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RoadRunner Owner`s Manual

1. at SMT pick point Output placement linear repeatability 25 mm Output placement rotational repeatability 5 Operating temperature range 20 40 C 68 104 F Temperature stabilization time after transportation 28h Humidity 5 90 1 24 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Chapter Installation For the Reject Bin location see Figure 19 on page 3 21 or see Reject Bin in the Service Manual Unpacking and installing the RoadRunner is easy It is deliv ered preassembled with a few exceptions There are four items that need to be installed onto the RoadRunner the Socket Adapter Actuator Plate and Precisor except on XLF models that are described in Chapter 3 and the Reject Bin which is described in this chapter Some RoadRunners require an additional item to install to adapt it to the SMT machine These are noted in the Mounting Instructions in this chapter where they apply All that is required to operate the programmer is an SMT machine position and two external facilities You may also need to install some pneumatic com ponents into your air supply line Lifting heavy objects improperly could injure you A The standard RoadRunner and shipping box weighs 26 kg 58 lbs maximum The XLF model Road Runner and box weighs 32 kg 70 lbs maximum This chapter includes Removing the Shipping Bracket Proper mounti
2. CAUTION Do not move the PNP head while the probe is in the DOWN position The probe might get damaged DO NOT SELECT THESE COMMANDS WHILE THE PROBE IS DOWN Home Purge Probe X speed or any of the Teach operations Tape Skt1 Reject Belt While performing any Teach procedure the PNP head may be moved incrementally with the Up Arrow or Down Arrow with the probe in the down position Use caution Setting the Belt Parameter To set up the output belt position for the PNP head 1 eee A On the Keypad press Menu until the top level menu is displayed Scroll to and select Operation Scroll to and select Teach Scroll to and select Belt The PNP head should move so probe 1 is positioned over the output belt Use the Up Arrow or Down Arrow buttons to change the value of the PNP head position until probe 1 places a device onto the output belt without striking the tab of the Reject Bin Press the Menu button to save your setting and move up to the next higher menu NOTE The probe tip should be placed in the DOWN position with a device attached to verify that it successfully clears the tab on the Reject Bin The device vacuum will need to be turned on and a device must be attached to verify this operation For details Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 29 Operation Supervisor Functions Setting Operational Parameters regarding turning on the vacuum an
3. 3 Scroll to and select System 4 Scroll to and select Update Software CAUTION Do not switch the power off while the update is in progress The RoadRunner might get damaged and require service 5 While the firmware is being updated the following message is dis played Update in progress Do not remove power until complete The three status lamps cycle on and off until the update is complete Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 33 Operation Supervisor Functions Network Settings 6 When the update has finished RoadRunner will beep and the blue status lamp will come on The following message is displayed on the Keypad Display Update complete Insert job card and Cycle Power to reboot 7 Inserta job card Switch the power OFF and then ON again to start the RoadRunner with the updated firmware NOTE Algorithm updates are not performed using the Update Software menu item Device algorithms do not reside within the RoadRunner itself They are provided by TaskLink with the pro gramming job on the PCMCIA memory card Algorithms are updated on TaskLink For more information regarding algorithm updates contact your Data I O sales represen tative Network Settings Network commands are covered in Chapter 2 See Configuring for Network Communication on page 2 31 Configuration The RoadRunner configuration command is under the System Config menu Here you wi
4. Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 1 17 Overview Specifications MYDATA Specifications MYDATA FACILITIES AC input voltage requirements 100 240 V 50 60 Hz single phase AC Input Power 100 W max Air requirements 2dm s 4 0scfm 52 MPa 7522 psi Air Inlet tube varies 6 mm 24 in amp 8 mm 31 in OD min MODELS SUPPORTED MYDATA models supported MY9 MY12 MY15 MY19 DIMENSIONS Width 78 mm 3 1 in without SMT Adapter Weight net 16 5 kg 36 3 Ibs without SMT Adapter Length with 33 cm reel 120 1 cm 47 3 in without SMT Adapter Approximate length protruding from SMT Feeder Table 59 2 cm 23 3 in includes 33 cm reel outer edge Height 49 4 cm 19 5 in includes 33 cm reel Input tape width supported 16 mm 24 mm 32 mm optional 12 mm 32 mm Large Format DEVICE OUTPUT PLACEMENT at SMT pick point Output placement linear repeatability 25 mm Output placement rotational repeatability 5 Operating temperature range 20 40 C 68 104 F Temperature stabilization time after transportation 28h Humidity 5 90 1 18 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Overview Specifications Panasonic CM20 CM120 CM301 Specifications panasonic cm20 120 CM301 FACILITIES AC input voltage requirement
5. Tape In Module compressed air Remove dust and debris with clean dry compressed air Entire System Vac Tool Perform the system self test once each week with power and air to verify proper operation of all internal electronic systems To run the self test perform the following 1 Enda job if one is running Weekly 2 Clear all devices from the sockets and from the conveyor belt 3 Toggle the power switch OFF then ON again The self test will begin automatically Check the LCD display for system errors Backplane to dry compressed air Remove the Socket Adapter and blow off the Backplane adapter terminals PCB terminals PNP Probe Tips water Clean with water on a clean lint free cloth or swab cloth or swab Check for wear replace the tips if necessary Chassis and Covers Isopropyl alcohol Clean with isopropyl alcohol on a cloth Lint free cloth NOTE Do not use solvents such as ace tone lacquer thinner mineral spirits or any type of abrasive compound on the Quarterly safety shield surfaces Use of these prod ucts will damage the safety shield surface and reduce visibility of the operating area 5 2 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Maintenance Preventive Maintenance Schedule Lubricating the Ball Screw Maintenance Schedule Interval Component Tools Required Action Ball Screw Stan Check that lubrication is still visible on the b
6. Unable to lower probe 4 See above 7 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 6 13 Troubleshooting Error Messages Unlisted Error Messages Lamp Color Error Message Resolution Unable to raise probe 1 The solenoid switch in the Pneumatic Module may be stuck Replace the Pneumatic Module Unable to raise probe 2 See above T Unable to raise probe 3 See above Unable to raise probe 4 See above T Unable to read Adapter Reinsert the Adapter board ID consistently Reinsert Adapter Unable to read Jobs direc Try a different Job card tory Try a different brand of PC Card reader writer to load the job with If the job has had any handling such as going through e mail then try a fresh job file transfer by FTP or Network Unable to reset program Programmer Module requires repair or replacement ming electronics Contact Data I O Customer Service Unrecognized Programmer Update to the latest RoadRunner software board VCC DAC calibration Programmer Module requires repair or replacement error Contact Data I O Customer Service blue DAC calibration error Programmer Module requires repair or replacement lamp is on Contact Data I O Customer Service VPP DAC calibration error Programmer Module requires repair or replacement Contact Data I O Customer Service VSense DAC calibration Programmer Module requires repair or
7. When the tape has advanced past the peel bar separate the cover tape from the device tape Thread the cover tape through the tape path as indicated in the tape threading diagram on the RoadRunner Attach it to the Cover Tape Reel A small piece of adhesive tape may be required to stick the cover tape to the Take Up Reel Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 15 Operation Operator Functions Setting Up RoadRunner for a Programming Job Fi igure 3 1 6 Attaching the Cover Tape to the Take up Reel on standard RoadRunners Siemens Model Shown The device tape is loaded The device tape must be aligned before running a job Refer to Aligning the Device Tape on page 3 17 XLF Models To load device tape into the RoadRunner XLF NOTE Make sure the Tape In Module is adjusted for your desired tape width See the spindle and brass button in Figure 3 14 on page 3 14 1 Ensure that the brass button on the spindle is rotated to the center to allow a reel to slide over it Install a reel of device tape Rotate the brass button to lock the reel in place Peel Bar winds up Cover Tape in the opposite direction than standard models Switch the power switch on and allow the system to start up Remove the Robotics Cover Insert the tape into the Tape In Module to engage with the sprocket c pe e a Press Menu until the top level menu is displayed 3 16 Data I
8. o T 9 99 MER JF Was AR 5 9 5 1 9 9 1 Oo a a T 0 o T 9 99 CCA IEEE HORE RET SJ T 11636 2006 jx XE HI F X SJ T 11636 2006 B DR Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 5 7 Maintenance Maintenance Sign off Charts Maintenance Sign off Charts Copy this chart RoadRunner SN to use near your For maintenance instructions see RoadRunner Preventive Maintenance Schedule on page 5 2 Enter name of people responsible or daily check marks Name Daily Blow off sockets Check Socket Sunday Monday Tuesday Wednesday Wear Yield and remedy Clean Conveyor Belt Thursday Friday Saturday Enter initials and date Weekly Blow out Tape In mta Date Module Jan Feb Perform System Self test Clean PNP Probe tips XY a URN Quarterly Clean covers NEUES nitial Date Check Vacuum Filters Jan Feb Mar Apr May Jun Check Ball Screw for visible lube Lube Ball Screw Enter initials and date core Yearly Lube Ball Screw Std imtial vate mer Diagnostic only a semiannually s Check wageto okay board voltage En
9. 12 mm 32 mm Large Format DEVICE OUTPUT PLACEMENT at SMT pick point Output placement linear repeatability 25 mm Output placement rotational repeatability x5 ENVIRONMENT Operating temperature range 20 40 C 68 104 F Temperature stabilization time after transportation 28h Humidity 5 90 1 16 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Overview Specifications Fuji NXT AIM Specifications Fuji NXT AIM FACILITIES AC input voltage requirements 100 240 V 50 60 Hz single phase AC Input Power 100 W max Air requirements 2 dm s 4 0 scfm 52 MPa 7522 psi Air Inlet tube 8 mm 31 in OD min MODELS SUPPORTED Fuji models supported NXT AIM DIMENSIONS Width 78 mm 3 1 in Weight net 17 kg 37 lbs Length with 33 cm 13 in reel 104 4 cm 41 1 in Approximate length protruding from SMT machine 74 cm 29 in Height with 33 cm 13 in reel 49 cm 19 5 in Input tape width supported 16 mm 24 mm 32 mm optional 12 mm 32 mm Large Format DEVICE OUTPUT PLACEMENT at SMT pick point Output placement linear repeatability 25 mm Output placement rotational repeatability x5 ENVIRONMENT Operating temperature range 20 40 C 68 104 F Temperature stabilization time after transportation 28h Humidity 5 90
10. Allow system dry runs e Enable and disable the output belt components e View other system sensors e Cycle each of the PNP probes and test all other pneumatic components Dry Run When Run Mode is selected in the Robot Diags menu use the Up Arrow or Down Arrow to toggle between Job and Dry Run Use Dry Run to check the mechanical function of the robotics Devices do not need to be present When Dry Run is visible at the keypad screen the program mer is disabled as well as two sensors the vacuum detect sensors and the cover tape broken sensor Dry Run can be used to isolate mechanical prob lems or when the RoadRunner is new or has just been repaired It can also be used to even out the conveyor belt when RoadRunner has been inactive for a week or more Belt When the Move command is selected in the Robot Diags Belt menu the belt can be set in motion with the Up Arrow forward or Down Arrow backward This allows the belt speed to be displayed The speed is a measurement of the time in milliseconds that it took the belt to travel one head distance The Measure Device command in Belt menu measures and cen ters the device at the End of Belt optic When starting a job RoadRunner automatically centers the first device to arrive at the end of the belt to set the pick point The Offset command in the Belt menu allows adjusting the device posi tion to accommodate the SMT pick head in the event that centering the device at the p
11. Down RoadRunner To shut down RoadRunner Press the Pause button Press Menu until the top level menu is displayed Scroll to and select End Job Programming and verification will continue only for devices still in the programming sockets They will be picked and placed on the output conveyor or into the Reject Bin as appropriate The job will then stop When the RoadRunner stops moving and the blue lamp illuminates switch the power OFF 0 Remove devices from the output belt Empty the Reject Bin 3 22 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Operation Operator Functions Miscellaneous Settings via the Menu Empty the Cover Tape Take Up Reel 7a Cut the cover tape near the Take Up Reel and pull the device tape out of the RoadRunner Use caution to ensure that no devices fall from the device tape and into the machine 7b Remove and empty the Take Up Reel containing the used cover tape Replace the Reel Miscellaneous Settings via the Menu Changing the Pass Limit An operator can change the Pass Limit at the RoadRunner Control Panel but it does not save the change to the job card The next time the job is run the original Pass Limit will be in effect To change the Pass Limit at the Control Panel 1 Select Job 2 Select Remaining Devices 3 Scroll to and Select an increment for adjustment 4 Press the Up or Down Arrow buttons as necessary 5 Press Menu Repeat
12. Life but cannot be changed If you don t replace the adapter RoadRunner will continue to alert you each time you start or pause a job These recurring alerts beep and message can be prevented Navigate the menu to and select System gt Adapter Alarm Press the ArrowDown button to set to OFF Press the Menu button To view Socket Adapter life see Adapter Life on page 6 4 in the Error Messages table under the section Yellow Lamp is on Adapter Clean Count Although not under the System menu the Socket Adapter Clean Count dis plays an Adapter maintenance is required message when the adapter has been actuated its recommended number of cycles between cleaning The counter can be reset after cleaning the sockets Also the cleaning interval setting can be changed Both are described in the Troubleshooting chapter see Adapter Maintenance on page 6 5 in the Error Messages table under the the section Yellow Lamp is on To display the number of actuations since the last cleaning scroll to and select Socket Adapter Statistics Clean Count 3 32 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Operation Supervisor Functions Setting System Parameters Updating Programmer Firmware Occasionally an Update may be made to RoadRunner s internal operating system to improve operability To take advantage of this improvement the new operating system must be uploaded into RoadRunner Software Ver
13. Networked Road Runners and click Configure TaskLink RoadRunner could be Configuring RoadRunner involves creating a network configuration card in a different city with TaskLink inserting the card into RoadRunner and setting RoadRunner Some of those activi network parameters ties are To create a network configuration card downloading jobs 1 Start TaskLink and click Help gt Help Topics In the contents to RoadRunner s m me expand Using Networked RoadRunners and click How to viewing statistic Configure RoadRunner Follow the instructions files jobs and PC Card space avail able NOTE The following steps are required after creating the network logging session configuration on a PC card and are repeated from the TaskLink instructions data viewing the RoadRunner firm Insert the Network Card into RoadRunner ware version On the Control Panel scroll to and select System gt Network sending firmware update files Press the Select button setting supervisor privileges Using the arrow buttons toggle Network Parm to Card On Rom Press the Menu button to save your changes Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 2 31 Installation Configuring for Network Communication Configuring RoadRunner 3 To save the network con figuration file set the System gt Network gt NetworkTxt param eter to Save 7 Cycle the power on RoadRunner
14. OVER TRAVEL SEN SOR IS DEFECTIVE Replace the Over Travel Sensor CAUSE D THE MOTION CONTROLLER PCB OR CABLE IS DEFECTIVE Contact Data I O Customer Service Unable to load and or start the internal serial port driver Turn the power off and back on Contact Data I O Customer Service Unable to lower probe 1 blue lamp is on CAUSE A INSUFFICIENT AIR PRESSURE Verify that the supply air is connected Verify that the supply air pressure is within the specified limits see specifications at the end of Chapter 1 CAUSE B PROBE SPEED IS TOO FAST OR TOO SLOW Verify that the system air pressure is within specified limits Adjust as required see specifications at the end of Chapter 1 Verify that the Probe speed is within limits readjust if necessary CAUSE C THE PICK OR TRAVEL DELAY VALUES ARE TOO LOW Reset the pick delay Reset the travel delay CAUSE D PROBE POSITION SENSOR IS MALFUNCTIONING OR OUT OF ADJUSTMENT Verify that the Probe Position Sensor is working Adjust the Probe Position Sensor CAUSE E HEAD UP SENSOR IS NOT ADJUSTED OR NOT WORKING PROPERLY Check that the probe Head up Sensor is working Realign the probe Head up Sensor CAUSE F A PINCHED AIR LINE OR MALFUNCTIONING SOLENOID VALVE Verify that the air lines are not pinched Verify correct solenoid operation Unable to lower probe 2 See above T Unable to lower probe 3 See above T
15. RoadRunner System 1 1 Puff 1 8 Purge 3 20 Robotic System description 1 6 precision 1 8 Running a Job See Starting a Job S Safe Operation 1 14 Safety about warnings 1 3 grounding 1 14 precautions 1 14 Safety Shields 1 12 Save Air 3 30 Save Network text parms 2 31 Schematic electrical 6 23 pneumatic 6 22 Selecting a job 3 5 3 18 Self test 2 30 5 8 Serial Number Server Settings 3 25 Session Data Log 3 38 Shipping Bracket removing 2 2 Shock Indicator description 2 2 photo 2 2 Shutting down 3 22 4 don t see Ozone in here It should be here Let us know about any items you can t find by e mailing userdocs dataio com R Regional power 2 25 Reject Bin emptying 3 21 position 3 28 Remaining devices 3 23 Restarting a paused job 3 19 Restarting a stopped job 3 19 Results 3 37 RoadRunner pick point about aligning 3 17 setting Tape parameter 3 27 Robot diagnostics menu 3 24 3 35 SIPLACE Regulator Kit 2 26 SMT Models Supported 1 15 to 1 24 SMT pick point about 1 10 adjusting 3 35 buffer 3 31 problems 6 15 teaching 3 27 SNS Settings 3 25 Socket disabled 6 3 purging 3 20 re enabling 6 3 wear 1 9 Socket 1 position 3 28 Socket Actuator Sensor 6 21 Index 4 Data I O ProLINE RoadRunner Owner s Manual 0 Socket Adapter changing 3 5 clean count 3 32 cleaning 5 2 errors 6 21 LED 6 21 life 3 32 statistics 3 37 Software update 3 33 Specifications 1 15 to 1 24 Starting
16. Shipping Bracket to the PNP Head Unscrew the two screws securing the Shipping Bracket to the Ball Screw housing Remove the Shipping Bracket Mounting the RoadRunner The RoadRunner is designed to mount to the SMT machine feeder table Multiple RoadRunners may be mounted on the same SMT machine ing RoadRunner to the feeder table It is heavy and drop ping it can cause serious damage to RoadRunner and anything it falls upon Use only approved hardware to mount RoadRunner to the SMT feeder table CAUTION Heavy weight Use great care when mount Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 2 3 Installation Mounting the RoadRunner Mounting RoadRunner Assembleon ACM Mounting RoadRunner Assembleon ACM Look ahead for mount ing instructions for your specific model of RoadRunner NOTE The Assembleon RoadRunner must be mounted to a Univer sal Feeder Table Adapter Install a Universal Feeder Table Adapter onto the ACM machine before continuing Also the ACM upper feeder guide must be used NOTE When selecting slot positions for RoadRunner consider that access to it is from the right side To mount the RoadRunner onto the SMT machine feeder bank perform the following 1 Hold the RoadRunner level and rest the nose on the feeder bank Ensure that the guide under the conveyor settles into a slot Figure 2 3 Mounting the RoadRunner o
17. The RoadRunner operator performs specific functions concerned with run ning programming jobs while a system supervisor has the ability to set RoadRunner operational parameters view operational statistics and perform various diagnostic routines Create programming jobs using TaskLink for Windows Operator Functions This section describes operator steps for setting up RoadRunner to Program devices Basic Operator Steps To set up RoadRunner to Program Devices the operator must 1 Change the Socket Adapter page 3 5 2 Change the Precisor page 3 7 standard models only 3 Change the Actuator Plate page 3 8 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 1 Operation Operator Functions Turning On System Power 4 Before inserting the PCMCIA card a job must 6 be created See TaskLink s 7 Handshake with RoadRunner on page 1 11 9 10 11 12 Adjust the Actuator Plate page 3 8 XLF models Insert a PCMCIA card Switch the power on Check the hardware setup page 3 9 If using an Adjustable Tape In Module set the width to match the device tape page 3 10 Load the device tape page 3 14 Align the device tape page 3 17 Clear away unwanted devices page 3 18 step 3 Press Start page 3 18 step 4 Turning On System Power Verify that the covers are in place that the power and air are connected and then switch the main power ON The three colored lamps i
18. are placed into the Reject Bin rather than on the belt Stopping or Fausing a Job To pause the RoadRunner after the current operation has finished press the Pause button on the Keypad To temporarily stop a job or in case of emergency press the Emergency Stop button The motor controlled parts will stop and can now be moved by hand NOTE Restarting after the Emergency Stop button has been pressed requires re aligning the device tape See Restarting a Stopped Job on page 3 19 NOTE The job statistics will continue when restarted after stop ping or pausing the job but not after ending or cancelling a job If the main power switch is ON power is applied to the electronic systems of the RoadRunner regardless of the position of the Emergency Stop button or safety shield Always turn the main power switch OFF before working inside the machine Restarting a Faused Job To restart the RoadRunner after a job has been paused press the Start button The paused job will resume Restarting a Stopped Job To restart the RoadRunner after the Emergency Stop button has been pressed perform the following 1 Twist the Emergency Stop button clockwise until it springs back to its normal operating position 2 Press Menu until the top level menu is displayed Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 19 Operation Operator Functions Programming Devices 3 20 Scr
19. cm 473 in includes SMT Adapter Approximate length protruding from SMT Feeder Table outer edge 56 cm 22 in 76 2 cm 30 in includes 33 cm reel 70 6 cm 278 in includes 33 cm reel Height 56 cm 22 in unchanged by reel 52 cm 20 5 in includes 33 cm reel 49 4 cm 195 in includes 33 cm reel Input tape width supported 16 mm 24 mm 32 mm optional 12 mm 16 mm 24 mm 32 mm 44 mm Opt 12 mm 16 mm 24 mm 32 mm optional 12 mm DEVICE OUTPUT PLACEMENT at SMT pick point Output placement linear repeatability 25 mm Output placement rotational repeatability ENVIRONMENT x5 Operating temperature range 20 40 68 104 F Temperature stabilization time after transportation 28h Humidity 5 90 Supported using S type feeder table in feeder positions 2 amp 4 except X3 in 4 only Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Specifications Universal GSM FACILITIES Overview Specifications Universal GSM AC input voltage requirements 100 240 V 50 60 Hz single phase AC Input Power 100 W max Air requirements 2dm s 4 0scfm 52 MPa 7522 psi Air Inlet tube varies 6 mm 24 in amp 8 mm 31 in OD min MODELS SUPPORTED Universal models supported GSM1 GSM2 DIMENSIONS Width 78 mm 3 1 in Weight net 17 kg 38 Ibs Le
