CONTENTS English Overview Installation PN 096-0226-002 Job Setup ProLINE-RoadRunner ™ Operator’s Guide for Siemens Operation Maintenance Troubleshooting
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.
Chapter 1 ProLINE-RoadRunner for Siemens........... 2 Jobs and Statistics........... 3 External View........... 4 Internal Components........... 5 Control Panel Lights........... 6 Control Panel Buttons........... 7 Overview Operator Menus........... 8 Supervisor Menus........... 9 Warnings and Cautions......... 12 Technical Support.........
The ProLINE-RoadRunner for Siemens 3 2 4 Data I/O is proud to introduce a revolutionary new inline solution for high-volume programming of electronic products. The ProLINE-RoadRunner: 1. Takes programmable devices from a reel... 1 2. Places them in sockets and programs them with your data... 3. Places them on a conveyor belt... 4. Delivers them to the pick point of your assembly machine.
Jobs and Statistics Programming Jobs TaskLink™ for Windows® is required to process devices on the ProLINE-RoadRunner. TaskLink allows you to create and manage a job database and it analyzes job statistics. PCMCIA cards are used to transfer jobs and statistics between TaskLink and RoadRunner. Statistics 3 ProLINE-RoadRunner Operator’s Guide A For more information on TaskLink, see the TaskLink Help Menu.
External View Front 6 5 7 (hidden) Back 4 8 3 2 1. Power and Air Connections 2. Power Switch 3. Handhold for lifting 4. PCMCIA Card Slot and Eject button 5. Control Panel 9 6. Conveyor Belt with Dust Cover 7. Mechanical Interface to Assembly Machine 1 8. Robotics Cover 10 9. Communications Cable (optional) 10.
Internal Components 1. Cover Tape Take-Up Reel 3 2. Tape-In Module 4 3. PNP Probes, Precisor, and Cover 4. Reject Bin 5.
Control Panel Lights 4 1 2 2. Yellow - Caution Indicator. Correct a problem or the machine will stop. 3. Green - Run Indicator. Lit: A job is running. Blinking: Programmed devices are not yet at the SMT pick point. 3 6 1. Blue - Stop Indicator. User intervention is required, or the unit is paused. (Do not remove PCMCIA card unless blue lamp is lit.) ProLINE-RoadRunner Operator’s Guide A 4. Emergency Stop - Press to stop the robot motors in an emergency.
Control Panel Buttons 2 1 1. Start - start or resume the chosen job. 2. Menu - exit to the previous menu, —or show the next message (deleting the current one), —or deselect an item. 3. Up and Down Arrows - move through menu items. 3 4. Select - select menu items. 4 7 5 ProLINE-RoadRunner Operator’s Guide A 5. Pause - interrupt the job without cancelling it.
Operator Menus Main Menu Job Advance Pocket Align Pocket Purge Socket • Light gray shaded fields cannot be changed. • For Advance Pocket, Align Pocket, and Purge, see Chapter 3 in the Owner’s Manual. 8 Results End Operator Menus are visible on the RoadRunner control panel, and can be navigated by using the Up Arrow and Down Arrow buttons. Socket Job View Job Name Device: E28F320 Checksum: 3FC00000 Mfg: INTEL Adapter: PA-G021 Prec: 621-0086-005 Act: 644-0016-001 Passed: 992 Failed: 4 System Yld: 98.
Supervisor Menus M a in M e n u Job Advance Pocket Align Pocket Purge Socket Home Operation System Robot Diagnostics Programmer Diags Event Log Job View Results • HOME sends the PNP Head to the Home position. • Light gray shaded fields cannot be changed. End Select So c ke t Job Name Device: E28F320 Checksum: 3FC00000 Mfg: INTEL Adapter: PA-G021 Prec: 621-0086-005 Act: 644-0016-001 Passed: 992 Failed: 4 System Yld: 98.7 Prgrmr Yld: 99.6 Handler Yld: 99.5 Parts/Hour: 255 MCBI: 201 Skt 1 Yld: 99.
