Panasonic KXF-493C Operating Instructions Manual
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Panasonic KXF-493C Operating Instructions Manual

Panasonic KXF-493C Operating Instructions Manual

Multi-functional chip mounter cm120
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Multi-functional Chip Mounter CM120
Operating Instructions
K X F - 4 9 3 C
Model No.
Maintenance Manual
(1/2)
Thank you for purchasing CM120, the multi-functional chip mounter.
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.
493C-E-MMAB-0009

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Summary of Contents for Panasonic KXF-493C

  • Page 1 Multi-functional Chip Mounter CM120 Operating Instructions K X F - 4 9 3 C Model No. Maintenance Manual (1/2) Thank you for purchasing CM120, the multi-functional chip mounter. Before placing the machine in service, be sure to read the instruction manual for proper usage.
  • Page 3 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.” WARNING DO NOT ALLOW ANY PERSON WHO HAS NOT RECEIVED SPECIAL TRAINING TO OPERATE THE MACHINE.
  • Page 4 SPECIFICATIONS a l i 1 “ ” e 1 “ ” n ∗ ∗ ∗ ∗ ∗ 1 ± ± ± % ∗ ∗ ∗ ∗ ∗ 2 i t l × × × × C ˚ C ˚ y t i i t a i d i , y t...
  • Page 5 ORGANIZATION OF MANUALS 6 manuals (Nonstandard version: 5 copies) are attached to this machine. They are classified into 5 types (Nonstandard version: 4 types). 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.
  • Page 6 = MEMO = 493C-E-MMA00-B01-00 Page 6...
  • Page 7 Maintenance Manual Maintenance Manual O N S C A U T I Y P R E A N C E S A F E T I N T E N A R M A C H I N G A M E T E R T E A R E G U L M A C H I N E P A R A M E T E R A N D...

  • Page 8: Table Of Contents

    SAFETY PRECAUTIONS ..............13 REGULAR MAINTENANCE Chapter Outline of Maintenance ................1-2 1-1-1 Checking the Operating Period, Contents and History Information ....1-2 1-1-2 Maintenance Mode ....................1-5 1-1-3 Regular Check Items for Period ................1-6 1-1-4 Regular Check Items for Each Unit ..............1-9 Lubricating ....................
  • Page 9 Replacing the Consumable Parts ............. 1-83 1-9-1 Replacing the Battery ..................1-83 1-9-2 Replacing Color Touch Panel Back Light ............1-85 Machine Parameter and Chapter Machine Parameter Teaching Machine Parameter ..................2-2 2-1-1 XY Plane Calibration ................... 2-3 2-1-2 Origin Offset ......................2-3 2-1-3 Status Indicator ....................
  • Page 10 SOLUTIONS FOR ERROR Chapter Error Messages ..................3-2 3-1-1 Errors in Using the Floppy Disk ................3-2 3-1-2 Errors during PT Network ..................3-2 3-1-3 Errors during the Self-diagnosis ................3-3 3-1-4 Immediate Stop Error ..................3-5 3-1-5 Emergency Stop Error ..................3-8 3-1-6 Axis Error of Emergency Stop ................
  • Page 11 Load Arrangement ..................3-36 3-3-1 Load Arrangement of Main Body ..............3-36 3-3-2 DT20F-20U Load Arrangement ................. 3-38 3-3-3 DT10F-3 Load Arrangement ................3-39 Load List ....................3-40 3-4-1 Load List of Main Body ..................3-40 3-4-2 DT20F-20U Load List ..................3-44 3-4-3 DT10F-3 Load List ....................
  • Page 12 LOAD CONNECTION DIAGRAM Appendix WIRING DIAGRAM (CE standard version) LOAD WIRING DIAGRAM (CE standard version) WIRING DIAGRAM (Nonstandard version) LOAD WIRING DIAGRAM (Nonstandard version) WIRING DIAGRAM (Common) LOAD WIRING DIAGRAM (Common) CONTROL BOX Appendix CPU BOX POWER BOX DRIVER BOX1 DRIVER BOX2 (CE standard version) PUMP UNIT...

