Panasonic KXF-E64C User manual

Modular Multi-functional Placement Machine DT401
Operating Instructions
Model No.
KXF-E64C
Maintenance Manual
Thank you for purchasing DT401, 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 read it if necessary.
E64C-E-MMAA-0006

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“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
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
E64C-E-MMA00-A01-01

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SPECIFICATIONS
Item Specifications
Mounting angle 0°to 359°(It can be set in increments of 0.01°.)
Mounting range Refer to the Reference Manual.
Board flow direction Refer to the Reference Manual.
Control system Microcomputer system
External memory Data is saved in PT. (Approximately 1 MB is required for saving a piece of data, depending
on the hard disk space of PT.) One type per 3.5-inch floppy disk
Program data ∗1Point count: Max. 10000 points
Machine body Normal service source: Three-phase 200±10 VAC or 400±20 VAC
Frequency: 50/60 Hz
Power source
Power source
for HUB ∗3Single-phase 100 VAC to 240 VAC
Machine body 1.5 kVA (Including a direct tray)
Rated capacity Power source
for HUB 150 VA
Supply air pressure 0.49 MPa - 0.78 MPa (Downstream from MR unit: 0.49 MPa - 0.54 MPa)
Supply air volume 100 L/min (A.N.R)
Outside dimension 1260 mm (W) ×2722 mm (D) ×2000 mm (H) (Including PATLITE)
Mass ∗21600 kg (Standard configuration, excluding a collectively-changing truck)
Environmental
condition
Temperature: 10°C to 35°C
Humidity: 25% to 60% (No condensation)
Transportation and
storage condition
Temperature: −20°C to 60°C
Humidity: 75% (No condensation)
Altitude Less than 1000 m above sea level
Noise < 63 dB (A)
∗ 1: PT prepares data. This machine can only modify some data.
∗ 2: Mass of the main body excluding the optional units
∗ 3: The power supply for HUB is an option. This power supply is required when you wish to
communicate with PT while the main power supply is OFF.
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The instruction manuals consist of Operations Manual, Programming Manual,
Reference Manual, Maintenance Manual, and Installation Manual. These manuals
describe the operations, programming, detailed functions, routine maintenance,
inspections, and much more.
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Organization of manuals
TOrganization of instruction manuals
This machine is accompanied with the following five manuals.
They are classified into five types to the purpose of work.
Use the appropriate one according to the purpose.
The production data of the line including this machine are programmed on PT.
Refer to the instruction manuals accompanied with PT.
Manuals for this machine
Manual type Explanation
Operations Manual This manual is organized for the operators and engineers of the machine,
describing operating instructions, precautions, and the other information
you should note.
Maintenance Manual This manual is organized for the persons who maintain the machine,
describing simple checks, adjustments, and replacement of consumable
parts.
And also troubleshooting is described.
Programming Manual This manual is organized for the engineers who program the production
data of the line, describing how to modify and manage the production data.
And also the error messages of the recognition device are described.
Reference Manual This manual describes the functions and operating instructions.
Installation Manual This manual describes installation procedures.
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About the wording in context
THow to read operating instructions
Description depends on the page; however, it is constructed basically as follows.
Explanation
? Title
@ Operation step number
A Actual operation
B Supplementary description
TSymbols used in this manual
In this manual, the following symbols are used for description.
:
Shows pressing a key on the touch
panel. : Shows an operation flow.
: Shows a reference item.
UNLOCK
o
START
:Means pressing
UNLOCK
and then
START
within 2 seconds.
Engineer
:Shows the operation for an
engineer.
A B
:
Means pressing B key with A key
held down.
Operator
:Shows the operation for an
operator.
3
2
4
1
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TABLE OF CONTENTS
SAFETY PRECAUTIONS.....................
..........................................
..................... 1
1. REGULAR MAINTENANCE............................1-1
1.1 Summary of Maintenance.....................................................................................1-2
1.1.1 Checking the Cycle and Details of Work, and the History Information .............................................1-2
1.1.2 About Maintenance Motion.............................................................................................................1-6
1.1.3 Periodic Check Items by Cycle.......................................................................................................1-7
1.1.4 Periodic Check Items by Unit..........................................................................................................1-8
1.1.5 Machine information.....................................................................................................................1-14
1.1.6 Updating the Component Units (Updating Each Board System) ..........................................................1-16
1.2 How to Grease....................................................................................................1-17
1.2.1 How to Set Cartridge and Use Grease Gun..................................................................................1-18
1.2.2 List of Grease in Use....................................................................................................................1-19
1.2.3 Detaching and Attaching Collectively-Changing Truck..................................................................1-20
1.2.4 How to Use the Feeder Table Raising Jig.....................................................................................1-26
1.2.5 Detaching and Attaching the Feeder-Table Cover.........................................................................1-29
1.3 Every-24-Hour Check [Daily]..............................................................................1-31
1.3.1 Checking the MR Unit [Before Operation].....................................................................................1-31
1.3.2 Cleaning the NG Components Ejection Box [After Operation].......................................................1-33
1.3.3 Cleaning the Used-Tape Box [After Operation].............................................................................1-34
1.4 Every-140-Hour Check [Once a Week]..............................................................1-35
1.4.1 Cleaning the Color Touch Panel...................................................................................................1-35
