Data I/O ProLINE RoadRunner, RoadRunner-XLF, TaskLink Owner's Manual

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Covers all models.
Includes a fill-in
maintenance chart.
Contents
Overview
Installation
Operation
See
separate Service Manual
Maintenance
ProLINE-RoadRunner
Owner’s Manual
Troubleshooting
TM
Glossary
PN 096-0240-005H
Index
1 Overview
1
General Descriptions • TaskLink™ • Safety Precautions • Specifications
2 Installation
2
Unpack • Setup • Power Up
3 Operation
3
Keypad Operation • Menus • Programming • Yields • Updates
Order form for Service Manual
(See separate Service Manual for:
4
• Replacement Procedures • Basic Spare Parts • Self-Service Spare Parts • Order Forms)
5 Maintenance
5
Preventive Schedule • Diagnostics • Sign-off Chart
6 Troubleshooting
6
Error Messages • Other Problems
Glossary
Index
Sales and Technical Support contact numbers are after the index.
G
I
Data I/O has endeavored to ensure that the information in this document is accurate and complete. Data I/O assumes no liability for errors, or for any incidental, consequential, indirect, or special damages, including, without limitation, loss of use, loss or alteration of data, delays, or lost profits or savings, arising from the use of this document or the product which it accompanies.
No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without written permission from Data I/O Corporation. Data I/O order forms may be reproduced for internal use only.
Data I/O is a registered trademark of Data I/O Corporation, as are
ProLINE‐RoadRunner and TaskLink.
Data I/O Corporation acknowledges the trademarks of other organizations for their respective products or services mentioned in this document.
The Technical Documentation Department also acknowledges the RoadRunner team members for their efforts in supporting the flow of information into this manual.
We are interested in your comments. email: [email protected]
© 2004–2010 Data I/O Corporation
All rights reserved
Contents
096-0240-005H
1 • Overview
RoadRunner is — 1–1
Warning and Caution Notes 1–3
Overall System Description 1–4
Development of the Programming Instructions for a Job
Control Panel 1–5
Blank Devices 1–5
Tape Advancement 1–5
Robotic System 1–6
Programmer Module 1–8
Output Conveyor 1–10
Reject Bin 1–10
TaskLink’s Handshake with RoadRunner 1–11
PCMCIA Memory Card Capacity Requirements

Safety 1–12

Precautions for Safe Operation 1–14
Specifications [Assembleon] 1–15
Specifications [Fuji QP, IP, XP] 1–16
Specifications [Fuji NXT, AIM] 1–17
Specifications [MYDATA] 1–18
Safety Features
1–4
1–11
1–12
Specifications [Panasonic CM20, CM120, CM301] 1–19
Specifications [Panasonic CM401, CM402, CM602, DT401] 1–20
Specifications [Panasonic MSF, MCF, MPAV2B, MPAG3] 1–21
Specifications [Siemens, XLF, SIPLACE X] 1–22
Specifications [Universal GSM] 1–23
Specifications [Universal Genesis] 1–24
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240
i
2 • Installation
Unpacking the RoadRunner 2–1
Removing the Shipping Bracket 2–2
Mounting the RoadRunner 2–3
Mounting RoadRunner [Assembleon ACM] 2–4
Mounting RoadRunner [MYDATA MY9, MY12, MY15, MY19] 2–
6
Mounting RoadRunner [Fuji QP242, QP351, IP3, XP142E] 2–8
Mounting RoadRunner [Fuji NXT, AIM] 2–10
Mounting RoadRunner [Panasonic MSF, MCF, MPA] 2–11
Mounting RoadRunner [Panasonic CM20, CM120, CM301] 2–
12
Mounting RoadRunner [Panasonic CM401, CM402, DT] 2–14
Mounting RoadRunner [Siemens 80F4, 80F5, F, S, HS] 2–17
Mounting RoadRunner [Siemens SIPLACE X2, X3, X4, X4i] 2–
20
Mounting RoadRunner [Universal GSM1,GSM2, Genesis] 2–22
Installing the Reject Bin 2–24
Making the Necessary Connections 2–25
Electrical Input Requirements 2–25
Pneumatic Input Requirements 2–26
Connecting the Communications Cable
2–28
Applying Power for the First Time 2–30
Turning Power On
2–30
Configuring for Network Communication 2–31
Configuring TaskLink 2–31
Configuring RoadRunner 2–31
3 • Operation
Operator Functions 3–1
Basic Operator Steps 3–1
Turning On System Power 3–2
Menus Available to the System Operator 3–3
Keypad Operation 3–4
Setting Up RoadRunner for a Programming Job
Programming Devices 3–18
Miscellaneous Settings via the Menu 3–23
Supervisor Functions 3–24
Menus Available to the System Supervisor
Setting Operational Parameters 3–27
Setting System Parameters 3–31
Network Settings 3–34
Configuration 3–34
Robot Diagnostics 3–35
Programmer Diagnostics 3–36
ii
3–5
3–24
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240
Event Log 3–37
Results 3–37
Session Data Log
3–38
4 • Service information . . .
. . . is in a separate manual, with its own Table of Contents and Index. 4–1
5 • Maintenance
Tools Required 5–1
Preventive Maintenance Schedule 5–2
Lubricating the Ball Screw
5–3
Diagnosing with the Adapter Board 5–5
Running Diagnostics on a Programmers

5–5
Electrical Equipment Disposal Notice 5–7
RoHS for China 5–7
Maintenance Sign-off Charts 5–8
Notes:
5–9
6 • Troubleshooting
Colored Lamp Significance 6–1
Resolving Problems 6–2
Testing the Programmer 6–2
Viewing Errors 6–2
Clearing Jammed Device Tape 6–2
Disabling and Enabling a Socket 6–3
Error Messages 6–4
No Change in Lamps 6–4
Yellow Lamp is On 6–4
Blue Lamp is On 6–7
Unlisted Error Messages 6–14
Problems, but no Error Message 6–15
Schematics 6–22
Pneumatic Schematic 6–22
Electrical Schematic 6–23
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240
iii
Glossary • Glossary of Terms
Alphabetical List of Terms Glossary–1
Index • Index
Alphabetical Index Listing Index–1
iv
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240
Chapter
1
1Overview
RoadRunner is —
ProLINE-RoadRunner™ is a compact, portable, automated
programming and handling system that mounts directly to a Surface Mount
Technology (SMT) Placement Machine. Easy to use and small enough to fit
within the profile of a component feeder, the ProLINE-RoadRunner programs and delivers devices to the pick region of placement machines, allowing our customers to integrate device programming and placement.
In this chapter you’ll
learn about
RoadRunner’s compact,
component units called
modules, safety precautions, ESD, and stopping
in an emergency. You can
also learn about the latest
programmer architecture
and High Force Conversion Kits.
RoadRunner is available for many different SMT Placement machines; some
are shown on the next page. Other models for each SMT machine may also
available, such as the RoadRunner-XLF (Extra Large Format). XLF
RoadRunners run devices up to 32 mm Wide x 32 mm Long x 6 mm High.
The Standard RoadRunner programs devices up 21.65 mm W x 15 mm L x
3 mm H.
The Three Parts of a ProLINE-RoadRunner System
PCMCIA Card
RoadRunner
TaskLink
Figure 1-1—The ProLINE-RoadRunner System is TaskLink Software,
a Job Card, and the RoadRunner [Universal Model shown]
(Notebook PC not included.)
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
1—1
Overview • RoadRunner is — ••
1
Fuji QP, IP
Assembleon
XLF on Siemens F5
Siemens
Fuji NXT, AIM
Universal GSM
Panasonic MSF
MYDATA
Panasonic CM20
Panasonic CM, DT
1—2
Figure 1-2—Various Standard RoadRunner
Models attached to corresponding SMT
machines and one XLF RoadRunner.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Overview • Warning and Caution Notes ••
1
Warning and Caution Notes
Special paragraphs in this manual warn about potentially hazardous situations and recommend safe practices to help avoid them.
! WARNING
Indicates conditions that can cause personal
injury or serious monetary loss.
A warning looks like this.
CAUTION: Indicates conditions that can cause damage to equipment.
A caution looks like this.
They are included to help the operator use the system safely and efficiently.
Key to Symbols Used in this Manual
General warning. Calls your attention to general caution and
warning notes.
Electrostatic Discharge (ESD) may cause damage. Discharge static against a common ground.
High voltage. Turn power off before removing electronics
cover.
Crush hazard. Keep hands away from moving parts.
b
Compressed air. Point air hoses away from body. Always
wear approved eye protection.
Heavy equipment. Use caution. May require two people. Or,
mount properly using approved hardware.
Equipment can tip over (such as feeder carts with some
RoadRunners on them). Remove RoadRunner before moving cart.
Collision hazard.Some situations can cause machinery to
collide with object or people items are installed incorrectly.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
1—3
Overview • Overall System Description •• Development of the Programming Instructions for a Job
1
Overall System Description
The ProLINE-RoadRunner System consists of RoadRunner (which attaches
to SMT Placement machines), TaskLink™ software for Windows-based
PCs, and a PCMCIA card (PC-Card). TaskLink is needed to create programming jobs for RoadRunner. PC-Cards store jobs and contain job statistics.
Using prepared programming instructions and blank devices, RoadRunner
picks, programs, and delivers the devices to the pick region of an SMT
Placement machine.
NOTE: This manual refers to the RoadRunner, TaskLink software,
and a job card as the “ProLINE-RoadRunner,” or the
“ProLINE-RoadRunner System.” The term “RoadRunner” then, is
used to mean the hardware unit that attaches to the SMT placement
machine.
Development of the Programming Instructions for a
Job
Programming instructions are developed using TaskLink™ for Windows.®
The instructions are stored on PCMCIA Type I or II job cards that are
formatted for RoadRunner.
A RoadRunner operator can start a job by inserting a job card and pressing
the Start button on the control panel.
Start
Figure 1-3—The RoadRunner Control Panel and Display Screen
1—4
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Overview • Overall System Description •• Tape Advancement
1
Control Panel
The Control Panel is a keypad and display that provides a User Interface
(UI) to the RoadRunner programming system.
The main function of the Control Panel is to accept input (commands) from
the operator via the keypad, while providing visual or auditory feedback to
the operator regarding status of the system.
Blank Devices
Before starting a job, the operator must mount a reel of tape containing blank
devices onto the RoadRunner or placement machine cart. Once the device
tape is threaded into the RoadRunner and a job is started, the RoadRunner
will pick devices from the tape and advance the tape automatically.
Periodically, new device tape must be loaded and the cover tape take-up reel
must be emptied.
Tape Advancement
Tape advancement includes three functions—advancing the device tape,
separating the cover tape from the device tape, and collecting the cover tape.
Tape-In Module
A stepper motor drives a sprocket that advances the device tape via
sprocket holes along the tape’s edge. Tape movement is stepped, allowing
the tape to stop each device directly under the pick point. The empty
device tape is expelled at the front of the RoadRunner or near the front
below the conveyor. Different Tape-In Modules are available for different
width device tape, and there is an adjustable module that accommodates
16, 24, and 32 mm tape.
The XLF models also have an adjustable Tape-In Module that accommodates 32 and 44 mm tape.
Cover Tape Module
The Cover Tape Module winds up used cover tape so it can be disposed of
by the operator. A DC motor, synchronized with the tape advance motor,
drives the Take-up Reel that winds up the separated cover tape. The cover
tape is threaded around a peel bar that separates it from the device tape.
Some cover tape is sticky enough that it will affix directly to the reel, while
other cover tape must be fastened to the reel with a piece of adhesive tape.
Refer to Figure .
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
1—5
Overview • Overall System Description •• Robotic System
1
Cover Tape
Motor
Cover Tape
Take-Up R eel
Figure 1-4—Loading Cover Tape [Siemens model shown]. Note that on XLF
Models the cover tape rotation is in the opposite direction.
Robotic System
A four-probe Pick and Place (PNP) head driven by a linear stage ball screw
constitutes RoadRunner’s robotic system.
NOTE: Some RoadRunner models are designed to operate with
fewer than four probes.
A stepper motor controls ball screw movement which produces travel in
the horizontal axis. Air cylinders control individual probe up and down
motion. Together, these components pick, collect, and place devices as
directed.
The standard robotic system uses the “collect and place” principle to:
• pick one device at a time from the device tape until four (or less depending on the Socket Adapter) devices are collected
• place the devices into the programming sockets, one at a time
• pick the programmed devices out of the sockets, one at a time
• gang place up to four devices on the conveyor belt, or place failed
devices into the Reject Bin.
RoadRunners, including the large format RoadRunners (XLF), may operate
with one, two, three, or four probes to collect and place devices, determined
by the Socket Adapter.
1—6
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Overview • Overall System Description •• Robotic System
1
PNP Head
(& Cover–
some
models)
Serial number
label
Linear Stage
Module
Programmer
Module
Figure 1-5—PNP Head Positioned above Programming Sockets
[Fuji Model Shown]
Pick and Place Head
The Pick and Place Head (PNP) is the portion of the robotic system responsible for picking, collecting, and placing devices. It houses four pneumatic
cylinders, and four hollow probes for air flow. The pneumatic cylinders
feature spring return to the upper position. The probes incorporate a measure
of compliance to allow contacting all sizes of devices without applying
excessive force.
The probes have rubber tips which must be kept clean in order to create
adequate suction against the device.
The PNP Assembly will not move until all four probes are in their up position.
Linear Stage
A linear stage—consisting of a stepper motor, encoder and ball screw—
moves the PNP head linearly to accommodate the following positions:
RoadRunner runs at
slow speed when the
Robotic Cover (safety
shield) is not in place.
• device tape pick point,
• reject bin,
• programmer sockets,
• and programmer sockets.
The linear stage motor receives signals from the motion controller via an
amplifier. The PNP head is, itself, part of the Linear Stage Module.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
1—7
Overview • Overall System Description •• Programmer Module
1
Figure 1-6—Pick and Place Assembly with Probes.
Not shown: PNP Cover and the Precisor (XLF models do not use either).
Vacuum Probes
The rubber-tipped probes use vacuum produced by the Pneumatic Module to
pick up devices. The probes also deliver a puff of air to release the devices.
Vacuum sensors detect whether a device is present at the end of each probe.
Device Placement Precision
On standard RoadRunners (not XLF), each probe brings its device into
contact with the alignment plate, called a precisor, to center the device on the
probe before placing it into a programming socket. Precisors are generally
device-package specific.
Programmer Module
The Programmer Module writes data into the devices. From a mechanical
standpoint, it consists of device-specific sockets on an adapter and an actuator. The Programmer Module is responsible for:
• opening the sockets
• ID checking, blank-checking, continuity-checking and erasing the
devices, if selected
• writing data to the devices
• verifying the data written to devices
Opening the Sockets
The device sockets on the adapter are normally closed. To open the sockets,
pneumatic cylinders pull the Actuator Plate down. Once the sockets are
loaded they close again, keeping the device leads in contact with the socket
pins.
1—8
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Overview • Overall System Description •• Programmer Module
1
High Force Actuation
Prior to October 2007, four pneumatic cylinders were used to pull the Actuator Plate down. Since 2007, and the introduction of our HIC Socket Adapters, more force is required. High Force Conversion Kits are available
allowing pre-2007 RoadRunners to use HIC Adapters. (Later models actuate
HIC Adapters without conversion kits.)
The following charts lists upgrade kits available for new programmers as
well as higher force actuation.
Sales Part Description
Description
RR-PROG MOD HF KIT FCII
–Upgrade to High Force FlashCORE II programmer.
RR-PROG HF UPGRADE KIT
–Upgrade to High Force actuation only.
RR-FCIII UPGRADE KIT
–Upgrade to FlashCORE III programmers.
Programming Devices
FlashCORE II is the second
iteration of this programming architecture. Contact
Data I/O for FlashCORE
Upgrade Kits.
The RoadRunner programmer architecture, called FlashCORE, was developed specifically for very high-speed programming of Flash memory
devices. Up to four devices are programmed simultaneously according to the
instructions from the particular job on the job card. Job cards must be
programmed using TaskLink for Windows.
In addition to programming the devices, the programmer can perform a
continuity check, a blank check, an electronic identification check, and a
data verification. If any of these tests fail, the programmer illuminates the
red LED in front of the socket(s) containing the failed device(s) and signals
the robotic system to place the device into the reject bin rather than on the
conveyor belt.
Programming yield statistics are displayed on the screen. If a job is paused or
ended, the statistics are written to the job card.
Programming sockets are a wear item, and therefore, must be replaced periodically. Socket manufacturers provide expected socket-insertion life cycles.
See “Preventive Maintenance Schedule” on page 5-2 for recommendations
for RoadRunner.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
1—9
Overview • Overall System Description •• Reject Bin
1
Output Conveyor
Successfully programmed devices are removed from the programming
sockets by the PNP Head and placed on the conveyor belt, then delivered
to the SMT Placement machine’s pick position.
The conveyor module includes a conveyor belt, a sensor that determines if
devices are at the SMT pick point, and in some models the path for the
empty device tape. The conveyor runs momentarily when a job is started to
determine if there are any unwanted devices on the belt (from a previous
job). The belt stops when a device is sensed at the SMT machine pick
point, when the robot places a new set of devices on the belt, or when it
times out.
Reject Bin
Devices that have failed programming, as determined by data verification,
are dropped into a Reject Bin inside RoadRunner.
The Reject Bin has a sensor that indicates when it is full by displaying a
message on the keypad screen; “Empty Reject Bin.”
1—10
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Overview • TaskLink’s Handshake with RoadRunner •• PCMCIA Memory Card Capacity Requirements
1
TaskLink’s Handshake with RoadRunner
TaskLink for Windows is the software program used to create programmer
instructions for the RoadRunner system. It consists of various utilities for
selecting
• the device to program,
• the data file to write to the device, and
• special programming options specific to the device.
NOTE: The term task refers to a device programming objective
being defined with TaskLink. The term job refers to a set of instructions for programming a specific number of devices with the
RoadRunner.
TaskLink must be installed on a Windows-based PC and configured to work
with the RoadRunner programmer.
To install TaskLink, see the instructions on the CD.
Parallel ATA-2 is an
interface standard for the
connection of storage
devices and uses a PCMCIA form factor: 85.6 ×
54 × 3.3 mm 68 pin dual
row connecting interface.
A PCMCIA memory card drive capable of reading and writing to Parallel
ATA-2 specification must be available to the computer being used. For more
about PCMCIA drives see “PCMCIA Memory Card Capacity Requirements” below.
See TaskLink’s on-screen Help (for RoadRunner) to create a RoadRunner
Job.
PCMCIA Memory Card Capacity Requirements
ProLINE-RoadRunner uses a 68 pin PCMCIA (PC) Card to transfer job
configuration and device programming data from TaskLink software
(running on a PC) to RoadRunner. The PC Card is used to store job files,
statistics/event log, algorithms, and even system updates.
Ensure the card you use will hold your device image data plus 130 KB for
statistics and event files. The general formula used to calculate required PC
card size for one job;
256 KB+device size+130 KB
Remember that 1 MB = 1024 KB.
In general, add 256 KB to device size (for system files). To calculate each
job size, sum all jobs together and add 130 KB for statistics and event files.
For example, when creating a card with two jobs, one for a 28F800 (1 MB)
device and one for a 29LV160 (2 MB) device you would need:
(256 KB+1024 KB)+(256 KB+2048 KB)+130 KB = 3714 KB = 3.8 MB
Use a 4 MB minimum ATA card for this configuration.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
1—11
Overview • Safety •• Safety Features
1
NOTE: The system operator can only access a single job from the
PCMCIA memory card. If there is more than one job on the card,
then the last job selected by the system supervisor is the one used. It
is recommended that only one job be placed on each PC Card to
avoid operator confusion.
NOTE: Data I/O recommends that a 2 MB minimum card be used
for even a single job.
CAUTION: PCMCIA Cards for use with RoadRunner
must be formatted with FAT 16. The current Windows
default is FAT 32. The card must be x40 speed.
For information on card reader/writers that work with your computer system
and ProLINE-RoadRunner, see Card Reader/Writers on our Web site at:
http://www.dataio.com/support/ and then:
1.
Click Knowledge Base Search.
2.
Sign in, or click Use the Knowledge Base without signing in.
3.
In the Keywords field, type Card Reader.
4.
Click Search.
5.
Click the document name to open it.
Safety
Safety Features
The RoadRunner has several safety systems to reduce the likelihood of
personal injury and machine damage during operation. These systems
include:
1.
1—12
Safety Shields and Interlocks
During RoadRunner operation the metal and plastic safety shield
(Robotics Cover) covers the operating area to protect operators from
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Overview • Safety •• Safety Features
1
injury. If the shield is opened, robot movement will reduce to halfspeed.
! WARNING
Risk of injury. System robotics can injure your
hands or fingers. Do not operate the RoadRunner
with covers removed. When working inside the
RoadRunner, turn the power off.
2.
Emergency Stop Button (E-Stop)
When the E-Stop button (located on the keypad) is pressed, the
RoadRunner automatically removes power from all motion motors. The
blue status lamp illuminates, and the programmer completes its programming cycle. The programmed devices will remain in their sockets.
Figure 1-7—Emergency (movement) Stop Button
! WARNING
Shock hazard. Do not use the E-Stop button to turn
off power to the RoadRunner. The E-Stop button
does not completely remove power from the
machine. Only power to the motion motors is shut off. Power
is still applied to all of the other electronic systems.
CAUTION: The Emergency Stop button does not stop the
SMT Placement equipment.
The Emergency Stop condition will not be cleared until the E-Stop button is
restored to its run position. To restore the button to the run position, turn the
Emergency Stop button clockwise until it springs back to its full height.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
1—13
Overview • Precautions for Safe Operation •• –
1
Precautions for Safe Operation
The RoadRunner System has been designed for safe and efficient operation.
The system can be dangerous if the RoadRunner safety features and
precautions in this manual are ignored.
To avoid possible personal injury or damage to the equipment, please
observe the following practices:
Electrostatic
Discharge
The circuit boards inside
RoadRunner are susceptible to electrostatic
discharge (ESD), which
can damage the circuitry.