  • Page 13: Safety Precautions

    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 the failure to read an indication is classified and described as follows.
  • Page 14 SAFETY PRECAUTIONS Be sure to observe WARNING Follow the warning indication. This is a label for ensuring the safe machine use. If you do not observe it, there is a risk of human injury or damage to property. The following warning labels are pasted on this machine. Follow the instructions on each label. If a label has come off, put a new one on a proper position.
  • Page 15 SAFETY PRECAUTIONS Be sure to observe WARNING Front view of warning label indicated positions (Nonstandard version) WARNING WARNING WORKER DO NOT DISABLE OPERATING SAFETY SENSOR IN THE BACK You will have serious Make sure that no injury by active part worker is in the back if you disable safety when machine...
  • Page 16 SAFETY PRECAUTIONS Be sure to observe WARNING Rear view of warning label attached positions (CE standard version) DANGER WARNING HOT SURFACE MACHINE WARNING FALLING DOWN You will have serious burn if you touch the Machine will fall down hot surface. if you slant machine WARNING more than 15 degrees...
  • Page 17 SAFETY PRECAUTIONS Be sure to observe WARNING Rear view of warning label attached positions (Nonstandard version) DANGER WARNING HOT SURFACE MACHINE You will have serious FALLING DOWN burn if you touch the hot surface. WARNING Machine will fall down if you slant machine more than 15 degrees 0 1 K F B in machine installation...
  • Page 18 SAFETY PRECAUTIONS Be sure to observe WARNING Direct tray feeder DT20F-20U (option) Warning label indicated positions DANGER To CM120 DO NOT TOUCH ACTIVE PART WHEN OPERATING You will have serious injury if you touch the active part. 0 1 J X A WARNING MACHINE FALLING DOWN...
  • Page 19 SAFETY PRECAUTIONS Be sure to observe WARNING If you sense any danger or abnormality, press an emergency stop button to stop the machine. If you continue to operate the machine in a dangerous or abnormal state, a breakdown or an accident will occur.

  • Page 20: Servo Switch Off

    SAFETY PRECAUTIONS Be sure to observe WARNING 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.
  • Page 21 SAFETY PRECAUTIONS Be sure to observe DANGER DO NOT TOUCH AC- DO NOT OPEN THE HOT SURFACE. TIVE PART WHEN COVER WHEN OPER- OPERATING. ATING. You will have serious burn if You will have serious injury if You will have serious injury if you touch the hot surface.
  • Page 22 SAFETY PRECAUTIONS Be sure to observe WARNING MACHINE FALLING DO NOT DISABLE HIGH VOLTAGE. DOWN. SAFETY SENSOR. (DT20F-20U (OPTION) You will have serious injury by Machine will fall down if you You will have serious electric active part if you disable safety slant machine more than 15 shock if you touch electric sensor.
  • Page 23 SAFETY PRECAUTIONS Be sure to observe WARNING DO NOT PLACE YOUR HANDS OR ONLY THE PERSON IN CHARGE OF BODY INSIDE ACTIVE PART OF THE MAINTENANCE MUST REPAIR OR MACHINE WHEN IT IS IN A SINGLE ADJUST THE MACHINE. STOP OR CYCLE STOP CONDITION. The machine may be incorrectly repaired or ad- justed, resulting in malfunction.
  • Page 24 SAFETY PRECAUTIONS Be sure to observe WARNING PERIODICALLY REMOVE DUST DO NOT DAMAGE POWER AND OTHER CORDS OR PLUGS. FROM POWER PLUG. Never damage, remake, bring close to heating appliances, bend forcibly, twist, pull, put heavy objects on, and bundle up. Dust on the plug may result in fire caused by Damaged cord and plug may cause electric shock, defective insulation because of moisture.
  • Page 25 SAFETY PRECAUTIONS Be sure to observe CAUTION BE CAREFUL WITH DO NOT PLACE ANY DO NOT PLACE ANY YOUR HANDS AND OBJECTS ON THE OBJECT AROUND FINGERS WHEN EMERGENCY STOP COVER. BUTTONS. CLOSING THE COVER. The cover may break due to the You will be unable to press a Your hands or fingers may be button to stop the machine in...
  • Page 26 SAFETY PRECAUTIONS Be sure to observe CAUTION BEFORE PERFORMING AUTOMATIC CARRY OUT PERIODIC MAINTE- WIDTH ADJUSTMENT, BE SURE TO NANCE AND INSPECTION. VERIFY NO BOARDS OR OTHER OBJECTS ARE ON THE CONVEYOR. If you fail to carry out periodic inspection and maintenance, the machine cannot exhibit its true performance.
  • Page 27 SAFETY PRECAUTIONS Be sure to observe About Interlock About Safety Cover Interlock 1. Basic feature of safety cover interlock Before starting regular automatic production on this machine, close all safety covers. Since a screen displays the message prompting you to supply a member when it needs to be supplied, open the corresponding cover according to the member to be supplied and then conduct the work.
  • Page 28 LEAD CHECKER (OPTION) ∗ This item is applied only for the machine with the lead checker. WARNING DO NOT LOOK AT A DIRECT LASER BEAM OR A REFLECTED LASER BEAM ON A MIRROR. Your eyes or body may be disabled. M72EB Reference Information 1) Laser unit specification...
  • Page 29 IDENTITY PLATE AND CAUTION LABEL Both an identity plate and a caution label for this product are attached to the machine. Operate and maintain the machine according to instructions on the label. ∗ The label below is not attached to the machine without the lead checker. Never diassemble LASER UNIT 493C-001P00.tiff...
  • Page 30 The serial plate attached to this machine indicates the model name and production number. CM120-MU Serial plate for CE standard version CM120-MU KXF-493C 493C-002P00.tiff ∗ The cover and the transformer of 400V are option for the nonstandard version. Serial plate for nonstandard version...
  • Page 31 SERIAL PLATE DT20F-20U Serial plate for CE standard version DT20F-20U KXF-4A3C 463C-AA00 Serial plate for nonstandard version DT20F-20U KXF-4A3C This is attached to the left on the rear side of machine. Actual numbers are shown on the plate instead of ∗. 493C-E-MMA00-A04-04 Page 31...
  • Page 32 PRECAUTIONS FOR USE How to stop the vacuum pump motor NOTICE Vacuum pump motor does not stop with emergency stop switch and cover switch. Stop it with main switch. Vacuum pump 493C-003P Page 32 493C-E-MMA00-A04-02...
  • Page 33 ILLUSTRATION IN MANUAL NOTICE This manual is for both CE standard and nonstandard versions. Therefore, this manual describes the machines using the illustrations of CE standard version. CE standard version Front side Rear side Orange Clear Green Feeder cover Conveyor cover Transformer of 400V 493C-001P...
  • Page 34 HOW TO SEE DESCRIPTION FOR OPERATION The description depends on each page, but basic structure is as follows. T i t l e T i t l e 1-1-1 Starting Production 1. Press Actual operation Actual operation Production • “Return to origin” for all axes are carried out. Operating procedure number Operating procedure number Supplementary description on operation...

