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RoadRunner Service Manual

1. 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 A 21 to determine which pulley your model has Smooth Notched Figure A 21 Visually inspect the Conveyor to determine if you have a notched pulley A metric scale or calipers is required E For more information see Removing the Conveyor 2 Pinch the Conveyor Motor Drive Belt midway between the pulleys and Module on page A 23 measure the distance between the belts at the pinched area measuring to the outside edge of the belts The distance should be 10mm 1mm 1 Remove the Conveyor Module Figure A 22 Checking Belt Tension and Loosening the Drive Motor Screws for Belt Adjustment CQ a ve 3 _ If the belt tension is not within tolerance loosen the two mounting For information on rein screws attaching the Conveyor Drive Motor to the mounting bracket stalling the conveyor see and adjust the motor position Retighten the screws page A 23 A 24 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon Conveyor Module 4 Recheck the pinched belt dimension 5 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 th
2. Contact Information See inside back cover Control Panel Module ordering A 30 removing A 31 Conveyor Belt Cover removing A 6 Conveyor Drive Belt adjusting A 24 Conveyor Dust Cover removing A 6 Conveyor Module A 22 A 26 A 52 A 56 drop height A 23 reinstalling A 23 removing A 23 Cover Tape Module ordering A 20 removing A 21 Cover Tape broken sensor A 12 Covers ordering A 4 Customer Training A 53 A 57 D Delay Times resetting A 35 E Electrostatic Discharge iii End of Belt Sensor adjusting A 25 reteaching A 26 testing A 25 ESD See Electrostatic Discharge F Front Cover removing A 5 Data I O e ProLINE RoadRunner Service Manual e 096 0246 Index 1 Index G G Grounding iii I UO Board A 52 Microcontroller A 56 Interconnect Panel A 43 Interface Manifold A 34 L P Pick and Place Head aligning A 33 ordering A 38 removing A 38 to A 39 Pick and Place Head Cover removing A 5 Pick delay time A 35 Pick Sensor See End of Belt Sensor Pneumatic Module adjusting See Probe vacuum sensor reinstalling A 18 removing A 16 4 dan t seefabbawocky in here It should behae Let us know about the items you can t find by e mailing userdocs dataio com Lower Cover removing A 5 M Manifold pneumatic A 14 Modules pictured A 2 replaceable A 1 Motion Controller PCB A 3 O Order Form Basic Spares Kit Parts A 54 Basic Spares Kit parts A 50 Control Pan
3. Pick and 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 Yes Yes Pick Delay Place Delay K Start gt Start gt Pick Place j lt SC Part on Tip j gt No Display error message Part on Tip Yes Display error message AS es Yes SS No VR VX v ves vr Turn Vacuum On ee LEY I N v D Extend Probe Extend Probe Y F H Factory Factory w F i 4 Apply Travel R r e setting is delay setting is y 250ms 250ms ees D KE No Display error message lt 2 Probe Down Ke No Display error message v v R Facto Apply Pick i H Turn Vacuum off a a delay setting is QO 200ms v Apply Place Factory setting delay is 100ms Part Present Yes Part Present TRUE A GEN Apply puff N v Raise probe Raise probe 4 Factory Apply Puff Factory setting Apply Travel r ply 4 setting is duration is 100ms delay LL 250ms Turn puff off Probe Up gt gt No Display error message Apply probe Factory setting Travel delay i
4. PNP Head Mounting Screws Figure A 34 Removing the PNP Head If you receive error messages relating to the Pick and Place function refer to the troubleshooting chart in chapter 7 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 Call Data I O or visit our Web site for part prices optional 5 Mail or FAX it with your purchase order to Data I O See the last page of this manual for contact information ProLINE RoadRunner Model No Serial No Model Name Part Description Qty Price Ea Totals PNP HEAD Pick and Place Head CABLE ASSY OPTIC HEAD Sensor Cable Assembly BRACKET PNP PNP Head Bracket RR VAC TIP Probe Tip RR CHAMBER FLOATING BLOCK Vacuum Chamber Block Signature Date Company A 38 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUGO04 CQ For screw locations see Figure A 34 on page A 38 a Tube Fitting and Gasket For more information see the Linear Stage Installa tion Verification on page A 48 Servi
5. 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 E replacing when cleaning fails to boost yield Refer to Changing the Socket Adapter in Chapter If replacing the Socket Adapter does not solve problems in the Programmer 3 of the Owner s Manual 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 Programmer Module removal directions start on page A 41 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 Data I O or visit our Web site for part prices optional 5 Mail or FAX it with your purchase order to Data I O See the last page of this manual for contact information ProLINE RoadRunner Model No Serial No Model Name Part Description Qty Price Ea Totals RR PROGRAMMER MOD Programmer Module PROGRAMMER ALIGNMENT TOOL Programmer Alignment Tool ASSY PROGRAMMER Programmer Module Microcontroller W GUIDE RR uC Signature Date Co
6. 01 For non service information see the Owner s Manual 096 0240 Precautions for Safe Operation iii Replaceable Modules A 1 Components Overview A 2 Component List A 3 Covers A 4 Removing the Robotics Cover A 5 Removing the PNP Head Cover A 5 Removing the Lower Cover A 5 Removing the Conveyor Dust Cover A 6 Removing the Conveyor Module Cover A 6 Tape In Module A 8 Removing the Adjustable Tape In Module A 9 Removing the Standard Tape In Module A 11 Pneumatic Module A 14 Replacing the Vacuum Filters A 15 Removing the Pneumatic Module A 16 Reinstalling the Pneumatic Module A 18 Cover Tape Module A 20 Removing the Cover Tape Module A 21 Conveyor Module A 22 Removing the Conveyor Module A 23 Adjusting the Conveyor Drive Belt Notched Only A 24 Adjusting the End of Belt Sensor A 25 Reject Bin A 28 Removing the Reject Bin Sensors A 29 Control Panel Module A 30 Removing the Control Panel Module A 31 Data I O e ProLINE RoadRunner Service Manual e 096 0246 Pick and Place Head A 33 Aligning the PNP Head A 33 Adjusting and Balancing Probe Speed A 33 Resetting the Pick Delay and Travel Delay Times A 35 Adjusting Probe Vacuum Sensors A 36 Removing the PNP Head A 38 Programmer Module A 40 Removing the Programmer Module A 41 Linear Stage Module A 46 Removing the Linear Stage Module A 47 Basic Spares Kit Memory RoadRunner A 50 Replacing Probe Tips A 51 Replacing the Air Inlet Tube Assembly A 5