20. device placement problems The Peel Bar position must be set for the new device tape Load device tape threading the cover tape as shown on the label on the RoadRunner a Align the Device Tape See Aligning the Device Tape AIl Models on page 3 17 Loosen the Peel screw and slide the Peel downstream until the straight edge is 1 to 2 mm left upstream of the left edge of the tape pocket eo Tighten the Peel Bar screw 32 44 mm Tape In Module XLF Models only A notch on the Tape In Module points to an etched number indicating the current setting NOTE If the Tape In Module has just been installed see the ProLINE RoadRunner Service Manual 002 or higher for the tape centering procedure before adjusting the width Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Operation Operator Functions Setting Up RoadRunner for a Programming Job Follow these steps to adjust the width of the Tape In Module to accommo Operator Functions date 44 mm tape width 1 With the E Stop pushed moved the PNP Head out of the way 2 Unscrew the Position Locking Screw most the way out using a 4 mm Allen wrench See Figure 3 12 Figure 3 12 XLF Models ONLY have a 32 44 mm Tape In Module The notch currently indicates 32 mm The Position Locking Screw is loosened The 32 mm Front Track is not shown 3 Slide the Selector Plate so the notch points to 44 an
21. machine After power is applied the RoadRunner performs a Self test During this test the RoadRunner verifies that all system components are present and func tioning and that all sensors are within calibration limits 2 30 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Installation Configuring for Network Communication Configuring RoadRunner Verify that all systems start up properly and that there are no errors or warn ings displayed on the keypad display screen If electrical or mechanical problems are noted turn off the RoadRunner and see Troubleshooting in Chapter 6 If you need help notify the local Data I O service representative In general the blue lamp should be illuminated indicating that there is no operation in progress before turning the power off Configuring for Network Communication To set up the network connection between RoadRunner and TaskLink both must be configured Configuring TaskLink What are the advantages of NOTE You must be using TaskLink version 5 0 or higher and networking RoadRunner Firmware version 5 0 or higher After TaskLink and RoadRunner are set up for networking you can perform many activities from TaskLink without using a PC Card to transfer the infor Configuring RoadRunner mation to RoadRunner In fact For instructions on configuring TaskLink start TaskLink and click Help gt Help Topics In the contents expand Using
22. moving parts Do not disable or attempt to defeat any of the protective safety features of this system Personal injury or equipment damage can occur if any safety systems on RoadRunner are disabled If you suspect that a safety feature of the RoadRunner is damaged or malfunctioning stop using the RoadRunner immediately and contact Data I O Customer Service or a local Data I O approved service representative Use extra caution when working around the RoadRunner s Output Belt RoadRunner s safety shields do not cover or fully enclose the output conveyor It is possible that an operator s hands other body parts or loose clothing can get caught or pinched in it Wearing hearing protection is recommended while operating the RoadRunner Sound pressure levels may exceed 85 decibels Shut off the pressurized air or disconnect the air hose before servicing pneumatic parts Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Specifications Assembleon FACILITIES Overview Specifications Assembleon AC input voltage requirements 100 240 V 50 60 Hz single phase AC Input Power 100 W max Air requirements 2 2dm s 4 0scfm 52 MPa 75 2psi Air Inlet tube varies 6 mm 24 in amp 8 mm 31 in OD min MODELS SUPPORTED Assembleon models supported with Assembleon Uni versal Adapter ACM ACM Micro AQ 1 AQ 2 D9 DIMENSIONS
23. onto a MYDATA MY Series Assembly Machine 1 51106 the supplied Feeder Bank Adapter onto the assembly machine feeder table at the desired slot Push it forward as far as it will go Figure 2 5 Install the Feeder Bank Adapter onto the SMT Machine separately 2 Holding RoadRunner at a slight angle slide it under the hook on the Feeder Bank Adapter so that the RoadRunner centering plate teeth engage the pin next to the hook hook Top View Into SMT Figure 2 6 Installing RoadRunner onto the Feeder Bank Adapter A dowel on the Adapter circled mates with the RoadRunner nose Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Installation Mounting the RoadRunner Mounting RoadRunner MYDATA MY9 MY12 MY15 MY19 3 Lower RoadRunner letting the Adapter dowels mate up with the bush ings in the RoadRunner Refer to Figure 2 6 4 Make sure that RoadRunner is secure 5 For first time use at this SMT machine adjust the Feeder Bank Adapter to align the pick points 5a Compare the SMT pick point to the RoadRunner pick point If adjustment is required continue Otherwise go to step 6 below Figure 2 7 Devices center at the pick point marks on the RoadRunner conveyor 5b Loosen four screws on top of the Feeder Bank Adapter Loosen four screws only one shown 3 igure 2 8 Adjusting the pick point 5c Screw the e
24. replacement error Contact Data I O Customer Service Waveform board not sup Update to the latest RoadRunner software If the error is not resolved ported by software the Programmer Module requires repair or replacement Contact Data I O Customer Service Wrong Adapter board Install the correct Adapter board installed for the Job selected Unlisted Error Messages Errors that are uncommon are not listed If you get an error message not listed above contact Data I O Customer Service 6 14 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Problems but no Error Message Troubleshooting Problems but no Error Message Use this chart if you experience problems for which no error message is dis played or an error message appears to be incorrectly displayed Symptom Possible Cause Corrective Action Conveyor Belt is empty but does not stop running Fibers are sticking up at the edges of the belt Trim belt edge fibers using small scissors or melt them off with a soldering iron Conveyor belt stops when no devices are present at the pick point The End of Belt Sensor optic is adjusted too low and is triggering on high spots on the belt Adjust the conveyor End of Belt Sensor optic See Adjusting the End of Belt Sensor in the Ser vice Manual Conveyor does not operate Conveyor belt motor malfunction or loose connection Conveyor belt is damaged or mi
25. steps if needed for another increment Changing Languages To change languages l Press the Select button and the Menu button simultaneously 2 Then press the Down Arrow or Up Arrow to locate the desired language 3 Press Menu twice Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 23 Operation Supervisor Functions Menus Available to the System Supervisor Supervisor Functions 3 24 In addition to the Operator functions described in the previous section the system supervisor performs many other functions While the operator pri marily runs programming jobs the system supervisor has the ability to set RoadRunner operational parameters and view operational statistics perform various diagnostic routines and monitor event logs for programming and diagnostics Additionally the system supervisor can create programming jobs using TaskLink for Windows software Menus Available to the System Supervisor To access the supervisor menus a special supervisor card must be created in TaskLink on a PCMCIA card When this special card is inserted into the RoadRunner the system supervisor has access to a number of menus that are not available to the operator Figure 3 21 shows the supervisor s menus that are in addition to the operators menus Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Operation Supervisor Functions Menus Available to the System Supervisor RoadRunne
26. try a fresh job file transfer by FTP or Network CRC error in file Make a new job card by recreating the job in TaskLink If this does not correct the error call Data I O Customer Service Comparator DAC error Contact Data I O Customer Service Controller board not sup ported by software Contact Data I O Customer Service Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Cover tape broken Troubleshooting Error Messages Blue Lamp is On CAUSE A COVER TAPE TAKE UP REEL IS FULL Empty the cover tape reel and rethread the cover tape CAUSE B THERE IS NO MORE INPUT MEDIA AVAILABLE Install new input media CAUSE C COVER TAPE SENSOR IS MALFUNCTIONING Contact Data I O Customer Service CAUSE D COVER TAPE MODULE IS BROKEN Replace the Cover Tape Take Up Module CAUSE E COVER TAPE MODULE DRIVE BELT IS SLIPPING Remove the Cover Tape Module re tension the belt and replace the Module or Contact Data I O Customer Service Data file is too large to fit in memory The device loaded may not be supported Device continuity error Clean the sockets See the daily maintenance schedule in chapter 5 Replace the socket adapter with a new one Increase the Place delay Device dropped from head l CAUSE A TAPE POCKET IS MISALIGNED Align the pocket tape CAUSE B HEAD IS MISALIGNED Reteach the Tape parameter and or the Skt1 param
27. 10 Overview Warning and Caution Notes Warning and Caution Notes Special paragraphs in this manual warn about potentially hazardous situa tions and recommend safe practices to help avoid them A warning looks like this CAUTION Indicates conditions that can cause damage to equip A caution looks like this ment Indicates conditions that can cause personal injury or serious monetary loss They are included to help the operator use the system safely and efficiently Key to Symbols Used in this Manual General warning Calls your attention to general caution and warning notes Electrostatic Discharge ESD may cause damage Dis charge static against a common ground High voltage Turn power off before removing electronics cover Crush hazard Keep hands away from moving parts Compressed air Point air hoses away from body Always wear approved eye protection Heavy equipment Use caution May require two people Or mount properly using approved hardware Equipment can tip over such as feeder carts with some RoadRunners on them Remove RoadRunner before mov ing cart Collision hazard Some situations can cause machinery to collide with object or people items are installed incorrectly gt gt lt lt gt lt lt Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 1 3 Overview Overall System Description Deve
28. 240 updated Mar2010 2 29 Installation Applying Power for the First Time Turning Power On Applying Power for the First Time Turning Power On For help with the Emer gency Stop button see Safety on page 1 12 For help with the Robotics Cover see Removing the Robotics Cover in the Ser vice Manual To install a Socket Adapter see Changing the Socket Adapter on page 3 5 Before the RoadRunner is turned on ensure the following e The external air line is connected and input air pressure is set to approx imately 5 17 Bars 75 PSI e The Emergency Stop button is in the released out position e Optional The Socket Adapter required for the programming task is installed on the programmer e Optional The communication cable is connected NOTE Although the Robotics Cover does not need to be in place at this time RoadRunner will emit beeps while the cover is off Once the above conditions have been verified turn the main power switch to the ON position i Figure 2 32 The RoadRunner Power Switch Power is now applied to the RoadRunner A job card must be inserted into the PCMCIA slot before devices can be programmed Electrical shock hazard If the main power switch is ON power is applied to the electronic systems of the RoadRunner regardless of the position of the E Stop button or safety shield Always turn the main power switch OFF before working inside of the
29. 3 Menus 3 3 3 24 Model 3 34 Mounting RoadRunner 2 3 Assembleon ACM 2 4 Fuji NXT AIM 2 10 Fuji QP242 QP351 IP3 2 8 MYDATA 2 6 Panasonic CM401 CM402 DT 2 12 2 14 Panasonic MSF MCF MPA 2 11 Siemens 2 17 Siemens SIPLACE X 2 20 Universal 2 22 Network card 2 31 Network Setting Parameters 3 25 Network Txt command 2 31 Networking 2 31 0 Odometer viewing 3 31 Operation menu 3 24 Operational parameters belt 3 29 reject 3 28 skt 1 3 28 tape 3 27 Operator menu 3 3 Operator steps 3 1 P Part See Device Pass Limit 3 23 PCMCIA card overview 1 4 PCMCIA memory requirement 1 11 Pick amp Place Head description 1 7 Pick attempts 3 30 Pick delay see Service Manual Pick devices 3 20 Pick failures 3 30 Pick point see SMT pick point or RoadRunner pick point Pick retries 3 30 Pneumatic Cylinders 1 7 Pneumatic Regulator Kit 2 26 to 2 27 PNP Head See Pick and Place Head Pocket Advance 3 30 Index Pocket Pitch changing 3 30 Pocket Tape jammed 6 2 Power requirements 2 25 Power Switch 2 30 Precisor Plate changing 3 7 description 1 8 Probe cycling 3 36 description 1 8 testing 3 36 Problems conveyor 6 15 device tape 6 17 picking and placing 6 17 to 6 18 PNP Head 6 20 programming 6 21 with devices 6 17 Programmer Module description 1 8 diagnostics 3 36 5 5 Programmer Port command 3 25 Programmer Upgrade Kits 1 9 Programming Results 3 37 Programming times 3 32 ProLINE
30. 5 Adptr Life 10000 Insertions 4220 Pass 4202 Fail 16 Yld 99 5 Socket Insertions 1055 Pass 1053 Fail 2 Yield 99 8 Socket 2 Insertions 1055 Pass 1055 Fail 0 Yield 100 Socket 3 Insertions 1055 Pass 1051 Fail 4 Yield 99 6 Socket 4 Insertions 1055 Pass 1045 Fail 10 Yield 99 0 Align Pocket When selected each push of the UP Arrow button advances the pocket tape 4 mm The DOWN Arrow button does nothing Purge Removes all devices from the Socket Adapter and places them into the Reject Bin Notes Right column bolded items can be changed Precisor is not required on XLF models Mean Cycles Between Interrupts Figure 3 1 RoadRunner Operator Menus Operation Operator Functions Keypad Operation pec Keypad Operation Operator Functions c This manual uses the word scroll to mean press the Up Arrow or Down Arrow The word select is used to mean press the Select but ton the button with the check mark on it For example Scroll to and select System To make selections with the keypad follow these general guidelines Navigate up to the desired menu or to the top menu by pressing the Menu button When you are at the top menu pressing Menu will have no effect Job is the top item on the top menu However you may need to press the Up Arrow button to see it in the display window Press the Down Arrow to move the tr
31. 9 5 in Input tape width supported 16 mm 24 mm 32 mm optional 12 mm 32 mm Large Format DEVICE OUTPUT PLACEMENT at SMT pick point Output placement linear repeatability 25 mm Output placement rotational repeatability x5 ENVIRONMENT Operating temperature range 20 40 C 68 104 F Temperature stabilization time after transportation 28h Humidity 5 90 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 1 21 Overview Specifications Siemens XLF SIPLACE X Specifications Siemens XLF SIPLACE X 1 22 FACILITIES AC input voltage requirements 100 240 V 50 60 Hz single phase AC Input Power 100 W max Air requirements 2dm s 4 0scfm 52 MPa 75 2 psi Air Inlet tube varies 6 mm 24 in amp 8 mm 31 in OD min MODELS SUPPORTED STD amp XLF models supported 4 SIPLACE X models supported gt model _ gt DIMENSIONS model gt model 80F4 80F5 F S HF HS Series D Series X3 SIPLACE X2 X3 X4 X4i Standard XLF models SIPLACE X Width 78 mm 3 1 in 99 5 mm 3 9 in 78 mm 3 1 in unaffected by SMT Adapter Weight net 15 kg 33 165 21 kg 45 Ibs 19 kg 41 Ibs includes SMT Adapter Length unaffected by reel Length including 33 cm reel Length including 33 cm reel 99 cm 39 in 118 cm 46 5 in 120 1
32. 96 0240 updated Mar2010 Error Message Resolution Error encountered reading file Make a new job card by recreating the job in TaskLink Errors encountered in SECTPROT TXT file for job Make a new job card by recreating the job in TaskLink Field Update failed On board FLASH is in unknown state Programmer Module requires repair or replacement Contact Data I O Customer Service Incompatible boards in Programmer Programmer Module requires repair or replacement Contact Data I O Customer Service Incorrect Programmer board configuration for Job The Job parameters are not compatible with the Programmer Check the Job parameters or Contact Data I O Customer Service Invalid Job name Make a new job card by recreating the job in TaskLink Invalid LCA file Reload the Job onto the card Invalid parameter name in file Reload the Job onto the card using the current version of TaskLink Invalid parameter value in file Reload the Job onto the card using the current version of TaskLink Job card not present Insert a card into the PCMCIA slot Job in progress End current job in order to proceed Using the keypad select End from the top level Job menu Missing parameter in file Reload the job Contact Data I O Customer Service Motor controller not Make sure Emergency Stop is not depressed responding No Adapter in
33. ALIGNMENT OF HEAD Align the Pick and Place Head CAUSE D VACUUM SENSORS ARE OUT OF ADJUSTMENT Adjust the vacuum sensors CAUSE E PROBE TIP NOT SEATED Remove and replace the rubber probe tip Verify that the rubber cup is on the probe CAUSE F THE PICK OR TRAVEL DELAY VALUES ARE TOO LOW Reset the pick delay Reset the travel delay Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 6 5 Troubleshooting Error Messages Yellow Lamp is On Yellow lamp is on CAUSE G PROBE SPEED IS TOO FAST OR TOO SLOW Verify that the system air pressure is within specified limits Adjust as required see specifications at the end of Chapter 1 Adjust the probe speed Reset the probe travel delay Device pick failure on See above i probe 2 Device pick failure on See above T probe 3 Device pick failure on See above T probe 4 Devices are on belt Remove devices if desired Devices are on belt START to continue PAUSE to can cel Remove devices if desired and select Start or Pause Inadequate air pressure detected Ensure that the supply air is connected Check that the supply air pressure is within the specified limits see specifications at the end of Chapter 1 Job name missing from JobParms txt file Make a new job card by recreating the job in TaskLink Reading Card Please Wait Wait Reject bin needs to be e
34. Adapter forward as far as it will go m Tighten the set screw to lock in place See Figure 2 16 99 Slide the Host Feeder onto the feeder slot immediately left of the Feeder Bank Adapter Mounting and Alignment fea tures Hook Dowel Set screw on the CM402 SMT Feeder Bank 4 Push the Host Feeder forward as far as it will go 2 14 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Installation Mounting the RoadRunner Mounting RoadRunner Panasonic CM401 CM402 DT To mount RoadRunner onto the Panasonic Feeder Bank Adapter 1 Slide RoadRunner under the hook on the Feeder Bank Adapter so that the RoadRunner centering plate teeth engage the pin next to the hook See Figure 2 17 RoadRunner Centering Plate 2 mA Figure 2 17 The Panasonic Feeder Bank Adapter has a hook and a pin 2 Lower RoadRunner so that the Feeder Bank Adapter dowel mates with the guide bushing on the RoadRunner conveyor See Figure 2 18 Figure 2 18 The dowel on the Adapter circled mates with Roadrunner 3 Verify that RoadRunner is secure To connect the Communication Cable into the Host Feeder 1 Correctly orient the connector the red dot will be on top and plug it into RoadRunner The socket is located on the back side facing the SMT feeder table 2 Orient and plug the other end of the cable into the Host Feeder 3 Screw in the two connector screws See Figure 2 19 Data
35. Advance the tape until one of the holes in the center of a tape pocket is close to the Tape In Module pick point Don t overshoot For Aligning Device Tape Press Menu until the top level menu is displayed see Figure 3 18 on page 3 18 B Scroll to and select Align Pocket A Using the Up Arrow button to advance the device tape line up approxi mately the center hole of one of the pockets with the pick point align ment mark If you pass the mark by more than one Up Arrow increment 2 mm use the next pocket Always approach the mark with the tape traveling forward D Press Menu Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 17 Operation Operator Functions Programming Devices Device Pocket Pick Point Alignment Mark Figure 3 18 Lining Up by eye the Device Pocket with the Alignment Mark alignment need not be exact as shown Programming Devices Device Socket Adapter Actuator Plate and precisor have already been installed For more informa tion see Setting Up Road Runner for a Programming Job on page 3 5 Once the RoadRunner has been properly configured device programming may begin There are several processes associated with successful device programming as well as recovering from job pauses or system shutdowns The processes are discussed in this section Starting a Job To start a programming job 1 Insta
36. Contact Data I O Customer Service SysFlash bin programmed Programmer Module requires repair or replacement in FLASH has failed check Contact Data I O Customer Service sum verification SysFlash bin was not read Contact Data I O Customer Service A new SysFlash bin file may be correctly This file may be required corrupted System and device algo Reload the Job onto the card rithm are not version com Check that your Job card algorithm files are compatible with the patible current system version The Adapter board is not Install the Adapter board installed The checksum of the Repeat update operation or contact Data I O Customer Service A new loaded Boot bin is bad Boot bin file may be required Update is not done The checksum of the Contact Data I O Customer Service A new SysFlash bin file may be loaded SysFlash Binis bad required Update is not done blue Unable to advance tape Make sure the Emergency Stop is not depressed lamp is on Check the tape path for obstruction Verify that the Tape In Sensor is working properly check connec tion at both ends of the cable 6 12 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Unable to home PNP head Troubleshooting Error Messages Blue Lamp is On CAUSE A EMERGENCY STOP IS DEPRESSED Twist the emergency stop button to release it CAUSE B THE HOME SENSOR IS DEFECTIVE Replace the Home Sensor CAUSE C THE POSITIVE OR NEGATIVE
37. Covers all models Includes a fill in maintenance chart separate Service Man Maintenance ProLINE RoadRunner Owner s Manual PN 096 0240 005H Data 1 Overview General Descriptions TaskLink Safety Precautions Specifications 2 Installation Unpack Setup Power Up 3 Operation Keypad Operation Menus Programming Yields Updates Order form for Service Manual See separate Service Manual for Replacement Procedures Basic Spare Parts Self Service Spare Parts Order Forms 5 Maintenance Preventive Schedule Diagnostics Sign off Chart 6 Troubleshooting Error Messages Other Problems Glossary Index Sales and Technical Support contact numbers are after the index Data I O has endeavored to ensure that the information in this document is accurate and complete Data I O assumes no liability for errors or for any incidental consequential indirect or special damages including without limitation loss of use loss or alteration of data delays or lost profits or savings arising from the use of this document or the product which it accompanies No part of this document may be reproduced or transmitted in any form or by any means electronic or mechanical for any purpose without written permission from Data T O Corporation Data I O order forms may be reproduced for internal use only Data I O is a registered trademark of Data I O Corporation as are ProLINE RoadR
38. Data I O or visit our Web site for part prices optional 5 Mail or FAX it with your purchase order to Data I O See the last page of this manual for contact information ProLINE RoadRunner Model No Serial No Model Name Part Description Qty Price Ea Totals RR SERV MANL 10 Service Manual SIPLACE X2 X3 X4 MYDATA MY9 MY12 MY15 MY19 RR SERV MANL A Service Manual Assembleon RR SERV MANL F Service Manual Fuji MFU QP242 QP351 IP3 NXT AIM RR SERV MANL P Service Manual Panasonic for MSF MCF MPAV2B MPAG3 RR SERV MANL K Service Manual Panasonic for CM20 CM120 CM301 RR SERV MANL CM Service Manual Panasonic for CM402 DT401 RR SERV MANL S Service Manual Siemens RR SERV MANL S XLF Service XLF Manual Siemens RR SERV MANL U Service Manual Universal GSM1 GSM2 GEN ESIS Signature Date Company Shaded items may use a different Model Name 4 2 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Chapter Maintenance In addition to the maintenance schedule which starts on the next page there are instructions for using a Diagnostics Adapter Board and sign off charts to fill in Tools Required Some of the tools required for maintaining the RoadRunner are e ESD grounding strap e isopropyl alcohol e four digit volt meter multi meter calibrated lint free cloth e vacuum tweezer
39. Extra Large Format RR 1 1 F Facilities description 2 25 FCI 1 9 FC II 1 9 Glossary 3 FC III Glossary 3 Feeder Comm 3 34 FFI Communication 3 34 Filter air 2 26 maintenance 5 3 moisture separator 2 26 Firmware update 3 33 FlashCORE 1 9 G Gateway GTW command 3 25 Gradual Tape Path see GTP Green lamp 3 18 Grounding 1 14 GTP Tape In Module 3 11 H Hardware configuration 3 34 Hardware checking setup 3 9 Hazardous Mtrls China 5 7 Head positions 3 27 to 3 29 HIC Socket Adapters 3 8 High Force Actuation 1 9 Hook 2 17 Hook Siemens XLF 2 19 Hours RoadRunner on time 3 31 HwCfgID 3 34 Index 2 Data I O ProLINE RoadRunner Owner s Manual 096 0240 Interlocks 1 12 IP Address 3 25 IP command 3 25 Job defining 3 5 menu 3 3 pausing 3 19 restarting 3 19 selecting 3 5 setting up 1 11 starting 3 18 statistics 1 9 stopping 3 19 Job card See PCMCIA card K Keypad conventions used in manual 3 4 layout 3 4 operation 3 4 scrolling 3 4 selecting commands 3 4 L Language changing 3 3 LED 3 19 also see Socket Adapter Linear Stage description 1 7 Log file 3 26 3 37 to 3 38 Lubrication 5 3 to 5 5 Lubrication sign off chart 5 8 M Maintenance daily 5 2 every 3 months 5 2 preventive 5 2 sign off charts 5 8 tools required 5 1 weekly 5 2 yearly 5 3 Measure Device 3 35 Memory card 1 11 Data I O ProLINE RoadRunner Owner s Manual 096 0240 Index 3 Index I Menu language 3
