Panasonic CM202 Series User manual

Operating Instructions
Model No. KXF-4U4C
KXF-D24C
KXF-E54C
Thank you for purchasing CM202, the modular high speed placement machine .
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.
4U4C-E-MMAB-0010
Modular High Speed Placement Machine CM202
Maintenance Manual(2/2)

1
“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.
For the training coursed you, make contact with Panasonic Factory Solutions Co., Ltd., PFAE or PIEL.”
Machine was manufactured by: Panasonic Factory Solutions Co., Ltd.
441-13, Nagahasu, Tateishi-machi, Tosu-city, Saga, Japan
TEL:[phone]
FAX:[phone]
For Service and Supply of Spares in Europe
you may contact Panasonic Europe:
Continental Europe
PFAE
Panasonic Factory Automation Europe
Winsbergring 15
22525 Hamburg Germany
Phone number :0049-(0)40-85386-321
Fax number : 0049-(0)40-85386-332
United Kingdom
PIEL
Panasonic Industrial Europe (U.K.)
Panasonic House, Willoughby Road
Bracknell, Berks. RG12 8 FP
Phone number : 0044-(0)1344-853267
Fax number : 0044-(0)1344-425970
Year: 2004
∗The model conforming to EC Machinery Directive and EMC Directive is CM202-DHU.
4U4C-E-MMA00-B01-01
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

2
SPECIFICATIONS
4U4C-E-MMA00-B01-02
∗1: Data are created in PT. This machine can correct only some pieces of data.
∗2: These are the weight of the main body except the optional devices.
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Item

3
4U4C-E-MMA00-B01-00
ORGANIZATION OF MANUALS
This machine is accompanied by four manuals (CM201-DU, CM202-DU, CM202-DHU: five manuals).
They are classified into three types (CM201-DU, CM202-DU, CM202-DHU: four types). Use each
manual according to the working purpose.
The production data of the line including this machine are programmed on PT. Refer to the instruction
manuals accompanied with PT.
Manuals of this machine
This manual is for the operators and engineers of the machine. It
describes the operating procedure, precautions and information which
is necessary for safe and effective operation.
Operating Manual
This
manual
This manual is for the persons who maintain the machine. It describes
simple inspection/adjustment and replacement of consumable parts.
Troubleshooting is also described.
Maintenance Manual (1/2, 2/2)
The assembly of each unit is individually indicated by the exploded
views of parts. Use this list when ordering parts or confirming the
assembly of parts.
Parts List
Installation Manual (Accompanies CM201-DU/202-DU/202-DHU only.)
This manual is for the installation of this machine.

44U4C-E-MMA00-B01-00
= MEMO =

5
1
2
3
Maintenance
Manual
4U4C-E-MMA00-A02-16
SAFETY PRECAUTIONS
REGULAR MAINTENANCE
MACHINE PARAMETER
SOLUTIONS FOR ERROR
APPENDIX