7. 1 Self Service Spares Kit Memory RoadRunner A 52 Basic Spares Kit Microcontroller RoadRunner A 54 Replacing Probe Tips A 55 Replacing the Air Inlet Tube Assembly A 55 Self Service Spares Kit ucontroller RoadRunner A 56 Socket Adapter Actuator and Precisor A 58 Alphabetical Index Index 1 Data I O e ProLINE RoadRunner Service Manual e 096 0246 Precautions for Safe Operation A 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 1s 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 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 To avoid possible personal injury or damage to the equipment please observe the following 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 ins
8. 246 Index e T Index 3 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 Awww dataio com and click ContactUs upper right then click Representative Search left side Then follow the instructions www dataio com www dataio cn www dataio de Data Data Data United States Germany When calling or writing please provide the following information e RoadRunner Serial number e Software Version displayed on the keyboard screen at start up turn the power off and then on again e Detailed description of the problem you are experiencing if any 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
9. 246 updated AUG04 A 45 Service Assembleon Linear Stage Module Linear Stage Module Electric Motor PNP Head the precisor Rail and and Encoder is still attached Ball Screw Cable Carrier A Figure A 43 The Linear Stage Module The Linear Stage part of the Robotic System consists of a rail and ball Q 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 A 38 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 Data I O or visit our Web site for part prices optional 5 Mail or FAX it with your purchase order to Data I O See the last page of this manual for contact information ProLINE RoadRunner Model No Serial No Model Name Part Description Qty Price Ea Totals RR LINEAR MODULE Linear Stage Module Signature Date Company A 46 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon Linear Stage Module Removing the Linear Stage Module 1 Switch the power off a 2 Disconnect the RoadRunner power cord and air supply For more information See Removing the Lower 3 Lift off the Robotic
10. AMMER MOD Programmer Module 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 RR PNEUMATIC MODULE Pneumatic Module RR DIAGNOSTICS BOARD Diagnostics Adapter Board DAB PROGRAMMER ALIGNMENT TOOL Programmer Alignment Tool Signature Date Company A 52 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon Self Service Spares Kit Memory RoadRunner The Self Service Spares Kit for Memory RoadRunner RR SELFSV SPARES KIT U A contains parts listed on page A 52 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 e 096 0246 updated AUG04 A 53 Service Assembleon Basic Spares Kit Microcontroller RoadRunner Basic Spare
11. AUG04 Service Assembleon Reject Bin Removing the Reject Bin Sensors 1 Turn the power off Disconnect the power cord and air supply Lift off the Robotics Cover CQ 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 A 23 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 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 Sensor Reject Bin Present Sensor wd Figure A 27 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 Reinstalling the Conveyor Module Reinstall the Lower Cover Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 A 29 Service Assembleon Control Panel Module Control Panel Module CEUTE TREN Figure A 28 Control Panel Module The C
12. Assy RR FILTER AIR 1 4 3 8 Filter Air 1 4 3 8 RR FILTER MIST SEP 1 4 3 8 Filter Mist RR MICRO BASIC SPARES KIT A Basic Spares Kit for uC all the above Signature Date Company A 54 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon Basic Spares Kit Microcontroller RoadRunner Replacing 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 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 e 096 0246 updated AUG04 A 55 Service Assembleon Self Service Spares Kit Microcontroller RoadRunner Self Service Spares Kit Microcontroller 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 Fiber Communication PCB Power Switc
13. Figure A S 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 16mm 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 A 12 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon Tape In Module Figure A 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 St
14. Linear Stage Installation Verification To replace the Linear Stage Module reverse the steps for removal and per form the following 1 With the power off cycle the PNP Head along the entire length of the Linear Stage Check that the Head Flag clears all three position sensors 2 Verify electrical and pneumatic connections as follows 2a Connect the air hose and turn the power on 2b Verify that the head homes er 2c Verify that the Position field at the keypad display toggles when E each probe is lowered by hand Robot Diagnostics gt Probe X gt For probe vacuum settings Position see Adjusting Probe Vac uum Sensors on page 2d Extend and retract each probe to verify correct plumbing Robot A 36 Diagnostics gt Probe X gt Position gt Arrow Up Down 2e Enable vacuum to each probe to verify correct plumbing Robot F j ar probe Speco TMa Diagnostics Probe X Vac Sense Arrow Up Down tion see Adjusting and Balancing Probe Speed on page A 33 Adjust the Probe Vacuum Sensors Verify correct Probe Speed For Programmer align ment see Aligning the Pro grammer Module on page A 43 Perform the Aligning the Programmer Module procedure X NS E Reteach the robot the four operation parameters Tape Socket1 Reject and Belt For reteaching the robot see Setting Operational Parameters in Chapter 3 of the Owner s Manual A 48 Data I O e ProLINE RoadRunner Service
