Panasonic KXF-4T3C User manual

Operating Instructions
Model No. KXF-4T3C
Thank you for purchasing CM20F, tthe 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.
4T3C-E-MMAB-0007
Multi-functional Chip Mounter CM20F
Maintenance Manual

Page 3
4T3C-E-MMA00-B01-00
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
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.
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
4 manuals are attached to this machine. They are classified into 4 types. Use each manual according
to the working purpose and person in charge.
The production data of the line including this machine are programed on PT.
Use the programming manual attached to PT.
Operating manual(operators)
Parts List
This manual is for the machine engineers, and describes operation
method and teaching of boards and parts.
Operating manual (engineers)
This manual is for machine maintenance, and describes the daily
checks, adjustment and replacement of consumable parts.
Troubleshooting is also included.
Maintenance manual
This machine’s manuals
This manual
4T3C-E-MMA00-B01-00

Page 5
4T3C-E-MMA00-A02-18
SAFETY PRECAUTIONS
REGULAR MAINTENANCE
MACHINE PARAMETER AND MACHINE PARAMETER TEACHING
SOLUTIONS FOR ERROR
UPDATING
APPENDIX
Maintenance Manual
Maintenance Manual
1
2
3
4

Page 6
SAFETY PRECAUTIONS................................................................ 11
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 .....................................................................1-8
1-2 Lubricating ................................................................................................ 1-11
1-2-1 Setting the Cartridge ......................................................................................... 1-11
1-2-2 Using the Grease Gun ......................................................................................1-12
1-2-3 Greasing Point ..................................................................................................1-13
1-3 Check Every 24 Hours (Routine).............................................................. 1-14
1-3-1 Checking the MR Unit (before Operation) .........................................................1-14
1-3-2 Cleaning the Feeder Setting Face (Before Operation) .....................................1-15
1-3-3 Cleaning the NG Chip Ejecting Box and Waste Tape Box (after Operation) .....1-16
1-4 Check Every 140 Hours (Once a Week) .................................................. 1-17
1-4-1 Cleaning the Color Touch Panel........................................................................1-17
1-4-2 Cleaning the Line Camera ................................................................................1-17
1-4-3 Cleaning the Waste Tape Duct ..........................................................................1-18
1-4-4 Cleaning the Transfer Head and Nozzle (Front Side) .......................................1-19
1-4-5 Cleaning the Nozzle Stocker and Nozzle ..........................................................1-44
1-4-6 Cleaning the Board Conveyor ...........................................................................1-47
1-5 Check Every 560 Hours (Once a Month) ................................................. 1-48
1-5-1 Transfer Head : Cleaning the Large Reflector ..................................................1-48
1-5-2 Checking the Board Transfer Belt and Roller ....................................................1-50
1-5-3 Lubricating the Board Conveyor .......................................................................1-52
1-5-4 Lubricating the X-Y Unit and Head Unit ............................................................1-55
1-5-5 Unit for Tube Feeder (Option) : Cleaning the Filter ...........................................1-61
1-5-6 Lubricating DT30F-20 (Option) .........................................................................1-63
1-6 Replacing the Consumable Parts ............................................................. 1-65
1-6-1 Replacing the Board Transfer Belt and Roller (3000 hours) .............................1-65
1-6-2 Unit for Tube Feeder (Option) : Replacing the Filter (3000 hours) ....................1-67
1-6-3 Vacuum Pump : Replacing the Filter Element, Valve and Packing (6000 hours) .......... 1-68
1-6-4 MR Unit :Replacing the Filter Element (18000 hours).......................................1-71
1-6-5 Transfer Head :Replacing the Arm and Spring (18000 hours) ..........................1-73
1-6-6 Replacing the Battery ........................................................................................1-75
1-6-7 Replacing Color Touch Panel Back Light ..........................................................1-77
4T3C-E-MMA00-A02-02

