Panasonic CM301 User manual

Operating Instructions
Model No. KXF-4H4C
KXF-4X4C
Thank you for purchasing CM301, the modular multi-functional 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.
4H4C-E-OMAB-0004
Modular Multi-functional Placement Machine CM301
Operating Manual

Page 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
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
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
4H4C-E-OMA00-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

Page 2
SPECIFICATIONS
4H4C-E-OMA00-B01-00
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Page 3
This manual is for the operators and engineers of this equipment and
for the engineers who program the production data. It describes
machine operation on the whole, setting of production materials,
machine adjustment, production data creation and so on.
ORGANIZATION OF MANUALS
This machine is accompanied by the following four manuals (CM301-DU: five manuals). They are
classified into three types (CM301-DU: 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.
Operating manual
Manuals of this equipment
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
This
manual
This manual is for the persons who maintain this equipment. It
describes simple inspection/adjustment and replacement of
consumable parts.
Troubleshooting is also described.
Maintenance manual (1/2,2/2)
This manual is for the installation of this equipment.
Installation manual
4H4C-E-OMA00-B01-00

Page 4 4H4C-E-OMA00-B01-00
= MEMO =

Page 5
1
2
3
4
5
6
7
8
9
10
Operating Manual
4H4C-E-OMA00-A02-15
SAFETY PRECAUTIONS
GENERAL DESCRIPTION
BASIC OPERATION
FUNCTIONS
PRODUCTION
SETTING PRODUCTION MATERIALS
FILE OPERATION
DATAMODIFICATION
TEACHING
CHANGING THE PRODUCTION BOARDS
OPTION
APPENDIX

Page 6 4H4C-E-OMA00-A02-02
SAFETY PRECAUTIONS................................................................ 11
Chapter 1 GENERAL DESCRIPTION
1-1 Names and Mechanism of Each Unit ......................................................... 1-2
1-1-1 Placement Machine (CM301)..............................................................................1-2
1-1-2 Tray Feeder (DT40T) ..........................................................................................1-9
1-2 Mounting Mechanism ............................................................................... 1-12
1-3 Equipment Specification........................................................................... 1-14
1-3-1 Machine Specification .......................................................................................1-14
1-3-2 Mounting Area...................................................................................................1-15
1-3-3 Board Flowing Direction....................................................................................1-15
1-3-4 Outer Dimensions .............................................................................................1-16
1-4 Other Specification ................................................................................... 1-17
1-4-1 Available Board Specification............................................................................1-17
1-4-2 Available Feeders .............................................................................................1-18
1-4-3 Nozzle Specifications ........................................................................................1-19
Chapter 2 BASIC OPERATION
2-1 Operating Panel ......................................................................................... 2-2
2-2 Touch Panel................................................................................................ 2-3
2-2-1 Touch Panel Configuration ..................................................................................2-3
2-2-2 Function Keys .....................................................................................................2-4
2-2-3 Switch Types and How to Operate......................................................................2-6
2-2-4 Messages............................................................................................................2-9
2-3 Main Menu................................................................................................ 2-10
2-4 Engineer Mode ......................................................................................... 2-12
2-4-1 How to Enter Engineer Mode............................................................................2-12
2-4-2 How to Change Password.................................................................................2-13
Chapter 3 FUNCTIONS
3-1 Menu Configuration .................................................................................... 3-2
3-1-1 Operator Mode ....................................................................................................3-2
3-1-2 Engineer Mode....................................................................................................3-3
3-2 Production Settings .................................................................................... 3-4
3-2-1 Nozzle Settings ...................................................................................................3-5
3-2-2 Selecting Tray Mode ...........................................................................................3-6
3-2-3 Calculating Chip Consumption............................................................................3-6
3-2-4 Board Transport ..................................................................................................3-8

