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ProLINE-RoadRunner Service Manual

1. 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 U 22 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal Cover Tape Module Removing the Cover Tape Module 1 Turn the power off Unplug the RoadRunner power cord Remove the Robotics Cover Remove the tape reel from the Cover Tape Module a JS a N Remove the three screws that mount the Cover Tape Module to the RoadRunner chassis Take Up Reel Cover Tape Module screws Ca Figure U 18 Location of the Cover Tape Module Mounting Screws with the Reel Removed 6 Disconnect the cable from the Cover Tape Module motor 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 Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO7 U 23 Service Universal e Conveyor Module Conveyor Module Mounting Screws Sensor Optic Cables Feeder Communication Cable and Motor Wires Figure U 19 Location of Wires and Screws on the Conveyor Module The conveyor belt the belt
2. 7 Unplug the PCMCIA Card Drive ribbon cable the Control Panel Rib bon Cable and the wires for the Emergency Stop button Keyboard Interface connector Mounting Screws 2 places CG emtcttistiiiian seia a PCMCIA card ie Der Miliscitee he RR drive cable H bites tithe connector Emergency Stop Button connector Figure U 31 Location of Connectors and Screws on the Control Panel 8 Remove the screws securing the Control Panel Module to the RoadRunner chassis Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U 35 Service Universal e Control Panel Module 9 Remove the Control Panel Module Replacement is the in the reverse order of removal When reassembled verify the proper operation of the the following e Card Reader and indicator lamps e Display e Keypad e Emergency Stop U 36 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO07 Service Universal 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 the PNP Head Adjusting and Balancing Probe Speed L g See Loading Device Tape and Aligning the Device Tape in Chapter 3 of the Owner s Manual Since device placement tolerance is small the PNP head may need aligning when a module is replaced or repaired The head may also
3. Figure U 58 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 theProLINE 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 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 NOTE For items not found here check the RoadRunner Owner s Manual A Adjustable Tape In Module aligning U 12 removing U 11 Air Filters description U 16 ordering U 16 replacing U 17 Air Paths keeping clean U 16 B Basic Spares Kit Lar
4. RR FILTER MIST SEP 1 4 3 8 Filter Mist separator RR SPARES KIT LF U UG Spares Kit uC GSM GE N all above Signature Date Company U 68 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal 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 on 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 Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO7 U 69 Service Universal e Self Service Spares Kit Large Format RoadRunner Self Service Spares Kit Large Format RoadRunner Head Limit Sensor Linear Stage Module Control Panel Module Reject Bin Conveyor Module Amplifier Fiber Cable Assembly Cover Tape Module Robot UO Board Optic Sensor Fibe
5. Air Inlet Tube Assembly Vacuum Filters Vacuum Chamber Blocks O Reject Bin with Reject Slide Pra Dust Cover Communication Cable Assembly Figure U 56 Parts in the Basic Spares Kit Large Format RoadRunner Two spare parts kits are available for the Microntroller RoadRunner Parts in the Basic Spares Kit are listed below For the larger kit Self Service Spares Kit see page U 70 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 your local Data I O sale representative 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 Sales Part Number Part Description Qty Price Ea Totals RR VAC TIP Probe Tip RR VAC FILTER Vacuum Filter RR COVER DUST U OR A Conveyor Dust Cover RR ASSY AIR TUBE Air Inlet Tube Assembly ASSY REJECT BIN RR uC Reject Bin Microcontroller RR SLEEVE TAKE UP WHEEL SLTD Cover Tape Take Up Reel Slotted RR SLEEVE TAKE UP WHEEL 6 HL Cover Tape Take Up Reel 6 Holes RR CHAMBER FLOATING BLOCK Vacuum Chamber Block RR CABLE COMM U Communications Cable Assy RR FILTER AIR 1 4 3 8 Filter Air 14 3 8
6. 4 S 6 Disconnect the RoadRunner power cord and air supply Lift off the Conveyor Dust Cover Remove the Conveyor Module Cover Remove two screws securing the Pin Block to the chassis Unplug the Feeder Communications Cable connector able Connector Right Side View Pin Block Screws Left Side View Figure U 20 Feeder Communications Cable 7 Push the Pin Block inside the chassis and remove the cable Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO07 U 25 Service Universal e Conveyor Module Removing the Conveyor Module 1 Turn the power off 2 Disconnect the RoadRunner power cord and air supply 3 Lift off the Conveyor Dust Cover to 4 Remove the Conveyor Module Cover For more information see 5 Cut the tie wraps securing the wires for the belt motor communications Removing the Conveyor and sensors Module Cover on page U 8 CAUTION Optic cables are fragile and may break Do not bend radically 6 Disconnect two connectors belt motor wires and Optical fiber Ampli fier wires Figure U 21 Conveyor Wire Connector Locations Circled Va 7 Remove the two screws attaching the Conveyor Module to the chassis ti E Convey or screw loca Lift the Conveyor Module free of the RoadRunner chassis tions see Figure U 19 Reinstalling the Conveyor Module To reinstall the conveyor reverse the removal steps plus perform the follow ing 1 Notice the lo
7. Actuator Plate 2 Plug in 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 the PNP Head from mov ing Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U S1 Service Universal Programmer Module U 52 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 NOTE Your RoadRunner may have a flow control that can be adjusted by hand or it may require a straight screwdriver 6 A Ge Locate the Programmer Flow Control and adjust it counter clockwise to full open then turn it clockwise 2 1 2 revolutions At the Control Panel press Menu Then scroll to and select Robot Diagnostics gt Socket gt 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 Actuate the programmer and watch the speed Adjust the Flow Control and retry if the actuator appears to hit the sockets too hard Use the Flow Control to soften the impact However too slow will cause timing prob lems as we
8. KIT STD U UG Spares Kit GSM or GEN all above Signature Date Company U 64 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO07 Service Universal 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 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 Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO7 U 65 Service Universal Self Service Spares Kit Standard RoadRunner Self Service Spares Kit Standard RoadRunner Control Panel Module Cover Tape Module Robot I O Board Communication PCB Power Switch Power Supply Module Head Limit Sensor Module amp Alignment Tool Reject Bin Linear Stage Module Conveyor Module Optic S
9. Slide Dust Cover Communication Cable Assembly Air Inlet Tube Assembly Vacuum Filters Figure U 54 Parts in the Basic Spares Kit Standard RoadRunner Two spare parts kits are available for the Standard RoadRunner Parts in the Basic Spares Kit are listed below For the larger kit Self Service Spares Kit see page U 66 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 your local Data I O sale representative 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 Sales Part Number Part Description Qty Price Ea Totals RR VAC TIP Probe Tip RR VAC FILTER Vacuum Filter RR COVER DUST U OR A Conveyor Dust Cover RR ASSY AIR TUBE Air Inlet Tube Assembly RR ASSY REJECT BIN Reject Bin RR SLEEVE TAKE UP WHEEL SLTD Cover Tape Take Up Reel Slotted RR SLEEVE TAKE UP WHEEL 6 HL Cover Tape Take Up Reel 6 Holes RR CHAMBER FLOATING BLOCK Vacuum Chamber Block RR CABLE COMM U Communications Cable Assy RR FILTER AIR 1 4 3 8 Filter Air 14 3 8 RR FILTER MIST SEP 1 4 3 8 Filter Mist separator RR SPARES