  • Page 35: Regular Maintenance

    Chapter REGULAR MAINTENANCE REGULAR MAINTENANCE Regular maintenance This chapter describes the regular maintenance of CM120-MU. Characteristics of regular maintenance of CM120-MU are to estimate a maintenance period automatically by the run time and inform it to the user. Carrying out mainte- nance, based on the run time, enables to run the machine in a more stable condition.

  • Page 36: Outline Of Maintenance

    Outline of Maintenance CM120-MU automatically estimates the time for the regular maintenance by the period time set in advance and the run time, and informs it to the user. Entering the maintenance completed after it can save the date of operation in the history. Also this information could be the standard to estimate the next maintenance period.
  • Page 37 Outline of Maintenance Select the blinking item on the “Main menu” screen. ∗ For the regular maintenance by our service technicians, select “Routine maintenance.” Move the cursor to the item blinking the column of caut, and press Manual . • Contents of item blinked on the “Main menu” screen is displayed on the screen for “Manual.”...
  • Page 38 Outline of Maintenance Press Finish . • The message for checking appear. 433C-EEn-MpMmRm-001 8. Press Yes . • “Run time” is reset, and that to next period is calculated. • “History” is renewed. ∗ Past maintenance history can be checked. Press History .

  • Page 39: Maintenance Mode

    Outline of Maintenance 1-1-2 Maintenance Mode CM120-MU has “Maintenance mode” in the program of the machine. Using this mode makes such maintenance as cleaning or lubricating more easily. Entering the maintenance mode Press Maintenance mode . 433C-EEn-MpMm-001 UNLOCK START Press •...

  • Page 40: Regular Check Items For Period

    Outline of Maintenance 1-1-3 Regular Check Items for Period This section divides check items and consumptive parts requiring the change for period, and describes in a list. See “Reference” for details of each item. 1. Regular check items every 24 hours (every day) 493C-012TE 2.
  • Page 41 Outline of Maintenance 3. Regular check items every 560 hours (every month) – – – l l o – l l o – l l o n i l l l a l l a n i l l l a n i l l l a l l a...
  • Page 42 Outline of Maintenance 6. Consumptive parts to be changed every 6000 hours (once a year) t l i – – 493C-031TE 7. Consumptive parts to be changed every 18000 hours (once three year) t l i – – – – 493C-032TE 493C-E-MMA01-A01-01 Page 1-8...

  • Page 43: Regular Check Items For Each Unit

    Outline of Maintenance 1-1-4 Regular Check Items for Each Unit Regular check items are divided for unit name. Make use of it for reference. List of regular check items for unit (1/2) t l i l l a n i l l l a n i l n i l...
  • Page 44 Outline of Maintenance l l a l l e l l e n i l l l a d i l o l l t f i l l l a t f i l t l i – 493C-016TE Regular check items are divided for the unit and illustrated.

  • Page 45: Nozzle Stocker

    Outline of Maintenance 5. Color touch panel 6. Left board conveyor 2) Linear bearing 1) Touch panel face 1) Screw shaft 2) Touch panel face rear side front side 4) Board transfer roller Ch Ex 3) Board transfer belt Ch Ex 5) Surface of board detection sensor Cl 8.
  • Page 46 Outline of Maintenance 13 Line camera 14. Load cell unit 1) Camera marker Ch Cl 2) Line camera cover glass 1) Top face Ch Cl Ch Cl 15. Feeder base (optional) 16. DT10F-3 (optional) 1) Feeder setting face Ch Cl 3) Empty tape duct Ch Cl 2) Empty tape box...