Supervisor Menus, continued Robot Diags Robot: Run Mode: Belt Sensors Socket Probe 1– 4 Head Position 10 P ro gr a m m e r Enabled Job/Dry Run Move:Fwd/Bkw Pick Sensor: 0 Speed: 400 ± 10 Measure Device Adjust Device Tape Sprocket: 0 Tape Broken: 0 Reject Full: 0 Reject Bin: 1 Air: 1 Interlock: 0 E-Stop: 0 +Overtravel: 0 Home: 1 State: Up Actuate: 0 Act.
Supervisor Menus, continued Opera tion Job Head Probes Teach Pick Retries: 2 Error Retries: 3 Pocket Pitch: 4 Pocket Advance: 3 Velocity: 250 Accel: 700 Puff: 50 Pick: 200 Place: 100 Travel: 250 Tape: 40.0 Skt 1: -26.85 Reject: -166 Belt: -180 Restore Defaults • Light gray shaded fields cannot be changed. 11 System Time Odometer Update Software Network System Hour: 4 Minute: 55 Month: 9 Day: 23 Year: 2002 Hours: 469.92 Devices: 24742 Timekeeping: OFF Erase: 0.0s Blankcheck: 0.0s Program: 0.
Warnings and Cautions 12 Compressed Air Point air hoses away from body. Always wear approved eye protection. Loud Noise Sound pressure levels may exceed 85db. Hearing protection is recommended for prolonged exposure at this level. High Voltage Turn power off before removing electronics cover. Heavy Object This equipment weighs approximately 15Kg (35 lbs). Do not drop. Mount only with approved hardware. Moving Parts Pinch warning. Keep hands away from moving parts.
Chapter 2 Mounting on the Assembly Machine...... 12 Connecting Power and Air ...... 16 Connecting the Communications Cable (optional).......18 Running the Self-Test ......
Mounting on the Assembly Machine To mount RoadRunner on an assembly machine: 1 1. With the feeder table pulled out, slide the supplied hook around a pin on the assembly machine feeder table. 2. Secure the hook to the table by tightening the thumbscrew. 2 NOTE: A black hook must be used on taller RoadRunners; a silver hook on older models. The label on the conveyor indicates which hook to use. Warning: Heavy; 16 kg (35 lbs). Do Not Drop. Mount Only With Approved Hardware.
3. Slide RoadRunner under the hook so that its centering teeth engage the pin next to the hook. 4 4. Lower RoadRunner allowing the feeder table dowels to mate up with the bushings in the RoadRunner housing. 5. Verify that RoadRunner is secure before moving the feeder table back into the SMT machine.
Connecting Power and Air To connect the power and the air: 2 1. Turn the RoadRunner power switch to the Off (0) position. 2. Grasp the air hose behind the “quick connect” collar and push it firmly onto the male fitting. The collar must be allowed to move back as it goes onto the fitting. 1 NOTE: Compressed air must be clean and dry at approximately 5.25 kgf/cm2(75 psi). Warning: Point Air Hoses Away From Body. Wear Approved Eye Protection.
3. Connect to a grounded power source using a cable with a standard IEC 320 plug. RoadRunner accepts power between 100 and 240 VAC, 50/60Hz. NOTE: To disconnect the air hose, grasp the collar on the connector and pull back. 3 The air line is equipped with a “quick connect” that will stop airflow when disconnected.
Connecting the Communications Cable To connect the Communications Cable (option): 1. Correctly orient the connector (the red dot will be on top) and plug it into RoadRunner. 1 The socket is located on the back side—facing the SMT feeder table.
2. Similarly orient and plug the other end of the cable into the SMT feeder table. Use the socket that corresponds with the track that RoadRunner is mounted on. To unplug the cable, pull back on the connector collar.
Running the Self-Test To run the Self-Test: 1. Turn the power switch On (I). All the control panel indicator lights will come on. When the Self-Test finishes, the blue light will remain on and the version number will display. 1 ProLINE-RoadRunner Data I/O Corporation Version: 02.00.00.B If all the indicator lights start blinking, a serious error has occurred. Turn the unit off then on again. If the error continues, have the unit serviced. 2. If no errors display, RoadRunner is operation ready.