10. U 44 Programmer Module U 46 Removing the Programmer Module U 47 NVRAM Battery U 54 Removing the NVRAM Battery U 55 Installing a new NVRAM Battery U 57 Reinstalling Components U 57 Reteaching the NVRAM U 58 Linear Stage Module U 60 Removing the Linear Stage Module U 61 Spare Parts Kits U 63 Basic Spares Kit Standard RoadRunner U 64 Replacing the Probe Tips U 65 Replacing the Air Inlet Tube Assembly U 65 Self Service Spares Kit Standard RoadRunner U 66 Basic Spares Kit Large Format RoadRunner U 68 Replacing the Probe Tips U 69 Replacing the Air Inlet Tube Assembly U 69 Self Service Spares Kit Large Format RoadRunner U 70 Socket Adapter Actuator and Precisor U 72 Alphabetical Index Index 1 Data I O e ProLINE RoadRunner Service Manual e 096 0252 Precautions for Safe Operation EN Electrostatic Discharge The circuit boards inside RoadRunner are suscepti ble to electrostatic discharge ESD which can damage the circuitry Also devices processed through the Roa dRunner are very sensitive to static and can be dam aged by accidental electro static 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 The RoadRunner System has been designed for safe and efficient opera
11. 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 Finish Then remove the PC card and insert the card into the target RoadRun ner Scroll to and select System gt Network gt Network Parm Press the Down Arrow to change Network Parm to Card Cycle the power on RoadRunner Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO07 Service Universal e NVRAM Battery Reteaching the Time settings To set the time 1 2 3 Press the Menu button In the top level memu scroll to and select System gt Time Scroll to Hour Set to the correct hour as follows e Press Select e Adjust number with the Up Arrow or Down Arrow e Press Menu to save Scroll to each remaining parameter Minutes Month Day Year and set in the same manner Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO7 U S59 Service Universal e Linear Stage Module Linear Stage Module Electric Motor PNP Head the precisor Rail and and Encoder is still attached Ball Screw Cable Carrier Figure U 51 The Linear Stage Module The Linear Stage part of the Robotic System consists of a rail and ball Ce 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 U 44 Da
12. chassis 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 e Ifyou 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 To center the tape path under the PNP probes 1 Load a piece of empty device tape into the Adjustable Tape In ATI Module Move the PNP Head so that Probe 1 is directly over the pick point Remove the PNP Head Cover by pulling it off Remove the rubber Probe Tip from Probe 1 Sch a Je 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 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 6 Loosen the Position Locking Screw U 12 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Slot to assist in sliding the Alignment Block Position Locking Screw Access to the Alignment Block Locking Screw Ee Service Universal Tape In Module Figure U 7 Aligning the Adjustable Tape In Module Loosen the Alignment Block Locking Screw with a 2 mm Allen Wrench A small access hole is provided S
13. 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 RR COVER CONVEYOR U OR A Conveyor Module Cover ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Ea Totals RR ROBOTICS COVER F U A Robotics Cover COVER PNP PNP Head Cover RR LOWER COVER Lower Cover RR COVER DUST U OR A Conveyor Dust Cover Signature Date Company Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal 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 pin 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 PNP Head Cover The PNP Head Cover is magnetically attached to the head and pulls off To replace it set it over the head and rock it until the metal ridges on the inside of the cover seat into notches on the head Removing the Lower Cover 1 Turn the power off 2 Disconnect the RoadRunner power cord and air supply NOTE The RoadRunner pressurized air sup
14. 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 Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO7 U 17 Service Universal e Pneumatic Module D M Thumbscrew Housin 9 Filter Locating Pins Gasket Ensure that the gasket does not fall out during removal or installation of the housing Figure U 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 L g The RoadRunner 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 GC For more information see Removing the Lower Cover on page U 7 GC For the location of Probe vacuum lines see Figure U 14 A MMN Turn the power off Disconnect the RoadRunner power cord and air supply Pull off the Robotics Cover Remove the Lower Cover NOTE The vacuum lines and air pressure lines must be reinstalled to their same locations Do not
15. 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 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 Call your local Data I O sale representative 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 Sales Part Number Part Description Qty Price Ea Totals RR ASSY CONV ADJ UNIV Conveyor Module RR CABLE COMM U Feeder Communication Cable ASSY ADJ TENS CNVR UNIVER Conveyor Module Microcontroller SAL RR uC Signature Date Company U 24 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal e Conveyor Module Removing the Communications Cable i See Removing the Con veyor Module Cover on page U 8 1 Turn the power off 2 3
16. need aligning if any of the following error messages are displayed e Device pick failure at input with probe n e Device pick failure on probe n e Device dropped from head n For head alignment procedures see Setting the Tape Parameter and Set ting the Skt 1 Parameter under heading Setting Operational Parameters 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 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 The speed should be 140 4 If it needs adjustment skip to step 8 If it does not need adjustment 5a Press Menu Data I O e ProL
17. reverse them Ensure that each line has a label before disconnecting n 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 To reconnect simply insert the tube into the housing sleeve pushing it all the way in U 18 Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 Service Universal e Pneumatic Module Push Down Pull Out Figure U 13 Disconnecting a Pneumatic Tube from the One touch Connector Probe Vacuum Lines Figure U 14 Location of Vacuum and Air Lines Va The pneumatic access 6 Remove the Pneumatic Access Cover cover secured with two 7 Disconnect the Pneumatic Manifold Supply Line at the One touch con screws is on the back hous nector on the manifold ing flange See Figure U 15 Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO7 U 19 Service Universal e Pneumatic Module 8 Unscrew the two screws from the 25 pin cable connector and unplug the connector from the manifold bracket 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 U 15 Location of the Pneumatic Manifold Supply Line and Wirin Connector 9 Remove the three screws securing the Pneumatic Module to the Road
18. sensor optic 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 Figure U 24 Testing the End of Belt Sensor The Conveyor Cover need not be removed U 28 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 W The Optic fiber Amplifier is mounted to the chassis under the Conveyor Mod ule End of Belt Sensor Optic End of Belt _ Optical fiber Amplifier Service Universal e Conveyor Module If Pick Sensor is not displayed when the beam is blocked check to make sure that all the sensor wires and fiber optics are connected prop erly 6a If Pick Sensor 1 still does not display then the Conveyor Module needs to be replaced 6b If Pick Sensor 1 does display see Reteaching the End of Belt Optical fiber Amplifier below Reteaching the End of Belt Optical Fiber Amplifier 1 2 3 WE For details on setting the Optical fiber Amplifier see the label on the inside of the Conveyor Cover shown in Figure U 26 Lift off the Conveyor Dust Cover Remove the Conveyor Module Cover Press the Emergency Stop button the conveyor belt can now be rotated by hand Clean the conveyor belt With isopropyl alcohol on a lint free cloth clean the exposed portion of the belt and then dry it Rotate the belt and repeat Manually rotate the belt so that the optical fiber amplifier
