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Service Manual for SIPLACE X & MYDATA SMTs

1. ud VA ee 0 Figure 28 Ribbon Cable Guard with Screw Locations Indicated 7 Unplug the PC Card Drive ribbon cable the Control Panel ribbon cable and the wires for the Emergency Stop button Keyboard Interface connector Mounting Screws 2 places Drive cable connector Emergency Stop Button connector Figure 29 Location of Connectors and Screws on the Control Panel 8 Remove the two screws securing the Control Panel Module to the M 10 RoadRunner chassis 9 Remove the Control Panel Module Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 37 M10 M 10 Service M10 Control Panel Module M 38 Replacement is the in the reverse order of removal When reassembled verify the proper operation of the following Card Reader and indicator lamps Display Keypad Emergency Stop Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Pick and Place Head Pick and Place Head The head assembly contains four probes each with Vacuum Tips and Vac uum Chamber Blocks Some parts can be replaced and some probe functions can be adjusted Aligning Pick and Place Points Adjusting and Balancing Probe Speed See Loading Device Tape and Aligning the Device Tape in Chapter 3 of the Owner s Manual Since device placement tolerance is small the system
2. Remove the three screws that mount the Cover Tape Module to the RoadRunner chassis Take Up Reel Cover Tape Module screws the Reel Removed 6 Disconnect the cable from the Cover Tape Module motor by pinching the clasp and pulling the connector apart Replacement of the Cover Tape Module is done in reverse order of removal NOTE There are two styles of Take Up Reel One has six holes shown and snaps onto the hub the other has two slots that you fit over pins on the hub and twist into place Use only the Take Up Reel appropriate for your hub M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 27 M10 M 10 Service M 10 Conveyor Module Conveyor Module Sensor Optic Cables and Motor Wires Figure 20 Location of the Mounting Screws circled on the Conveyor Module Some models have SMT Adapters attached to the chassis nose It does not need to be removed to remove the Conveyor Module The conveyor belt the belt motor and the End of Belt Sensor make up the main parts of the Conveyor Module If the conveyor belt becomes creased it will cause devices placed on the crease to be mispositioned For this reason a Conveyor Module with a creased or damaged belt should be immediately replaced However a belt can become set in the shape it was left in after several days of inactivity This can be easily remedied by running the RoadRunner in Dry Run mode for two min
3. Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 1 M10 M 10 Service M 10 Replaceable Modules Replaceable Modules Replaceable modules include Tape In Module Pneumatic Module Conveyor Module Cover Tape Module Control Panel Module PNP Head subassembly Linear Stage Module Programmer Module with PNP Head Tools required for RoadRunner maintenance are listed in the Owner s Manual under Tools Required on page 5 1 Some components can be replaced or adjusted at the customer location Replacement and adjustment procedures for those components are included in this chapter Some modules can be removed and sent to Data I O or a local representative for servicing or exchanging Within each main section of this chapter is an order form with relevant Sales Part Numbers These names represent the RoadRunner configu ration at the time of printing this manual only and may not be the same as your unit However the Sales Part Numbers usually correspond to the latest interchangeable replacement Some of the tools required are Metric hex keys Allen wrenches a volt meter or multi meter and a metric scale or calipers CAUTION Electrostatic discharge may damage parts Before servicing place the RoadRunner on an ESD safe workstation M 2 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Replaceable Modules Blank
4. For installation operation maintenance and troubleshooting see the ProLINE RoadRunner Owner s Manual ProLINE RoadRunner Service Manual 5 SIPLACE X MYDATA Data PN 096 0262 001A Model 2010 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 I O Corporation Data I O order forms may be reproduced for immediate customer use only Data I O TaskLink and ProLINE RoadRunner are trademarks of Data I O Corporation Data I O Corporation acknowledges the trademarks of other organizations for their respective products or services mentioned in this document Data I O Corporation also acknowledges the RoadRunner team members for supporting the flow of information into this manual We are interested in your comments Please e mail userdocs dataio com 2010 Data I O Corporation All rights reserved Table of Contents 096 0262 001A For non service information see the Owner s Manual 0
5. 6 If Pick Sensor 1 is not displayed when the beam is blocked 6a check to make sure that all the sensor wires and fiber optics are connected properly 6b the Conveyor Module may need to be replaced 7 If Pick Sensor 1 does display see Reteaching the End of Belt optical fiber amplifier below Reteaching the End of Belt Optical Fiber Amplifier Ld 1 Remove Conveyor Module Cover For more information see Removing the Conveyor 2 Clean the conveyor belt with isopropyl alcohol on a lint free cloth Module Cover on page clean the exposed portion of the belt and then dry it M 10 3 Press the Emergency Stop button the conveyor belt can now be rotated by hand 4 Rotate the belt toward SMT machine and clean and dry this section Repeat until the entire belt is clean and dry The Optic fiber Amplifier is mounted to the chassis under the Conveyor Mod 6 Atthis spot place a device on the SMT pick point so it blocks the optic beam Manually rotate the belt so that the optical fiber amplifier displays its highest value ule See Figure 23 7 Push Set on the optical fiber amplifier M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 31 Service M10 Conveyor Module End of Belt Sensor Optic End of Belt Optical fiber Amplifier 3 M10 Figure 24 M 10 M 32 For details on setting the Optical fiber Amplifier see the
6. RR PNEUMATIC MODULE Pneumatic Module RR DIAGNOSTICS BOARD Diagnostics Adapter Board DAB PROGRAMMER ALIGNMENT TOOL Programmer Alignment Tool Signature Date Company M 68 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Self Service Spares Kit Standard RoadRunner The Self Service Spares Kit for Standard RoadRunner contains parts listed on page M 68 It is available to those who have attended an Advanced RoadRunner Service course NOTE When ordering make sure that the kit designates the correct FlashCORE programmer FC2 or FC3 for example it should match the one you have A different model programmer will not run your programming jobs or work with your firmware Customer Training For information about advanced training contact the Data I O Customer Service Center A training course may be ordered when purchasing a RoadRunner or at a later time NOTE This manual does not list replacement instructions for all the parts in the Self Service Spares Kit such as the Robot I O Board or the Communications PCB For additional information contact Data I O or your nearest authorized representative To find your nearest representative see the instructions on the last page of this manual M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 69 Service M 10 Basic Spares Kit Large Format RoadRunner Basic Spares Kit La
7. 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 Optional Call your local Data I O sale rep resentative for part prices or use our Web page for Requesting Quotes 5 E mail to OrderAdmin dataio com or FAX to 425 867 6972 with your purchase order Lighter colored items are for the Large Format models only Figure 25 The Reject Bin ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Totals RR ASSY REJECT BIN Reject Bin RR REJECT BIN SENSOR Reject Bin Full Sensor RR SLOT SENSOR CABLE Reject Bin Present Sensor ASSY REJECT BIN RR uC Reject Bin Large Format M 10 Signature Date Company M 34 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Reject Bin Removing the Reject Bin Sensors 1 Turn the power off Disconnect the power cord and air supply Lift off the Robotics Cover Remove Lower Cover For more information see Remove the Conveyor Module screws the wires do not need to be Removing the Conveyor unplugged and lift the module out of the way Module on page M 29 2 3 4 Push the head away from the programmer 5 6 7 Lift out the Reject Bin 8 Unplug the sensor wire connectors J1C and J1C2 from the Interconnect Panel Cut wi
8. Adapter Figure 56 Precisor Actuator and Socket Adapter Locations A precisor is a plate that assists in aligning devices on the probes before they are placed into the programming sockets The Actuator Plate opens the sockets on the Socket Adapter assisted by air cylinders The Socket Adapter is the interface between the specific device and the pro grammer Socket manufacturers specifications are used for expected socket life Since these three parts Precisor Plate Actuator Plate and Socket Adapter are determined by the device package they may need to be replaced for each new device type you wish to program Call Data I O Cus tomer Service or contact your nearest authorized Data I O representative for parts or device programming kits Contact information is on the last page of this manual See the ProLINE RoadRunner Owner s Manual for the following e To remove the Precisor see Changing the Precisor in Chapter 3 e To remove the Actuator Plate see Changing the Actuator Plate in Chapter 3 e To remove the Socket Adapter see Changing the Socket Adapter in Chapter 3 M 74 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 NOTE For items not found here check the RoadRunner Owner s Manual A Actuator Plate M 74 Adjustable Tape In Module aligning M 14 removing M 13 Air Filters description M 18 ordering M 18 replacing M 19 Air Paths keeping clean M
9. Adapter in Chapter 3 of the Owner s Manual Remove the Conveyor Module Cover Lift out the Reject Bin 10 Remove screws from the Conveyor Module and set the Module aside For more information see wires are still attached Removing the Conveyor 11 Remove the Reject Bin Bracket Sensors do not need to be removed Module on page M 29 Wires do not need to be unplugged Move it out of the way Reject Bin Bracket A Figure 37 Reject Bin Bracket Screw Locations M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 49 M10 M 10 Service M 10 Programmer Module L g Cables are identified in Figure 38 below To locate the Flow Control and Cable J5C see Figure 39 CAUTION Ribbon cables can get damaged if pulled or pinched Cable damage is often not visible Pull cables by the connector only 12 Unplug the ribbon cable J4 from the Programmer Module 13 Unplug the Cable J3 from the Programmer Module 14 Remove the PCMCIA PCB by removing four socket head cap screws and lifting up on the PCB Set it aside the cable is still attached 15 Unplug the Motion Controller Cable 709 0560 from the left side of the Programmer Module 16 If equipped unplug the Ethernet Cable 701 3215 from the left side of the Programmer Module adjacent to the Motion Controller Cable Cable J4 connector Cable J3 connector PCMCIA Cable PCB Motion Cont
