TOWA LCM1010 User manual

COMPRESSION MOLDING SYSTEM
&
LCM1010
Operation Manual
-v '•e
Do not attempt to operate the Compression-Molding System until
the information in this manual has been read and fully understood
Always keep this manual near the machine so that operators and
ser ice personnel can consult it at any time.
TCWA TOW A Corporation
5 Kamichoshi-cho, Kamitoba, Minami-ku, Kyoto 601-8105 JAPAN
DOC NO.M-A0097040301 -OP-2.3

LCM 1010 Instruction Manual
Fore ord
Please accept our gratitude on the purchase of this machine.
Operation procedures, safety precautions and general handling of the Auto-Mold Pac aging System
are explained in this manual.
Although this machine is designed and manufactured with the principle of safety in mind, there
remains the potential for dangerous accidents due to operational mista es or improper daily care and
maintenance. Before starting operation please read and study this operation manual carefully to
ensure safe and efficient operation. The manual should be ept ngar the machine and be easily
accessible to operators and service personnel.
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If this manual is missing or damaged, as for new copies from our customer service center (please
refer to Section 1.2 Customer Service Center).
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LCM 1010 Instruction Manual
Configuration of Manuals
The following manuals are used in conjunction with the operation of this machine.
Installation Manual л
Procedures and safety precautions for machine storage, transport and set-up of the
Compression-Molding System are explained in this manual.
Persons concerned with machine storage, transport and set-up please refer to this
manual!
Operation Manual *“'~
Procedures and safety precautions for general operation, start-up and running of the
Compression-Molding System are explained in this manual.
Persons concerned with machine operation please refer to this manual.
Maintenance Manual
Procedures and safety precautions for cleaning, lubrication, inspection and parts
replacement of the Compression-Molding System are explained in this manual.
Persons concerned with maintenance and inspection please refer to this manual.
Regarding Special Terms Used in this Manual
The following terms used in this manual are referred to by shortened forms.
Both substrates and lead frames are referred to as ‘L/F’.
Regarding Trademarks ;
Windows is a registered trademark of Microsoft Corporation in the U.S.A. and
other countries. ■ r
The corporation names and product names referred to in this manual are the
intellectual property of each respecti e, right-holding corporation.
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LCM 1010 Instruction Manual
User Qualifications
Operation, maintenance and installation should only be conducted by persons qualified in the
corresponding areas. User qualifications are as follows.
USER QUALIFICATIONS
Operator
Reading and understanding of the operation manual;
Sufficient nowledge regarding machine operation and
safety; Ability to cany out product insertion and discharge,
and normal operation.
“V» _
Maintenance engineer
Comprehension of maintenance training guidelines;
Sufficient nowledge regarding machine operation, safety,
functions, manual procedures, and procedures for entering
the machine interior; Ability to carry out operation according
to received guidelines.
Service engineer Designation by TOWA Corporation; Comprehensive nowl
edge of machine operation and safety precautions.
Warning Messages and Definitions
The warning messages used in this manual and on the warning stic ers affixed to the machine
are classified in accordance with the degree of foreseeable ris (foreseeable extent of
accident), using the three levels of “DANGER”, “WARNINGS and “CAtJTION”
Always observe the safety precautions contained in this.man.ual and affixed to the machine.
Be sure to have fully understood the warnings and theirSefinitions. ;
WARNING , J- DEFINITION
A DANGER “DANGER" indicates an imminently hazardous situa
tion, which if ignored could result in death or serious
injury.
“WARNING” indicates a potentially hazardous situa
tion, which if ignored could result in death or serious
injury.
И WARNING
A CAUTION “CAUTION” calls attention to instructions that should
be obser ed to a oid minor or moderate personal
injury and/or equipment damage.
NOTE Indicates points that require attention.
TCWA

LCM 1010 Instruction Manual
About this Manual
This manual contains detailed information on the operation of the TOWA Compression-
Molding System (LCM 1040).
This manual is composed of the following sections.