64U4C-E-MMA00-A02-06
SAFETY PRECAUTIONS.................................................................. 1
Chapter 1REGULAR 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 Motions ..........................................................................................1-5
1-1-3 Regular Check Items for Period ..........................................................................1-6
1-1-4 Regular Check Items for Each Unit .....................................................................1-8
1-1-5 Machine Information..........................................................................................1-12
1-1-6 Component Unit Update (Update of Each Board System) ................................1-13
1-1-7 Action Check .....................................................................................................1-14
1-2 Lubricating ................................................................................................ 1-15
1-2-1 Loading and Using the Grease Gun .................................................................1-16
1-2-2 Greasing Point ..................................................................................................1-18
1-2-3 Setting and Removing the Feeder Base Cover (Only for DU/DHU Specifications) ... 1-19
1-3 Check Every 24 Hours (Routine).............................................................. 1-20
1-3-1 Checking the MR Unit (before Operation) .........................................................1-20
1-3-2 Cleaning the Cover Glass for the Line Camera (before Operation) ..................1-21
1-3-3 Cleaning the Tape Feeder Setting Face (before Operation) .............................1-21
1-3-4 Cleaning the NG Chip Discharge Box (after Operation) ...................................1-22
1-3-5 Cleaning the Used Tape Box (after Operation) .................................................1-22
1-4 Check Every 140 Hours (Once a Week) .................................................. 1-24
1-4-1 Cleaning the Color Touch Panel........................................................................1-24
1-4-2 Cleaning and Lubricating the Tape Feeder Table ..............................................1-25
1-4-3 Cleaning and Lubricating the Nozzle ................................................................1-28
1-4-4 Cleaning the Support Pin Batch Exchange Table .............................................1-42
1-4-5 Checking and Lubricating the Board Conveyor ................................................1-44
1-4-6 Lubricating the X-Y Unit and Z Unit...................................................................1-50
1-4-7 Cleaning the Line Camera Lens .......................................................................1-59
1-4-8 Cleaning the Forced-Chip-Ejecting Unit ............................................................ 1-60
1-5 Check Every 560 Hours (Once a Month) ................................................. 1-61
1-5-1 Cleaning the Lubricating the Transfer Head .....................................................1-61
1-5-2 Cleaning and Lubricating the Cutting Unit ........................................................1-68
1-5-3 How to Check the Setting of the Blow Pressure ...............................................1-72
1-6 Check Every 3000 Hours (Once Six Months)........................................... 1-74
1-6-1 Exchanging the Board Transfer Belt and Roller ................................................1-74
1-7 Check Every 6000 Hours (Once a Year) .................................................. 1-76
1-7-1 Exchanging the Cutter Blade ............................................................................1-76
1-7-2 Replacing the Vacuum Pump ............................................................................1-82
1-7-3 Replacing the Indicator .....................................................................................1-84
1-7-4 Transfer Head : Replacing the Air Cylinder (Replacing Kit) ..............................1-85

7
4U4C-E-MMA00-A02-08
1-7-5 Tape Feeder Base : Replacing the Air Cylinder ................................................1-85
1-7-6 Color Touch Panel : Replacing the Back Light ..................................................1-85
1-8 Check Every 12000 Hours (Once Two Years).......................................... 1-86
1-8-1 Transfer Head : Replacing the valve (For the Vacuum Change) ......................1-86
1-8-2 XY Unit : Replacing (Replacing Kit) the Valve (For Selecting the Nozzle, For the Cylinder) . 1-88
1-8-3 Tape Feeder Base : Replacing the Valve (For Cylinder of the Tape Feeder)....1-92
1-9 Check Every 18000 Hours (Once Three Years) ....................................... 1-93
1-9-1 Transfer Head : Replacing the Shaft.................................................................1-93
1-9-2 Transfer Head : Nozzle Holder • Clamp Arm • Spring for Clamp Claw Holder •
Spring for Nozzle Cushion ................................................................................1-93
1-9-3 XY Unit : Cable Bear .........................................................................................1-93
1-10 Replacing Consumable Parts................................................................... 1-94
1-10-1 Replacing Color Touch Panel Back Light ..........................................................1-94
Chapter 2MACHINE PARAMETER
2-1 Machine Parameter .................................................................................... 2-2
2-1-1 Origin offset.........................................................................................................2-3
2-1-2 Judgment Value ..................................................................................................2-4
2-1-3 Nozzle Mount Pickup Position ............................................................................2-5
2-1-4 Nozzle Height......................................................................................................2-5
2-1-5 Optional Setting...................................................................................................2-6
2-1-6 Moving Parameter Setting...................................................................................2-7
2-1-7 Nozzle Changer ..................................................................................................2-7
2-1-8 Heat Calibration Mark .........................................................................................2-8
2-1-9 Mount Position ....................................................................................................2-8
2-1-10 Board Positioning ................................................................................................2-9
2-1-11 XY Plane Calibration ...........................................................................................2-9
2-1-12 Network.............................................................................................................2-10
2-1-13 Camera .............................................................................................................2-11
2-1-14 Light Quantity....................................................................................................2-11
2-1-15 Pick-up Position ................................................................................................2-12
2-1-16 Status Indicator .................................................................................................2-12
2-2 Procedures of Machine Parameter Teaching ........................................... 2-13
2-2-1 Origin Pickup Mounting Height..........................................................................2-15
2-2-2 Board Recognition Camera XY-axis Origin Offset ...........................................2-22
2-2-3 Chip Recognition Camera θ-axis Origin Offset .................................................2-24
2-2-4 XY Plane Calibration .........................................................................................2-28
2-2-5 Pick-up Position ................................................................................................2-30
2-2-6 Mount Position ..................................................................................................2-34