1.4.2 Cleaning the Transfer Head..........................................................................................................1-36
1.4.3 Cleaning Support Pins Collectively-Changing Tables....................................................................1-44
1.4.4 Cleaning Line Camera Cover Glass..............................................................................................1-47
1.4.5 Cleaning the Line-Camera Lens Cover Glass...............................................................................1-48
1.4.6 Cleaning the Tape Feeder Installation Surface .............................................................................1-49
1.5 Every-560-Hour Check [Once a Month] .............................................................1-50
1.5.1 Greasing Board Conveyor............................................................................................................1-50
1.5.2 Greasing the XY unit....................................................................................................................1-54
1.5.3 Cleaning the Nozzles and the Nozzle Changer.............................................................................1-60
1.5.4 Checking the Board Conveyor......................................................................................................1-63
1.5.5 Greasing Cutting Unit...................................................................................................................1-66
1.5.6 Greasing the Z Unit......................................................................................................................1-68
1.5.7 Cleaning the Large Reflector and the Vacuum Filter.....................................................................1-69
1.5.8 Cleaning Vacuum-Pump Filter......................................................................................................1-74
1.5.9 Checking the Cover Safety Switches............................................................................................1-76
1.5.10 Cleaning the Board Detection Sensor.........................................................................................1-78
1.6 Every-1500-Hour Check [Once per Three Months]............................................1-79
1.6.1 Greasing the Support Unit Upper-Limit Stoppers ..........................................................................1-79
1.7 Every-3000-Hour Check [Once per Six Months] ................................................1-80
1.7.1 Cleaning Back Side of Line-Camera Cover...................................................................................1-80
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1.8 Every-6000-Hour Check [Once a Year]..............................................................1-81
1.8.1 Replacing the Vacuum Pump ...................................................................................................... 1-81
1.8.2 Replacing Indicating Lamp .......................................................................................................... 1-83
1.8.3 Color Touch Panel: Replacing the Backlight ................................................................................ 1-84
1.9 Every-18000-Hour Check [Once per Three Years] ............................................1-85
1.9.1 Transfer Head: Clamping Claws, Spring for Holding Clamping Claws......................................... 1-85
1.9.2 XY Unit: Cable Bear .................................................................................................................... 1-85
1.10 Replacing the Consumable Parts .....................................................................1-86
1.10.1 Replacing the Backlight of the Color Touch Panel...................................................................... 1-86
1.10.2 Replacing the Blow Valve.......................................................................................................... 1-89
1.10.3 Replacing the Vacuum Valve..................................................................................................... 1-93
1.10.4 Replacing the Cleaning Valve.................................................................................................... 1-98
1.10.5 Replacing the Board Transport Belts and Rollers......................................................................1-101
1.10.6 Checking the Width-Adjustment Timing Belts............................................................................1-102
1.10.7 Replacing the Width-Adjustment Timing Belts...........................................................................1-103
2. MACHINE PARAMETERS ............................. 2-1
2.1 About Machine Parameters ..................................................................................2-2
2.1.1 Origin Offset.................................................................................................................................. 2-3
2.1.2 Defectiveness Criteria ................................................................................................................... 2-4
2.1.3 Option Configuration...................................................................................................................... 2-5
2.1.4 Operation Parameter Configuration ............................................................................................. 2-10
2.1.5 Nozzle Changer .......................................................................................................................... 2-11
2.1.6 Heat Correction Mark .................................................................................................................. 2-12
2.1.7 Mount Position ............................................................................................................................ 2-12
2.1.8 Board Positioning ........................................................................................................................ 2-13
2.1.9 Plane Correction ......................................................................................................................... 2-13
2.1.10 Network..................................................................................................................................... 2-14
2.1.11 Camera ..................................................................................................................................... 2-15
2.1.12 Light Quantity ............................................................................................................................ 2-15
2.1.13 Pick-up Position......................................................................................................................... 2-16