Also, devices processed
through the RoadRunner
are very sensitive to
static and can be
damaged by accidental
electrostatic discharge
while being handled.
The easiest way to
prevent damage from
ESD is to make sure a
common static potential
(ground) exists between
static-sensitive devices
or components, their
environment, and the
operator.
•
Only trained personnel should install, maintain, repair, or troubleshoot
this system.
•
Do not operate the ProLINE-RoadRunner unless you have been thoroughly trained, and have read and understand the instructions in this
manual, particularly those that describe the system’s safety features.
•
Do not use ProLINE-RoadRunner for any application other than its
intended use.
•
Do not operate the system if the guards or safety devices are not in
their normal operating positions.
•
Do not operate RoadRunner with any of the outer sheet metal panels
removed.
•
Do not operate RoadRunner while servicing, replacing, or adjusting any
component unless directed to do so in this manual. Make sure that the
RoadRunner is properly shut down before performing any of these
operations.
•
Do not place any part of your body near or in the direct path of moving
parts.
•
Do not disable or attempt to defeat any of the protective safety features
of this system. Personal injury or equipment damage can occur if any
safety systems on RoadRunner are disabled. If you suspect that a safety
feature of the RoadRunner is damaged or malfunctioning, stop using the
RoadRunner immediately and contact Data I/O Customer Service or a
local Data I/O approved service representative.
•
Use extra caution when working around the RoadRunner’s Output Belt.
RoadRunner’s safety shields do not cover or fully enclose the output
conveyor. It is possible that an operator’s hands, other body parts, or
loose clothing can get caught or pinched in it.
•
Wearing hearing protection is recommended while operating the
RoadRunner. Sound pressure levels may exceed 85 decibels.
•
Shut off the pressurized air or disconnect the air hose before servicing
pneumatic parts.
Perform all repairs at an
ESD-safe workstation.
–
1—14
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Overview • Specifications [Assembleon] •• –
1
Specifications [Assembleon]
FACILITIES
AC input voltage requirements
100-240 V~ ; 50/60 Hz (single phase)
AC Input Power
100 W (max)
Air requirements @ 2dm3/s (4.0scfm)
.52 MPa (75±2psi)
Air Inlet tube (varies)
6 mm (.24 in.) &
8 mm (.31 in.) OD min.
MODELS SUPPORTED
Assembleon models supported (with Assembleon Universal Adapter)
ACM, ACM Micro, AQ-1, AQ-2, D9
DIMENSIONS
Width
78 mm (3.1 in.)
Weight (net)
17 kg (38 lbs)
Length with 33 cm (13 in.) reel
124.5 cm (49 in.)
Approximate length protruding
from SMT machine
63.5 cm (25 in.)
Height with 33 cm (13 in.) reel
49.5 cm (19.5 in.)
Input tape width supported
16 mm; 24 mm; 32 mm (optional:
12 mm, 32 mm-Large Format)
DEVICE OUTPUT PLACEMENT
(at SMT pick point)
Output placement linear repeatability
±.25 mm
Output placement rotational repeatability
±5°
ENVIRONMENT
Operating temperature range
20–40°C (68–104°F)
Temperature stabilization time after transportation
≥ 8h
Humidity
5–90%
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
1—15
Overview • Specifications [Fuji QP, IP, XP] •• –
1
Specifications [Fuji QP, IP, XP]
FACILITIES
AC input voltage requirements
100-240 V~ ; 50/60 Hz (single phase)
AC Input Power
100 W (max)
Air requirements @ 2dm3/s (4.0scfm)
.52 MPa (75±2 psi)
Air Inlet tube (varies)
6 mm (.24 in.) &
8 mm (.31 in.) OD min.
MODELS SUPPORTED
Fuji models supported
QP242, IP3, QP351, XP142E
DIMENSIONS
Width
78 mm (3.1 in.)
Weight (net)
14 kg (32 lbs)
Length with 33 cm (13 in.) reel
91.5 cm (36 in.)
Approximate length protruding
from SMT machine
0 cm (0 in.)
Height with 33 cm (13 in.) reel
49 cm (19.5 in.)
Input tape width supported
16 mm; 24 mm; 32 mm (optional:
12 mm, 32 mm-Large Format)
DEVICE OUTPUT PLACEMENT (at SMT pick
point)
Output placement linear repeatability
±.25 mm
Output placement rotational repeatability
±5°
ENVIRONMENT
1—16
Operating temperature range
20–40°C (68–104°F)
Temperature stabilization time after transportation
≥ 8h
Humidity
5–90%
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Overview • Specifications [Fuji NXT, AIM] •• –
1
Specifications [Fuji NXT, AIM]
FACILITIES
AC input voltage requirements
100-240 V~ ; 50/60 Hz (single phase)
AC Input Power
100 W (max)
Air requirements @ 2 dm3/s (4.0 scfm)
.52 MPa (75±2 psi)
Air Inlet tube
8 mm (.31 in.) OD min.
MODELS SUPPORTED
Fuji models supported
NXT, AIM
DIMENSIONS
Width
78 mm (3.1 in.)
Weight (net)
17 kg (37 lbs)
Length with 33 cm (13 in.) reel
104.4 cm (41.1 in)
Approximate length protruding
from SMT machine
74 cm (29 in).
Height with 33 cm (13 in.) reel
49 cm (19.5 in)
Input tape width supported
16 mm; 24 mm; 32 mm (optional:
12 mm, 32 mm-Large Format)
DEVICE OUTPUT PLACEMENT (at SMT pick
point)
Output placement linear repeatability
±.25 mm
Output placement rotational repeatability
±5°
ENVIRONMENT
Operating temperature range
20–40°C (68–104°F)
Temperature stabilization time after transportation
≥ 8h
Humidity
5–90%
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
1—17
Overview • Specifications [MYDATA] •• –
1
Specifications [MYDATA]
FACILITIES
AC input voltage requirements
100-240 V~ ; 50/60 Hz (single phase)
AC Input Power
100 W (max)
Air requirements @ 2dm3/s (4.0scfm)
.52 MPa (75±2 psi)
Air Inlet tube (varies)
6 mm (.24 in.) &
8 mm (.31 in.) OD min.
MODELS SUPPORTED
MYDATA models supported
MY9, MY12, MY15, MY19
DIMENSIONS
Width
78 mm (3.1 in.) without SMT Adapter
Weight (net)
16.5 kg (36.3 lbs) without SMT Adapter
Length with 33 cm reel
120.1 cm (47.3 in.) without SMT Adapter
Approximate length protruding from SMT Feeder Table
outer edge
59.2 cm (23.3 in.) includes 33 cm reel
Height
49.4 cm (19.5 in.) includes 33 cm reel
Input tape width supported
16 mm; 24 mm; 32 mm (optional:
12 mm, 32 mm-Large Format)
DEVICE OUTPUT PLACEMENT
(at SMT pick point)
Output placement linear repeatability
±.25 mm
Output placement rotational repeatability
±5°
ENVIRONMENT
1—18
Operating temperature range
20–40°C (68–104°F)
Temperature stabilization time after transportation
≥ 8h
Humidity
5–90%
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Overview • Specifications [Panasonic CM20, CM120, CM301] •• –
1
Specifications [Panasonic CM20, CM120, CM301]
FACILITIES
AC input voltage requirements
100-240 V~ ; 50/60 Hz (single phase)
AC Input Power
100 W (max)
Air requirements at 2dm3/s (4.0scfm)
.52 MPa (75±2 psi)
Air Inlet tube
8 mm (.31 in.) OD min.
MODELS SUPPORTED
Panasonic models supported
CM20, CM120, CM301
DIMENSIONS
Width
7.8 cm (3.1 in.)
Weight (net)
14 kg (30.9 lbs)
Length with 33 cm (13 in.) reel
84 cm (33 in)
Approximate length protruding
from SMT machine (including reel)
61 cm (24 in)
Height with 33 cm (13 in.) reel
50 cm (19.7 in.)
Input tape width supported
16 mm; 24 mm; 32 mm (optional:
12 mm, 32 mm-Large Format)
DEVICE OUTPUT PLACEMENT (at SMT pick
point)
Output placement linear repeatability
±.25 mm
Output placement rotational repeatability
±5°
ENVIRONMENT
Operating temperature range
20–40°C (68–104°F)
Temperature stabilization time after transportation
≥ 8h
Humidity
5–90%
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
1—19
Overview • Specifications [Panasonic CM401, CM402, CM602, DT401] •• –
1
Specifications [Panasonic CM401, CM402, CM602, DT401]
FACILITIES
AC input voltage requirements
100-240 V~ ; 50/60 Hz (single phase)
AC Input Power
100 W (max)
Air requirements @ 2dm3/s (4.0scfm)
.52 MPa (75±2 psi)
Air Inlet tube
8 mm (.31 in.) OD min.
MODELS SUPPORTED
Siemens models supported
CM401, CM402, CM602, DT401. A
Panasonic Feeder Bank Adapter and
Host Feeder are required.
DIMENSIONS
Width
7.8 cm (3.1 in.)
Weight (net)
15 kg (33 lbs)
Length without reel
99 cm (39 in.)
Approximate length protruding
from SMT machine
55 cm (21.6 in.)
Height without reel
56 cm (22 in.)
Input tape width supported
16 mm; 24 mm; 32 mm (optional:
12 mm, 32 mm-Large Format)
DEVICE OUTPUT PLACEMENT (at SMT pick
point)
Output placement linear repeatability
±.25 mm
Output placement rotational repeatability
±5°
ENVIRONMENT
1—20
Operating temperature range
20–40°C (68–104°F)
Temperature stabilization time after transportation
≥ 8h
Humidity
5–90%
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Overview • Specifications [Panasonic MSF, MCF, MPAV2B, MPAG3] •• –
1
Specifications
[Panasonic MSF, MCF, MPAV2B, MPAG3]
FACILITIES
AC input voltage requirements
100-240 V~ ; 50/60 Hz (single phase)
AC Input Power
100 W (max)
Air requirements at 2dm3/s (4.0scfm)
.52 MPa (75±2 psi)
Air Inlet tube
8 mm (.31 in.) OD min.
MODELS SUPPORTED
Panasonic models supported
MSF, MPAV2B, MPAG3,MCF
DIMENSIONS
Width
78 mm (3.1 in.)
Weight (net)
16 kg (35 lbs)
Length with 33 cm (13 in.) reel
115 cm (45.25 in.)
Approximate length protruding
from SMT machine
76 cm (30 in.)
Height with 33 cm (13 in.) reel
49.5 cm (19.5 in.)
Input tape width supported
16 mm; 24 mm; 32 mm (optional: 12
mm, 32 mm-Large Format)
DEVICE OUTPUT PLACEMENT
(at SMT pick point)
Output placement linear repeatability
±.25 mm
Output placement rotational repeatability
±5°
ENVIRONMENT
Operating temperature range
20–40°C (68–104°F)
Temperature stabilization time after transportation
≥ 8h
Humidity
5–90%
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
1—21
Overview • Specifications [Siemens, XLF, SIPLACE X] •• –
1
Specifications [Siemens, XLF, SIPLACE X]
FACILITIES
AC input voltage requirements
100-240 V~ ; 50/60 Hz (single phase)
AC Input Power
100 W (max)
Air requirements @ 2dm3/s (4.0scfm)
.52 MPa (75±2 psi)
Air Inlet tube (varies)
6 mm (.24 in.) &
8 mm (.31 in.) OD min.
MODELS SUPPORTED
STD & XLF models supported 
SIPLACE X models supported 
• 80F4; 80F5, F, S, HF, HS Series*,
D Series*, X3*
• SIPLACE X2, X3, X4, X4i
model ——
DIMENSIONS — model ——
model ——
Standard
XLF models
SIPLACE X
Width
78 mm (3.1 in.)
99.5 mm (3.9 in.)
78 mm (3.1 in.) (unaffected by SMT Adapter)
Weight (net)
15 kg (33 lbs)
21 kg (45 lbs)
19 kg (41 lbs) includes SMT Adapter
Length (unaffected by reel)
Length including 33 cm reel
Length including 33 cm reel
99 cm (39 in.)
118 cm (46.5 in.)
120.1 cm (47.3 in.) includes SMT Adapter
Approximate length protruding from SMT Feeder
Table outer edge
56 cm (22 in.)
76.2 cm (30 in.) includes (33 cm) reel
70.6 cm (27.8 in.) includes 33 cm reel
Height
56 cm (22 in.) (unchanged by reel)
52 cm (20.5 in.) includes (33 cm) reel
49.4 cm (19.5 in.) includes 33 cm reel
Input tape width supported
16 mm, 24 mm, 32 mm (optional: 12 mm)
16 mm, 24 mm, 32 mm, 44 mm (Opt: 12 mm)
16 mm, 24 mm, 32 mm (optional: 12 mm)
DEVICE OUTPUT PLACEMENT (at SMT pick point)
Output placement linear repeatability
±.25 mm
Output placement rotational repeatability
±5°
ENVIRONMENT
Operating temperature range
20–40°C (68–104°F)
Temperature stabilization time after transportation
≥ 8h
Humidity
5–90%
* Supported using S-type feeder table in feeder positions 2 & 4, except X3 in 4 only.
1—22
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Overview • Specifications [Universal GSM] •• –
1
Specifications [Universal GSM]
FACILITIES
AC input voltage requirements
100-240 V~ ; 50/60 Hz (single phase)
AC Input Power
100 W (max)
Air requirements @ 2dm3/s (4.0scfm)
.52 MPa (75±2 psi)
Air Inlet tube (varies)
6 mm (.24 in.) &
8 mm (.31 in.) OD min.
MODELS SUPPORTED
Universal models supported
GSM1; GSM2
DIMENSIONS
Width
78 mm (3.1 in.)
Weight (net)
17 kg (38 lbs)
Length with 33 cm (13 in.) reel
124. 5cm (49 in.)
Approximate length protruding
from SMT Placement machine
80.8 cm (31.8 in.)
Height with 33 cm (13 in.) reel
49.5 cm (19.5 in.)
Input tape width supported
16 mm; 24 mm; 32 mm (optional:
12 mm, 32 mm-Large Format)
DEVICE OUTPUT PLACEMENT
(at SMT pick point)
Output placement linear repeatability
±.25 mm
Output placement rotational repeatability
±5°
ENVIRONMENT
Operating temperature range
20–40°C (68–104°F)
Temperature stabilization time after transportation
≥ 8h
Humidity
5–90%
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
1—23
Overview • Specifications [Universal Genesis] •• –
1
Specifications [Universal Genesis]
FACILITIES
AC input voltage requirements
100-240 V~ ; 50/60 Hz (single phase)
AC Input Power
100 W (max)
Air requirements @ 2dm3/s (4.0scfm)
.52 MPa (75±2 psi)
Air Inlet tube
8 mm (.31in.) OD min.
MODELS SUPPORTED
Universal models supported
Genesis
DIMENSIONS
Width
78 mm (3.1 in.
Weight (net)
18.2 kg (40 lbs)
Length with 33 cm (13 in.) reel
124. 5 cm (51.8 in.)
Approximate length protruding
from SMT Placement machine
72.1 cm (28.4 in.)
Height with 33 cm (13 in.) reel
49.5 cm (19.5 in.)
Input tape width supported
16 mm; 24 mm; 32 mm (optional:
12 mm, 32 mm-Large Format)
DEVICE OUTPUT PLACEMENT
(at SMT pick point)
Output placement linear repeatability
±.25 mm
Output placement rotational repeatability
±5°
ENVIRONMENT
1—24
Operating temperature range
20–40°C (68–104°F)
Temperature stabilization time after transportation
≥ 8h
Humidity
5–90%
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Chapter
2
2Installation
For the Reject Bin location
see Figure 19 on page 3-21
or see “Reject Bin” in the
Service Manual.”
Unpacking and installing the RoadRunner is easy. It is delivered preassembled with a few exceptions. There are four items that need to
be installed onto the RoadRunner: • the Socket Adapter, • Actuator Plate,
• and Precisor (except on XLF models) that are described in Chapter 3,
• and the Reject Bin which is described in this chapter. Some RoadRunners
require an additional item to install to adapt it to the SMT machine. These
are noted in the Mounting Instructions in this chapter where they apply. All
that is required to operate the programmer is an SMT machine position and
two external facilities. (You may also need to install some pneumatic components into your air supply line.)
! WARNING
Lifting heavy objects improperly could injure you.
The standard RoadRunner and shipping box weighs
26 kg (58 lbs) maximum. The XLF model RoadRunner and box weighs 32 kg (70 lbs) maximum.
This chapter includes:
•
•
•
•
•
•
•
Removing the Shipping Bracket
Proper mounting procedure for each model
Installing the Reject Bin
Pneumatic and Electrical requirements
Connecting the Communications Cable (applicable models)
Applying power
Setting the network configuration (optional).
Unpacking the RoadRunner
The RoadRunner is transported in an antistatic bag packaged in a heavy corrugated box with foam padding. On arrival, ensure that there is no damage to
the exterior of the box since this may also indicate damage to the machine
inside. If there is significant damage to the box or shipping container, contact
your local Data I/O approved service representative immediately.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
2—1
Installation • Removing the Shipping Bracket ••
It takes about eight hours for the RoadRunner temperature to stabilize to the
new environment after shipping. Do not run a job before RoadRunner has
stabilized—the chassis should be at room temperature.
After opening the box containing the RoadRunner, inspect for damage that
may have occurred during shipment. Two shock indicators have been
applied to the shipping box for your assurance that the RoadRunner has not
been mishandled during shipping. They are orange plastic indicators,
2 inches (50.8 mm) long applied with adhesive backing. If the RoadRunner
has sustained sufficient impact (25G) during shipment, the groove on either
side of the label will be black or a color darker than the body color. See
Figure 2-1. If this is the case, contact your local Data I/O Support Representative immediately. Both grooves the same color as the body indicate that no
impact has occurred.
2
Figure 2-1—Shock Indicator is Indicating that an Impact has Occurred
(Left Side, black arrow [<])
A list of contents is included in the box. Check that you have received everything on the list. (Additional items ordered, such as spare parts, are shipped
in a separate box.)
Removing the Shipping Bracket
RoadRunners shipped prior to 2009 had a bracket securing the PNP Head. It
must be removed before operating the RoadRunner. If the bracket was reinstalled for subsequent shipping, you should check that it is again removed
prior to operating the RoadRunner. It is the brightly painted bracket that can
be seen extending out from under the PNP Head Cover, if installed. Refer to
the figure below.
2—2
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Installation • Mounting the RoadRunner ••
Ball Screw
Rail HousBall Screw
Yellow
Shipping
Bracket
Top View
Side
Head
Cover
(some
PNP Head
Figure 2-2—Shipping Bracket (Plan and Elevation Views)
To remove the Shipping Bracket:
1.
Remove the Robotics Cover by grasping the outer edges and pulling.
2.
If your PNP head has a cover, remove the cover by pulling it straight off
the magnetized head bracket.
3.
Unscrew the socket head screw securing the Shipping Bracket to the
PNP Head.
4.
Unscrew the two screws securing the Shipping Bracket to the Ball
Screw housing.
5.
Remove the Shipping Bracket.
Mounting the RoadRunner
The RoadRunner is designed to mount to the SMT machine feeder table.
Multiple RoadRunners may be mounted on the same SMT machine.
CAUTION: Heavy weight. Use great care when mounting RoadRunner to the feeder table. It is heavy, and dropping it can cause serious damage to RoadRunner and
anything it falls upon. Use only approved hardware to
mount RoadRunner to the SMT feeder table.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
2—3
2
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Assembleon ACM]
Mounting RoadRunner [Assembleon ACM]
2
NOTE: The Assembleon RoadRunner must be mounted to a Universal Feeder Table Adapter. Install a Universal Feeder Table Adapter
onto the ACM machine before continuing.
Look ahead for mounting instructions for your
specific model of
RoadRunner.
Also, the ACM upper feeder guide must be used.
NOTE: When selecting slot positions for
RoadRunner, consider that access to it is
from the right side.
To mount the RoadRunner onto the SMT machine feeder bank, perform the
following:
1.
Hold the RoadRunner level and rest the nose on the feeder bank. Ensure
that the guide under the conveyor settles into a slot.
Figure 2-3—Mounting the RoadRunner onto a Feeder Bank Changer.
CAUTION: Feeder carts might become unstable. The
RoadRunner can also be mounted on feeder carts and
feeder test stands. However, some carts/stands were not
designed for the heavy overhang of the RoadRunner and
may tip over easily, especially if the wheels encounter bumps. Use
caution; don’t use (and do label) unsafe carts.
2—4
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Assembleon ACM]
2.
Level the RoadRunner while continuing to support the weight, and slide
it forward as far as it will go.
3.
Make sure the RoadRunner feels securely supported before letting go.
It will latch to the feeder bank under its own weight.
2
Latch
Figure 2-4—Slide the RoadRunner Forward
4.
Check again that the RoadRunner is secure.
The RoadRunner is now mounted to the feeder bank.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
2—5
Installation • Mounting the RoadRunner •• Mounting RoadRunner [MYDATA MY9, MY12, MY15, MY19]
Mounting RoadRunner [MYDATA MY9, MY12, MY15,
MY19]
2
CAUTION: Heavy weight. Use great care when mounting RoadRunner to the feeder table. It is heavy, and
dropping it can cause serious damage to RoadRunner
and anything it falls upon. Use only approved hardware
to mount RoadRunner to the SMT feeder table.
To mount the Feeder Bank Adapter and RoadRunner onto a MYDATA
MY-Series Assembly Machine:
1.
Slide the supplied Feeder Bank Adapter onto the assembly machine
feeder table at the desired slot. Push it forward as far as it will go.
Figure 2-5—Install the Feeder Bank Adapter onto the SMT Machine
separately.
2.