19. E See Cable JSC in Figure U 41 U 48 17 18 19 See Unplug the Ribbon Cable J4 from the Programmer Module Unplug the Cable J3 from the Programmer Module Remove the PCMCIA Cable PCB by removing four socket head cap screws and lifting up on the PCB Set it aside the cable is still attached Unplug the Motion Controller Cable 709 0560 from the left side of the Programmer Module If equipped unplug the Ethernet Cable 701 3215 from the left side of the Programmer Module adjacent to the Motion Controller Cable PCMCIA Cable PCB Tape Path Bracket Figure U 40 Cable Connectors and Fastener Locations for Tape Path Bracket arrows and PCMCIA Cable PCB circles Remove three screws from the Tape Path Bracket and lift out the bracket Disconnect the air tube from the Programmer Module at the Flow Con trol It is a one touch fitting Disconnect the Programmer Module s Actuator Position Sensor Cable J5C from the Cable Interconnect Panel Cut the cable ties some models only Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal e Programmer Module Actuator Ki kb At a R Position Sensor hh a Cable J5C Air tube p e connectos to S this Programmer V Flow Control Figure U 41 Cable Interconnect Panel Cables J3 and J4 have been unplugged 20 Remove four button head socket screws attaching the Programm
20. INE RoadRunner Service Manual 096 0252 updated DECO7 U 37 Service Universal Pick and Place Head U 38 5b Scroll to and select the next probe 5c Repeat from step 4 for each probe 6 Remove the Lower Cover and the Conveyor Module Cover 7 Locate the Interface Manifold it is mounted on the chassis below and to the right of the Reject Bin Your model may have locknut rings on the flow controls which must be loosened before flow adjustment Flow Control adjustment stem for Probe 1 Figure U 32 Interface Manifold Adjustment stems may have thumbscrews or slots for screwdriver 8 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 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 13 Repeat steps 4 and on for the next probe 14 When finished see Adjusting Probe Raising Speed some models or replace both covers and remove the device tape Adjusting Probe Raising Speed NOTE Probe lowering speed should be set first See Adjusting and Balancing Probe Speed on page U 37 If the probe raising speed is too fast devices may rotate excessively after a pick operation and cause alignment prob
21. Runner chassis Figure U 1 6 Pneumatic Module fastener locations The Probe Vacuum Tubes have been Disconnected GC 10 Lift the Pneumatic Module enough to remove the four Probe Air Tubes To identify tubing lines see and the Socket Actuator Air Tube one touch fittings Figure U 14 and Figure U 15 11 Lift the Pneumatic Module free from the RoadRunner chassis U 20 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal e Pneumatic Module Reinstalling the Pneumatic Module Installation is done in the reverse order of removal then the following post installation adjustments are required 1 At the Control Panel verify proper electrical and pneumatic connec tions as follows la Extend and retract each probe to verify correct plumbing Robot Diagnostics Probe X Position Arrow Up Down 1b Enable vacuum to each probe to verify correct plumbing Robot Diagnostics Probe X Vac Sense Arrow Up Down lc Enable probe Puff and verify correct switching of positive air pressure at the probe tips Robot Diagnostics Probe I Puff Up Down Arrow 1d Check the operation of the Socket Actuator Robot Diagnostics Socket State Up Down Arrow For step 2 see Adjusting EE Probe Vacuum Sensors on 2 Adjust the probe vacuum sensors page U 42 3 Adjust probe speed For step 3 see Adjusting and Balancing Probe Speed on page U 37 D
22. Runners 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 Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO7 U 1 Service Universal Replaceable Modules Replaceable Modules Replaceable modules include e Tape In Module e Pneumatic Module e Conveyor Module e Cover Tape Module e Control Panel Module e PNP Head subassembly e Linear Stage Module e Programmer Module with PNP Head KR 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 correspond to the latest interchangeable replacement Some of the tools required are Metric hex keys Allen wrenches e a volt meter or multi meter and a metric scale or calipers CAUTION Electrostatic dis
23. To Table of Contents SSG A EH ProLINE RoadRunner Service Manual for Universal GSM amp Genesis GSM supports Placement Machines GSM1 and GSM2 Genesis supports Placement Machine Genesis Data PN 096 0252 002 For installation operation maintenance and troubleshooting see the ProLiNE RoadRunner Owner s Manual Data I O has made a conscientious effort 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 IO Corporation Data I O order forms may be reproduced for internal use only Data IO is a registered trademark of Data I O Corporation 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 their efforts and for supporting the flow of information into this manual We are intere
24. ape In Module RR SLOT SENSOR CAB Tape Advance Sensor Cable Assy RR SLOT SENSOR CAB Cover Tape Broken Sensor Cable Assy RR TAPE IN 32MM LF Kit Tape In Module Large Format Signature Date Company U 10 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal Tape In Module Removing the Adjustable Tape In Module For the Standard Tape In Module see page page U 12 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 ATI Module required only if exchanging the module Position Locking Screw Tape Guide 9 H i KA Figure U 5 The Adjustable Tape In Module in Unscrew the Position Locking Screw and lift the subassembly away from the Base as far as the wires allow a Check that wire labels are clearly marked and unplug the wires for the 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 Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U 11 Service Universal e Tape In Module 8 Lift the Base from the
25. ape In Module Screws circled The Tape In Module uses a sensor to determine if the cover tape is present or broken and another to send sprocket motion feedback to the system control ler The Tape In Module advances the device tape If the device tape is jamming in the sprocket or tape path there could be a problem with the Tape In Module Refer to the Troubleshooting chapter to identify the problem If the problem is the Tape In Module remove it and return it to Data I O for repair or replacement 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 Call your local Data I O sale representative 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 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 RR TAPE IN KIT ADJUSTABLE Kit Adjustable T
26. are stamped on the manifold 5 Watch the probe to observe the probe raising speed The probe should wl be fully up the very instant that the head jogs back and forth a couple millimeters For more information see Covers on page U 6 If the probe is fully up too soon before the head jogs or too late after the head jogs remove the Lower Cover and the Conveyor Module Cover Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO7 U 39 Service Universal Pick and Place Head 6 Loosen the locknut ring on the Probe Speed Flow Control for Probe 1 or current probe on the Interface Manifold 7 Manually adjust the speed by hand using the knob on the in line flow control for Probe raising speed see figure above Adjust the probe raising speed until it synchronizes with the head jog 8 Tighten the locknut ring 9 Press Menu to deselect the current probe 10 Scroll to and select the next probe 11 Repeat these steps from step 4 and on for each probe 12 When finished replace both covers and remove the device tape U 40 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO07 Pic Part on Tip No Turn Vacuum On Extend Probe Yes Part Present No y Raise probe Apply Travel delay Probe Up Yes Yes Yes Display error message Service Universal Pick and Place Head Resetti
27. assemblies U 1 SMT machines supported U 1 Socket Adapter wear U 46 Spare parts U 66 locating U 64 U 68 Microcontroller U 70 ordering U 68 ordering U 64 Spares Kits U 63 Standard Tape In Module See Tape In Module T Tape In Module aligning U 14 jamming U 10 ordering parts U 10 removing U 13 Tape In Module Also see Adjustable Tape In Module Throughput U 37 Data I O e ProLINE RoadRunner Service Manual e 096 0252 Index e R Time Settings U 59 Training U 67 U 71 Travel delay time U 41 Tube fittings U 19 U Communications Cable U 24 V Vacuum Sensor Probe adjusting U 42 W Warning electrical shock U 7 Warranty work U 1 Index 3 Index e W Index 4 Data I O e ProLINE RoadRunner Service Manual e 096 0252 Sales and Technical Support World Wide Data I O Corporation 6464 185th Avenue N E Suite 101 Redmond WA USA 98052 Telephone 425 881 6444 inside US 1 800 332 8246 Fax 425 867 6972 E mail support dataio com Contact Data I O World Wide Support or your local representative To find your local representative on our Web site go to http www 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 United States China Germany When calling or writing please provide the following information e RoadRunner Serial number e Software Ver