84U4C-E-MMA00-A02-04
Chapter 3SOLUTIONS FOR ERROR
3-1 Error Messages (Error List) ........................................................................ 3-2
3-1-1 Use of Error Message List...................................................................................3-2
3-1-2 Errors during PT Network....................................................................................3-2
3-1-3 Errors during Self-diagnosis ................................................................................3-3
3-1-4 Single Stop Error .................................................................................................3-4
3-1-5 Emergency Stop Error ........................................................................................3-4
3-2 Check and Solutions .................................................................................. 3-7
3-2-1 Air Pressure Drop................................................................................................3-7
3-2-2 Vacuum Pump Thermal Error
Power Box Over Heat .........................................................................................3-8
3-2-3 CPU Box Over Heat ............................................................................................3-9
3-2-4 PCB Recognition Error ......................................................................................3-10
3-2-5 SSR Ready Error .............................................................................................. 3-11
3-2-6 DC down ...........................................................................................................3-12
3-2-7 Self-Diagnosis Error ..........................................................................................3-16
3-2-8 Nozzle Setting Error ..........................................................................................3-18
3-2-9 Returning from Power Interruptions Occurred during Operation ......................3-24
3-3 Load Arrangement .................................................................................... 3-25
3-3-1 Load Arrangement of CM202 ............................................................................3-25
3-3-2 Load Arrangement of CM201 ............................................................................3-27
3-3-3 Load Arrangement of CM202-DS......................................................................3-29
3-3-4 Load Arrangement of CM201-DS......................................................................3-32
3-4 Load List ................................................................................................... 3-36
3-4-1 Load List of CM202 ...........................................................................................3-36
3-4-2 Load List of CM201 ...........................................................................................3-38
3-4-3 Load List of CM202-DS .....................................................................................3-40
3-4-4 Load List of CM201-DS .....................................................................................3-40
3-5 The Input and Output Check of the Machine............................................ 3-56
3-5-1 The Input Check after Error...............................................................................3-56
3-5-2 The Output Check after Error ............................................................................3-57
INDEX
ROUTINE CHECK LIST
MATERIAL SAFETY DATA SHEET

9
4U4C-E-MMA00-A02-01
Appendix A I/O MAP
Appendix B LOAD WIRING DIAGRAM
B-1 LOAD WIRING DIAGRAM
B-2 LOAD WIRING DIAGRAM (FEEDER PART)
B-3 LOAD WIRING DIAGRAM (HEAD PART)
B-4 LOAD WIRING DIAGRAM (CONVEYOR WIRING)
B-5 LOAD WIRING DIAGRAM (EXTENSION CONVEYOR 1)
B-6 LOAD WIRING DIAGRAM (EXTENSION CONVEYOR 2)
B-7 LOAD WIRING DIAGRAM (ONLY FOR DHU SPECIFICATIONS)
Appendix C CONTROL BOX
C-1 CPU BOX
C-2 CPU BOX (ONLY FOR DHU SPECIFICATIONS)
C-3 POWER BOX
Appendix D SET UP DIAGRAM
Appendix E WHOLE CONNECTION DIAGRAM
(ONLY FOR EUROPEAN SPECIFICATIONS)
Appendix F OPTION
F-1 CONVEYOR SPEED CONTROL UNIT
F-2 CONVEYOR SPEED CONTROL UNIT SETUP DIAGRAM
F-3 CONVEYOR SPEED CONTROL UNIT BOX DIAGRAM
Appendix G AIR CIRCUIT DIAGRAM

10 4U4C-E-MMA00-A02-01
= MEMO =

Page 1
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.
These symbols indicate an action that must not be carried out.
DANGER
WARNING
CAUTION
These symbols indicate an action that must be carried out.
444C-E-XXA00-A03-01

Page 2
SAFETY PRECAUTIONS
Be sure to observe
DANGER
444C-E-XXA00-A03-01
L06EB
DO NOT OPEN THE
COVER WHEN OPER-
ATING.
You will have serious injury if
you touch the active part inside.
L02E
DO NOT TOUCH AC-
TIVE PART WHEN
OPERATING.
You will have serious injury if
you touch the active part.

