MDC ECM97 pick and place system

MDC ECM97 pick and place system

I bought this machine in 2013 to assemble DiscFerret PCBs. It's turned into a project in itself!

The control PC is an old Pentium PC, with a Kumagai KP422 motion control card and an MDC custom 16-bit PC I/O card.

Unfortunately MDC Co. now appears to be out of business (as of late 2019), so parts availability is precisely nil. I am looking into the possibility of machining new nozzles.

Wanted -- Things I'm looking for

Hard disk images from ECM series machines – a “dd” image or similar.
- MDC accidentally left the source code for the ECM software on the drive of some machines, as a series of deleted PowerBASIC files.
- I hope that with a few more disk images (especially one from a lightly-used machine) I can reconstruct the code.
Documentation and/or software for the Kumagai KP422 motion controller card.
- Japanese or English is fine!
- May also be known as the HD422 or HD411
Spare nozzles – the entire ECM series uses the same nozzles (ECM93, ECM95, ECM97, ECM98, ECM99, ECM Luna).

Please email philpem@gmail.com if you have any of the above.

Configuration and specifications

ECM97 Console variant with Cyberoptics LaserAlign HD component alignment system, top-down teaching camera and automatic fiducial sensor (EYE sensor)
Two feeder mounts (front and back) for a total of 48 feeders
Mix of 8mm, 12mm and 18mm feeders
Vibratory feeder
PCB conveyor

Specifications according to this page:

Accuracy ± 0.1mm
Air supply 60psi (4.14bar, 4.22kgf/cm2)
Min PCB size 2 x 2 inch (50 x 50 mm)
Max PCB size 14 x 17.5 inch (355 x 445mm)
X/Y axis drives: AC servo motor, 1/100mm step
Theta axis drive: Stepping motor, 0.2-degree step
Z-axis drive: Stepping motor, 0.05mm step
Chip sizes: 0201 to 0804, SOIC/PLCC up to 20mm in length. Fine pitch to 20 mils (0.5mm).
Placement rate: Manufacturer's spec 3600cph, 4000cph under optimal conditions. (Realistically? Probably about half that)

Documentation

English translation of the ECM97 I/O card pinouts and functions table
My ECM97 cheat-sheet (work in progress)
MDC A3 mechanical drawings – these are in handwritten Japanese. I would appreciate help translating them!
- ECM97 I/O card pinouts and functions – 2-head (motor/air or motor/motor) with KP422 I/O card (075879) – translated version above
- “Right” feeder/pusher pneumatics and manifold (076173)
- “Left” feeder/pusher pneumatics and manifold (076172)
- Camera? (075684)
- Feeder rack (074910B)
- Servo motor assembly (075760A)
- X axis assembly (075756A)
- Y axis assembly (075758B)
- Head pneumatics panel (076246)
- Nozzle holder (075801)
- Pneumatic panel piping diagram
- PCB holder/conveyor ECM96 (076273)
- LaserAlign head (076159)
- Pick-up head (076226)
MDC A2 diagrams (not scanned yet)
- ECM98 Electrical Box (Single Head) (076162)
- Tape Feeder PCB (Twin Pusher) (076249)
- ECM97 Motor Wiring Assembly (076294)
- ECM97 Heater Wiring Assembly (076295)
- ECM97 Tape Index Electrical Diagram, KP422 only (075921)
- ECM97 Main Frame Wiring Assembly (075922A)
ECM93, ECM96, ECM97 installation guide
ECM97 Preliminary Manual
ECM93/ECM96/ECM97 Data Input and Calibration – includes copies of pages from the Installation Guide
Mekko 8mm tape feeder cassette
Service Bulletin -- LaserAlign sensors – LaserAlign cleaning, setup and configuration.
Setup notes

Component documentation:

Keyence AP-20A digital pressure sensor
CyberOptics LaserAlign manual
Takex F5RN optical fibre sensor spec sheet (EYE sensor / fiducial detect)

Software

I have a complete hard drive image of my ECM97's PC, with various versions of the ECM software. I am working on extracting the necessary parts of the ECM driver software.

The ECM hard drive image contains the following additional tools:

Panasonic PANATERM servo driver configuration software
LaserAlign LA_VIEW software configured for the LaserAlign HD

Nozzles

MDC nozzle drawing

Standard

Nozzle number	Part number	OD	ID	Part suitability
1	074966	0.9	0.5	0402, 0603 chip packages.
1	074966	0.9	0.5	MDC: 1005, 1608, “Super mini”
2	074954	1.2	0.8	0805, 1206 chip packages. “Case A” tantalum.
2	074954	1.2	0.8	MDC: 2125, 3126, “Mini Mould”, ~~“Tantalum D”~~
3	074970	2.0	1.4	Small SMD diodes, “Case B” and “Case C” tantalum.
3	074970	2.0	1.4	MDC: “Mini Power”, “Tantalum B”, “Tantalum C”.
4	–	–	–	Slot reserved for nozzle changing or expansion nozzles
4	–	–	–	MDC: n/a
5	074955	4.0	2.0	SMD diodes, SOP, “Case D” tantalum.
5	074955	4.0	2.0	MDC: “Mini Power”, SOP, ~~“Tantalum A”~~
6	074956	7.0?		Quad flatpack ICs. Two-part nozzle; has a nozzle and a collar which enlarges the OD to 7mm.
6	074956	7.0?		MDC: QFP

Optional

Part number	OD	ID	Part suitability
074965	–	0.8mm radius	1/16W and 1/8W MELF
074969	–	1.2mm radius	1/4W MELF
076596	0.5	0.25	0201 chip components (0603 metric)

Servo drive serial cable

To configure the servo drives or retune them (e.g. to fix control loop instability), you need a Panasonic DV0P0790 serial cable kit and the “PANATERM” software. These have not been available for some time, but the cable is easy to make, and PANATERM is easy to run on a DOS PC.

DB25 (PC serial)   ->   RJ12 (servo drive SER connector)

  Pin 2 (TX)       ->   2 (RX)
  Pin 3 (RX)       ->   5 (TX)
  Pin 7 (GND)      ->   3 (GND)
  
  Pin 4 (RTS)  ----+
                   |
  Pin 5 (CTS)  ----+

Connectors

KP422 I/O card
- IDEC JM series, 20 and 40 way (discontinued, now produced by KEL)
  - Alternative: KEL 8800 series
  - PCB-mount right-angle
    - 8830-020-170L-F right angle PCB mount, 20 way
    - 8830-040-170L-F right angle PCB mount. 40 way
  - PCB-mount straight
    - 8830-020-170S-F straight PCB mount, 20 way
    - 8830-040-170S-F straight PCB mount, 40 way
  - Cable-mount receptacle
    - 8822-020-171-F receptacle cable side, 20 way
    - 8822-040-171-F receptacle cable side, 40 way
MDC PC I/O card
- IDC, ?? way

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