15. Manual e 096 0246 updated AUG04 Service Assembleon e Linear Stage Module Blank page Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 A 49 Service Assembleon Basic Spares Kit Memory RoadRunner Basic Spares Kit Memory RoadRunner Cover Tape Reel Vacuum Chamber Blocks e Reject Bin with Reject Slide Dust Cover Communication Cable Air Inlet Tube Assembly Vacuum Filters Figure A 46 Locating parts in the Basic Spares Kit Two spare parts kits are available for the RoadRunner Parts in the Basic Spares Kit are listed below For the larger kit Self Service Spares Kit see page A 52 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 Data I O or visit our Web site for part prices optional 5 Mail or FAX it with your purchase order to Data I O See the last page of this manual for contact information ProLINE RoadRunner Model No Serial No Model Name Part Description Qty Price Ea Totals RR 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 REJECT BIN Reject Bin RR SLEEVE TAKE UP WHEEL SL
16. P Slide the cover up toward the Control Panel to unhook a clip in the lower left corner then lift off See Figure A 3 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 A 5 Service Assembleon Covers D D Figure A 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 CQ 3 Remove the three screws that hold the Conveyor Module Cover to the For screw locations see chassis Figure A 2 A 6 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon Covers Blank page Data I O e ProLINE RoadRunner Service Manual 096 0246 updated AUG04 A 7 Service Assembleon Tape In Module Tape In Module These locations on all RoadRunner models This location on early RoadRunner models without an adjustable standoff A 4 Sr Va w E mmm Kai N FZ A Pl NY gt 7 Figure A 4 Location of Tape In Malla 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 pat
17. 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 A 56 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon Self Service Spares Kit Microcontroller RoadRunner The Self Service Spares Kit for Microcontroller RR MICRO SELFSV SPARES KIT UA contains parts listed on page A 56 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 e 096 0246 updated AUG04 A 57 Service Assembleon Socket Adapter Actuator and Precisor Socket Adapter Actuator and Precisor Precisor Actuator Plate Socket Adapter Figure A 50 Precisor Actuator and Socket Adapter Locations A precisor
18. TD 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 A Communications Cable Assy RR FILTER AIR 1 4 3 8 Filter Air 1 4 3 8 RR FILTER MIST SEP 1 4 3 8 Filter Mist RR BASIC SPARES A Basic Spares Kit all the above Signature Date Company A 50 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon Basic Spares Kit Memory RoadRunner Replacing 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 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 A S51 Service Assembleon Self Service Spares Kit Memory RoadRunner Self Service Spares Kit Memory RoadRunner Head Limit Sensor Cont
19. Table of Contents Safety Precautions Non service information isin the ProLINE RoadRunner Owner s Manual ProLiINE RoadRunner Service Manual for Assembleon ACM Data PN 096 0246 001 Data I O has attempted to ensure that the information in this document is accurate and complete Data I O assumes no liability for errors or for any incidental consequential indirect or special damages including without limitation loss of use loss or alteration of data delays or lost profits or savings arising from the use of this document or the product which it accompanies No part of this document may be reproduced or transmitted in any form or by any means electronic or mechanical for any purpose without written permission from Data T O Corporation Data I O order forms may be reproduced for internal use only Data I O is a registered trademark of Data I O Corporation TaskLink is a trademark of Data I O Corporation ProLINE RoadRunner is a trademark 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 interested in your comments email userdocs dataio com 2004 Data I O Corporation All rights reserved Table of Contents 096 0246 0
20. andoff 7 mm wrench Figure A 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 SY Ok Oe R Put the rubber tip back onto Probe 1 Data I O e ProLINE RoadRunner Service Manual 096 0246 updated AUG04 A 13 Service Assembleon Pneumatic Module Pneumatic Module Data I O Parts Ordering Information Figure A 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 probe 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 pick failure at input with probe 1 Instructions 1 Cop
21. ase 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 If your RoadRunner is past warranty period you may elect to repair it on site if you have a certified technician The End of Belt sensor optic can be adjusted and the sensor controller 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 Data I O or visit our Web site for part prices optional 5 Mail or FAX it with your purchase order to Data I O See the last page of this manual for contact information ProLINE RoadRunner Model No Serial No Model Name Part Description Qty Price Ea Totals RR ASSY CONV ADJ UNIV Conveyor Module ASSY ADJ TENS CNVR UNIVER Conveyor Module Microcon SAL RR uC troller Signature Date Company A 22 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon 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 IE 4 Remove the Conveyor Module Cover For more information see 5 Cut the t