Page 7
Chapter 2MACHINE PARAMETER AND
MACHINE PARAMETER TEACHING
2-1 Machine Parameter .................................................................................... 2-2
2-1-1 Origin Offset ........................................................................................................2-3
2-1-2 XY Plane Calibration ...........................................................................................2-3
2-1-3 Status Indicator ...................................................................................................2-4
2-1-4 Head and Head Camera .....................................................................................2-4
2-1-5 Lead Checker (Optional) .....................................................................................2-5
2-1-6 Stroke End .........................................................................................................2-5
2-1-7 Tray Feeder (Optional) ........................................................................................2-6
2-1-8 Nozzle Stocker ....................................................................................................2-6
2-1-9 Recognition .........................................................................................................2-7
2-1-10 Camera ...............................................................................................................2-7
2-1-11 Chip Eject ............................................................................................................2-8
2-1-12 PCB Positioning ..................................................................................................2-8
2-1-13 Heat Calibration Mark .........................................................................................2-9
2-1-14 Network .............................................................................................................2-10
2-1-15 Feeder Base...................................................................................................... 2-11
2-1-16 Feeder Timer ..................................................................................................... 2-11
2-1-17 Mount Stage ......................................................................................................2-12
2-1-18 Action Parameter Configuration ........................................................................2-12
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 .........................................................................................2-21
2-2-3 Head Z Origin ....................................................................................................2-25
2-2-4 Head Stroke End ...............................................................................................2-30
2-2-5 Magnification of Line Camera ...........................................................................2-35
2-2-6 Origin Teaching of Theta of Line Camera and Head .........................................2-38
2-2-7 Line Camera and Head Position .......................................................................2-42
2-2-8 Line Camera Image Calibration ........................................................................2-52
2-2-9 Nozzle Stocker ..................................................................................................2-56
2-2-10 Feeder Base......................................................................................................2-59
2-2-11 Tape Feeder Height ..........................................................................................2-63
4T3C-E-MMA00-A02-01

Page 8
Chapter 3 SOLUTIONS FOR ERROR
3-1 Error Messages (Error List) ........................................................................ 3-2
3-1-1 Use of Error Message List...................................................................................3-2
3-1-2 Axis Error Code List ............................................................................................3-3
3-1-3 Errors in Using the Floppy Disk...........................................................................3-5
3-1-4 Errors during PT Network....................................................................................3-5
3-1-5 Errors during the Self-diagnosis..........................................................................3-6
3-1-6 Immediate Stop Error ..........................................................................................3-8
3-1-7 Emergency Stop Error ......................................................................................3-10
3-1-8 Errors during Self-diagnosis of DT30 ................................................................3-14
3-1-9 DT30 Immediate Stop Errors ............................................................................3-15
3-1-10 DT30 Emergency Stop Errors ...........................................................................3-16
3-2 Check and Solutions ................................................................................ 3-18
3-2-1 Disk is Write Protect..........................................................................................3-18
3-2-2 Format Error......................................................................................................3-18
3-2-3 Emergency Switch ON ......................................................................................3-19
3-2-4 Servo Switch OFF .............................................................................................3-19
3-2-5 Safety Relay Error
Safety Ready Error
Cover Open
Area Sensor Detect...........................................................................................3-20
3-2-6 Tape Feeder Setting Error (#1) and (#2) ...........................................................3-20
3-2-7 Air Pressure Drop..............................................................................................3-21
3-2-8 Production End Signal ON ................................................................................3-21
3-2-9 Ring Load Check...............................................................................................3-22
3-2-10 CPU Box Overheat Warning / Error
Table Lower Center Overheat Warning / Error
Table Center Tape Feeder Overheat Warning / Error
Head Driver Overheat Warning / Error..............................................................3-23
3-2-11 TL-axis Brake Open Error .................................................................................3-25
3-2-12 XY Driver Error..................................................................................................3-25
3-2-13 TL- and TP- axis Driver Error ............................................................................3-26
3-2-14 Vacuum Pump 1 Thermal Error
Vacuum Pump 2 Thermal Error
Vacuum Pump 3 Thermal Error.........................................................................3-27
3-2-15 Area Sensor Detect (Operator-side)
Area Sensor Detect (Antioperator-side) ............................................................3-28
3-2-16 Chip Eject Conveyor Full Stop ..........................................................................3-28
3-2-17 Tape Float Detected (#1)
Tape Float Detected (#2)...................................................................................3-29
3-2-18 DT30F (# 2 and 3) Magazine Exchange Door Open ........................................3-29
3-2-19 PCB Recognition Error......................................................................................3-30
3-2-20 Chip Pickup Error ..............................................................................................3-31
3-2-21 Mount Position Recognition Error .....................................................................3-31
3-2-22 RS485 Communication Error ............................................................................3-32
4T3C-E-MMA00-A02-00

