Panasonic KXF-1E4C User manual

Operating Instructions
Model No.
Maintenance Manual
KXF-1E4C
KXF-1F4C
Thank you for purchasing SP28P, the high speed screen printer.
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.
1E4C-E-MMAB-0013
High Speed Screen Printer SP28P

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.
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
TEL:[phone]
FAX:[phone]
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
∗The model conforming to EC Machinery Directive and EMC Directive is SP28P-DHU.
1E4C-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

2
SPECIFICATIONS
1E4C-E-MMA00-B01-00
1E4C-445TE
metI noitacificepS
emittcatgnitnirPnoitomgnitnirp+s6:UHD/HD
ezisdraobgnitnirP mm0.4otmm5.0:ssenkcihT,mm05xmm05:.niM,mm063xmm064:.xaM
emarfksaM mm055xmm006,mm055xmm056,mm637xmm637
epyteegeeuqS
drowS,eegeeuqserauqS,)dradnatS(eegeeuqsgnitnirpdeeps-hgiH
talF,eegeeuqscillateM,eegeeuqscillatemgnitnirpdeeps-hgiH,eegeeuqs
)noitpO(eegeeuqs
htgneleegeeuqS)dradnatS(mm084=L
deepseegeeuqSs/mm052ots/mm01
erusserpeegeeuqS
01x5:eegeeuqsgnitnirpdeeps-hgiH
2-
01x04otN
2-
adnemmocereW(N
01x01foerusserpgnitnirp
2-
01x51otN
2-
01x01wolebsgnitteS.N
2-
yamN
01x51:eegeeuqscillateM().ylbatstnirpton
2-
01x02otN
2-
).N
noitomeegeeuqS noitcnufaivelbaegnahcsiedomeegeeuqselbuoddnaeegeeuqselgniS
.hctiws
ecnerefergninoitisopdraoB ).sutlusnoC.deriuqersitnemtsujdalellarapeegeeuqS(ecafdnednaretneC
dohtemgnixifdraoB )noitpo(dohtemnoitcusdraoB,)dradnatS(dohtemgnipmalclacinahceM
noisicerpgninoitisopemarfksaM ±,noitceridY-Xnimm5 ±5.1 °noitceridgnitatorni
ecnaraelCmm3+otmm5.0-
noitareleccayticolevesaeler-ksaM
/lortnocyticolev-mrofinu/lortnoc
deeps-hgih/lortnocelpitlum
lortnocnoitarelecca
s/mm1.0/s/mm5ots/mm1.0yticolevlanimret,s/mm50.0yticolevlaitinI
s/mm01ots/mm1.0/s/mm5ots/mm1.0/s/mm5ot
noitcnufgninaelcediskcabksaM)gnitanretlA(tewroyrD
emittcatgninaelcksaM deepsgninaelcdnaezisdraobnognidneped,dradnatsnis62
]elcyc1yrD[
ezisrepapgninaelC mm084htdiWm81htgneL)mm83retemaiDedisnI(hcni-5.1
ecivednoitcusmuucaV )noitpO(pmupmuucaV,)dradnatS(rewolB
snoisnemidretuO
htdiW)royevnocfoecafdnE(mm0581
htpeDmm0771
thgieH mm0341
)rotacidnisutatsehtgnidulcnI(mm0002
ssaM )snoitpotuohtiW:noitarugifnocdradnatS(gk0551
erusserpriA nim/l03ytitnauqylppuSaPM87.0otaPM94.0
ylppusrewoP
egatlovlamroN
1.3esahp-eerhT,zH06/05,V002CA:HD
)AVk1.8:dellatsnItinUlortnoCerutarepmeT(AVk
1.3esahp-eerhT,zH06/05,V004CA:UHD
)AVk1.8:dellatsnItinUlortnoCerutarepmeT(AVk
elbatpecca.xaM
noitautculf ±%5
egatlovtupnI V022/V002:HD
V044/V004/V083:UHD
snoitidnoC 01:erutarepmeT °53otC °C
gnisnednocnon%08ot%53:ytidimuH
esioN 47 Bd

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
3 manuals (4 manuals for SP-28P-DHU/DU) are attached to this machine. They are classified into 3
types (4 types for SP-28P-DHU/DU) . 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
Manuals of this equipment
This manual is for the persons who maintain this equipment. It de-
scribes simple inspection/adjustment and replacement of consumable
parts.
Troubleshooting is also described.
Maintenance manual
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 is for the installation of this equipment.
Installation manual
This
manual
1E4C-E-MMA00-B01-00