22. bot 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 13545 If it needs adjustment skip to step 6 If it does not need adjustment 5a Press Menu Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 A 33 Service Assembleon Pick and Place Head A 34 10 11 12 13 5b Scroll to and select the next probe 5c Repeat steps 4 and on Remove the Conveyor Module Cover Loosen the locknut ring on the Probe Speed Flow Control for Probe 1 or current probe on the Interface Manifold The Interface Manifold is mounted on the chassis below and to the right of the Reject Bin Flow Control adjustment stem for Probe 1 7 Figure A 31 Interface Manifold Adjustment stems may have thumbscrews or slots for screwdriver Adjust the Probe Speed flow control for Probe 1 or current probe while watching the speed displayed at the keypad screen When the speed is within the proper range press Menu probe motion will stop Tighten the locknut ring on the Flow Control Recheck the speed If it is outside the proper range then readjust Scroll to and select the next Probe Repeat steps 4 and on for the next probe Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon
23. ce Assembleon 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 catriage 7 Lightly pull the head a couple of centimeters away from the carriage 8 Remove four pneumatic tubes with fittings from the back of the head with a straight screwdriver Note that each has a washer Figure A 35 The PNP Head Partially Removed 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 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 e 096 0246 updated AUG04 A 39 Service Assembleon Programmer Module Programmer Module Programmer Module PCMCIA Cable Board Connector for Cable J4 Figure A jana i Cable J4 has bean Unplugged
24. cting 5 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 Push Down Pull Out A 4 a Figure A 13 Disconnecting a Pneumatic Tube from the One touch Connector A 16 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon e Pneumatic Module Probe Vacuum Lines Figure A 14 Location of Vacuum and Air Lines Q Pneumatic access cover secured with two screws 7 Disconnect the Pneumatic Manifold Supply Line at the One touch con are on the back housing nector on the manifold flange See Figure A 15 6 Remove the Pneumatic Access Cover 8 Unscrew the two screws from the 25 pin cable connector and unplug the connector from the manifold bracket Probe Air Lines Supply Line One touch Connector Pneumatic Manifold 25 Pin Connector two 1 5mm Allen fasteners Access hole to the other fastener Figure A 15 Location of the Pneumatic Manifold Supply Line and Wiring Connector Data I O e ProLINE RoadRunner Service Manual 096 0246 updated AUG04 A 17 Service Assembleon Pneumatic Module 9 Remove the three screws securing the Pneumatic Module to the RoadRunner chassis Figure A 16 Pneumatic Module fast
25. dule Data I O e ProLINE RoadRunner Service Manual 096 0246 updated AUG04 A 41 Service Assembleon Programmer Module Cable J4 connector Cable J3 connector Motion Controller Cable connector is hidden under the ribbon cable WE See Cable JSC in Figure A 39 below A 42 13 14 15 16 17 18 19 Actuator Position Sensor Cable Tie Cable J5C Air tube connector for the Programmer Module eee 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 A 38 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 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 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon Pr
26. e 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 sen sor controller is functioning see below If the sensor is functioning but parts are still passing the pick point reteach the sensor controller Testing the End of Belt Sensor 1 From the top level menu select Robot Diagnostics Select Belt Select Pick Sensor Put your finger at the SMT pick point to block the sensor optic ee Za The Control Panel display will show Pick Sensor I whenever your fin ger is blocking the beam and Pick Sensor 0 when not blocked a sn oe Figure A 23 Testing the End of Belt Sensor The Conveyor Cover need not be removed Universal Shown 6 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 Data I O e ProLINE RoadRunner Service Manual 096 0246 updated AUG04 A 25 Service Assembleon Conveyor Module IE The controller is mounted to the chassis under the Conveyor Module End of Belt Sensor Optic End of Belt Sensor Controller E For detai
27. el Module A 30 Conveyor Belt Module A 22 Cover Tape Module A 20 Covers A 4 Linear Stage Module A 46 Pneumatic Module A 14 PNP Head A 38 Programmer Module A 40 Reject Bin A 28 Self Service Spares Kit Parts A 52 A 56 Tape In Module A 8 Vacuum Filters A 14 Overview of Components A 2 Index 2 Probe balancing speed A 33 speed specification A 34 speed adjusting A 33 vacuum sensor adjusting A 36 Probe Tip replacing A 51 A 55 Programmer Module alignment A 44 alignment tool A 43 description A 40 reinstalling A 43 removing A 41 Puff duration A 35 R Reject Bin bracket A 29 full sensor A 28 sensor removal A 29 Robot I O Board A 52 A 56 S Safety grounding iii precautions ili Self Service Spares Kit Memory A 52 ordering A 52 Data I O e ProLINE RoadRunner Service Manual e 096 0246 Microcontroller A 56 ordering A 56 Serial Number location A 3 Service component overview figure A 2 replacing assemblies A 1 Socket Adapter wear A 40 Spare Parts ordering A 50 Spare parts icrocontroller locating A 56 Memory locating A 50 A 52 Microcontroller locating A 54 ordering A 54 T Tape In Module aligning A 12 jamming A 8 ordering parts A 8 removing A 11 Throughput A 33 Training A 53 A 57 Travel delay time A 35 Tube fittings A 16 U Communications Cable A 22 V Vacuum Sensor Probe adjusting A 36 W Warning electrical shock A 5 Data I O e ProLINE RoadRunner Service Manual e 096 0