10. Socket Actuator Sensor Tape In amp Cover Tape Broken Sensors far side of Tape In Module Note The Tape In Module must be ordered separately not part of kit Power Supply Module Figure 55 Self Service Spares Kit Large Format RoadRunner 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 Optional Call your local Data I O sale rep resentative for part prices or use our Web page for Requesting Quotes 5 E mail to OrderAdmin dataio com or FAX to 425 867 6972 with your purchase order Lighter colored items are for the Large Format models only ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Ea Totals RR PWR SWITCH Power Switch Rocker RR PWR SUPPLY Power Supply Module RR REJECT BIN SENS Reject Bin Sensor Cable Assy RR LIMIT SENSOR CA Head Limit Sensor Cable Assy RR SLOT SENSOR CA Slot Sensor Cable Assembly Tape RR OPTIC SENSOR Optical Sensor Fiber side RR LINEAR MODULE Linear Stage Module 7502417001 Conveyor Module 7502423001 Programmer Module 7502327002 Programmer Module FCIII RR CTRL PNL MODULE Control Panel Module RR PCMCIA CABLE Control Panel Cable RR COVER TAPE MOD Cover Tape Mod
11. millimeters If the probe is fully up too soon before the head jogs or too late after Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 41 M10 M 10 Service M10 Pick and Place Head For more information see D Covers page M 68 M 42 10 11 12 13 the head jogs remove the Lower Cover and the Conveyor Module Cover Loosen the locknut ring on the in line Flow Control for Probe 1 or cur rent probe Manually adjust the speed by hand using the knob on the in line flow control for Probe 1 raising speed see figure above Adjust the probe raising speed until it synchronizes with the head jog Tighten the locknut ring Press Menu to deselect the current probe Scroll to and select the next probe Repeat these steps from step 4 and on for each probe This procedure affects the probe down speed slightly See the previous heading Adjusting and Balancing Probe Speed and recheck the probe speed When finished replace both covers and remove the device tape Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Pic Part on Tip No Turn Vacuum On Extend Probe Apply Travel delay Yes Apply Pick delay Part Present No y Raise probe Apply Travel delay Probe Up Yes Yes Yes Display error message Service M10 Pick a
12. 18 Allowable device sizes M 65 B Basic Spares Kit Large Format M 70 Standard M 66 Broken tape sensor M 16 C Components listed M 4 Contact Information See inside back cover Control Panel removing M 37 Control Panel Module ordering M 36 Conveyor Belt Cover removing M 10 Conveyor Module M 28 M 32 M 68 M 72 drop height M 29 reinstalling M 29 removing M 29 Cover Tape Module ordering M 26 removing M 27 Cover Tape broken sensor M 16 Covers ordering M 8 Customer Training M 69 M 73 D Delay Times resetting M 43 Device sizes allowed M 65 E Electrostatic Discharge iii End of Belt Sensor adjusting M 30 reteaching 1 Testing M 30 ESD See Electrostatic Discharge Data I O ProLINE RoadRunner Service Manual 096 0262 Index 1 Index F F Filter air M 66 M 70 vacuum M 66 M 70 FlashCORE II M 65 FlashCORE M 65 Front Cover removing M 9 G Grounding iii I Board M 68 M 72 Interconnect Panel M 51 Order Form Basic Spares Kit M 66 M 70 Control Panel Module M 36 Conveyor Belt Module M 28 Cover Tape Module M 26 Covers M 8 Linear Stage Module M 62 NVRAM Battery M 56 Pneumatic Module M 18 PNP head M 46 Programmer Module M 48 Reject Bin M 34 Self Service Spares Kit M 68 M 72 Tape In Module M 12 Vacuum Filters M 18 Overview of Components M 4 1 dant sesEyjafjallajckull in here It should behae Let us know about the items you can t find by e mailing userd
13. 4 If it needs adjustment skip to Part B Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 39 Service M10 Pick and Place Head If it does not need adjustment 5 Press Menu 5b Scroll to and select the next probe 5c Repeat from step 4 for each probe End of Part A Part B Electric shock hazard Do not touch any electronics that become exposed when the cover s is removed Use caution and heed the following instructions closely 6 Remove the Lower Cover and the Conveyor Module Cover 7 Locate the Probe Interface Manifold it is mounted on the chassis below and to the right of the Reject Bin M10 Flow Control adjustment stem for Probe 1 Figure 30 Interface Manifold Adjustment stems have screwdriver slots 8 Loosen the locknut rings and adjust the Probe Speed flow control for Probe 1 or current probe while watching the speed displayed at the keypad screen 9 When the speed is within the proper range 140 4 press Menu probe motion will stop 10 Tighten the locknut ring on the Flow Control if applicable to your model 11 Recheck the speed If it is outside the proper range then readjust 12 Scroll to and select the next probe M 10 14 When finished see Adjusting Probe Raising Speed next heading Repeat steps 4 and on for the next probe M 40 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Ser
14. Bin Assy Vacuum Tips amp Vacuum Chamber Blocks 0 ay Air Inlet B Tube Assembly acuum Filters 7 Figure 52 Parts in the Basic Spares Kit Standard RoadRunner MIO Two spare parts kits are available for each Standard RoadRunner Parts in the Basic Spares Kit are listed below For the larger kit Self Service Spares Kit see page M 68 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 Optional Call your local Data I O sale rep resentative for part prices or use our Web page for Requesting Quotes 5 E mail to OrderAdmin dataio com or FAX to 425 867 6972 with your purchase order ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Ea Totals RR VAC TIP Probe Tip RR VAC FILTER Vacuum Filter RR ASSY AIR TUBE Air Inlet Tube Assembly RR ASSY REJECT BIN Reject Bin Assy RR SLEEVE TAKEUP WHEEL6HL Cover Tape Take Up Reel 6 Holes RR CHAMBER FLOATING BLOCK Vacuum Chamber Block RR FILTER AIR 1 4 3 8 Filter Air 4 3 8 RR FILTER MIST SEP 1 4 3 8 Filter Mist separator M 10 RR SPARES KIT M10 Spares Kit amp all above Signature Date Company M 66 Data I O ProLINE RoadRunner Service
15. 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 Name telephone number address and e mail address
16. label on the inside of the Conveyor Cover shown in Figure 23 Reteaching the End of Belt Sensor 8 Remove the device from the belt and then rotate the belt toward SMT machine until the optical fiber amplifier displays its lowest value 9 Push Set on the optical fiber amplifier again NOTE In general the End of Belt Optical fiber Amplifier should display a number less than 21 when a device is present at the SMT pick point and greater than 90 when no device is present If it is not possible to achieve numbers less than 21 and greater than 90 by adjusting the optic beam the conveyor module must be replaced The Optical fiber Amplifier must always operate in Turbo mode Figure 24 End of Belt Optical fiber Amplifier Label on the Conveyo Cover Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 10 Conveyor Module Blank page M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 33 Service M 10 Reject Bin Reject Bin M10 Reject Bin The Reject Bin is not fastened in and therefore is ready to be lifted out of the RoadRunner Lift up and then out The Reject Bin Full Sensor senses when the bin is full and requires empty ing The Reject Bin Present sensor senses the bin s presence The sensors are attached to the Reject Bin Bracket Data I O Parts Ordering Information Instructions 1 Copy this page
17. page M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 3 10 Components Overview Components Overview CAUTION To prevent damage when unplugging cables pull the connector and not the wires M10 Shown with all 21 covers removed Lower Cover Robotics Cover Conveyor Cover 22 Figure 1 Component Overview SMT Adapter not shown Before repair work begins place the RoadRunner on an CAUTION Electrostatic discharge may damage parts ESD safe workstation M 10 M 4 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Components Overview Component List Modules are listed in bold type Modules are assem blies installed replaced as a unit A 0 d Control Panel Module page 6 Head Limit Cable 3 sensors Linear Stage Tape In Module page M 12 Socket Adapter Serial Number Label Programmer Module page M 48 Pick and Place PNP Head Reject Bin Rubber Probe Tips Socket Actuator Sensor Conveyor Module page M 28 End Of Belt Sensor Optic Nose End Of Belt Optical fiber Amplifier Interface Manifold Interconnect Panel Vacuum Filters Communication connection Pneumatic Module page M 18 Power Supply Motion Controller PCB Air inlet connection Power Switch SMT Communi
18. 96 0240 Precautions for Safe Operation iii RoadRunner Models Covered 1 Replaceable Modules M 2 Components Overview 4 Component List M 5 SMT to RoadRunner Adapters 6 Covers M 8 Removing the Robotics Cover M 9 Removing the Lower Cover M 9 Removing the Conveyor Module Cover M 10 Tape In Module M 12 Removing the Adjustable Tape In Module M 13 Removing the Standard Tape In Module M 15 Pneumatic Module M 18 Replacing the Vacuum Filters 9 Removing the Pneumatic Module M 20 Reinstalling the Pneumatic Module 3 Adjusting the Low Air Pressure Sensor 3 Cover Tape Module 6 Removing the Cover Tape Module 7 Conveyor Module 8 Removing the Conveyor Module M 29 Adjusting the End of Belt Sensor 0 Reject Bin M 34 Removing the Reject Bin Sensors M 35 Control Panel Module M 36 Removing the Control Panel Module 7 Data I O ProLINE RoadRunner Service Manual 096 0262 Pick and Place Head 39 Aligning Pick and Place Points 9 Adjusting and Balancing Probe Speed M 39 Adjusting Probe Raising Speed 1 Resetting the Pick Delay and Travel Delay Times M 43 Adjusting Probe Vacuum Sensors 4 Removing the PNP Head 6 Programmer Module 8 Removing the Programmer Module 9 NVRAM Battery M 56 Removing the NVRAM Battery M 57 Installing a new NVRAM Battery 9 Reinstalling Components 9 Reteaching the NVRAM 0 Linear Stage Module 2 Removing the Linear Stage Module 3 Spare Parts Kits M 65 Basic Spares Kit Stand