  • Page 47: Lubricating

    Lubricating This section describes setting and using the cartridge of grease gun belonging to the machine, and precautions of lubricating. The grease gun consists of following 4 parts. Make sure of firm setting of the nozzle to the main body, before use. Nozzle Oil cylinder Grease gun...

  • Page 48: Using The Grease Gun

    Lubricating Put the cartridge in the oil cylinder and fit the cylinder to the main body. Unlock the chain from the groove of oil cylinder, and put it back in the cylinder. ∗ Move the lever several times, and check coming out of grease from the nozzle tip.

  • Page 49: Greasing Point

    Lubricating 1-2-3 Greasing Point NOTICE Be careful not to stain the belt with grease, in greasing. Remained grease worsens the belt early. Main parts requiring lubrication Linear bearing Ball screw Bearing and cam follower 273C-IL087 Lubricating the linear bearing Move the sliding unit to the edge. Clean the old grease.
  • Page 50 Lubricating Oils l l a k i l 433C-022TE Page 1-16 493C-E-MMA01-A02-01...

  • Page 51: Check Every 24 Hours (Every Day)

    Check Every 24 Hours (Every Day) 1-3-1 Checking the MR Unit (before Poeration) Check and clean the air pressure and drain of MR unit. Checking the MR unit Check the air pressure. ∗ Air pressure standard 0.49 MPa to 0.78 MPa Air pressure gauge 493C-001P ∗...

  • Page 52: Cleaning The Feeder Setting Face (Before Operation)

    Check Every 24 Hours (Every Day) 1-3-2 Cleaning the Feeder Setting Face (before Operation) Before setting the tape feeder and tube feeder to feeder base (option) of them, clean the setting face. Dust on the setting face can cause the fault pickup. SERVO OFF ( ) ON (...

  • Page 53: Cleaning The Ng Chip Ejecting Box And Empty Tape Box (After Operation)

    Check Every 24 Hours (Every Day) 1-3-3 Cleaning the NG Chip Ejecting Box and Empty Tape Box (after Operation) After production, clean NG chip ejecting box and empty tape box. ∗ The empty tape box is attached to the feeder base (optional). ∗...

  • Page 54: Cleaning The Empty Tape Duct

    Check Every 24 Hours (Every Day) 1-3-4 Cleaning the Empty Tape Duct This is the part to prevent the empty tape from interfering the operation and to put it in the empty tape box. Much tape in the duct may cause to prevent running the tape feeder. Turn off the power.

  • Page 55: Check Every 140 Hours (Every Week)

    Check Every 140 Hours (Every Week) This section describes the maintenance every 140 hours. As check every 140 hours has many items, the operation order is constructed according to the following principle, to operate effectively. → → Front side → Rear side → →...

  • Page 56: Cleaning The Line Camera (Front Side)

    Check Every 140 Hours (Every Week) 1-4-2 Cleaning the Line Camera (Front Side) Clean the line camera cover glass and camera marker of the line camera. Dirt on these may cause the fault recognition. Turn off the power. ∗ Check that the power has already been turned off.

  • Page 57: Cleaning The Color Touch Panel (Rear Side)

    Check Every 140 Hours (Every Week) 1-4-3 Cleaning the Color Touch Panel (Rear Side) ∗ This section describes the operation with the power turned off at the rear side of machine. Turn off the power. ∗ Otherwise, check that the power has already been turned off.

  • Page 58: Checking The Movement Of Safety Area Sensor (Front Side) : General Safety Specification

    Check Every 140 Hours (Every Week) 1-4-5 Checking the Movement of Safety Area Sensor (Front Side) : General safety specification ∗ This section describes the operation with the power ON at the front side of the machine. WARNING DO NOT DISABLE SAFETY SENSOR. You will have serious injury by active part if you disable safety sensor.

  • Page 59: Cleaning The Transfer Head And Nozzle (Front Side)