Holding RoadRunner at a slight angle, slide it under the hook on the
Feeder Bank Adapter so that the RoadRunner centering plate teeth
engage the pin next to the hook.
pin
hook
Top View
 Into SMT
Figure 2-6—Installing RoadRunner onto the Feeder Bank Adapter. A dowel
on the Adapter (circled) mates with the RoadRunner nose.
2—6
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Installation • Mounting the RoadRunner •• Mounting RoadRunner [MYDATA MY9, MY12, MY15, MY19]
3.
Lower RoadRunner letting the Adapter dowels mate up with the bushings in the RoadRunner. Refer to Figure 2-6.
4.
Make sure that RoadRunner is secure.
5.
For first time use at this SMT machine, adjust the Feeder Bank Adapter
to align the pick points.
5a. Compare the SMT pick point to the RoadRunner pick point. If
adjustment is required, continue. Otherwise, go to step 6 below.
Figure 2-7—Devices center at the pick point marks on the RoadRunner
conveyor.
5b. Loosen four screws on top of the Feeder Bank Adapter.
Loosen four screws
(only one shown)
Adjust
Figure 2-8—Adjusting the pick point.
5c. Screw the end screw in or out until the RoadRunner pick point is
aligned with the SMT pick point.
5d. Retighten the four top screws.
6.
Connect the communications cable. For more, see “MYDATA Communications” on page 2-28.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
2—7
2
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Fuji QP242, QP351, IP3, XP142E]
Mounting RoadRunner [Fuji QP242, QP351, IP3, XP142E]
CAUTION: Heavy weight. Use great care when mounting RoadRunner to the feeder table. It is heavy, and
dropping it can cause serious damage to RoadRunner
and anything it falls upon. Use only approved hardware
to mount RoadRunner to the SMT feeder table.
2
To mount the RoadRunner onto the Multi-Feeder Unit (MFU), complete the
following procedure:
1.
Align and push the communications cable into a connector in the MFU.
NOTE: When selecting slot positions for
RoadRunner, consider that access to it is
from the right side.
Figure 2-9—The Communications Cable is inserted into the MFU.
NOTE: The assembly machine pick point will correspond with the
MFU slot number that is in-line with the conveyor belt. Make sure
conveyor belt is closest to the slot number that the communication
cable is plugged into.
2.
2—8
Hold the RoadRunner at a slight nose-down angle and rest the nose on
the feeder bank. Ensure that the guide under the conveyor settles into a
slot by pushing the RoadRunner gently to one side until you feel resistance.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Fuji QP242, QP351, IP3, XP142E]
2
Figure 2-10—The RoadRunner mounted onto a Multi Feeder Unit (MFU)
CAUTION: Feeder carts might become unstable.
RoadRunner can also be mounted on feeder carts and
feeder test stands. However, some carts/stands were not
designed for the heavy overhang of RoadRunner and
may tip over easily, especially if the wheels encounter bumps. Use
caution; don’t use (and do label) unsafe carts.
3.
Slide RoadRunner forward until it comes to a solid stop. The nose will
fit under the lip on the MFU.
4.
Lower RoadRunner fully to ensure that the steel angle under the conveyor settles into the spring clamp on the MFU.
Spring
Clamp
Figure 2-11—The angle bracket on RoadRunner fits into the MFU Spring
Clamp.
5.
Ensure that RoadRunner is secure.
RoadRunner is now mounted to the Fuji MFU.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
2—9
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Fuji NXT, AIM]
Mounting RoadRunner [Fuji NXT, AIM]
CAUTION: Heavy weight. Use great care when mounting RoadRunner to the feeder table. It is heavy, and
dropping it can cause serious damage to RoadRunner
and anything it falls upon. Use only approved hardware
to mount RoadRunner to the SMT feeder table.
2
To mount RoadRunner onto a Feeder Table:
NOTE: When selecting slot positions
for RoadRunner, consider that access to
it is from the right side.
Also, do not use the four left-most slots
on the table or the two right-most slots.
1.
Hold RoadRunner, one hand in the handhold and one under the Conveyor, so the Conveyor overlaps the Feeder Table by 40 mm and is
above a slot.
Figure 2-12—Mounting RoadRunner onto the SMT Feeder Table.
2—10
2.
Lower RoadRunner allowing the nose to rest on the Feeder Table.
Ensure that it settles into a slot.
3.
Still holding the handhold, slide RoadRunner forward as far as it will
go. RoadRunner locks into place.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Panasonic MSF, MCF, MPA]
Mounting RoadRunner [Panasonic MSF, MCF, MPA]
CAUTION: Heavy weight. Use great care when mounting RoadRunner to the feeder table. It is heavy, and
dropping it can cause serious damage to RoadRunner
and anything it falls upon. Use only approved hardware
to mount RoadRunner to the SMT feeder table.
NOTE: When selecting slot positions for
RoadRunner, consider that access to it is
from the right side.
To mount RoadRunner for Panasonic onto a feeder cart:
1.
While holding RoadRunner level, let the nose rest on the cart. Line up
the hook with a slot.
Figure 2-13—Mounting RoadRunner onto a feeder cart.
2.
Slide RoadRunner forward as far as it will go.
The communication path will connect automatically.
3.
Ensure that RoadRunner is secure.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
2—11
2
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Panasonic CM20, CM120, CM301]
Mounting RoadRunner [Panasonic CM20, CM120, CM301]
CAUTION: Heavy weight. Use great care when mounting RoadRunner to the feeder bank. It is heavy, and
dropping it can cause serious damage to RoadRunner
and anything it falls upon. Use only approved hardware
to mount RoadRunner to the SMT feeder bank.
2
NOTE: When selecting slot
positions for RoadRunner, consider that access to it is from
the right side.
Also, on STM machine CM20
make sure the RoadRunner
does not interfere with the handle on the machine cover.
To mount RoadRunner onto the Feeder Bank:
1.
Hold RoadRunner at slight nose-down angle and rest the nose on the
feeder bank.
2.
Align the nose with a slot on the feeder bank. Ensure RoadRunner
engages with one of the slots and the corresponding pin/rib as you push
forward.
3.
When it stops going forward push down on the RoadRunner to engage
the rollers on the bottom of the conveyor into the groove on the bank.
See the figure below.
Rollers
Figure 2-14—Rollers on the bottom of the Conveyor Module fit into the
groove on the feeder bank.
4.
2—12
Check that the RoadRunner is stable by rocking it cautiously.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Panasonic CM20, CM120, CM301]
2
Figure 2-15—RoadRunner/Panasonic mounted on the Feeder Bank.
To remove the RoadRunner, lift up on the operator end and pull back out of
the SMT machine.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
2—13
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Panasonic CM401, CM402, DT]
Mounting RoadRunner [Panasonic CM401, CM402, DT]
CAUTION: Heavy weight. Use great care when mounting RoadRunner to the feeder bank. It is heavy, and
dropping it can cause serious damage to RoadRunner
and anything it falls upon. Use only approved hardware
to mount RoadRunner to the SMT feeder bank.
2
NOTE: When selecting slot positions for
RoadRunner, consider that access to it is from
the right side.
A Panasonic Feeder Bank Adapter and Host Feeder unit must be mounted to
the SMT Feeder Bank prior to mounting the RoadRunner. Then the RoadRunner can be mounted onto the Adapter. The steps for connecting the communication cable follow.
To mount the Feeder Bank Adapter and Host Feeder:
1.
Align the Feeder Bank Adapter with the numbered feeder slots and slide
it forward to engage the alignment features. Push the Feeder Bank
Adapter forward as far as it will go.
2.
Tighten the set screw to lock in place. See Figure 2-16.
3.
Slide the Host Feeder onto the feeder slot immediately left of the Feeder
Bank Adapter.
Mounting and
Alignment features:
Hook
Dowel
Set screw
Figure 2-16—Panasonic Feeder Bank Adapter and Host Feeder mounted
on the CM402 SMT Feeder Bank
4.
2—14
Push the Host Feeder forward as far as it will go.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Panasonic CM401, CM402, DT]
To mount RoadRunner onto the Panasonic Feeder Bank Adapter:
1.
Slide RoadRunner under the hook on the Feeder Bank Adapter so that
the RoadRunner centering plate teeth engage the pin next to the hook.
See Figure 2-17.
2
RoadRunner Centering
Plate
Figure 2-17—The Panasonic Feeder Bank Adapter has a hook and a pin.
2.
Lower RoadRunner so that the Feeder Bank Adapter dowel mates with
the guide bushing on the RoadRunner conveyor. See Figure 2-18.
Figure 2-18—The dowel on the Adapter (circled) mates with Roadrunner.
3.
Verify that RoadRunner is secure.
To connect the Communication Cable into the Host
Feeder:
1.
Correctly orient the connector (the red dot will be on top) and plug it
into RoadRunner. The socket is located on the back side—facing the
SMT feeder table.
2.
Orient and plug the other end of the cable into the Host Feeder.
3.
Screw in the two connector screws. See Figure 2-19.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
2—15
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Panasonic CM401, CM402, DT]
2
Figure 2-19—RoadRunner is mounted and the Communication Cable is
plugged into the Panasonic Host Feeder unit.
2—16
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Siemens 80F4, 80F5, F, S, HS]
Mounting RoadRunner [Siemens 80F4, 80F5, F, S, HS]
CAUTION: Heavy weight. Use great care when mounting RoadRunner to the feeder table. It is heavy, and
dropping it can cause serious damage to RoadRunner
and anything it falls upon. Use only approved hardware
to mount RoadRunner to the SMT feeder table.
NOTE: When selecting slot positions for
RoadRunner, consider that access to it is
from the right side.
To mount the RoadRunner onto the machine feeder table, perform the following:
CAUTION: There are different hooks. Use of the wrong hook will
cause mounting and device pick problems. Use the hook with black
knob or the hook with the Hex socket screw as shown on the label
located on the RoadRunner Conveyor. You might also have a black
hook which is for the taller, later model of RoadRunner. The new
Hex-socket screw hook and the black anodized hook are interchangeable.
1.
Slide the proper mounting hook around a pin on the feeder table where
the RoadRunner is to be mounted. Refer to Figures 2-20, 2-21, 2-22,
and 2-23 for placement details.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
2—17
2
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Siemens 80F4, 80F5, F, S, HS]
2
Latest Hook
Hook for early RoadRunners
Figure 2-20—Positioning the RoadRunner
Mounting Hook—ensure the correct hook is used.
Figure 2-21—The Hex socket-screw-hook for taller RoadRunners
[Siemens].
Edge of
RoadRunner
RoadRunner
teeth
Mount-
 into SMT
RoadRunAlignment
Plate
Figure 2-22—Hook Location Relative to standard RoadRunner Placement.
(not XLF models). Top View
2—18
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Siemens 80F4, 80F5, F, S, HS]
Edge of
RoadRunner
RoadRunner
teeth
Mount-
2
 into SMT
RoadRunner
Hook
Alignment
Plate
Figure 2-23—Hook Location Relative to RoadRunner-Siemens XLF
Placement. Top view.
! WARNING
RoadRunner is heavy and can fall if the correct
mounting hook is not properly attached. Falling
can injure you or damage RoadRunner. The hook
is absolutely required. Do not attempt to mount
RoadRunner onto the feeder table without the hook installed
onto the table.
2.
Tighten the hook thumbscrew or the 3 mm socket-head adjustment
screw, as applicable.
3.
Slide RoadRunner under the hook so that the teeth engage the pin next
to the hook as shown in Figure 2-22 and below in Figure 2-24.
Teeth on
RoadRunner
Siemens
Figure 2-24—Early model Siemens RoadRunner Mounted onto the SMT
Feeder Table [Siemens]
4.
Test to ensure RoadRunner is secure.
RoadRunner is now mounted to the SMT feeder table.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
2—19
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Siemens SIPLACE X2, X3, X4, X4i]
Mounting RoadRunner [Siemens SIPLACE X2, X3, X4, X4i]
CAUTION: Heavy weight. Use great care when mounting RoadRunner to the feeder table. It is heavy, and
dropping it can cause serious damage to RoadRunner
and anything it falls upon. Use only approved hardware
to mount RoadRunner to the SMT feeder table.
2
! WARNING
machine.
FEEDER CARTS CAN TIP causing personal injury or
damage. Remove RoadRunner from the Feeder
Cart before pulling the cart away from the SMT
NOTE: When selecting slot positions for
RoadRunner, consider that access to it is
from the right side.
NOTE: The SMT Adapter for
SIPLACE X RoadRunner must
be attached to RoadRunner
before being mounting onto a
Feeder Bank.
If the SMT Adapter is not
attached to the RoadRunner,
contact Data I/O support— attaching it requires removing the
RoadRunner Conveyor Cover.
To mount the RoadRunner onto the machine feeder table, perform the following:
1.
2—20
Holding RoadRunner level, align the grooves on the Adapter with ribs
on the Feeder Bank, and slide RoadRunner as far forward as it will go.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Siemens SIPLACE X2, X3, X4, X4i]
2
Figure 2-25—The SMT Adapter on SIPLACE X RoadRunner mates with ribs
on the Feeder Bank.
2.
Make sure that the SMT latches onto the RoadRunner, and that
RoadRunner is secure.
Connect the communications cable (described in “Siemens SIPLACE X
Series Communications” on page 2-29).
Remember to remove RoadRunner from the Feeder Cart prior to removing
the Feeder Cart from the SIPLACE Machine.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
2—21
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Universal GSM1,GSM2, Genesis]
Mounting RoadRunner [Universal GSM1,GSM2, Genesis]
CAUTION: Heavy weight. Use great care when mounting RoadRunner to the feeder table. It is heavy, and
dropping it can cause serious damage to RoadRunner
and anything it falls upon. Use only approved hardware
to mount RoadRunner to the SMT feeder table
2
To mount the RoadRunner onto the Universal machine feeder bank, perform
the following:
! WARNING
Collision hazard. If mounted incorrectly, the GSM
pick head might collide with RoadRunner. For this
reason Data I/O recommends mounting
RoadRunner only on the front feeder banks near Beam-2.
If RoadRunner is mounted on banks 3 and 4 (the rear feeder
banks), ensure that the feeder bank is in the outbound position only and NOT in the inbound or double inbound positions.
Do NOT remove the GSM CE Cover that covers the upper half
of the GSM feeder bank opening.
NOTE: When selecting slot positions for
RoadRunner, consider that access to it is
from the right side.
1.
2—22
Hold the RoadRunner level and rest the nose on the feeder bank. Ensure
that the guide under the conveyor settles into a slot.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Installation • Mounting the RoadRunner •• Mounting RoadRunner [Universal GSM1,GSM2, Genesis]
2
Figure 2-26—Mounting RoadRunner onto a Feeder Bank Changer.
CAUTION: Feeder carts can become unstable. RoadRunner can
also be mounted on feeder carts and feeder test stands. However,
some carts/stands were not designed for the heavy overhang of
RoadRunner and may tip over easily, especially if the wheels
encounter bumps. Use caution; don’t use (and do label) unsafe
carts.
2.
Level RoadRunner while continuing to support the weight, and slide it
forward as far as it will go.
3.
If RoadRunner feels securely supported, let go.
Its own weight will cause it to latch to the feeder bank.
Latch
Figure 2-27—Slide the RoadRunner Forward
4.
Cautiously rock RoadRunner to ensure that it is secure.
RoadRunner is now mounted to the feeder bank.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
2—23
Installation • Installing the Reject Bin •• —
Installing the Reject Bin
—
The Reject Bin may not be in place when you receive your RoadRunner.
When it is in place, it sits between the beginning of the Conveyor and the
RoadRunner chassis.
2
NOTE: The Reject Bin for a Standard RoadRunner does not fit into
a RoadRunner XLF (Extra Large Format).
Figure 2-28—The Reject Bin. (The Reject Bin for the RoadRunner XLF
looks slightly different.)
To install the Reject Bin, hold the small, channel-shaped chute with thumb
and forefinger like you might hold a movie ticket. With the chamber horizontal, move the bin straight over the conveyor and just under the black Linear Stage until it stops against the chassis. Lower it as far as it will go.
CAUTION: The PNP Head might collide with the Reject Bin if the
Reject Bin is not installed properly. You can test the clearance by
pushing the E-Stop and then manually pushing the PNP Head over
to the Reject Bin.
NOTE: RoadRunner will not function without the Reject Bin in
place.
2—24
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Installation • Making the Necessary Connections •• Electrical Input Requirements
Making the Necessary Connections
The RoadRunner requires only two external facilities: electrical AC power
and standard shop pressurized air. The specific requirements are stated
below as well as on labels inside the RoadRunner. Refer to Figure 2-29 for
facility connection locations.
2
Siemens 80F, S,
HS Series,
D Series &
Pansonic CM401,
CM402, DT401
Assembleon
ACM
E
E
E
E
XLF model
E
Fuji QP242,
QP351, IP3
Siemens 80F, S,
HS Series, D Series
Fuji NXT
E & AIM,
Panasonic MSF,
MCF, MPA,
Universal GSM,
Genesis
SIPLACE XSeries, MYDATA
MY Series
=AC Power =Air Fitting E=Ethernet =Communications
Figure 2-29—RoadRunner Facilities Connection Points.
For models where no Communication Connection is indicated, the
connection is on the far side (not visible here).
Electrical Input Requirements
The RoadRunner uses 100-240VAC, 50/60Hz, single phase power. The
required power is supplied through a single connection on the RoadRunner’s
end panel. RoadRunner uses a standard IEC-320-C13 power cord. The
power supply is self-regulating, and requires no special settings for regional
power requirements.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
2—25
Installation • Making the Necessary Connections •• Pneumatic Input Requirements
Power is applied to the internal systems of the RoadRunner when the power
switch is ON. All power is removed when the power switch is OFF.
! WARNING
Electrical shock hazard. If the main power switch is
ON, power is applied to the electronic systems of
RoadRunner, regardless of the position of the Emergency-Stop button or safety shield. Always turn the main
power switch OFF before working inside the machine.
2
Pneumatic Input Requirements
RoadRunner requires a pressurized air source connected to the
RoadRunner’s end panel. RoadRunner requires clean, dry, oil-free air, at
approximately 5.17 Bars (517 kPa) (75 psi) from an industrial grade compressor. The compressor tank should be of sufficient volume to maintain
constant air pressure at a minimum of 113 Liters/minute (4 cubic feet/minute). A 10 micron filter/separator/regulator must be installed between
the compressor and the RoadRunner to extract any contaminants and
moisture before the air enters the machine.
Pneumatic Regulator Kit
Proper operation of RoadRunner on SMT machines is accomplished by
installing a Data I/O Regulator Kit. The kit ensures consistent air pressure
and is required for proper RoadRunner operation.
Check with Data I/O for your kit availability and installation instructions.
The Regulator Kit Model Name (for ordering) for Assembleon Fuji, Panasonic, and Universal is RR-REGULATOR KIT-UF.
Figure 2-30—Regulator Kit for Placement Machines
(Instructions for RoadRunner/Siemens are listed below.)
2—26
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Installation • Making the Necessary Connections •• Pneumatic Input Requirements
CAUTION: Oil, excessive moisture, or poorly filtered air will
obstruct RoadRunner’s internal air paths, affect system performance, and void the warranty related to air system failure. If oil or
excessive moisture is detected, contact your local Data I/O
approved service representative immediately.
Inlet Tube
The 6 mm diameter inlet tube assembly, supplied, has a quick-disconnect fitting that pushes onto the RoadRunner air connector. Allow the collar to
move while you push the fitting onto the connector.
To remove the inlet air assembly, slide the sleeve on the tube connector back
and pull it off. The tube fitting has an automatic shut off and may be
removed without shutting off the air pressure.
NOTE: If the compressor cannot maintain the correct air pressure
and volume, the RoadRunner will not operate correctly.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
2—27
2
Installation • Making the Necessary Connections •• Connecting the Communications Cable
Connecting the Communications Cable
On some RoadRunners, a communications cable allows direct communication between the RoadRunner and the SMT machine. Others use pins that
connect when RoadRunner is mounted correctly.
2
After physical connection has been made, most SMT Placement machines
require unique setup instruction for communicating with RoadRunner. These
are often supplied in a separate Customer Service Letter.
Figure 2-31—[Siemens] Communications Cable Plugged into the SIPLACE
Feeder Table
Assembleon ACM Communications
For location of the communication socket see
Figure 2-29 on page 2-25.
Orient the cable connector and plug it into the RoadRunner. Plug the other
end into the ACM communications cable.
MYDATA Communications
Orient the Feeder Bank Adapter cable connector and plug the communication cable into the RoadRunner socket on the far end of the electronics housing—facing the feeder table.
To unplug the cable, pull back on the connector collar.
Fuji MFU QP242, QP351, IP3 Communications
Communication cable connection is performed when mounting RoadRunner
onto a Fuji Manual Feeder Unit. See “Mounting RoadRunner [Fuji QP242,
QP351, IP3, XP142E]” on page 2-8.
Fuji NXT, AIM Communications
Communications are automatically connected when the unit is properly
mounted to an SMT machine. A barcode is supplied on the left side of the
RoadRunner for assisting placement machine setup with FujiTrax.
2—28
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Installation • Making the Necessary Connections •• Connecting the Communications Cable
Pansonic MSF, MCF, MPA Communications
Communications are automatically connected when the unit is properly
mounted to an SMT machine feeder cart.
Pansonic CM401, CM402, DT401 Communications
Communication cable connection is performed when mounting RoadRunner
onto a Panasonic Feeder Bank Adapter. See “To connect the Communication
Cable into the Host Feeder:” on page 2-15.
Siemens 80F4, 80F5 Communications (Std and XLF)
Orient the cable connector with the red dot on top and plug the communication cable into the RoadRunner socket on the far end of the electronics housing—facing the feeder table. Plug the other end into the socket on the SMT
feeder table that corresponds with the track the RoadRunner is mounted in.
NOTE: RoadRunner firmware version 02.01.00.B or later is
required for Siemens communications.
To unplug the cable, pull back on the connector collar.
Siemens SIPLACE X Series Communications
Orient the cable connector and plug the communication cable into the
RoadRunner socket on the far end of the electronics housing—facing the
feeder table. There may be a red dot on top for orientation. Plug the other
end into the socket on the SMT Adapter below the conveyor.