19. ARES KIT LF M10 Spares Kit Large Format all above Signature Date Company M 70 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Basic Spares Kit Large Format RoadRunner Replacing the Probe Tips The rubber tip pulls straight off Hold a new tip with the square hole oriented to the square end of the probe and work it onto the probe Replacing the Air Inlet Tube Assembly To remove the Air Inlet Tube Assembly at the RoadRunner air connector 1 Stop or pause the job if one is running 2 If there are any devices currently on the probes remove them they will fall off when air is removed 3 Pull the collar on the quick release fitting back as you pull the tube assembly off the connector The quick release fitting has a safety shut off feature the compressed air need not be turned off To connect an Air Inlet Tube Assembly push it onto the RoadRunner con nector M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 71 M10 M 10 Service M 10 Self Service Spares Kit Large Format RoadRunner Self Service Spares Kit Large Format RoadRunner Head Limit Sensor Reject Bin Sensors Linear Stage Module Control Panel Module Conveyor Module Amplifier Fiber Cable Assembly Cover Tape Module Robot I O Board Optic Sensor Fiber Communication PCB Power Switch 1 Programmer Module FCII or FCIII
20. Covers Blank page M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 11 M10 M 10 Service M 10 Tape In Module Tape In Module Remove the Position Locking Screw to remove the Tape In Module body after which the two Base Mounting Screws are accessible Figure 4 Adjustable Tape In Module shown Location of the Position Locking Screw Base Mounting Screws are Hidden The Tape In Module advances the device tape The Tape Advance Sensor senses sprocket motion while a second sensor determines if cover tape is broken If the device tape is not advancing correctly there could be a problem with the Tape In Module Refer to the Troubleshooting chapter of the RoadRunner Owner s manual to identify the problem If the problem is the Tape In Module remove it and return it to Data I O for repair or replace ment If your RoadRunner is past warranty period you may elect to repair it on site if you have a certified technician Two sensors on the far side of this module can be replaced independently 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 Optional Call your local Data I O sale rep resentative for part prices or use our Web page for Requesting Quotes 5 E mail to OrderAdmin dataio com or FAX t
21. Finish Remove the PC card and insert the card into the target RoadRunner Scroll to and select System gt Network gt Network Parm Press the Down Arrow to change Network Parm to Card Cycle the power on the RoadRunner M 60 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M10 Battery Reteaching the Time settings To set the time 1 2 3 Press the Menu button In the top level menu scroll to and select System gt Time Scroll to Hour Set to the correct hour as follows Press Select Adjust number with the Up Arrow or Down Arrow Press Menu to save Scroll to each remaining parameter Minutes Month Day Year and set in the same manner M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 61 Service M 10 Linear Stage Module Linear Stage Module Electric Motor Cable Carrier Rail and PNP Head the precisor and Encoder Ball Screw is still attached Figure 49 The Linear Stage Module M10 The Linear Stage part of the Robotic System consists of a rail and ball screw a stepper motor with encoder and a cable carrier The Linear Stage is removed as a module with the PNP Head To remove the PNP Head only see Removing the PNP Head on page M 46 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 ch
22. Manual 096 0262 updated MAR2010 Service M 10 Basic Spares Kit Standard RoadRunner Replacing the Probe Tips The rubber tip pulls straight off To install a rubber tip hold it with the square hole oriented to the square end of the probe and work it onto the probe Replacing the Air Inlet Tube Assembly To remove the Air Inlet Tube Assembly at the RoadRunner air connector 1 Stop or pause the job if is running 2 If there are any devices currently on the probes remove them they will fall off when air is removed 3 Pull the collar on the quick release fitting back as you pull the tube assembly off the connector The quick release fitting has a safety shut off feature the compressed air need not be turned off To connect an Air Inlet Tube Assembly push it onto the RoadRunner con nector M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 67 M10 M 10 Service M 10 Self Service Spares Kit Standard RoadRunner Self Service Spares Kit Standard RoadRunner Head Limit Sensor Reject Bin Sensors Linear Stage Module Control Panel Module Conveyor Module Amplifier Fiber Cable Assembly Cover Tape Module g Robot I O Optic Sensor Fiber Communication PCB Power Switch 1 Programmer Module FCII or FCIII Socket Actuator Sensor Tape In amp Cover Tape Broken Sensors far side of Tape In Module Note The Tape In M
23. Module from the chassis as far as wires will allow NOTE The 16 mm and 24 mm Tape In Modules have spacers that could fall out They must be saved and reused on reinstallation Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 15 M 10 M10 M 10 Service M 10 Tape In Module Check that the wire labels clearly marked and unplug the wires for the Tape Advance Sensor the Cover Tape Broken Sensor and the Tape In Motor The sensors may be replaced independently of the module NOTE The two sensors are the same where they plug in deter mines their function Cover Tape Broken Sensor Tape Advance Sensor Tape In Motor i EI 3 Figure 8 Location of Sensors and Motor on the Tape In Module 6a To replace the Tape Advance Sensor or the Cover Tape Broken Sensor remove the screw attaching the sensor to the module The cables have been unplugged from the connector in a previous step Replacement is in the reverse order of removal with these precautions e Ensure that cable connectors are mated correctly e Ensure that no wires or hoses get pinched Ensure that the Module seats on the standoffs and spacers 16 mm and 24mm Modules e If you are installing a Tape In Module other than the one you removed you need to align it to the PNP Head by performing the Tape In align ment procedure See following heading Aligning the Standard Tape In Modu
24. ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 23 M10 M 10 Service M10 Pneumatic Module 3 With the power and the air on check that the Low Air Pressure Sensor LED is lit 4 Reduce the inlet air pressure to 4 48 Bar 65 psi at the external pneu matic filter regulator 5 With a small screwdriver rotate the sensor adjustment screw coun ter clockwise until the LED goes out Then turn it clockwise just until the LED lights Dp Fe Figure 17 Adjusting the Low Pressure Sensor on the Pneumatic Module The arrow points to the adjustment screw The LED is circled 6 Replace the Electronics Covers 7 Release the E Stop M 24 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M10 Pneumatic Module blank page M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 25 M10 M 10 Service M 10 Cover Tape Module Cover Tape Module Take Up Reel mounts onto 2 pins Tape Tension Roller Tape Broken Roller with sensor hidden a Figure 168 Cover Tape Rollers Tensioning Roller and Tape Broken Roller If the Cover Tape Module fails to wind tape onto the reel first check to see if the reel is full Also check that there is tension against the Tape Broken Roller If the Take Up Reel is not full but the module is not winding tape then the Cover Tape Module is suspect C
25. RAM Battery Signature Date Company M 56 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M10 Battery Removing the NVRAM Battery The battery is an integral part of the PowerCap Module The entire PowerCap cap must be replaced The PowerCap Module is located on the back side of the RPX_LITE circuit board 1 Switch the RoadRunner power off Disconnect RoadRunner power cord and air supply Lift off the Robotics Cover Remove the Lower Cover zc ws gc IBS Unplug ribbon cable J4 from the Programmer Module and move it out of the way See figure This cable does not detach from the board PCMCIA Cable PCB Figure 44 Ribbon cable J4 not shown has been disconnected from the programmer PCMCIA PCB screws are circled 6 Remove the PCMCIA PCB by removing four socket head cap screws and lifting the PCB up Lay it aside the cable is still attached See fig ure above 7 Remove four socket head screws securing the RPX LITE board to the Waveform PCB and lift the board up See figure below M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 57 Service M 10 Battery 4 PTA EP Figure 45 The RPX Lite screws are circled The PCMCIA PCB has been removed 8 Turn the board over and locate the PowerCap Module MIO 9 Inserta small slotted screwdriver into the PowerCap cap s
26. Ribbon cable J4 not shown is disconnected The NVRAM Battery is on the far side of the second board down If you had X ray vision you could see it where the dashed yellow square is drawn RoadRunner uses a lithium battery to power the non volatile read only memory If information stored in is lost RoadRunner will not function correctly If RoadRunner displays the error message NVRAM Battery Failed NVRAM data will be lost when RoadRunner is switched off and the battery will need to be replaced After a new battery has been installed in RoadRunner perform the simple procedure which follows the battery replacement instructions to reteach the PNP Head positions the Socket Status Network Settings and the time and date It takes approximately 40 minutes to replace the battery and an additional 20 minutes to reteach the system 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 Optional Call your local Data I O sale rep resentative for part prices or use our Web page for Requesting Quotes 5 E mail to OrderAdmin dataio com or FAX to 425 867 6972 with your purchase order ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Ea Totals RR BATTERY PACK LITHIUM NV
27. adRunner pressur ized air supply tube has a quick disconnect fitting with an automatic shut off The line may be disconnected without shutting off the sup ply line air pressure L 3 For more information see Removing the Lower 8 Cover on page M 9 For the location of Probe vacuum lines see Figure 14 A MMN Turn the power off Disconnect the RoadRunner power cord and air supply Pull off the Robotics Cover Remove the Lower Cover s NOTE The vacuum lines and air pressure lines must be reinstalled to their same locations Do not reverse them Ensure that each line has a label before disconnecting A Disconnect the four vacuum lines on the manifold adjacent to the filters To release the One touch connector push the connector sleeve and pull the tube simultaneously See figure below To reconnect simply insert the tube into the housing sleeve pushing it all the way in M 20 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Pneumatic Module Y Push Down Pull Out Figure 13 Disconnecting a Pneumatic Tube from the One touch Connector Probe Vacuum Lines Iei Ue Socket Actuator E m Air Line Figure 14 Location of Vacuum and Air Lines M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 21 M10 Service M10 Pneumatic Module The pneumatic access cover