Page 7
4H4C-E-OMA00-A02-01
3-2-5 Feeder Arrangement ...........................................................................................3-9
3-2-6 Changing Support Pins .....................................................................................3-11
3-2-7 Tray Counter .....................................................................................................3-12
3-2-8 Tray Pallet Setup...............................................................................................3-14
3-2-9 Motion Setup.....................................................................................................3-14
3-3 Production Information ............................................................................. 3-16
3-3-1 Run Information.................................................................................................3-16
3-3-2 Stop Information................................................................................................3-17
3-3-3 Pick-up Information ...........................................................................................3-18
3-3-4 Reset.................................................................................................................3-19
3-4 Machine Adjustment ................................................................................. 3-20
3-4-1 Returning to Origin............................................................................................3-20
3-4-2 Conveyor Width Adjustment..............................................................................3-21
3-4-3 Board Transport ................................................................................................3-21
3-4-4 Nozzle Changing...............................................................................................3-22
3-4-5 Pick-up and Mounting Motions..........................................................................3-22
3-4-6 Tray Adjustment ................................................................................................3-23
3-4-7 Input Check.......................................................................................................3-24
3-4-8 Output Check ....................................................................................................3-25
3-4-9 Axis Information ................................................................................................3-26
3-4-10 Recognition Device Maintenance .....................................................................3-26
3-4-11 Ring Load Information.......................................................................................3-26
3-5 Machine Settings...................................................................................... 3-27
3-5-1 Switches for Adjustment....................................................................................3-27
3-5-2 Pick-up Position Learning .................................................................................3-28
3-5-3 Defective Head..................................................................................................3-28
3-5-4 Setting Time ......................................................................................................3-29
3-5-5 Setting Backlight ...............................................................................................3-29
3-5-6 Customizing Operator Mode .............................................................................3-30
Chapter 4PRODUCTION
4-1 Production Work Flow ................................................................................ 4-2
4-2 Before Production....................................................................................... 4-3
4-2-1 Start-up Inspection..............................................................................................4-3
4-2-2 Checking Air Pressure ........................................................................................4-4
4-3 Starting Production..................................................................................... 4-5
4-3-1 Starting up Machine ............................................................................................4-5
4-3-2 Starting Operation...............................................................................................4-6
4-3-3 Self-diagnosis......................................................................................................4-7
4-3-4 Returning to Origin..............................................................................................4-8
4-4 During Production....................................................................................... 4-9
4-4-1 Information and Functions during Production .....................................................4-9
4-5 Production Stop........................................................................................ 4-10
4-5-1 Stop Operation..................................................................................................4-10

Page 8 4H4C-E-OMA00-A02-02
4-5-2 Information and Functions during Stop .............................................................4-12
4-6 Completion of Production ......................................................................... 4-13
4-6-1 Automatic Stop..................................................................................................4-13
4-6-2 Finishing Machine .............................................................................................4-13
Chapter 5 SETTING PRODUCTION MATERIALS
5-1 Setting Trays .............................................................................................. 5-2
5-1-1 Setting Tray onto Pallet.......................................................................................5-2
5-1-2 Offset Block for Pallet..........................................................................................5-4
5-1-3 Setting Tray Magazine into Tray Feeder .............................................................5-6
5-2 Setting Tape Feeders ................................................................................. 5-8
5-2-1 How to Set...........................................................................................................5-9
5-2-2 How to Remove.................................................................................................5-11
5-3 Supplying Chips during Production .......................................................... 5-13
5-3-1 Supplying Chips to Tray Feeder........................................................................5-13
5-3-2 Tray Feeder Tables Motion in Supplying Chips.................................................5-14
5-3-3 Supplying Chips to Tape Feeder .......................................................................5-15
Chapter 6 FILE OPERATION
6-1 Loading Data .............................................................................................. 6-2
6-2 Loading and Saving the Machine Parameter ............................................. 6-3
6-2-1 Loading the Machine Parameter.........................................................................6-3
6-2-2 Saving the Machine Parameter...........................................................................6-4
6-3 File Operation of the Floppy Disk ............................................................... 6-5
Chapter 7 DATA MODIFICATION
7-1 Data Modification Menu.............................................................................. 7-2
7-2 PCB Data ................................................................................................... 7-3
7-3 Board Recognition Data ............................................................................. 7-4
7-3-1 Selecting REF .....................................................................................................7-5
7-3-2 Evolution Data.....................................................................................................7-6
7-4 Feeder Layout / Stock Data........................................................................ 7-7
7-4-1 Occupancy ..........................................................................................................7-8
7-4-2 Complete Part Information ..................................................................................7-9
7-4-3 Angle Definition...................................................................................................7-9
7-5 Chip Data / Tray Data............................................................................... 7-10
7-5-1 Detail Chip Data ................................................................................................7-12
7-5-2 Extension Chip Data .........................................................................................7-13
7-5-3 Selecting REF ...................................................................................................7-14
7-6 Nozzle Arrangement Data ........................................................................ 7-15