To unplug the cable, pull back on the connector collar.
Universal GSM1, GSM2, GENESIS Communications
Communications are automatically connected when the unit is properly
mounted to an SMT machine.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
2—29
2
Installation • Applying Power for the First Time •• Turning Power On
Applying Power for the First Time
Turning Power On
2
For help with the Emergency Stop button see
“Safety” on page 1-12.
For help with the Robotics
Cover see “Removing the
Robotics Cover” in the Service Manual.
To install a Socket Adapter
see“Changing the Socket
Adapter” on page 3-5.
Before the RoadRunner is turned on, ensure the following:
• The external air line is connected, and input air pressure is set to approximately 5.17 Bars (75 PSI).
• The Emergency-Stop button is in the released (out) position.
• Optional: The Socket Adapter required for the programming task is
installed on the programmer.
• Optional: The communication cable is connected.
NOTE: Although the Robotics Cover does not need to be in place at
this time, RoadRunner will emit beeps while the cover is off.
Once the above conditions have been verified, turn the main power switch to
the ON position.
I
0
on
off
Figure 2-32—The RoadRunner Power Switch
Power is now applied to the RoadRunner. (A job card must be inserted into
the PCMCIA slot before devices can be programmed.)
! WARNING
Electrical shock hazard. If the main power switch is
ON, power is applied to the electronic systems of the
RoadRunner, regardless of the position of the E-Stop
button or safety shield. Always turn the main power switch
OFF before working inside of the machine.
After power is applied, the RoadRunner performs a Self-test. During this test
the RoadRunner verifies that all system components are present and functioning, and that all sensors are within calibration limits.
2—30
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Installation • Configuring for Network Communication •• Configuring RoadRunner
Verify that all systems start up properly, and that there are no errors or warnings displayed on the keypad display screen. If electrical or mechanical
problems are noted, turn off the RoadRunner and see Troubleshooting in
Chapter 6. If you need help, notify the local Data I/O service representative.
In general, the blue lamp should be illuminated, indicating that there is no
operation in progress, before turning the power off.
Configuring for Network Communication
To set up the network connection between RoadRunner and TaskLink, both
must be configured.
Configuring TaskLink
What are the
advantages of
networking?
NOTE: You must be using TaskLink version 5.0 or higher, and
RoadRunner Firmware version 5.0 or higher.
After TaskLink and
RoadRunner are set up
For instructions on configuring TaskLink, start TaskLink and click Help >
for networking, you
Help Topics. In the contents expand (+) Using Networked Roadcan perform many
Runners and click Configure TaskLink.
activities from
TaskLink without
using a PC Card to
transfer the inforConfiguring RoadRunner
mation to
RoadRunner. In fact
RoadRunner could be
Configuring RoadRunner involves creating a network configuration card
in a different city.
with TaskLink, inserting the card into RoadRunner, and setting RoadRunner
Some of those activinetwork parameters.
ties are:
To create a network configuration card:
• downloading jobs
1. Start TaskLink and click Help > Help Topics. In the contents
to RoadRunner(s)
expand (+) Using Networked RoadRunners and click How to
• viewing statistic
Configure RoadRunner. Follow the instructions.
files, jobs, and PC
Card space availNOTE: The following steps are required after creating the network
able
configuration on a PC card (and are repeated from the TaskLink
• logging session
instructions).
data
• viewing the
RoadRunner firm2. Insert the Network Card into RoadRunner.
ware version
3. On the Control Panel, scroll to and select System > Network.
• sending firmware
4. Press the Select button.
update files
• setting supervisor
5. Using the arrow buttons, toggle Network Parm: to Card.
privileges.
6. Press the Menu button to save your changes.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
2—31
2
Installation • Configuring for Network Communication •• Configuring RoadRunner
7.
2
To save the network configuration file, set the
System > Network
> NetworkTxt parameter to Save.
2—32
Cycle the power on RoadRunner so that new network settings take
effect.
NOTE: The network configuration file is automatically deleted
from the PC Card at the end of the process. This prevents accidentally configuring two RoadRunner programmers with the same network settings.
RoadRunner is now configured to communicate with a network. Plug in a
10BaseT Network Cable. The connection is shown in Figure 2-29.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Chapter
3
3Operation
The ProLINE-RoadRunner operates with a set of job instructions that can be configured and contained on a PCMCIA memory card. The
instructions provide a detailed description of the programming requirements
for a particular semiconductor device or group of devices. A PCMCIA card
is referred to as a job card after a set of instructions are written to it. There
may be more than one set of instructions on the PCMCIA memory card, with
the maximum number depending upon the card’s memory capacity. However, one set per card is recommended.
Within the two levels of
functions mentioned
here, there are many
menu commands to customize RoadRunner
operation.
There are two levels of functions:
• those performed by an operator
• those performed by the supervisor
Some of the functions of the RoadRunner, like calibration, are only available
to the system supervisor. Additionally, RoadRunner job creation is generally
considered a system supervisor function.
The RoadRunner operator performs specific functions concerned with running programming jobs while a system supervisor has the ability to set
RoadRunner operational parameters, view operational statistics and perform
various diagnostic routines. Create programming jobs using TaskLink for
Windows.
Operator Functions
This section describes operator steps for setting up RoadRunner to Program
devices.
Basic Operator Steps
To set up RoadRunner to Program Devices, the operator must:
1.
Change the Socket Adapter, page 3-5.
2.
Change the Precisor, page 3-7 (standard models only).
3.
Change the Actuator Plate, page 3-8.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
3—1
Operation • Operator Functions •• Turning On System Power
Before inserting the
PCMCIA card a job must
be created. See “TaskLink’s
Handshake with
RoadRunner” on page
1-11.
4.
Adjust the Actuator Plate, page 3-8 (XLF models).
5.
Insert a PCMCIA card.
6.
Switch the power on.
7.
Check the hardware setup, page 3-9.
8.
If using an Adjustable Tape-In Module, set the width to match the
device tape, page 3-10
9.
Load the device tape, page 3-14
10. Align the device tape, page 3-17
11. Clear away unwanted devices, page 3-18 (step 3)
12. Press “Start,” page 3-18 (step 4)
3
Turning On System Power
Verify that the covers are in place, that the power and air are connected, and
then switch the main power ON. The three colored lamps illuminate while
the system starts and the RoadRunner performs a Self-test of its internal
electronics and sensors. When it is ready to accept commands, only the blue
lamp will be on. Verify that there are no errors indicated on the Keypad Display.
3—2
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Operator Functions •• Menus Available to the System Operator
Menus Available to the System Operator
The RoadRunner operator, with an operator card, can access a limited number of RoadRunner menus.
RoadRunner Ver 05.35.00.C Operator Menu
Main Menu
Advance Pocket
Job
Advance Pocket
Align Pocket
Purge
Socket
When selected, each push of the UP Arrow
(or DOWN Arrow) button advances (or
reverses) the pocket tape by one pocket pitch.
Holding a button down will continually move
the tape.
Results
Reset Clean Count
Clean Count
Clean Alert: 3500
No: 22113204
Mfg: 09/23/02
Actuations:1055
Adptr. Life: 10000
Insertions: 4220
Pass: 4202
Fail: 16
Yld: 99.5
Socket 1
Insertions: 1055
Pass: 1053
Fail: 2
Yield: 99.8
Socket 2
Insertions: 1055
Pass: 1055
Fail: 0
Yield: 100
Socket 3
Insertions: 1055
Pass: 1051
Fail: 4
Yield: 99.6
Socket 4
Insertions: 1055
Pass: 1045
Fail: 10
Yield: 99.0
Align Pocket
Job
View
Socket
Socket 1: ENABLED
Socket 2: ENABLED
Socket 3: ENABLED
Socket 4: ENABLED
Adapter Statistics
Job Name
Device: E28F320
Checksum: 3FC00000
Mfg: INTEL
Adapter: PA-G021
When selected, each push of the UP Arrow
button advances the pocket tape 4 mm. The
DOWN Arrow button does nothing.
Prec: 621-0086-0051
Act: 644-0016-001
Encrypted: Yes/No
Passed: 992
Failed: 4
System Yld: 98.7
Prgrmr Yld: 99.6
Handler Yld: 99.5
Parts/Hour: 255
Removes all devices from the Socket Adapter
and places them into the Reject Bin.
Purge
MCBI: 2012
Skt 1 Yld: 99.9
Skt 2 Yld: 100
Skt 3 Yld: 100
Skt 4 Yld: 100
Skt Cycles: 249
End
Remaining Devices Remaining: 77
+-1
+-10
+-100
+-1000
+-10000
Select
Job 1
Job 2
End of List
Notes:
• Right column bolded items can be changed.
1 Precisor is not required on XLF models.
2 Mean Cycles Between Interrupts.
Figure 3-1—RoadRunner Operator Menus
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
3—3
3
Operation • Operator Functions •• Keypad Operation
Keypad Operation
Operator Functions
To make selections with the keypad follow these general guidelines:
• Navigate up to the desired menu (or to the top menu) by
pressing the Menu button.
This manual uses the word
scroll to mean “press the
Up Arrow or Down Arrow.”
3
The word select is used to
mean “press the Select button,” (the button with the
check mark on it).
For example, “Scroll to and
select System.”
•
•
•
•
Start
When you are at the top menu, pressing Menu will have no
effect. (Job is the top item on the top menu. However, you
may need to press the Up Arrow button to see it in the display
window.)
Press the Down Arrow to move the triangular indicator down
the list to the desired command. The command is not selected
until the Select button is pressed.
Press the Select button to select the item indicated. The menu
will change or the triangular indicator will change to a circle
when the item is selected.
With some functions, the way the Up Arrow and Down
Arrow keys function will change while that item is selected.
For example, when Advance Pocket is selected, the Up
Arrow advances the device tape rather than scrolling the
menu. See Figure 3-2.
To deselect an item press Menu. The circle will change back
to a triangular indicator.
•start the job
•resume the job
Menu
•deselect an item
•back out to the next higher menu
•erase error message
Up Arrow
•scroll up the menu
•other actions if certain items are
selected
Down Arrow
•scroll down the menu
•other actions if certain items are
selected
Select
•select the indicated item
•show the submenu
Pause
•pause the job
Figure 3-2—Keypad Layout
3—4
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Operator Functions •• Setting Up RoadRunner for a Programming Job
Setting Up RoadRunner for a Programming Job
Operator Functions
Before programming devices, several steps must be taken to ensure that the
RoadRunner is properly configured.
Job cards for RoadRunner
may also be used in
Data I/O’s FlashPAK programmer.
Options comprising a job, or task, are normally selected at a PC by a
ProLINE-RoadRunner system supervisor or someone from the engineering
staff. The instructions are then written to a PCMCIA memory card. The
instructions (or “job card”) are inserted into the RoadRunner. RoadRunner
uses job instructions to program semiconductor devices. A job contains the
programming algorithm, the number of devices to process, special device
options, and other items important for the programming of the device.
Once the PCMCIA memory card (PC-Card) is inserted into the RoadRunner,
the job is ready to run. If more than one job resides on the card, then the job
last selected by the system supervisor will be run.
If the card has administrator authority then the operator can change the
selected job. Decide which job you wish to run, then see the following sections for RoadRunner preparation and setup.
Changing the Socket Adapter
The Socket Adapter is the interface between the device and the programmer.
Each individual package type that is processed by the RoadRunner has its
own unique Socket Adapter.
Socket Adapters for
Data I/O’s FlashPAK programmer are interchangeable with RoadRunner
Socket Adapters.
See the Socket Adapter
screws in Figure 3-3.
To change the Socket Adapter:
1.
Switch the RoadRunner power switch off [0].
(Operators may push the Emergency-Stop button instead of switching
the power switch off.)
2.
Lift off the Robotics Cover.
3.
Move the PNP head away from the programmer socket module to allow
room to work. When power is switched off, or the E-Stop is engaged,
the head is easily moved back and forth by hand.
4.
Pull the Actuator Plate away from the RoadRunner by sliding it from the
grooved brackets.
5.
Unscrew the two captive screws that secure the adapter bracket. Once
loosened, the screws will remain in the bracket screw holes.
CAUTION:
Electrostatic discharge (ESD) may damage
parts. Before touching the adapter card, discharge static electricity
from yourself by touching a common ground or an unpainted metal
surface.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
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Operation • Operator Functions •• Setting Up RoadRunner for a Programming Job
Operator Functions
Figure 3-3—Removing the Screws Securing the Socket Adapter
3
6.
Rotate the adapter bracket up.
7.
Lift the adapter free, being careful not to damage the electronic circuitry
attached to, or surrounding, the adapter.
Adapter
bracket in the
up position
Figure 3-4—Removing the Socket Adapter
CAUTION: Collision Hazard. Do not move the PNP
head while the Socket Adapter Bracket is in the UP
position. The head might get damaged. Always lower the
bracket and screw it down before moving the PNP head.
For more information, see
“Changing the Actuator
Plate” on page 3-8.
8.
Insert the correct adapter, ensuring that it seats correctly on the dowel
pins.
9.
Lower the adapter bracket and screw in the screws.
10. Slide the Actuator Plate back into place. (The Actuator Plate and Socket
Adapter must match.)
11. When you are finished, release the Emergency-Stop button.
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Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Operator Functions •• Setting Up RoadRunner for a Programming Job
Changing the Precisor
Operator Functions
The precisor assists in properly aligning each device before it is placed into
the programming socket. Each precisor is shaped to correspond with a specific device.
NOTE: RoadRunner XLF Models do not use precisors.
To change the precisor:
1.
Push the Emergency-Stop button.
2.
Lift off the Robotics Cover.
3.
Lift off the PNP head Cover.
4.
Being careful not to disturb the probe tips, pull the precisor plate down
from the magnetized surface above. (We suggest grasping the ends with
a thumb and finger and lowering one end away from the head at a time.)
Figure 3-5—Removing the Precisor [Siemens Model Shown]
5.
Install the new precisor. Make sure that the name on the precisor faces
up and the small dowel pin holes near the precisor edges mate up with
the dowel pins on the PNP head. There should be no visible gap
between the precisor and the PNP head.
Figure 3-6—Identifying the New Precisor
6.
When you are finished, release the Emergency-Stop button.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
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Operation • Operator Functions •• Setting Up RoadRunner for a Programming Job
Operator Functions
Changing the Actuator Plate
The Actuator Plate is used to open the sockets on the Socket Adapter so that
the devices can be placed inside.
Non-adjustable Actuator Plates are used on standard RoadRunners only—
not XLF models. These non-adjustable Actuator Plates have unique shapes
designed to work with specific adapters.
To change the Actuator Plate (all types):
3
If you have a FlashPAK
desktop programmer, you
may be able to use your
RoadRunner Actuator
Plate on your FlashPAK.
To check if the plate Part
Number (PN) required is
the same, use TaskLink:
(1) select the appropriate
Programming System,
(2) edit a Task,
(3) in the Task tab select
your primary device,
(4) click Footnotes to see
the PN required.
1.
Ensure that the actuator is in the up-position (sockets closed). If it is
down, shut off the air supply.
2.
Push the Emergency-Stop button.
3.
Lift off the Robotics Cover.
4.
Push the PNP head away from the Actuator Plate by hand to allow room
to work. (Do not attempt to push the PNP head with the E-Stop unemployed. First push the E-Stop.)
5.
Pull the Actuator Plate away from the RoadRunner by sliding it out
from the grooved brackets.
Figure 3-7—Changing the Actuator Plate
6.
Slide the correct Actuator Plate into the grooved brackets, ensuring that
it snaps firmly into place.
Non-symmetrical plates are marked with an arrow indicating the direction to insert it.
7.
Release the Emergency-Stop button.
NOTE: Without a job card inserted, the topics below cannot be
accomplished. See “Supervisor Functions” on page 3-24 for creating a job card.
Adjusting an Adjustable Actuator Plate
The adjustable Actuator Plate is used on XLF RoadRunners to open the
sockets on the Socket Adapter so that the devices can be placed inside. There
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Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Operator Functions •• Setting Up RoadRunner for a Programming Job
are two types of Adjustable Actuator Plate: one is designed for HIC adapters
and can be identified by the three dots machined into the side.
Operator Functions
One
adjustable
bar with two
screws
(2 places
on each
Actuator
Plate).
3
Figure 3-8—Adjustable Actuator Plates: Standard (top) and HIC, identifiable by the three dots.
To adjust the Adjustable Actuator Plate (both types):
1.
Ensure that the actuator is in the up-position (sockets closed). If it is
down, shut off the air supply.
2.
Push the Emergency-Stop button.
3.
Lift off the Robotics Cover.
4.
Push the PNP head away from the Actuator Plate by hand to allow room
to work. (Do not attempt to push the PNP Head with the E-Stop unemployed. First push the E-Stop.)
5.
With a 2 mm Allen Wrench, loosen both screws for one sliding bar and
slide it inboard (toward center) as far as it will go.
6.
Then slide the bar outboard just far enough to allow a device/card to
pass and fit into the socket.
7.
Tighten the two screws for that bar.
8.
Perform steps 5, 6, and 7 for the second bar.
9.
Push the actuator down to verify proper socket open/close action.
With vacuum tweezers, place a device into a socket to verify clearance
between the bars.
10. Switch on the air supply if necessary and release the E-Stop.
Checking the Hardware Setup
For more help see “Keypad
Operation” on page 3-4.
To check the hardware setup, perform the following:
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
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Operation • Operator Functions •• Setting Up RoadRunner for a Programming Job
1.
With the power on and system ready (the blue light is the only light on),
insert a job card.
2.
Using the control panel buttons, press the Menu button until the top
level menu is displayed.
3.
Scroll to and select Job.
4.
Scroll to and select View.
The list of hardware required for the job will be displayed.
5.
Scroll through the list of hardware settings. Verify that each of the following job-specific hardware pieces is installed on RoadRunner:
Operator Functions
3
Device:
Check this against the label on the reel of unprogrammed devices
Checksum:
Check that this is the unique job ID number you
wish to run. Checksum represents either the
checksum of the device data, or the checksum of
the device data plus extra bytes of storage for certain devices. The checksum represents the data in
its original endian (byte order) as of Version
03.00.01.C.
Mfg:
Check that the device manufacturer listed matches
the actual device manufacturer.
Adapter:
Check this against the label on the socket adapter.
Prec:
Check this against the (package-specific) number
etched on the precisor plate. Not required on XLF.
Act:
Check this against the (package-specific) number
on the actuator.
Also check that the Tape Advance module accommodates the appropriate
width tape for the devices to be programmed.
Make any changes necessary to comply with the data in the Control Panel
Display.
Changing Tape Width on Adjustable Tape-In Modules
Don’t know which
Tape-In Module you
have? Look at the images
on the next few page—the
shape of the peel bar is
different for each model.
There are three different adjustable Tape-In Modules. Adjustment of each is
described in the following headings.
16/24/32 mm Tape-In Module (Standard Adjustable)
If you use a 16/24/32 mm Adjustable Tape-In Module, follow these steps to
adjust the width:
1.
3—10
Loosen the Position Locking Screw using a 4 mm Allen Wrench and
then rotate the 3-Position Spacer with your finger until you read 16, 24
or 32, corresponding to your device tape width. Retighten the screw.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Operator Functions •• Setting Up RoadRunner for a Programming Job
Operator Functions
Position Locking
Screw
3
Figure 3-9—Adjustable Tape-In Module. The 3-Position Spacer is set for 24
mm device tape.
2.
Rotate the Peel Bar for the cover tape counterclockwise 180 degrees to
the up position.
Front Track
Figure 3-10—The Adjustable Tape-In Module with Peel Bar Rotation
Shown.
3.
Lift and move the magnetic Front Track to the position that fits your
tape width.
4.
Rotate the Peel Bar back down.
16/24/32 mm Tape-In Module (GTP–Gradual Tape Path)
If you use a 16/24/32 mm GTP Adjustable Tape-In Module follow these
steps to adjust the width:
1.
Loosen the Peel Bar Screw, and rotate the Peel Bar 90° out of the way.
Then retighten the screw. See Figure 3-11 below.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
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Operation • Operator Functions •• Setting Up RoadRunner for a Programming Job
Position Locking Screw
Operator Functions
A
3
Peel Bar
3-Position Spacer
B
Figure 3-11—The Peel Bar on the GTP T-I Module is down [A] and up [B].
The Front Track (arrow) is also adjustable.
2.
Loosen the Position Locking Screw (Figure 3-11) using a 4 mm Hex
Key and then rotate the 3-Position Spacer with your finger until you
read 16, 24 or 32, corresponding to your device tape width. Retighten
the screw.
3.
Lift up and move the magnetic Front Track to the position that fits your
tape width. Refer to Figure 3-11.
4.
Loosen the Peel Bar screw and rotate the Peel Bar back down and slide
it to the far left.
NOTE: There is no need to re-center the tape path to the PNP
probes unless you experience device placement problems.
5.
The Peel Bar position must be set for the new device tape. Load device
tape threading the cover tape as shown on the label on the RoadRunner.
6.
Align the Device Tape. See “Aligning the Device Tape—All Models”
on page 3-17.
7.
Loosen the Peel Bar screw and slide the Peel Bar downstream until the
straight edge is 1 to 2 mm left (upstream) of the left edge of the tape
pocket.
8.
Tighten the Peel Bar screw.
32/44 mm Tape-In Module [XLF Models only]
A notch on the Tape-In Module points to an etched number indicating the
current setting.
NOTE: If the Tape-In Module has just been installed, see the
ProLINE-RoadRunner Service Manual -002 or higher for the tape
centering procedure before adjusting the width.
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Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Operator Functions •• Setting Up RoadRunner for a Programming Job
Operator Functions
Follow these steps to adjust the width of the Tape-In Module to accommodate 44 mm tape width:
1.
With the E-Stop pushed, moved the PNP Head out of the way.
2.
Unscrew the Position Locking Screw most the way out using a 4 mm
Allen wrench. See Figure 3-12.