28. ard RoadRunner 6 Replacing the Probe Tips 7 Replacing the Air Inlet Tube Assembly 67 Self Service Spares Kit Standard M 68 Basic Spares Kit Large Format RoadRunner M 70 Replacing the Probe Tips 1 Replacing the Air Inlet Tube Assembly M 71 Self Service Spares Kit Large Format 2 Socket Adapter Actuator and Precisor 4 Alphabetical Index Index 1 Data I O ProLINE RoadRunner Service Manual 096 0262 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 Electrostatic Discharge The circuit boards inside RoadRunner are suscep tible to electrostatic dis charge ESD which can damage the circuitry Also devices processed through the RoadRunner are very sensitive to static and can be dam aged by accidental elec trostatic discharge while being handled The easiest way to pre vent damage from ESD is to make sure a com mon static potential ground exists between static sensitive devices or components their environment and the operator Perform all repairs at an ESD safe workstation 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 be
29. assis under the Robotics Cover 3 Fill in the quantity for the item s desired 4 Optional Call your local Data I O sale rep resentative for part prices or use our Web page for Requesting Quotes 5 E mail to OrderAdmin dataio com or FAX to 425 867 6972 with your purchase order ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Ea Totals RR LINEAR MODULE Linear Stage Module M P Signature Date Company M 62 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Linear Stage Module Removing the Linear Stage Module 1 Switch the power off 2 Disconnect the RoadRunner power cord and air supply See Removing the Lower Cover on page M 9 3 Lift off the Robotics Cover 4 Pull off the PNP Head Cover It is magnetically attached to the head See Removing the Con 5 Remove the Lower Cover veyor Module Cover on 6 Remove the Conveyor Module Cover page M 10 7 Remove the Conveyor Module screws the wires do not need to be unplugged and lift it out of the way 8 Liftout the Reject Bin 9 Label if necessary and disconnect four black Linear Stage air hoses from the Probe Control Manifold s upper surface The Probe Control Manifold is located below the Reject Bin Bracket 10 Label if necessary and disconnect four colored air hoses from the Probe Control Manifold 11 Unplug
30. at is known to function If components are still not functioning after connections are tested return the Control Panel Module to Data I O for repair NOTE Do not disassemble the Control Panel Module If a compo nent is not functioning send the entire Control Panel Module back to Data 1 0 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 Optional Call your local Data I O sale rep resentative for part prices or use our Web page for Requesting Quotes 5 E mail to OrderAdmin dataio com or FAX to 425 867 6972 with your purchase order ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Ea Totals RR CONTROL PANEL M Control Panel Module Signature Date Company M 36 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service MI10 Control Panel Module Removing the Control Panel Module 1 Pause the RoadRunner When the blue lamp is on remove the PC Card Turn the power off For more information see Removing the Robotics Cover on page M 9 Disconnect the RoadRunner power cord and air supply Remove the Robotics Cover Remove the PCMCIA Ribbon Cable Guard by unscrewing the two screws securing it 0 0 d
31. bes are still attached Ensure that each has a gasket 2 Install the head Bracket onto the head 3 Attach the tubes to the probes 4 Install the head to the Linear Stage with the two socket screws Use Loctite 222 or equivalent 5 Perform the Linear Stage Reinstallation Verification procedure For more information see the Linear Stage Installa tion Verification on page M 10 M 64 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 47 Service M 10 Programmer Module Programmer Module Programmer Module Cable J4 PCMCIA Cable Board M10 For more information see Changing the Socket Adapter in Chapter 3 of the Owner s Manual with two arrows The Programmer Module consists of the WaveForm Board Main Controller Board BackPlane Board the Socket Adapter and the Socket Actuator that opens and closes the programmer sockets If Socket Adapter sockets become worn the Socket Adapter needs attention The Socket Adapter needs cleaning when yield drops and needs replacing when cleaning fails to boost yield If replacing the Socket Adapter does not solve problems in the Programmer Module see Diagnosing with the Adapter Board in Chapter 5 of the Owner s Manual or contact Data I O for Programmer Module replacement or repair Data I O Parts Ordering Information Instructions 1 Copy this page 2 Fill in your RoadRunner model and seria
32. cations PCB Robot I O PCB Cover Tape Module page M 26 Robotics Cover Open Sensor CAUTION Electrostatic discharge may damage parts Before repair work begins place the RoadRunner on an ESD safe work Station Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 5 M 10 M10 M 10 10 Components Overview SMT to RoadRunner Adapters Some RoadRunner models use hardware to adapt to specific Surface Mount Technology feeder tables and carts In most cases the SMT Adapter also facilitates the communication connection between the SMT and RoadRun ner Mounting procedures supplied assemblies and responsibilities vary with each model therefore attention to these details is important CAUTION Feeder carts can become unstable The 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 can tip over easily especially if the wheels encounter bumps Use caution don t use and do label unsafe carts Adapter for Siemens SIPLACE X Machines mounts to RoadRunner before mounting onto SMT machine Adapter for MYDATA SMT Machine mounts to the feeder table separately Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Components Overview blank page M 10 Data I O ProLINE RoadRunner S
33. e Pneumatic Module Figure 11 Pneumatic Module and four Vacuum Filter locations The Pneumatic Module controls vacuum and blow off air to the probes as well as pressurized air to the probe cylinders and programmer socket cylin ders Pneumatic Module suction is affected by clogged or dirty filters or hoses and by improper connections If the vacuum filters are clogged or dirty vacuum sensors have difficulty detecting whether a device is on the probe or not This can result in error messages such as Device pick failure at input with probe 1 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 Optional Call your local Data I O sale rep resentative for part prices or use our Web page for Requesting Quotes 5 E mail to OrderAdmin dataio com or FAX to 425 867 6972 with your purchase order ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Ea Totals RR VAC FILTER Vacuum filter ASSY PNEUMATIC MODULE Pneumatic Module Signature Date Company M 18 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Pneumatic Module If you experience problems such as dropped devices or pick failures replace the vacuum
34. electrical connector J8B from the extension cable connector It goes to the linear stage motor The cable is tucked beneath the Tape In Module and pulls out far enough for connector access See figure below Motor Encoder Encoder Ribbon Cable Connector J8B E P Figure 50 Wires from the Linear Stage Motor terminate at intermediate connector JSB beneath the Tape In Module 12 Unplug the ribbon cable at the Linear Stage Encoder 13 Remove eight screws securing the Linear Stage Module to the chassis M 10 Slide the head out of the way as necessary See the figure below Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 63 M10 M 10 Service M 10 Linear Stage Module Figure 51 Linear Stage Screw Locations Linear Stage Installation Verification To replace the Linear Stage Module reverse the steps for removal and per form the following 1 For probe vacuum Settings see Adjusting Probe Vac uum Sensors on page 44 For probe speed informa tion see Adjusting and Balancing Probe Speed on page M 39 For Programmer align ment see Aligning the Pro grammer Module on page 52 For reteaching the robot see Setting Operational Parameters Chapter 3 of the Owner s Manual 5 For Conveyor Module reinstallation see heading Reinstalling the Con veyor Module earlier in this manual With the
35. en 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 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
36. ervice Manual 096 0262 updated MAR2010 M 7 M10 M 10 Service M 10 Covers Covers Lower Cover Robotics Cover Conveyor Module Cover Locating dowel pin for Robotics Cover Figure 2 Covers with Screw Locations Indicated by Circles The RoadRunner has three removable covers e Robotics Cover Lower Cover e Conveyor Module Cover The Robotics Cover shields the tape path and the programmer 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 Optional Call your local Data I O sale rep resentative for part prices or use our Web page for Requesting Quotes 5 E mail to OrderAdmin dataio com or FAX to 425 867 6972 with your purchase order ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Ea Totals RR ROBOTICS COVER RU A Robotics Cover RR LOWER COVER Lower Cover RR COVER CONVEYOR U OR Conveyor Module Cover Signature Date Company Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Covers Removing the Robotics Cover Grasp the outer edges of the Robotics Cover and gently pull away from the Control Panel and out There is a locating dowel p
37. evel menu on the display select Operation gt Ye N Scroll to and select Probes Scroll to and select the setting you wish to adjust Use the Arrow Up and Arrow Down buttons to change the setting When finished select Menu M 43 Service M10 Pick and Place Head Adjusting Probe Vacuum Sensors 1 Select Menu until you reach the top menu level and select Robot Diag nostics la Scroll to and select Probe 1 1b Scroll to and select Vacuum Press the Up Arrow to enable the probe Electric shock hazard The following procedures require the Electronics Cover s to be removed while power is on Only touch items described in the proce dures Use caution 2 Remove the Lower Cover M10 2a Turn the vacuum sensor adjustment screw for Probe 1 the first adjustment block counter clockwise just until the red LED adja cent to the adjustment screw illuminates Adjustment LED for Probe 1 typical Vacuum Sensor Adjustment Screw for Probe 1 typical Solenoid switches for Probe 1 typical Figure 33 Pneumatic Valve Block When the vacuum for Probe 1 is enabled the small LED on each of the two solenoids white arrows for M 10 Probe 1 will be unlit M 44 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M10 Pick and Place Head 2b Then turn the same vacuum sensor adjustment screw 1 revolution clockwise until the red LED goes out Con