40. I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 2 15 Installation Mounting the RoadRunner Mounting RoadRunner Panasonic CM401 CM402 DT Figure 2 19 RoadRunner is mounted and the Communication Cable is plugged into the Panasonic Host Feeder unit 2 16 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Installation Mounting the RoadRunner Mounting RoadRunner Siemens 80 4 80F5 F S HS Mounting RoadRunner Siemens 80F4 80F5 F S HS CAUTION Heavy weight Use great care when mount ing RoadRunner to the feeder table It is heavy and dropping it can cause serious damage to RoadRunner and anything it falls upon Use only approved hardware to mount RoadRunner to the SMT feeder table NOTE When selecting slot positions for RoadRunner consider that access to it is from the right side To mount the RoadRunner onto the machine feeder table perform the fol lowing CAUTION There are different hooks Use of the wrong hook will cause mounting and device pick problems Use the hook with black knob or the hook with the Hex socket screw as shown on the label located on the RoadRunner Conveyor You might also have a black hook which is for the taller later model of RoadRunner The new Hex socket screw hook and the black anodized hook are inter changeable Hook must be Hook must be installed as ri 1 Slide the proper mountin
41. Link see the instructions on the CD A PCMCIA memory card drive capable of reading and writing to Parallel ATA 2 specification must be available to the computer being used For more about PCMCIA drives see PCMCIA Memory Card Capacity Require ments below See TaskLink s on screen Help for RoadRunner to create a RoadRunner Job PCMCIA Memory Card Capacity Requirements ProLINE RoadRunner uses a 68 pin PCMCIA PC Card to transfer job configuration and device programming data from TaskLink software running on a PC to RoadRunner The PC Card is used to store job files statistics event log algorithms and even system updates Ensure the card you use will hold your device image data plus 130 KB for statistics and event files The general formula used to calculate required PC card size for one job 256 KB device size 130 KB Remember that 1 MB 1024 KB In general add 256 KB to device size for system files To calculate each job size sum all jobs together and add 130 KB for statistics and event files For example when creating a card with two jobs one for a 28F800 1 MB device and one for a 29LV160 2 MB device you would need 256 1024 KB 256 KB 2048 KB 130 KB 3714 KB 3 8 MB Use a4 MB minimum ATA card for this configuration Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 1 11 Overview Safety Safety Features Safety 1 12 NOTE The system operator can only access
42. M402 CM602 DT401 A Panasonic Feeder Bank Adapter and Host Feeder are required DIMENSIONS Width 7 8 cm 3 1 in Weight net 15 kg 33 Ibs Length without reel 99 cm 39 in Approximate length protruding 55 cm 21 6 in from SMT machine Height without reel 56 cm 22 in Input tape width supported 16 mm 24 mm 32 mm optional 12 mm 32 mm Large Format DEVICE OUTPUT PLACEMENT at SMT pick point Output placement linear repeatability 25 mm Output placement rotational repeatability 5 ENVIRONMENT Operating temperature range 20 40 C 68 104 F Temperature stabilization time after transportation 28h Humidity 5 90 1 20 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Overview Specifications Panasonic MSF MCF MPAV2B MPAG3 Specifications panasonic MSF MCF MPAV2B MPAG3 FACILITIES AC input voltage requirements 100 240 V 50 60 Hz single phase AC Input Power 100 W max Air requirements at 2dm s 4 0scfm 52 MPa 7522 psi Air Inlet tube 8 mm 31 in OD min MODELS SUPPORTED Panasonic models supported MSF MPAV2B MPAG3 MCF DIMENSIONS Width 78 mm 3 1 in Weight net 16 kg 35 Ibs Length with 33 cm 13 in reel 115 cm 45 25 in Approximate length protruding from SMT machine 76 cm 30 in Height with 33 cm 13 in reel 49 5 cm 1
43. Manual 096 0240 updated Mar2010 Operation Supervisor Functions Session Data Log EID mismatched electronic ID OE other errors Check TaskLink s Session Data Logging dialog box to discover if it is enabled and if so what location it is written to Open TaskLink click Setup gt Session Data Logging Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 39 Operation Supervisor Functions Session Data Log blank page 3 40 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Service information Isin a separate manual with its own Table of Contents and Index The separate Service Manual that came with this Owner s Manual can be placed into this three ring binder The Service Manual covers removal and replacement procedures for most of RoadRunner s modules It also lists part numbers called Model Names for ordering replacement parts Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Aug07 4 1 Service information If you wish to order another Service Manual use the Order Form below There are standard RoadRunner models and XLF models extra large for mat for many SMT Manufacturers Data I O Parts Ordering Information Instructions 1 Copy this page 2 Fill in your RoadRunner model and serial numbers see the label on the chassis under the Robotics Cover 3 Fill in the quantity for the item s desired 4 Call
44. O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Operation Operator Functions Setting Up RoadRunner for a Programming Job 6 Scroll to and select Advance Pocket CAUTION Devices might fall into and jam the RoadRunner Do not advance devices past the RoadRunner s pick point Remove devices with a vacuum tweezer 7 Press the Up Arrow button to advance the tape 8 Stop when the tape has advanced past the Peel Bar Adjust the Peel Bar so that it is between pockets allowing a device to be picked cleanly from the pocket and still covering the next device 9 Separate the cover tape from the device tape 10 Thread the cover tape through the tape path as indicated in the tape threading diagram on the RoadRunner Attach it to the Cover Tape Reel A small piece of adhesive tape may be required to stick the cover tape to the Take Up Reel Aligning the Device Tape All Models The device tape pockets must be aligned with the pick point alignment mark on the Tape In Module so that probes can pick the devices accurately To align the device tape 1 Load the device tape as described in the previous section Loading Device Tape For more information see Loading Device Tape on page 3 14 CAUTION Device tape can jam if devices fall into tape A path Do not advance tape pockets with devices in them past the pick point Remove the devices as necessary with a vacuum tweezer N
45. RoadRunner will operate without all the necessary informa tion or devices to run Synonymous with trial run DUT Device Under Test referring to the device that will be programmed or verified ESD Electrostatic Discharge ESD can damage programmable devices and other static sensi tive electronic components Ethernet The most popular type of local area network which sends its communications through radio frequency signals carried by a coaxial cable Software protocols used by Ethernet systems vary but include Novell Netware and TCP IP Glossary 2 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated 10Jul08 Glossary of Terms F FC II FlashCORE II is the name of the second generation of FlashCORE programmers with more flexibility and supports more microcontrollers FlashCORE III is the name of the third generation of FlashCORE programmers Jan 2010 with faster file download speeds and support for files greater than 4 GBytes up to 32 Gbits FEPROM Flash Erasable Programmable Read Only Memory Similar to EEPROM but erasing can be done in blocks or to the whole chip firmware Software stored in ROM or PROM essential programs that remain even when the system is turned off FLASH See FEPROM gantry The ball screw that supports the pick and place head and moves it horizontally in the X direction only in this case GND Ground graphical user All the p
46. Runner and anything it falls upon Use only approved hardware to mount RoadRunner to the SMT feeder table To mount the RoadRunner onto the Universal machine feeder bank perform the following Collision hazard If mounted incorrectly the GSM pick head might collide with RoadRunner For this reason Data 1 0 recommends mounting RoadRunner only on the front feeder banks near Beam 2 If RoadRunner is mounted on banks 3 and 4 the rear feeder banks ensure that the feeder bank is in the outbound posi tion only and NOT in the inbound or double inbound posi tions Do NOT remove the GSM CE Cover that covers the upper half of the GSM feeder bank opening NOTE When selecting slot positions for RoadRunner consider that access to it is from the right side 1 Hold the RoadRunner level and rest the nose on the feeder bank Ensure that the guide under the conveyor settles into a slot 2 22 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Installation Mounting the RoadRunner Mounting RoadRunner Universal GSM1 GSM2 Genesis Figure 2 26 Mounting RoadRunner onto a Feeder Bank Changer CAUTION Feeder carts can become unstable RoadRunner can also be mounted on feeder carts and feeder test stands However some carts stands were not designed for the heavy overhang of RoadRunner and may tip over easily especially if the wheels encounter bumps Use caution don t use an
47. The SMT Adapter for SIPLACE X RoadRunner must be attached to RoadRunner before being mounting onto a Feeder Bank If the SMT Adapter is not attached to the RoadRunner contact Data I O support attaching it requires removing the RoadRunner Conveyor Cover To mount the RoadRunner onto the machine feeder table perform the fol lowing 1 Holding RoadRunner level align the grooves on the Adapter with ribs on the Feeder Bank and slide RoadRunner as far forward as it will go 2 20 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Installation Mounting the RoadRunner Mounting RoadRunner Siemens SIPLACE X2 X3 X4 X4i Figure 2 25 The SMT Adapter on SIPLACE X RoadRunner mates with ribs on the Feeder Bank 2 Make sure that the SMT latches onto the RoadRunner and that RoadRunner is secure Connect the communications cable described in Siemens SIPLACE X Series Communications on page 2 29 Remember to remove RoadRunner from the Feeder Cart prior to removing the Feeder Cart from the SIPLACE Machine Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 2 21 Installation Mounting the RoadRunner Mounting RoadRunner Universal GSM1 GSM2 Genesis Mounting RoadRunner Universal GSM1 GSM2 Genesis CAUTION Heavy weight Use great care when mount ing RoadRunner to the feeder table It is heavy and dropping it can cause serious damage to Road
48. This glossary defines terms and acronyms used in this manual Actuator Plate A plate that opens a socket s for loading a device s algorithm A software file containing specific step by step calculations required by the programmer to program a device Allen Wrench Hex Key ATA Advanced Technology Attachment The specification for a disk drive interface standard based on the IBM PC ISA 16 bit bus interface ATA flash card A read writable card with flash memory that uses the ATA interface Backplane Board A printed circuit board that connects the Waveform Board to the Socket Adapter Board bit The smallest unit of storage that can take one of two values such as true and false or 0 and 1 boot To load and initialize the operating system on a computer bus A set of connections for connecting various functional units in a computer CAN Network A serial bus network that can handle communication between many pieces of equipment CFM Cubic Feet per Minute a volume time measure of the rate of air flow Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated 10Jul08 One CFM 28 32 liters per minute Glossary 1 Glossary of Terms D checksum A computed value which is transmitted or stored along with the data in order to detect corruption of the data chip See Device co
49. Width 78 mm 3 1 in Weight net 17 kg 38 Ibs Length with 33 cm 13 in reel 124 5 cm 49 in Approximate length protruding from SMT machine 63 5 cm 25 in Height with 33 cm 13 in reel 49 5 cm 19 5 in Input tape width supported 16 mm 24 mm 32 mm optional 12 mm 32 mm Large Format DEVICE OUTPUT PLACEMENT at SMT pick point Output placement linear repeatability 25 mm Output placement rotational repeatability x5 ENVIRONMENT Operating temperature range 20 40 C 68 104 F Temperature stabilization time after transportation 2 8h Humidity 5 90 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 1 15 Overview Specifications Fuji IP XP Specifications Fuji QP IP XP FACILITIES AC input voltage requirements 100 240 V 50 60 Hz single phase AC Input Power 100 W max Air requirements 2dm s 4 0scfm 52 MPa 7522 psi Air Inlet tube varies 6 mm 24 in amp 8 mm 31 in OD min MODELS SUPPORTED Fuji models supported QP242 IP3 QP351 XP142E DIMENSIONS Width 78 mm 3 1 in Weight net 14 kg 32 165 Length with 33 cm 13 in reel 91 5 cm 36 in Approximate length protruding 0 in from SMT machine Height with 33 cm 13 in reel 49 cm 19 5 in Input tape width supported 16 mm 24 mm 32 mm optional
50. a Job 3 18 Starting RoadRunner 2 30 3 2 Statistics 1 9 3 37 Steps for programming devices 3 1 Stopping a job 3 19 Subnet SUB command 3 25 Supervisor card 3 24 Supervisor menu 3 24 3 36 Surface mount assembly machine mounting Road Runner onto 2 3 to 2 22 System menu 3 24 System parameter setting 3 31 T Tape Advance Motor 1 5 Tape position 3 27 Tape In Module adjusting 3 10 to 3 13 description 1 5 Task defining 3 5 TaskLink description 1 11 other information sources 1 11 overview 1 4 Teach function head positions 3 27 Tests performed 1 9 2 30 Threading Cover Tape 3 16 Timekeeping 3 32 Tools 5 1 Travel delay see Service Manual Troubleshooting error message 6 4 to 6 14 no error message displayed 6 15 to 6 21 Unpacking 2 1 Update software 3 33 Data I O ProLINE RoadRunner Owner s Manual 096 0240 Index T V Version Number firmware 3 33 Warning E Stop button 1 13 fast robot 1 13 heavy object 2 1 mounting hook 2 19 Warning Lamps 6 1 Waveform Board testing 5 5 X XLF Model 1 1 X series Siplace 3 34 Y Yellow light 6 1 Yields 3 37 Index 5 Index Y Index 6 Data I O ProLINE RoadRunner Owner s Manual 096 0240 Sales and Technical Support World Wide Data I O Corporation Redmond WA USA 98052 Telephone 425 881 6444 inside US 1 800 332 8246 Fax 425 867 6972 E mail support dataio com Contact your local Data I O representative or see th
51. a single job from the PCMCIA memory card If there is more than one job on the card then the last job selected by the system supervisor is the one used It is recommended that only one job be placed on each PC Card to avoid operator confusion NOTE Data I O recommends that a 2 MB minimum card be used for even a single job must be formatted with FAT 16 The current Windows CAUTION PCMCIA Cards for use with RoadRunner A default is FAT 32 The card must be x40 speed For information on card reader writers that work with your computer system and ProLINE RoadRunner see Card Reader Writers on our Web site at http www dataio com support and then 1 Click Knowledge Base Search 2 Sign in or click Use the Knowledge Base without signing in 3 In the Keywords field type Card Reader 4 Click Search 5 Click the document name to open it Safety Features The RoadRunner has several safety systems to reduce the likelihood of personal injury and machine damage during operation These systems include 1 Safety Shields and Interlocks During RoadRunner operation the metal and plastic safety shield Robotics Cover covers the operating area to protect operators from Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Overview Safety Safety Features injury If the shield is opened robot movement will reduce to half speed 0 Risk of injury System robotics can injure your h
52. all screw Quarterl dard RoadRunner and that it is clean y only Lubricate if necessary see Ball Screw under Yearly continued maintenance Ball Screw XLF XLF Extra Large Format RoadRunners RoadRunner only Lubriplate DS Replenish the ball screw grease See Lubricating the ES 4 or equivalent Ball Screw and subhead XLF RoadRunner Extra Larger Format on page 5 4 Conveyor Belt Visually inspect for frayed edges separating seam and gouges Vacuum Filters Remove each filter from the Pneumatic Module to check for dirt filter is no longer white Replace with new fil ter if necessary Refer to Replacing the Vacuum Filters in Chapter 4 Maintenance interval may be adjusted depending on your findings Ball Screw Grease Shell AV2 STANDARD RoadRunners or equivalent Replenish the ball screw grease See Lubricating the Ball Screw below and subhead Standard RoadRun Yearly ners Programmer Diagnostic Adapter Perform the Diagnostic Adapter Board DAB test The Waveform Circuit BoardPN9102200 procedure is outlined at the end of this maintenance Board and Robot RoadRunner firm schedule T O Board ware version 1 00 10 A or later 4 mm Allen NOTE This maintenance is optional The Wrench DAB can be purchased from Data I O or your Data I O Representative The RoadRunner s DACs are self calibrating and rely on a precision voltage source for this action If the mea sured voltage is outside of th
53. ands or fingers Do not operate the RoadRunner with covers removed When working inside the RoadRunner turn the power off 2 Emergency Stop Button E Stop When the E Stop button located on the keypad is pressed the RoadRunner automatically removes power from all motion motors The blue status lamp illuminates and the programmer completes its pro gramming cycle The programmed devices will remain in their sockets Figure 1 7 Emergency movement Stop Button Shock hazard Do not use the E Stop button to turn A off power to the RoadRunner The E Stop button does not completely remove power from the machine Only power to the motion motors is shut off Power is still applied to all of the other electronic systems CAUTION The Emergency Stop button does not stop the SMT Placement equipment The Emergency Stop condition will not be cleared until the E Stop button is restored to its run position To restore the button to the run position turn the Emergency Stop button clockwise until it springs back to its full height Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 1 13 Overview Precautions for Safe Operation Precautions for Safe Operation The RoadRunner System has been designed for safe and efficient operation The system can be dangerous if the RoadRunner safety features and precautions in this manual are ignored A Electrostatic Discharge The circuit boards i
54. be tip Verify that the rubber cup is on the probe CAUSE G THE PICK OR TRAVEL DELAY VALUES ARE TOO LOW Reset the Pick delay See the Service Manual Reset the Travel delay See the Service Manual CAUSE H PROBE SPEED IS TOO FAST OR TOO SLOW Verify that the system air pressure is within specified limits Adjust as required see specifications at the end of Chapter 1 Verify that the Probe speed is within limits readjust if necessary Reset the probe travel delay blue Device pick failure at input lampison with probe 2 No device is on probe 1 To continue select Start from the keypad This will temporarily dis able the probe The next probe will attempt to pick See above Device pick failure at input with probe 3 No device is on probe lor 2 To continue select Start from the keypad This will temporarily disable the probe The next probe will attempt to pick See above T Device pick failure at input with probe 4 No device is on probe 1 2 or 3 See above Emergency Stop is acti vated Ensure that the RoadRunner is safe to start and then restore power by twisting the Emergency Stop button to release it 6 10 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Troubleshooting Error Messages Blue Lamp is On Lamp Color blue lamp is on blue lamp is on Data I O ProLINE RoadRunner Owner s Manual 0
55. c MSF MCF MPA Communications Communications are automatically connected when the unit is properly mounted to an SMT machine feeder cart Pansonic CM401 CM402 DT401 Communications Communication cable connection is performed when mounting RoadRunner onto a Panasonic Feeder Bank Adapter See To connect the Communication Cable into the Host Feeder on page 2 15 Siemens 80F4 80F5 Communications Std and XLF Orient the cable connector with the red dot on top and plug the communica tion cable into the RoadRunner socket on the far end of the electronics hous ing facing the feeder table Plug the other end into the socket on the SMT feeder table that corresponds with the track the RoadRunner is mounted in NOTE RoadRunner firmware version 02 01 00 B or later is required for Siemens communications To unplug the cable pull back on the connector collar Siemens SIPLACE X Series Communications Orient the cable connector and plug the communication cable into the RoadRunner socket on the far end of the electronics housing facing the feeder table There may be a red dot on top for orientation Plug the other end into the socket on the SMT Adapter below the conveyor To unplug the cable pull back on the connector collar Universal GSM 1 GSM2 GENESIS Communications Communications are automatically connected when the unit is properly mounted to an SMT machine Data I O ProLINE RoadRunner Owner s Manual 096 0
56. c part of the programmer that holds a device in place so that it can be programmed SRAM Static Random Access Memory system parameters System wide parameters that are metered are real clock time and odometer information T Tape In Module The subassembly on the RoadRunner that controls the feed rate of the pocket tape TaskLink Data I O s software for creating programming jobs for RoadRunner as well as FlashPAK FLX500 Sprint Family Programmers and UniSite family Programmers It is a Windows based program that simplifies task management teach To communicate your directives to the RoadRunner throughput The rate at which correctly programmed devices are produced tip A rubber fitting inserted onto the end of a probe that allows it to achieve the vacuum seal required to pick and hold a device TPn Test Point number TSOP Thin Small Outline Package V vacuum chamber block The toric shaped metal at the end of each probe The vacuum chamber block aids the pre cisor in centering a device vacuum tool A hand tool that uses suction to manipulate objects Handy Vac is such a tool Vcc DAC Voltage Collector Common Digital to Analog Converter Used to generate the supply power for the devices to be programmed or verified VDC Volts of Direct Current verify A device operation that compares data in a programmed devi
57. ce with data in RAM or in a disk file With logic devices verifying can also include functional testing VPP DAC Voltage Programming Power Digital to Analog Converter A DAC that controls the pro gramming power supply for devices Glossary 6 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated 10Jul08 Glossary of Terms X XLF Acronym for eXtra Large Format XLF model RoadRunners program devices up to 32 mm x 32 mm 44 mm tape width Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Glossary 7 Glossary of Terms X blank page Glossary 8 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated 10Jul08 c Remember to check the Service Manual index for items not found here Index A Actuator Plate actuate duration 3 36 adjusting 3 8 changing 3 8 description 3 8 for HIC adapters 3 8 verify correct one 3 9 Adapter Alarm 3 32 Adapter Clean Count 3 32 Adapter see Socket Adapter Adjustable Actuator Plate 3 8 Adjusting GTP Tape In Module 3 11 Adptr Life 6 4 Air Also see Pneumatic connection 2 26 filter requirement 2 26 requirements 2 26 saving 3 30 Algorithm updates 3 34 Aligning device tape 3 17 Ball Screw description 1 7 Ball Screw lubricating 5 3 to 5 5 Belt Offset 3 35 Belt position 3 29 Belt Settings 3 31 Black Hook 2 17 Blue light 2 31 6 1 C Card Network 2 31 operator 3 3 PCMCIA 1 11 supervisor 3 24 Carrier Tape Se
58. cket uet p oe ee pi La an Leer 1 Actuation VVV 22 AN pHa VACUUM MODULE R e B Exhaust Exhaust Exhaust 4 E Silencer Silencer M Silencer H Vacuum Vacuum jVacuum Vacuum T _ Switch Switch LSwitch_ Switch Go PEA Ejector D Ejector A D Ejector D Ejector A OA Suction Needle Suction 9 Needle Suction Needle Suction Needle Air Sensor Filter Valve Filter Valve Filter Valve Filter Valve us Suppl Breakin Suppl Breakin Suppl Breakin Suppl Breaki Vane Valve n Valve Vaive Valve 2 Valve Valve d 1 Y Y Y ALAM dA 4 dl Ai 72 PIR R PIR R PIR R PIR R Source 5 4081 1 1 1 52 MEM 2dm s Figure 6 2 The pneumatic schematic effective for production RoadRunners shipped after June 2007 The pneumatic system of the ProLINE RoadRunner consists of a PNP Head Pneumatic Module and an Interface Manifold The pick head uses six pneu matic cylinders and compliant vacuum probes to move devices through the unit The electrically controlled Pneumatic Module creates a vacuum at the pick head and pressurized air supplied at both the PNP Head and Program ming Module The Interface Manifold is a partition between the PNP Head and Pneumatic Manifold providing flow control to the PNP Head cylinders 6 22 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Trouble