3
Figure 3-12—XLF Models ONLY, have a 32/44 mm Tape-In Module. The
notch currently indicates 32 mm. The Position Locking Screw is loosened.
The 32 mm Front Track is not shown.
3.
Slide the Selector Plate so the notch points to 44 and tighten the Locking
Screw.
4.
Remove the magnetic Front Track for 32 mm (if it is installed) by first,
loosening the two Peel Bar screws.
Peel Bar Screws
Peel Bar
32 mm Front Track
Figure 3-13—XLF Models ONLY, the 32 mm Front Track is installed.
5.
Lift the 32 mm track slightly to clear the locating pins and tip it back
90° (away from you). Slide it out to the left.
NOTE: For 32 mm device tape, install the Front Track in the
reverse order as removal. Then slide the Selector Plate as described
above so the notch points to 32.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
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Operation • Operator Functions •• Setting Up RoadRunner for a Programming Job
Loading Device Tape
Operator Functions
Devices to be programmed with the RoadRunner are sealed in device tape on
a tape reel. Device tape (carrier tape) consists of pocketed tape which holds
the devices and cover tape. The cover tape is a self-adhesive or heat-sealed
tape. The maximum size tape reel you can use on a RoadRunner is 13 inch
(33 cm) diameter.
The Tape-In Module simultaneously feeds the device tape into the machine
and strips off the cover tape.
NOTE: Several different Tape-In Modules are available for
RoadRunner. Ensure that you use the proper tape width for your
module, or that the module is adjusted for your tape width. If you
have an Adjustable Tape-In Module, see instructions starting on
page 3-10 for changing the tape width.
3
All Models Except XLF
To load device tape into the RoadRunner:
1.
Refer to Figure 3-14 through
Figure 3-16 throughout this
procedure.
[All models except standard Siemens] Ensure that the brass button on
the spindle is rotated to the center to allow a reel to slide over it. Install a
reel of device tape. Rotate the brass button to lock the reel in place.
[Siemens except XLF] Ensure that the device tape reel is properly
installed in the Feeder Cart rack. A reel axle must be used.
Figure 3-14—Locking a Reel onto the RoadRunner Spindle
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Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Operator Functions •• Setting Up RoadRunner for a Programming Job
Operator Functions
Peel Bar
Tape threading Diagram
3
Figure 3-15—Loading a Device Tape [Standard Siemens Model Shown]
2.
Switch the power switch on [I] and allow the system to start up.
3.
Remove the Robotics Cover.
4.
Insert the tape into the Tape-In Module to engage with the sprocket.
5.
Press Menu until the top level menu is displayed.
6.
Scroll to and select Advance Pocket.
CAUTION: Device tape can jam if devices fall into tape
path. Do not advance tape pockets with devices in them
past the pick point. Remove the devices as necessary with a
vacuum tweezer.
For sticking tape to the
Take-Up Reel see
Figure 3-16 on page 3-16.
7.
Press the Up Arrow button to advance the tape.
8.
When the tape has advanced past the peel bar, separate the cover tape
from the device tape.
9.
Thread the cover tape through the tape path as indicated in the tape
threading diagram on the RoadRunner. Attach it to the Cover Tape Reel.
A small piece of adhesive tape may be required to stick the cover tape to
the Take-Up Reel.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
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Operation • Operator Functions •• Setting Up RoadRunner for a Programming Job
Operator Functions
Figure 3-16—Attaching the Cover Tape to the Take-up Reel on standard
RoadRunners [Siemens Model Shown].
3
The device tape is loaded. The device tape must be aligned before running a
job. Refer to “Aligning the Device Tape” on page 3-17.
XLF Models
To load device tape into the RoadRunner XLF:
NOTE: Make sure the Tape-In Module is adjusted for your desired
tape width.
See the spindle and brass
button in Figure 3-14 on
page 3-14
1.
Ensure that the brass button on the spindle is rotated to the center to
allow a reel to slide over it. Install a reel of device tape. Rotate the brass
button to lock the reel in place.
Peel Bar
Figure 3-17—XLF Models ONLY: Loading device tape. Note that the reel
winds up Cover Tape in the opposite direction than standard models.
3—16
2.
Switch the power switch on and allow the system to start up.
3.
Remove the Robotics Cover.
4.
Insert the tape into the Tape-In Module to engage with the sprocket.
5.
Press Menu until the top level menu is displayed.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Operator Functions •• Setting Up RoadRunner for a Programming Job
6.
Scroll to and select Advance Pocket.
Operator Functions
CAUTION: Devices might fall into and jam the RoadRunner. Do
not advance devices past the RoadRunner’s pick point. Remove
devices with a vacuum tweezer.
7.
Press the Up Arrow button to advance the tape.
8.
Stop when the tape has advanced past the Peel Bar. Adjust the Peel Bar
so that it is between pockets, allowing a device to be picked cleanly
from the pocket and still covering the next device.
9.
Separate the cover tape from the device tape.
10. Thread the cover tape through the tape path as indicated in the tape
threading diagram on the RoadRunner. Attach it to the Cover Tape Reel.
A small piece of adhesive tape may be required to stick the cover tape to
the Take-Up Reel.
Aligning the Device Tape—All Models
The device tape pockets must be aligned with the pick point alignment mark
on the Tape-In Module so that probes can pick the devices accurately.
To align the device tape:
1.
For more information, see
“Loading Device Tape” on
page 3-14.
Load the device tape as described in the previous section, “Loading
Device Tape.”
CAUTION: Device tape can jam if devices fall into tape
path. Do not advance tape pockets with devices in them
past the pick point. Remove the devices as necessary with a
vacuum tweezer.
For Aligning Device Tape
see Figure 3-18 on page
3-18.
2.
Advance the tape until one of the holes in the center of a tape pocket is
close to the Tape-In Module pick point. Don’t overshoot.
3.
Press Menu until the top level menu is displayed.
4.
Scroll to and select Align Pocket.
5.
Using the Up Arrow button to advance the device tape, line up (approximately) the center hole of one of the pockets with the pick point alignment mark. If you pass the mark (by more than one Up-Arrowincrement; 2 mm), use the next pocket. Always approach the mark with
the tape traveling forward.
6.
Press Menu.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
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Operation • Operator Functions •• Programming Devices
Operator Functions
Device Pocket
“Pick Point”
Alignment Mark
Figure 3-18—Lining Up, by eye, the Device Pocket with the Alignment
Mark—alignment need not be exact as shown.
3
Programming Devices
Once the RoadRunner has been properly configured, device programming
may begin. There are several processes associated with successful device
programming, as well as recovering from job pauses or system shutdowns.
The processes are discussed in this section.
Starting a Job
To start a programming job:
1.
Device Tape, Socket
Adapter, Actuator Plate, and
precisor have already been
installed. For more information see “Setting Up RoadRunner for a Programming
Job” on page 3-5.
Install the Robotics Cover (Safety Shield).
NOTE: If the Robotics Cover is not in place, RoadRunner will beep
and run at a slower speed.
2.
Switch the RoadRunner power on [I].
3.
Insert the PCMCIA memory card containing the job to be run.
4.
Clear the conveyor belt of any unneeded devices.
5.
On the Keypad, press the Start button.
(If more than one job is on a card, the job that was preselected by the
supervisor is the one that will begin running.)
6.
Once the PCMCIA memory card is inserted into the RoadRunner, the
job is ready to run. If more than one job resides on the card, then the job
last selected by the system supervisor will be run.
The green status lamp will flash until programmed devices reach the end of
the conveyor belt. When devices have been transported to the SMT machine
pick area, the RoadRunner will pause and wait for the SMT machine to pick
the devices. The green lamp will stop flashing and stay illuminated while the
job is running.
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Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Operator Functions •• Programming Devices
Operator Functions
When a device is picked by the SMT machine, the belt moves forward, presenting another device to the SMT pick head. When a sufficient number of
devices have been picked, the RoadRunner places another group of programmed devices on the belt.
A red LED will light at each programming socket that fails to successfully
program a device. Failed devices are placed into the Reject Bin rather than
on the belt.
Stopping or Pausing a Job
To pause the RoadRunner after the current operation has finished, press the
Pause button on the Keypad.
To temporarily stop a job, or in case of emergency, press the
Emergency-Stop button. The motor-controlled parts will stop and can now
be moved by hand.
NOTE: Restarting after the Emergency-Stop button has been
pressed requires re-aligning the device tape. See “Restarting a
Stopped Job” on page 3-19.
NOTE: The job statistics will continue when restarted after stopping or pausing the job (but not after ending or cancelling a job).
! WARNING
If the main power switch is ON, power is applied
to the electronic systems of the RoadRunner,
regardless of the position of the Emergency-Stop
button or safety shield. Always turn the main power switch
OFF before working inside the machine.
Restarting a Paused Job
To restart the RoadRunner after a job has been paused, press the Start button.
The paused job will resume.
Restarting a Stopped Job
To restart the RoadRunner after the Emergency-Stop button has been
pressed, perform the following:
1.
Twist the Emergency Stop-button clockwise until it springs back to its
normal operating position.
2.
Press Menu until the top level menu is displayed.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
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Operation • Operator Functions •• Programming Devices
Operator Functions
3.
Scroll to and select Align Pocket.
4.
Press the Up Arrow button to advance the device tape until the next
(not previous) pocket center hole lines up (approximately) with the
mark in the metal.
5.
Press the Start button. The paused or stopped job will resume.
Disabling and Enabling a Socket
If a single socket produces an excessive number of errors during
RoadRunner operation, it is automatically disabled to increase programming
yield. RoadRunner will also disable a socket if a probe drops a device while
attempting to pick it from the socket. If the socket is known to be good, it
may be re-enabled by performing the following:
3
CAUTION: Make sure that the socket is empty by visually
inspecting it before enabling a socket.
1.
Press the Pause button on the Keypad if a job is currently running.
2.
Press the Menu button until the top level menu is displayed.
3.
Scroll to and select Socket.
4.
Scroll until the disabled socket is indicated. Press the Select button.
5.
Press the Up Arrow to Enable the socket. (To Disable it, press the Down
Arrow button.)
Purging the Sockets
The Purge command in the Operator’s Menu picks devices out of the programming sockets and places them into the Reject Bin. Purge cannot be used
while a job is running—the blue lamp must be on. Purge can be used when
sockets become disabled and the job has been stopped.
Ending (Cancelling) a Job
RoadRunner will end a job automatically when the number of programmed
devices equals the number that the particular job was set up to run (the Pass
Limit). The job may have been set to program an infinite number of devices,
in which case it will not stop automatically.
To stop a job see “Stopping or Pausing a Job” on page 3-19.
To cancel a job without finishing it:
1.
3—20
Press the Pause button on the Keypad.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Operator Functions •• Programming Devices
NOTE: All job statistics will end (and be stored on the memory
card) when you cancel or end a job.
Operator Functions
2.
Scroll to and select Job.
3.
Scroll to and select End.
Programming and verification will continue only for devices still in the
programming sockets. They will be picked and placed on the output
conveyor or into the Reject Bin, as appropriate. The job will then stop.
4.
Clear away excess devices from the output belt.
5.
Empty the Reject Bin as described in the next section.
3
Emptying the Reject Bin
To empty the Reject Bin, pause the RoadRunner and remove the Reject Bin
by its finger tab. Lift the bin up and pull out. Replace the bin once it has been
emptied. See Figure 3-19.
CAUTION: Collision hazard. To prevent damage to the
probe, ensure that the Reject Bin is completely in place
so the probe will not hit it.
Figure 3-19—Replacing the Reject Bin. (Bin for Standard RoadRunner
shown.)
Emptying the Cover Tape Module
When the Tape Take-Up Reel (part of the Cover Tape Module) looks full, the
used cover tape needs to be removed.
NOTE: Not all RoadRunners have a Cover Tape Reel.
To empty the cover tape reel:
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
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Operation • Operator Functions •• Programming Devices
Operator Functions
1.
Press the Pause button.
2.
Rotate the cover tape Take-Up Reel backward to free up the tape.
3.
Unwind just enough cover tape for restarting it onto the reel, then cut
the cover tape near the Take-Up Reel.
4.
Depending on your configuration, either:
4a. Pull the cover tape Take-Up Reel straight out from RoadRunner,
or
4b. Rotate the Take-Up Reel while holding the hub stationary until the
holes line up with the pins on the hub, and then pull straight out.
3
Figure 3-20—Removing the Cover Tape Take-up Reel [Fuji Shown].
For more information see
“Loading Device Tape” on
page 3-14.
5.
Unwind the used cover tape from the reel and discard it.
6.
Slide the cover tape Take-Up Reel back onto the hub and rotate it until
the holes line up with the steel pins. You may need to prevent the inner
cylinder from rotating. Some types of reels require rotating the reel
again so the curved slots capture the pins.
7.
Rethread the cover tape onto the reel —a small piece of adhesive tape
may be required.
Shutting Down RoadRunner
To shut down RoadRunner:
For more information, see
“Emptying the Cover Tape
Module” on page 3-21.
3—22
1.
Press the Pause button.
2.
Press Menu until the top level menu is displayed.
3.
Scroll to and select End Job.
Programming and verification will continue only for devices still in the
programming sockets. They will be picked and placed on the output
conveyor or into the Reject Bin, as appropriate. The job will then stop.
4.
When the RoadRunner stops moving and the blue lamp illuminates,
switch the power OFF [0].
5.
Remove devices from the output belt.
6.
Empty the Reject Bin.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Operator Functions •• Miscellaneous Settings via the Menu
7.
Operator Functions
Empty the Cover Tape Take-Up Reel:
7a. Cut the cover tape near the Take-Up Reel and pull the device tape
out of the RoadRunner. Use caution to ensure that no devices fall
from the device tape and into the machine.
7b. Remove and empty the Take-Up Reel containing the used cover
tape. Replace the Reel.
Miscellaneous Settings via the Menu
Changing the Pass Limit
An operator can change the Pass Limit at the RoadRunner Control Panel, but
it does not save the change to the job card. The next time the job is run, the
original Pass Limit will be in effect.
To change the Pass Limit at the Control Panel:
1.
Select Job.
2.
Select Remaining Devices.
3.
Scroll to and Select an increment for adjustment.
4.
Press the Up or Down Arrow buttons as necessary.
5.
Press Menu. Repeat steps if needed for another increment.
Changing Languages
To change languages:
1.
Press the Select button and the Menu button simultaneously.
2.
Then press the Down Arrow or Up Arrow to locate the desired language.
3.
Press Menu twice.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
3—23
3
Operation • Supervisor Functions •• Menus Available to the System Supervisor
Supervisor Functions
In addition to the Operator functions described in the previous section, the
system supervisor performs many other functions. While the operator primarily runs programming jobs, the system supervisor has the ability to set
RoadRunner operational parameters and view operational statistics, perform
various diagnostic routines, and monitor event logs for programming and
diagnostics. Additionally, the system supervisor can create programming
jobs using TaskLink for Windows software.
Menus Available to the System Supervisor
3
To access the supervisor menus, a special supervisor card must be created in
TaskLink on a PCMCIA card. When this special card is inserted into the
RoadRunner, the system supervisor has access to a number of menus that are
not available to the operator. Figure 3-21 shows the supervisor’s menus that
are in addition to the operators menus.
3—24
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Supervisor Functions •• Menus Available to the System Supervisor
RoadRunner Ver 05.35.00.C Supervisor Menu
Main Menu
OERATORSUPERVISOR
Job
Home
1
Operation
1
System
1
Robot Diagnostics
1
Programmer Diags
Event Log
Home
Job Name
Device: E28F320
Checksum: 3FC00000
Mfg: INTEL
Adapter: PA-G021
621-0086-0052
Results
Prec:
Act: 644-0016-001
Encrypted: Yes/No
Passed: 992
Failed: 4
System Yld: 98.7
Prgrmr Yld: 99.6
Handler Yld: 99.5
Parts/Hour: 255
MCBI: 2013
Skt 1 Yld: 99.9
Skt 2 Yld: 100
Skt 3 Yld: 100
Skt 4 Yld: 100
Skt Cycles: 249
End
Remaining Devices Remaining: 77
+-1
+-10
+-100
+-1000
+-10000
Select
Job 1
Job 2
End of List
Time
Operation
Job
Job
View
System
Sends the PNP Head to the Home position.
Head
Probes
Teach4
Pick Retries: 2
Error Retries: 3
Pocket Pitch: 4
Pocket Advance: 3
Save Air: On
Belt
Clear Belt: Off
Buffer: 1
Prefill: ON
Warning Msg:
ON / OFF
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
Odometer
3
Update Software
Network
Adapter Alarm
Configuration
Network Parm:
NVRAM/Card
NetworkTxt: Del/Save
Status: Enabled/Disabled
PGM: Fred’sRR2
IP: 139.138.16.215
Prog Port: 7596
Eth Port:100-BT/10-BT5
SUB: 255.255.248
GTW: 139.138.16.1
SNS: 0.0.0.0
SNS Port: 7500
HST: rr215.nt.data-io
DOM: nt.data-io.com
DNS: 139.138.16.105
DTS: 139.138.16.13
Remote Port: 0
Debug Port: 0
E_Addr: 0010EC002211
Clear NetParms
On/Off
Firmware Version
Ver 05.35.00.C
Installed Boards
Bkpln Brd Id: 2
EP860 48Mhz6
WFB FCIII Id:
1287
Adptr Brd Id: 3
Hardware Config
HwCfgIds 1, 3, 4
View Prog Keys
Prog Key information
Set Prog Key
Remove Prog Key
Model: name,
name-uC, name-XLF
Feeder Comm:
SBelt/FFI
Reel Detect: Enable/Disable
Notes:
• Right column bolded items can be changed.
• For information not described in the Owner’s
Manual see the Operator’s Guide.
• Values shown are for EXAMPLE ONLY.
1
See the ‘Operator’s Menu’ list for this item.
Precisor is not required on XLF models.
3 Mean Cycles Between Interrupts.
4 Teach value examples are for standard
RoadRunners only, not XLF models.
5
With FlashCORE III programmer only.
6 or Control Boards EP860 80Mhz,
EP860 50Mhz, DI/O 48Mhz, DW 48Mhz, or
CW 48Mhz.
7
or Waveform Boards WFB FCII Id: n, WFB
FCI(L)Id: n, or WFB FCI(H)Id: n.
Hour: 23
Minute: 59
Month: 12
Day: 31
Year: 2009
Hours: 469.92
Devices: 24742
Timekeeping: OFF
Erase: 0.0s
Blankcheck: 0.0s
Program: 0.0s
Verify: 0.0s
2A
Continued on the next page.
Figure 3-21—RoadRunner Supervisor Menus. Values are examples only.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
3—25
Operation • Supervisor Functions •• Menus Available to the System Supervisor
Supervisor
Functions
Robot Diags
Robot:
Run Mode:
Belt
Sensors
3
Socket
Enabled
Job / Dry Run
Move: Fwd / Bkw
Pick Sensor: 0
Speed: 400 ± 10
Measure Device
Offset: 0.00
Repeatability Test
Start
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.Duration:1508
Probe 1
Probe 2
Probe 3
Probe 4
Head Position
Programmer
Programr: Enabled
Exercise Display
Test Cycles: 3
Test All: PASS
Bus Test: PASS
Adtr ID Test: PASS
LED Dvr Test: PASS
G Node Test: PASS
Vcc OC Test: PASS
Vpp OC Test: PASS
I2C Bus Test: PASS
DAC Ref Test: PASS
GSlew Test: PASS
High RAM Test:
Continuity Loop: 3
Position: Up
Vacuum: Enabled
Puff: Enabled
Vac Sense: 1
Speed: 135 ± 5
[same as Probe 1]
[same as Probe 1]
[same as Probe 1]
Head: 0
Diags
Programmer
Diagnostic
tests require
a Diagnostic
Adapter
Board for all
items below
this line.
Event Log
View
Clear
NOTES:
8 Act. Duration is set by the Socket Adapter.
Figure 3-22—Continuation of Supervisor Menus
3—26
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Supervisor Functions •• Setting Operational Parameters
Setting Operational Parameters
Supervisor
Functions
While it is usually not necessary to change the system’s operational parameters, some of them may require adjustment when changing to a different
device package. All of them require setting after replacing the NVRAM battery since this information is stored in Non-Volatile RAM. The Teach function in the Operation menu contains the most often adjusted parameters. The
following sections describe procedures for these four Teach parameters in
detail. After that, common job parameters that can be customized are discussed.
Operation > Teach > _________
Tape: Used to teach the PNP head the position
of the tape pocket at the pick point.
below
Skt 1: Used to teach the PNP head the position
of the first socket in the Socket Adapter
board.
page 3-28
Reject: Used to teach the PNP head the position
of the tab on the Reject Bin so that
rejected devices will slide into the bin.
page 3-28
Belt: Used to teach the PNP head the position
of the place point on the output belt.
page 3-29
3
Under some circumstances the keypad display may direct you to home the
head before setting the operation parameters.
To home the head: From the top level menu, scroll to and select Home. Wait
for the head to stop moving.
For details regarding step 1
see “Loading Device Tape”
on page 3-14 and “Aligning
the Device Tape—All Models” on page 3-17.
For more help see “Keypad
Operation” on page 3-4.
Setting the “Tape” Parameter
To set the tape pocket position at the PNP pick point:
1.
Load and align the device tape. “See Loading Device Tape” and “Aligning Device Tape.”
2.
On the Keypad, press the Menu button until the top level menu is displayed.
3.
Scroll to and select Operation.
4.
Scroll to and select Teach.
5.
Scroll to and select Tape. The PNP head should move so probe #1 is
positioned over the device tape pick position.
6.
Use the Up Arrow or Down Arrow buttons to move the PNP head until
probe #1 is perfectly centered over the hole in the center of the device
tape. Pushing probe #1 down by hand and holding it while making this
adjustment aids in judging when the probe is centered.
7.
Press the Menu button to record your setting and move up to the next
higher menu.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
3—27
Operation • Supervisor Functions •• Setting Operational Parameters
Supervisor
Functions
CAUTION: Do not move the PNP head while the probe
is in the DOWN position. The probe might get damaged.