41E4C-E-MMA00-B01-00
= MEMO =

5
1
2
3
4
5
Maintenance
Maintenance
Manua
Manual l
1E4C-E-MMA00-A02-14
SAFETY PRECAUTIONS
REGULAR MAINTENANCE
MACHINE PARAMETER
ADJUSTING THE MACHINE CONDITION
SOLUTIONS FOR ERROR
TROUBLE SHOOTING
APPENDIX

6
SAFETY PRECAUTIONS.................................................................. 1
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 Regular Check Items for Period ..........................................................................1-5
1-1-3 Regular Check Items for Each Unit .....................................................................1-8
1-2 Lubricating ................................................................................................ 1-14
1-2-1 Loading the Grease Gun ...................................................................................1-14
1-2-2 Using the Grease Gun ......................................................................................1-15
1-2-3 Greasing Points.................................................................................................1-16
1-3 Check Every 24 Hours (Routine).............................................................. 1-17
1-3-1 Urethane Squeegee : Check for Wear and Damage(Before Operation)...........1-17
1-3-2 Checking for Abnormal Noise (After Setup and during Operation) ...................1-18
1-3-3 Cleaning the Squeegee Holder (After Operation) .............................................1-19
1-3-4 Cleaning the Board Positioning Lifter (After Operation) ....................................1-21
1-3-5 Cleaning the Board Holding Unit (Option) (After Operation) .............................1-24
1-3-6 Checking for Wear and Damage on the Blade and the Side Rubber (Before
Operation) .........................................................................................................1-25
1-3-7 Clean the Blade (After Operation) .....................................................................1-26
1-4 Check Every 140 Hours (Once a Week) .................................................. 1-27
1-4-1 Cleaning the Vacuum Component of the Mask Cleaning..................................1-27
1-4-2 Checking for Clogging of the Solvent Dispensing Nozzle .................................1-29
1-4-3 Cleaning the Filter of the Temperature Controller (Option) ...............................1-31
1-4-4 Cleaning the Printing Unit (Option) ...................................................................1-32
1-5 Check Every 560 Hours (Once a Month) ................................................. 1-36
1-5-1 Checking the Board Transfer Belts ...................................................................1-36
1-5-2 Cleaning and Lubricating the X-Y Table (Ball Screw) .......................................1-39
1-5-3 Checking the Air Pressure of Squeegee Rising ................................................1-41
1-5-4 Checking the MR Unit .......................................................................................1-42
1-5-5 Checking the Air Pressure of the Process Pump ..............................................1-43
1-6 Check Every 1000 Hours (Once Two Months) ......................................... 1-46
1-6-1 Cleaning and Lubricating the Linear Shaft for Squeegee Head ........................1-46
1-6-2 Cleaning and Lubricating the Mask Cleaning Unit ............................................1-47
1-6-3 Cleaning and Lubricating the Squeegee Axis Ball Screw .................................1-49
1-6-4 Cleaning and Lubricating the Recognition Unit (Ball Screws) ...........................1-50
1-6-5 Cleaning and Lubricating the Board Positioning Lift .........................................1-51
1-6-6 Cleaning and Lubricating the Transfer Conveyor (Both Sides) .........................1-53
1-7 Check Every 1500 Hours (Once Three Months) ...................................... 1-54
1-7-1 Cleaning and Lubricating the Recognition Unit (X- and Y-axis Linear Bearings) ... 1-54
1-7-2 Checking for the Damage to the Belt for the Cleaning Paper Take-up Roll ......1-55
1-7-3 Cleaning and Lubricating the X-Y Table (X and Y-axis Linear Bearing) ............1-56
1E4C-E-MMA00-A02-01