28. en wrenches a volt meter or multi meter and a metric scale or calipers CAUTION Electrostatic discharge may damage parts Before ser vicing place the RoadRunner on an ESD safe workstation Data I O e ProLINE RoadRunner Service Manual 096 0246 updated AUG04 A 1 Service Assembleon e Components Overview Components Overview Shown 3 plac s Robotics Cover not shown PNP Cover not shown Conveyor Module Cover not shown Lower cover not shown Figure A 1 Component Overview CAUTION Place RoadRunner on an ESD safe workstation CAUTION To prevent damage when unplugging cables pull the connector and not the wires Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon e Components Overview Component List Modules are listed in bold type 1 Se mm 2 bn FY N ken e ken ben e e A vn A U NY KF O Conveyor Dust Cover End Of Belt Sensor Optic Mounting Guide Bar End Of Belt Sensor Controller Interface Manifold Mounting Latch 17 Control Panel Module page A 30 Pick and Place PNP Head Rubber Probe Tips Head Limit Cable 3 sensors Socket Adapter Serial Number Label Linear Stage Module page A 46 Reject Bin Interconnect Panel Conveyor Module page A 22 Socket Actuator Sensor Programmer Module page A 40 Vacuum Filters Pneumatic Module page A 14 Power Supply Mo
29. ener locations The Probe Vacuum Tubes have been Disconnected E 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 A 14 and Figure A 15 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 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 gt Probe I gt Puff gt Up Down Arrow E For step 2 see Adjusting Probe Vacuum Sensors on page A 36 2 Adjust the probe vacuum sensors 3 Adjust probe speed For step 3 see Adjusting and Balancing Probe Speed on page A 33 A 18 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon e Pneumatic Module Blank Page Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 A 19 Service Assembleon e Cover Tape Module Cover Tape Module Ta
30. er IS Is COVER PNP PNP Head Cover RR LOWER COVER Lower Cover RR COVER DUST U OR A Conveyor Dust Cover RR COVER CONVEYOR U OR A Conveyor Module Cover Signature Date Company A 4 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Q For screw locations see Figure A 2 Service Assembleon 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 supply 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 Remove the five screws that hold the Lower Cover to the chassis
31. h Programmer Module 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 A 49 Self Service Spares Kit Microcontroller 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 Data I O or visit our Web site for part prices optional 5 Mail or FAX it with your purchase order to Data I O See the last page of this manual for contact information ProLINE RoadRunner Model No Serial No Model Name Part Description Qty Price Ea Totals RR PWR SWITCH Power Switch Rocker RR PWR SUPPLY Power Supply Module RR LIMIT SENSOR CA Head Limit Sensor Cable Assy RR SLOT SENSOR CA Slot Sensor Cable Assembly Tape RR REJECT BIN SENS Reject Bin Sensor RR OPTIC SENSOR Optical Sensor Fiber side RR LINEAR MODULE Linear Stage Module ASSY ADJ TENS CNVR UNIVER Conveyor Module Adj Tension SAL RR uC ASSY PROGRAMMER W GUIDE RR uC Programmer Module controller 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
32. h 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 Data I O or visit our Web site for part prices optional 5 Mail or FAX it with your purchase order to Data I O See the last page of this manual for contact information ProLINE RoadRunner Model No Serial No Model Name Part Description Qty Price Ea Totals RR 16MM TAPEIN KIT Kit Tape In Module 16mm RR 24MM TAPEIN KIT Kit Tape In Module 24mm RR 32MM TAPEIN KIT Kit Tape In Module 32mm RR ADJUSTABLE TAPE IN KIT Kit Adjustable Tape In Module RR SLOT SENSOR CAB Tape Advance Sensor Cable Assy RR SLOT SENSOR CAB Cover Tape Broken Sensor Cable Assy ASSY TAPE IN RRuC Kit Tape In Module Microcontroller Signature Date Company A 8 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUGO04 Service Assembleo
33. he pressurized air or disconnect the air hose before servicing pneumatic parts Data I O e ProLINE RoadRunner Service Manual e 096 0246 111 Blank page Data I O e ProLINE RoadRunner Service Manual e 096 0246 Service Assembleon 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 Replaceable Modules Replaceable modules include e Tape In Module e Pneumatic Module e Conveyor Module e Cover Tape Module Control Panel Module e PNP Head subassembly e Linear Stage Module Programmer Module with PNP Head Ca Tools required for RoadRunner maintenance are listed in 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 Model Names These names represent the RoadRunner configuration at the time of printing this manual only and may not be the same as your unit However the Model Names will always get you the latest interchange able replacement Some of the tools required are Metric hex keys All
34. he top of the Alignment Block accommodates a flat screwdriver to assist in sliding the block 9 Tighten the Position Locking Screw 10 Recheck alignment 11 Tighten the Alignment Block Locking Screw 12 Replace the Probe Tip 13 Replace the PNP Head Cover Removing the Standard Tape In Module For the Adjustable Tape In Module see page A 9 1 Turn the power off CQ 2 Disconnect the RoadRunner power cord and air supply For removing the covers 3 see Covers on page A 4 Remove the Robotics Cover and Lower Cover Remove the three or four screws depending on your model that con For the location of the nect the Tape In Module to the chassis Chassis SCrews see Figure A 4 in 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 0246 updated AUG04 A ll Service Assembleon 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 Sensor Tape Advance Sensor Tape In Motor GAE j A lt gt gt 3 A gt