Chapter 3 Inserting a Job Card ..... 22 Changing the Precisor ..... 24 Changing the Actuator Plate..... 26 Changing the Socket Adapter..... 28 Adjusting the Tape-In Module ..... 30 Loading a Reel of Devices ..... 32 Job Setup 21 ProLINE-RoadRunner Operator’s Guide A Aligning the Tape Pockets .....
Inserting a Job Card 1 To run a job, insert a TaskLink job card in the PCMCIA card slot. Use only TYPE I or TYPE II PCMCIA cards. To insert a job card: ProLINE-RoadRunner Data I/O Corporation Version 02.00.00.B 1. If the power switch is on, make sure the blue lamp is lit. Caution: Electrostatic Discharge May Cause Damage. Discharge Static Against Common Ground Prior to Inserting Job Card.
2. Slide the job card into the PCMCIA card slot. NOTE: When fully inserted, the job card extends slightly from the PCMCIA card slot. 3 2 3. The Card Eject button can be pushed to remove the card. Do not eject the card unless the blue lamp is lit (or the power is off).
Changing the Precisor To change the precisor: PNP Head Cover 3 1. Select Job, then End, wait for the blue lamp to light and turn the power Off (0). 2. Lift off the Robotics Cover. 3. Starting at one end, pull the precisor down off the magnet, and then pull the other end off. The PNP Head Cover can be removed for easier access. Warning: Pinch Warning. Keep Hands Away From Moving Parts.
4. When inserting the new precisor, make sure that the part number faces up and that the small holes near the precisor edge fit over the dowel pins on the PNP head. There should be no visible gap between the precisor and the head.
Changing the Actuator Plate To change the Actuator Plate: PNP Head 1. Select Job, then End, wait for the blue lamp to light and turn the power Off (0). 2. Lift off the Robotics Cover. Once power is off, the PNP Head can be moved by hand to allow access to the Actuator Plate. Warning: Pinch Warning. Keep Hands Away From Moving Parts.
3. Pull the Actuator Plate to slide it out of the grooved brackets. NOTE: The Actuator Plate must be out to access or change the Socket Adapter. To change the Socket Adapter, see the procedure on the following page.
Changing the Socket Adapter To change the Socket Adapter (with the Actuator Plate removed): 1. Make sure the power is Off (0). 2. Unscrew the two captive screws and lift the adapter bracket. 2 2 Warning: Pinch Warning. Keep Hands Away From Moving Parts. Caution: Electrostatic Discharge May Cause Damage. Discharge Static Against Common Ground.
3. Without touching the gold contact surfaces on the bottom of the adapter, lift the adapter free. 4. Insert the correct adapter, making sure that it seats on the dowel pins. NOTE: Each type of device may have its own Socket Adapter. 5. Tighten the screws and replace the Actuator Plate.
Adjusting the Tape-In Module If you have an Adjustable Tape-In Module, you may need to adjust the tape width. Non-Adjustable Adjustable Tape-In Module only— If the etched number on the 3-Position Spacer does not match your tape width dimension (mm): Adjustable Current Setting 2 30 ProLINE-RoadRunner Operator’s Guide 1. With the power off (0), move the PNP Head out of the way. 2. Loosen the Position Locking Screw using a 4 mm Allen wrench.
3 5 3. Rotate the 3-Position Spacer with your finger until you read 16, 24 or 32, corresponding to your tape width. 4. Retighten the Position Locking Screw. 4 5. Rotate the Peel Bar counterclockwise 180 degrees to the up position. 6 6 6. Lift and move the magnetic Front Track to the position that fits your tape width. 7. Rotate the Peel Bar back down.
Loading a Reel of Devices To load a reel of devices: 1. Make sure the reel is correctly installed in the rack of the assembly machine. NOTE: A reel axle is required. 2. Insert the tape into the Tape-In Module and onto the sprocket. 2 4 3. Select Advance Pocket from the Operator Menu, then press the Up Arrow button. 4. When the tape is advanced past the peel bar, separate the cover tape from the device tape.