38. eyor fasteners 3d Recheck the height after tightening the fasteners Adjusting the End of Belt Sensor The End of Belt Sensor Optic stops the conveyor belt when devices reach the pick point The optic operates by sending a beam across the pick point between two fiber optic sensors When a device breaks the beam the End of Belt Optic stops the belt The most likely indication that the End of Belt Optic is out of adjustment or broken is that devices fall off the end of the conveyor If devices are falling off the end of the conveyor first test to make sure the optical fiber amplifier is operating see below If the sensor is operating but devices are still passing the pick point reteach the optical fiber amplifier Testing the End of Belt Sensor 1 From the top level menu select Robot Diagnostics 2 Select Belt 3 Select Pick Sensor CAUTION Collision hazard Make sure that the SMT Machine is stopped and that it is safe to open the safety shield before reaching into the work area 4 With the SMT gantry safely stopped out of the way put your finger at the SMT pick point to block the sensor optic see next image below 5 The Control Panel display will show Pick Sensor 1 whenever your fin ger is blocking the beam and Pick Sensor 0 when not blocked Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Conveyor Module Figure 22 Testing the End of Belt Sensor
39. filters below adjust the vacuum sensor page M 44 or see the chapter on Troubleshooting NOTE In normal low dust conditions Vacuum Filters must be replaced every 6 months Replacement may need to be done more frequently in dustier environments Replacing the Vacuum Filters 1 Turn the power off 2 Disconnect RoadRunner power cord and air supply For more information see 3 Remove the Robotics and Lower Covers Covers on page M 8 4 Remove the square plastic housings with the Vacuum Filters by unscrewing the thumbscrews from the valve block NOTE Ensure that the gasket between the housing and the valve block does not fall out during removal or installation of the hous ing If it does install the gasket into the groove on the valve block CAUTION The housing has two locating pins To prevent damage orient the housing correctly when reinstalling M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 19 M10 M 10 Service M10 Pneumatic Module nN Thumbscrew Housin 0 Filter Locating Pins Gasket Ensure that the gasket does not fall out during removal or installation of the housing Figure 12 Vacuum Filter Components Remove the filter from the plastic housing When installing a new filter make sure the rubber gasket is in place between the housing and the valve block Removing the Pneumatic Module The Ro
40. he PNP Head from mov ing CAUTION Pinch hazard Keep hands and fingers away from the PNP Head Gantry lead screw and programmer actuator The E Stop does not stop the programmer from actuating opening and closing the sockets CAUTION Shock hazard The E Stop does not stop electrical flow to internal electronics 5 Insert a job card with Supervisor authority and switch the power on 6 Locate the Actuation Flow Control and adjust it counter clockwise to full open then turn it clockwise 2 1 2 revolutions 7 At the Control Panel press Menu Then scroll to and select Robot Diagnostics Socket State After selecting the State command a dot or bullet appears next to it Then the Down Arrow and Up Arrow buttons will actuate the programmer KEEP FINGERS AWAY FROM THE PROGRAMMER AND ACTUATOR PLATE 8 Actuate the programmer and watch the speed If the actuator appears to hit the sockets too hard adjust the flow control and then retry Use the flow control to soften the impact However setting speed too slow may cause timing problems as well as reduced throughput Reinstall all RoadRunner covers Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Programmer Module Blank page M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 55 M10 M 10 Service M10 Battery NVRAM Battery Figure 43 The Programmer
41. heck for these e loose take up reel not seated on the pins loose or broken drive belt malfunctioning motor malfunctioning clutch assembly a motor connector that is loose or disconnected the tape tension roller does not roll freely If the problem is the motor or drive belt then the Cover Tape Module needs to be replaced The module can be returned to Data I O for repair If your RoadRunner is past warranty period you may elect to repair it on site if you have a certified technician 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 Optional Call your local Data I O sale rep resentative for part prices or use our Web page for Requesting Quotes 5 E mail to OrderAdmin dataio com or FAX to 425 867 6972 with your purchase order ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Ea Totals RR COVER TAPE MOD Cover Tape Module Signature Date Company M 26 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M10 Cover Module Removing the Cover Tape Module 1 Turn the power off Unplug the RoadRunner power cord Remove the Robotics Cover Remove the Take Up reel from the Cover Tape Module e dB
42. ide is not shown 3 Remove the rubber tip from Probe 4 and extend it into the alignment tool hole 4 If the probe passes through the hole easily then the right side of the programmer is properly aligned skip to step 4 3a If probe 4 does not pass through easily loosen the upper right Pro grammer Module mounting screw two revolutions 3b Adjust the right Position Alignment set screw accordingly 3c When done tighten the upper right programmer mounting screw 4 Retest If the module requires further adjustment be sure to loosen the left or right mounting screw first 5 Remove the Alignment Tool 6 Replace the rubber probe tips Complete the Programmer Module installation by installing the Reject Bin Bracket and the Conveyor Module Covers should get installed after the next section Adjusting the Actuation Speed The programmer actuation speed needs to be adjusted so that it doesn t slam the Actuator Plate down onto the sockets If it is too fast causing a hard landing devices may bounce For the steps below refer to Figure 39 on page M 10 51 1 Install a Socket Adapter and Actuator Plate Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 53 M10 M 10 Service M 10 Programmer Module M 54 2 Plugin the AC Power cable 3 Connect external air source ensuring that it is set to approximately 5 17 Bars 75 PSI 4 Press the Emergency Stop button to prevent t
43. in on the end opposite the Control Panel Module NOTE The Robotics Cover can be removed while the RoadRunner is running However the robot speed reduces by 50 Shock Warning Do not remove the Lower Cover or the Conveyor Module Cover while the RoadRunner is plugged in Removing the Lower Cover 1 Turn the power off 2 Disconnect the RoadRunner power cord and air supply NOTE The RoadRunner pressurized air supply tube has a quick disconnect fitting called a one touch fitting with an automatic shut off The line may be disconnected without shutting off the supply line air pressure 3 Lift off the Robotics Cover 4 Remove the five screws that hold the Lower Cover to the chassis PO Or see 5 Slide the cover up toward the Control Panel to unhook a clip in the Figure 2 lower left corner then lift off For a detail of the cover clip see Figure 3 M 10 Figure 3 Detail of Clip View looking at the Inside of the Lower Cover Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 9 Service M10 Covers Removing the Conveyor Module Cover 1 Turn the power off 2 Disconnect the RoadRunner power cord and air supply 3 Remove the three screws that hold the Conveyor Module Cover to the For screw locations see chassis Figure 2 M10 M 10 M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10
44. ires for Tape Advance Sensor the Cover Tape Broken Sensor and the Tape In Motor NOTE The two sensors are the same where they plug in deter mines their function The sensors may be replaced independently of the module 7 Remove the three screws that attach the ATI Base to the chassis See the figure below M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 13 Service M 10 Tape In Module 8 3 _ EI IL Figure 6 Adjustable Tape In Module Bas x Lift the Base from the chassis Replacement is in the reverse order of removal with these precautions MIO Ensure that cable connectors are mated correctly Ensure that no wires or hoses get pinched If you are installing a Tape In Module other than the one you removed you need to align it to the PNP Head by performing the alignment pro cedure See next heading Aligning the Adjustable Tape In Module There may be an optional h method using a Tape In Alignment Jig Contact 2 Data I O support for 3 more information 4 5 M 10 To center the tape path under the PNP probes Either load a piece of empty device tape into the Adjustable Tape In ATD Module Move the PNP Head so that Probe 1 is directly over the pick point Remove the rubber Probe Tip from Probe 1 Extend Probe 1 fully by pushing down on the block below the spring to visually compare the position of the hole in the center of the tape
45. l numbers see the label on the chassis under the Robotics Cover 3 Fill in the quantity for the item s desired 4 Optional Call your local Data I O sale rep resentative for part prices or use our Web page for Requesting Quotes 5 E mail to OrderAdmin dataio com or FAX to 425 867 6972 with your purchase order ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Ea Totals 7502327002 ASS Y PROGRAMMER W GUIDE FC2 7502423001 ASS Y PROGRAMMER W GUIDE FC3 6950019001 Programmer Alignment Tool Signature Date Company M 48 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Programmer Module Removing the Programmer Module NOTE Only technicians who have taken the ProLINE RoadRunner Service training course should attempt to remove the Programmer Module A special tool Programmer Alignment Tool is required from Data I O to reinstall the Programmer Module See the order form on the previous page This tool is also included in the Self Service Spares Kit 1 Switch the power off 2 Disconnect the RoadRunner power cord and air supply 3 Lift off the Robotics Cover 4 Push the head away from the programmer 5 Remove the Lower Cover 6 Remove the Actuator Plate by sliding it out of the bracket 7 Optional Remove the Socket Adapter For more information see Changing the Socket 8 9