35. ie wraps securing the wires for the belt motor communications Removing the Conveyor and sensors Module Cover on page A 6 CAUTION Optic cables are fragile and may break Do not bend radically 6 Disconnect two connectors belt motor wires and sensor controller wires i i Figure A 20 Conveyor Wire Connector Locations Circled WE 7 Remove the two screws attaching the Conveyor Module to the chassis For Conveyor screw loca 8 Lift the Conveyor Module free of the RoadRunner chassis tions see Figure A 19 Reinstalling the Conveyor Module To reinstall the conveyor reverse the removal steps plus performe the fol lowing 1 Notice the locating pin on the chassis for location 2 Set the conveyor height as follows 2 With the RoadRunner in its normal upright position and the con Push probe here with finger veyor fasteners in but not tightened move the PNP Head over the 5 R g conveyor belt 2b Place your thinnest device on the belt below Probe 1 o o o o Oo SI oo 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 UU 2d Recheck the height after tightening the fasteners Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 A 23 Service Assembleon Conveyor Module
36. ignature Date Company A 20 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon e 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 see Note on this page Cover Tape Module screws 4 E 5 Figure A 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 0246 updated AUG04 A 21 Service Assembleon Conveyor Module Conveyor Module Mounting Screws Sensor Optic Cables Feeder Communication Cable and Motor Wires Figure A 19 Location of Wires and Screws on 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 cre
37. 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 inside the back cover of this manual See the ProLINE RoadRunner Owner s Manual for the following 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 To remove the Socket Adapter see Changing the Socket Adapter in Chapter 3 A 58 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Index A Adjustable Tape In Module aligning A 10 removing A 9 Air Filters description A 14 ordering A 14 replacing A 15 Air Paths keeping clean A 14 B Basic Spares Kit Memory A 50 Memory ordering A 50 Microcontroller A 54 Microcontroller ordering A 54 Broken tape sensor A 12 C Components listed A 2
38. ke Up Reel pins Tape Broken Roller with Sensor hidden Figure A 17 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 a loose or broken drive belt 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 Data I O or visit our Web site for part prices optional 5 Mail or FAX it with your purchase order to Data I O See the last page of this manual for contact information ProLINE RoadRunner Model No Serial No Model Name Part Description Qty Price Ea Totals RR COVER TAPE MOD Cover Tape Module S
39. level and select Robot Diag nostics Sa Scroll to and select Probe I 5b Scroll to and select Vacuum 5c Press the Up Arrow to enable the probe Remove the Lower Cover Press Probe down by hand until it contacts the tape pocket and hold it Ta 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 illuminates 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 A 33 Pneumatic Valve Block A 36 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon e 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 8a Scroll to and select Probe I 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 e 096 0246 updated AUG04 A 37 Service Assembleon Pick and Place Head Removing the
40. ller must always operate in Turbo mode Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon Conveyor Module Data I O e ProLINE RoadRunner Service Manual 096 0246 updated AUG04 A 27 Service Assembleon Reject Bin Reject Bin Reject Bin Figure A 26 The 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 Bin Present sensor senses when the bin is not in place They 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 Data I O or visit our Web site for part prices optional 5 Mail or FAX it with your purchase order to Data I O See the last page of this manual for contact information ProLINE RoadRunner Model No Serial No Model Name Part Description Qty Price Ea Totals RR 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 A 28 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated
41. locks 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 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 Parameter both in Chapter 3 of the Owner s Manual If the probe speed is too fast devices in the carrier tape bounce 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 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 Ro
42. ls on setting the Sensor Controller see the label on the inside of the Conveyor Cover and shown in Figure A 25 A 26 Ga 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 Sensor Controller below Reteaching the End of Belt Sensor Controller 1 Lift off the Conveyor Dust Cover 2 Remove the Conveyor Module Cover 3 Press the Emergency Stop button the conveyor belt can now be rotated by hand 4 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 5 Manually rotate the belt so that the sensor controller displays its highest value Place a device on the SMT pick point so it blocks the optic beam 7 Push Set on the sensor controller Figure A 24 Reteaching the End of Belt Sensor Universal Shown 8 Remove the device from the belt and then rotate the belt until the sensor controller displays its lowest value 9 Push Set on the sensor controller again NOTE In general the End of Belt Sensor Controller should dis play 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 pos sible to achieve numbers less than 21 and greater than 90 by adjusting the optic beam the conveyor module must be replaced The Sensor Contro