1 GENERAL INFORMATION ■
This section contains^ the general machine outline, customer service information, and
4 * *
the limited warranty.
2 SAFETY
This section contains important safety precaution information. Be sure that the
instructions in this section have been read and fully understood before operating the
machine.
3 OUTLINE OF MACHINE
This section outlines the general use, structure and movement of the machine.
4 OPERATION SWITCHES AND BUTTONS
This section contains information regarding the operation panel and the operation
switches and buttons.
5 PREPARATION
This section explains preparations that are necessary before operation, as well as
emergency stopping and restarting procedures.
6 OPERATION
This section contains information regarding procedures fpr "insertion apd removal of
wor , and general operation procedures of the machine. A'
It is necessary to use the information in this section in conjunction with that of section
4, and to have sufficient understanding of both sections.
7 DISPOSAL
This section is about disposal of the machine and its components.
NOTE Optional applications are indicated by an asterisk (*).
TSWA

LCM 1010 Instruction Manual
CONTENTS
1 GENERAL INFORMATION
1.1 General Information .f:. .................... 1-1
1.2 Customer Service Center ................................................................................................ 1-2
1.3 Limited Warranty ........................................ 1-3
a *
2 SAFETY . . ' "
2.1 General Safety Rules .................................................................... 2-2
2.2 Special Safety Rules ................ ..................................................................................................... 2- 3
2.3 Hazard Indication Stic ers .......................................................................................................... 2- 5
2.3.1 Handling of Hazard Indication Stic ers ................................................................... 2-5
2.3.2 Points Where Hazard Indication Stic ers Are Affixed ........................................... 2-6
2.4 Dangerous Areas and Access Procedures ................................................................................. 2-21
2.4.1 Dangerous Areas ......................................................................................................... 2-21
2.4.2 Access Procedures for Dangerous Areas ................................................................ 2-25
2.5 Types and Functions of Safety Related Equipment ................................................................ 2-27
2.6 Inspection of Safety Related Equipment Operability ............................................................. 2-39
2.7 Protective Gear ............................................................................................................................. 2-39
2.8 Noise ............................................................................................................................................. 2-40
2.9 Exhaust Gas and Dust ....................................................................... 2-41
3 OUTLINE OF MACHINE
3.1 Purpose of Machine ............................................................ „жй-.:..,. ............... 3-1
3.2 Machine Specifications and Exterior Diagrams ....A ............... 1 3- 2
3.2.1 Machine Specifications ................................. .«.5. 3-2
3.2.2 Machine Exterior Diagrams ....................................... l!& ........ 3-4
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3.3 Name and Outline of Each Section ................................. л'- ..... 3-6
3.3.1 Section Names .............................. '. ................................ :.. ........................................ 3-6
3.3.2 Section Outlines... ........................................................................................................ 3- 9
4 OPERATION SWITCHES AND BUTTONS
4.1 Main Operation Panel .................................................................. 4-3
4.2 Press Operation Panels .............................................................................................................. 4- 5
4.3 Other Operation Switches and Buttons ..................................................................................... 4-8
5 PREPARATION
5.1 Pre-Operation Preparation ........................................................................................................... 5-1
5.1.1 Pre-Operation Confirmation Item s ........................................................................... 5-1
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LCM 1010 Instruction Manual
5.1.2 Power ON/OFF Procedures ......................................................... 5-2
5.1.3 Air Supply Valve ON/OFF Procedures ....................... . .......... ............................... 5- 3
5.2 EMERGENCY STOP and Restart ............................................................................................. 5-4
5.2.1 EMERGENCY STOP ................................................. : ................... 5-4
5.2.2 Restart ........................ & 5- 6
6 OPERATION
6.1 Starting Operation and Completing Opefation ...ч ......... 6-1
6.1.1 Starting Operation ......................................... 6-1