Page 9
3-2-23 Driver Error........................................................................................................3-33
3-2-24 Emergency Switch ON ......................................................................................3-36
3-2-25 Servo Switch OFF .............................................................................................3-36
3-3 Load Arrangement .................................................................................... 3-37
3-3-1 Load Arrangement of Main Body ......................................................................3-37
3-3-2 Load Arrangement of DT30F-20 .......................................................................3-38
3-4 Load List ................................................................................................... 3-39
3-4-1 Load List of Main Body .....................................................................................3-39
3-4-2 Load List of DT30F-20 ......................................................................................3-44
3-5 The Input and Output Check of Machine.................................................. 3-45
3-5-1 The Input Check after Error...............................................................................3-45
3-5-2 The Output Check after Error ............................................................................3-46
INDEX
4T3C-E-MMA00-A02-01
Chapter 4UPDATING
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 System Updating ........................................................................................ 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

Page 10 4T3C-E-MMA00-A02-02
Appendix A I/O MAP
Appendix B LOAD WIRING DIAGRAM
B-1 LOAD WIRING DIAGRAM
B-2 LOAD WIRING DIAGRAM (SMEMA VERSION)
B-3 LOAD WIRING DIAGRAM (EU VERSION)
B-4 LOAD WIRING DIAGRAM (TOUCH PANEL WIRING DIAGRAM)
Appendix C CONTROL BOX
C-1 CPU BOX
C-2 PUMP UNIT
Appendix D SETUP DIAGRAM
Appendix E DIRECT TRAY FEEDER (DT30F-20)
E-1 LOAD WIRING DIAGRAM
E-2 SET UP DIAGRAM
Appendix F OPTION WIRING DIAGRAM
F-1 TUBE FEEDER
F-2 PARTS DISCHARGE CONVEYOR
Appendix G AIR CIRCUIT DIAGRAM

Page 11
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 failure to read an indica-
tion 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.
This symbol indicates an action that must not be carried out.
DANGER
WARNING
CAUTION
These symbols indicate an action that must be carried out.
4T3C-E-MMA00-A03-00

Page 12
SAFETY PRECAUTIONS
Be sure to observe
DANGER
4T3C-E-MMA00-A03-01

Page 13
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
4T3C-AA00
E
M
E
R
G
E
N
C
Y
S
T
O
P
E
M
E
R
G
E
N
C
Y
S
T
O
P
E
M
E
R
G
E
N
C
Y
S
T
O
P
E
M
E
R
G
E
N
C
Y
S
T
O
P
4T3C-E-MMA00-A03-00
3 Left pole on front side 1 Front operation panel
4 Left pole on rear side2 Rear operation panel
483C-AA03
E
M
E
R
G
E
N
C
Y
S
T
O
P
OFF
SERVO
ON
E
M
E
R
G
E
N
C
Y
S
T
O
P
EMERGENCY
Direct tray feeder
DT30F-20 (option)
• Pressing the emergency stop button
of direct tray feeder immediately stops
the operation of both the mounter and
the feeder.
• Pressing an emergency stop button
on the mounter stops the operation of
the feeder, too.

Page 14
SAFETY PRECAUTIONS
Be sure to observe
The breaker to which the
machine is connected.
Turn it off.
1
M73EB
2
WARNING
4T3C-AA00
R
E
L
E
A
S
E
T
R
I
P
O
F
F
O
N
R
E
S
E
T
Turn it off. 3
4T3C-E-MMA00-A03-00
OFF ( ) ON ( )
SERVO
STOP UNLOCK
SUPPLY
START
SELECT
KEY LOCK
Turn it off.
On the front panel
3
OFF ( ) ON ( )
SERVO
STOP UNLOCK
SUPPLY
START
SELECT
KEY LOCK
Turn it off.
On the rear panel
483C-AA03
OFF
SERVO
ON
E
M
E
R
G
E
N
C
Y
S
T
O
P
EMERGENCY
Direct tray feeder
DT30F-20 (option)
3Turn 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.
Repairing such as a control BOX. --------------------------------------------- Cut off the power supplying to the
machine.
Turning OFF the power supply routinely------------------------------------- Turn OFF the power supply.
Replacing a control part such as a sensor
Disassembling or replacing parts
Changing production board types or working for daily inspection ----- Turn OFF the servo switch.
Placing a board onto the conveyor or removing one from there
1
3
2