DO NOT SELECT THESE COMMANDS WHILE THE
PROBE IS DOWN: Home, Purge, Probe #X speed, or
any of the Teach operations—Tape, Skt1, Reject, Belt.
While performing any Teach procedure, the PNP head may be
moved incrementally with the Up Arrow or Down Arrow with the
probe in the down position. Use caution.
Setting the “Skt 1” Parameter
To set the socket #1 position for the PNP head:
3
1.
On the Keypad, press the Menu button until the top level menu is displayed.
2.
Scroll to and select Operation.
3.
Scroll to and select Teach.
4.
Scroll to and select Skt1. The PNP head should move so probe #1 is
positioned over socket #1.
5.
Use the Up Arrow or Down Arrow buttons to move the PNP head until
probe #1 is perfectly centered over socket #1. Pushing probe #1 down
by hand and holding it while making this adjustment aids in judging
when the probe is centered.
6.
Press the Menu button to record your setting and move up to the next
higher menu.
CAUTION: Do not move the PNP head while the probe
is in the DOWN position. The probe might get damaged.
DO NOT SELECT THESE COMMANDS WHILE THE
PROBE IS DOWN: Home, Purge, Probe #X speed, or
any of the Teach operations—Tape, Skt1, Reject, Belt.
While performing any Teach procedure, the PNP head may be
moved incrementally with the Up Arrow or Down Arrow with the
probe in the down position. Use caution.
Setting the “Reject” Parameter
To set the Reject Bin position for the PNP head:
3—28
1.
On the Keypad, press the Menu button until the top level menu is displayed.
2.
Scroll to and select Operation.
3.
Scroll to and select Teach.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Supervisor Functions •• Setting Operational Parameters
Supervisor
Functions
4.
Scroll to and select Reject. The PNP head should move so probe #1 is
positioned over the tab on the Reject Bin.
5.
Use the Up Arrow or Down Arrow buttons to change the value of the
PNP head position until probe #1 is perfectly centered over the tab on
the Reject Bin.
6.
Press the Menu button to record your setting and move up to the next
higher menu.
NOTE: The probe should be placed in the DOWN position to verify
that it is accurately centered on the tab of the Reject Bin. For
details regarding lowering the probe tip see “Robot Diagnostics”
on page 3-35. When performing this operation, there is a risk of the
probe tip striking the tab on the Reject Bin. To reduce the likelihood
of damage to the probe tip, do not leave the probe in the DOWN
position.
CAUTION: Do not move the PNP head while the probe
is in the DOWN position. The probe might get damaged.
DO NOT SELECT THESE COMMANDS WHILE THE
PROBE IS DOWN: Home, Purge, Probe #X speed, or
any of the Teach operations—Tape, Skt1, Reject, Belt.
While performing any Teach procedure, the PNP head may be
moved incrementally with the Up Arrow or Down Arrow with the
probe in the down position. Use caution.
Setting the “Belt” Parameter
To set up the output belt position for the PNP head:
1.
On the Keypad, press Menu until the top level menu is displayed.
2.
Scroll to and select Operation.
3.
Scroll to and select Teach.
4.
Scroll to and select Belt. The PNP head should move so probe #1 is
positioned over the output belt.
5.
Use the Up Arrow or Down Arrow buttons to change the value of the
PNP head position until probe #1 places a device onto the output belt
without striking the tab of the Reject Bin.
6.
Press the Menu button to save your setting and move up to the next
higher menu.
NOTE: The probe tip should be placed in the DOWN position with
a device attached to verify that it successfully clears the tab on the
Reject Bin. The device vacuum will need to be turned on and a
device must be attached to verify this operation. For details
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
3—29
3
Operation • Supervisor Functions •• Setting Operational Parameters
Supervisor
Functions
regarding turning on the vacuum and lowering the probe tip see
“Robot Diagnostics” on page 3-35.
CAUTION: Do not move the PNP head while the probe
is in the DOWN position. The probe might get damaged.
DO NOT SELECT THESE COMMANDS WHILE THE
PROBE IS DOWN: Home, Purge, Probe #X speed, or
any of the Teach operations—Tape, Skt1, Reject, Belt.
While performing any Teach procedure, the PNP head may be
moved incrementally with the Up Arrow or Down Arrow with the
probe in the down position. Use caution.
3
Operation > Job >
Other Operation menu items offer customizing actions that may affect
throughput. These items are in the Operation > Job menu, and discussed below.
Pick Retries: Sets the number of attempts the probe makes to pick up a
device before it moves to the next socket or tape pocket. The default is 2.
Error Retries: Sets the number of cycles the probe leaves a device in a
socket before disabling it, in the event of a repeated errors of the same type
(such as continuity). The default is 3.
Pocket Pitch: Allows fine tuning the tape movement to match the tape
pocket pitch. This change only affects the current run. To change the pitch
for subsequent job runs, edit the job in TaskLink as follows: 1) In TaskLink,
select the job, 2) Click Edit, 3) Click the Media tab, 4) Change the pitch, 5)
Click OK, 6) Load the job.
Pocket Advance: Sets the number of tape advances, and therefore
Probe pick attempts from the tape, before displaying an error message. The
default, and maximum, is three. For example, set Pocket Advance to one if
you want RoadRunner to stop after two consecutive pick failures.
Save Air: When it is ON, this option shuts off air to the probes for the
moments that it is not needed. The Save Air option should be OFF if the
SMT machine has higher throughput than the RoadRunner.
Save Air EXAMPLES:
• When set to OFF: the probes pick more devices from the sockets even
though the belt is full of devices, and they hover over the belt waiting
for space to place them.
• When set to ON: the probes do not pick more devices when the belt is
already full. Instead, the air (vacuum) stops until the belt starts moving
again. Then the vacuum starts and probes continue to pick devices.
3—30
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Supervisor Functions •• Setting System Parameters
Supervisor
Functions
Belt
> Clear: Removes all devices from the Conveyor Belt by running them
off the end of the belt. Although it is a fast method of clearing the belt,
devices will end up on the floor rather than in the Reject Bin.
> Buffer: Sets the number of times the PNP Head places a group of
devices onto the Conveyor Belt before sending them down to the pick point.
A group of devices is four if four sockets program simultaneously. This
effectively limits the space between each group placed on the belt.
> Prefill: When Enabled, the PNP Head places as many groups of
devices onto the Conveyor Belt as possible until the End-of-Belt sensor is
tripped. Tripping the End-of-Belt sensor at any time will stop filling the belt
and reset the Prefill command to Disabled. Prefill only occurs at the
beginning of a job and will be disabled if devices are detected on the belt at
the start of a job.
Setting System Parameters
The only system parameter that can be set is the real time clock. The odometer reading can be viewed only, and RoadRunner firmware can be updated
from the System menu.
Setting the Real Time Clock
Generally, the only adjustment that will need to be made in this menu (Time
function of the System menu) is the setting of the real time clock. The time
and date are maintained by a lithium backup battery associated with the
clock circuits on the programmer CPU. If the programmer module is
replaced, the time may need to be reset.
To adjust the RoadRunner time and date:
1.
Press the Menu button until the top level menu is displayed.
2.
Scroll to and select System.
3.
Scroll to and select Time.
4.
Scroll until the time or date parameter requiring adjustment is indicated.
Press the Select button.
5.
Press the Up Arrow or Down Arrow buttons to adjust the parameter.
Press the Select button.
Press the Menu button once to go back one menu level. Repeat steps 4
through 6 until the time is set correctly.
Odometer
The odometer displays total hours that the RoadRunner has been powered
up and the total number of devices placed onto the conveyor belt since creation.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
3—31
3
Operation • Supervisor Functions •• Setting System Parameters
To view the odometer:
Supervisor
Functions
1.
Press the Menu button until the top level menu is displayed.
2.
Scroll to and select System.
3.
Scroll to and select Odometer.
Also within the Odometer Menu is a Timekeeping command that records
specific processing times in seconds. When Timekeeping is set to ON, times
for these functions— Erase, Blankcheck, Program, and Verify— are
recorded after each programming event. They are also written to the
Event.log file. To turn Timekeeping on:
3
1.
Scroll to and select System.
2.
Scroll to and select Odometer.
3.
Scroll to and select Timekeeping (the triangle at the beginning of the
line changes to a circle).
4.
Press the Arrow Up button to change to ON.
5.
Press the Menu button (or Start).
The next time you program a device the times will be available. Navigate to
Timekeeping again to see them.
Timekeeping resets to OFF each time RoadRunner power is switched on.
Adapter Alarm
The Adapter Clean count /
Clean Alert are different
from this Adapter life cycle
count. See next heading.
RoadRunner beeps and displays a “Life exceeded” message when the Socket
Adapter has exceeded the manufacturer’s recommended total number of
actuations (a number viewable at Adapter Statistics > Adapter
Life but cannot be changed). If you don’t replace the adapter, RoadRunner
will continue to alert you each time you start or pause a job. These recurring
alerts (beep and message) can be prevented. Navigate the menu to and select
System > Adapter Alarm. Press the ArrowDown button to set to
OFF. Press the Menu button. To view Socket Adapter life, see Adapter Life
on page 6-4 in the Error Messages table under the section “Yellow Lamp is
on.”
Adapter Clean Count
Although not under the System menu, the Socket Adapter Clean Count displays an “Adapter maintenance is required” message when the adapter has
been actuated its recommended number of cycles between cleaning. The
counter can be reset after cleaning the sockets. Also, the cleaning interval
setting can be changed. Both are described in the Troubleshooting chapter:
see Adapter Maintenance on page 6-5 in the Error Messages table under the
the section “Yellow Lamp is on.” To display the number of actuations since
the last cleaning, scroll to and select Socket > Adapter Statistics
> Clean Count.
3—32
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Supervisor Functions •• Setting System Parameters
Updating Programmer Firmware
Supervisor
Functions
Occasionally, an Update may be made to RoadRunner’s internal operating
system to improve operability. To take advantage of this improvement, the
new operating system must be uploaded into RoadRunner. Software Version
is displayed on the keyboard screen at start-up (turn the power off and then
on again).
The update process begins at TaskLink. RoadRunner system updates, as well
as new device and Socket Adapter support, arrive on a compact disk (CD).
Install the update CD onto the computer that has TaskLink on it. It will generally self-install. When you restart TaskLink the following pop-up message
will appear:
3
Figure 3-23—New Software Pop-up
Create a RoadRunner System Update Card in TaskLink. Refer to the
TaskLink help menu for more information.
To perform the RoadRunner update after the update card has been created:
RoadRunner Firmware is
another name for
RoadRunner System
Software.
1.
Insert the PCMCIA memory card with the updated RoadRunner firmware into the PCMCIA card slot beneath the Keypad.
2.
Press the Menu button on the Keypad until the top level menu is
reached. (You are at the top level when pressing Menu does not change
the display.)
3.
Scroll to and select System.
4.
Scroll to and select Update Software.
CAUTION: Do not switch the power off while the update is in
progress. The RoadRunner might get damaged and require service.
5.
While the firmware is being updated, the following message is displayed:
Update in progress.
Do not remove power
until complete.
The three status lamps cycle on and off until the update is complete.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
3—33
Operation • Supervisor Functions •• Network Settings
6.
Supervisor
Functions
When the update has finished, RoadRunner will beep and the blue status
lamp will come on. The following message is displayed on the Keypad
Display:
--Update complete-Insert job card and
cycle Power to reboot.
7.
Insert a job card. Switch the power OFF and then ON again to start the
RoadRunner with the updated firmware.
NOTE: Algorithm updates are not performed using the Update
Software menu item. Device algorithms do not reside within the
RoadRunner itself. They are provided by TaskLink with the programming job on the PCMCIA memory card.
3
Algorithms are updated on TaskLink. For more information
regarding algorithm updates contact your Data I/O sales representative.
Network Settings
Network commands are covered in Chapter 2. See “Configuring for Network
Communication” on page 2-31.
Configuration
The RoadRunner configuration command is under the System > Config
menu. Here you will find the model designation of your RoadRunner, such
as Model: Siemens-XLF, for example, for RoadRunner eXtra-LargeFormat for Siemens SMT machines.
The Feeder Comm command allows setting Siemens RoadRunners
shipped after September 2007 to FFI so it communicates with
SIPLACE X-Series placement machines.
Installed Boards and Hardware Configuration Identification
(HwConfigId) are listed, which aid in determining if new device support
algorithms are compatible with your RoadRunner hardware.
Miscellaneous items under System > Config are:
• several Prog Key commands used for, and described in, our secure
digital management software (sold separately)
• (a special request option) a Reel Detect command which detects
when a reel of devices has been removed and signals the SMT line. The
default is Disabled.
3—34
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Supervisor Functions •• Robot Diagnostics
Robot Diagnostics
Supervisor
Functions
The robot diagnostics menu contains a series of utilities used to verify proper
operation and to troubleshoot the robotic system. These utilities are also useful when performing tests from other system menus.
The basic functions provided by the utilities in this menu are:
For the Robot Diagnostics
menu see Figure 3-21 on
page 3-25.
•
•
•
•
•
Enable and disable the robot subsection
Allow system dry runs
Enable and disable the output belt components
View other system sensors
Cycle each of the PNP probes and test all other pneumatic components
Dry Run
When Run Mode is selected in the Robot Diags menu, use the Up
Arrow or Down Arrow to toggle between Job and Dry Run. Use Dry
Run to check the mechanical function of the robotics. Devices do not need
to be present. When Dry Run is visible at the keypad screen the programmer is disabled as well as two sensors: the vacuum detect sensors and the
cover-tape-broken sensor. Dry Run can be used to isolate mechanical problems or when the RoadRunner is new or has just been repaired. It can also be
used to even out the conveyor belt when RoadRunner has been inactive for a
week or more.
Belt
When the Move command is selected in the Robot Diags > Belt
menu, the belt can be set in motion with the Up Arrow (forward) or Down
Arrow (backward). This allows the belt speed to be displayed. The speed is a
measurement of the time in milliseconds that it took the belt to travel one
head distance.
The Measure Device command in the Belt menu measures and centers the device at the End-of-Belt optic. (When starting a job, RoadRunner
automatically centers the first device to arrive at the end of the belt to set the
pick point.)
The Adjust Device
command:
1/4 mm
1/4 mm
The Offset command in the Belt menu allows adjusting the device position to accommodate the SMT pick head in the event that centering the
device at the pick point (via the Measure Device command) is undesirable. Scroll to and select [] Robot Diags > Belt > Offset. Push the
Up or Down Arrow once to adjust and wait for the belt to adjust the position.
Press Menu to record and exit the Offset command.
Sensors
Selecting Robot Diagnostics, then Sensors, displays the state of the sensors.
1 = blocked. 0 = unblocked. Menu items + Overtravel and – Overtravel
must be selected to see the current setting.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
3—35
3
Operation • Supervisor Functions •• Programmer Diagnostics
Socket
Supervisor
Functions
The current state of the programming socket can be viewed and toggled with
the Up and Down Arrows when State is selected.
By selecting Actuate, a socket delay time in milliseconds can be added with
the Up Arrow. Zero is the default.
An actuator duration is set automatically for each Socket Adapter type. Use
the Act. Duration command to manually reset the delay value in milliseconds. The new value will be retained in memory until a different adapter
is installed. The default is zero. A few special Socket Adapters have a long
duration incorporating double opening and closing action.
Cycling the PNP Probes
3
The most frequently used utility is likely to be the Probe operations. The
Probe menu selections allow the system supervisor to raise and lower each
of the probes, turn vacuum on and off to the probe tip, and turn positive pressure (puff) air on and off to the probe tip.
To cycle the PNP probes:
For correct speed setting
see “Adjusting and Balancing Probe Speed” in the
Service Manual.
1.
Press the Menu button until the top level menu is displayed.
2.
Scroll to and select Robot Diagnostics.
3.
Scroll to and select Probe X , where X is the probe number to be
cycled.
4.
Scroll to and select Position.
5.
Press the Up Arrow or Down Arrow buttons to toggle UP/DOWN.
Other probe functions, Vacuum, Puff, Vac Sense, and Speed, can be
viewed or toggled with the Up Arrow or Down Arrow buttons also. For
example: when Speed is selected for probe #1, and a device is present at the
pick point, then probe #1 will move down and up intermittently, and display
the speed in the Control Panel screen. Press Menu to stop
Head Position
When the head is homed and Head Position is selected from the Robot Diagnostics menu, the display shows approximately 0 ( ±20 ).
Programmer Diagnostics
PROGRAMMER DIAGS is another menu that the system supervisor may use.
With the exception of Continuity Loop, all items listed after Exercise Display
are for displaying the results of a diagnostic test using the Diagnostic
Adapter Board (DAB), model name RR-DIAG ADAPTER. The DAB
detects problems related to programmer hardware failure—the Waveform
Circuit Board and BackPlane Circuit Board. It does not test the Robot I/O
3—36
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Supervisor Functions •• Event Log
Board or system timing. Instructions for performing the DAB test are in
“Diagnosing with the Adapter Board” on page 5-5.
Supervisor
Functions
Programmer allows disabling the Programmer Module.
Exercise Display verifies that the display and keypad are working properly. When the keypad symbols are displayed in the screen, pressing each
corresponding keypad button erases that image from the screen.
Continuity Loop allows changing the number of continuity tests performed prior to programming a device.
Event Log
3
The Event Log lists status messages for Data I/O engineers. If Timekeeping
is switched ON, it also lists programming times for each process.
Circled entries
are recorded
only if Timekeeping is
on.
06/19/03 11:41:49; BoardAdapter; Current adapter actuation count = 248
06/19/03 11:41:49; PG; 2 of 2 devices programmed
06/19/03 11:41:49; ;Verify - 2.2607 sec
06/19/03 11:41:49; ;Program - 5.4461 sec
06/19/03 11:41:49; ;BlankCheck - 1.5480 sec
06/19/03 11:41:49; ;Erase - 0.7084 sec
06/19/03 11:41:39; PG; Erasing devices
06/19/03 11:41:38; Alg; FPGA_F004: shift_clock: using divider =3333
06/19/03 11:41:38; Alg; FPGA_F004: device_clock: using divider =6
Figure 3-24—Sample of the EVENTLOG.TXT file in
the FDROOT > System folder.
Results
View
 Results
End
Select
In addition to the number of devices Passed and Failed, the results listed
in the Control Panel display under the Job > Results menu offer valuable
information for tracking and ensuring optimum performance.
The System Yld eliminates rejected devices from the yield statistics.
The formula is: Devices placed on belt / (Devices picked from input +
Devices dropped at input).
The Prgmr Yld eliminates dropped devices from the yield statistics. This
gives an indication of how well the RoadRunner programmer is performing.
The formula is: Devices placed on belt / (Devices placed on belt + Devices
rejected).
The Handler Yld is the overall yield. The formula is: (Devices placed on
belt + rejected) / (Devices picked at input + Dropped at input).
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
3—37
Operation • Supervisor Functions •• Session Data Log
Individual socket yields are also calculated. This data can be useful for troubleshooting low throughput, for example, situations when the programmer
yield drops long before the socket Actuations count nears the Adapter Life
count (see Socket > Adapter Statistics). It will be easy to see if one socket of
the four is the cause, in which case that socket can be disabled.
Supervisor
Functions
MCBI is the mean device count between interruptions.
Skt Cycles is the number of socket actuations during the current job.
Adapter Statistics
Many statistics for the Socket Adapter itself are listed in the Socket Menu
under Adapter Statistics.
3
Socket 2: ENABLED
Socket 3: ENABLED
Socket 4: ENABLED
 Adapter Statistics
No. is a unique identification number for the currently installed Socket
Adapter.
Mfg. is the date the currently installed Socket Adapter was first put into use.
Actuations is the number of times the Socket Adapter has been actuated
during its life.
Insertions is the total number of device insertions for the life of the
Socket Adapter. For example, if all four sockets were loaded every time the
sockets were actuated, the number of insertions would be: Actuations x 4.
Also listed in the Adapter Statistics menu are Pass, Fail, and Yield calculations for the currently installed adapter and separate statistics for each
individual socket.
Session Data Log
Device socket activity is recorded in the Session Data Log. If Session Data
Logging is enabled in TaskLink, then a log file will be generated for each
programming session and saved when the session ends. It records counts of
14 possible actions at each socket. The codes for these actions are as follows:
PASS - # of passed devices
CF
NB
IB
PF
VF1
VF2
FT1
FT2
SFF
SFB
DO
EF
3—38
Continuity Failures
Blank error (not blank)
Illegal Bit (not applicable to FLX)
Programming failed
Failed first verify pass
Failed second verify pass (not applicable to FLX)
Failed first functional test (not applicable to FLX)
Failed second functional test (not applicable to FLX)
Security bit failed to program (not applicable to FLX)
Programmed security bit failed (not applicable to FLX)
Device overcurrent error
Erase failed
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Operation • Supervisor Functions •• Session Data Log
Supervisor
Functions
EID
OE
mismatched electronic ID
other errors
Check TaskLink’s Session Data Logging dialog box to discover if it is
enabled, and if so, what location it is written to. (Open TaskLink, click
Setup > Session Data Logging.)
3
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
3—39
Operation • Supervisor Functions •• Session Data Log
3
blank page
3—40
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
4Service information . . .
. . . is in a separate manual, with its own Table of Contents and
Index.
The separate Service Manual (that came with this Owner’s Manual) can be
placed into this three-ring binder.
The Service Manual covers removal and replacement procedures for most of
RoadRunner’s modules. It also lists part numbers, called Model Names, for
ordering replacement parts.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Aug07]
4—1
Service information . . . •
If you wish to order another Service Manual, use the Order Form below.
There are standard RoadRunner models and XLF models (extra-large format) for many SMT Manufacturers.
Data I/O Parts Ordering Information
4
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
RR-SERV-MANL-10
Qty
Price Ea.
Totals
Service Manual, SIPLACE X2, X3, X4, X4I.