6.1.2 Completing Operation ................... '1 ...................................... 6-3
6.2 Insertion of Wor ; Related Items ............. ... 6- 4
6.2.1 Cover Opening/Closing Procedure ........................................................................... 6-6
6.2.2 Setting up Release Film (Unwinding side) ..................... . ......................................... 6- 7
6.2.3 Removing Release Film (Winding side) ........................................ 6-8
6.2.4 How to Change Width of Release Film .......................................................................6-9
6.2.5 Release Film Winding Procedure ............................................................................. 6-10
6.2.6 Substrate Mounting Procedure.................................................................................. 6-12
6.2.7 Substrate Removing Procedure ................................................................................ 6-13
6.2.8 Resin Exchange Procedure (Charging Resin into the Cartridge)......................... 6-14
6.2.9 Resin Exchange Procedure (Mounting the Cartridge to the Machine) .............. 6-16
6.2.10 Resin Dispensing Volume Correcting Procedure ................................................... 6-19
6.2.11 IN/OUT Magazine Inserting / Removing Process ................................................. 6-21
6.3 Automatic Operation ................................................................................................................... 6-23
6.3.1 Outline of Automatic Operation ................................................................................ 6-23
6.3.2 Conditions for Starting Automatic Operation .......................................................... 6-24
6.3.3 PROCESS AUTO Operation ........................................... .^4,..r .............. ,.-.U ........... 6-25
6.3.4 LINE AUTO Operation (Semiautomatic) ................... :Г.Г5?:..’ ............................... 6-26
6.4 Errors and Alarms ............................................................................ glATL. ............................ 6-28
6.4.1 Error and Alarm Displays .......................................................... $-.4 .................. 6-28
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6.4.2 What to do when errors and alarms occur ....... ^ ............... 6-29
6.5 Resetting Immediate Stop .......................................... .....*. ................... 6-30
7 DISPOSAL
7.1 Environment Protection ............................................................................................................... 7-1
7.2 Information Regarding Chemical Content 7- 2
TSWA

LCM 1010 Instruction Manual 1 GENERAL INFORMATION
1 GENERAL INFORMATION
1.1 General Information .............................................................. 1-1
■rjT'
1.2 Customer Ser ice Center ................................................ 1-2
1.3 Limited Warranty .................................................................. 1-3
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1 GENERAL INFORMATION LCM 1010 Instruction Manual
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TCWA

LCM 1010 Instruction Manual 1 GENERAL INFORMATION
1 GENERAL INFORMATION
This section contains the general machine outline, customer service information, and the limited
warranty.
■d?.
1.1 General Information
- The customer must know that this machine in ol es potential hazards. Ne er
attpmpt to operate this machinery until the instructions written in this manual ha e
been read and fully understood. .
Always follow the instructions in'this manual wheojparrying out a job.
vf
- TOWA Corporation is not liable for any damage or injury arising from an
indi idual's failure to follow the instructions contained in this manual, failure to
exercise due care and caution, or misuse or modification of the machine without
prior written consent from TOWA Corporation.
- In today's rapidly changing manufacturing industry, with new materials, processes and
higher speed equipment, the potential for exposure to accidents is increasing.
TOWA Corporation cannot anticipate every possible circumstance that could involve
potential hazards.
The warnings in this manual are, therefore, not all-inclusive.
Actions that cannot or must not be conducted are too innumerable to detail in this manual.
Please regard any activity not explicitly allowed or explained in this manual as prohibited.
Regard as “Cannot” unless “Can” is clearly indicated in this manual.
When operating the machine, pay sufficient attention to;g§rieral safqty-measures, not only
,P* <s£T - - T
to the safety precautions explained in this manual and the”waming stic ers affixed to the
machine itself. 4 s . ’
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- Copyright® 2010 TOWA CORPORATION •
This manual is copyrighted and all rights are reserved.
This manual may not, in whole or part, be copied, photocopied or reproduced in any way,
without prior written consent from TOWA Corporation.
- The contents of this manual are based on the information and machine specifications
available at the time of shipment of the machine. The contents of this manual may be
altered due to the modification of the machine or for the improvement of the manual.