5. Thread the cover tape up through the cover tape path and attach it to the Cover Tape Take-Up Reel. Advance the tape as necessary. 5 NOTE: A small piece of adhesive tape may be needed to stick the cover tape to the Take-Up Reel. 6. Turn the Take-Up Reel to take up slack cover tape. Align the tape pockets as described in the following procedure.
Aligning the Tape Pockets To align the tape pockets: 1. Select Align Pocket from the Operator Menu. 1 Job Advance Pocket > Align Pocket Purge 2 2. Press the Up Arrow button to advance the tape until the next tape pocket center hole is approximately centered at the pick point alignment mark. Do not advance devices past the pick point. They may fall and jam the tape path. Do not use the Down Arrow to align.
Chapter 4 Running a Job ......... 36 Pausing or Stopping a Job ......... 37 Ending a Job ......... 38 Emptying the Reject Bin ......... 40 Emptying Cover Tape ......... 41 Shutting Down ......... 42 Restarting a Job .........
Running a Job To run a job: 1. Insert a job card in the PCMCIA card slot. 2. Clear the conveyor belt of any unneeded devices. > Job Advance Pocket Align Pocket Purge 3. Press Start. 3 When the programmed devices reach the assembly machine pick point, the belt will pause and the green lamp will stay lit without blinking. 1 36 The green lamp will start blinking.
Pausing or Stopping a Job 2 To pause at the end of the current operation: 1. Press Pause on the control panel. To instantly stop in an emergency situation: > Job Advance Pocket Align Pocket > Job Advance Pocket Align Pocket 2. Press the Emergency Stop button. 1 Warning Electrical shock hazard. The E-Stop does not stop electricity to RoadRunner.
Ending a Job Whenever you are going to change job cards, you must first end the current job. To end the current job: > Job Advance Pocket Align Pocket 2 View Results > End 1 38 ProLINE-RoadRunner Operator’s Guide A 1. Press Pause button. 2. Choose End from the Job Menu. Job is in the main menu. The system will finish processing devices and place the devices on the belt, but no additional devices will get picked from the tape.
3. Clear away excess devices from the conveyor belt. 3 4. Empty the Reject Bin. (See next heading.) 5. Empty the Cover Tape Take-Up Reel. (See “Emptying Cover Tape” ahead several pages.
Emptying the Reject Bin To empty the Reject Bin: 1. Press the Pause button. 2 2. Pull the Reject Bin out by grabbing the finger tab and then lift up and out. When reinserting the Reject Bin, be sure the bin is completely lowered so that the tab is positioned out of the path of the probes. Warning: Pinch Warning. Keep Hands Away From Moving Parts.
Emptying Cover Tape To empty the Cover Tape Take-Up Reel: 1. Press Pause. 2. Cut the cover tape, leaving enough slack to reattach. 3. Pull the Take-Up Reel straight out. (Reels with slots require rotating before pulling off.) 4 3 5 4. Unwind the used cover tape and discard it. 5. Replace the Take-Up Reel—slide it on and rotate it to line up with the pins, and push (or twist). Warning: Pinch Warning. Keep Hands Away From Moving Parts.
Shutting Down To shut down RoadRunner: 1. Press Pause. 2. Select End Job from the Job Menu and wait for all devices to be placed on the belt. > Job Advance Pocket Align Pocket 3 3. Turn the power Off (0). 4. Remove devices from the conveyor belt.
5. Empty the Reject Bin. 5 6. Remove and empty the Take-Up Reel. (For more, see the previous heading.) 7. Remove the air hose or shut off the air flow. NOTE: When disconnecting the air hose, pull the connector collar back as you pull the connector off.
Restarting a Job 1 3 To restart RoadRunner after a pause or an emergency stop: Job Advance Pocket > Align Pocket Purge 1. Turn the Emergency Stop button clockwise to release it, if needed. 2. Press Menu until the main level menu is displayed 4 3. Select Align Pocket. 5 4. Press the Up Arrow to advance the device tape until the next pocket center hole lines up with the alignment mark. 5. Press Start. The job will resume.
Chapter 5 Cleaning with Air.......... 46 Cleaning with Alcohol.......... 47 Running the Self-Test..........