2.1.14 Status Indicator Lamp................................................................................................................ 2-16
2.1.15 Each-Angle Head Position......................................................................................................... 2-17
2.1.16 Head Rotation Center................................................................................................................ 2-17
2.1.17 Stroke End ................................................................................................................................ 2-18
2.1.18 Mounting Load .......................................................................................................................... 2-18
2.1.19 Components-Ejection Destination.............................................................................................. 2-19
2.1.20 Lead Checker (Option) .............................................................................................................. 2-19
2.1.21 Components-Ejection Position (Option) ..................................................................................... 2-20
2.2 Procedures of Machine Parameter Teaching .....................................................2-21
2.2.1 Board Recognition Camera X- and Y-Axis Origins Offset ............................................................. 2-23
2.2.2 Z-axis Origin Offset ..................................................................................................................... 2-25
2.2.3 Chip Recognition Camera θ-Axis Origin Offset............................................................................. 2-33
2.2.4 Width-Adjustment Axis Origin Offset............................................................................................ 2-40
2.2.5 Board Positioning and Mount Height............................................................................................ 2-42
2.2.6 Plane Correction ......................................................................................................................... 2-49
2.2.7 Pick-up Position .......................................................................................................................... 2-53
2.2.8 Nozzle Changing Position............................................................................................................ 2-61
2.2.9 Light Quantity .............................................................................................................................. 2-65
2.2.10 Load Head ................................................................................................................................2-67
2.2.11 Lead Checker (Option) .............................................................................................................. 2-74
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3. SOLUTIONS FOR ERRORS...........................3-1
3.1 Error Message Listings.........................................................................................3-2
3.1.1 How to See Error Message Listings ...................................................................................................3-2
3.1.2 Errors in PT Communications.............................................................................................................3-3
3.1.3 Errors in Self-diagnosis.......................................................................................................................3-3
3.1.4 Immediate Stop Errors........................................................................................................................3-7
3.1.5 Emergency Stop Errors.....................................................................................................................3-12
3.2 Check and Solution.............................................................................................3-30
3.2.1 Air Pressure Error.............................................................................................................................3-30
3.2.2 Vacuum Pump Thermal Abnormality and Power Box Temperature Abnormality.............................3-31
3.2.3 CPU Box Temperature Abnormality .................................................................................................3-32
3.2.4 Board Recognition Error ...................................................................................................................3-32
3.2.5 SSR Ready Error ..............................................................................................................................3-34
3.2.6 Drop in Voltage .................................................................................................................................3-35
3.2.7 Bad Nozzle Detected / Bad Nozzle Rate Over.................................................................................3-41
3.2.8 Pick-up Errors, Drop of Chips...........................................................................................................3-42
3.3 Load Arrangement Drawings..............................................................................3-43
3.3.1 Common ...........................................................................................................................................3-43
3.3.2 Multi-Functional Head Type..............................................................................................................3-46
3.4 Load Lists ...........................................................................................................3-47
3.4.1 Motor List ..........................................................................................................................................3-47
3.4.2 SOL List ............................................................................................................................................3-48
3.4.3 Sensor List (PH)................................................................................................................................3-49
3.4.4 Sensor List (LS) ................................................................................................................................3-50
3.5 Machine’s Input/Output Check............................................................................3-51
3.5.1 Input Check after Error Occurred......................................................................................................3-51
3.5.2 Output Check after Error Occurred...................................................................................................3-53
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INDEX
PERIODIC CHECK LIST
APPENDIX 1. I/O MAP
1-1 DT401-F
1-2 DT40S-20 (OPTION)
1-3 DT45T-40 (OPTION)
APPENDIX 2. AIR CIRCUIT DIAGRAM
APPENDIX 3. MATERIAL SAFETY DATA SHEET
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= MEMO =
E64C-E-MMA00-A02-00