    Check Every 140 Hours (Every Week) 1-4-6 Cleaning the Transfer Head and Nozzle (Front Side) This section describes cleaning the nozzle holder and vacuum filter of transfer head used at the feeder bay 4, and the nozzle set on the transfer head. At first, understand the role of each part and carry out the maintenance following procedures.
  • Page 60 Check Every 140 Hours (Every Week) Vacuum filter of transfer head This is in the air pass, and prevents the dust in the air from entering the machine. Dust clogged in this part makes setting up the vacuum at the nozzle tip slow, and does not activate the quality of machine itself.
  • Page 61 Check Every 140 Hours (Every Week) Checking the arrangement of nozzle To check and clean each part, it is necessary to remove and set nozzles of transfer head. To prevent fault setting, output the position of each nozzle before operation. Press Product config...
  • Page 62 Check Every 140 Hours (Every Week) Removing the nozzle Move the head unit to the feeder bay 4 in the “Maintenance mode,” and remove the nozzle. SERVO Turn on the servo switch. OFF ( ) ON ( UNLOCK Move to Press feeder bay 4 •...
  • Page 63 Check Every 140 Hours (Every Week) Hold the nozzle tip and pull out it toward right down of the transfer head. ∗ Pulling it toward the side may remove the claw (clamp) of nozzle holder. Claws (clamp) Nozzle holder Nozzle 433C-057P 433C-086E ∗...
  • Page 64 Check Every 140 Hours (Every Week) Cleaning the vacuum filter Turn on the servo switch. SERVO OFF ( ) ON ( UNLOCK UNLOCK AZ axis Press down UNLOCK BZ axis CZ axis , and down down • Each of A, B, and C transfer heads falls down, and the pin fixing the vacuum filter appears from the shade of cover.
  • Page 65 Check Every 140 Hours (Every Week) Remove the vacuum filter with a pair Vacuum filter of tweezers. ∗ Remove the vacuum filter from each of A, B, and C of transfer head. 433C-055P 493C-027E Tweezers Wash the vacuum filter. Otherwise, remove the dust with an air ejector.
  • Page 66 Check Every 140 Hours (Once a Week) Filter warning is displayed When filter warning is displayed, clean the vacuum route along with the following flowchart. Filter warning 1. Cleaning filter (first time) “Vacuum pressure check” OK? “Filter check” 1. Cleaning filter Is judgment OK? (second time) “Vacuum pressure...
  • Page 67 Check Every 140 Hours (Once a Week) Cleaning the filter Clean the vacuum filter inside of transfer head. For cleaning the filter, “1-4-6 Cleaning the Transfer Head and Nozzle 4. Cleaning the vacuum filter.” Checking the vacuum pressure and the cleaned filter Enter the maintenance mode first.
  • Page 68 Check Every 140 Hours (Once a Week) DP3-80 DP3-80 . Check the displayed value of vacuum sensor. ∗ If the absolute value of displayed one is less OUT 1 OUT 1 OUT 2 OUT 2 than 320, it is OK, and proceed to “Yes” of the MODE MODE flowchart.
  • Page 69 Check Every 140 Hours (Once a Week) Exchanging the filter SERVO OFF ( ) ON ( . Turn on the servo switch. ∗ If it has already been turned on, this is unnec- essary. UNLOCK . Press and “(head to operate) axis down.”...
  • Page 70 Check Every 140 Hours (Once a Week) Vacuum filter . Remove the vacuum filter with twee- zers. ∗ Remove the vacuum filter from the transfer head. 433C-055P 493C-027E Tweezers Vacuum filter . Return the new vacuum filter to the former position with tweezers. Projection ∗...
  • Page 71 Check Every 140 Hours (Once a Week) . Setting the vacuum sensor . Turn off the servo switch. SERVO OFF ( ) ON ( ∗ If it has already been turned off, this is unnec- essary. . Remove the nozzle from the transfer head.
  • Page 72 Check Every 140 Hours (Once a Week) . Record the value of vacuum sensor DP3-80 DP3-80 of each head. ∗ Here suppose the value as follows, for explain- ing later. OUT 1 OUT 2 OUT 1 OUT 2 Value of head A is PA0 MODE MODE 0-ADJ...
  • Page 73 Check Every 140 Hours (Once a Week) DP3-80 DP3-80 . Press the (mode) key of vacuum MODE sensor once. ∗ The sensor displays “P-1.” (The setting value OUT 1 OUT 2 OUT 1 OUT 2 or “P-1” appears in turn.) MODE MODE 0-ADJ...
  • Page 74 Check Every 140 Hours (Once a Week) DP3-80 DP3-80 . Press the (mode) key of vacuum MODE sensor four times. • The inspection mode (current value) reap- OUT 1 OUT 2 OUT 1 OUT 2 pears. MODE MODE 0-ADJ SUNX 0-ADJ SUNX 443C-361E...
  • Page 75 Check Every 140 Hours (Once a Week) Cleaning the route of piping . Turn on the servo switch. SERVO ∗ If it has already been turned on, this is unnec- ) ON ( OFF ( essary. UNLOCK . Press and “(head to operate) axis down.”...
  • Page 76 Check Every 140 Hours (Once a Week) . Remove the vacuum filter with twee- zers. Vacuum filter ∗ Remove the vacuum filter from each transfer head. 433C-055P 493C-027E Tweezers . Remove the filter housing from the transfer head. Filter housing ∗...
  • Page 77 Check Every 140 Hours (Once a Week) . Return the filter housing and the filter to the former position. . Set the pin to the transfer head. ∗ Tighten the pin with the screw driver. Pins Screw driver 433C-059P . Remove the silicon tube of nozzle holder.
  • Page 78 Check Every 140 Hours (Every Week) Cleaning the nozzle (change) Clean nozzles with checking. As for the nozzle or nozzle reflector with damage, change them to new ones. As for the nozzle with a pickup pad, check for the damage on the pickup pad. Air ejector Remove the dust in the air pass of nozzle with an air ejector.
  • Page 79 Check Every 140 Hours (Every Week) Changing the pickup pad The nozzle with pickup pad made of polyurethane is used, for the stable pickup of chips. For the pickup pad with some damages, change that pad or nozzle itself. (Nozzle No. 1004 and 1005) Remove the damaged pickup pad.
  • Page 80 Check Every 140 Hours (Every Week) Setting the nozzle Set the nozzle checking the nozzle arrangement in the illustration on the touch panel screen, which is output at the operating procedure “1 Checking the arrangement of nozzle.” SERVO Turn on the servo switch. OFF ( ) ON ( UNLOCK...
  • Page 81 Check Every 140 Hours (Every Week) ∗ The theta direction stopper is the part to reduce the deviation of theta axis of nozzle and transfer head. If the wider groove of nozzle reflector is fitted to the theta direction stopper, the gap between them worsens the mount angle accuracy.