Page 9
7-7 Nozzle Stock Data.................................................................................... 7-16
7-8 Block Attribute Data .................................................................................. 7-17
7-9 Mount Data............................................................................................... 7-18
7-10 Function Switch ........................................................................................ 7-19
7-11 Library Display.......................................................................................... 7-20
7-12 Data Check............................................................................................... 7-22
Chapter 8 TEACHING
8-1 Before Teaching.......................................................................................... 8-2
8-1-1 Recognition .........................................................................................................8-2
8-1-2 Lamp Value Adjustment Setting ..........................................................................8-2
8-2 Board Recognition Teaching ...................................................................... 8-3
8-2-1 Board Recognition ..............................................................................................8-3
8-2-2 Flowchart of Board Recognition Teaching...........................................................8-3
8-2-3 Teaching Procedures ..........................................................................................8-4
8-3 Bad Mark Recognition Teaching................................................................. 8-9
8-3-1 Bad Mark Recognition.........................................................................................8-9
8-3-2 Flowchart of Bad Mark Recognition Teaching.....................................................8-9
8-3-3 Teaching Procedures ........................................................................................8-10
8-4 Mount Point Recognition Teaching.......................................................... 8-15
8-4-1 Teaching Procedure .............................................................................................8-15
8-5 Chip Recognition Teaching....................................................................... 8-18
8-5-1 Chip Recognition...............................................................................................8-18
8-5-2 Flowchart of Chip Recognition Teaching...........................................................8-18
8-5-3 Before the Chip Recognition Teaching..............................................................8-20
8-5-4 Teaching Procedures (Block Match Recognition) .............................................8-23
8-6 Teaching the Mount Position .................................................................... 8-30
8-6-1 Teaching the Mount Position .............................................................................8-30
8-6-2 Creating Procedure...........................................................................................8-30
8-7 Pickup Position Learning Teaching .......................................................... 8-35
8-8 Tray Pickup Position Teaching ................................................................. 8-38
8-8-1 Teaching Procedure .............................................................................................8-38
Chapter 9 CHANGING THE PRODUCTION BOARDS
9-1 Changing the Production Data ................................................................... 9-2
9-2 Adjusting the Transfer Rail Width ............................................................... 9-4
9-3 Setting the Support Pin .............................................................................. 9-6
9-4 Nozzle Exchange ....................................................................................... 9-9
9-4-1 Checking the Nozzle Arrangement .....................................................................9-9
9-4-2 Nozzle Exchange of the Nozzle Changer ........................................................9-11
9-5 Setting and Checking the Production Materials ....................................... 9-13
9-6 Board Transfer Test .................................................................................. 9-14
9-7 Checking the Mount State through the Conditional Mount....................... 9-16
4H4C-E-OMA00-A02-03

Page 10
Chapter 10 OPTION
10-1 Transport Speed Variable Adjustment ...................................................... 10-2
10-1-1 Transport Speed Variable Adjustment...............................................................10-2
10-1-2 Deceleration Speed Adjustment Procedure ......................................................10-3
10-1-3 Transport Speed Adjustment Procedure ...........................................................10-5
INDEX
Appendix A RECOGNITION DEVICE (HGR-12)
4H4C-E-OMA00-A02-01

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.
These symbol indicate an action that must not be carried out.
DANGER
WARNING
CAUTION
These symbol indicate an action that must be carried out.
4H4C-E-OMA00-A03-02

Page 12
SAFETY PRECAUTIONS
Be sure to observe
DANGER
4H4C-E-OMA00-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 13
SAFETY PRECAUTIONS
Be sure to observe
E
M
E
R
G
E
N
C
Y
S
T
O
P
2Emergency stop button
(At the rear side)
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 CM301-D. 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 it.
M104E
WARNING
E
M
E
R
G
E
N
C
Y
S
T
O
P
4H4C-E-OMA00-A03-00
1Emergency stop button
(At the front side)
E
M
E
R
G
E
N
C
Y
S
T
O
P
CM301-D
4H4C-AA01

Page 14
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 CM301-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 it.
M104E
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
1Emergency stop button
(At the front side)
2Emergency stop button
(At the rear side)
CM301-DU
4X4C-AA00
WARNING
E
M
E
R
G
E
N
C
Y
S
T
O
P
4H4C-E-OMA00-A03-00

Page 15
SAFETY PRECAUTIONS
Be sure to observe
Cut off the power supplying
to the machine.
Turn OFF the
breaker that is
connented to the
machine.
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
1
M73EB
2
1
2
3
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
CM301-D
4H4C-AA01
Turn OFF the power
supply.
Turn OFF the servo
switch.
Rear panel
Turn OFF the servo
switch.
Front panel
WARNING
3
4H4C-E-OMA00-A03-00

Page 16
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
CM301-DU
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
4X4C-AA00
Turn OFF the power
supply.
Turn OFF the servo
switch.
Rear panel
Turn OFF the servo
switch.
Front panel
3
4H4C-E-OMA00-A03-00

Page 17
SAFETY PRECAUTIONS
Be sure to observe
4H4C-E-OMA00-A03-02
WARNING

Page 18
SAFETY PRECAUTIONS
Be sure to observe
WARNING
L13EB
DO NOT DISABLE
SAFETY SENSOR.
You will have serious injury by
active part if you disable safety
sensor.
Do not remove the sensor,
put any objects in or turn off
the switch so that the safety
sensor work properly and
effectively.
WORKER OPERATING
IN THE BACK.
If you start the machine without
confirming that it is safe to do
so, it may cause injury to the
worker behind the machine.
Make sure that no worker is
in the back when machine
starting.
L18EB
WORKER OPERATING
IN THE FRONT.
If you start the machine without
confirming that it is safe to do
so, it may cause injury to the
worker in front of the machine.
Make sure that no worker is
in the front when machine
starting.
L19EB
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
L11E
WATCH YOUR
HANDS OR FIN-
GERS.
You will have serious injury if
you touch active part.
4H4C-E-OMA00-A03-02
L14EB
ELECTRIC SHOCK.
You will have serious electric
shock if you touch electric
active part inside.
L41EB
TAKE CARE NOT TO
TOUCH CUTTER
You will have serious injury if
you touch cutter.