Cleaning with Air To prevent dust accumulation, inject compressed air into the following component areas: 1. Tape-In Module (weekly). 2. Sockets (daily). Sockets should be opened and closed by hand while air is injected. 1 2 NOTE: Compressed air must be clean and dry. Warning: Point Air Hoses Away From Body. Wear Approved Eye Protection.
Cleaning with Alcohol 2 To prevent dust and oil accumulations, clean the following component areas with isopropyl alcohol on a lint-free cloth. 1. Chassis and Covers (every 3 months). 2. Conveyor belt (daily). See "Device Rotation" in the Troubleshooting chapter. 1 NOTE: Dry the conveyor belt before rotating it. These intervals are based on running 40,000 devices weekly.
Running the Self-Test Run the Self-Test procedure approximately once a week. To run the Self-Test procedure: 1. Press Pause. 3 > Job Advance Pocket Align Pocket 2. Clear all devices from the sockets and from the conveyor belt. 3. Toggle the power switch off and then back on. 1 The Self-Test will run, checking the condition of the components. 4. Check the display for system errors.
Chapter 6 Viewing Errors............ 50 Enabling a Socket............ 52 Clearing Jammed Tape............ 53 Device Rotation............ 54 Technical Support............
Viewing Errors To view and correct errors: 1. Messages will appear in the keypad display. 2. Check the condition—tape path, Reject Bin, etc.—implied by the message. 1 Inadequate Air Pressure > U8 RevA ID27 Devices: 800 Rejected: 0 Parts/Hr: 567 3 If you cannot correct the error condition, contact a service technician. 3. Press Menu to remove the message. If there are other error messages the next one will appear.
Some common error messages are listed below. For more information see “Troubleshooting” in the ProLINE-RoadRunner Owner’s Manual. Stop Caution Motor Controller not responding Lamp Color E r ro r M e s s a g e No change in lamps Yellow Card not present Blue Blue Blue 1 Reject Bin needs to be emptied Cover tape broken Emergency Stop is activated1 Motor controller not responding Twist the Emergency Stop button to release it.
Enabling a Socket If a socket repeatedly becomes disabled, RoadRunner should be serviced. To re-enable a disabled socket: 1. Choose Socket from the top level menu. 2. Arrow down and select the disabled socket from the Socket menu. (A dot appears.) 1 52 Advance Pocket Align Pocket Purge > Socket 3 • Socket 1: Disabled Socket 2: Enabled Socket 3: Enabled Socket 4: Enabled ProLINE-RoadRunner Operator’s Guide A 3. Press the Up Arrow button to re-enable the socket.
Clearing Jammed Tape 2 Cut Cvr 4 2 Cut Pckt Tape If the tape jams, an error message displays and the blue lamp illuminates. To clear the tape path: 1. Press the Emergency Stop button (to continue the job later) or select Job, then End, and turn the power off. 2. Unroll one turn of cover tape and cut it near the Take-Up Reel. 3 3. Pull the tape out backwards until the cover tape end is free. 4. Cut the device tape. 5. Pull the tape out where it exits to remove it from the machine.
Device Rotation If devices rotate excessively on the conveyor belt: 3 Clean 1. Press Pause. Wait for all the devices to get picked from the belt. 2. Press the Emergency Stop. 3 Dry 3 Rotate & Repeat 54 ProLINE-RoadRunner Operator’s Guide A 3. Remove the Dust Cover and clean only the exposed surface of the conveyor belt with isopropyl alcohol on a lint-free cloth, then dry it. Rotate the belt by hand and repeat until clean. 4.
Technical Support Contact your local Data I/O representative. Worldwide To find your local representative, go to http://www.dataio.com/contact/repsearch.asp Data I/O Corporation Shipping address: 10525 Willows Road N.E. Redmond, WA USA 98052 Mailing address: P.O. Box 97046 Redmond, WA USA 98073-9746 Telephone: Fax: E-mail: 425-867-6870 USA Only: 1-800-332-8246 425-882-1043 support@data-io.com You can also find answers by visiting our Knowledge Base on our Web site at www.dataio.
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