43. mmer Module mounting screws two revo lutions 3 Remove the rubber tip from Probe 1 and extend Probe into the align ment fixture hole for socket 1 If the probe passes through the hole eas ily then the left side of the programmer is properly aligned skip to step 4 3a If Probe 1 does not pass through easily 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 cha sis A 44 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon Programmer Module lt x oe gt d a M a Figure A 42 Programmer Module Alignment Screws the Left Hand Screw is not shown 4 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 4a If probe 4 did not pass through easily adjust the right Position Adjustment set screw accordingly 5 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 6 Remove the Alignment Tool Complete the Programmer Module installation by installing the Reject Bin Bracket the Tape Path Bracket the Conveyor Module the Reject Bin and the Lower Cover Data I O e ProLINE RoadRunner Service Manual e 096 0
44. mpany A 40 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon Programmer Module Removing the Programmer Module CQ For more information See Changing the Socket Adapter of the Owner s Manual See Removing the Con veyor Module on page A 23 E Cables are identified in Figure A 38 below NOTE Only technicians who have taken the ProLINE RoadRunner Service training course should attempt to remove the Programmer Module A special 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 S S zl Six Oe OY Lift out the Reject Bin Remove screws from the Conveyor Module and set it aside wires are still attached 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 Ga a Figure A 37 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 12 Unplug the Ribbon Cable J4 from the Programmer Mo
45. n 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 oe Ge W Extend Probe 1 fully by pushing down on the block below the spring to Push probe here with finger visually compare the position of the hole in the center of the tape pocket mB H g 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 A 10 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon e Tape In Module Slot to assist in sliding the Alignment Block Position Locking Screw Access to the Alignment Block Locking Screw Figure A 7 Aligning the Adjustable Tape In Module 7 Loosen the Alignment Block Locking Screw with a 2 mm Allen Wrench A small access hole is provided 8 Slide the Alignment Block left or right as needed to bring the device tape in line with the probe A slot in t
46. n e Tape In Module Removing the Adjustable Tape In Module For the Standard Tape In Module see page A 11 1 Turn the power off 2 Disconnect the RoadRunner power cord and air supply For removing the covers see Covers on page A 4 3 Remove the Robotics Cover and Lower Cover 4 Remove the two screws attaching the Tape Guide to the Adjustable For the location of the Tape In ATI Module chassis screws see Figure A 4 Position Locking Screw Tape Guide Figure A 5 The Adjustable Tape In Module 5 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 0246 updated AUG04 A 9 Service Assembleon Tape In Module Figure A 6 Adjustable Tape In Module Base 8 Lift the Base from the 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 I
47. ogrammer Module Figure A 39 Cable Interconnect Panel 20 Remove four button head socket screws attaching the Programmer Module to the chassis f Al Figure A 40 Location of Programmer Screws 21 Lift the Programmer Module out from the chassis NOTE If you see any shims under the Programmer Module it is an old model Discard the shims when installing a new 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 Reinstall 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 Data I O e ProLINE RoadRunner Service Manual 096 0246 updated AUG04 A 43 Service Assembleon Programmer Module e eg Figure A 41 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 1 Install the Programmer Alignment Tool model name PROGRAMMER ALIGNMENT TOOL onto the Programmer Module in place of a socket adapter 2 Loosen the upper two Progra
48. ontrol 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 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 Data I O or visit our Web site for part prices optional 5 Mail or FAX it with your purchase order to Data I O See the last page of this manual for contact information ProLINE RoadRunner Model No Serial No Model Name Part Description Qty Price Ea Totals RR CONTROL PANEL M Control Panel Module Signature Date Company A 30 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon Control Panel Module Removing the Control Panel Module 1 Pause the RoadRunner Remove the PCMCIA card
49. rol Panel Module l Cover Tape Module Robot UO Board Communication PCB Power Switch Power Supply Module Programmer Module 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 Reject Bin Linear Stage Module Optic Sensor Fiber Socket Actuator Sensor Conveyor Module Amplifier Fiber Cable Assembly Figure A 47 Locating Parts in the Self Service Spares Kit 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 Data I O or visit our Web site for part prices optional 5 Mail or FAX it with your purchase order to Data I O See the last page of this manual for contact information ProLINE RoadRunner Model No Serial No Model Name Part Description Qty Price Ea Totals RR PWR SWITCH Power Switch Rocker RR PWR SUPPLY Power Supply Module RR LIMIT SENSOR CA Head Limit Sensor Cable Assy RR SLOT SENSOR CA Slot Sensor Cable Assembly Tape RR REJECT BIN SENS Reject Bin Sensor RR OPTIC SENSOR Optical Sensor Fiber side RR LINEAR MODULE Linear Stage Module RR ASSY CONV ADJ UNIV Conveyor Module Adj Tension RR PROGR