59. d or a stop is impending It does not require imme diate attention Example Reject bin needs to be emptied Blue lamp lights CRITICAL or FATAL Message Stops the RoadRunner The job cannot continue without operator action Critical example Reject bin is full Fatal example Unable to raise probe 1 NOTE A lit blue lamp with no messages indicates that the Road Runner is stopped not currently running a job Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 6 1 Troubleshooting Resolving Problems Testing the Programmer Resolving Problems In case of a system failure the onboard diagnostic system will in most cases notify the user Most subsystem failures or anomalies detected by sys tem sensors will be displayed on the keypad screen Testing the Programmer In addition to the onboard diagnostic system a Diagnostic Adapter Board DAB model name RR DIAG ADAPTER detects problems related to pro grammer hardware failure The DAB tests the Waveform Circuit Board and BackPlane Circuit Board parts of the RoadRunner programmer The DAB does not test the Robot I O Board or system timing See Diagnosing with the Adapter Board on page 5 5 Viewing Errors If an error occurs a message should be displayed on the keypad screen and the yellow or blue status lamp will illuminate The blue status lamp denotes that the RoadRunner has stopped The yellow status indicator den
60. d do label unsafe carts 2 Level RoadRunner while continuing to support the weight and slide it forward as far as it will go 3 If RoadRunner feels securely supported let go Its own weight will cause it to latch to the feeder bank Figure 2 27 Slide the RoadRunner Forward 4 Cautiously rock RoadRunner to ensure that it is secure RoadRunner is now mounted to the feeder bank Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 2 23 Installation Installing the Reject Bin Installing the Reject Bin The Reject Bin may not be in place when you receive your RoadRunner When it is in place it sits between the beginning of the Conveyor and the RoadRunner chassis NOTE The Reject Bin for a Standard RoadRunner does not fit into a RoadRunner XLF Extra Large Format Figure 2 28 The Reject Bin The Reject Bin for the RoadRunner XLF looks slightly different To install the Reject Bin hold the small channel shaped chute with thumb and forefinger like you might hold a movie ticket With the chamber hori zontal move the bin straight over the conveyor and just under the black Lin ear Stage until it stops against the chassis Lower it as far as it will go CAUTION The PNP Head might collide with the Reject Bin if the Reject Bin is not installed properly You can test the clearance by pushing the E Stop and then manually pushing the PNP Head over to t
61. d lowering the probe tip see Robot Diagnostics on page 3 35 DO NOT SELECT THESE COMMANDS WHILE THE PROBE IS DOWN Home Purge Probe X speed or any of the Teach operations Tape Skt1 Reject Belt While performing any Teach procedure the PNP head may be moved incrementally with the Up Arrow or Down Arrow with the probe in the down position Use caution CAUTION Do not move the PNP head while the probe is in the DOWN position The probe might get damaged Operation gt Job gt Other Operation menu items offer customizing actions that may affect throughput These items are in the Operation gt Job menu and dis cussed below Pick Retries Sets the number of attempts the probe makes to pick up a device before it moves to the next socket or tape pocket The default is 2 Error Retries Sets the number of cycles the probe leaves a device in a socket before disabling it in the event of a repeated errors of the same type such as continuity The default is 3 Pocket Pitch Allows fine tuning the tape movement to match the tape pocket pitch This change only affects the current run To change the pitch for subsequent job runs edit the job in TaskLink as follows 1 In TaskLink select the job 2 Click Edit 3 Click the Media tab 4 Change the pitch 5 Click OK 6 Load the job Pocket Advance Sets the number of tape advances and therefore Probe pick attempts from the tape before displaying an error messa
62. d tighten the Locking Screw 4 Remove the magnetic Front Track for 32 mm if it is installed by first loosening the two Peel Bar screws Peel Bar Screws Peel Bar 32 mm Front Track Figure 3 13 XLF Models ONLY the 32 mm Front Track is installed 5 Lift the 32 mm track slightly to clear the locating pins and tip it back 90 away from you Slide it out to the left NOTE For 32 mm device tape install the Front Track in the reverse order as removal Then slide the Selector Plate as described above so the notch points to 32 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 13 Operation Operator Functions Setting Up RoadRunner for a Programming Job Refer to Figure 3 14 through Figure 3 16 throughout this procedure Loading Device Tape Devices to be programmed with the RoadRunner are sealed in device tape on a tape reel Device tape carrier tape consists of pocketed tape which holds the devices and cover tape The cover tape is a self adhesive or heat sealed tape The maximum size tape reel you can use on a RoadRunner is 13 inch 33 cm diameter The Tape In Module simultaneously feeds the device tape into the machine and strips off the cover tape NOTE Several different Tape In Modules are available for RoadRunner Ensure that you use the proper tape width for your module or that the module is adjusted for your tape width If you have an Adjustable Tape In Mod
63. d with the tape advance motor drives the Take up Reel that winds up the separated cover tape The cover tape is threaded around a peel bar that separates it from the device tape Some cover tape is sticky enough that it will affix directly to the reel while other cover tape must be fastened to the reel with a piece of adhesive tape Refer to Figure Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 1 5 Overview Overall System Description Robotic System Cover Tape Motor Cover Tape Take Up Reel Nu um _ Figure 1 4 Loading Cover Tape Siemens model shown Note that on XLF Models the cover tape rotation is in the opposite direction Robotic System A four probe Pick and Place PNP head driven by a linear stage ball screw constitutes RoadRunner s robotic system NOTE Some RoadRunner models are designed to operate with fewer than four probes A stepper motor controls ball screw movement which produces travel in the horizontal axis Air cylinders control individual probe up and down motion Together these components pick collect and place devices as directed The standard robotic system uses the collect and place principle to e pick one device at a time from the device tape until four or less depend ing on the Socket Adapter devices are collected e place the devices into the programming sockets one at a time e pick the programmed devices out of the sockets one at a ti
64. dated Mar2010 Operation Supervisor Functions Event Log Board or system timing Instructions for performing the DAB test are in Diagnosing with the Adapter Board on page 5 5 Programmer allows disabling the Programmer Module Exercise Display verifies that the display and keypad are working prop erly When the keypad symbols are displayed in the screen pressing each corresponding keypad button erases that image from the screen Continuity Loop allows changing the number of continuity tests per formed prior to programming a device Event Log The Event Log lists status messages for Data I O engineers If Timekeeping is switched ON it also lists programming times for each process Circled entries m are tecorded 06 19 03 11 41 49 BoardAdapter Current adapter actuation count 248 only if Time 6 19 03 11 41 49 PG 2 of 2 devices programmed keeping is 06 19 03 11 41 49 Verify 2 2607 sec 06 19 03 11 41 49 Program 5 4461 sec 06 19 03 11 41 49 BlankCheck 1 5480 sec NL 06 19 03 11 41 49 0 7084 sec 06 19 03 11 41 39 PG Erasing devices 06 19 03 11 41 38 Alg FPGA F004 shift clock using divider 23333 06 19 03 11 41 38 Alg FPGA F004 device clock using divider 26 Figure 3 24 Sample of the EVENTLOGTXT file in the FDROOT System folder Results In addition to the number of devices Passed and Failed the results listed in the Control Panel display under the Job Re
65. device LED Light Emitting Diode M mA milliampere MB Megabyte 1 048 576 bytes 1 024 x 1 024 or 10242 Mean Count Between Interruption Micro Ball Grid Array Sometimes written as MBGA menu A screen display that lists available command choices Motion Controller A printed circuit board that controls the gantry motor for pick and place movement It Board interfaces with the PC Controller Board and the Robot I O Board N NVM Non Volatile Memory NVRAM Non Volatile Random Access Memory odometer Meters hours and devices information used for calculating yields OEM Original Equipment Manufacturer open collector Outputs can be wire OR ed only one logic level outputs operation Parameters that a supervisor sets to restrict the operations of the RoadRunner parameters operational Statistics for a specific operation statistics PC Personal Computer PCI Peripheral Component Interconnect A standard for connecting peripherals to a personal computer Glossary 4 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated 10Jul08 PCMCIA card Glossary of Terms Q Personal Computer Memory Card International Association card A lightweight remov able module about the size of a credit card It is a plug and play module which uses a 16 bit socket and a 68 pin connector pick position The physical posit
66. device sockets on the adapter are normally closed To open the sockets pneumatic cylinders pull the Actuator Plate down Once the sockets are loaded they close again keeping the device leads in contact with the socket pins 1 8 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Overview Overall System Description Programmer Module High Force Actuation Prior to October 2007 four pneumatic cylinders were used to pull the Actua tor Plate down Since 2007 and the introduction of our HIC Socket Adapt ers more force is required High Force Conversion Kits are available allowing pre 2007 RoadRunners to use HIC Adapters Later models actuate HIC Adapters without conversion kits The following charts lists upgrade kits available for new programmers as well as higher force actuation Sales Part Description Description RR PROG MOD HF KIT FCII Upgrade to High Force FlashCORE II programmer RR PROG HF UPGRADE KIT Upgrade to High Force actuation only RR FCIII UPGRADE KIT Upgrade to FlashCORE III programmers c FlashCORE Il is the second iteration of this program ming architecture Contact Data I O for FlashCORE Upgrade Kits Programming Devices The RoadRunner programmer architecture called FlashCORE was devel oped specifically for very high speed programming of Flash memory devices Up to four devices are programmed simultaneously according to the instructions from th
67. e Sprocket 0 Tape Broken 0 Reject Full 0 Reject Bin Air Interlock 0 E Stop 0 Overtravel 0 Home State Up Actuate Act Duration 1 50 Position Up Vacuum Enabled Puff Enabled Vac Sense Speed 135 5 same as Probe 1 same as Probe 1 same as Probe 1 Head 0 Programmer Diags iim Programmer Diagnostic tests require a Diagnostic Adapter Board for all items below this line Event Log NOTES 8 Act Duration is set by the Socket Adapter Figure 3 22 Continuation of Supervisor Menus 3 26 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Operation Supervisor Functions Setting Operational Parameters Setting Operational Parameters For details regarding step 1 see Loading Device Tape on page 3 14 and Aligning the Device Tape All Mod els on page 3 17 ME For more help see Keypad Operation on page 3 4 While it is usually not necessary to change the system s operational parame ters some of them may require adjustment when changing to a different device package All of them require setting after replacing the NVRAM bat tery since this information is stored in Non Volatile RAM The Teach func tion in the Operation menu contains the most often adjusted parameters The following sections describe procedures for these four Teach parameters in detail After that common
68. e acceptable range send RoadRunner or just the Programmer Module to Data I O or an approved service center for repair Lubricating the Ball Screw The ball screw is part of the Linear Stage The PNP Head is screwed to the ball screw slide Standard RoadRunners The Ball Screw OEM used Shell AV2 If a grease gun is used requires reteaching two head positions To replenish the ball screw grease 1 Turn the power off 2 Wipe off the old grease Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 5 Maintenance Preventive Maintenance Schedule Lubricating the Ball Screw 3 Remove the two screws securing the PNP Head to the slide 3 mm hex key and move the head out of the way enough to access the grease fit tings Hoses are still attached Figure 5 1 Ball Screw slide grease fittings circled on the Standard Road Runner The PNP Head has been removed 4 Apply at the 3 mm nozzle on the ball slide fittings The NSK grease nozzle designation is HGP NZ3 Supply grease until it comes out from the ball slide Move the slide by hand to work the grease into all areas 5 Reinstall the head with the two screws 6 Reteach the head the Tape Position page 3 27 and Skt 1 positions page 3 28 If a grease gun is not used To replenish the ball screw grease 1 Turn the power off 2 Wipe off the old grease 3 Apply grease directly to the rail and ball groove
69. e contacts below To find your local representa tive on our Web site go to http www dataio com and click ContactUs upper right then click Representative Search left side Then follow the instructions www dataio com www dataio cn www dataio de Data Data Data United States j Germany RoadRunner Serial number e Software Version displayed on the keyboard screen at start up turn the power off and then on again e Detailed description of the problem you are experiencing if any Error messages if any Device manufacturer part number package style and number of pins if device related telephone number and address B u
70. e cotton swabs optional e water for cleaning e Grease Shell AV2 Standard RoadRunner Lubriplate DS ES 4 XLF RoadRunner Hex Keys Allen wrenches e OPTIONAL grease gun 5 mm through 5 mm with nozzle NSK HGP NZ3 Standard Road Runner only with nozzle for fitting Fitting B M6F XLF RoadRunner compressed air Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 5 1 Maintenance Preventive Maintenance Schedule Preventive Maintenance Schedule To ensure that the RoadRunner continues to operate at its greatest capabili ties perform the preventive maintenance steps at the intervals indicated in chart on the following page This chart is based on programming 20 000 devices each week If you pro cess more than that preventive maintenance should be performed more often Maintenance Schedule Interval Component Tools Required Action Conveyor Belt Isopropyl alcohol Clean the exposed portion with isopropyl alcohol on a Lint free cloth cloth then dry it Rotate the belt and repeat Sockets compressed air Remove dust and debris with clean dry compressed air Press down on the socket opener to ensure dust and Daily debris are cleared from beneath the contacts as well Check for wear replace the Socket Adapter module if necessary 4mm Allen Wrench Or as needed for best throughput Remove the Socket Adapter and clean in an ultrasonic bath with approved cleaning fluid
71. e device tape Change over steps 3 1 Checksum 3 10 Clean Alert 6 5 Clean Count 3 32 6 5 Cleaning chassis 5 2 conveyor belt 5 2 probe tips 5 2 sockets 5 2 Clock setting 3 31 Communication 2 28 Communications Cable 2 28 Config 3 34 Data I O ProLINE RoadRunner Owner s Manual 096 0240 Index 1 Index D Configure RoadRunner 2 31 Connections See Facilities Continuity Error retries 3 30 Continuity Test 3 37 Control Panel Layout 1 4 testing 3 37 Conveyor overview 1 10 Cover Tape loading 1 6 threading 3 16 Cover Tape Module description 1 5 emptying 3 21 Customizing RoadRunner operation 3 30 D DAB 5 5 Device centering 3 35 off centering see Belt offset 3 35 Device Count RoadRunner Total 3 31 Device tape aligning 3 17 description 3 14 loading 3 14 3 16 removing 3 22 Diagnostics board 5 5 menu 3 25 programmer 3 36 5 5 Robot 3 35 test 5 5 Disabling a Socket 3 20 Dry Run 3 35 Electrical connection 2 25 Electrical power requirements 2 25 turning off 3 22 turning on 3 2 Electrostatic Discharge 1 14 Emergency Stop button 1 13 restoring power 1 13 safety precaution 2 26 Emptying cover tape reel 3 21 Enabling a Socket 3 20 Error Retries 3 30 Errors blue lamp is on 6 7 to 6 14 informative 6 4 messages 6 1 no error message displayed 6 15 resolutions 6 4 types 6 1 viewing messages 6 2 yellow lamp is on 6 4 to 6 7 ESD See Electrostatic Discharge Event Log 3 25 3 32 3 37
72. e individual tests listed rather than Test All For Programmer Module The pass fail test results are displayed on the RoadRunner keypad display removal instructionssee while test result details are written to fdrroot system diaglog txt Removing the Program on the PCMCIA card If any of the tests show FAIL on the keypad display mer Module in the Service for example Adtr ID Test FAIL remove and return the Program Manual mer Module along with the PCMCIA card containing the test results to Data I O Corporation or to your nearest Data I O approved service center For contact numbers see the inside back cover 5 6 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Maintenance Electrical Equipment Disposal Notice Electrical Equipment Disposal Notice This symbol displayed on your Data I O product indicates that the item must not be discarded with general municipal waste Return products displaying this symbol to Data I O so that they may be recycled reused or otherwise properly disposed of in accordance with the European Union s WEEE Directive Data I O will at no cost to the equipment owner collect this equipment and process it accordingly Contact your nearest Data I O office to receive infor mation about returning marked products with no charge ROHS for China Notice of Restriction of Hazardous Substances pertaining to China BED RNR 06 Cr SKE PBB 08 R PBDE
73. e particular job on the job card Job cards must be programmed using TaskLink for Windows In addition to programming the devices the programmer can perform a continuity check a blank check an electronic identification check and a data verification If any of these tests fail the programmer illuminates the red LED in front of the socket s containing the failed device s and signals the robotic system to place the device into the reject bin rather than on the conveyor belt Programming yield statistics are displayed on the screen If a job is paused or ended the statistics are written to the job card Programming sockets are a wear item and therefore must be replaced peri odically Socket manufacturers provide expected socket insertion life cycles See Preventive Maintenance Schedule on page 5 2 for recommendations for RoadRunner Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 1 9 Overview Overall System Description Reject Bin 1 10 Output Conveyor Successfully programmed devices are removed from the programming sockets by the PNP Head and placed on the conveyor belt then delivered to the SMT Placement machine s pick position The conveyor module includes a conveyor belt a sensor that determines if devices are at the SMT pick point and in some models the path for the empty device tape The conveyor runs momentarily when a job is started to determine if there are any unwanted devices
74. el 700 Puff 50 Pick 200 Place 100 Travel 250 Tape 40 0 Skt 1 26 85 Reject 166 Belt 180 Restore Defaults Hour 23 Minute 59 Month 12 Day 31 Year 2009 Hours 469 92 Devices 24742 Timekeeping OFF Erase 0 0s Blankcheck 0 0s Program 0 0s Verify 0 0s Network Parm NVRAM Card NetworkTxt Del Save Status Enabled Disa bled PGM Fred sRR2 IP 139 138 16 215 Prog Port 7596 Eth Port 100 BT 10 BT gt SUB 255 255 248 GTW 139 138 16 1 SNS 0 0 0 0 SNS Port 7500 HST rr215 nt data io DOM nt data io com DNS 139 138 16 105 DTS 139 138 16 13 Remote Port Debug Port O E Addr 0010 002211 Clear NetParms On Off Firmware Version Ver 05 35 00 C Installed Boards Bkpln Brd Id 2 EP860 48Mhz WEB FCIII Id 1287 Adptr Brd Id 3 Hardware Config HwCfglds 1 3 4 View Prog Keys Prog Key informa tion Set Prog Key Remove Prog Key Model name name uC name XLF Feeder Comm SBelt FFI Reel Detect Ena ble Disable Continued on the next page Figure 3 21 RoadRunner Supervisor Menus Values are examples only 3 25 Operation Supervisor Functions Menus Available to the System Supervisor f Robot Diags Supervisor Functions Enabled Job Dry Run Move Fwd Bkw Pick Sensor 0 Speed 400 10 Measure Device Offset 0 00 Repeatability Test Start Tap
75. en the probe is centered 7 Press the Menu button to record your setting and move up to the next higher menu Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 27 Operation Supervisor Functions Setting Operational Parameters CAUTION Do not move the PNP head while the probe is in the DOWN position The probe might get damaged DO NOT SELECT THESE COMMANDS WHILE THE PROBE IS DOWN Home Purge Probe X speed or any of the Teach operations Tape Skt1 Reject Belt While performing any Teach procedure the PNP head may be moved incrementally with the Up Arrow or Down Arrow with the probe in the down position Use caution Setting the Skt 1 Parameter To set the socket 1 position for the PNP head 1 On the Keypad press the Menu button until the top level menu is dis played 2 Scrollto and select Operation 3 Scroll to and select Teach 4 Scroll to and select Skt1 The PNP head should move so probe 1 is positioned over socket 1 5 Use the Up Arrow or Down Arrow buttons to move the PNP head until probe 1 is perfectly centered over socket 1 Pushing probe 1 down by hand and holding it while making this adjustment aids in judging when the probe is centered 6 Press the Menu button to record your setting and move up to the next higher menu DO NOT SELECT THESE COMMANDS WHILE THE PROBE IS DOWN Home Purge Probe X speed or any of the Teach operations Tape Skt1 Rejec
76. er vice Probe does not extend fully when placing devices on the belt The probe is not straight on the PNP Head The precisor is not in place accu rately Probe speed is too slow Conveyor height is too low Contact Data I O Customer Ser vice Check the precisor position e Adjust probe speed See Adjust ing and Balancing Probe Speed in the Service Manual Adjust the conveyor height See Reinstalling the Conveyor Mod ule in the Service Manual 6 20 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Troubleshooting Problems but no Error Message Programming Errors See Socket Failure Socket failure sockets fail to pro Dirty or worn Socket Adapter See Device continuity error in gram devices successfully red light the Error Messages chart in the on the Socket Adapter illuminates Blue Lamp section Waveform Board or Backplane Board malfunction Perform the DAB test See Diag nosing with the Adapter Board on page 5 5 Incorrect programming parameters e Review the Job Statistics TaskLink to identify problem For example if the wrong devices are used for the selected job TaskLink will show an Electronic ID Error Socket Actuator fails to open sock Check the air regulator ets properly due to low air pressure Socket Actuator position sensor is Inspect sensor Tighten or replace loose or malfunctioning F
77. eter CAUSE C WRONG OR MISALIGNED PRECISOR Install the correct precisor or position it correctly on the dowel pins precisors are marked for corresponding device packages CAUSE D VACUUM SENSORS ARE OUT OF ADJUSTMENT Adjust the vacuum sensors CAUSE E PROBE TIP IS NOT SEATED Reinstall probe tip or replace To continue select Start on the keypad Device dropped from head See above T 2 Device dropped from head above T 3 blue Device dropped from head above T lampison 4 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 6 9 Troubleshooting Error Messages Blue Lamp is On Device pick failure at input with probe 1 Device pick failure at input with probe 1 continued To continue select Start from the keypad This will temporarily dis able the probe The next able probe will attempt to pick CAUSE A THE POCKET IS EMPTY Verify there are devices in the tape CAUSE B WRONG OR MISALIGNED PRECISOR Install the correct precisor or position it correctly on the dowel pins precisors are marked for corresponding device packages CAUSE C MISALIGNMENT OF POCKET Select Align Tape from the top level menu CAUSE D MISALIGNMENT OF HEAD Align the Pick and Place Head CAUSE E VACUUM SENSORS ARE OUT OF ADJUSTMENT Check the vacuum sensors reset if necessary CAUSE F PROBE TIP NOT SEATED Remove and replace the rubber pro
