE COVER
WHEN
OPERATING
You will have serious
injury if you touch the
active part inside.
493C-E-MMA00-A03-01
0 1 N C B
WARNING
ELECTRIC
SHOCK
You will have serious
electric shock if you
touch electric active
part inside.

Page 16
SAFETY PRECAUTIONS
Be sure to observe
M32E
WARNING
493C-E-MMA00-A03-01
Rear view of warning label attached positions (CE standard version)
493C-004P00.tiff
0 1 P 9 B
WARNING
DO NOT DISABLE
SAFETY SENSOR
You will have serious
injury by active part
if you disable safety
sensor.
0 1 N C B
WARNING
ELECTRIC
SHOCK
You will have serious
electric shock if you
touch electric active
part inside.
0 1 K 1 B
DANGER
DO NOT OPEN
THE COVER
WHEN
OPERATING
You will have serious
injury if you touch the
active part inside.
0 1 J X A
DANGER
DO NOT TOUCH
ACTIVE PART
WHEN
OPERATING
You will have serious
injury if you touch the
active part.
0 1 N L B
WARNING
WORKER
OPERATING
IN THE FRONT
Make sure that no
worker is in the front
when machine
starting.
∗Electrical
power
indication.f
∗Electrical
power
indication.f
0 1 N C B
WARNING
ELECTRIC
SHOCK
You will have serious
electric shock if you
touch electric active
part inside.
0 1 K F B
DANGER
HOT SURFACE
You will have serious
burn if you touch the
hot surface.
0 1 N J B
WARNING
MACHINE
FALLING DOWN
Machine will fall down
if you slant machine
more than 15 degrees
in machine installation
or removal.

Page 17
SAFETY PRECAUTIONS
Be sure to observe
Rear view of warning label attached positions (Nonstandard version)
M32E
WARNING
493C-AB00
0 1 P 9 B
WARNING
DO NOT DISABLE
SAFETY SENSOR
You will have serious
injury by active part
if you disable safety
sensor.
0 1 N C B
WARNING
ELECTRIC
SHOCK
You will have serious
electric shock if you
touch electric active
part inside.
0 1 N L B
WARNING
WORKER
OPERATING
IN THE FRONT
Make sure that no
worker is in the front
when machine
starting.
0 1 J X A
DANGER
DO NOT TOUCH
ACTIVE PART
WHEN
OPERATING
You will have serious
injury if you touch the
active part.
0 1 K 1 B
DANGER
DO NOT OPEN
THE COVER
WHEN
OPERATING
You will have serious
injury if you touch the
active part inside.
0 1 N C B
WARNING
ELECTRIC
SHOCK
You will have serious
electric shock if you
touch electric active
part inside.
493C-E-MMA00-A03-01
0 1 K F B
DANGER
HOT SURFACE
You will have serious
burn if you touch the
hot surface.
0 1 N J B
WARNING
MACHINE
FALLING DOWN
Machine will fall down
if you slant machine
more than 15 degrees
in machine installation
or removal.

Page 18
SAFETY PRECAUTIONS
Be sure to observe
433C-065E
WARNING
0 1 N J B
WARNING
MACHINE
FALLING DOWN
Machine will fall down
if you slant machine
more than 15 degrees
in machine installation
or removal.
0 1 P 6 A
WARNING
MAGAZINE LIFT
MOVING UP AND
DOWN
You will have serious
injury if you touch
moving magazine lift.
0 1 K 1 B
DANGER
DO NOT OPEN
THE COVER
WHEN
OPERATING
You will have serious
injury if you touch the
active part inside.
0 1 J X A
DANGER
DO NOT TOUCH
ACTIVE PART
WHEN
OPERATING
You will have serious
injury if you touch the
active part.
Direct tray feeder
DT20F-20U (option)
Warning label indicated positions
To CM120
493C-E-MMA00-A03-00

Page 19
SAFETY PRECAUTIONS
Be sure to observe
If you sense any danger or abnormality, press an emergency stop button to
stop the machine.
If you continue to operate the machine in a dangerous or abnormal state, a breakdown or an
accident will occur.
There are four emergency stop buttons. Pressing any one of them stops operation. Press the nearest one.
Remove the cause of the danger or abnormality, then re-start the machine. To reset the emergency stop button,
pull it forward.
M33E-2B
WARNING
1 Front operation panel
4 Left on rear side
493C-001P00.tiff
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3 Left on front side
2 Rear operation panel
493C-E-MMA00-A03-00

Page 20
SAFETY PRECAUTIONS
Be sure to observe
The breaker to which the
machine is connected.
Turn it off.
Observe the following items before placing your hand or other part of your
body in an active part of the machine in order to feed production material,
change machine set-up, or adjust machine settings.
You may be injured if the machine is actuated. Also you may be struck by an electric shock.
There are three levels of procedure, shown below, for each kind of work.
Cutting off the power supply of the machine -----------For repairing the control box
Power supply OFF-------------------------------------------- This is used to turn off power supply normally.
For replacing the control part such as the sensor
For disassembling or replacing parts
Servo switch OFF--------------------------------------------- For changing production board and daily inspection
For placing or removing board on the conveyor
For setting production materials such as the feeder
1
M73EB
2
WARNING
1
2
3
(On the rear panel.)
493C-001P00.tiff
R
E
L
E
A
S
E
T
R
I
P
O
F
F
O
N
R
E
S
E
T
Turn it OFF.
STEP SELECT
C
K
C
K
OFF ( ) ON ( )
SERVO
Turn it OFF.
3
3
493C-E-MMA00-A03-00