50. s 250ms Yes J Part on tip Noca Turn Part Presen Yes Display dropped part Probe Up V No Display error message vacuum off TRUE error message a Ba Yes No Yes fa go t pick y Done retry sequence go to Ghee Frane not shown not shown Figure A 32 Pick and Place Delay Flow Charts These values only affect the internal verification delay time as indicated in the flow charts To reset delay times 1 From the top level menu on the display select Operation 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 Mi y E When finished select Menu Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 A 35 Service Assembleon Pick and Place Head Adjusting Probe Vacuum Sensors a For more information See Loading Device Tape and Aligning the Device Tape in Chapter 3 of the Owner e Manual Adjustment LED for Probe 1 typical Vacuum Sensor Adjustment Screw for Probe 1 typical 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
51. s Cover Cover on page A 5 4 Pull off the PNP Head Cover It is magnetically attached to the head I 5 Remove the Lower Cover See Removing the Con 6 Remove the Conveyor Module Cover veyor Module on page A 23 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 Reject 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 A 44 Wires from the Linear Stage Motor terminate at intermediate connector J8B beneath the Tape In Module 12 Unplug the ribbon cable at the Linear Stage Encoder Data I O e ProLINE RoadRunner Service Manual 096 0246 updated AUG04 A 47 Service Assembleon Linear Stage Module 13 Remove eight screws securing the linear stage to the chassis Slide the head out of the way See the figure below 4 N P ai Figure A 45 Linear Stage Screw Locations Two are hidden by the head
52. s Kit Microcontroller RoadRunner Cover Tape Reel Air Inlet Tube Assembly Vacuum Filters Vacuum Chamber Blocks e Reject Bin with Reject Slide Dust Cover Communication Cable Figure A 48 Locating parts in the Basic Spares Kit Microcontroller Two spare parts kits are available for the Microcontroller RoadRunner Parts in the Basic Spares Kit are listed below For the larger kit Self Service Spares Kit see page A 56 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 Data I O or visit our Web site for part prices optional 5 Mail or FAX it with your purchase order to Data I O See the last page of this manual for contact information ProLINE RoadRunner Model No Serial No Model Name Part Description Qty Price Ea Totals RR 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 A Communications Cable
53. t 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 Thumbscrew u Fo Filter Locating Pins Gasket Ensure that the gasket does not fall out when removing or installing the housing Figure A 12 Vacuum Filter Components Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 A 15 Service Assembleon Pneumatic Module 5 Remove the filter from the plastic housing 6 When installing a new filter make sure the rubber gasket is in place between the housing and the valve block Removing the Pneumatic Module CQ 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 Q For more information see Removing the Lower Cover on page A 5 amp For the location of Probe vacuum lines see Figure A 14 1 Turn the power off 2 Disconnect the RoadRunner power cord and air supply 3 Pull off the Robotics Cover 4 Remove the Lower Cover 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 disconne
54. tion Controller PCB Air inlet connection SMT Communications PCB Power Switch Robot I O PCB Tape In Module page A 8 Cover Tape Module page A 20 Robotics Cover Open Sensor EN 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 0246 updated AUG04 Service Assembleon Covers Covers PNP Head Robotics Cover sed Cover T k ee 3 _ ott Le A Locating dowel pin for Robotics Cover Conveyor Conveyor Lewat Module Cover Dust Cover Cover Figure A 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 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 Data I O or visit our Web site for part prices optional 5 Mail or FAX it with your purchase order to Data I O See the last page of this manual for contact information Data I O Parts Ordering Information ProLINE RoadRunner Model No Serial No Model Name Part Description Qty Price Ea Totals RR ROBOTICS COVER FU A Robotics Cov
55. tructions 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 e 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 approved 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 t
56. when the blue light is on Turn the power off GC For more information see Removing the Robotics Cover on page A 5 Disconnect the RoadRunner power cord and air supply Remove the Robotics Cover SSO e Za Remove the PCMCIA Ribbon Cable Guard by unscrewing the two screws securing it Guard Figure A 29 Ribbon Cable Guard with Screw Locations Indicated 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 KOMMMITSSITSSKRKKKN drive cable H LILSRIUIURT connector Emergency Stop Button connector Figure A 30 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 0246 updated AUG04 A 31 Service Assembleon 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 A 32 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon Pick and Place Head Pick and Place Head The head assembly contains four probes each with Vacuum Tips and Vac uum Chamber B
57. y 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 Data I O or visit our Web site for part prices optional 5 Mail or FAX it with your purchase order to Data I O See the last page of this manual for contact information ProLINE RoadRunner Model No Serial No Model Name Part Description Qty Price Ea Totals RR VAC FILTER Vacuum filter ASSY PNEUMATIC MODULE Pneumatic Module Signature Date Company A 14 Data I O e ProLINE RoadRunner Service Manual e 096 0246 updated AUG04 Service Assembleon e Pneumatic Module If you experience problems such as dropped devices or pick failures replace the vacuum filters page A 15 adjust the vacuum sensor page A 36 or see the chapter on Troubleshooting in the Owner s Manual 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 Q For more information see Covers on page A 4 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 from the valve block NOTE Ensure that the gaske

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