78. g hook around a pin on the feeder table where the RoadRunner is to be mounted Refer to Figures 2 20 2 21 2 22 and 2 23 for placement details Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 2 17 Installation Mounting the RoadRunner Mounting RoadRunner Siemens 80 4 80F5 F S HS 2 18 Latest Hook Hook for early RoadRunners Figure 2 20 Positioning the RoadRunner Mounting Hook ensure the correct hook is used 2 gure 2 21 The Hex socket screw hook for taller RoadRunners Siemens Edge of RoadRunner a Mount a 7 7 6 2 wo d 1 1 into SMT D e p nagar 2 1 RoadRun 15 Alignment DNE MES E Plate Figure 2 22 Hook Location Relative to standard RoadRunner Placement not XLF models Top View Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Installation Mounting the RoadRunner Mounting RoadRunner Siemens 80F4 80F5 F S HS Edge of RoadRunner RoadRunner Mount teet EN _ bee 4225 _ 1 into SMT O 1 X 4 i p 7 l RoadRunner NY Alignment a Plate gt lt XDe 498 EF Figure 2 23 Hook Location Relative to RoadRunner Siemens XLF Placement Top view RoadRunner is heavy and can fall if the correct mounting hook is n
79. ge The default and maximum is three For example set Pocket Advance to one if you want RoadRunner to stop after two consecutive pick failures Save Air When it is ON this option shuts off air to the probes for the moments that it is not needed The Save Air option should be OFF if the SMT machine has higher throughput than the RoadRunner Save Air EXAMPLES e When set to OFF the probes pick more devices from the sockets even though the belt is full of devices and they hover over the belt waiting for space to place them When set to ON the probes do not pick more devices when the belt is already full Instead the air vacuum stops until the belt starts moving again Then the vacuum starts and probes continue to pick devices Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Operation Supervisor Functions Setting System Parameters Belt gt Clear Removes all devices from the Conveyor Belt by running them off the end of the belt Although it is a fast method of clearing the belt devices will end up on the floor rather than in the Reject Bin gt Buffer Sets the number of times the PNP Head places a group of devices onto the Conveyor Belt before sending them down to the pick point A group of devices is four if four sockets program simultaneously This effectively limits the space between each group placed on the belt gt Prefill When Enabled the PNP Head places as many groups of devices
80. he Reject Bin NOTE RoadRunner will not function without the Reject Bin in place 2 24 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Installation Making the Necessary Connections Electrical Input Requirements Making the Necessary Connections The RoadRunner requires only two external facilities electrical AC power and standard shop pressurized air The specific requirements are stated below as well as on labels inside the RoadRunner Refer to Figure 2 29 for facility connection locations Siemens 80F S HS Series D Series amp Assembleon Pansonic 401 CM402 DT401 XLF model Fuji QP242 od Fuji NXT amp AIM m QP351 IP3 Panasonic MSF Siemens 80F S MCF MPA HS Series D Series Universal GSM Genesis SIPLACE X Series MYDATA MY Series Figure 2 29 RoadRunner Facilities Connection Points For models where no Communication Connection is indicated the connection is on the far side not visible here Electrical Input Requirements The RoadRunner uses 100 240VAC 50 60Hz single phase power The required power is supplied through a single connection on the RoadRunner s end panel RoadRunner uses a standard IEC 320 C13 power cord The power supply is self regulating and requires no special settings for regional power requirements Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 2 25 Installation Making the Necessar
81. he main function of the Control Panel is to accept input commands from the operator via the keypad while providing visual or auditory feedback to the operator regarding status of the system Blank Devices Before starting a job the operator must mount a reel of tape containing blank devices onto the RoadRunner or placement machine cart Once the device tape is threaded into the RoadRunner and a job is started the RoadRunner will pick devices from the tape and advance the tape automatically Periodically new device tape must be loaded and the cover tape take up reel must be emptied Tape Advancement Tape advancement includes three functions advancing the device tape separating the cover tape from the device tape and collecting the cover tape Tape In Module A stepper motor drives a sprocket that advances the device tape via sprocket holes along the tape s edge Tape movement is stepped allowing the tape to stop each device directly under the pick point The empty device tape is expelled at the front of the RoadRunner or near the front below the conveyor Different Tape In Modules are available for different width device tape and there is an adjustable module that accommodates 16 24 and 32 mm tape The XLF models also have an adjustable Tape In Module that accommo dates 32 and 44 mm tape Cover Tape Module The Cover Tape Module winds up used cover tape so it can be disposed of by the operator A DC motor synchronize
82. hecksum of the device data plus extra bytes of storage for cer tain devices The checksum represents the data in its original endian byte order as of Version 03 00 01 C Mfg Check that the device manufacturer listed matches the actual device manufacturer Adapter Check this against the label on the socket adapter Prec Check this against the package specific number etched on the precisor plate Not required on XLF Act Check this against the package specific number on the actuator Also check that the Tape Advance module accommodates the appropriate width tape for the devices to be programmed Make any changes necessary to comply with the data in the Control Panel Display Changing Tape Width on Adjustable Tape In Modules There are three different adjustable Tape In Modules Adjustment of each is described in the following headings 16 24 32 mm Tape In Module Standard Adjustable If you use a 76 24 32 mm Adjustable Tape In Module follow these steps to adjust the width 1 Loosen the Position Locking Screw using a 4 mm Allen Wrench and then rotate the 3 Position Spacer with your finger until you read 16 24 or 22 corresponding to your device tape width Retighten the screw 3 10 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Operation Operator Functions Setting Up RoadRunner for a Programming Job Position Locking Screw Figure 3 9 Adjustable Tape In Mod
83. iangular indicator down the list to the desired command The command is not selected until the Select button is pressed Press the Select button to select the item indicated The menu will change or the triangular indicator will change to a circle when the item is selected With some functions the way the Up Arrow and Down Arrow keys function will change while that item is selected For example when Advance Pocket is selected the Up Arrow advances the device tape rather than scrolling the menu See Figure 3 2 To deselect an item press Menu The circle will change back to a triangular indicator Start Menu Up Arrow Down Arrow Select Pause start the job resume the job deselect an item back out to the next higher menu erase error message scroll up the menu other actions if certain items are selected scroll down the menu other actions if certain items are selected select the indicated item show the submenu pause the job Figure 3 2 Keypad Layout 3 4 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Operation Operator Functions Setting Up RoadRunner for a Programming Job Setting Up RoadRunner for a Programming J ob L3 Job cards for RoadRunner may also be used in Data I O s FlashPAK pro grammer Socket Adapters for Data I O s FlashPAK pro grammer are interchange able with RoadRunner Socke
84. ick point via the Measure Device command 18 undesir able Scroll to and select Y Robot Diags Belt Offset Push the Up or Down Arrow once to adjust and wait for the belt to adjust the position Press Menu to record and exit the Offset command Sensors Selecting Robot Diagnostics then Sensors displays the state of the sensors 1 blocked 0 unblocked Menu items Overtravel and Overtravel must be selected to see the current setting Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 35 Operation Supervisor Functions Programmer Diagnostics For correct speed setting see Adjusting and Balanc ing Probe Speed in the Service Manual Socket The current state of the programming socket can be viewed and toggled with the Up and Down Arrows when State is selected By selecting Actuate a socket delay time in milliseconds can be added with the Up Arrow Zero is the default An actuator duration is set automatically for each Socket Adapter type Use the Act Duration command to manually reset the delay value in milli seconds The new value will be retained in memory until a different adapter is installed The default is zero A few special Socket Adapters have a long duration incorporating double opening and closing action Cycling the PNP Probes The most frequently used utility is likely to be the Probe operations The Probe menu selections allow the system supervisor to ra
85. ied with new adapters ordered Install the CD for the new adapter or device or algorithm onto the computer containing TaskLink NOTE The CD has the TaskLink Version and RoadRunner System Software version written on the face of it If the RoadRunner System Software version is different from the version shown on the RoadRunner startup screen then you must also update the RoadRunner firmware Then make a new job card by recreating the job in TaskLink Cannot load device algo rithm from Job card Make a new job card by recreating the job in TaskLink Update the RoadRunner firmware by making a System Update card with TaskLink Cannot open Boot bin Create a new System Update card at TaskLink and update RoadRunner Cannot open sockets Make sure supply air is connected Verify that the supply air pressure is within the specified limits See specifications at the end of Chapter 1 Also in the Service Manual see Adjusting the Low Air Pressure Sensor some models Cannot open SysFlash bin Create a new System Update card at TaskLink and update RoadRunner Checksum error in Image bin file The checksum that RoadRunner calculates doesn t match the check sum contained within the job Reload the job onto the card in TaskLink Try a new PC card Try a different brand of PC Card reader writer to load the job with If the job file has had any handling such as going through e mail then
86. igure 2 1 If this is the case contact your local Data I O Support Represen tative immediately Both grooves the same color as the body indicate that no impact has occurred Figure 2 1 Shock Indicator is Indicating that an Impact has Occurred Left Side black arrow A list of contents is included in the box Check that you have received every thing on the list Additional items ordered such as spare parts are shipped in a separate box Removing the Shipping Bracket RoadRunners shipped prior to 2009 had a bracket securing the PNP Head It must be removed before operating the RoadRunner If the bracket was rein stalled for subsequent shipping you should check that it is again removed prior to operating the RoadRunner It is the brightly painted bracket that can be seen extending out from under the PNP Head Cover if installed Refer to the figure below Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Installation Mounting the RoadRunner BallScrew ese Rail Hous C Ball Screw Yellow Shipping Head Cover some PNP Head Figure 2 2 Shipping Bracket Plan and Elevation Views To remove the Shipping Bracket 1 2 Remove the Robotics Cover by grasping the outer edges and pulling If your PNP head has a cover remove the cover by pulling it straight off the magnetized head bracket Unscrew the socket head screw securing the
87. igure 6 1 Socket Actuator Sensor Universal model shown Malfunctioning Waveform Board Replace the Programmer Module Backplane Board or CPU Board See Removing the Programmer Module in the Service Chapter Incompatible device data Recreate the job in TaskLink Faulty devices Use new reel of device tape Sockets disabled or continuity errors Dirty or worn Socket Adapter Remove and clean the Socket excessive Adapter in an ultrasonic cleaning tank Replace the Socket Adapter See Changing the Socket Adapter on page 3 5 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 6 21 Troubleshooting Schematics Pneumatic Schematic Schematics Pneumatic and electrical schematics are reproduced on labels inside the RoadRunner as well as below Pneumatic Schematic INTERFACE MANIFOLD PICK HEAD CM RD C ae Ae 1 PROBE Vacuum Cup a 0 4 1 1 1 n DAV n 1 pa T T 3 lt 3 1 RI 1 B lg m n So
88. into the socket 7 Tighten the two screws for that bar 8 Perform steps 5 6 and 7 for the second bar 9 Push the actuator down to verify proper socket open close action With vacuum tweezers place a device into a socket to verify clearance between the bars 10 Switch on the air supply if necessary and release the E Stop Checking the Hardware Setup For more help see Keypad To check the hardware setup perform the following Operation on page 3 4 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 9 Operation Operator Functions Setting Up RoadRunner for a Programming Job Don t know which Tape In Module you have Look at the images on the next few page the shape of the peel bar is different for each model 1 With the power on and system ready the blue light is the only light on insert a job card 2 Using the control panel buttons press the Menu button until the top level menu is displayed 3 Scroll to and select Job 4 Scroll to and select View The list of hardware required for the job will be displayed 5 Scroll through the list of hardware settings Verify that each of the fol lowing job specific hardware pieces is installed on RoadRunner Device Check this against the label on the reel of unpro grammed devices Checksum Check that this is the unique job ID number you wish to run Checksum represents either the checksum of the device data or the c
89. ion where the pick and place head picks up devices Pick and Place The mechanism that supports the probe that picks up and places devices Head pindriver Waveform Board circuitry that determines the function of the contact pins PLCC Plastic Leaded Chip Connector PNP Pick and Place head Also referred to as P amp P pocket parameters The pitch of the device tape pockets The pocket tape pitch is the number of sprocket holes between the pocket centers pocket tape The pocketed film that carries the devices This term usually implies that the cover tape has been removed Also called device pocket tape precisor A mechanical part that attaches to the pick and place head to align parts as they are taken from tape probe A device attached to the pick and place head that picks up carries and releases devices Each probe has a rubber tip on the end that allows it to create a good vacuum seal on the device programming The process of electronically writing data into a device Burning is another term used to describe this operation Input devices are usually blank or un programmed output devices are usually programmed devices programming Module that contains the programming electronic circuit boards required to program a module device in the socket PSI Pounds per Square Inch a measurement of pressure One PSI 0 07031 kg per cm Puff A
90. ise and lower each of the probes turn vacuum on and off to the probe tip and turn positive pres sure puff air on and off to the probe tip To cycle the PNP probes 1 Press the Menu button until the top level menu is displayed 2 Scroll to and select Robot Diagnostics 3 Scrollto and select Probe X where X is the probe number to be cycled 4 Scroll to and select Position Press the Up Arrow or Down Arrow buttons to toggle UP DOWN Other probe functions Vacuum Puff Vac Sense and Speed can be viewed or toggled with the Up Arrow or Down Arrow buttons also For example when Speed is selected for probe 1 and a device is present at the pick point then probe 1 will move down and up intermittently and display the speed in the Control Panel screen Press Menu to stop Head Position When the head is homed and Head Position is selected from the Robot Diag nostics menu the display shows approximately 0 20 Programmer Diagnostics PROGRAMMER DIAGS is another menu that the system supervisor may use With the exception of Continuity Loop all items listed after Exercise Display are for displaying the results of a diagnostic test using the Diagnostic Adapter Board DAB model name RR DIAG ADAPTER The DAB detects problems related to programmer hardware failure the Waveform Circuit Board and BackPlane Circuit Board It does not test the Robot I O 3 36 Data I O ProLINE RoadRunner Owner s Manual 096 0240 up
91. job parameters that can be customized are dis cussed Operation Teach Tape Usedto teach the PNP head the position below of the tape pocket at the pick point Skt 1 Usedto teach the PNP head the position page 3 28 of the first socket in the Socket Adapter board Reject Used to teach the PNP head the position page 3 28 of the tab on the Reject Bin so that rejected devices will slide into the bin Belt Used to teach the PNP head the position page 3 29 of the place point on the output belt Under some circumstances the keypad display may direct you to home the head before setting the operation parameters To home the head From the top level menu scroll to and select Home Wait for the head to stop moving Setting the Tape Parameter To set the tape pocket position at the PNP pick point 1 Load and align the device tape See Loading Device Tape and Align ing Device Tape 2 Onthe Keypad press the Menu button until the top level menu is dis played 3 Scroll to and select Operation 4 Scroll to and select Teach 5 Scroll to and select Tape The PNP head should move so probe 1 is positioned over the device tape pick position 6 Use the Up Arrow or Down Arrow buttons to move the PNP head until probe 1 is perfectly centered over the hole in the center of the device tape Pushing probe 1 down by hand and holding it while making this adjustment aids in judging wh
92. lace The Actuator Plate and Socket Adapter must match 11 When you are finished release the Emergency Stop button 3 6 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Operation Operator Functions Setting Up RoadRunner for a Programming Job Changing the Precisor The precisor assists in properly aligning each device before it is placed into the programming socket Each precisor is shaped to correspond with a spe cific device NOTE RoadRunner XLF Models do not use precisors To change the precisor 1 Push the Emergency Stop button Lift off the Robotics Cover Lift off the PNP head Cover Loc gm Being careful not to disturb the probe tips pull the precisor plate down from the magnetized surface above We suggest grasping the ends with a thumb and finger and lowering one end away from the head at a time Figure 3 5 Removing the Precisor Siemens Model Shown 5 Install the new precisor Make sure that the name on the precisor faces up and the small dowel pin holes near the precisor edges mate up with the dowel pins on the PNP head There should be no visible gap between the precisor and the PNP head Figure 3 6 Identifying the New Precisor 6 When you are finished release the Emergency Stop button Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 7 Operation Operator Functions Setting Up RoadRunner for a Pr
93. ll find the model designation of your RoadRunner such as Model Siemens XLF for example for RoadRunner eXtra Large Format for Siemens SMT machines The Feeder Comm command allows setting Siemens RoadRunners shipped after September 2007 to FFI so it communicates with SIPLACE X Series placement machines Installed Boards and Hardware Configuration Identification HwConfiglId are listed which aid in determining if new device support algorithms are compatible with your RoadRunner hardware Miscellaneous items under System Config are e several Prog Key commands used for and described in our secure digital management software sold separately e a special request option Reel Detect command which detects when a reel of devices has been removed and signals the SMT line The default is Disabled Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Operation Supervisor Functions Robot Diagnostics Robot Diagnostics For the Robot Diagnostics menu see Figure 3 21 on page 3 25 The Adjust Device command A 1 4mm 1 4 The robot diagnostics menu contains a series of utilities used to verify proper operation and to troubleshoot the robotic system These utilities are also use ful when performing tests from other system menus The basic functions provided by the utilities in this menu are e Enable and disable the robot subsection e
94. ll the Robotics Cover Safety Shield NOTE If the Robotics Cover is not in place RoadRunner will beep and run at a slower speed Switch the RoadRunner power on I Insert the PCMCIA memory card containing the job to be run Clear the conveyor belt of any unneeded devices m On the Keypad press the Start button If more than one job is on a card the job that was preselected by the supervisor is the one that will begin running o Once the PCMCIA memory card is inserted into the RoadRunner the job is ready to run If more than one job resides on the card then the job last selected by the system supervisor will be run The green status lamp will flash until programmed devices reach the end of the conveyor belt When devices have been transported to the SMT machine pick area the RoadRunner will pause and wait for the SMT machine to pick the devices The green lamp will stop flashing and stay illuminated while the job is running 3 18 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Operation Operator Functions Programming Devices When a device is picked by the SMT machine the belt moves forward pre senting another device to the SMT pick head When a sufficient number of devices have been picked the RoadRunner places another group of pro grammed devices on the belt A red LED will light at each programming socket that fails to successfully program a device Failed devices
95. lluminate while the system starts and the RoadRunner performs a Self test of its internal electronics and sensors When it is ready to accept commands only the blue lamp will be on Verify that there are no errors indicated on the Keypad Dis play 3 2 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Operation Operator Functions Menus Available to the System Operator Menus Available to the System Operator The RoadRunner operator with an operator card can access a limited num ber of RoadRunner menus RoadRunner Ver 05 35 00 C Operator Menu Job Advance Pocket Align Pocket Purge Socket Job Name Device E28F320 Checksum 3FC00000 Mfg INTEL Adapter 021 Prec 621 0086 005 Act 644 0016 001 Encrypted Yes No Passed 992 Failed 4 System Yld 98 7 Prgrmr Yld 99 6 Handler Yld 99 5 Parts Hour 255 MCBI 201 Skt Yld 99 9 Skt 2 Yld 100 Skt 3 Yld 100 Skt 4 Yld 100 Skt Cycles 249 Remaining 77 0 0 0 0 Job Job 2 End of List Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Advance Pocket When selected each push of the UP Arrow or DOWN Arrow button advances or reverses the pocket tape by one pocket pitch Holding a button down will continually move the tape Socket Reset Clean Count Clean Count Clean Alert 3500 No 22113204 Mfg 09 23 02 Actuations 05
96. lopment of the Programming Instructions for a Job Overall System Description The ProLINE RoadRunner System consists of RoadRunner which attaches to SMT Placement machines TaskLink software for Windows based PCs and a PCMCIA card PC Card TaskLink is needed to create program ming jobs for RoadRunner PC Cards store jobs and contain job statistics Using prepared programming instructions and blank devices RoadRunner picks programs and delivers the devices to the pick region of an SMT Placement machine NOTE This manual refers to the RoadRunner TaskLink software and a job card as the ProLINE RoadRunner or the ProLINE RoadRunner System The term RoadRunner then is used to mean the hardware unit that attaches to the SMT placement machine Development of the Programming Instructions for a Job Programming instructions are developed using TaskLink for Windows The instructions are stored on PCMCIA Type I or II job cards that are formatted for RoadRunner A RoadRunner operator can start a job by inserting a job card and pressing the Start button on the control panel Figure 1 3 The RoadRunner Control Panel and Display Screen 1 4 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Overview Overall System Description Tape Advancement Control Panel The Control Panel is a keypad and display that provides a User Interface UI to the RoadRunner programming system T
97. me e gang place up to four devices on the conveyor belt or place failed devices into the Reject Bin RoadRunners including the large format RoadRunners XLF may operate with one two three or four probes to collect and place devices determined by the Socket Adapter 1 6 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Overview Overall System Description Robotic System A Serial number label SL Linear Stage Programmer Module Module RoadRunner runs at slow speed when the Robotic Cover safety shield is not in place Figure 1 5 PNP Head Positioned above Programming Sockets Fuji Model Shown Pick and Place Head The Pick and Place Head PNP is the portion of the robotic system responsi ble for picking collecting and placing devices It houses four pneumatic cylinders and four hollow probes for air flow The pneumatic cylinders feature spring return to the upper position The probes incorporate a measure of compliance to allow contacting all sizes of devices without applying excessive force The probes have rubber tips which must be kept clean in order to create adequate suction against the device The PNP Assembly will not move until all four probes are in their up posi tion Linear Stage A linear stage consisting of a stepper motor encoder and ball screw moves the PNP head linearly to accommodate the following positions device tape pick