28. ata I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U 21 Service Universal e Cover Tape Module Cover Tape Module Take Up Reel pins Tape Broken Roller with Sensor hidden ad i pn s Figure U 1 7 Cover Tape Tensioning the Tape Broken Roller and Sensor 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 Check for these e loose reel not seated on the pins e loose or broken drive belt e malfunctioning motor e malfunctioning clutch assembly or e a motor connector that is loose or disconnected If the problem is the motor or drive belt then the Cover Tape Module needs to be replaced and 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 Call your local Data I O sale representative 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
29. cating pin on the chassis for location er 2 Set the conveyor height as follows Push probe here with finger 2a With the RoadRunner in its normal upright position and the con o o mp g veyor fasteners in but not tightened move the PNP Head over the conveyor belt 2b Place your thinnest device on the belt below Probe 1 U 26 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DEC07 Service Universal e Conveyor Module 2c Lower Probe fully pushing on the block below the spring Adjust the conveyor height so that the probe tip just barely con tacts the device on the belt then tighten the fasteners 2d Recheck the height after tightening the fasteners Adjusting the Conveyor Drive Belt Notched Only Your RoadRunner model may have a conveyor with a smooth pulley or a notched pulley The drive belt never needs adjusting on models with the smooth pulley See Figure U 22 to determine which pulley your model has Smooth Notched Figure U 22 Visually inspect the Conveyor to determine if you have a notched pulley A metric scale or calipers is required W For more information see Removing the Conveyor Pinch the Conveyor Motor Drive Belt midway between the pulleys and Module on page U 26 measure the distance between the belts at the pinched area measuring to the outside edge of the belts The distance should b
30. cement Removal procedures are on the following page 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 your local Data I O sale representative 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 Sales Part Number Part Description Qty Price Ea Totals PNP HEAD Pick and Place Head RR VAC TIP Probe Tip BRACKET PNP PNP Head Bracket RR CHAMBER FLOATING BLOCK Vacuum Chamber Block Signature Date Company U 44 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 wel For screw locations see Figure U 35 on page U 42 Tube Fitting and Gasket For more information see the Linear Stage Installa tion Verification on page U 62 Service Universal 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 Remove the PNP Head Cover 5 Disconnect the tube from the top of each probe 6 Remove two socket head cap screws attaching the head to the ball screw carriage 7 Lightly pull the head a couple of centimeters away from the carriage 8 Remove f
31. charge may damage parts Before ser vicing place the RoadRunner on an ESD safe workstation U 2 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal Replaceable Modules Blank page Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U 3 Service Universal e Components Overview Components Overview Cover shown away from conveyor Conveyor Module Cover not shown CAUTION To prevent damage when unplugging cables pull the connector and not the wires 3 plac s Robotics Cover not shown Lower cover not shown PNP Cover h S not shown 23 24 gi l Figure U 1 Component Overview GSM Model shown Genesis Model has longer converyor R CAUTION Electrostatic discharge may damage parts Before repair work begins place the RoadRunner on an ESD safe work station U 4 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal e Components Overview Component List 1 Control Panel Module page U 34 Va 2 Pick and Place PNP Head Modules are listed in bold type Modules are assem 3 Rubber Probe Tips G asa 4 Head Limit Cable 3 sensors unit 5 Socket Adapter 6 Serial Number Label 7 Linear Stage Module page U 54 8 Reject Bin 9 Interconnect Panel 10 Conveyor Module page U 24 11 Conveyor Dust Cover 12 End Of Belt Sensor Optic 13 SMT Communication Connec
32. ck failure at input with probe 1 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 your local Data I O sale representative 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 Sales Part Number Part Description Qty Price Ea Totals RR VAC FILTER Vacuum filter ASSY PNEUMATIC MODULE Pneumatic Module Signature Date Company U 16 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO07 Service Universal e Pneumatic Module If you experience problems such as dropped devices or pick failures replace the vacuum filters page U 16 adjust the vacuum sensor page U 40 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 wel For more information see Covers on page U 6 1 Turn the power off 2 Disconnect the RoadRunner power cord and air supply 3 Remove the Robotics and Lower Covers 4 Remove the square plastic housings with the Vacuum Filters by unscrewing the thumbscrews
33. connections are tested return the Con trol 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 I O 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 your local Data I O sale representative 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 Sales Part Number Part Description Qty Price Ea Totals RR CONTROL PANEL M Control Panel Module Signature Date Company U 34 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal e Control Panel Module Removing the Control Panel Module 1 Pause the RoadRunner Remove the PCMCIA card when the blue light is on Turn the power off a For more information see Removing the Robotics Cover on page U 7 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 SN gs a Guard Figure U 30 Ribbon Cable Guard with Screw Locations Indicated
34. der your spares kit Spares Kits for Specific Models Model Basic Spares Kit Sales Number Self Service Spares Sales Number Standard FC I Universal GSM RR SPARES KIT STD U RR SELFSV SPARES UA Standard FC I Universal Genesis RR SPARES KIT STD UG RR SELFSV SPARES UG Large Format Universal GSM RR SPARES KIT LF U Large Format Universal Genesis RR SPARES KIT LF UG Standard FC II Universal GSM2 RR SPARES KIT STD U RR SELFSV SPARES FC2 UA Standard FC II Universal Genesis RR SPARES KIT STD UG RR SELFSV SPARES FC2 UG IShipped prior to August 2007 Self Serve FC I kits upgrade the programmer to FC II Shipped after July 2007 Contents of the some of the kits are listed on the following pages FlashCORE II FC ID is the latest version of the standard RoadRunner Large Format LF RoadRunner is for programming devices whose length is larger than 15 mm and height thickness is larger than 3 mm Model Maximum a device size Length mm Width mm Height mm Standard 15 21 65 3 Large Format LF 24 21 65 6 On RoadRunner the width is perpendicular to the direction of device travel Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U 63 Service Universal Basic Spares Kit Standard RoadRunner Basic Spares Kit Standard RoadRunner Cover Tape Reel Vacuum Chamber Blocks e Reject Bin with Reject
35. displays its highest value Place a device on the SMT pick point so it blocks the optic beam Push Set on the optical fiber amplifier 8 9 Figure U 25 Reteaching the End of Belt Sensor Remove the device from the belt and then rotate the belt until the Opti cal fiber Amplifier displays its lowest value 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 Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO7 U 29 Service Universal e Conveyor Module NA Figure U 26 End of Belt Optical fiber Amplifier Label on the Conveyor Cover U 30 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal e Conveyor Module Blank page Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U 31 Service Universal e Reject Bin Reject Bin Reject Bin The Reject Bin is not fastened in and lifts 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 Bi