7
1-7-4 Cleaning and Lubricating the Linear Bearing of Squeegee Axis .......................1-58
1-7-5 Cleaning and Lubricating the Y-axis Linear Bearing of Mask Cleaning ............1-59
1-8 Check Every 3000 Hours (Once Six Months)........................................... 1-60
1-8-1 Lubricating the Fulcrum of Squeegee Open and Close, and Joint ...................1-60
1-8-2 Lubricating the Hinge for Mask Cleaning ..........................................................1-61
1-8-3 Lubricating the Hinge for Cover Open and Close, and the Damper Fulcrum ...1-62
1-9 Consumable Parts to be Changed Every 3000 to 6000 Hours ................ 1-63
1-9-1 Changing the Board Transfer Belts and Rollers (3000 Hours) ..........................1-63
1-9-2 Changing the Belt for Paper Cleaning Take-up Roll (3000 Hours)....................1-66
1-9-3 Changing the Blower Filters (3000 Hours) ........................................................1-67
1-9-4 Changing the Filters (6000 Hours) ....................................................................1-68
Chapter 2 MACHINE PARAMETER
2-1 Items of Machine Parameter ...................................................................... 2-2
2-1-1 Origin Offset 1 .....................................................................................................2-3
2-1-2 Origin Offset 2 .....................................................................................................2-3
2-1-3 Network Setting (Only for PT Specifications) ......................................................2-4
2-1-4 Status Indicator ...................................................................................................2-5
2-1-5 Judgment Value ..................................................................................................2-5
2-1-6 Camera ...............................................................................................................2-6
2-1-7 Other Offset.........................................................................................................2-6
2-1-8 Operation Parameter Setting ..............................................................................2-7
2-1-9 Option Setting .....................................................................................................2-7
2-1-10 Data Check .........................................................................................................2-8
2-2 Machine Maintenance ................................................................................ 2-9
2-2-1 Routine Maintenance ..........................................................................................2-9
2-2-2 Changing Consumable Parts ............................................................................ 2-11
2-2-3 Machine Information and Version History .........................................................2-12
2-3 Machine Parameter Teaching ................................................................... 2-13
Chapter 3 ADJUSTING THE MACHINE CONDITION
3-1 Each Sensor Adjustment ............................................................................ 3-2
3-1-1 Board Detection Sensor of the Center Conveyor ................................................3-2
3-1-2 Vacuum Sensor (Option) ...................................................................................3-12
3-1-3 Cleaning Solvent Empty Sensor .......................................................................3-20
3-2 Replacing the Consumable Parts ............................................................. 3-23
3-2-1 Replacing the Urethane Squeegee ...................................................................3-23
3-2-2 Replacing the Blade ..........................................................................................3-24
3-2-3 Replacing the Side Rubber (Prevention of the Leakage Solder) ......................3-26
3-2-4 Replacing the Battery ........................................................................................3-28
3-2-5 Replacing Coler Touch Panel Back Light ..........................................................3-30
1E4C-E-MMA00-A02-02

8
3-3 Updating the Recognition Device ............................................................. 3-32
3-3-1 Updating Procedures ........................................................................................3-32
3-3-2 Error Massages in Updating .............................................................................3-33
3-4 System Updating ...................................................................................... 3-34
3-4-1 Installing the System .........................................................................................3-34
3-4-2 Installing the Screen Transfer System ..............................................................3-34
3-4-3 Installing the System Disk .................................................................................3-35
Chapter 4 SOLUTIONS FOR ERROR
4-1 Error Messages (Error List) ........................................................................ 4-2
4-1-1 Use of Error Message List...................................................................................4-2
4-1-2 Errors in Using the Floppy Disk...........................................................................4-3
4-1-3 Errors during PT Network....................................................................................4-3
4-1-4 Errors during the Self-diagnosis ..........................................................................4-4
4-1-5 Immediate Stop Error ..........................................................................................4-5
4-1-6 Emergency Stop Error ........................................................................................4-6
4-1-7 Axis Error of Emergency Stop .............................................................................4-9
4-1-8 Reading ASCII Data for the File Operation / Errors in Saving ..........................4-10
4-2 Check and Solutions ................................................................................ 4-11
4-2-1 Air Pressure Drops ............................................................................................ 4-11
4-2-2 Pre Process Production End ............................................................................. 4-11
4-2-3 Thermal Trip Detection (Blower) .......................................................................4-12
4-2-4 Power Box Fan Motor .......................................................................................4-12
4-2-5 Temperature Sensor..........................................................................................4-13
4-2-6 Lift Axis Brake off Under Axis Brake off.............................................................4-13
4-2-7 Thermal Trip Detection (Vacuum Pump) ...........................................................4-14
4-2-8 PCB Recognition Error ......................................................................................4-15
4-2-9 Returning to Origin Error Feedback Error .........................................................4-16
4-2-10 Driver Error........................................................................................................4-17
4-2-11 Errors in Board Transport-Out ...........................................................................4-19
4-3 Load Arrangement .................................................................................... 4-22
4-4 Load List ................................................................................................... 4-26
4-5 The Input and Output Check of Machine.................................................. 4-32
4-5-1 Input Check after Error ......................................................................................4-32
4-5-2 Output Check after Error ...................................................................................4-33
Chapter 5 TROUBLE SHOOTING
5-1 Solutions for Followings ............................................................................. 5-2
5-1-1 Solder Remaining on the Mask ...........................................................................5-2
5-1-2 Wrong Print State ................................................................................................5-3
5-1-3 Errors ..................................................................................................................5-3
1E4C-E-MMA00-A02-03