  • Page 82: Checking The Movement Of Safety Area Sensor (Rear Side) : General Safety Specification

    Check Every 140 Hours (Every Week) 1-4-7 Checking the Movement of Safety Area Sensor (Rear Side) : General safety specification ∗ This section describes the operation with the power turned on at the rear side of machine. Check the proper operation of safety area sensor (rear side). Checking “1-4-5 Checking the Movement of Safety Area Sensor (front side)”...

  • Page 83: Nozzle Stocker

    Check Every 140 Hours (Every Week) Remove the nozzle from the nozzle stocker. 433C-067P Remove the dust in the nozzle stocker with tweezers. 433C-068P Clean the top face of nozzle stocker with a cloth soaked with the waterfree alcohol. ∗ Especially be careful not leave dirt on the contacting face between it and the nozzle reflector.
  • Page 84 Check Every 140 Hours (Every Week) Clean (change) the removed nozzle. Cleaning nozzle “1-4-6 Cleaning the Transfer Head and Nozzle 5. Cleaning the nozzle (change)” 433C-061P 433C-062P Set the nozzle to the nozzle stocker. ∗ Check the arrangement of nozzle on the “Nozzle arrangement”...
  • Page 85 Check Every 140 Hours (Every Week) UNLOCK Noz stk Press shtr close • The shutter of nozzle stocker closes. ∗ Check that the shutter is properly closed. If the nozzle deviates from the set position, the shutter may not be closed. In such a case, open the shutter again, and insert the nozzle properly.

  • Page 86: Cleaning The Board Holder

    Check Every 140 Hours (Every Week) 1-4-9 Cleaning the Board Holder Clean the surroundings of board holder and support pin inserting part, and apply grease to the linear bearing of board holder (board width adjustment), linear bearings of left and right conveyor, and screw shaft.
  • Page 87 Check Every 140 Hours (Every Week) Pull out all of the support pins (sup- port pins). ∗ When the accurate position is required in setting the support pin, as the dual-side mounting is set, mark at the inserting part and so on.

  • Page 88: Check Every 560 Hours (Every Month)

    Check Every 560 Hours (Every Month) 1-5-1 Checking the Exhaust Cleaner (before Operation) Check and clean the water in exhaust cleaner. Checking the exhaust cleaner Check the water. ∗ Before the cleaner is half filled, empty the water. ∗ Water in the cleaner depends upon the condi- tion for each machine.

  • Page 89: Transfer Head : Cleaning The Large Reflector

    Check Every 560 Hours (Every Month) 1-5-2 Transfer Head : Cleaning the Large Reflector The large reflector is at the lower part of the transfer head, and makes the shade of chips reflecting the LED lighting in recognition. Dirt on this large reflector can be the cause of fault recognition. UNLOCK Move to Press...
  • Page 90 Check Every 560 Hours (Every Month) Clean the large reflector with a clean cloth. . Applying the lubricant to the claws (clamps) • Replenish the oil groove on the claw (clamp) tip with the lubricant. To prevent adhesion to around the claw (clamp), remove it from a nozzle holder, put the lubricant on the tip of a small-sized flat screw driver,...