36. e 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 U 70 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DEC07 Service Universal Self Service Spares Kit Large Format RoadRunner The Self Service Spares Kit for Large Format RoadRunner GSM and Gene sis contact Support for Sales PN contains parts listed on page U 70 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 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 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 Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO7 U 71 Service Universal Socket Adapter Actuator and Precisor Socket Adapter Actuator and Precisor Precisor Actuator Plate Socket Adapter U 72 nh ok of D gt i
37. e 10 mm 1 mm 1 Remove the Conveyor Module Screws for Belt Adjustment Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U 27 Service Universal e Conveyor Module 3 If the belt tension is not within tolerance loosen the two mounting screws attaching the Conveyor Drive Motor to the mounting bracket and adjust the motor position Retighten the screws wel 4 Recheck the pinched belt dimension 5 For information on rein stalling the conveyor see page U 26 When the belt tension is correctly adjusted replace the Conveyor Mod ule and test for device rotation Adjusting the End of Belt Sensor The End of Belt Sensor Optic stops the conveyor belt when parts reach the pick point The optic functions 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 parts fall off the end of the conveyor If parts are falling off the end of the conveyor first test to make sure the Optical fiber Amplifier is functioning see below If the sensor is function ing but parts are still passing the pick point reteach the Optical fiber Ampli fier Testing the End of Belt Sensor 1 From the top level menu select Robot Diagnostics Select Belt Select Pick Sensor 2 3 4 Put your finger at the SMT pick point to block the
38. ed service representative e 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 e Wearing hearing protection is recommended while operating the RoadRunner Sound pressure levels may exceed 85 decibels e Shut off the pressurized air or disconnect the air hose before servicing pneumatic parts Data I O e ProLINE RoadRunner Service Manual e 096 0252 iii Blank page Data I O e ProLINE RoadRunner Service Manual e 096 0252 Service Universal Data I O s ProLINE RoadRunner supports several Universal Placement machines with four models RoadRunner Models Covered This manual supports two Standard models of RoadRunner which support several SMT Placement machines as noted e RoadRunner Universal GSM GSM1 GSM e RoadRunner Universal Genesis Genesis In addition there is a Large Format LF version RoadRunner of each model GSM LF and Genesis LF LF RoadRunners run devices up to 21 65 mm Wide x 24 mm Long x 6 mm High in 32 mm device tape Many modules and components on the RoadRunner are designed to be ser viced or replaced by qualified technicians You may wish to keep backup modules or components for replacements The replaced module or compo nent may be sent to Data I O for repair or adjustment NOTE Send Road
39. ee the last page of this manual for contact information ProLINE RoadRunner Model No Serial No Sales Name Part Description Qty Price Ea Totals RR BATTERY PACK LITHIUM NVRAM Battery Signature Date Company U S54 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal e NVRAM 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 seu gee Ge 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 U 46 Ribbon Cable J4 not shown has been disconnected from the programmer PCMCIA screws are circler 6 Remove the PCMCIA Cable PCB by removing four socket head cap screws and lifting the PCB up Lay it aside the cable is still attached See figure above 7 Remove four socket head screws securing the RPX_LITE board to the Waveform PCB and lift the board up See figure below Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U S55 Service Universal NVRAM Battery U 56 e Se al amp s Ce Fi
40. el menu on the display select Operation wa fF YN Scroll to and select Probes When finished select Menu Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 Scroll to and select the setting you wish to adjust Use the Arrow Up and Arrow Down buttons to change the setting U 41 Service Universal Pick and Place Head Adjusting Probe Vacuum Sensors L g See Loading Device Tape and Aligning the Device Tape both in the Owner s Manual under heading Setting Up RoadRunner for a Programming Job Adjustment LED for Probe 1 typical Vacuum Sensor Adjustment Screw for Probe 1 typical gt Load empty device tape into RoadRunner Advance the tape until the hole in the center of a tape pocket is aligned within one scroll button increment of the scribe mark on the input tape module Push the Emergency Stop button Pushing the head with your hand center the probe on the hole in the center of the device tape pocket Select Menu until you reach the top menu level and select Robot Diag nostics Sa Scroll to and select Probe 1 5b Scroll to and select Vacuum 5c Press the Up Arrow to enable the probe Remove the Lower Cover Press Probe 1 down by hand until it contacts the tape pocket and hold it 7a Turn the vacuum sensor adjust screw for Probe 1 the first adjust ment block counter clockwise until the red LED adjacent to the adjustment screw il
41. ensor Fiber side Socket Actuator Sensor Tape In amp Cover Tape Broken Sensors far side of Tape In Module Note The Tape In Module may be ordered separately not part of kit Amplifier Fiber Cable Assembly 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 your local Data I O sale representative 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 Figure U 55 Parts in the Self Service Spares Kit Standard RoadRunner 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 CABLE Head Limit Sensor Cable Assy RR SLOT SENSOR CABLE Slot Sensor Cable Assembly Tape RR OPTIC SENSOR Optical Sensor Fiber side RR LINEAR MODULE Linear Stage Module RR ASSY CONV ADJ UNIV Conveyor Module GSM ASSY CNVR 16MM GEN Conveyor Module Genesis RR PROGRAMMER MOD Programmer Module FC II amp Lbl RR CTRL PNL MODULE Control Panel Module RR PCMCIA CABLE Control Panel Cable RR COVER TAPE MOD Cover Tape Mod
42. er Module to the chassis Figure U 42 Location of Programmer Screws 21 Lift the Programmer Module out from the chassis NOTE If you see shims under the Programmer Module it is an old model Discard the shims when installing a new Module Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U 49 Service Universal Programmer Module Reinstalling the Programmer Module To reinstall a Programmer Module perform the following steps 1 Reinstall a Programmer Module ensuring that no wires or hoses are pinched and tighten the four screws 2 Reconnect the air tube 3 Reinstall all cable connectors 4 Plug in the PCMCIA Cable PCB and install the four screws Align the Programmer Module as described below before completing rein stallation Aligning the Programmer Module Align the Programmer Module as follows Figure U 43 The Programmer Module Alignment Tool Installed on the Programmer CAUTION Chassis might get damaged Loosen the Programmer Module mounting screws two upper screws before each attempt to adjust the Programmer Alignment Screws Install the Programmer Alignment Tool sales part number PROGRAM MER ALIGNMENT TOOL onto the Programmer Module in place of a socket adapter 2 Remove the rubber tip from Probe 1 and extend Probe 1 into the align ment fixture hole for socket 1 If the probe passes through the hole eas ily then the left
43. ff cycle the PNP Head along the entire length of the Linear Stage Check that the Head Flag clears all three position sensors Verify electrical and pneumatic connections as follows 2a Connect the air hose and turn the power on 2b Verify that the head homes 2c Verify that the Position field at the keypad display toggles when each probe is lowered by hand Robot Diagnostics Probe X Position 2d Extend and retract each probe to verify correct plumbing Robot Diagnostics Probe X Position Arrow Up Down 2e 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 Belt U 62 Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 Spare Parts Kits Service Universal Spare Parts Kits 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 as shown in the chart below Use the Sales Number to or