Page 1
SAFETY PRECAUTIONS
Be sure to observe
The precautions that shall be observed in order to prevent an injury to the user or the
other persons, and damage to property, are described as follows.

The degrees of danger or injury, resulting from incorrect usage owing to failure to read an
indication, are classified and described as follows.
DANGER This indication refers to a situation which is considered that there is
imminent danger of death or serious injury.
WARNING This indication refers to a situation which is considered that there is a
possibility of death or serious injury.
CAUTION This indication refers to a situation which is considered that there is a
possibility of only injury or physical damage.

The matters that shall be observed are classified by the symbols as shown below, and
described.
(The following are the examples of the symbols.)
This kind of symbol indicates the matters to which attention must be paid.
This kind of symbol indicates an action that must not be carried out.
This kind of symbol indicates an action that must be carried out.
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Page 2
DANGER
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Page 3
E64C-AC00
WARNING
If you sense any danger or abnormality, press an emergency stop button to
stop operation.
If you continue to operate the machine in a dangerous or abnormal state, an accident or a
breakdown will occur.

DT401-F has two emergency stop buttons. Pressing any one of them stops operation.
Press the nearest one.
Eliminate the cause of danger or abnormality, and then restart operation.
To reset, pull the emergency stop button.
Emergency stop button
(At the rear side)
M107
Emergency stop button
(At the front side)
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Page 4
WARNING
Observe the following matters if putting your hands or part of body into a
moving part of the machine in such cases of feeding production materials,
changing production models, or adjustments.
You may potentially be injured if the machine is actuated.
And also you may potentially receive an electric shock.
There are three levels of steps as follows, to each kind of work.
Repairing such as a control BOX --------------------------------
-
Cut off the power supplying to
this machine.
Turning OFF the power supply routinely--------------------------
-
Replacing a control part such as a sensor
Disassembling or replacing parts
Turn OFF the power and stop
the air supply.
Lock the power supply switch
and the main air valve.
Changeover or working for daily check ---------------------------
-

Setting the nozzles in the nozzle changer
Maintenance of the inside of the machine
Turn OFF the servo switch, and
then open the safety cover.
Turn OFF the servo
switch, and then open
the safety cover.
Cut off the power supplying
to this machine.
Rear panel
OFF ( ) ON ( )
SERVO
STOP UNLOCK
STEP
START
LIGHT ON SELECT
KEY LOCK BACK LIGHT OFF
Turn OFF the breaker that
is connected to the
machine.
Turn OFF the power supply.
R
E
S
E
T
O
F
F
O
N
T
R
I
P
P
E
D
Turn OFF the servo switch,
and then open the safety
cover.
Stop the air supply.
SMCPRESSURE
MPa
OUT
SET
4Z4C-823E
Front panel
OFF ( ) ON ( )
SERVO
STOP UNLOCK
STEP
START
LIGHT ON SELECT
KEY LOCK BACK LIGHT OFF
M73B
E64C-E-XXA00-A03-00
E64C-AC00

Page 5
E64C-002E
WARNING
Beware of guide for feeder cart.
You may potentially stumble over the guide for feeder cart and get injured when operating
without the feeder cart.

We recommend that you should paste yellow and black tapes for danger indication onto the floor where is
120 mm or more away from around the machine, in order to draw a distinct line between the operator area
and the maintenance area (see Fig.2).

We recommend that you should keep away from the most protrudent part (guide for feeder cart) of the
machine by 120 mm or more (outside of the area with yellow and black stripes), as indicated by Fig.2.
Guide for feeder cart
Fig.1
Color
Yellow
Black Fig.2 (Top view)
M108
E64C-E-XXA00-A03-00
E64C-001E
1
2

Page 6
4Z4C-828E
E64C-AC00
WARNING
Do not peer into the board eject area.
Ejected boards can strike and injure eyes.

In case you use the machine on a standalone basis, be careful of the receipt of unloaded boards. Normally
we cannot look inside the opening for unloading because the machine is installed close to the next machine
in whole line. If, however, you use it on a standalone basis, it is possible. We recommend you to add a buffer
stocker to the unloading side.
Board flow direction Do not look inside.
Machine’s side view
E-PW0106M1
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Page 7
WARNING
Avoid putting your hands in the openings between feeders on the truck.
Your hands may potentially be injured by the moving parts in the machine.
We recommend that you fill the truck with feeders or dummy ones so that you will not
accidentally put your hands into the machine.
M114
Avoid working with the conveyor cover opened.
Your hands may potentially be injured by the moving parts in the machine.
Cover
M115
E64C-E-XXA00-A03-00
E64C-011E
E64C-010E
E64C-AC00

Page 8
WARNING
In maintenance, be careful not to receive an electric shock.
Even if the power supply switch is turned OFF in maintenance, the power is still supplied
as far as the primary line of the power supply switch; therefore, you may potentially
receive an electric shock.
M111
E64C-AC00
L1
L2
L3
PE
4Z4C-825E
E64C-E-XXA00-A03-01