Page 3
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 two emergency stop buttons on CM201-D/DU/DH/DS. Pressing any one of them stops operation.
Press the nearest one.
Remove the cause of the danger or abnormality, then re-start operation.
To reset the emergency stop button, pull the button.
M107E
1Emergency stop button
(At the front side)
2Emergency stop button
(At the rear side)
CM201-D/DU/DH/DS (As for the explanation, the illustration of CM201-DH is used.)
4V4C-AA00
WARNING
444C-E-XXA00-A03-03

Page 4
SAFETY PRECAUTIONS
Be sure to observe
M107E
CM202-D/DU (As for the explanation, the illustration of CM202-DU is used.)
1Emergency stop button
(At the front right)
2Emergency stop button
(At the front center)
4Emergency stop button
(At the rear center)
3Emergency stop button
(At the rear right)
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 on CM202-D/DU. Pressing any one of them stops operation.
Press the nearest one.
Remove the cause of the danger or abnormality, then re-start operation.
To reset the emergency stop button, pull the button.
4Q4C-901E
WARNING
444C-E-XXA00-A03-01

Page 5
SAFETY PRECAUTIONS
Be sure to observe
WARNING
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 two emergency stop buttons on CM202-DH/DHU/DK/DS. Pressing any one of them stops operation.
Press the nearest one.
Remove the cause of the danger or abnormality, then re-start operation.
To reset the emergency stop button, pull the button.
CM202-DH/DHU/DK/DS (As for the explanation, the illustration of CM202-DH is used.)
2Emergency stop button
(At the rear side)
1Emergency stop button
(At the front side)
4U4C-AA00
M107E
444C-E-XXA00-A03-03

Page 6
SAFETY PRECAUTIONS
Be sure to observe
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
Setting production materials such as feeders
M73EB
1
2
3
CM201-D/DU/DH/DS (As for the explanation, the illustration of CM201-DH is used.)
WARNING
Cut off the power supplying
to the machine.
Turn OFF the
breaker that is
connented to the
machine.
12
R
E
L
E
A
S
E
T
R
I
P
O
F
F
O
N
R
E
S
E
T
3
OFF ( ) ON ( )
SERVO
STOP UNLOCK
STEP
START
LIGHT ON SELECT
KEY LOCK BACK LIGHT OFF
OFF ( ) ON ( )
SERVO
STOP UNLOCK
STEP
START
LIGHT ON SELECT
KEY LOCK BACK LIGHT OFF
4V4C-AA00
Turn OFF the power
supply.
Turn OFF the servo
switch.
Rear panel
Turn OFF the servo
switch.
Front panel
3
444C-E-XXA00-A03-02

Page 7
SAFETY PRECAUTIONS
Be sure to observe
WARNING
1
2
R
E
L
E
A
S
E
T
R
I
P
O
F
F
O
N
R
E
S
E
T
OFF ( ) ON ( )
SERVO
STOP UNLOCK
STEP
START
LIGHT ON SELECT
KEY LOCK BACK LIGHT OFF
CM202-D/DU (As for the explanation, the illustration of CM202-DU is used.)
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
Setting production materials such as feeders
Cut off the power supplying
to the machine.
Turn OFF the
breaker that is
connented to the
machine.
Turn OFF the power supply.
Turn OFF the servo switch.
Front panel
Turn OFF the servo
switch.
Rear panel
4Q4C-901E
1
2
3
OFF ( ) ON ( )
SERVO
STOP UNLOCK
STEP
START
LIGHT ON SELECT
KEY LOCK
KEY LOCK
BACK LIGHT OFF
BACK LIGHT OFF
3
3
444C-E-XXA00-A03-00
M73EB

Page 8
SAFETY PRECAUTIONS
Be sure to observe
WARNING
CM202-DH/DHU/DK/DS (As for the explanation, the illustration of CM202-DH is used.)
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
Setting production materials such as feeders
4U4C-AA00
444C-E-XXA00-A03-02
1
2
3
1
2
R
E
L
E
A
S
E
T
R
I
P
O
F
F
O
N
R
E
S
E
T
Cut off the power supplying
to the machine.
Turn OFF the
breaker that is
connented to the
machine.
Turn OFF the servo
switch.
Rear panel
OFF ( ) ON ( )
SERVO
STOP UNLOCK
STEP
START
LIGHT ON SELECT
KEY LOCK BACK LIGHT OFF
3
OFF ( ) ON ( )
SERVO
STOP UNLOCK
STEP
START
LIGHT ON SELECT
KEY LOCK BACK LIGHT OFF
Turn OFF the servo switch.
Front panel
3
M73EB