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1 GENERAL INFORMATION LCM 1010 Instruction Manual
1.2 Customer Service Center
If there are any questions or concerns regarding this manual, or more detailed information and/
or additional manuals are required, please contact the customer service center at the location
noted below, referring to the machine model, its manufacturing number, and the manual
number.
Inquiry URL page to product:
http://www.towajapan.co.jp/english/contact/i_products/index.htm
& «•
TOWA CORPORATION SALES ADMINISTRATION DEPARTMENT
5 Kamichoshi-cho, Kamitoba, Minami- u, Kyoto, 601-8105, JAPM1
Phone: [phone].
Fax: [phone]
COMPRESSION MOLDING SYSTEM
LCM1010
Operation Manual
ТСРгЧА СофеиЕел
DOC Ne.uxoooocooax-op-l
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Manual number
Nameplate label
© Resin Module
A0005920301 ZZB
POWER
SUPPLY
AC 200V.3-PHASE
21.0 KVA
0 .4 5-0 .6 MPa
500 NL/Min
AIR EXHAUST
WATER
SUPPLY 0 MPa
0 L/Mln
T S W A
© Press Module
A0005920302 I ZZB
AIR EXHAUST
1800 kg
T 9 W A
® Handler Module
A0005920304 ZZB
T& W A
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LCM 1010 Instruction Manual 1 GENERAL INFORMATION
1.3 Limited Warranty
This machine is covered by the following warranty, with the exceptions mentioned below.
The warranty for the Press parts shown below is effective for a period of five years, and that
for the other parts is effective for a one-year period, starting from the time of delivery of the
machine to the customer. Any defects and/or malfunctions which occur during the period of
warranty will be repaired and/or defeptiye parts replaced, as soon as possible and free-of-
charge, if and only if the defects and/or malfunctions have been caused by shortcomings in the
design1 and/or manufacturing of the machine by TOWA Corporation.
Upper Platen LoweTPIaten
Slide Platen Slider
Tie Bar Tie Bar Nut
'g 'y
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’ XT’*' '
However, in the event that bush points of these parts become damaged, the warranty period is
reduced to one year.
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1 GENERAL INFORMATION LCM 1010 Instruction Manual
TOWA Corporation offers the same service for parts or products attached to or mounted in the
machine, which are not manufactured by TOWA Corporation; however,’ this service is limited
to the specific warranty period of each part or product.
The warranty period of the dry-pump is 1 year or 3000 hours of operation time whichever is
earlier. л
The following cases will not be covered under the warranty so the customer will be charged
for service and/or parts, even during the period of warranty:
6 ' *
(1) Parts designated by TOWA Corporation as consumption articles (parts that are subject
to normal wear and tear).
(2) Damage or malfunction due to misuse, improper repair or modification by the customer.
(3) Damage or malfunction caused by the customer’s failure to perform maintenance,
inspection and lubrication as specified in the instruction manuals.
(4) Damage due to falling or dropping during transport by the customer.
(5) Damage caused by fire, earthqua e, flood, lightning, or other natural disasters.
(6) Damage caused, under abnormal circumstances, by the use of substances such as
organic solvents or corrosive gases, etc., or by the use of strong magnetic fields, etc.
(7) Damage caused by abnormalities of voltage, hydraulic pressure, water pressure, and/or
pneumatic pressure.
(8) Other damage or malfunction deemed to be the responsibility of the customer.
(9) Damage or malfunction of the parts due to the constituents which come from the
molding materials (resins, substrate, etc), releasing film, and pre-tape.
(10) Damage or malfunction when wor s (substrate, resin, magazine, etc) not within the
tolerance specified in the customer specification are used.