98. mergency Stop button NOTE Without a job card inserted the topics below cannot be accomplished See Supervisor Functions on page 3 24 for cre ating a job card Adjusting an Adjustable Actuator Plate The adjustable Actuator Plate is used on XLF RoadRunners to open the sockets on the Socket Adapter so that the devices can be placed inside There 3 8 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Operation Operator Functions Setting Up RoadRunner for a Programming Job are two types of Adjustable Actuator Plate one is designed adapters and can be identified by the three dots machined into the side One adjustable bar with two screws 2 places on each Actuator Plate dus _ Figure 3 8 Adjustable Actuator Plates Standard top and HIC identifi able by the three dots To adjust the Adjustable Actuator Plate both types 1 Ensure that the actuator is in the up position sockets closed If it is down shut off the air supply 2 Push the Emergency Stop button 3 Liftoff the Robotics Cover 4 Pushthe PNP head away from the Actuator Plate by hand to allow room to work Do not attempt to push the PNP Head with the E Stop unem ployed First push the E Stop 5 With a2 mm Allen Wrench loosen both screws for one sliding bar and slide it inboard toward center as far as it will go 6 Then slide the bar outboard just far enough to allow a device card to pass and fit
99. mmed devices equals the number that the particular job was set up to run the Pass Limit The job may have been set to program an infinite number of devices in which case it will not stop automatically To stop a job see Stopping or Pausing a Job on page 3 19 To cancel a job without finishing it 1 Press the Pause button on the Keypad Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Operation Operator Functions Programming Devices NOTE All job statistics will end and be stored on the memory card when you cancel or end a job 2 Scroll to and select Job 3 Scroll to and select End Programming and verification will continue only for devices still in the programming sockets They will be picked and placed on the output conveyor or into the Reject Bin as appropriate The job will then stop 4 Clear away excess devices from the output belt 5 Empty the Reject Bin as described in the next section Emptying the Reject Bin To empty the Reject Bin pause the RoadRunner and remove the Reject Bin by its finger tab Lift the bin up and pull out Replace the bin once it has been emptied See Figure 3 19 CAUTION Collision hazard To prevent damage to the probe ensure that the Reject Bin is completely in place so the probe will not hit it 9 e A p Figure 3 19 Replacing the Reject Bin Bin for Standard RoadRunner shown Emptying the Cover Ta
100. mmunication The various settings that determine the I O characteristics of your equipment The param parameters eters include baud rate stop bits data bits handshaking and others Communications A circuit board that allows communication with the host handler Module Interface Board contacts The electrically conductive metal leads on a socket module which conduct programming signals from the programmer to the pins on the device in the socket continuity check A preprogramming test that checks the device for electrical connections to the socket No electrical connection to the die Not all pins are checked during this test CPLD Complex Programmable Logic Device CPU Central Processing Unit DAB Diagnostic Adapter Board DAC Digital to Analog Converter device A programmable integrated circuit You may have heard other terms such as chip micro chip semiconductor device PROM or DUT Device Under Test device package The protective container or housing for an electronic device with external terminals to provide electrical access to the components inside device tape The device pocket tape the devices and the cover tape before they are separated Diagnostic Adaptor A circuit board that replaces the Socket Adapter Board for performing programmer hard ware diagnostics DIP Dual Inline Package cubic decimeter per second DRAM Dynamic Random Access Memory dry run A state or action in which the
101. more sockets have Ensure that the Job options are correct and agree with the type of pulled over current device Sockets will be disabled if programmer hardware is degraded VCC for socket 1 has Ensure that the Job options are correct and agree with the type of pulled over current device Sockets will be disabled if programmer hardware is degraded VCC for socket 2 has See above 1 pulled over current VCC for socket 3 has See above T pulled over current VCC for socket 4 has See above T pulled over current VPP for socket 1 has pulled See above T over current VPP for socket 2 has pulled See above T over current VPP for socket 3 has pulled See above T over current VPP for socket 4 has pulled See above T over current Waiting for belt to clear Wait Yellow Lamp is On Yellow A bad Update Card was Make sure you are not using a Job card lamp ison detected Cannot proceed Try using another PCMCIA card Update operation Adapter life has been Replace the Socket Adapter or expect a decline in throughput exceeded This message displays when socket manufacturers recommended number of actuations is exceeded The Adapter Life number may be viewed but not changed on the RoadRunner menu by selecting Socket gt Adapter Statistics gt Adptr Life 6 4 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Adapter maintenance is required The cleaning interval has been exceeded Troubleshooting Error Me
102. mp tied Remove devices from the reject bin Socket 1 Disabled error limit exceeded Select Pause If there is a device in the socket remove it and re enable the socket Ensure that the Job options in TaskLink are correct and agree with the type of device If this problem persists a new socket adapter or programmer may be needed Socket 2 Disabled error See above T limit exceeded Socket 3 Disabled error See above T limit exceeded Socket 4 Disabled error See above T limit exceeded Unexpected device on probe 1 No operator intervention is necessary The device is dropped into the reject bin Unexpected device on See above T probe 2 Unexpected device on See above T probe 3 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Troubleshooting Error Messages Blue Lamp is On Unexpected device on See above T probe 4 Blue Lamp is On Blue Adapter board not compati Contact Data I O Customer Service lampison ble with other boards Adapter board not sup The required software is on the RoadRunner compact disk CD that is ported by software supplied with new adapters ordered Install the CD for the new adapter or device or algorithm onto the computer containing TaskLink NOTE The CD has the TaskLink Version and RoadRunner System Software version written on the face of it If the RoadRunner System Software version is different fr
103. ms but no Error Message Symptom Possible Cause Corrective Action PNP Head position accuracy suf fers Positions for Tape socket reject and belt are programmed incor rectly PNP Head limit switches are mal functioning The Sensor Flag is out of adjust ment The Linear Stage Encoder is loose or malfunctioning Linear Stage Motor malfunction Motion Controller Board malfunc tion Main Controller Board to Motion Controller Board cable is damaged or disconnected Linear Stage Motor or sensor cables are damaged or disconnected Linear Stage Motor stalls Reteach the head positions See Setting Operational Parameters on page 3 27 Contact Data I O Customer Ser vice Adjust The Limit Sensor Flag is on top of the head Inspect connection Replace Robot I O Board or Contact Data I O Customer Service Replace Robot I O Board or Con tact Data I O Customer Service e Contact Data I O Customer Ser vice Inspect cable and connection Contact Data I O Customer Ser vice Inspect cables and connection Replace or Contact Data I O Cus tomer Service Check for excessive drag Contact Data I O Customer Service Power up fails After turning power On the display is blank and or the machine emits a high pitch tone Bad Socket Adapter Bad programmer Turn power Off Remove the Socket Adapter Turn the power On e Contact Data I O Customer S
104. munica tion between the RoadRunner and the SMT machine Others use pins that connect when RoadRunner is mounted correctly After physical connection has been made most SMT Placement machines require unique setup instruction for communicating with RoadRunner These are often supplied in a separate Customer Service Letter Figure 2 31 Siemens Communications Cable Plugged into the SIPLACE Feeder Table Assembleon ACM Communications Orient the cable connector and plug it into the RoadRunner Plug the other end into the ACM communications cable MYDATA Communications Orient the Feeder Bank Adapter cable connector and plug the communica tion cable into the RoadRunner socket on the far end of the electronics hous ing facing the feeder table To unplug the cable pull back on the connector collar Fuji MFU OP242 OP351 P3 Communications Communication cable connection is performed when mounting RoadRunner onto a Fuji Manual Feeder Unit See Mounting RoadRunner Fuji QP242 QP351 IP3 XP142E on page 2 8 Fuji NXT AIM Communications Communications are automatically connected when the unit is properly mounted to an SMT machine A barcode is supplied on the left side of the RoadRunner for assisting placement machine setup with FujiTrax 2 28 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Installation Making the Necessary Connections Connecting the Communications Cable Pansoni
105. n ual Devices rotate excessively on the conveyor belt Dust or dirt on the conveyor belt ncorrect conveyor drive belt ten sion on models with cog drive Conveyor drop height is incorrect Clean the conveyor belt See the daily maintenance schedule on page 5 2 Adjust the conveyor drive belt See Adjusting the Conveyor Drive Belt Notched Only in the Service Manual Adjust Conveyor drop height See Reinstalling the Conveyor Mod ule in the Service Manual Devices run off the end of the belt The End of Belt Sensor optic is adjusted too high and is allowing devices to pass under it or it is mal functioning Adjust the conveyor End of Belt Sensor optic See Adjusting the End of Belt Sensor in the Ser vice Manual Inspect the optic connection Replace the Conveyor Module or Contact Data I O Customer Ser vice Emergency Stop release causes RoadRunner to emit a high pitch squeal The PNP head has been moved a long distance from its position prior to pushing the E Stop and cannot recover Push the E Stop again and return the head to its previous position then release the E Stop or turn the power switch Off 0 and then back On Error message Device pick failure on probe X at input is displayed when the pocket is empty The probe vacuum sensors are not properly adjusted Adjust the probe vacuum sensor See Adjusting Probe Vacuum Sensors in
106. n or dirty socket If the socket is known to be good then it may be re enabled by per forming the following NOTE Before enabling a socket that has been automatically dis abled be absolutely sure that it is not damaged in some way Repeated failures on a single socket usually indicate socket failure or damage of some sort even if it is not readily apparent If no damage is suspected or visible ensure that there are no devices in the socket before enabling 1 Press the Pause button on the Keypad if a job is currently running 2 Press the Menu button until Job is displayed 3 Press the Up Arrow or Down Arrow buttons until Socket is displayed Press the Select button 4 Press the Up Arrow or Down Arrow buttons until the disabled socket is highlighted Press the Select button 5 Press the Up Arrow button to change the state of the socket from Dis abled to Enabled Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 6 3 Je e Troubleshooting Error Messages No Change in Lamps Error Messages Lamp Color Error Message Resolution No Change in Lamps Nochange Card not present Insert or re insert a job card into the PCMCIA card slot in lamps More than one socket Ensure that the Job options are correct and agree with the type of pulled over current device Sockets will be disabled if programmer hardware is degraded One or
107. n the feeder bank 4 Check that the RoadRunner is stable by rocking it cautiously 2 12 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Installation Mounting the RoadRunner Mounting RoadRunner Panasonic CM20 CM120 CM301 Figure 2 15 RoadRunner Panasonic mounted on the Feeder Bank To remove the RoadRunner lift up on the operator end and pull back out of the SMT machine Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 2 13 Installation Mounting the RoadRunner Mounting RoadRunner Panasonic CM401 CM402 DT Mounting RoadRunner Panasonic CM401 CM402 DT CAUTION Heavy weight Use great care when mount ing RoadRunner to the feeder bank It is heavy and dropping it can cause serious damage to RoadRunner and anything it falls upon Use only approved hardware to mount RoadRunner to the SMT feeder bank NOTE When selecting slot positions for RoadRunner consider that access to it is from the right side A Panasonic Feeder Bank Adapter and Host Feeder unit must be mounted to the SMT Feeder Bank prior to mounting the RoadRunner Then the Road Runner can be mounted onto the Adapter The steps for connecting the com munication cable follow To mount the Feeder Bank Adapter and Host Feeder 1 Align the Feeder Bank Adapter with the numbered feeder slots and slide it forward to engage the alignment features Push the Feeder Bank
108. nd screw in or out until the RoadRunner pick point is aligned with the SMT pick point 5d Retighten the four top screws 6 Connect the communications cable For more see MYDATA Commu nications on page 2 28 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 2 7 Installation Mounting the RoadRunner Mounting RoadRunner Fuji QP242 QP351 IP3 XP142E Mounting RoadRunner Fuji QP242 QP351 IP3 XP142E CAUTION Heavy weight Use great care when mount ing RoadRunner to the feeder table It is heavy and dropping it can cause serious damage to RoadRunner and anything it falls upon Use only approved hardware to mount RoadRunner to the SMT feeder table To mount the RoadRunner onto the Multi Feeder Unit MFU complete the following procedure 1 Align and push the communications cable into a connector in the MFU NOTE When selecting slot positions for RoadRunner consider that access to it is from the right side Figure 2 9 The Communications Cable is inserted into the MFU NOTE The assembly machine pick point will correspond with the MFU slot number that is in line with the conveyor belt Make sure conveyor belt is closest to the slot number that the communication cable is plugged into n Hold the RoadRunner at a slight nose down angle and rest the nose on the feeder bank Ensure that the guide under the conveyor settles into a slot by pushing
109. ng procedure for each model Installing the Reject Bin Pneumatic and Electrical requirements Connecting the Communications Cable applicable models Applying power Setting the network configuration optional Unpacking the RoadRunner The RoadRunner is transported in an antistatic bag packaged in a heavy cor rugated box with foam padding On arrival ensure that there is no damage to the exterior of the box since this may also indicate damage to the machine inside If there is significant damage to the box or shipping container contact your local Data I O approved service representative immediately Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 2 1 Installation Removing the Shipping Bracket It takes about eight hours for the RoadRunner temperature to stabilize to the new environment after shipping Do not run a job before RoadRunner has stabilized the chassis should be at room temperature After opening the box containing the RoadRunner inspect for damage that may have occurred during shipment Two shock indicators have been applied to the shipping box for your assurance that the RoadRunner has not been mishandled during shipping They are orange plastic indicators 2 inches 50 8 mm long applied with adhesive backing If the RoadRunner has sustained sufficient impact 25G during shipment the groove on either side of the label will be black or a color darker than the body color See F
110. ngth with 33 cm 13 in reel 124 5 49 in Approximate length protruding from SMT Placement machine 80 8 cm 31 8 in Height with 33 cm 13 in reel 49 5 cm 19 5 in Input tape width supported 16 mm 24 mm 32 mm optional 12 mm 32 mm Large Format DEVICE OUTPUT PLACEMENT at SMT pick point Output placement linear repeatability 25 mm Output placement rotational repeatability x5 ENVIRONMENT Operating temperature range 20 40 C 68 104 F Temperature stabilization time after transportation 2 8h Humidity 5 90 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 1 23 Overview Specifications Universal Genesis Specifications Universal Genesis FACILITIES AC input voltage requirements 100 240 V 50 60 Hz single phase AC Input Power 100 W max Air requirements 2dm s 4 0scfm 52 MPa 7522 psi Air Inlet tube 8 mm 3lin OD min MODELS SUPPORTED Universal models supported Genesis DIMENSIONS Width 78 mm 3 1 in Weight net 18 2 kg 40 Ibs Length with 33 cm 13 in reel 124 5 cm 51 8 in Approximate length protruding 72 1 cm 28 4 in from SMT Placement machine Height with 33 cm 13 in reel 49 5 cm 19 5 in Input tape width supported 16 mm 24 mm 32 mm optional 12 mm 32 mm Large Format DEVICE OUTPUT PLACEMENT
111. nly approved hardware to mount RoadRunner to the SMT feeder table To mount RoadRunner onto a Feeder Table NOTE When selecting slot positions for RoadRunner consider that access to it is from the right side Also do not use the four left most slots on the table or the two right most slots 1 Hold RoadRunner one hand in the handhold and one under the Con veyor so the Conveyor overlaps the Feeder Table by 40 mm and is above a slot Figure 2 12 Mounting RoadRunner onto the SMT Feeder Table 2 Lower RoadRunner allowing the nose to rest on the Feeder Table Ensure that it settles into a slot 3 Still holding the handhold slide RoadRunner forward as far as it will go RoadRunner locks into place 2 10 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Installation Mounting the RoadRunner Mounting RoadRunner Panasonic MSF MCF MPA Mounting RoadRunner Panasonic MSF MCF MPA CAUTION Heavy weight Use great care when mount ing RoadRunner to the feeder table It is heavy and dropping it can cause serious damage to RoadRunner and anything it falls upon Use only approved hardware to mount RoadRunner to the SMT feeder table NOTE When selecting slot positions for RoadRunner consider that access to it is from the right side To mount RoadRunner for Panasonic onto a feeder cart 1 While holding RoadRunner level let the nose rest on the ca
112. nside RoadRunner are suscep tible to electrostatic discharge ESD which can damage the circuitry Also devices processed through the RoadRunner are very sensitive to static and can be damaged by accidental electrostatic discharge while being handled The easiest way to prevent damage from ESD is to make sure a common static potential ground exists between static sensitive devices or components their environment and the operator Perform all repairs at an ESD safe workstation 1 14 To avoid possible personal injury or damage to the equipment please observe the following practices Only trained personnel should install maintain repair or troubleshoot this system Do not operate the ProLINE RoadRunner unless you have been thor oughly trained and have read and understand the instructions in this manual particularly those that describe the system s safety features Do not use ProLINE RoadRunner for any application other than its intended use Do not operate the system if the guards or safety devices are not in their normal operating positions Do not operate RoadRunner with any of the outer sheet metal panels removed Do not operate RoadRunner while servicing replacing or adjusting any component unless directed to do so in this manual Make sure that the RoadRunner is properly shut down before performing any of these operations Do not place any part of your body near or in the direct path of
113. nto a Feeder Bank Changer CAUTION Feeder carts might become unstable The A RoadRunner can also be mounted on feeder carts and feeder test stands However some carts stands were not designed for the heavy overhang of the RoadRunner and may tip over easily especially if the wheels encounter bumps Use caution don t use and do label unsafe carts 2 4 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Installation Mounting the RoadRunner Mounting RoadRunner Assembleon ACM 2 Level the RoadRunner while continuing to support the weight and slide it forward as far as it will go 3 Make sure the RoadRunner feels securely supported before letting go It will latch to the feeder bank under its own weight Figure 2 4 Slide the RoadRunner Forward 4 Check again that the RoadRunner is secure The RoadRunner is now mounted to the feeder bank Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 2 5 Installation Mounting the RoadRunner Mounting RoadRunner MYDATA MY9 MY12 MY15 MY19 Mounting RoadRunner MYDATA MY9 MY12 MY15 MY 19 CAUTION Heavy weight Use great care when mount ing RoadRunner to the feeder table It is heavy and dropping it can cause serious damage to RoadRunner and anything it falls upon Use only approved hardware to mount RoadRunner to the SMT feeder table To mount the Feeder Bank Adapter and RoadRunner
114. of the screw shaft Move the ball slide so the grease permeates into it XLF RoadRunner Extra Larger Format The OEM used type Lubriplate DS ES 4 www lubriplate com The re lubrication interval varies depending on the operating conditions of the rolling guides A six month interval or 1000 hours of usage is gener ally recommended You should use approximately 12 13 g of lubricant on the screw when re lubricating the assembly If a grease gun is used To replenish the ball screw grease 1 Turn the power off 2 Wipe off the old grease 3 Apply at the grease nozzle to the ball slide fitting There is only one fit ting it is on the far conveyor side of the slide The grease fitting is B M6F Supply grease until it comes out from the ball slide Move the slide by hand to work the grease into all areas 5 4 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Maintenance Diagnosing with the Adapter Board Running Diagnostics on a Programmers If a grease gun is not used To replenish the ball screw grease Turn the power off ya Wipe off the old grease 2 Apply grease directly to the rail and ball groove of the screw shaft Move the ball slide so the grease permeates into it Diagnosing with the Adapter Board The Diagnostic Adapter Board DAB part number 910 2200 003 or later detects problems related to programmer hardware failure the Waveform Circuit Board and BackPlane Circ
115. ogramming Job If you have a FlashPAK desktop programmer you may be able to use your RoadRunner Actuator Plate on your FlashPAK To check if the plate Part Number PN required is the same use TaskLink 1 select the appropriate Programming System 2 edit a Task 3 in the Task tab select your primary device 4 click Footnotes to see the PN required Changing the Actuator Plate The Actuator Plate is used to open the sockets on the Socket Adapter so that the devices can be placed inside Non adjustable Actuator Plates are used on standard RoadRunners only not XLF models These non adjustable Actuator Plates have unique shapes designed to work with specific adapters To change the Actuator Plate all types 1 eo zi Ensure that the actuator is in the up position sockets closed If it is down shut off the air supply Push the Emergency Stop button Lift off the Robotics Cover Push the PNP head away from the Actuator Plate by hand to allow room to work Do not attempt to push the PNP head with the E Stop unem ployed First push the E Stop Pull the Actuator Plate away from the RoadRunner by sliding it out from the grooved brackets Figure 3 7 Changing the Actuator Plate Slide the correct Actuator Plate into the grooved brackets ensuring that it snaps firmly into place Non symmetrical plates are marked with an arrow indicating the direc tion to insert it Release the E