MYDATA MY9, MY12, MY15, MY19
$
$
RR-SERV MANL A
Service Manual, Assembleon
$
$
RR-SERV MANL F
Service Manual, Fuji MFU, QP242, QP351, IP3,
NXT, AIM
$
$
RR-SERV MANL P
Service Manual, Panasonic, for MSF, MCF,
MPAV2B, MPAG3
$
$
RR-SERV MANL K
Service Manual, Panasonic, for CM20, CM120,
CM301
$
$
RR-SERV MANL CM
Service Manual, Panasonic, for CM402, DT401
$
$
RR-SERV MANL S
Service Manual, Siemens
$
$
RR-SERV MANL S-XLF
Service XLF Manual, Siemens
$
$
RR-SERV MANL U
Service Manual, Universal GSM1, GSM2, GENESIS
$
$
Signature:__________________________Date:____________Company:________________________
Shaded items may use a different Model Name.
4—2
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Chapter
5
5Maintenance
In addition to the maintenance schedule, which starts on the
next page, there are instructions for using a Diagnostics Adapter Board, and
sign-off charts to fill in.
Tools Required
Some of the tools required for maintaining the RoadRunner are:
•
ESD grounding strap
•
isopropyl alcohol
•
four digit volt meter/multi-meter (calibrated)
•
lint-free cloth
•
vacuum tweezer
•
cotton swabs (optional)
•
water for cleaning
•
Grease
–Shell AV2 (Standard RoadRunner)
–Lubriplate DS-ES 4 (XLF RoadRunner)
•
Hex Keys (Allen wrenches),
.5 mm through 5 mm
•
OPTIONAL: grease gun
– with nozzle NSK HGP NZ3 (Standard RoadRunner only)
–with nozzle for fitting Fitting B-M6F (XLF
RoadRunner)
•
compressed air
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
5—1
Maintenance • Preventive Maintenance Schedule ••
Preventive Maintenance Schedule
To ensure that the RoadRunner continues to operate at its greatest capabilities, perform the preventive maintenance steps at the intervals indicated in
chart on the following page.
This chart is based on programming 20,000 devices each week. If you process more than that, preventive maintenance should be performed more
often.
Maintenance Schedule
Interval
Component
Tools Required
Action
Conveyor Belt
Isopropyl alcohol
Lint-free cloth
Clean the exposed portion with isopropyl alcohol on a
cloth, then dry it. Rotate the belt and repeat.
Sockets
compressed air
Remove dust and debris with clean, dry compressed air.
Press down on the socket opener to ensure dust and
debris are cleared from beneath the contacts as well.
Check for wear; replace the Socket Adapter module if
necessary.
Daily
4mm Allen Wrench Or, as needed for best throughput:
Remove the Socket Adapter and clean in an ultrasonic
bath with approved cleaning fluid.
Tape-In Module
compressed air
Remove dust and debris with clean, dry compressed air.
Entire System
Vac-Tool
Perform the system self-test once each week, with
power and air, to verify proper operation of all internal
electronic systems.
To run the self-test perform the following:
5
Weekly
Quarterly
5—2
1.
End a job if one is running.
2.
Clear all devices from the sockets and from
the conveyor belt.
3.
Toggle the power switch OFF, then ON again.
The self-test will begin automatically. Check
the LCD display for system errors.
Backplane-toadapter terminals
dry compressed air
Remove the Socket Adapter and blow off the Backplane
PCB terminals.
PNP Probe Tips
water
cloth or swab
Clean with water on a clean, lint-free cloth or swab.
Check for wear; replace the tips if necessary.
Chassis and Covers
Isopropyl alcohol
Lint-free cloth
Clean with isopropyl alcohol on a cloth.
NOTE: Do not use solvents such as acetone, lacquer thinner, mineral spirits, or
any type of abrasive compound on the
safety shield surfaces. Use of these products will damage the safety shield surface
and reduce visibility of the operating area.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]]
Maintenance • Preventive Maintenance Schedule •• Lubricating the Ball Screw
Maintenance Schedule
Interval
Quarterly
continued
Component
Tools Required
Check that lubrication is still visible on the ball screw
and that it is clean.
Lubricate if necessary—see Ball Screw under “Yearly”
maintenance.
Ball Screw — Standard RoadRunner
only
Ball Screw — XLF
RoadRunner only
Action
Lubriplate DSES 4 or equivalent
XLF (Extra-Large Format) RoadRunners:
Replenish the ball screw grease. See Lubricating the
Ball Screw, and subhead “XLF RoadRunner (ExtraLarger Format)” on page 5-4.
Conveyor Belt
Visually inspect for frayed edges, separating seam, and
gouges.
Vacuum Filters
Remove each filter from the Pneumatic Module to check
for dirt (filter is no longer white). Replace with new filter if necessary. Refer to Replacing the Vacuum Filters
in Chapter 4. (Maintenance interval may be adjusted
depending on your findings.)
Ball Screw
Grease: Shell AV2
or equivalent
STANDARD RoadRunners:
Replenish the ball screw grease. See Lubricating the
Ball Screw (below) and subhead Standard RoadRunners.
Programmer
(Waveform Circuit
Board and Robot
I/O Board)
Diagnostic Adapter
Board PN 9102200.
RoadRunner firmware version
1.00.10.A or later.
4 mm Allen
Wrench
Perform the Diagnostic Adapter Board (DAB) test. The
procedure is outlined at the end of this maintenance
schedule.
Yearly
NOTE: This maintenance is optional. The
DAB can be purchased from Data I/O or
your Data I/O Representative.
5
The RoadRunner’s DACs are self-calibrating and rely
on a precision voltage source for this action. If the measured voltage is outside of the acceptable range, send
RoadRunner (or just the Programmer Module) to
Data I/O or an approved service center for repair.
Lubricating the Ball Screw
The ball screw is part of the Linear Stage. The PNP Head is screwed to the
ball screw slide.
Standard RoadRunners
The Ball Screw OEM used Shell AV2.
If a grease gun is used (requires reteaching two head positions)
To replenish the ball screw grease:
1.
Turn the power off.
2.
Wipe off the old grease.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]]
5—3
Maintenance • Preventive Maintenance Schedule •• Lubricating the Ball Screw
3.
Remove the two screws securing the PNP Head to the slide (3 mm hex
key) and move the head out of the way enough to access the grease fittings. (Hoses are still attached.)
Figure 5-1—Ball Screw slide grease fittings (circled) on the Standard RoadRunner. The PNP Head has been removed.
4.
Apply at the 3 mm nozzle on the ball slide fittings. The NSK grease
nozzle designation is HGP NZ3. Supply grease until it comes out from
the ball slide. Move the slide by hand to work the grease into all areas.
5.
Reinstall the head with the two screws.
6.
Reteach the head the Tape Position (page 3-27) and Skt 1 positions
(page 3-28).
If a grease gun is not used
To replenish the ball screw grease:
5
1.
Turn the power off.
2.
Wipe off the old grease.
3.
Apply grease directly to the rail and ball groove of the screw shaft.
Move the ball slide so the grease permeates into it.
XLF RoadRunner (Extra-Larger Format)
The OEM used type Lubriplate DS-ES 4. (www.lubriplate.com)
The re-lubrication interval varies depending on the operating conditions of
the rolling guides. A six month interval (or 1000 hours of usage) is generally recommended. You should use approximately 12-13 g of lubricant on
the screw when re-lubricating the assembly.
If a grease gun is used
To replenish the ball screw grease:
5—4
1.
Turn the power off.
2.
Wipe off the old grease.
3.
Apply at the grease nozzle to the ball slide fitting. There is only one fitting—it is on the far (conveyor) side of the slide. The grease fitting is
B-M6F. Supply grease until it comes out from the ball slide. Move the
slide by hand to work the grease into all areas.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]]
Maintenance • Diagnosing with the Adapter Board •• Running Diagnostics on a Programmers
If a grease gun is not used
To replenish the ball screw grease:
1.
Turn the power off.
2.
Wipe off the old grease.
3.
Apply grease directly to the rail and ball groove of the screw shaft.
Move the ball slide so the grease permeates into it.
Diagnosing with the Adapter Board
The Diagnostic Adapter Board (DAB), part number 910-2200-003 or later,
detects problems related to programmer hardware failure—the Waveform
Circuit Board and BackPlane Circuit Board. It does not test the Robot I/O
Board or system timing. (RoadRunner firmware version 1.00.10.A, or later,
is required.)
Running Diagnostics on a Programmers
To run the diagnostic test:
1.
Turn the RoadRunner power switch off.
2.
Lift off the Robotics Cover.
CAUTION: To prevent ESD shock, before you touch the
Socket Adapter, discharge static electricity from yourself
by touching a common ground or an unpainted metal
surface.
When power is turned off,
the head is easily moved
back and forth by hand.
3.
Move the Pick and Place Head away from the programmer socket module to allow room to work.
4.
Pull the Actuator Plate away from the RoadRunner by sliding it out
from the grooved brackets.
5.
Unscrew the two captive screws that secure the Socket Adapter bracket
and rotate the adapter bracket up.
6.
Lift the adapter free, being careful not to damage the electronic circuitry.
7.
Insert the Diagnostic Adapter Board ensuring that it seats correctly on
the adapter pins.
8.
Lower the adapter bracket and screw in the screws.
9.
Insert a supervisor PC-Card into the RoadRunner.
10. Turn the RoadRunner power switch On.
11. Scroll to and select Programmer Diags on the keypad screen.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]]
5—5
5
Maintenance • Diagnosing with the Adapter Board •• Running Diagnostics on a Programmers
12. Scroll to and select Test All, or select one of the individual tests listed
(rather than Test All).
For Programmer Module
removal instructionssee
“Removing the Programmer Module” in the Service
Manual.
The pass/fail test results are displayed on the RoadRunner keypad display,
while test result details are written to /fdrroot/system/diaglog.txt
on the PCMCIA card. If any of the tests show FAIL on the keypad display
(for example: Adtr ID Test: FAIL) remove and return the Programmer Module, along with the PCMCIA card containing the test results, to
Data I/O Corporation or to your nearest Data I/O approved service center.
For contact numbers see the inside back cover.
5
5—6
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]]
Maintenance • Electrical Equipment Disposal Notice •• –
Electrical Equipment Disposal Notice
–
This symbol (displayed on your Data I/O product) indicates
that the item must not be discarded with general municipal
waste. Return products displaying this symbol to Data I/O
so that they may be recycled, reused, or otherwise properly
disposed of, in accordance with the European Union's
WEEE Directive.
Data I/O will, at no cost to the equipment owner, collect this equipment and
process it accordingly. Contact your nearest Data I/O office to receive information about returning marked products with no charge.
RoHS for China
Notice of Restriction of Hazardous Substances pertaining to China:
᦭ኂ‛䋼៪‫ܗ‬㋴
ㇱઙฬ⒓
᩹᨞
ᠲ૞ਬ᥻ࠊৄ䴶ᵓ
ᜪขེ䇗ᭈ㋏㒳
‫׺‬ᏺᇕ㺙㋏㒳
ୱ⁁䕧ܹ῵ഫ
㓪⿟఼῵ഫ
⥄ࡼᴎẄ㞖㋏㒳
⬉⑤
ⓨ᳆⋉㋏㒳
ប೙ᮨഫ CCA
⒮ࡼӴ䗕㋏㒳
䪙 (Pb)
X
X
X
X
X
X
X
X
X
X
X
ᳮ (Hg)
O
O
O
O
O
O
O
O
O
O
O
䬝 (Cd)
O
O
O
O
O
O
O
O
O
O
O
౐ચ䫀 (Cr6+)
O
O
O
O
O
O
O
O
O
O
O
ᄙ⒈㘨㣃 (PBB)
O
O
O
O
O
O
O
O
O
O
O
ᄙ⒈Ѡ㣃䝮 (PBDE)
O
O
O
O
O
O
O
O
O
O
O
5
O㧦⴫␜䆹᳝ᆇ⠽䋼೼䆹఼ӊ᠔᳝ഛ䋼ᴤ᭭Ёⱘ৿䞣ഛ೼ SJ/T 11636-2006 ᷛ‫ޚ‬㾘ᅮⱘ䰤䞣㽕∖ҹϟDŽ
X㧦⴫␜䆹᳝ᆇ⠽䋼㟇ᇥ೼䆹䚼ӊⱘᶤϔഛ䋼ᴤ᭭Ёⱘ৿䞣䍙ߎ SJ/T 11636-2006 ᷛ‫ޚ‬㾘ᅮⱘ䰤䞣㽕∖DŽ
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]]
5—7
Maintenance • Maintenance Sign-off Charts •• –
Maintenance Sign-off Charts
Copy this chart
to use near your
RoadRunner.
RoadRunner SN________
For maintenance instructions see
“Preventive Maintenance Schedule” on page 5-2.
Enter name of people responsible or daily check marks:
Daily
• Blow off sockets
• Check Socket
Wear (Yield) and
remedy
• Clean Conveyor
Belt
Name
Sunday
Monday
Tuesday
Wednesday Thursday
Friday
Saturday
Enter initials and date:
Weekly
• Blow out Tape-In
Module
• Perform System
Self-test
• Clean PNP Probe
tips.
5
Initial—Date
Jan.
Feb.
Mar.
Apr.
May
Jun.
Jul.
Aug.
Sep.
Oct.
Nov.
Dec.
Quarterly
Enter initials and date:
• Clean covers
Initial—Date
• Check Vacuum
Jan.–Feb.–Mar.
Apr.–May–Jun.
Jul.–Aug.–Sep.
Oct.–Nov.–Dec.
Filters
• Check Ball Screw
for visible lube
• Lube Ball Screw
Enter initials and date:
.
(XLF only)
Yearly
• Perform ProgramInitial—Date
• Lube Ball Screw (Std
mer Diagnostic
20___
only)
test (semiannually
• Check waveform
okay)
board voltage
5—8
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]]
Maintenance • Maintenance Sign-off Charts •• Notes:
Notes:
5
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]]
5—9
Maintenance • Maintenance Sign-off Charts •• Notes:
blank page
5
5—10
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]]
Chapter
6
6Troubleshooting
This chapter describes error messages and failure symptoms along with probable steps for resolution. The “Error
Messages” chart is organized by lamp color when the error is displayed, and
then alphabetically by error message within each color section.
NOTE: These procedures should be performed by qualified service
personnel.
NOTE: Some RoadRunners operate with fewer than four sockets.
The troubleshooting help that follows lists error messages for four
sockets (four probes) but resolutions apply to RoadRunners as
applicable.
Colored Lamp Significance
There are three types of messages displayed by the RoadRunner at the control panel.
Status lamps do not change—INFORMATIVE Message; Indicates a
machine state. It does not require attention. Example: “Waiting for belt to
clear...”
Yellow lamp lights—WARNING; Indicates that the system is not running at
its optimum, has degraded, or a stop is impending. It does not require immediate attention. Example: “Reject bin needs to be emptied.”
Blue lamp lights—CRITICAL or FATAL Message; Stops the RoadRunner.
The job cannot continue without operator action. Critical example: “Reject
bin is full.” Fatal example: “Unable to raise probe 1.”
NOTE: A lit blue lamp with no messages indicates that the RoadRunner is stopped (not currently running a job).
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
6—1
Troubleshooting • Resolving Problems •• Testing the Programmer
Resolving Problems
In case of a system failure, the onboard diagnostic system will, in most
cases, notify the user. Most subsystem failures or anomalies detected by system sensors will be displayed on the keypad screen.
Testing the Programmer
In addition to the onboard diagnostic system, a Diagnostic Adapter Board
(DAB), model name RR-DIAG ADAPTER, detects problems related to programmer hardware failure. The DAB tests the Waveform Circuit Board and
BackPlane Circuit Board—parts of the RoadRunner programmer. The DAB
does not test the Robot I/O Board or system timing.
See “Diagnosing with the Adapter Board” on page 5-5.
Viewing Errors
If an error occurs, a message should be displayed on the keypad screen, and
the yellow or blue status lamp will illuminate. The blue status lamp denotes
that the RoadRunner has stopped. The yellow status indicator denotes an
abnormal condition that may cause the RoadRunner to stop.
To view and correct errors, perform the following:
1.
On the Keypad, press the Menu button to remove the error messages. If
there are other error messages, the next one will appear.
2.
Check the error as implied by the message and correct it as necessary.
Clearing Jammed Device Tape
If the tape advances incorrectly or not at all, it may be jammed inside the
RoadRunner. To clear the tape path:
6
For information about
loading the device and
cover tape into the
RoadRunner, refer to
“Loading Device Tape” on
page 3-14.
6—2
1.
Press the Emergency Stop button (to continue the job later) or select
Job, then End, and turn the power off.
2.
Cut the cover tape near the Take-Up Reel.
3.
Remove the device tape from the RoadRunner by pulling it back out
from the input side. It should pull from the machine easily.
4.
Inspect the device tape and remove any flaws, cuts, or breaks in the tape
before reloading it.
NOTE: A common cause of jammed device tape is inferior tape
splices.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Troubleshooting • Resolving Problems •• Disabling and Enabling a Socket
Disabling and Enabling a Socket
If a single socket produces an excessive number of errors during
RoadRunner operation, it is automatically disabled to improve throughput
and reduce the likelihood of rejecting good devices due to a worn or dirty
socket. If the socket is known to be good, then it may be re-enabled by performing the following:
NOTE: Before enabling a socket that has been automatically disabled, be absolutely sure that it is not damaged in some way.
Repeated failures on a single socket usually indicate socket failure
or damage of some sort, even if it is not readily apparent.
If no damage is suspected or visible ensure that there are no devices
in the socket before enabling.
1.
Press the Pause button on the Keypad if a job is currently running.
2.
Press the Menu button until Job is displayed.
3.
Press the Up Arrow or Down Arrow buttons until Socket is displayed.
Press the Select button.
4.
Press the Up Arrow or Down Arrow buttons until the disabled socket is
highlighted. Press the Select button.
5.
Press the Up Arrow button to change the state of the socket from Disabled to Enabled.
6
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
6—3
Troubleshooting • Error Messages •• No Change in Lamps
Error Messages
Lamp
Color
Error Message
Resolution
No Change in Lamps
No change
in lamps
6
Card not present.
Insert (or re-insert) a job card into the PCMCIA card slot.
More than one socket
pulled over-current.
• Ensure that the Job options are correct and agree with the type of
device.
Sockets will be disabled if programmer hardware is degraded
One or more sockets have
pulled over current.
• Ensure that the Job options are correct and agree with the type of
device.
Sockets will be disabled if programmer hardware is degraded.
VCC for socket 1 has
pulled over current.
• Ensure that the Job options are correct and agree with the type of
device.
Sockets will be disabled if programmer hardware is degraded.
VCC for socket 2 has
pulled over current.
See above.
↑
VCC for socket 3 has
pulled over current.
See above.
↑
VCC for socket 4 has
pulled over current.
See above.
↑
VPP for socket 1 has pulled
over current.
See above.
↑
VPP for socket 2 has pulled
over current.
See above.
↑
VPP for socket 3 has pulled
over current.
See above.
↑
VPP for socket 4 has pulled
over current.
See above.
↑
Waiting for belt to clear...
Wait.
Yellow Lamp is On
Adptr.
Life
Yellow
lamp is on
A bad Update Card was
detected. Cannot proceed
Update operation.
• Make sure you are not using a Job card.
• Try using another PCMCIA card.
Adapter life has been
exceeded.
Replace the Socket Adapter or expect a decline in throughput.
This message displays when socket manufacturers recommended
number of actuations is exceeded. The Adapter Life number may be
viewed (but not changed) on the RoadRunner menu by selecting
Socket > Adapter Statistics > Adptr. Life.
6—4
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Troubleshooting • Error Messages •• Yellow Lamp is On
Lamp
Color
Clean
Alert.
Clean
Count
Error Message
Resolution
Adapter maintenance is
required. The cleaning
interval has been exceeded.
Clean the Socket Adapter. For cleaning information, see Sockets in the
Daily Maintenance schedule.
The clean interval is determined by the number set in the Clean Alert.
To reset the counter, on the RoadRunner Menu navigate to Socket >
Adapter Statistics > Reset Clean Count. Press the Select button.
To change the alert number, on the RoadRunner Menu select Socket >
Adapter Statistics > Clean Alert. Use the Up or Down Arrow buttons
to raise or lower the number. Set it to 0 to disable the alert feature.
. . . Yellow
lamp is on
...
Cover open.
Close the cover.
Device pick failure at input
with probe 2.
No operator intervention is necessary.
(A device is on probe 1.) Operation will continue without a device on
this probe.
Device pick failure at input
with probe 3.
See above.
↑
Device pick failure at input
with probe 4.
See above.
↑
Device pick failure on
probe 1.
(Pick failure at the socket.)
No operator intervention is necessary.
The programmer socket and probe will be disabled.
CAUSE A: DEVICE IS TILTED IN THE SOCKET
• Remove the device from the socket.
If this error occurs often:
CAUSE B: SOCKET IS NOT COMPLETELY OPENED
• Verify that the Actuator Plate is fully compressing and opening the
sockets. Check for interference.
• Verify that the system air pressure is within specified limits. Adjust
as required; see specifications at the end of Chapter 1.
CAUSE C: MISALIGNMENT OF HEAD
• Align the Pick and Place Head.
CAUSE D: VACUUM SENSORS ARE OUT OF ADJUSTMENT
• Adjust the vacuum sensors.
CAUSE E: PROBE TIP NOT SEATED
• Remove and replace the rubber probe tip.
• Verify that the rubber cup is on the probe.
CAUSE F: THE PICK OR TRAVEL DELAY VALUES ARE TOO
LOW
• Reset the pick delay.
• Reset the travel delay.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
6—5
6
Troubleshooting • Error Messages •• Yellow Lamp is On
Lamp
Color
Error Message
Resolution
CAUSE G: PROBE SPEED IS TOO FAST OR TOO SLOW
• Verify that the system air pressure is within specified limits. Adjust
as required; see specifications at the end of Chapter 1.
• Adjust the probe speed.
• Reset the probe travel delay.
. . . Yellow
lamp is on
...