(11) Damage or malfunction due to additions or/and modifications of the software or/and
hardware without prior approval of TOWA Corporation. ' * '
Ma e sure to have made bac -ups of data and ta en any other related.measures in advance, as
there exists the possibility of losing previously stored data luring repair wor or replacement
of parts. . ’
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LCM 1010 Instruction Manual 2 SAFETY
2 SAFETY
2.1 General Safety Rules ............................................................. 2- 2
2.2 Special Safety Rules ...... . ......... . ......... . ................ . 2- 3
2.3 Hazard Indication Stickers ..................................................... 2- 5
& *
2.3.1 Handling of Hazard'Indication Stickers ...................... 2- 5
2.3.2 Points Where Hazard Indication
”4* v£
Stickers Are Affixed ................................................... 2-6
2.4 Dangerous Areas and Access Procedures ........................... 2-21
2.4.1 Dangerous Areas ...................................................... 2-21
2.4.2 Access Procedures for Dangerous Areas ................ 2-25
2.5 Types and Functions of Safety Related Equipment 2-27
2.6 Inspection of Safety Related Equipment Operability 2-39
2.7 Protecti e Gear ..................................................................... 2-39
2.8 Noise .................................................................... 2-40
2.9 Exhaust Gas and Dust ................... ....AT ........ 2-41
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LCM 1010 Instruction Manual 2 SAFETY
2 SAFETY
This section contains warning definitions, general safety measures and information on safety precau
tions that must be observed.
The information given in this section provides guidelines for the prevention of accidents.
In addition to the safety instructions of sections 2.1 “General Safety Rules” and 2.2 “Special Safety
Rules” please observe the following precautions.
s ' 3'
- Machine maintenance must be performed by a service engineer ho
has received safety-related training an4.instruction and has
comprehensive kno ledge of the machine.
*4 . 't.
- Machine operators should al ays observe the arnings and
instructions stated in this manual.
- If problems arise hich cannot be rectified by the user, or if there
are any questions, concerns or unclear points, contact the Customer
Service Center (see section 1.2). Never proceed ith operation until
an appropriate course of action has been negotiated and any
problems resolved. Mishandling of the machine may endanger
orkers as ell as result in equipment damage or malfunction.
A DANGER
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2 SAFETY LCM 1010 Instruction Manual
2.1 General Safety Rules
The following are general rules for safe use of the machine.
Be sure to observe and fully understand these safety rules.
A DANGER Do not allo any inflammable materials, such as kerosene, gasoline,
benzine, thinner, alcohol, etc.near the machine. Failure to observe
may result in explosion and/or fire.
a 31
Do not set up the machine in an'area here there is the possibility
of flammable gas being generated. Failure to observe may result in
explosion and/or fire.
WARNING Do not touch operation buttons or s itches ith et hands. Failure
to observe may result in electric shock if the grounding is of poor
quality and/or there is a short circuit.
If malfunctions occur hile performing inspection of the machine, or
hen machine activity is unstable, carry out the indicated course of
action as instructed (push the Emergency-Stop button, etc.), and
remain calm. Failure to carry out the instructions as indicated may
cause malfunction and/or result in injury.
Operation of this machine is restricted to those ho have received
comprehensive instruction and training regarding machine
operation and safety precautions. Wear the designated ork
clothing, shoes and protective gear, and take care to observe the
follo ing:
- Tie back long hair and ear a hat. Do not уфрг necklaces or
neckties.
- Do not put in ones pockets items that ecruid easily fall inside the
machine, such as coins, pens, and the likeTt Г ^
Make sure that the safety covers for each section have all been
installed before running inspection of the machine. Do not open any
of the safety covers during machine operation.
A CAUTION - Be sure to clean up any spills or leaks of ater, oil, grease, etc.
immediately. Failure to observe may result in injury due to slipping.
- Do not allo any horseplay or noisemaking in the ork area.
Failure to observe may result in unexpected injury.
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LCM 1010 Instruction Manual 2 SAFETY
2.2 Special Safety Rules
The following special rules for safe use are peculiar to this machine.
Be sure to observe and fully understand these special safety rules in conjunction with the
general safety rules. ж .