  • Page 91: Checking The Board Transfer Belts And Rollers

    Check Every 560 Hours (Every Month) 1-5-3 Checking the Board Transfer Belts and Rollers Check the board transfer belt and roller of the left and right board conveyors and board holder. Checking procedures 1. Checking the damage of belt and the eccentric of roller Changing the belts and rollers 2.
  • Page 92 Check Every 560 Hours (Every Month) Checking the tension of belt Measuring position Measure it at the center of span Left board conveyor Board holder Right board conveyor Measuring position Measuring method Measure the deflection (δ) of belt when pressing at the specified tension F with a tension gauge. Tension gauge Deflection δ...
  • Page 93 Check Every 560 Hours (Every Month) Adjusting the tension When the tension of belt is improper by check, move the pulley for tension adjustment and adjust the tension. Adjusting at the left and right board conveyors ∗ Move the pulley for tension adjustment and adjust.

  • Page 94: Lubricating The Board Holder And Board Conveyor

    Check Every 560 Hours (Every Month) 1-5-4 Lubricating the Board Holder and Board Conveyor Clean the surroundings of board holder and support pin inserting part, and apply grease to the linear bearing of board holder (board width adjustment), linear bearings of left and right conveyor, and screw shaft.
  • Page 95 Check Every 560 Hours (Every Month) Pull out all of the support pins (sup- port pins). ∗ When the accurate position is required in setting the support pin, as the dual-side mounting is set, mark at the inserting part and so on.
  • Page 96 Check Every 560 Hours (Every Month) Turn off the servo switch. SERVO OFF ( ) ON ( Directly apply grease to each point. [Oil : ALBANIA 2] ∗ Apply grease to both sides of rail at the middle position. Left board conveyor Board holder Right conveyor board Screw shaft...
  • Page 97 Check Every 560 Hours (Every Month) UNLOCK Press and Wd adj . • The board holder and left and right board conveyors go and return at full stroke of width adjustment axis repeatedly, spreading the grease to whole part of linear bearing and ball screw.

  • Page 98: Lubricating The Board Holder

    Check Every 560 Hours (Every Month) 1-5-5 Lubricating the Board Holder Lubricate the linear bearing and nine ball screws of board holder. These operation can be done through the grease nipple on the side of board holder. ∗ Carry out the operation with the board holder risen following the previous page. Turn off the servo switch.
  • Page 99 Check Every 560 Hours (Every Month) Turn on the servo switch. SERVO ) ON ( OFF ( UNLOCK Press and (Continuous mov- ing) PCB stage . • The board holder repeats moving up and down, spreading the grease to the whole part of linear bearing and ball screw for elevating.

  • Page 100: Lubricating The X-Y Unit And Head Unit (Rear Side)

    Check Every 560 Hours (Every Month) 1-5-6 Lubricating the X-Y Unit and Head Unit (Rear Side) Lubricate to the linear bearing and ball screw of each axis of X-Y unit and Z- axis ball screw of each A, B, and C transfer head through the grease nipple. Turn on the servo switch.
  • Page 101 Check Every 560 Hours (Every Month) Lubricate the ball screw and linear bearing of Y-axis of X-Y unit. [Oil : ALBANIA 2] Y-axis ball screw Back side 433C-075P 433C-074P Y-axis ball screw Y-axis linear bearing (right conveyor side) Y-axis linear bearing (left conveyor side) 433C-077P 433C-076P Sliding unit...
  • Page 102 Check Every 560 Hours (Every Month) UNLOCK UNLOCK AZ axis Press down UNLOCK CZ axis BZ axis , and down down in order . • Each of A, B, and C transfer heads falls down, and the grease nipple of ball screw of transfer head Z-axis appears from the shade of plate.
  • Page 103 Check Every 560 Hours (Every Month) Lubricate AZ-, BZ-, and CZ- axis of head unit through the grease nipple. [Oil : ALBANIA 2] AZ-axis BZ- axis CZ-axis 433C-079P SERVO Turn on the servo switch. OFF ( ) ON ( UNLOCK Press and (Continuous moving) UNLOCK...
  • Page 104 Check Every 560 Hours (Every Month) UNLOCK Press and UX . • After Y-axis of X-Y unit moves to the origin, X- axis goes and returns at full stroke of X-axis repeatedly, spreading the grease to the whole part. UNLOCK Press and UY .

  • Page 105: Lubricating Dt10F-3 (Optional) : General Safety Specification

    Check Every 560 Hours (Every Month) 1-5-7 Lubricating DT10F-3 (optional) : General safety specification Direct tray feeder is all optional. This section describes lubricating DT10F-3. Directly apply grease to the grooves of six liner bearings. Turn off the power. Linear bearing Apply grease to the linear bearing nearest to the board conveyor.

  • Page 106: Lubricating Dt20F-20U (Optional)

    Check Every 560 Hours (Every Month) 1-5-8 Lubricating DT20F-20U (Optional) This section describes lubricating DT20F-20U. Turn off the power. 463C-AE00 Empty tray ejecting part Lubricate the linear bush of the empty tray ejecting part. [Oil : ALBANIA 2] ∗ Directly apply grease and slowly move the sliding part at full stroke several times after applying.
  • Page 107 Check Every 560 Hours (Every Month) Lubricate the sliding pack of the tray supply part. [Oil : ALBANIA 2] Sliding pack 463C-AE00 Tray supplying part 433C-091P Lubricate the cam follower of the lifter. [Oil : ALBANIA 2] 433C-090P ∗ Lubricate through the grease nipple. Lubricate the ball screw of the lifter.