116. oll to and select Align Pocket 4 Press the Up Arrow button to advance the device tape until the next not previous pocket center hole lines up approximately with the mark in the metal 5 Press the Start button The paused or stopped job will resume Disabling and Enabling a Socket If a single socket produces an excessive number of errors during RoadRunner operation it is automatically disabled to increase programming yield RoadRunner will also disable a socket if a probe drops a device while attempting to pick it from the socket If the socket is known to be good it may be re enabled by performing the following CAUTION Make sure that the socket is empty by visually inspecting it before enabling a socket Press the Pause button on the Keypad if a job is currently running Press the Menu button until the top level menu is displayed Scroll to and select Socket Scroll until the disabled socket is indicated Press the Select button eA VN Press the Up Arrow to Enable the socket To Disable it press the Down Arrow button Purging the Sockets The Purge command in the Operator s Menu picks devices out of the pro gramming sockets and places them into the Reject Bin Purge cannot be used while a job is running the blue lamp must be on Purge can be used when sockets become disabled and the job has been stopped Ending Cancelling a Job RoadRunner will end a job automatically when the number of progra
117. om the version shown on the RoadRunner startup screen then you must also update the RoadRunner firmware Then make a new job card by recreating the job in TaskLink Algorithm is not compati ble with system software Reload Job onto card All sockets are disabled Ensure that the Job options are correct and agree with the type of device All sockets pulled over cur rent No operator intervention necessary Backplane board not sup ported by software Contact Data I O Customer Service Boot bin is not read cor rectly This file may be cor rupted Replace the update card with a new one Boot bin is too big Call Data I O service Contact Data I O Customer Service Boot bin programmed in FLASH has failed check sum verification Call Data I O Customer Service Cannot close Boot bin Replace the update card with a new one Cannot close sockets Check for interference or jammed actuator plate Verify that the Socket Open Sensor is working properly Cannot close SysFlash bin Get a new update card Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Troubleshooting Error Messages Blue Lamp is On blue lamp is on Cannot find Device Algo rithm file Check your Job card Try making a new job card by recreating the job in TaskLink The required software is on the RoadRunner compact disk CD that is suppl
118. on the belt from a previous job The belt stops when a device is sensed at the SMT machine pick point when the robot places a new set of devices on the belt or when it times out Reject Bin Devices that have failed programming as determined by data verification are dropped into a Reject Bin inside RoadRunner The Reject Bin has a sensor that indicates when it is full by displaying a message on the keypad screen Empty Reject Bin Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Overview TaskLink s Handshake with RoadRunner PCMCIA Memory Card Capacity Requirements TaskLink s Handshake with RoadRunner Parallel ATA 2 is interface standard for the connection of storage devices and uses a PCM CIA form factor 85 6 x 54 x 3 3 mm 66 pin dual row connecting interface TaskLink for Windows is the software program used to create programmer instructions for the RoadRunner system It consists of various utilities for selecting the device to program the data file to write to the device and special programming options specific to the device NOTE The term task refers to a device programming objective being defined with TaskLink The term job refers to a set of instruc tions for programming a specific number of devices with the RoadRunner TaskLink must be installed on a Windows based PC and configured to work with the RoadRunner programmer To install Task
119. onto the Conveyor Belt as possible until the End of Belt sensor is tripped Tripping the End of Belt sensor at any time will stop filling the belt and reset the Prefill command to Disabled Prefill only occurs at the beginning of a job and will be disabled if devices are detected on the belt at the start of a job Setting System Parameters The only system parameter that can be set is the real time clock The odome ter reading can be viewed only and RoadRunner firmware can be updated from the System menu Setting the Real Time Clock Generally the only adjustment that will need to be made in this menu Time function of the System menu is the setting of the real time clock The time and date are maintained by a lithium backup battery associated with the clock circuits on the programmer CPU If the programmer module is replaced the time may need to be reset To adjust the RoadRunner time and date Press the Menu button until the top level menu is displayed Scroll to and select System Scroll to and select Time PE Wy Scroll until the time or date parameter requiring adjustment is indicated Press the Select button 5 Press the Up Arrow or Down Arrow buttons to adjust the parameter Press the Select button Press the Menu button once to go back one menu level Repeat steps 4 through 6 until the time is set correctly Odometer The odometer displays total hours that the RoadRunner has been powered up and the total n
120. ot properly attached Falling can injure you or damage RoadRunner The hook Is absolutely required Do not attempt to mount RoadRunner onto the feeder table without the hook installed onto the table 2 Tighten the hook thumbscrew or the 3 mm socket head adjustment screw as applicable 3 Slide RoadRunner under the hook so that the teeth engage the pin next to the hook as shown in Figure 2 22 and below in Figure 2 24 Teeth on RoadRunner Siemens Figure 2 24 Early model Siemens RoadRunner Mounted onto the SMT Feeder Table Siemens 4 Test to ensure RoadRunner is secure RoadRunner is now mounted to the SMT feeder table Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 2 19 Installation Mounting the RoadRunner Mounting RoadRunner Siemens SIPLACE X2 X3 X4i Mounting RoadRunner Siemens SIPLACE X2 X3 X4 X4i CAUTION Heavy weight Use great care when mount ing RoadRunner to the feeder table It is heavy and dropping it can cause serious damage to RoadRunner and anything it falls upon Use only approved hardware to mount RoadRunner to the SMT feeder table FEEDER CARTS causing personal injury or damage Remove RoadRunner from the Feeder Cart before pulling the cart away from the SMT machine NOTE When selecting slot positions for RoadRunner consider that access to it is from the right side NOTE
121. otes an abnormal condition that may cause the RoadRunner to stop To view and correct errors perform the following 1 On the Keypad press the Menu button to remove the error messages If there are other error messages the next one will appear 2 Check the error as implied by the message and correct it as necessary Clearing Jammed Device Tape For information about loading the device and cover tape into the RoadRunner refer to Loading Device Tape on page 3 14 If the tape advances incorrectly or not at all it may be jammed inside the RoadRunner To clear the tape path 1 Press the Emergency Stop button to continue the job later or select Job then End and turn the power off 2 Cut the cover tape near the Take Up Reel 3 Remove the device tape from the RoadRunner by pulling it back out from the input side It should pull from the machine easily 4 Inspect the device tape and remove any flaws cuts or breaks in the tape before reloading it NOTE A common cause of jammed device tape is inferior tape splices 6 2 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Troubleshooting Resolving Problems Disabling and Enabling a Socket Disabling and Enabling a Socket If a single socket produces an excessive number of errors during RoadRunner operation it is automatically disabled to improve throughput and reduce the likelihood of rejecting good devices due to a wor
122. packing the RoadRunner 2 1 Removing the Shipping Bracket 2 2 Mounting the RoadRunner 2 3 Mounting RoadRunner Assembleon ACM 2 4 Mounting RoadRunner MYDATA MY9 MY12 MY15 MY19 2 6 Mounting RoadRunner Fuji QP242 QP351 IP3 XP142E 2 8 Mounting RoadRunner Fuji NXT AIM 2 10 Mounting RoadRunner Panasonic MSF MCF MPA 2 11 Mounting RoadRunner Panasonic CM20 CM120 CM301 2 12 Mounting RoadRunner Panasonic CM401 CM402 DT 2 14 Mounting RoadRunner Siemens 80F4 80F5 S HS 2 17 Mounting RoadRunner Siemens SIPLACE X2 X4 X4i 2 20 Mounting RoadRunner Universal GSM1 GSM2 Genesis 2 22 Installing the Reject Bin 2 24 Making the Necessary Connections 2 25 Electrical Input Requirements 5 Pneumatic Input Requirements 6 Connecting the Communications Cable 8 Applying Power for the First Time 2 30 Turning Power 2 30 Configuring for Network Communication 2 31 Configuring TaskLink 2 31 Configuring RoadRunner 2 31 3 Operation Operator Functions 3 1 Basic Operator Steps 3 1 Turning On System Power 3 2 Menus Available to the System Operator 3 3 Keypad Operation 3 4 Setting Up RoadRunner for a Programming Job 3 5 Programming Devices 3 18 Miscellaneous Settings via the Menu 3 23 Supervisor Functions 4 Menus Available to the System Supervisor 4 Setting Operational Parameters 3 27 Setting System Parameters 3 31 Network Settings 3 34 Configuration 3 34 Robot Diagnostics 3 35 P
123. pe Module When the Tape Take Up Reel part of the Cover Tape Module looks full the used cover tape needs to be removed NOTE Not all RoadRunners have a Cover Tape Reel To empty the cover tape reel Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 21 Operation Operator Functions Programming Devices For more information see Loading Device Tape on page 3 14 c For more information see Emptying the Cover Tape Module on page 3 21 Press the Pause button Rotate the cover tape Take Up Reel backward to free up the tape Unwind just enough cover tape for restarting it onto the reel then cut the cover tape near the Take Up Reel Depending on your configuration either 4a Pull the cover tape Take Up Reel straight out from RoadRunner or 4b Rotate the Take Up Reel while holding the hub stationary until the holes line up with the pins on the hub and then pull straight out Figure 3 20 Removing the Cover Tape Take up Reel Fuji Shown Unwind the used cover tape from the reel and discard it Slide the cover tape Take Up Reel back onto the hub and rotate it until the holes line up with the steel pins You may need to prevent the inner cylinder from rotating Some types of reels require rotating the reel again so the curved slots capture the pins Rethread the cover tape onto the reel a small piece of adhesive tape may be required Shutting
124. point programmer sockets reject bin and programmer sockets The linear stage motor receives signals from the motion controller via an amplifier The PNP head is itself part of the Linear Stage Module Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 1 7 Overview Overall System Description Programmer Module o T md Figure 1 6 Pick and Place Assembly with Probes Not shown PNP Cover and the Precisor XLF models do not use either lt Vacuum Probes The rubber tipped probes use vacuum produced by the Pneumatic Module to pick up devices The probes also deliver a puff of air to release the devices Vacuum sensors detect whether a device is present at the end of each probe Device Placement Precision On standard RoadRunners not XLF each probe brings its device into contact with the alignment plate called a precisor to center the device on the probe before placing it into a programming socket Precisors are generally device package specific Programmer Module The Programmer Module writes data into the devices From a mechanical standpoint it consists of device specific sockets on an adapter and an actu ator The Programmer Module is responsible for e opening the sockets e ID checking blank checking continuity checking and erasing the devices if selected e writing data to the devices e verifying the data written to devices Opening the Sockets The
125. r Ver 05 35 00 C Supervisor Menu Main Menu OPERATOR SUPERVISOR Job Home Operation System Robot Diagnostics Programmer Diags Event Log Job Name Device E28F320 Checksum 3FC00000 Mfg INTEL Adapter PA G021 Prec 621 0086 005 Act 644 0016 001 Encrypted Yes No Passed 992 Failed 4 System Yld 98 7 Prgrmr Yld 99 6 Handler 99 5 Parts Hour 255 MCBI 201 Skt Yld 99 9 Skt 2 Yld 100 Skt 3 Yid 100 Skt 4 Yid 100 Skt Cycles 249 Remaining 77 1 10 100 End of List Notes Right column bolded items can be changed For information not described in the Owner s Manual see the Operator s Guide Values shown are for EXAMPLE ONLY See the Operator s Menu list for this item A Precisor is not required on XLF models 3 Mean Cycles Between Interrupts Teach value examples are for standard RoadRunners only not XLF models 5 With FlashCORE III programmer only 6 Control Boards EP860 80Mhz EP860 50Mhz DI O 48Mhz DW 48Mhz or CW 48Mhz 7 or Waveform Boards WFB FCII Id n WFB FCI L Id n or WFB FCI H Id n Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Sends the PNP Head to the Home position Operation Pick Retries 2 Error Retries 3 Pocket Pitch 4 Pocket Advance 3 Save Air On Belt Clear Belt Off Buffer Prefill ON Warning Msg ON OFF Velocity 250 Acc
126. redefined on screen elements for example dialog boxes menus icons buttons interface GUI fields used to interact with the system software H Hex Key Allen Wrench HIC Socket Socket Adapters with High Insertion Count sockets Adapters VO Input Output I O Module An input or output I O unit which presents unprogrammed devices to the system input or collects devices after they have been programmed and marked output IDE Integrated Drive Electronics An interface for connecting additional hard drives to a com puter ISA Industry Standard Architecture A bus standard for IBM compatibles JEDEC Joint Electron Device Engineering Council job A set of instructions used by the RoadRunner containing all the device programming parameters required to set up and program a specific set of semiconductor devices Used interchangeably with task JTAG Joint Test Action Group kit A collection of RoadRunner tasks that are run successively Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Glossary 3 Glossary of Terms L kgf cm kilograms force per square centimeter L laptop A portable computer LCA Logic Configure able Array A logic device using RAM for programming LCD Liquid Crystal Display lead The connection legs that extend from the body of a
127. rogrammer Diagnostics 3 36 Data I O ProLINE RoadRunner Owner s Manual 096 0240 Event Log 3 37 Results 7 Session DataLog 3 38 Service information 1S a separate manual with its own Table of Con tents and Index 4 1 5 Maintenance Tools Required 5 1 Preventive Maintenance Schedule 5 2 Lubricating the Ball Screw 3 Diagnosing with the Adapter Board 5 5 Running Diagnostics a Programmers 5 5 Electrical Equipment Disposal Notice 5 7 RoHS for China 5 7 c Maintenance Sign off Charts 5 8 Notes 5 9 6 Troubleshooting Colored Lamp Significance 6 1 Resolving Problems 6 2 Testing the Programmer 2 Viewing Errors 2 Clearing Jammed Device Tape 6 2 Disabling and Enabling a Socket 3 Error Messages 6 4 No Change in Lamps 6 4 Yellow Lamp is On 4 Blue Lamp is 7 Unlisted Error Messages 6 14 Problems but no Error Message 6 15 Schematics 6 22 Pneumatic Schematic 2 Electrical Schematic 3 Data I O ProLINE RoadRunner Owner s Manual 096 0240 ili Glossary Glossary of Terms Alphabetical List of Terms 1 Index Index Alphabetical Index Listing Index 1 Data I O ProLINE RoadRunner Owner s Manual 096 0240 Chapter Overview RoadRunner is In this chapter you ll learn about RoadRunner 5 compact component units called modules safety precau tions ESD and stopping in an emergency You can also learn about the la
128. rt Line up the hook with a slot ay S Figure 2 13 Mounting RoadRunner onto feeder cart 2 Slide RoadRunner forward as far as it will go The communication path will connect automatically 3 Ensure that RoadRunner is secure Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 2 11 Installation Mounting the RoadRunner Mounting RoadRunner Panasonic CM20 CM120 CM301 Mounting RoadRunner Panasonic CM20 CM120 CM301 CAUTION Heavy weight Use great care when mount ing RoadRunner to the feeder bank It is heavy and dropping it can cause serious damage to RoadRunner and anything it falls upon Use only approved hardware to mount RoadRunner to the SMT feeder bank NOTE When selecting slot positions for RoadRunner con sider that access to it is from the right side Also on STM machine CM20 make sure the RoadRunner does not interfere with the han dle on the machine cover To mount RoadRunner onto the Feeder Bank 1 Hold RoadRunner at slight nose down angle and rest the nose on the feeder bank 2 Align the nose with a slot on the feeder bank Ensure RoadRunner engages with one of the slots and the corresponding pin rib as you push forward 3 When it stops going forward push down on the RoadRunner to engage the rollers on the bottom of the conveyor into the groove on the bank See the figure below Rollers groove o
129. s 100 240 V 50 60 Hz single phase AC Input Power 100 W max Air requirements at 2dm s 4 0scfm 52 MPa 7522 psi Air Inlet tube 8 mm 31 in OD min MODELS SUPPORTED Panasonic models supported 20 120 CM301 DIMENSIONS Width 7 8 cm 3 1 in Weight net 14 kg 30 9 165 Length with 33 cm 13 in reel 84 cm 33 in Approximate length protruding from SMT machine including reel 61 cm 24 in Height with 33 cm 13 in reel 50 cm 19 7 in Input tape width supported 16 mm 24 mm 32 mm optional 12 mm 32 mm Large Format DEVICE OUTPUT PLACEMENT at SMT pick point Output placement linear repeatability 25 mm Output placement rotational repeatability x5 ENVIRONMENT Operating temperature range 20 40 C 68 104 F Temperature stabilization time after transportation 28h Humidity 5 90 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 1 19 Overview Specifications Panasonic CM401 CM402 CM602 DT401 Specifications panasonic 61401 CM402 CM602 DT401 FACILITIES AC input voltage requirements 100 240 V 50 60 Hz single phase AC Input Power 100 W max Air requirements 2dm s 4 0scfm 52 MPa 7522 psi Air Inlet tube 8 mm 31 in OD min MODELS SUPPORTED Siemens models supported CM401 C
130. s aligned The End of Belt Sensor optic is mal functioning is out of adjustment too low or has loose connection Robot I O Board malfunction Inspect the connection Replace the Conveyor Module if necessary or contact Data I O Customer Ser vice Replace the Conveyor Module or contact Data I O Customer Ser vice Adjust the conveyor End of Belt Sensor optic See Adjusting the End of Belt Sensor in the Ser vice Manual Inspect the optic connection Replace the Conveyor Module or Contact Data I O Customer Ser vice Replace Robot I O Board or Con tact Data I O Customer Service Conveyor Belt slips on pulleys or devices bounce about on the belt Room temperature is below 20 C 68 F Raise room temp and allow time for conveyor casting to adjust Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 6 15 Troubleshooting Problems but no Error Message Cover tape does not peel and store properly Cover Tape Take Up Reel is broken or binding The Cover Tape Module clutch assembly is malfunctioning Cover Tape Module drive belt is loose and slipping Cover tape broken or twisted or slip ping Loose or bad connection to the Take Up Motor The Broken Tape Sensor is malfunc tioning Inspect and replace if necessary See Removing the Cover Tape Module in the Service Manual Inspect and replace if necessary See Removing
131. shooting Schematics Electrical Schematic Electrical Schematic ProLINE RoadRunner Cable Interconnect User Interface Assy PCMCIA socket Tape Motor E Stop Interlock 3 Lin Stage Sprocket Tape 5 5 amp Tape Motor P 3 5 c c c 8 E 8 5 pm c c Module Switch Earth2 Programmer Optics Power J4 Present Entr Open Ethernet 456 2480 1022 vic sic Jac Jac Robot I O PCB J2c Jac J15D 3150 Belt Motor J1D Belt Sensor Motion Controller Communication Supply Communications P N 631 0145 006 Figure 6 3 Electrical Schematic for all RoadRunner Models Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 6 23 Troubleshooting Schematics Electrical Schematic 6 24 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 A Glossary of Terms
132. sion is displayed on the keyboard screen at start up turn the power off and then on again The update process begins at TaskLink RoadRunner system updates as well as new device and Socket Adapter support arrive on a compact disk CD Install the update CD onto the computer that has TaskLink on it It will gen erally self install When you restart TaskLink the following pop up message will appear i TaskLink has detected that new ProLINE RoadRunner Firmware files have recently been installed on this PC To update your local ProLINE RoadRunner machine s with this firmware create a System Update card in TaskLink and then use the card to update the machines To update your networked ProLINE RoadRunner machines either transfer the files over the network to the machines or create a System Update card in TaskLink and then use the card to update the machines x Figure 3 23 New Software Pop up Create a RoadRunner System Update Card in TaskLink Refer to the TaskLink help menu for more information L _ To perform the RoadRunner update after the update card has been created RoadRunner Firmware is another name for RoadRunner System Insert the PCMCIA memory card with the updated RoadRunner firm ware into the PCMCIA card slot beneath the Keypad Software 2 Press the Menu button on the Keypad until the top level menu is reached You are at the top level when pressing Menu does not change the display
133. so that new network settings take effect NOTE The network configuration file is automatically deleted from the PC Card at the end of the process This prevents acciden tally configuring two RoadRunner programmers with the same net work settings RoadRunner is now configured to communicate with a network Plug in a 10BaseT Network Cable The connection is shown in Figure 2 29 2 32 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Chapter 3 Operation The ProLINE RoadRunner operates with a set of job instruc tions that can be configured and contained on a PCMCIA memory card The instructions provide a detailed description of the programming requirements for a particular semiconductor device or group of devices A PCMCIA card is referred to as a job card after a set of instructions are written to it There may be more than one set of instructions on the PCMCIA memory card with the maximum number depending upon the card s memory capacity How ever one set per card is recommended There are two levels of functions Within the two levels of e those performed by an operator functions mentioned e those performed by the supervisor here there are many menu commands to cus Some of the functions of the RoadRunner like calibration are only available tomize RoadRunner to the system supervisor Additionally RoadRunner job creation is generally operation considered a system supervisor function
134. ssages Yellow Lamp is On Clean the Socket Adapter For cleaning information see Sockets in the Daily Maintenance schedule The clean interval is determined by the number set in the Clean Alert To reset the counter on the RoadRunner Menu navigate to Socket gt Adapter Statistics Reset Clean Count Press the Select button To change the alert number on the RoadRunner Menu select Socket gt Adapter Statistics gt Clean Alert Use the Up or Down Arrow buttons to raise or lower the number Set it to 0 to disable the alert feature Cover open Close the cover Device pick failure at input No operator intervention is necessary with probe 2 A device is on probe 1 Operation will continue without a device on this probe Device pick failure at input See above 7 with probe 3 Device pick failure at input See above dk with probe 4 Yellow Device pick failure on lampison probe 1 Pick failure at the socket No operator intervention is necessary The programmer socket and probe will be disabled CAUSE A DEVICE IS TILTED IN THE SOCKET Remove the device from the socket If this error occurs often CAUSE B SOCKET IS NOT COMPLETELY OPENED Verify that the Actuator Plate is fully compressing and opening the sockets Check for interference Verify that the system air pressure is within specified limits Adjust as required see specifications at the end of Chapter 1 CAUSE C MIS
135. stalled Install the socket adapter for the devices being programmed No Job Selected Select a Job Supervisor Mode Verify that the job card has a job written on it NVRAM Battery Failed Programmer Module requires repair or replacement Contact Data I O Customer Service PNP motor controller not responding Make sure Emergency Stop is not depressed Programmer continuous over current error No operator intervention required Programmer FPGA Failure Programmer Module requires repair or replacement Contact Data I O Customer Service Programmer Shift Chain Failure Contact Data I O Customer Service 6 11 Troubleshooting Error Messages Blue Lamp is On Lamp Color Error Message Resolution Reject bin full CAUSE A REJECT BIN IS FULL Empty device reject bin CAUSE B THE SENSOR IS DEFECTIVE OR NEEDS ADJUST MENT Verify that the sensor is working adjust or replace Reject Bin not detected Install the reject bin Ensure that it is correctly in place SECTPROT TXT file not Reload job onto card found for job Size of Image bin file Ensure the correct data file is being specified in TaskLink incorrect SysFlash bin is too big to fit Programmer Module requires repair or replacement in the on board FLASH Contact Data I O Customer Service SysFlash bin is too big Programmer Module requires repair or replacement Call Data I O service