Page 15
SAFETY PRECAUTIONS
Be sure to observe
WARNING
4T3C-E-MMA00-A03-01

Page 16
SAFETY PRECAUTIONS
Be sure to observe
WARNING
M03EB
DO NOT PLACE ANY
OBJECTS WHICH
CARRY ELECTRIC
CURRENT INSIDE THE
ELECTRICAL EQUIP-
MENTS.
There is a risk of electric shock
or leak.
M09E
TAKE CARE NOT TO
PINCH YOUR HANDS
OR FINGERS.
You will have serious injury if
your hands or fingers are
caught in the conveyors during
manual (or automatic) width
adjustment.
TURN OFF THE
SERVO SWITCH BE-
FORE PLACING A
BOARD ON OR RE-
MOVING IT FROM THE
CONVEYOR.
You will have serious injury if
the machine is actuated.
M35E
4T3C-E-MMA00-A03-01
DO NOT DISAS-
SEMBLE THE LASER
UNIT.
(LEAD CHECKER
(OPTION) )
If you disassemble the unit,
safety can not be ensured. You
may be injured or machine may
break down.
If a breakdown occurs,
consult the manufacturer.
M42E

Page 17
SAFETY PRECAUTIONS
Be sure to observe
WARNING
M08E
ONLY THE PERSON IN CHARGE OF
MAINTENANCE MUST REPAIR OR
ADJUST THE MACHINE.
The machine may be incorrectly repaired or ad-
justed, resulting in malfunction.
Have the machine repaired or adjusted by a
trained professional maintenance engineer.
Consult the manufacturer for training.
DO NOT PLACE YOUR HANDS OR
BODY INSIDE ACTIVE PART OF THE
MACHINE WHEN IT IS IN A SINGLE
STOP OR CYCLE STOP CONDITION.
The machine has been stopped only temporarily.
You may be injured if the sensors are actuated and
the machine moves unexpectedly.
Turn OFF the servo switch before placing your
hands or body inside the active part.
M34EB
M02E
BEFORE INSPECTING PNEUMATIC
EQUIPMENTS, CUT OFF THE AIR
SUPPLY AND EXHAUST AIR FROM
THE EQUIPMENTS.
You will have serious injury if the residual pressure
actuates the machine.
Before inspecting pneumatic equipment, cut off
the air supply and exhaust the air from the
equipment.
Switch OFF the power.
M11E
DO NOT ALLOW ANY PERSON WHO
HAS NOT RECEIVED SPECIAL
TRAINING TO OPERATE THE MA-
CHINE.
The machine may be operated improperly and
injure you.
Either carry out training by yourself, or consult
the manufacturer.
M62EB
DO NOT TURN OFF THE SERVO
SWITCH DURING
OPERATION.
The machine may get out of control and injure you.
Before turning OFF the servo switch, bring the
machine to a temporary stop state, such as a
single stop state and a cycle stop state or an
operation stop state.
M63E
DO NOT MOVE ANY AXES (INCLUD-
ING HEADS) MANUALLY WHILE
TURNING OFF AND THEN ON THE
SERVO SWITCH UNDER A SINGLE
STOP, CYCLE STOP OR MACHINE
ADJUSTMENT MENU.
The machine may be actuated suddenly and injure
you when the servo switch is turned on.
If any axes (or the heads) are moved, press the
emergency stop button, and then reset the
switch. Restart operation through the main
menu.
4T3C-E-MMA00-A03-01