44. gain 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 power 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 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 Pararmeter in Chap ter 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 If your RoadRunner is networked to a computer with TaskLink you need to configure the network settings again grammer Port Prog Port Subnet Mask Sub and Gateway GTW are listed in the RoadRunner menu under System gt Network U 58 1 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
45. ge Format U 68 ordering U 68 Memory ordering U 64 Standard U 64 Broken tape sensor U 14 C Communications Cable removing U 25 Components listed U 4 Contact Information See inside back cover Control Panel removing U 35 Control Panel Module ordering U 34 Conveyor Belt Cover removing U 8 Conveyor Drive Belt adjust U 27 Conveyor Dust Cover removing U 8 Conveyor Module U 24 U 29 U 66 U 70 drop height U 26 reinstalling U 26 removing U 26 Cover Tape Module ordering U 22 removing U 23 Cover Tape broken sensor U 14 Covers ordering U 6 Customer Training U 67 U 71 D Delay Times resetting U 41 E Electrostatic Discharge U iii End of Belt Sensor adjusting U 28 reteaching U 29 Testing U 28 ESD See Electrostatic Discharge Data I O e ProLINE RoadRunner Service Manual e 096 0252 Index 1 Index e F F Filter air U 64 U 68 vacuum U 64 U 68 FlashCORE II U 63 Front Cover removing U 7 G Grounding U iii I UO Board U 66 U 70 Interconnect Panel U 49 Interface Manifold U 38 O Order Form Basic Spares Kit parts U 64 U 68 Control Panel Module U 34 Conveyor Belt Module U 24 Cover Tape Module U 22 Covers U 6 Large Format parts U 70 Linear Stage Module U 60 NVRAM Battery U 54 Pneumatic Module U 16 PNP head U 44 Programmer Module U 46 Reject Bin U 32 Self Service Spares Kit parts U 66 U 70 Tape In Module U 10 Vacuum Filters U 16 Overview of Components U 4 1 dan t seRasdta in
46. gure U 47 The RPX Lite screws ar circled The PCMCIA Cable PCB has been removed 8 Turn the board over and locate the PowerCap Module 9 Insert a small flat head screwdriver into the PowerCap slot 10 Gently pull back the screwdriver handle until the side of the cap releases from the module base See figure below Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal e NVRAM Battery Figure U 49 Removing the cap from the base Installing a new NVRAM Battery 1 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 U 50 Attaching a new PowerCap NVRAM 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 Cable board plug in ribbon cable J4 install the lower cover Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO07 U 57 Service Universal NVRAM Battery GC The RoadRunner IP Pro 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 a
47. here It should behae Let us know about the items you can t find by e mailing userdocs dataio com L Large Format RoadRunners U 1 U 63 LF see Large Format Lower Cover removing U 7 M Manifold pneumatic U 16 MFU RoadRunner U 1 Modules pictured U 4 replaceable U 2 Motion Controller PCB U 5 N NVRAM battery installing U 57 removing U 55 reteaching U 58 to U 59 NXT RoadRunner U 1 P Pick and Place Head aligning U 37 ordering U 44 removing U 44 to U 45 Pick and Place Head Cover removing U 7 Pick delay time U 41 Pick Sensor See End of Belt Sensor Pneumatic Module adjusting See Probe vacuum sensor reinstalling U 21 removing U 18 PowerCap Module see NVRAM battery Probe balancing speed U 37 speed specification U 38 speed adjusting U 37 vacuum sensor adjusting U 42 Probe Tip replacing U 65 U 69 Programmer Module alignment U 50 alignment tool U 50 description U 46 reinstalling U 50 Index 2 Data I O e ProLINE RoadRunner Service Manual e 096 0252 removing U 47 Puff duration U 41 R Reject Bin bracket U 33 full sensor U 32 sensor removal U 33 Reteaching Head Positions U 58 Robot I O Board U 66 U 70 S Safety grounding U iii precautions U iii Self Service Spares Large Format U 70 Self Service Spares Kit locations U 70 Memory ordering parts U 66 Standard locations U 66 Serial Number location U 5 Service component overview figure U 4 replacing
48. ht mounting screws 2 Loosen the Locknut on the Adjustable Standoff 7 mm wrench Figure U 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 poy Se P Put the rubber tip back onto Probe 1 Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U 15 Service Universal e Pneumatic Module Pneumatic Module Data I O Parts Ordering Information Figure U 11 Pneumatic Module and Vacuum Filter Locations The Pneumatic Module controls vacuum and blowoff air to the probes as well as pressurized air to the probes cylinders and programmer socket cylin 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 pi
49. ject Bin Bracket 10 Label if necessary and disconnect four colored air hoses from the Interface Manifold 11 Unplug 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 Figure U 52 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 to the chassis Slide the head out of the way See the figure below Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U 6l Service Universal e Linear Stage Module i For probe vacuum settings see Adjusting Probe Vac uum Sensors on page U 42 For probe speed informa tion see Adjusting and Balancing Probe Speed on page U 37 For Programmer align ment see Aligning the Pro grammer Module on page U 50 For reteaching the robot see Setting Operational Parameters Chapter 3 of the Owner s Manual e Figure U 53 Linear Stage Screw Locations Two are hidden by the head Linear Stage Installation Verification To replace the Linear Stage Module reverse the steps for removal and per form the following 1 2 Ev a zu pa With the power o
50. lems or it can knock devices off the probes It could also bend the motion limit pin on the PNP Head Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO07 Service Universal Pick and Place Head RoadRunner models shipped after 2007 allow customers to set the probe up speed NOTE RoadRunners shipped prior to 2007 only have the probe lowering speed controllers installed In line flow controllers can be installed on older machines to add the probe raising speed control capability Contact your nearest Data I O Representative To adjust the probe raising speed rr d P 8 Sp For more information See Loading Device Tape and Aligning the Device Tape in Chapter 3 of the Owner s Manual 1 Load and align the device tape without peeling off the cover tape The Cover Tape Peel Bar and Spool will not be used away from moving parts The following procedures require the Robotics Cover to be removed while mechanical parts are in motion Use caution G Pinch point Moving mechanical parts Keep hands 2 Scroll to and select Robot Diagnostics Ee Scroll to and select Probe 1 gt e Scroll to and select Speed The probe will move to the device pick point and cycle continuously Probe Raising Speed in line flow controls Probe Lowering Speed flow controls on the Interface manifold Figure U 33 The in line flow controls for adjusting the Probe Speed Probe numbers
51. lide 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 flat screwdriver to assist in sliding the block Tighten the Position Locking Screw Recheck alignment Tighten the Alignment Block Locking Screw Replace the Probe Tip Replace the PNP Head Cover Removing the Standard Tape In Module 1 wl 2 For more information see 3 Covers on page U 6 4 For the location of the chassis screws see Figure U 4 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 Module from the chassis as far as wires will allow NOTE The 16mm and 24mm Tape In Modules have spacers that could fall out They must be saved and reused on reinstallation Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO7 U 13 Service Universal e Tape In Module Cover Tape ER Check that wire labels are 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 Broken Se
52. ll as reduce throughput Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO07 Service Universal e Programmer Module Blank page Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U 53 Service Universal NVRAM Battery NVRAM Battery Figure U 45 The Programmer with Ribbon Cable J4 not shown discon nected The NVRAM Battery is on the far side of the next board down RoadRunner uses a lithium battery to power the non volatile read only memory NVRAM If information stored in NVRAM is lost RoadRunner will not function correctly If RoadRunner displays this error message NVRAM Battery Failed NVRAM data will be lost when RoadRunner is switched off and the battery needs to be replaced After a new battery has been installed in RoadRunner perform the simple procedure that 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 Call your local Data I O sale representative for part prices optional 5 Mail or FAX it with your purchase order to Data I O S