136. sults menu offer valuable information for tracking and ensuring optimum performance The System Yld eliminates rejected devices from the yield statistics The formula is Devices placed on belt Devices picked from input Devices dropped at input The Prgmr Y1d eliminates dropped devices from the yield statistics This gives an indication of how well the RoadRunner programmer is performing The formula is Devices placed on belt Devices placed on belt Devices rejected The Handler 1 15 the overall yield The formula is Devices placed on belt rejected Devices picked at input Dropped at input Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 37 Operation Supervisor Functions Session Data Log Individual socket yields are also calculated This data can be useful for trou bleshooting low throughput for example situations when the programmer yield drops long before the socket Actuations count nears the Adapter Life count see Socket gt Adapter Statistics It will be easy to see if one socket of the four is the cause in which case that socket can be disabled is the mean device count between interruptions Skt Cycles is the number of socket actuations during the current job Adapter Statistics Many statistics for the Socket Adapter itself are listed in the Socket Menu under Adapter Statistics No is a unique identification number for the currently installed Socke
137. surge of air through the pick and place probes to release a device QFP Quad Flat Pack register A high speed memory location in a computer s CPU Robot I O Board A printed circuit board that provides an interface between the Waveform Board and the Motion Controller Board and robot sensors It controls power distribution S SCFM Standard Cubic Feet per Minute a measurement of flow SCSI Interface Small Computer System Interface A processor independent standard for system level interfacing between a computer and intelligent devices semiconductor A programmable integrated circuit Also called devices they are made of a material whose electrical conductivity is between that of a conductor and that of an insulator Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Glossary 5 Glossary of Terms T SMA Surface Mount Assembly An assembly or machine that utilizes technology for mounting devices onto circuit boards by connecting leads on the surface of the board rather than through a hole on the board SMD Surface Mounted Device SMT Surface Mount Technology SNS Serial Number Server socket adapter A part that allows a socket to fit the programmer Socket Adapter Board A printed circuit board that connects to the Backplane Board to supply the electrical con nections for programming devices socket module The device specifi
138. t Adapter Mfg is the date the currently installed Socket Adapter was first put into use Actuations is the number of times the Socket Adapter has been actuated during its life Insertions is the total number of device insertions for the life of the Socket Adapter For example if all four sockets were loaded every time the sockets were actuated the number of insertions would be Actuations x 4 Also listed in the Adapter Statistics menu are Pass Fail and Yield cal culations for the currently installed adapter and separate statistics for each individual socket Session Data Log Device socket activity is recorded in the Session Data Log If Session Data Logging is enabled in TaskLink then a log file will be generated for each programming session and saved when the session ends It records counts of 14 possible actions at each socket The codes for these actions are as follows PASS of passed devices CF Continuity Failures NB Blank error not blank IB Illegal Bit not applicable to FLX PF X Programming failed VF1 Failed first verify pass VF2 Failed second verify pass not applicable to FLX Failed first functional test not applicable to FLX FT2 Failed second functional test not applicable to FLX SFF Security bit failed to program not applicable to FLX SFB Programmed security bit failed not applicable to FLX DO Device overcurrent error EF Erase failed 3 38 Data I O ProLINE RoadRunner Owner s
139. t Belt While performing any Teach procedure the PNP head may be moved incrementally with the Up Arrow or Down Arrow with the probe in the down position Use caution CAUTION Do not move the PNP head while the probe is in the DOWN position The probe might get damaged Setting the Reject Parameter To set the Reject Bin position for the PNP head 1 On the Keypad press the Menu button until the top level menu is dis played 2 Scroll to and select Operation 3 Scroll to and select Teach 3 28 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 4 fA Operation Supervisor Functions Setting Operational Parameters Scroll to and select Reject The PNP head should move so probe 1 is positioned over the tab on the Reject Bin Use the Up Arrow or Down Arrow buttons to change the value of the PNP head position until probe 1 is perfectly centered over the tab on the Reject Bin Press the Menu button to record your setting and move up to the next higher menu NOTE The probe should be placed in the DOWN position to verify that it is accurately centered on the tab of the Reject Bin For details regarding lowering the probe tip see Robot Diagnostics on page 3 35 When performing this operation there is a risk of the probe tip striking the tab on the Reject Bin To reduce the likelihood of damage to the probe tip do not leave the probe in the DOWN position
140. t Tape In Module Remove tape trim up tape if nec essary and reload Inspect and tighten or replace See Removing the Adjustable Tape In Module or Removing the Standard Tape In Module in the Service Manual Inspect connection replace Tape In Module if necessary See Removing the Adjustable Tape In Module or Removing the Standard Tape In Module in the Service Manual Replace Robot I O Board or Con tact Data I O Customer Service Devices are dropped from the probes but the machine fails to rec ognize that they were dropped The probe vacuum sensors are not properly adjusted Adjust the probe vacuum sensor See Adjusting Probe Vacuum Sensors in the Service Manual Devices bounce out of the carrier tape during the pick event Probes travel too fast Adjust and balance the probe speed See Adjusting and Bal ancing Probe Speed in the Ser vice Manual Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 6 17 Troubleshooting Problems but no Error Message Symptom Possible Cause Corrective Action Devices hit Socket Adapter and possibly fall off the probe as the head starts to move Probe raising speed is too slow Adjust the probe raising speed See Adjusting Probe Raising Speed in the Service Manual Travel Delay is too short See Resetting Pick Delay and Travel Delay Times in the Service ma
141. t Adapters See the Socket Adapter screws in Figure 3 3 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Before programming devices several steps must be taken to ensure that the RoadRunner is properly configured Options comprising a job or task are normally selected at a PC by a ProLINE RoadRunner system supervisor or someone from the engineering staff The instructions are then written toa PCMCIA memory card The instructions or job card are inserted into the RoadRunner RoadRunner uses job instructions to program semiconductor devices A job contains the programming algorithm the number of devices to process special device options and other items important for the programming of the device Once the PCMCIA memory card PC Card is inserted into the RoadRunner the job is ready to run If more than one job resides on the card then the job last selected by the system supervisor will be run If the card has administrator authority then the operator can change the selected job Decide which job you wish to run then see the following sec tions for RoadRunner preparation and setup Changing the Socket Adapter The Socket Adapter is the interface between the device and the programmer Each individual package type that is processed by the RoadRunner has its own unique Socket Adapter To change the Socket Adapter Switch the RoadRunner power switch off 0 Operators may push the Emergency Stop b
142. ter initials and date Jul Aug Sep Oct Nov Dec Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Maintenance Maintenance Sign off Charts Notes Notes Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 5 9 Maintenance Maintenance Sign off Charts Notes blank page 5 10 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Chapter Troubleshooting This chapter describes error messages and failure symp toms along with probable steps for resolution The Error Messages chart is organized by lamp color when the error is displayed and then alphabetically by error message within each color section NOTE These procedures should be performed by qualified service personnel NOTE Some RoadRunners operate with fewer than four sockets The troubleshooting help that follows lists error messages for four sockets four probes but resolutions apply to RoadRunners as applicable Colored Lamp Significance There are three types of messages displayed by the RoadRunner at the con trol panel Status lamps do not change INFORMATIVE Message Indicates a machine state It does not require attention Example Waiting for belt to clear Yellow lamp lights WARNING Indicates that the system is not running at its optimum has degrade
143. test programmer architecture and High Force Conver sion Kits ProLINE RoadRunner is a compact portable automated programming and handling system that mounts directly to a Surface Mount Technology SMT Placement Machine Easy to use and small enough to fit within the profile of a component feeder the ProLINE RoadRunner pro grams and delivers devices to the pick region of placement machines allow ing our customers to integrate device programming and placement RoadRunner is available for many different SMT Placement machines some are shown on the next page Other models for each SMT machine may also available such as the RoadRunner XLF Extra Large Format XLF RoadRunners run devices up to 32 mm Wide x 32 mm Long x 6 mm High The Standard RoadRunner programs devices up 21 65 mm W x 15 mmL x 3mmH The Three Parts of a ProLINE RoadRunner System RoadRunner PCMCIA Card TaskLink Figure 1 1 The ProLINE RoadRunner System is TaskLink Software a Job Card and the RoadRunner Universal Model shown Notebook PC not included Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 1 1 Overview RoadRunner is Fuji QP IP XLF on Siemens F5 MYDATA 4 4 CM20 Figure 1 2 Various Standard RoadRunner Models attached to corresponding SMT machines and one XLF RoadRunner 1 2 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar20
144. the Cover Tape Module in the Service Manual Adjust drive belt tension or remove module and replace e Remove and reload cover tape Use adhesive tape if slipping e Inspect and replace Cover Tape Module if necessary Inspect connection replace sensor if necessary Cover tape jams into Tape In Mod ule 6 16 Cover tape not pulled tight when loading Pull cover tape tightly when load ing it onto the Cover Tape Reel Ensure cover tape is fully removed from exposed tape in the Tape In Module Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Troubleshooting Problems but no Error Message Symptom Possible Cause Corrective Action Device tape does not index prop erly Tape is damaged The tape pocket pitch is non stan dard or the software value for pocket pitch is incorrect Device tape is incompatible with the Tape In Module Empty tape is binding in the dis charge path Tape In Sensor is loose or malfunc tioning Tape In drive motor malfunction Robot I O Board malfunction Inspect tape Remove and cut tape or use new reel Change the Pocket Pitch for this job in TaskLink Version 4 6 or greater 1 Open TaskLink 2 Select the job 3 Click Edit 4 Click the Media tab 5 Change the pitch 6 Click OK and 7 Load the job Then notify Datal O of the possible device Algorithm error Use correct tape or install correc
145. the RoadRunner gently to one side until you feel resis tance 2 8 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Installation Mounting the RoadRunner Mounting RoadRunner Fuji QP242 QP351 IP3 XP142E adRunner mounted onto a Multi Feeder Unit MFU Figure 2 10 The Ro CAUTION Feeder carts might become unstable RoadRunner also be mounted feeder carts and feeder test stands However some carts stands were not designed for the heavy overhang of RoadRunner and may tip over easily especially if the wheels encounter bumps Use caution don t use and do label unsafe carts 3 Slide RoadRunner forward until it comes to a solid stop The nose will fit under the lip on the MFU 4 Lower RoadRunner fully to ensure that the steel angle under the con veyor settles into the spring clamp on the MFU Figure 2 11 The angle bracket on RoadRunner fits into the MFU Spring Clamp 5 Ensure that RoadRunner is secure RoadRunner is now mounted to the Fuji MFU Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 2 9 Installation Mounting the RoadRunner Mounting RoadRunner Fuji NXT AIM Mounting RoadRunner Fuji NXT AIM CAUTION Heavy weight Use great care when mount ing RoadRunner to the feeder table It is heavy and dropping it can cause serious damage to RoadRunner and anything it falls upon Use o
146. the Service Manual 6 18 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 PNP Head fails to transport devices Troubleshooting Problems but no Error Message A cylinder is stuck or spring is bro ken Pneumatic tubes leaking or discon nected Malfunctioning pneumatic valve or insufficient air flow A vacuum pressure switch is out of adjustment or malfunctioning Damaged or worn probe tip Excessive puff blow off air Incorrect Precisor installed The Precisor does not locate device center within tolerance Values for probe pick place puff or travel delay are out of adjustment Robot I O Board malfunction Replace the PNP Head See Removing the PNP Head in the Service Manual Inspect and repair Replace pneumatic filters Inspect or replace the Pneumatic Module or Contact Data I O Cus tomer Service See Adjusting Probe Vacuum Sensors in the Service Manual Replace the Pneumatic Module see Removing the Pneumatic Module in the Service Manual Replace probe tip e Contact Data Customer Ser vice Replace Precisor Contact Data I O Customer Ser vice See Resetting the Pick Delay and Travel Delay Times in the Ser vice Manual Replace Robot I O Board or Con tact Data I O Customer Service Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 6 19 Troubleshooting Proble
147. uit Board It does not test the Robot I O Board or system timing RoadRunner firmware version 1 00 10 A or later is required Running Diagnostics on a Programmers When power is turned off the head is easily moved back and forth by hand To run the diagnostic test 1 Turn the RoadRunner power switch off 2 Lift off the Robotics Cover CAUTION To prevent ESD shock before you touch the AA Socket Adapter discharge static electricity from yourself by touching a common ground or an unpainted metal surface Move the Pick and Place Head away from the programmer socket mod ule to allow room to work 4 Pullthe Actuator Plate away from the RoadRunner by sliding it out from the grooved brackets 5 Unscrew the two captive screws that secure the Socket Adapter bracket and rotate the adapter bracket up 6 Lift the adapter free being careful not to damage the electronic cir cuitry 7 Insert the Diagnostic Adapter Board ensuring that it seats correctly on the adapter pins 8 Lower the adapter bracket and screw in the screws 9 Insert a supervisor PC Card into the RoadRunner 10 Turn the RoadRunner power switch On 11 Scroll to and select Programmer Diags on the keypad screen Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 5 5 Maintenance Diagnosing with the Adapter Board Running Diagnostics on a Programmers 12 Scroll to and select Test All or select one of th
148. ulator Kit for Placement Machines Instructions for RoadRunner Siemens are listed below 2 26 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Installation Making the Necessary Connections Pneumatic Input Requirements CAUTION Oil excessive moisture or poorly filtered air will obstruct RoadRunner 5 internal air paths affect system perfor mance and void the warranty related to air system failure If oil or excessive moisture is detected contact your local Data I O approved service representative immediately Inlet Tube The 6 mm diameter inlet tube assembly supplied has a quick disconnect fit ting that pushes onto the RoadRunner air connector Allow the collar to move while you push the fitting onto the connector To remove the inlet air assembly slide the sleeve on the tube connector back and pull it off The tube fitting has an automatic shut off and may be removed without shutting off the air pressure NOTE If the compressor cannot maintain the correct air pressure and volume the RoadRunner will not operate correctly Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 2 27 Installation Making the Necessary Connections Connecting the Communications Cable Connecting the Communications Cable For location of the nication socket see Figure 2 29 on page 2 25 On some RoadRunners a communications cable allows direct com
149. ule The 3 Position Spacer is set for 24 mm device tape 2 Rotate the Peel Bar for the cover tape counterclockwise 180 degrees to the up position Front Track Figure 3 10 The Adjustable Tape In Module with Peel Bar Rotation Shown 3 Lift and move the magnetic Front Track to the position that fits your tape width 4 Rotate the Peel Bar back down 16 24 32 mm Tape In Module GTP Gradual Tape Path If you use a 76 24 32 mm GTP Adjustable Tape In Module follow these steps to adjust the width 1 Loosen the Peel Bar Screw and rotate the Peel Bar 90 out of the way Then retighten the screw See Figure 3 11 below Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 11 Operation Operator Functions Setting Up RoadRunner for a Programming Job 3 12 Position Locking Screw Peel Bar 3 Position Spacer The Front Track arrow is also adjustable M Loosen the Position Locking Screw Figure 3 11 using a 4 mm Hex Key and then rotate the 3 Position Spacer with your finger until you read 16 24 or 32 corresponding to your device tape width Retighten the screw Lift up and move the magnetic Front Track to the position that fits your tape width Refer to Figure 3 11 B Loosen the Peel Bar screw and rotate the Peel Bar back down and slide it to the far left NOTE There is no need to re center the tape path to the PNP probes unless you experience
150. ule see instructions starting on page 3 10 for changing the tape width All Models Except XLF To load device tape into the RoadRunner All models except standard Siemens Ensure that the brass button on the spindle is rotated to the center to allow a reel to slide over it Install a reel of device tape Rotate the brass button to lock the reel in place Siemens except XLF Ensure that the device tape reel is properly installed in the Feeder Cart rack A reel axle must be used Figure 3 14 Locking a Reel onto the RoadRunner Spindle 3 14 Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 Operation Operator Functions Setting Up RoadRunner for a Programming Job Peel Bar Tape thread ing Diagram Cv m doce pe Figure 3 15 Loading a Device Tape Standard Siemens Model Shown Switch the power switch on I and allow the system to start up Remove the Robotics Cover Insert the tape into the Tape In Module to engage with the sprocket Press Menu until the top level menu is displayed Scroll to and select Advance Pocket CAUTION Device tape can jam if devices fall into tape A path Do not advance tape pockets with devices in them past the pick point Remove the devices as necessary with a vacuum tweezer 99 For sticking tape to the Take Up Reel see Figure 3 16 on page 3 16 Press the Up Arrow button to advance the tape
151. umber of devices placed onto the conveyor belt since cre ation Data I O ProLINE RoadRunner Owner s Manual 096 0240 updated Mar2010 3 31 Operation Supervisor Functions Setting System Parameters L3 The Adapter Clean count Clean Alert are different from this Adapter life cycle count See next heading To view the odometer Press the Menu button until the top level menu is displayed 2 Scroll to and select System 3 Scroll to and select Odometer Also within the Odometer Menu is a Timekeeping command that records specific processing times in seconds When Timekeeping is set to ON times for these functions Erase Blankcheck Program and Verify are recorded after each programming event They are also written to the Event log file To turn Timekeeping on 1 Scroll to and select System 2 Scroll to and select Odometer 3 Scroll to and select Timekeeping the triangle at the beginning of the line changes to a circle 4 Press the Arrow Up button to change to ON 5 Press the Menu button or Start The next time you program a device the times will be available Navigate to Timekeeping again to see them Timekeeping resets to OFF each time RoadRunner power is switched on Adapter Alarm RoadRunner beeps and displays a Life exceeded message when the Socket Adapter has exceeded the manufacturer s recommended total number of actuations a number viewable at Adapter Statistics gt Adapter
152. unner and TaskLink Data I O Corporation acknowledges the trademarks of other organizations for their respective products or services mentioned in this document The Technical Documentation Department also acknowledges the RoadRunner team members for their efforts in supporting the flow of information into this manual We are interested in your comments email userdocs dataio com 2004 2010 Data I O Corporation All rights reserved Contents 096 0240 005H 1 Overview RoadRunner is 1 1 Warning and Caution Notes 1 3 Overall System Description 1 4 Development of the Programming Instructions for a Job 4 Control Panel 1 5 Blank Devices 1 5 Tape Advancement 1 5 Robotic System 1 6 Programmer Module 1 8 Output Conveyor 1 10 Reject Bin 0 TaskLink s Handshake with RoadRunner 1 11 PCMCIA Memory Card Capacity Requirements 1 Safety 1 12 Safety Features 1 12 Precautions for Safe Operation 1 14 Specifications Assembleon 1 15 Specifications Fuji QP IP XP 1 16 Specifications Fuji NXT AIM 1 17 Specifications MYDATA 1 18 Specifications Panasonic CM20 CM120 CM301 1 19 Specifications Panasonic CM401 CM402 CM602 DT401 1 20 Specifications Panasonic MSF MCF MPAV2B MPAG3 1 21 Specifications Siemens XLF SIPLACE X 1 22 Specifications Universal GSM 1 23 Specifications Universal Genesis 1 24 Data I O ProLINE RoadRunner Owner s Manual 096 0240 1 2 Installation Un
153. utton instead of switching the power switch off 2 Lift off the Robotics Cover 3 Move the PNP head away from the programmer socket module to allow room to work When power is switched off or the E Stop is engaged the head is easily moved back and forth by hand 4 Pull the Actuator Plate away from the RoadRunner by sliding it from the grooved brackets 5 Unscrew the two captive screws that secure the adapter bracket Once loosened the screws will remain in the bracket screw holes CAUTION Electrostatic discharge ESD may damage parts Before touching the adapter card discharge static electricity from yourself by touching a common ground or an unpainted metal surface Operation Operator Functions Setting Up RoadRunner for a Programming Job 6 Rotate the adapter bracket up 7 Lift the adapter free being careful not to damage the electronic circuitry attached to or surrounding the adapter Adapter bracket in the up position CAUTION Collision Hazard Do not move the PNP head while the Socket Adapter Bracket is in the UP position The head might get damaged Always lower the bracket and screw it down before moving the PNP head 8 Insert the correct adapter ensuring that it seats correctly on the dowel pins 9 Lower the adapter bracket and screw in the screws For more information see 10 Changing the Actuator Plate on page 3 8 Slide the Actuator Plate back into p
154. y Connections Pneumatic Input Requirements Power is applied to the internal systems of the RoadRunner when the power switch is ON All power is removed when the power switch is OFF Electrical shock hazard If the main power switch is A ON power is applied to the electronic systems of RoadRunner regardless of the position of the Emer gency Stop button or safety shield Always turn the main power switch OFF before working inside the machine Pneumatic Input Requirements RoadRunner requires a pressurized air source connected to the RoadRunner s end panel RoadRunner requires clean dry oil free air at approximately 5 17 Bars 517 kPa 75 psi from an industrial grade com pressor The compressor tank should be of sufficient volume to maintain constant air pressure at a minimum of 113 Liters minute 4 cubic feet min ute A 10 micron filter separator regulator must be installed between the compressor and the RoadRunner to extract any contaminants and moisture before the air enters the machine Pneumatic Regulator Kit Proper operation of RoadRunner on SMT machines is accomplished by installing a Data I O Regulator Kit The kit ensures consistent air pressure and is required for proper RoadRunner operation Check with Data I O for your kit availability and installation instructions The Regulator Kit Model Name for ordering for Assembleon Fuji Pana sonic and Universal is RR REGULATOR KIT UF Figure 2 30 Reg

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