46. le You can see an adjustment stud when you look down at the Tape In Module from the top as shown in the figure below M 16 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Tape In Module Figure 9 Some Tape In Modules have an Adjustable Standoff for setting the Alignment with the Probes The wrench flats and Locknut identify the Adjustment Stud from a non adjustable Standoff To align the Tape In Module 1 Loosen the top left and bottom right mounting screws 2 Loosen the Locknut on the Adjustable Standoff 7 mm wrench Cap Locknut Base 7 Figure 10 Adjustable Stud for the Standard Tape In Module 3 Adjust the Cap of the Adjustable Standoff 6 mm wrench until the Tape In Module is in line with a PNP Probe To do that 3a Place a small piece of device tape on the Tape In Module 3b Remove the rubber tip from Probe 1 3c Extend Probe 1 fully by pushing down on the block below the spring 3d Adjust the Standoff to visually align the hole in the center of the tape pocket with the probe Screw the Locknut until it rests tight against the Cap to lock it in place Tighten the other two mounting screws Recheck alignment loosen the Locknut and readjust if necessary DP gx dm Put the rubber tip back onto Probe 1 M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 17 M10 M 10 Service M10 Pneumatic Modul
47. levels may exceed 85 decibels Shut off the pressurized air or disconnect the air hose before servicing pneumatic parts Data I O ProLINE RoadRunner Service Manual 096 0262 lii Blank page Data I O ProLINE RoadRunner Service Manual 096 0262 Service M10 This model of Data I O s ProLINE RoadRunner supports many assembly machines programming and delivering microchips from the feeder bank This service chapter covers only the models listed below RoadRunner Models Covered This manual covers two Standard models of RoadRunner which support these SMT Placement machines e RoadRunner SIPLACE X X2 X3 X4 and X4i e RoadRunner MYDATA MY9 MY12 MY15 and MY19 NOTE This manual does not cover service instruction for XLF eXtra Large Format RoadRunners If there is an XLF RoadRunner for your assembly machine it has a separate man ual Runs devices up to 32 mm Wide x 32 mm Long x 6 mm High Many modules and components on the RoadRunner are designed for easy service or replacement by qualified technicians You may wish to keep backup modules or components for replacements The replaced module or component may be sent to Data I O for repair or adjustment NOTE Send RoadRunners under warranty back to Data I O If your RoadRunner is NOT under warranty you have the option of repairing it with instructions in this manual or sending it back to Data I O See the inside back cover for contact information
48. lot 10 Gently pull back the screwdriver handle until the side of the cap releases from the module base See figure below Remove the cap M 10 M 58 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M10 Battery Figure 47 Removing the cap from the base Installing a new NVRAM Battery l Align a new PowerCap cap contact springs tabs with the base contact lands 2 Hook the PowerCap cap flange under the module base board Center the cap on the base See figure below 3 Push down on the cap until the side with the slot snaps onto the base Figure 48 Attaching a new PowerCap battery to the Power Cap Module base Reinstalling Components Reinstallation of components is in reverse order of removal Briefly install the RPX Lite board install the PCMCIA PCB plug in ribbon cable J4 install the Lower Cover M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 59 Service M10 Battery Reteaching the NVRAM After a new battery has been installed in RoadRunner you need to teach it the PNP Head positions the Socket Status Network Settings and the time and date so that they can be stored again in NVRAM The following proce dures are covered in more detail in the RoadRunner Owner s Manual as noted in many of the steps below To reteach the NVRAM 1 Connect the air supply and po
49. may need aligning when a module is replaced or repaired The head may also need aligning if any of the following error messages are displayed e Device pick failure at input with probe e Device pick failure on probe n e Device dropped from head n For system alignment procedures see Setting the Tape Parameter and Set ting the Skt 1 Parameter under the heading Setting Operational Parame ters in Chapter 3 of the Owner s Manual If the probe speed is too fast devices in the carrier tape become unsettled as a probe strikes a device during the pick routine If the probe speed is too slow throughput will suffer and device placement problems may occur Adjust the probe speed with power and pressurized air on Ensure that vac uum to all probes is disabled before starting this procedure The easiest way to ensure this is to cycle the power Part A 1 Load and align the device tape without peeling off the cover tape The Cover Tape Peel Bar and Spool will not be used Pinch point Moving mechanical parts Keep hands A away from moving parts The following procedures require the Robotics Cover to be removed while mechanical parts are in motion Use caution 2 Scroll to and select Robot Diagnostics 3 Scroll to and select Probe 1 4 Scroll to and select Speed The probe will move to the device pick point and cycle continuously 5 Read the speed that is now displayed in the screen M 10 The speed should be 140
50. nd Place Head Resetting the Pick Delay and Travel Delay Times The delay times do not change and do not usually require adjustment The factory set values are indicated in the following flow charts k Delay Factory setting is 250 ms Display error message Factory setting is 200 ms Part Present TRUE Factory setting is 250 ms Display error message Turn vacuum off No go to pick retry sequence not shown Place Delay Start Place No Display error message Yes No Y Extend Probe i Factory Apply Travel setting is delay 250 ms Yes No gt Display error message v Turn Vacuum off Apply Place delay Y Apply puff Y Raise probe Factory setting is 100 ms Apply Puff duration Y Turn puff off 1 Apply probe Travel delay Probe Up Yes Y go to Check Probe for Device not shown Factory setting is 130 ms Factory setting is 250 ms No Display error message Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Figure 32 Pick and Place Delay Flow Charts NOTE Changes to these values are not recommended These values only affect the internal verification delay time as indicated in the flow charts To reset delay times 1 From the top l
51. not severely 6 Disconnect two connectors belt motor wires and optical fiber amplifier wires by pinching the clasp open and pulling the connector apart Locating pin is visible after the conveyor is removed Figure 21 Conveyor Wire Connectors 7 Remove two screws attaching the Conveyor Module to the chassis For Conveyor screw loca 8 Lift the Conveyor Module free of RoadRunner chassis tions see Figure 20 Reinstalling the Conveyor Module To reinstall the conveyor reverse the removal steps plus perform the follow ing 1 Notice the conveyor locating pin on the chassis You may need to lift the Conveyor Module slightly to engage the pin 2 Check that no wires are pinched between the Conveyor and the chassis M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 29 M10 M 10 M 30 Service M 10 Conveyor Module Push probe here with finger 3 Set the conveyor height as follows 3a With the RoadRunner in its normal upright position and the con veyor fasteners snug but not tightened move the PNP Head by hand so it is over the conveyor belt 3b Place your thinnest device on the belt below Probe 1 3c Lower Probe fully pushing on the nut directly above the probe stem With the probe fully extended adjust the conveyor height so there is approximately a 1 mm gap between the probe tip and the device on the belt Then tighten the conv
52. o 425 867 6972 with your purchase order ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Ea Totals RR TAPE IN 12MM Tape In Module 12mm RR TAPE IN 16MM Tape In Module 16mm RR TAPE IN 24MM Tape In Module 24mm RR TAPE IN 32MM Tape In Module 32mm 7502296001 Tape In Adjustable RR SLOT SENSOR CAB Tape Advance Sensor Cable Assy RR SLOT SENSOR CAB Cover Tape Broken Sensor Cable Assy 5 5 65 Signature Date Company M 12 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Tape In Module Removing the Adjustable Tape In Module For the Standard Tape In Module see page M 15 1 Turn the power off 2 Disconnect the RoadRunner power cord and air supply 3 Remove the Robotics Cover and Lower Cover 4 Remove the two screws attaching the Tape Guide to the Adjustable Tape In ATT Module required only if exchanging the module you will reuse this same guide Position Locking Screw Tape Guide AR g Figure 5 The Adjustable Tape In Module with Tape Guide noted Unscrew the Position Locking Screw with a 4 mm hex key and lift the subassembly away from the Base as far as the wires allow Check that wire labels clearly marked and unplug the w
53. ocs dataio com Interface Manifold M 40 L Large Format RoadRunners M 1 M 65 LF see Large Format Lower Cover removing M 9 M Manifold pneumatic M 18 Modules pictured M 4 replaceable M 2 Motion Controller M 5 N NVRAM battery installing M 59 removing M 57 reteaching M 60 to M 61 P Pick and Place Head aligning M 39 ordering M 46 removing M 46 to M 47 Pick delay time M 43 Pick Sensor See End of Belt Sensor Pneumatic Module adjusting See Probe vacuum sensor reinstalling M 23 removing M 20 PowerCap Module see NVRAM battery Precisor M 74 Probe balancing speed M 39 raising speed M 41 speed specification M 40 speed adjusting M 39 vacuum sensor adjusting M 44 Probe Tip replacing M 67 M 71 Index 2 Data I O ProLINE RoadRunner Service Manual 096 0262 Index Programmer Module Travel delay time M 43 alignment M 52 Tube fittings M 21 alignment tool M 51 description M 48 reinstalling M 51 removing M 49 Puff duration M 43 Vacuum Sensor Probe adjusting M 44 R Reject Bin Warning electrical shock M 9 bracket M 35 Warranty work M 1 full sensor M 34 sensor removal M 35 Reteaching Head Positions M 60 X RoadRunner Models M 65 Robot I O Board M 68 M 72 XLF M 65 S Safety grounding iii precautions iii Self Service Spares Large Format M 72 Standard RoadRunner M 68 Serial Number location M 5 Service component overview figure M 4 replacing assemblie