53. luminates If the vacuum for Probe 1 is enabled the two small LEDs on the solenoids for Probe 1 will be unlit Solenoid switches _ Ii for Probe 1 typical Figure U 35 Pneumatic Valve Block U 42 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO07 Service Universal Pick and Place Head 7b Turn the vacuum sensor adjust screw for Probe 1 clockwise until the red LED goes out Continue turning the screw 1 revolution clockwise Release the probe allowing it to resume the up position 8 Select Menu until you reach the top menu level again and select Robot Diagnostics Sa Scroll to and select Probe 1 8b Scroll to and select Vacuum 8c Press the Down Arrow to disable the probe 9 Manually position probes 2 3 and 4 over the hole in the tape pocket and repeat steps 5 through 7 for each 10 Re install the Lower Cover when finished Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO7 U 43 Service Universal Pick and Place Head Mounting Screws Data I O Parts Ordering Information Removing the PNP Head Figure U 36 Removing the PNP Head If you receive error messages relating to the Pick and Place function refer to the troubleshooting chart in chapter 9 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 repla
54. n Present sensor senses the bins presence The sensors are attached to the Reject Bin Bracket 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 your local Data I O sale representative 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 Figure U 27 The Reject Bin ProLINE RoadRunner Model No Serial No Sales Part Number Part Description Qty Price Ea Totals RR REJECT BIN Reject Bin RR REJECT BIN SENS Reject Bin Full Sensor RR SLOT SENSOR CAB Reject Bin Present Sensor ASSY REJECT BIN RR uC Reject Bin Microcontroller Signature Date Company U 32 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal Reject Bin Removing the Reject Bin Sensors 1 Turn the power off Disconnect the power cord and air supply Lift off the Robotics Cover wl Remove the Lower Cover For more information see Remove the Conveyor Module screws the wires do not need to be Removing the Conveyor unplugged and lift it out of the way Module on page U 26 2 3 4 Push the head away from the programmer 5 6 7 Lift out the Reject Bin 8 Unplug the sens
55. ng 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 Apply Travel Factory delay setting is 250ms No Display error message Apply Pick Factory thon setting Part Present TRUE Factory setting is 250ms No Display error message Turn vacuum off No v go to pick retry sequence not shown Start Place Part on Tip No Display error message Yes Place in reject bin No v Extend Probe Apply Travel Place Delay go to Ye 5 bs Factory delay Yes Turn Vacuum off H No gt Display error message setting is 250ms Apply Place Factory setting delay is 100ms D Apply puff v Raise probe Apply Puff Factory setting duration is 100ms D Turn puff off D Apply probe Factory setting Travel delay Probe Up Yes v go to Check Probe for Device not shown is 250ms No Display error message Figure U 34 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 lev
56. ng the Socket Adapter For more information see does not solve problems in the Programmer Module see Diagnosing with Changing the Socket the Adapter Board in Chapter 5 of the Owner s Manual or contact Data I O Adapter in Chapter 3 of for Programmer Module replacement or repair the Owner s Manual Some HIC sockets require the High Force Programmer A kit to convert to a HF Programmer is available see Order Form below Programmer Module removal directions start on page U 47 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 your local Data I O sale representative 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 Sales Part Number Part Description Qty Price Ea Totals RR PROG MOD HF KIT FCI High Force FC II Programmer PROGRAMMER ALIGNMENT TOOL Programmer Alignment Tool RR PROG HF UPGRADE KIT High Force FC I Progmr Upgrade Kit Signature Date Company U 46 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DEC07 Service Universal e Programmer Module Removing the Programmer Module NOTE Only technicians who have taken the ProLINE RoadR
57. nsor Tape Advance Sensor Tape In Motor emer a Pers a Figure U 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 e Ensure that the Module seats on the standoffs and spacers 16 mm and 24mm Modules e Ifyou are installing a Tape In Module different from the one you removed you need to align it to the PNP Head by performing the align ment procedure See following heading Aligning the Standard Tape In Module Some Tape In Modules are not adjustable Others are mounted on an Adjust able Standoff for alignment purposes If your model has the Adjustable Standoff you will see the adjustment stud from the top as you look down at the Tape In Module as shown in the figure below U 14 Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO7 Service Universal Tape In Module Figure U 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 rig
58. or wire connectors J1C and J1C2 from the Interconnect Panel Cut wire ties as necessary 9 Remove three socket head screws securing the Reject Bin Bracket to the chassis and lift it out Reject Bin Full Sensors Reject Bin Present Sensor Interconnect Panel Figure U 28 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 e Reinstall the Conveyor Module Set the Conveyor height as described in For reinstalling the Reinstalling the Conveyor Module Conveyor Module see e Reinstall the Lower Cover page U 26 Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U 33 Service Universal e Control Panel Module Control Panel Module SMIT kand IERZMIIDTTTO HIRTT Figure U 29 Control Panel Module The Control Panel Module consists of the PCMCIA Card Drive the Stop button the Indicator Lights Control Panel buttons and LCD screen If any of the components in the Control Panel Module are not functioning correctly check the wiring connections and the condition of the PCMCIA card Test the PCMCIA Card Drive with a card that is known to function If com ponents are still not functioning after
59. our pneumatic tubes with fittings from the back of the head with a straight screwdriver Note that each has a washer A gt s i gt Figure U 37 The PNP Head Partially Remove 9 Remove two Head Bracket screws from each side of the head 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 tubes are still attached Ensure that each has a gasket 2 Install the head Bracket onto the head 3 Plug in the electric connector and tie wrap to the tie wrap block 4 Attach the tubes to the probes 5 Install the head to the Linear stage with the two socket screws Use Loc tite 6 Perform the Linear Stage Reinstallation Verification procedure Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO7 U 45 Service Universal Programmer Module Programmer Module Programmer Module PCMCIA Cable Board Connector for Cable J4 Ze mm A e E h E Figure U 3S Programmer Module Cable J4 has been Unplugged 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 Programmer Module sockets become worn the Socket Adapter needs attention The Socket Adapter needs cleaning when yield drops and needs A replacing when cleaning fails to boost yield If replaci
60. ply tube has a quick disconnect fitting with an automatic shut off The line may be dis connected without shutting off the supply line air pressure Remove the Robotics Cover wel Remove the five screws that hold the Lower Cover to the chassis For screw locations see Pime G2 Slide the cover up toward the Control Panel to unhook a clip in the lower left corner then lift off For a detail of the cover clip see Figure U 3 Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U 7 Service Universal e Covers N KY D o o f Figure U 3 Detail of Clip on the Inside of the Lower Cover Removing the Conveyor Dust Cover The Conveyor Dust Cover lifts off two dowel pins Removing the Conveyor Module Cover 1 Turn the power off 2 Disconnect the RoadRunner power cord and air supply wel 3 Remove the three screws that hold the Conveyor Module Cover to the For screw locations see chassis Figure U 2 U 8 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal Covers Blank page Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U 9 Service Universal e Tape In Module Tape In Module These locations on all RoadRunner models This location on early RoadRunner models without an adjustable standoff ek A D CA mw 2 A A Figure U 4 Location of T