  • Page 108: Check Every 3000 Hours (Once Per Half A Year)

    Check Every 3000 Hours (Once per Half a Year) 1-6-1 Lubricating the Linear Encoder One linear encoder is used for each of X-and Y-axis of X-Y unit in this machine. Applying grease for specified terms successfully lessens the wear of dust seal and sliding resistor of detected head to the minimum.
  • Page 109 Check Every 3000 Hours (Once Per Half a Year) UNLOCK Press and UX, UY . • The X-Y unit moves to the origin position. C B A Front side 433C-090E SERVO OFF ( ) ON ( Turn off the servo switch. Push the dust seal B into the left position at full length of linear en- coder.
  • Page 110 Check Every 3000 Hours (Once Per Half a Year) Apply grease to the grease applying face of the dust seal B with fingers. [Oil: MOLYKOTE EM-50L] 433C-101E Turn on the servo switch. SERVO OFF ( ) ON ( X-axis linear encoder UNLOCK Press and UX .

  • Page 111: Consumable Parts To Be Changed Every 3000 Hours (Once Per Half A Year)

    Consumable Parts to be Changed Every 3000 Hours (Once per Half a Year) 1-7-1 Changing the Board Transfer Belts and Rollers It needs to change the board transfer belts and rollers on the board holder and left and right board conveyors regularly, as the consumptive parts.
  • Page 112 Consumptive Parts to be Changed Every 3000 Hours (Once per Half a Year) Catch the flat part of belt with fin- gers. Flat part 273C-IL050 273C-0021 Move the flat part to the roller. 273C-0022 Remove the belt pulling out. 3Y3C-081P 493C-E-MMA01-A10-00 Page 1-78...
  • Page 113 Consumptive Parts to be Changed Every 3000 Hours (Once per Half a Year) Changing board transfer rollers For the board transfer roller of board holder, carry out the operation holding the nut on the back side. Remove the board transfer roller with a hexagonal wrench.

  • Page 114: Consumable Parts To Be Changed Every 6000 Hours (Once A Year)

    Consumable Parts to be Changed Every 6000 Hours (Once a Year) 1-8-1 Procedures for Replacing Consumables Used on the Vacuum Pump Periodic checks Inspect consumables periodically by referring to the table below once you start to use the machine. See the section, “List of Consumables” for details of consumables. Items Inspection and maintenance Method...
  • Page 115 Consumptive Parts to be Changed Every 6000 Hours (Once a Year) Procedures for replacing consumables See the resolution view of DOP-80SKMA on the next page. The vacuum pump consists of two of the same components. This part describes how to replace on the right side, and use the same procedure for the other side.
  • Page 116 Consumptive Parts to be Changed Every 6000 Hours (Once a Year) Replacing the silencer 1. To set the silencer, pinch the tip of the body, which is the side without screw, and screw it in. At the point that the screw becomes a little tight, give an additional tightening by about 1/4 rotation by using the spanner that fits the width across flat of the hexagonal part.

  • Page 117: Replacing The Consumable Parts

    Replacing the Consumable Parts 1-9-1 Replacing the Battery The lithium battery is used for each backup type of this machine. Battery type and purpose to use ST : CM120 Module Type Maker Number Voltage Purpose to use Backup of mount data and SCMYEX Lithium battery MATSUSHITA VL2330/1HF 3.0V/50mAh (SCMWEX)
  • Page 118 Replacing the Consumable Parts Setting position of battery PR13 PRM8 MCMJEX NFMECX NFMHEX ELL2EX SCMWEX EC73CX MC14EX MC14EX 493C-021P 433C-110E PRMAEC SCMYEX (PRMCEA) (SCMWEX) 493C-E-MMA01-A11-02 Page 1-84...

  • Page 119: Replacing Color Touch Panel Back Light

    Replacing the Consumable Parts 1-9-2 Replacing Color Touch Panel Back Light Back Light Built-in Color Touch Panel Position (Front side, Rear side) The color touch panel of this machine has a back light built-in. Back light Color touch panel Front cover 493C-049E WARNING CUT OFF THE POWER SUPPLY BEFORE CARRYING OUT ANY WORK FOR...
  • Page 120 Replacing the Consumable Parts . Remove one M3 countersunk screw, and remove the hatch (plate) for back light replacement. One M3 countersunk screw Hatch (Plate) for back light replacement 493C-026P . Raise the bending 1 with a needle- nose plier and the like, and pull out the power supply connector.

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