54. odule may be ordered separately not part of kit Power Supply Module Figure 53 Parts in the Self Service Spares Kit Standard RoadRunner 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 Optional Call your local Data I O sale rep resentative for part prices or use our Web page for Requesting Quotes 5 E mail to OrderAdmin dataio com or FAX to 425 867 6972 with your purchase order ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Ka Totals RR PWR SWITCH Power Switch Rocker RR PWR SUPPLY Power Supply Module RR REJECT BIN SENSOR Reject Bin Sensor Cable Assy RR LIMIT SENSOR CABLE Head Limit Sensor Cable Assy RR SLOT SENSOR CABLE Slot Sensor Cable Assembly Tape RR OPTIC SENSOR Optical Sensor Fiber RR LINEAR MODULE Linear Stage Module 7502417001 Conveyor Module 7502423001 Programmer Module 7502327002 Programmer Module FC RR CTRL PNL MODULE Control Panel Module RR PCMCIA CABLE Control Panel Cable RR COVER TAPE MOD Cover Tape Module RR ROBOT I O COMM Robot I O Board Module RR FIBER OPTIC CA Amplifier Fiber Cable Assembly RR SMT COMM PORT Communications PCB
55. ollows 3a Extend and retract each probe to verify correct plumbing Robot Diagnostics Probe X Position Arrow Up Down 3b Enable vacuum to each probe to verify correct plumbing Robot Diagnostics Probe X Vac Sense Arrow Up Down Enable probe Puff and verify correct switching of positive air ME pressure at the probe tips Robot Diagnostics Probe 1 Puff For step 4 see Adjusting Up Down Arrow s UN 3d Check the operation of the Socket Actuator Robot Diagnostics dL ci Socket State Up Down Arrow For step 5 see Adjusting 4 Adjust the probe vacuum sensors and Balancing Probe 5 Adjust probe speed Speed on page M 39 Adjusting the Low Air Pressure Sensor The Low Air Pressure Sensor is part of the Pneumatic Module and is set at the factory to shut off the incoming air if the pressure drops below 4 48 Bars 65 psi If you are experiencing air pressure problems for example sockets Chapter 6 of the don t open this sensor can be adjusted as follows Owner s Manual has a Troubleshooting Chart that can direct you to adjustment proce dures for specific 1 Push the E Stop problems Electric shock hazard The following procedures To adjust the Low Air Pressure Sensor require the Electronics Cover s to be removed while power is on Only touch items described in the proce dures Use caution M 10 2 Remove the Electronics Covers Data I O
56. pocket to the probe If the probe is centered over the hole then the tape path is centered Replace the Probe tip you are done centering the tape path Otherwise continue Loosen the Position Locking Screw with a 4 mm hex key M 14 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Slot to assist in sliding the Alignment Block Position Locking Screw Access to the Alignment Block Locking Screw zi ge 10 11 Service M 10 Tape In Module Figure 7 Aligning the Adjustable Tape In Module Loosen the Alignment Block Locking Screw with a 2 mm hex key A small access hole is provided Slide the Alignment Block left to move the tape out or right to move the tape in as needed to bring the device tape in line with the probe A slot in the top of the Alignment Block accommodates a slotted screw driver to assist in sliding the block Tighten the Position Locking Screw Recheck alignment Tighten the Alignment Block Locking Screw Reinstall the Probe Tip Removing the Standard Tape In Module 1 2 For more information see Covers on page M 8 3 4 For the location of the chassis screws see Figure 4 3 Turn the power off Disconnect the RoadRunner power cord and air supply Remove the Robotics Cover and Lower Cover Remove the three or four screws depending on your model that con nect the Tape In Module to the chassis Lift the Tape In
57. power off slide the PNP Head along the entire length of the Linear Stage Check that the Head Flag small bracket on top the head clears the position sensors Verify electrical and pneumatic connections as follows 3a Connect the air hose and turn the power on 3b Verify that the head homes 3c Verify that the Position field at the keypad display toggles when each probe is lowered by hand Robot Diagnostics Probe X Position 3d Extend and retract each probe to verify correct plumbing Robot Diagnostics Probe X Position Arrow Up Down 3e Enable vacuum to each probe to verify correct plumbing Robot Diagnostics Probe X Vac Sense Arrow Up Down Adjust the Probe Vacuum Sensors Verify correct Probe Speed Perform the Aligning the Programmer Module procedure Reteach the robot the four operation parameters Tape Socket1 Reject and M 64 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service MI0 Spare Parts Kits Spare Parts Kits Model Kits of spares parts prevent long delays if you experience down time due to part wear or failure There are two types of spares kits a Basic Spares Kit and a Self Service Spares Kit The Self Service contains more parts and requires technicians who have attended an Advanced RoadRunner Service course to replace the components Each of these two spares kits is available for several different RoadRunner models Spare kits for o
58. purchase order ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Ea Totals PNP HEAD 4 PROBE Pick and Place Head RR VAC TIP Vacuum tip 4 57 mm OD 6070173006 PNP Head Bracket M 10 RR CHAMBER FLOATING BLOCK Vacuum Chamber Block Signature Date Company M 46 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M10 Pick and Place Head To remove the Pick and Place Head 1 Turn the power off 2 Disconnect the RoadRunner power cord and air supply 3 Remove the Robotics Cover 4 Label and disconnect the tube from the top of each probe 5 Remove two socket head cap screws attaching the head to the ball screw carriage 3 mm hex key For screw locations see Figure 33 on page M 44 Lightly pull the head a couple of centimeters away from the carriage 7 Label each of the four pneumatic tubes With a slotted screwdriver remove the pneumatic tubes with fittings from the back of the head Note that each has a washer Figure 35 The four fittings on the back of the PNP Head The PNP Head has been unbolted from the Linear Stage Module 8 Remove two Head Bracket screws from each side of the head 2 mm hex key Tube Fitting and Gasket To reinstall a PNP Head reverse the steps for removal and perform the fol lowing 1 Install the four fittings onto the new head the tu
59. re ties as necessary 9 Remove three socket head screws securing the Reject Bin Bracket to the chassis and lift it out Reject Bin Full gt gt 3 Sensors Reject Bin Present Sensor Interconnect Panel Figure 26 Reject Bin Sensors and Bracket Screw Locations 10 Unscrew one screw through each sensor to remove the sensor NOTE The Reject Bin Full Sensor consists of two sensors They should be replaced as a set To install the Reject Bin Full Sensor reverse the removal procedures e Reinstall the Sensors and the Reject Bin Bracket prr e Reinstall the Conveyor Module Set the Conveyor height as described in or reinstalling the dp Conyejor Moule d s BOUE the Conveyor Module M 10 page 29 e Reinstall the Lower Cover Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 35 M10 M 10 Service M10 Control Panel Module Control Panel Module Witnditren a Figure 27 Control Panel Module The Control Panel Module consists of the PC Card Drive the Stop button the Indicator Lamps Control Panel buttons and LCD screen If any of the components in the Control Panel Module are not operating correctly check the wiring connections and the condition of the PC Card Trouble with PC Cards is often because the card has become corrupt or was incorrectly formatted must be FAT 16 not FAT 32 Test the PC Card Drive with a card th
60. rge Format RoadRunner Cover Tape Reel Serial No Reject Bin Assy Vacuum Tips amp Vacuum Chamber Blocks 0 Air Inlet Tube Assembly Vacuum Filters M10 Figure 54 Parts in the Basic Spares Kit Large Format RoadRunner Two spare parts kits are available for the Large Format RoadRunner Parts in the Basic Spares Kit are listed below For the larger kit Self Service Spares Kit see page M 72 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 Optional Call your local Data I O sale rep resentative for part prices or use our Web page for Requesting Quotes 5 E mail to OrderAdmin dataio com or FAX to 425 867 6972 with your purchase order Lighter colored items are for the Large Format models only ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Ea Totals RR VAC TIP Probe Tip RR VAC FILTER Vacuum Filter RR ASSY AIR TUBE Air Inlet Tube Assembly ASSY REJECT BIN RR uC Reject Bin Assy Large Format RR SLEEVE TAKEUP WHEEL6HL Cover Tape Take Up Reel 6 Holes RR CHAMBER FLOATING BLOCK Vacuum Chamber Block RR FILTER AIR 1 4 3 8 Filter Air 14 3 8 RR FILTER MIST SEP 1 4 3 8 Filter Mist separator M 10 RR SP
61. roller Cable connector is hidden under the ribbon cable T f gt T y 4 Figure 38 Cable Connectors and PCMCIA PCB fasteners 17 Disconnect the air tube from the Programmer Module at the Flow Con trol It is a one touch fitting 18 Disconnect the Programmer Module s Actuator Position Sensor Cable J5C from the Cable Interconnect Panel Cut the cable ties M 50 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Programmer Module Actuator Position Sensor Cable J5C Air tube connects to this Am n oat Programmer Flow Control Figure 39 Cable Interconnect Panel Cables J3 and J4 have been unplugged 19 Remove four button head socket screws attaching the Programmer Module to the chassis Figure 40 Location of Programmer Screws 20 Lift the Programmer Module out from the chassis Reinstalling the Programmer Module To reinstall a Programmer Module perform the following steps M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 51 M10 M 10 Service M 10 Programmer Module 3 4 5 6 Plug the Ethernet Cable RJ45 Motion Control Cable into the left side of the Module Reinstall a Programmer Module ensuring that no wires or hoses are pinched and tighten the four screws Reconnect the air tube Reinstall all cable connectors Plug in the PCMCIA PCB and install the four screws Reins
62. s M 1 SMT machines supported M 1 Socket Adapter M 74 wear M 48 Spare parts see Basic Spares or Self Service Spares Spares Kits models of M 65 Standard Tape In Module See Tape In Module T Tape In Module aligning M 16 jamming M 12 ordering parts M 12 removing M 15 Tape In Module Also see Adjustable Tape In Module Throughput M 39 Time Settings M 61 Training M 69 M 73 Data I O ProLINE RoadRunner Service Manual 096 0262 Index 3 Index X4 Index 4 Data I O ProLINE RoadRunner Service Manual 096 0262 Sales and Technical Support World Wide Data I O Corporation o Redmond WA USA 98052 ne om 4 Telephone 1 425 881 6444 inside US 1 800 332 8246 USA Fax 1 425 867 6972 Contact Data I O World Wide Support or your local representative To find your local representative on our Web site go to http Awww dataio com and click Contact Us 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 China Germany Support support dataio com support dataio com support dataio com Sales salesDIOAmerica dataio com ChinaSales dataio com salesgmbh data io de When calling or writing please provide the following information RoadRunner Serial number e Software Version displayed on the keyboard screen at start up turn the power off and then on again