61. r side Communication PCB Power Switch Socket Actuator Sensor Tape In amp Cover Tape Broken Sensors far side of Tape In Module Note The Tape In Module may be ordered separately not part of kit Power Supply Module Figure U 57 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 Call your local Data I O sale representative 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 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 ASSY ADJTENSCNVR UIC RRUC Conveyor Module Adj Tension HC AASSY PROGRAMMER W GUIDE RR uC Programmer Module ptcontroller RR CTRL PNL MODULE Control Panel Module RR PCMCIA CABLE Control Panel Cable RR COVER TAPE MOD Cover Tape Modul
62. side of the programmer is properly aligned skip to step 3 2a If Probe 1 does not pass through easily loosen the upper two Pro grammer Module mounting screws two revolutions U S50 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal e Programmer Module 2b Adjust the left Position Adjustment set screw 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 two Programmer Module screws As VK A F Z i Jiad i Figure U 44 Programmer Module Alignment Screws the Left Hand Screw is not shown 3 Without the rubber tip on extend probe 4 into the alignment fixture hole for socket 4 If the probe passes through the hole easily then the right side of the programmer is properly aligned skip to step 5 3a If probe 4 did not pass through easily adjust the right Position Adjustment set screw accordingly 4 Tighten the upper two Programmer Module screws and retest If the module requires further adjustment be sure to loosen the upper two mounting screws first 5 Remove the Alignment Tool 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 U 41 on page U 49 1 Install a Socket Adapter and
63. sion 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 e Error messages if any e Device manufacturer part number package style and number of pins if device related e Name telephone number and address Lierse Bai
64. sted in your comments email userdocs dataio com 2004 2008 Data I O Corporation All rights reserved Table of Contents 096 0252 002 For non service information see the Owner s Manual 096 0240 Precautions for Safe Operation iii RoadRunner Models Covered U 1 Replaceable Modules U 2 Components Overview U 4 Component List U 5 Covers U 6 Removing the Robotics Cover U 7 Removing the PNP Head Cover U 7 Removing the Lower Cover U 7 Removing the Conveyor Dust Cover U 8 Removing the Conveyor Module Cover U 8 Tape In Module U 10 Removing the Adjustable Tape In Module U 11 Removing the Standard Tape In Module U 13 Pneumatic Module U 16 Replacing the Vacuum Filters U 17 Removing the Pneumatic Module U 18 Reinstalling the Pneumatic Module U 21 Cover Tape Module U 22 Removing the Cover Tape Module U 23 Conveyor Module U 24 Removing the Communications Cable U 25 Removing the Conveyor Module U 26 Adjusting the Conveyor Drive Belt Notched Only U 27 Adjusting the End of Belt Sensor U 28 Reject Bin U 32 Removing the Reject Bin Sensors U 33 Data I O e ProLINE RoadRunner Service Manual e 096 0252 1 Control Panel Module U 34 Removing the Control Panel Module U 35 Pick and Place Head U 37 Aligning the PNP Head U 37 Adjusting and Balancing Probe Speed U 37 Adjusting Probe Raising Speed U 38 Resetting the Pick Delay and Travel Delay Times U 41 Adjusting Probe Vacuum Sensors U 42 Removing the PNP Head
65. ta 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 your local Data I O sale representative 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 Sales Part Number Part Description Qty Price Ea Totals RR LINEAR MODULE Linear Stage Module Signature Date Company U 60 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DEC07 Service Universal Linear Stage Module Removing the Linear Stage Module 1 Switch the power off WE 2 Disconnect the RoadRunner power cord and air supply See Removing the Lower Cover on page U 7 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 age U 8 SS 7 Remove the Conveyor Module screws the wires do not need to be unplugged and lift it out of the way 8 Lift out the Reject Bin 9 Label if necessary and disconnect four black Linear Stage air hoses from the Interface Manifold s upper surface The Interface Manifold is located below the Re
66. tion 14 Mounting Guide Bar 15 End Of Belt Optical fiber Amplifier 16 Interface Manifold 17 Mounting Latch 18 Socket Actuator Sensor 19 Programmer Module page U 46 20 Vacuum Filters 21 Pneumatic Module page U 15 22 Power Supply 23 Motion Controller PCB 24 Air inlet connection 25 SMT Communications PCB 26 Power Switch 27 Robot I O PCB 28 Tape In Module page U 9 29 Cover Tape Module page U 22 30 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 e ProLINE RoadRunner Service Manual 096 0252 updated DEC07 U 5 Service Universal Covers e Covers PNP Head Lower Cover Robotics Cover ad Cover E ka H al Locating dowel pin for Robotics Cover Conveyor Conveyor Module Cover Dust Cover Figure U 2 Covers with Screw Locations Indicated by Circles The RoadRunner has five removable covers e Robotics Cover e PNP Head Cover e Lower Cover e Conveyor Dust 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 Call your local Data I O sale representative
67. tion The sys tem can be dangerous if the RoadRunner safety features and precautions in this manual are ignored To avoid possible personal injury or damage to the equipment please observe the fol lowing practices e Only trained personnel should install maintain repair or troubleshoot this system e 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 e Do not use ProLINE RoadRunner for any application other than its intended use e Do not operate the system if the guards or safety devices are not in their normal operating positions e Do not operate RoadRunner with any of the outer sheet metal panels removed e 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 s Do not place any part of your body near or in the direct path of moving parts e 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 approv
68. 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 U 66 Data I O e ProLINE RoadRunner Service Manual e 096 0252 updated DECO7 Service Universal Self Service Spares Kit Standard RoadRunner The Self Service Spares Kit for Standard RoadRunner GSM RR SELFSV SPARES UA or GENESIS RR SELFSV SPARES UG contains parts listed on page U 66 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 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 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 Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO07 U 67 Service Universal Basic Spares Kit Large Format RoadRunner Basic Spares Kit Large Format RoadRunner Cover Tape Reel
69. unner 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 Switch the power off Disconnect the RoadRunner power cord and air supply Lift off the Robotics Cover Push the head away from the programmer Remove the Lower Cover Remove the Actuator Plate by sliding it out of the bracket Optional Remove the Socket Adapter Remove the Conveyor Module Cover rr See Changing the Socket Adapter in Chapter 3 of Remove screws from the Conveyor Module and set it aside wires are the Owner s Manual still attached O S zl Six Oe Ze OY Lift out the Reject Bin j Remove the Reject Bin Bracket Sensors do not need to be removed Wires do not need to be unplugged Move it out of the way See Removing the Con veyor Module on page U 26 La Figure U 39 Reject Bin Bracket Screw Locations CAUTION Ribbon Cables might get damaged if pulled or pinched Cable damage is often not visible Pull cables by the con nector only Data I O e ProLINE RoadRunner Service Manual 096 0252 updated DECO7 U 47 Service Universal Programmer Module Cables are identified in Figure U 40 below Cable J4 connector 12 13 14 15 16 Cable J3 connector Motion Controller Cable connector is hidden under the ribbon cable W

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