ElWARNING When inserting tablets, follo the instructions detailed in the tablet
supply manufacturer's safety data-sheet (MSDS) regarding chemical
materials, etc., and be sure to ear protective eye ear, a protective
dust mask and gloves. „ ~
Fine particles and dust from tablets maybe harmful to ones health.
Before starting operation, be sure to activate the factory's ventilation
system, in concurrence ith the instructions detailed in the tablet
supply manufacturer's safety data-sheet (MSDS) regarding chemical
materials, etc.
Do not run operations on the machine hen the factory's ventilation
system is stopped or out of order.
Gases emitted during melting of tablets may be harmful to ones
health.
Due to high temperature of the upper part of the mold, please be
sure that only non-flammable resins are inserted. Insertion of
substances other than non-flammable resins may cause gas
emissions and/or fire.
Mold die transport must not be performed by operators.
Failure to observe may result in fatal injury. Mold die transport must
be conducted by maintenance engineer^ ho have/obtained the
required qualifications.
A CAUTION - The mold die and the Press section remf in at high temperatures
even hen the po er sources аш off. There is a danger of getting
burned if these areas are touched carelessly. Be sure to ear
protective gear hile orking.
- Do not open any safety doors (safety covers) during operation.
These safety doors (safety covers) are outfitted ith electromagnetic
lock safety s itches that lock during operation. If these doors are
forced open, there is a danger of machine damage and/or arm injury.
• Pay sufficient attention hen opening and closing covers and
doors. There is a danger of injury if hands or other body parts
become caught.
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2 SAFETY LCM 1010 Instruction Manual
A CAUTION Install fire-extinguishing equipment near this machine. While this
machine is mainly manufactured from fire-resistant materials such
as steel, many plastic parts (hosing, acrylic, elastic, etc.) are used as
ell.
Although these parts are not combustible as such, there is the
danger of fire occurring due to malfunctioning high temperature
equipment, such as heaters, motors, po er sources, transformers
and the like.
si *
This machine uses an ionizer and produces an extremely small
quantity of ozone.
In airtight conditions, this ozone ill have harmful physical effects
on orkers. Before operating this machine, be sure to turn on
outdoor ventilation equipment.
When handling ork materials, ear protective gloves and be sure
to keep hands and fingers properly covered. Work material edges
may cause injury to hands or fingers.
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LCM 1010 Instruction Manual 2 SAFETY
2.3 Hazard Indication Stickers
The hazard indication stic ers are affixed at points where special attention is required. Ma e
sure that all stic ers have been affixed correctly, and that the warnings themselves are always
sufficiently grasped and observed.
2.3.1 Handling of Hazard Indication Stickers
Hazard Indication Stic ers should be handled as follows.
•i ’ *■
■F*
- Be sure that the content of the hazard indication stic ers is completely legible.
Clean or replace stic ers if their content and/or'illustrations become illegible.
- Clean hazard indication stic ers with a soft cloth, mild detergent and water.
Do not use gasoline, organic solvents, etc.
- Please replace the hazard indication stic ers if they become damaged or lost, or if
their content remains illegible even after cleaning. To order new hazard
indication stic ers, please contact the TOWA Corporation Customer Service
Center (see section 1.2), referring to the machine model and manufacturing
number.
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2 SAFETY LCM1010 Instruction Manual
2.3.2 Points Where Hazard Indication Stickers Are Aff xed
Hazard Indication stic er illustrations and danger information, and the points where
stic ers are affixed are as shown below.
- Danger of Entanglefhent in Rotating Machinery
The sticker shown below indicates a danger of a part of ones body getting
entangled in rotating or otherwise mo ing machinery.
(A) Exterior (Semi-Automatic) *
Points where hazard indication stickers are
affixed (A): ^
A1: Press Module front door
Tr
A2: Press Module bac door
A3: Resin Module fi'ont door
A4: Resin Module bac door
A' Д И Л И
MECHANICAL HAZARD
May entangle hands
or fingers.
Turn po er off for
mechanical parts
before maintenance.
* А И # Л Й 1 &
т т ш ^ т т ш А
т ш ш ш ,
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