63. secured with two screws is on the back hous ing flange See Figure 15 8 Unscrew the two screws from the 25 pin cable connector and unplug the connector from the manifold bracket 3 6 Remove the Pneumatic Access Cover 7 Disconnect the Pneumatic Manifold Supply Line at the One touch con nector on the manifold Probe Air Lines Pneumatic Manifold Supply Line One touch Connector 25 Pin Connector two 1 5mm Allen fasteners Access hole to the other fastener Figure 15 Location of the Pneumatic Manifold Supply Line and Wiring Connector 9 Remove the three screws securing the Pneumatic Module to the RoadRunner chassis See figure below m 4 Figure 16 Pneumatic Module fastener locations The Probe Vacuum Tubes have been disconnected To identify tubing lines see Figure 14 and Figure 15 10 Lift the Pneumatic Module enough to remove the four Probe Air Tubes and the Socket Actuator Air Tube one touch fittings M 22 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Pneumatic Module 11 Lift the Pneumatic Module free from the RoadRunner chassis Reinstalling the Pneumatic Module Installation is done in the reverse order of removal then the following post installation adjustments are required 1 Reconnect the power and pressurized air 2 Switch the power on 3 Control Panel verify proper electrical and pneumatic connec tions as f
64. tall the Reject Bin Align the Programmer Module as described below before completing rein stallation Aligning the Programmer Module Align the Programmer Module as follows Programmer CAUTION Chassis can get damaged Loosen the Programmer Module mounting screws two upper screws refer to Figure 40 before each attempt to adjust the Programmer Alignment Screws refer to Figure 42 Install the Programmer Alignment Tool sales part number is GRAMMER ALIGNMENT TOOL onto the Programmer Module in place of a Socket Adapter Remove the rubber tip from Probe 1 the far left probe and extend Probe into the alignment tool hole 1 If the probe passes through the hole easily then the left side of the programmer is properly aligned skip to step 3 M 52 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Programmer Module 2a If Probe 1 does not pass through easily loosen the upper left Pro grammer Module mounting screw two revolutions See figure below 2b Adjust the left Position Alignment set screw adjacent to the mounting screw with a 2 mm hex key so that the probe does pass through easily Turn the screw clockwise to move the module away from the chassis 2c When done tighten the upper left Programmer Module screw Ref Upper mounting screw hole 4 gt _4 Figure 42 Programmer Module Alignment Screws the screw on the left s
65. ther versions may have become available since the printing of this manual Use the Sales Num bers below to order your spares kit or contact Data I O Sales Spares Kits for Specific Models Basic Spares Kit Sales Number Self Service Spares Sales Number Standard FC III RR SPARES KIT M10 RR SELFSV SPARES FC3 M10 Standard FC II same as FC III RR SELFSV SPARES FC2 M10 Large Format RR SPARES KIT LF M10 Contents of some of the kits are listed on the following pages Some Differences of the Specific Models FlashCORE III FC III is the latest programming architecture for the stan dard RoadRunner at time of printing this manual Large Format LF RoadRunner is for programming devices whose length is larger than 15 mm and or height thickness is larger than 3 mm NOTE The LF RoadRunner picks and places with only two probes at a time to accommodate the larger devices Model Maximum device size Length mm Width mm Height mm Standard 15 21 65 3 Large Format LF 24 21 65 6 XLF 32 22 6 1 XLF model is not covered in this manual On RoadRunner device width is perpendicular to the direction of device tape travel M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 65 Service M 10 Basic Spares Kit Standard RoadRunner Basic Spares Kit Standard RoadRunner Cover Tape Reel Serial No Reject
66. tinue turning the screw 1 2 to 1 more revolution clockwise 2c Test the setting by blocking air at the probe tip with your finger The LED should illuminate Adjust if necessary 3 Select Menu until you reach the top menu level again and select Robot Diagnostics 3a Scroll to and select Probe 1 3b Scroll to and select Vacuum 3c Press the Down Arrow to disable the probe 4 Repeat steps 1 through 3 for each probe 5 Re install the Cover when finished M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 45 Service M10 Pick and Place Head Removing the PNP Head Mounting Screws Figure 34 Removing the PNP Head M10 If you receive error messages relating to the Pick and Place function refer to the troubleshooting chapter in the Owner s Manual If you experience trouble with the Pick and Place Head that is not covered in this manual remove the head and send it to Data I O Customer Service for repair or replacement Removal procedures are on the following page 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 Optional Call your local Data I O sale rep resentative for part prices or use our Web page for Requesting Quotes 5 E mail to OrderAdmin dataio com or FAX to 425 867 6972 with your
67. ule RR ROBOT I O COMM Robot I O Board Module RR FIBER OPTIC CA Amplifier Fiber Cable Assembly RR SMT COMM PORT Communications PCB RR PNEUMATIC MODULE Pneumatic Module RR DIAGNOSTICS BOARD Diagnostics Adapter Board DAB PROGRAMMER ALIGNMENT TOOL Programmer Alignment Tool Signature Date Company Choose one Programmer Module or M 72 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M 10 Self Service Spares Kit Large Format RoadRunner The Self Service Spares Kit for Large Format RoadRunner contains parts listed on page M 72 It is available to those who have attended an Advanced RoadRunner Service course Customer Training For information about advanced training contact the Data I O Customer Service Center training course may be ordered when purchasing a RoadRunner or at a later time NOTE This manual does not list replacement instructions for all the parts in the Self Service Spares Kit For additional information contact Data I O or your nearest authorized representative To find your nearest representative see the instructions on the last page of this manual M 10 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 M 73 M10 M 10 Service M 10 Socket Adapter Actuator and Precisor Socket Adapter Actuator and Precisor Precisor Actuator Plate Socket
68. utes Robot Diagnostics gt Run Mode gt Dry Run The entire Conveyor Module can be removed and replaced or sent to Data I O for repair The End of Belt sensor optic can be adjusted and the Optical fiber Amplifier retaught 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 Optional Call your local Data I O sale rep resentative for part prices or use our Web page for Requesting Quotes 5 E mail to OrderAdmin dataio com or FAX to 425 867 6972 with your purchase order ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Ea Totals 7502417001 Conveyor Module SIPLACE X 7502417001 Conveyor Module MYDATA Signature Date Company M 28 Data I O ProLINE RoadRunner Service Manual 096 0262 updated MAR2010 Service M10 Conveyor Module Removing the Conveyor Module 1 Turn the power off 2 Disconnect the RoadRunner power cord and air supply 3 Lift off the Robotics Cover 4 Remove Conveyor Module Cover For more information see 5 Cutthe cable ties securing the wires for the belt motor and sensors Removing the Conveyor Module Cover on page M 10 CAUTION Optic cables are fragile and may break Use care to bend only gradually and gently
69. vice M10 Pick and Place Head Adjusting Probe Raising Speed NOTE Probe lowering speed should be set first See Adjusting and Balancing Probe Speed on page M 39 If the probe raising speed is too fast devices may rotate excessively after a pick operation and cause alignment problems devices may even fall off the probes It could also bend the motion limit pin on the PNP Head To adjust the probe raising speed c 1 Load and align the device tape without peeling off the cover tape The For more information See Loading Device lape and Aligning the of the Owner s Manual Pinch point Moving mechanical parts Keep hands A away from moving parts The following procedures require the Robotics Cover to be removed while mechanical parts are in motion Use caution Cover Tape Peel Bar and Spool will not be used 2 Scroll to and select Robot Diagnostics 3 Scroll to and select Probe 1 4 Scroll to and select Speed The probe will move to the device pick point and cycle continuously Probe Raising Speed flow controls are in the lines Probe Lowering Speed flow controls are on the Interface manifold and require a screw driver to adjust Figure 31 The in line flow controls for adjusting the Probe Speed Probe numbers are stamped on the manifold 5 Watch the probe to observe the probe raising speed The probe should be fully up the very instant that the head jogs back and forth a couple M 10
70. wer cord to RoadRunner 2 Switch the power on 3 Insert a PC card with Supervisor Authority into RoadRunner For help on setting Supervisor Authority open TaskLink and click Help gt Help Topics gt Menus gt Tools Menu gt Set Administrator Privileges gt How to Set Adminis trative Privileges 4 Press the Menu button on the RoadRunner Control Panel Head Positions 1 Teach the Tape pocket position see Setting the Tape Parameter in Chapter 3 of the Owner s Manual 2 Teach the Socket 1 position see Setting the Skt 1 Parameter in Chapter 3 of the Owner s Manual 3 Teach the Reject Bin position see Setting the Reject Parameter in Chapter 3 of the Owner s Manual 4 Teach the Belt position see Setting the Belt Parameter in Chapter 3 of the Owner s Manual Network Values T If your RoadRunner is networked to a computer with TaskLink you need to configure the network settings again The RoadRunner IP Pro grammer Port Prog Port Subnet Mask Sub and Gateway GTW are listed in the RoadRunner menu under System gt Network 1 pee M 10 Use the Network Wizard in TaskLink Tools gt Create Network Configuration Card to create a Network Configuration card Generally the previous network values are automatically inserted except a zero or a dummy number will be placed into the IP address field Enter data for the IP address Programmer Port Subnet Mask and Gateway When done click

Service Manual for SIPLACE X & MYDATA SMTs

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Service Manual for SIPLACE X &amp; MYDATA SMTs

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Service Manual for SIPLACE X & MYDATA SMTs