Page 18
SAFETY PRECAUTIONS
Be sure to observe
WARNING
DO NOT DAMAGE POWER AND
OTHER CORDS OR PLUGS.
Damaged cord and plug may cause electric shock,
short circuit or fire.
Hold the plug when plugging in or unplugging.
Cord and plug repairs should be attempted only
by the person competent to do the electrical
work, or contact the manufacturer.
M85E
Never damage, remake, bring
close to heating appliances, bend
forcibly, twist, pull, put heavy
objects on, and bundle up.
PERIODICALLY REMOVE DUST
FROM POWER PLUG.
Dust on the plug may result in fire caused by
defective insulation because of moisture.
Pull out the power plug and wipe off dirt with dry
cloth.
If the machine is not going to be used for a long
period, turn off the breaker connected with the
machine.
M86E
FIRMLY INSERT THE
POWER AND OTHER
PLUGS.
Imperfect plugging in may
cause fire because of electric
shock and generated heat.
Do not use the damaged
plug or loose outlet.
M87E M88E
DO NOT INSERT OR
REMOVE POWER AND
OTHER PLUGS BY
WET HAND.
If plugged in or unplugged by
wet hand, it may result in
electric shock.
USE THE SPECIAL-
IZED OUTLET AND
BREAKER EXCLU-
SIVELY.
If the breaker is shared be-
tween machines, it may cause
fire because of generated heat.
Check the dissipation power
in your Standard Specifica-
tion before consulting an
electrical contractor.
M89EB
M06E
GROUND THE MA-
CHINE PROPERLY.
There is a risk of an electric
shock or leak.
Consult a professional
electrical contractor.
4T3C-E-MMA00-A03-01

Page 19
SAFETY PRECAUTIONS
Be sure to observe
M27E
DO NOT GIVE A
SHOCK TO THE ELEC-
TRICAL EQUIPMENTS.
There is a risk of an electric
shock, leak or malfunction of
the machine.
CAUTION
M15E
DO NOT PLACE ANY
OBJECT AROUND
EMERGENCY STOP
BUTTONS.
You will be unable to press a
button to stop the machine in
case of emergency.
DO NOT PLACE ANY
OBJECTS ON THE
COVER.
The cover may break due to the
weight of the objects and injure
you.
M16EB M17EB
BE CAREFUL WITH
YOUR HANDS AND
FINGERS WHEN
CLOSING THE
COVER.
Your hands or fingers may be
caught in the cover and injured.
M20E
DO NOT BLOCK OFF
THE OUTLET OR IN-
LET OF THE FAN.
The temperature inside of the
machine will rise and the
machine may malfunction.
Do not block off the outlet or
inlet of the fan.
Periodically clean the filters
of the outlet and inlet.
M23E
ONLY THE PERSON IN
CHARGE MUST
CHANGE THE DATA.
The machine may runaway or
malfunction.
The data must be changed
only by a trained specialist
in charge.
M24EB
TAKE AWAY TOOLS
FROM THE INSIDE OF
THE MACHINE.
The machine may malfunction
as a result of a tool left inside.
Before operating the ma-
chine, verify that no tools are
left inside.
M25E
BE CAREFUL OF THE
WEIGHT OF THE
FEEDER.
A large feeder is so heavy that
it may be damaged or injure
you if it is dropped.
4T3C-E-MMA00-A03-01
M18E
DO NOT CLIMB OR
RIDE ON THE MA-
CHINE.
You may fall from or get caught
in the machine and get injured.

Page 20
SAFETY PRECAUTIONS
Be sure to observe
CAUTION
WEAR A PROTECTIVE
HAT AND GOGGLES
FOR MAINTENANCE
WORK.
Your head or eyes may be
injured while performing main-
tenance work.
M44E
M39E
CARRY OUT PERIODIC MAINTE-
NANCE AND INSPECTION.
If you fail to carry out periodic inspection and
maintenance, the machine cannot exhibit its true
performance. Also, it may break down or produce
defectives.
Periodic inspection and maintenance should be
carried out by a trained person in charge of
maintenance according to the instructions in
MAINTENANCE MANUAL.
BEFORE PERFORMING AUTOMATIC
WIDTH ADJUSTMENT, BE SURE TO
VERIFY NO BOARDS OR OTHER
OBJECTS ARE ON THE CONVEYOR.
Boards or other objects may drop from the con-
veyor, causing damage to the boards or the ma-
chine.
If there are any boards or other objects on the
conveyor, turn OFF the servo switch and remove
them.
M36E
DO NOT DISAS-
SEMBLE THE CAM-
ERA UNIT.
You may be injured or the
machine may break down.
If a breakdown occurs,
consult the manufacturer.
M41E
4T3C-E-MMA00-A03-01