9
INDEX
ROUTINE CHECK LIST
Appendix A I/O MAP
Appendix B LOAD CONNECTION DIAGRAM
B-1 WIRING BLOCK DIAGRAM
B-2 LOAD WIRING DIAGRAM (SP28P-DH/DHU)
B-3 LOAD WIRING DIAGRAM (SP28P-DU/DHU)
Appendix C CONTROL BOX DIAGRAM
C-1 CPU BOX
C-2 POWER BOX
C-3 400V TRANS BOX (SP28P-DU/DHU)
Appendix D JUNCTION BOARD
D-1 EC14EX
D-2 EC55CX
D-3 RL12CX
Appendix E SET UP DIAGRAM
Appendix F WHOLE CONNECTION DIAGRAM
(SP28P-DU/DHU)
Appendix G AIR CIRCUIT DIAGRAM
1E4C-E-MMA00-A02-03

10 1E4C-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 symbol indicate an action that must not be carried out.
DANGER
WARNING
CAUTION
These symbol indicate an action that must be carried out.
1E4C-E-XXA00-A03-01

Page 2
SAFETY PRECAUTIONS
Be sure to observe
1E4C-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.
DANGER
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. 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.
SP28P-DH/D (The explanation by using SP28P-DH illustration)
M33E-2B
1E4C-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
1E4C-E-XXA00-A03-00
WARNING
2 Emergency stop bottom (rear)
1 Emergency stop
bottom (front)

Page 4
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. 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.
SP28P-DHU/DU (The explanation by using SP28P-DH illustration)
M33E-2B
1E4C-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
1E4C-E-XXA00-A03-00
WARNING
2 Emergency stop bottom (rear)
1 Emergency stop
bottom (front)

Page 5
SAFETY PRECAUTIONS
Be sure to observe
OFF ( ) ON ( )
SERVO
STOP UNLOCK
STEP
START
LIGHT ON
SELECT
KEY LOCK
KEY LOCK
BACK LIGHT OFF
Cutting of the power
supply of the machine.
Turn off the breaker
to which the ma-
chine is connected.
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.
For repairing the control box. ---------------------------------- Cutting off the power suly of the machine.
This is used to turn off power supply normally. ----------- Power supply OFF
For replacing the control part such as the sensor
For disassembling or replacing parts
For changing production board and daily inspection ---- Servo switch OFF
For placing or removing board on the conveyor
For setting production materials such as the feeder
SP28P-DH/D (The explanation by using SP28P-DH illustration)
M73EB
R
E
L
E
A
S
E
T
R
I
P
O
F
F
O
N
R
E
S
E
T
Turn off the power. Turn off the servo
switch.
Front panel
1E4C-AA00
2
321
1E4C-E-XXA00-A03-00
WARNING
1
3

Page 6
SAFETY PRECAUTIONS
Be sure to observe
OFF ( ) ON ( )
SERVO
STOP UNLOCK
STEP
START
LIGHT ON SELECT
KEY LOCK BACK LIGHT OFF
Cutting of the power
supply of the machine.
Turn off the breaker
to which the ma-
chine is connected.
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.
For repairing the control box. ---------------------------------- Cutting off the power suly of the machine.
This is used to turn off power supply normally. ----------- Power supply OFF
For replacing the control part such as the sensor
For disassembling or replacing parts
For changing production board and daily inspection ---- Servo switch OFF
For placing or removing board on the conveyor
For setting production materials such as the feeder
SP28P-DHU/DU (The explanation by using SP28P-DH illustration)
M73EB
R
E
L
E
A
S
E
T
R
I
P
O
F
F
O
N
R
E
S
E
T
Turn off the power. Turn off the servo
switch.
Front panel
1E4C-AA00
2
321
1E4C-E-XXA00-A03-00
WARNING
1
3

Page 7
SAFETY PRECAUTIONS
Be sure to observe
1E4C-E-XXA00-A03-02
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.
No open flame
E-PC010401

Page 8
SAFETY PRECAUTIONS
Be sure to observe
1E4C-E-XXA00-A03-01
WARNING
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.
M02E
BEFORE INSPECTING PNEUMATIC
EQUIPMENT, CUT OFF THE AIR
SUPPLY AND EXHAUST AIR FROM
THE COMPONENTS.
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.
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
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.
NO OPEN FLAME.
Solvent may catch fire.
Keep away from fire.
L30E
L14EB
ELECTRIC SHOCK.
You will have serious electric
shock if you touch electric
active part inside.