6
6—6
Device pick failure on
probe 2.
See above.
↑
Device pick failure on
probe 3.
See above.
↑
Device pick failure on
probe 4.
See above.
↑
Devices are on belt.
Remove devices if desired.
Devices are on belt. START
to continue. PAUSE to cancel.
Remove devices if desired and select Start or Pause.
Inadequate air pressure
detected.
• Ensure that the supply air is connected.
• Check that the supply air pressure is within the specified limits (see
specifications at the end of Chapter 1).
Job name missing from
JobParms.txt file
Make a new job card by recreating the job in TaskLink.
Reading Card
...Please Wait
Wait.
Reject bin needs to be emptied.
Remove devices from the reject bin.
Socket 1 Disabled error
limit exceeded.
• Select Pause. If there is a device in the socket remove it and reenable the socket.
• Ensure that the Job options in TaskLink are correct and agree with
the type of device.
If this problem persists, a new socket adapter or programmer may be
needed.
Socket 2 Disabled error
limit exceeded.
See above.
↑
Socket 3 Disabled error
limit exceeded.
See above.
↑
Socket 4 Disabled error
limit exceeded.
See above.
↑
Unexpected device on
probe 1.
No operator intervention is necessary. The device is dropped into the
reject bin.
Unexpected device on
probe 2.
See above.
↑
Unexpected device on
probe 3.
See above.
↑
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Troubleshooting • Error Messages •• Blue Lamp is On
Lamp
Color
Error Message
Resolution
Unexpected device on
probe 4.
See above.
↑
Blue Lamp is On
Blue
lamp is on
Adapter board not compatible with other boards.
Contact Data I/O Customer Service.
Adapter board not supported by software.
The required software is on the RoadRunner compact disk (CD) that is
supplied with new adapters ordered. Install the CD for the new
adapter, (or device or algorithm) onto the computer containing
TaskLink.
NOTE: The CD has the TaskLink Version and
RoadRunner System Software version written on the
face of it. If the RoadRunner System Software version
is different from the version shown on the RoadRunner
startup screen, then you must also update the
RoadRunner firmware.
Then make a new job card by recreating the job in TaskLink.
Algorithm is not compatible with system software.
Reload Job onto card.
All sockets are disabled.
Ensure that the Job options are correct and agree with the type of
device.
All sockets pulled over current.
No operator intervention necessary.
Backplane board not supported by software.
Contact Data I/O Customer Service.
Boot.bin is not read correctly. This file may be corrupted.
Replace the update card with a new one.
Boot.bin is too big. Call
Data I/O service.
Contact Data I/O Customer Service.
Boot.bin programmed in
FLASH has failed checksum verification.
Call Data I/O Customer Service.
Cannot close Boot.bin.
Replace the update card with a new one.
Cannot close sockets.
• Check for interference or jammed actuator plate.
• Verify that the Socket Open Sensor is working properly.
Cannot close SysFlash.bin.
Get a new update card.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
6
6—7
Troubleshooting • Error Messages •• Blue Lamp is On
Lamp
Color
Error Message
Resolution
Cannot find Device Algorithm file. Check your Job
card.
• Try making a new job card by recreating the job in TaskLink.
• The required software is on the RoadRunner compact disk (CD) that
is supplied with new adapters ordered. Install the CD for the new
adapter, (or device or algorithm) onto the computer containing
TaskLink.
NOTE: The CD has the TaskLink Version and
RoadRunner System Software version written on the
face of it. If the RoadRunner System Software version
is different from the version shown on the RoadRunner
startup screen, then you must also update the
RoadRunner firmware.
Then make a new job card by recreating the job in TaskLink.
. . .blue
lamp is on
...
Cannot load device algorithm from Job card.
• Make a new job card by recreating the job in TaskLink.
• Update the RoadRunner firmware by making a System Update card
with TaskLink.
Cannot open Boot.bin.
Create a new System Update card at TaskLink and update
RoadRunner.
Cannot open sockets.
• Make sure supply air is connected.
• Verify that the supply air pressure is within the specified limits. See
specifications at the end of Chapter 1. Also, in the Service Manual,
see Adjusting the Low Air Pressure Sensor, some models.
Cannot open SysFlash.bin.
Create a new System Update card at TaskLink and update
RoadRunner.
Checksum error in
Image.bin file
• The checksum that RoadRunner calculates doesn't match the checksum contained within the job. Reload the job onto the card in
TaskLink.
• Try a new PC card.
• Try a different brand of PC Card reader/writer to load the job with.
• If the job file has had any handling, such as going through e-mail,
then try a fresh job file (transfer by FTP or Network)
CRC error in file
Make a new job card by recreating the job in TaskLink. If this does not
correct the error, call Data I/O Customer Service.
Comparator/DAC error.
Contact Data I/O Customer Service.
Controller board not supported by software.
Contact Data I/O Customer Service.
6
6—8
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Troubleshooting • Error Messages •• Blue Lamp is On
Lamp
Color
Error Message
Resolution
Cover tape broken.
CAUSE A: COVER TAPE TAKE-UP REEL IS FULL
• Empty the cover tape reel and rethread the cover tape.
CAUSE B: THERE IS NO MORE INPUT MEDIA AVAILABLE
• Install new input media.
CAUSE C: COVER TAPE SENSOR IS MALFUNCTIONING
• Contact Data I/O Customer Service.
CAUSE D: COVER TAPE MODULE IS BROKEN
• Replace the Cover Tape Take-Up Module.
CAUSE E: COVER TAPE MODULE DRIVE BELT IS SLIPPING.
• Remove the Cover Tape Module, re-tension the belt and replace the
Module, or Contact Data I/O Customer Service.
Data file is too large to fit
in memory.
The device loaded may not be supported.
Device continuity error.
• Clean the sockets (See the daily maintenance schedule in chapter 5.)
• Replace the socket adapter with a new one.
• Increase the Place delay
Device dropped from head
1.
CAUSE A: TAPE POCKET IS MISALIGNED
• Align the pocket tape.
CAUSE B: HEAD IS MISALIGNED
• Reteach the “Tape” parameter and/or the “Skt1” parameter.
CAUSE C: WRONG OR MISALIGNED PRECISOR
• Install the correct precisor (or position it correctly on the dowel
pins); precisors are marked for corresponding device packages.
CAUSE D: VACUUM SENSORS ARE OUT OF ADJUSTMENT
• Adjust the vacuum sensors.
CAUSE E: PROBE TIP IS NOT SEATED
• Reinstall probe tip or replace.
To continue, select Start on the keypad.
. . .blue
lamp is on
...
Device dropped from head
2.
See above.
↑
Device dropped from head
3.
See above.
↑
Device dropped from head
4.
See above.
↑
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
6
6—9
Troubleshooting • Error Messages •• Blue Lamp is On
Lamp
Color
Error Message
Resolution
Device pick failure at input,
with probe 1.
To continue, select Start from the keypad. This will temporarily disable the probe. The next able probe will attempt to pick.
CAUSE A: THE POCKET IS EMPTY.
• Verify there are devices in the tape.
CAUSE B: WRONG OR MISALIGNED PRECISOR
• Install the correct precisor (or position it correctly on the dowel
pins); precisors are marked for corresponding device packages.
CAUSE C: MISALIGNMENT OF POCKET.
• Select Align Tape from the top level menu.
CAUSE D: MISALIGNMENT OF HEAD
• Align the Pick and Place Head.
CAUSE E: VACUUM SENSORS ARE OUT OF ADJUSTMENT
• Check the vacuum sensors; reset if necessary.
CAUSE F: PROBE TIP NOT SEATED
• Remove and replace the rubber probe tip.
• Verify that the rubber cup is on the probe.
CAUSE G: THE PICK OR TRAVEL DELAY VALUES ARE TOO
LOW
• Reset the Pick delay. See the Service Manual.
• Reset the Travel delay. See the Service Manual.
. . . blue
lamp is on
...
Device pick failure at input,
with probe 1. (continued)
CAUSE H: PROBE SPEED IS TOO FAST OR TOO SLOW
• Verify that the system air pressure is within specified limits. Adjust
as required; see specifications at the end of Chapter 1.
• Verify that the Probe speed is within limits; readjust if necessary.
• Reset the probe travel delay.
Device pick failure at input,
with probe 2.
(No device is on probe 1.)
To continue, select Start from the keypad. This will temporarily disable the probe. The next probe will attempt to pick .
6
• See above.
6—10
↑
Device pick failure at input,
with probe 3.
(No device is on probe 1or 2.)
To continue, select Start from the keypad.
This will temporarily disable the probe. The next probe will attempt to
pick .
• See above. ↑
Device pick failure at input,
with probe 4.
(No device is on probe 1, 2, or 3.)
See above. ↑
Emergency Stop is activated.
Ensure that the RoadRunner is safe to start and then restore power by
twisting the Emergency Stop button to release it.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Troubleshooting • Error Messages •• Blue Lamp is On
Lamp
Color
. . .blue
lamp is on
...
. . .blue
lamp is on
...
Error Message
Resolution
Error encountered reading
file.
Make a new job card by recreating the job in TaskLink.
Errors encountered in
SECTPROT.TXT file for
job
Make a new job card by recreating the job in TaskLink.
Field Update failed. Onboard FLASH is in
unknown state.
Programmer Module requires repair or replacement.
Contact Data I/O Customer Service.
Incompatible boards in
Programmer.
Programmer Module requires repair or replacement.
Contact Data I/O Customer Service.
Incorrect Programmer
board configuration for Job.
The Job parameters are not compatible with the Programmer. Check
the Job parameters or Contact Data I/O Customer Service.
Invalid Job name.
Make a new job card by recreating the job in TaskLink.
Invalid LCA file.
Reload the Job onto the card.
Invalid parameter name in
file:...
Reload the Job onto the card using the current version of TaskLink.
Invalid parameter value in
file:...
Reload the Job onto the card using the current version of TaskLink.
Job card not present.
Insert a card into the PCMCIA slot.
Job in progress. End current
job in order to proceed.
Using the keypad, select End from the top level Job menu.
Missing parameter in file:...
• Reload the job.
• Contact Data I/O Customer Service.
Motor controller not
responding.
Make sure Emergency Stop is not depressed.
No Adapter installed.
Install the socket adapter for the devices being programmed.
No Job Selected.
• Select a Job (Supervisor Mode).
• Verify that the job card has a job written on it.
NVRAM Battery Failed.
Programmer Module requires repair or replacement.
Contact Data I/O Customer Service.
PNP motor controller not
responding.
Make sure Emergency Stop is not depressed.
Programmer continuous
over-current error.
No operator intervention required.
Programmer FPGA Failure.
Programmer Module requires repair or replacement.
Contact Data I/O Customer Service.
Programmer Shift Chain
Failure.
Contact Data I/O Customer Service.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
6
6—11
Troubleshooting • Error Messages •• Blue Lamp is On
Lamp
Color
Error Message
Resolution
Reject bin full.
CAUSE A: REJECT BIN IS FULL
• Empty device reject bin.
CAUSE B: THE SENSOR IS DEFECTIVE OR NEEDS ADJUSTMENT
• Verify that the sensor is working; adjust or replace.
6
. . .blue
lamp is on
...
6—12
Reject Bin not detected.
Install the reject bin. Ensure that it is correctly in place.
SECTPROT.TXT file not
found for job.
Reload job onto card.
Size of Image.bin file
incorrect.
Ensure the correct data file is being specified in TaskLink.
SysFlash.bin is too big to fit
in the on-board FLASH.
Programmer Module requires repair or replacement.
Contact Data I/O Customer Service.
SysFlash.bin is too big.
Call Data I/O service.
Programmer Module requires repair or replacement.
Contact Data I/O Customer Service.
SysFlash.bin programmed
in FLASH has failed checksum verification.
Programmer Module requires repair or replacement.
Contact Data I/O Customer Service.
SysFlash.bin was not read
correctly. This file may be
corrupted.
Contact Data I/O Customer Service. A new SysFlash.bin file may be
required.
System and device algorithm are not version compatible.
• Reload the Job onto the card.
• Check that your Job card algorithm files are compatible with the
current system version.
The Adapter board is not
installed.
Install the Adapter board.
The checksum of the
loaded Boot.bin is bad.
Update is not done.
Repeat update operation or contact Data I/O Customer Service. A new
Boot.bin file may be required.
The checksum of the
loaded SysFlash.Bin is bad.
Update is not done.
Contact Data I/O Customer Service. A new SysFlash.bin file may be
required.
Unable to advance tape.
• Make sure the Emergency Stop is not depressed.
• Check the tape path for obstruction.
• Verify that the Tape-In Sensor is working properly; check connection at both ends of the cable.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Troubleshooting • Error Messages •• Blue Lamp is On
Lamp
Color
Error Message
Resolution
Unable to home PNP head.
CAUSE A: EMERGENCY STOP IS DEPRESSED
• Twist the emergency-stop button to release it.
CAUSE B: THE HOME SENSOR IS DEFECTIVE
• Replace the Home Sensor.
CAUSE C: THE POSITIVE OR NEGATIVE OVER-TRAVEL SENSOR IS DEFECTIVE
• Replace the Over-Travel Sensor
CAUSE D: THE MOTION CONTROLLER PCB OR CABLE IS
DEFECTIVE
• Contact Data I/O Customer Service.
Unable to load and/or start
the internal serial port
driver.
• Turn the power off and back on.
• Contact Data I/O Customer Service.
Unable to lower probe 1.
CAUSE A: INSUFFICIENT AIR PRESSURE
• Verify that the supply air is connected.
• Verify that the supply air pressure is within the specified limits (see
specifications at the end of Chapter 1).
CAUSE B: PROBE SPEED IS TOO FAST OR TOO SLOW
• Verify that the system air pressure is within specified limits. Adjust
as required; see specifications at the end of Chapter 1.
• Verify that the Probe speed is within limits; readjust if necessary.
CAUSE C: THE PICK OR TRAVEL DELAY VALUES ARE TOO
LOW
• Reset the pick delay.
• Reset the travel delay.
CAUSE D: PROBE POSITION SENSOR IS MALFUNCTIONING
OR OUT OF ADJUSTMENT
• Verify that the Probe Position Sensor is working.
• Adjust the Probe Position Sensor.
. . .blue
lamp is on
...
CAUSE E: HEAD-UP SENSOR IS NOT ADJUSTED OR NOT
WORKING PROPERLY
• Check that the probe Head-up Sensor is working.
• Realign the probe Head-up Sensor.
6
CAUSE F: A PINCHED AIR LINE OR MALFUNCTIONING
SOLENOID VALVE
• Verify that the air lines are not pinched.
• Verify correct solenoid operation.
Unable to lower probe 2.
See above.
↑
Unable to lower probe 3.
See above.
↑
Unable to lower probe 4.
See above.
↑
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
6—13
Troubleshooting • Error Messages •• Unlisted Error Messages
Lamp
Color
. . .blue
lamp is on
...
6
Error Message
Resolution
Unable to raise probe 1.
The solenoid switch in the Pneumatic Module may be stuck. Replace
the Pneumatic Module.
Unable to raise probe 2.
See above.
↑
Unable to raise probe 3.
See above.
↑
Unable to raise probe 4.
See above.
↑
Unable to read Adapter
board ID consistently.
Reinsert Adapter.
Reinsert the Adapter.
Unable to read Jobs directory.
• Try a different Job card.
• Try a different brand of PC Card reader/writer to load the job with.
• If the job has had any handling, such as going through e-mail, then
try a fresh job file (transfer by FTP or Network)
Unable to reset programming electronics.
Programmer Module requires repair or replacement.
Contact Data I/O Customer Service.
Unrecognized Programmer
board.
Update to the latest RoadRunner software.
VCC DAC calibration
error.
Programmer Module requires repair or replacement.
Contact Data I/O Customer Service.
VIH DAC calibration error.
Programmer Module requires repair or replacement.
Contact Data I/O Customer Service.
VPP DAC calibration error.
Programmer Module requires repair or replacement.
Contact Data I/O Customer Service.
VSense DAC calibration
error.
Programmer Module requires repair or replacement.
Contact Data I/O Customer Service.
Waveform board not supported by software.
Update to the latest RoadRunner software. If the error is not resolved,
the Programmer Module requires repair or replacement.
Contact Data I/O Customer Service.
Wrong Adapter board
installed for the Job
selected.
Install the correct Adapter board.
Unlisted Error Messages
Errors that are uncommon are not listed. If you get an error message not
listed above, contact Data I/O Customer Service.
6—14
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Troubleshooting • Problems, but no Error Message •• –
Problems, but no Error Message
–
This is for the header; otherwise previous. H2
text displays. Must delete from TOC.
Use this chart if you experience problems for which no error message is displayed, or an error message appears to be incorrectly displayed.
Symptom
Possible Cause
Corrective Action
Conveyor Belt is empty but does
not stop running.
Fibers are sticking up at the edges of
the belt.
• Trim belt edge fibers using small
scissors or melt them off with a
soldering iron.
Conveyor belt stops when no
devices are present at the pick point.
The End-of-Belt Sensor optic is
adjusted too low and is triggering on
high spots on the belt.
• Adjust the conveyor End-of-Belt
Sensor optic. See “Adjusting the
End-of-Belt Sensor” in the Service Manual.
Conveyor does not operate.
Conveyor belt motor malfunction or
loose connection.
• Inspect the connection. Replace
the Conveyor Module if necessary
or contact Data I/O Customer Service.
Conveyor belt is damaged or misaligned.
• Replace the Conveyor Module or
contact Data I/O Customer Service.
The End-of-Belt Sensor optic is malfunctioning, is out of adjustment
(too low), or has loose connection.
• Adjust the conveyor End-of-Belt
Sensor optic. See “Adjusting the
End-of-Belt Sensor” in the Service Manual.
Inspect the optic connection.
Replace the Conveyor Module or
Contact Data I/O Customer Service.
Robot I/O Board malfunction.
• Replace Robot I/O Board or Contact Data I/O Customer Service.
Room temperature is below 20° C
(68° F)
• Raise room temp and allow time
for conveyor casting to adjust.
Conveyor Belt slips on pulleys or
devices bounce about on the belt.
6
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
6—15
Troubleshooting • Problems, but no Error Message •• –
Symptom
Possible Cause
Corrective Action
Cover tape does not peel and store
properly.
Cover Tape Take-Up Reel is broken
or binding.
• Inspect and replace if necessary.
See “Removing the Cover Tape
Module” in the Service Manual.
The Cover Tape Module clutch
assembly is malfunctioning.
• Inspect and replace if necessary.
See “Removing the Cover Tape
Module” in the Service Manual.
Cover Tape Module drive belt is
loose and slipping.
• Adjust drive belt tension or
remove module and replace.
Cover tape broken or twisted or slipping.
• Remove and reload cover
tape.Use adhesive tape if slipping.
Loose or bad connection to the
Take-Up Motor.
• Inspect and replace Cover Tape
Module if necessary
The Broken Tape Sensor is malfunctioning.
• Inspect connection; replace sensor
if necessary.
Cover tape not pulled tight when
loading.
• Pull cover tape tightly when loading it onto the Cover Tape Reel.
Ensure cover tape is fully
removed from exposed tape in the
Tape-In Module.
Cover tape jams into Tape-In Module.
6
6—16
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Troubleshooting • Problems, but no Error Message •• –
Symptom
Possible Cause
Corrective Action
Device tape does not index properly.
Tape is damaged.
• Inspect tape. Remove and cut tape
or use new reel.
The tape pocket pitch is non-standard, or the software value for
pocket pitch is incorrect.
• Change the Pocket Pitch for this
job in TaskLink, Version 4.6 or
greater. 1. Open TaskLink, 2.
Select the job, 3. Click Edit, 4.
Click the Media tab, 5. Change
the pitch, 6. Click OK, and 7.
Load the job. Then notify
Data I/O of the possible device
Algorithm error.
Device tape is incompatible with the
Tape-In Module.
• Use correct tape or install correct
Tape-In Module
Empty tape is binding in the discharge path.
• Remove tape, trim up tape if necessary and reload.
Tape-In Sensor is loose or malfunctioning.
• Inspect and tighten or replace. See
“Removing
the
Adjustable
Tape-In Module,” or “Removing
the Standard Tape-In Module” in
the Service Manual.
Tape-In drive motor malfunction.
• Inspect
connection;
replace
Tape-In Module if necessary. See
“Removing
the
Adjustable
Tape-In Module,” or “Removing
the Standard Tape-In Module” in
the Service Manual.
Robot I/O Board malfunction.
• Replace Robot I/O Board or Contact Data I/O Customer Service.
Devices are dropped from the
probes but the machine fails to recognize that they were dropped.
The probe vacuum sensors are not
properly adjusted.
• Adjust the probe vacuum sensor.
See “Adjusting Probe Vacuum
Sensors” in the Service Manual.
Devices bounce out of the carrier
tape during the pick event.
Probes travel too fast.
• Adjust and balance the probe
speed. See “Adjusting and Balancing Probe Speed” in the Service Manual.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
6—17
6
Troubleshooting • Problems, but no Error Message •• –
Symptom
Possible Cause
Corrective Action
Devices hit Socket Adapter (and
possibly fall off the probe) as the
head starts to move.
Probe-raising speed is too slow.
• Adjust the probe-raising speed.
See “Adjusting Probe Raising
Speed” in the Service Manual.
• Travel Delay is too short. See
“Resetting Pick Delay and Travel
Delay Times” in the Service manual.
Devices rotate excessively on the
conveyor belt.
• Dust or dirt on the conveyor belt.
• Clean the conveyor belt. See the
daily maintenance schedule on
page 5-2.
• Incorrect conveyor drive belt tension on models with cog drive.
• Adjust the conveyor drive belt.
See “Adjusting the Conveyor
Drive Belt (Notched Only)” in the
Service Manual.
• Conveyor drop-height is incorrect
• Adjust Conveyor drop height. See
“Reinstalling the Conveyor Module” in the Service Manual.
Devices run off the end of the belt.
The End-of-Belt Sensor optic is
adjusted too high and is allowing
devices to pass under it, or it is malfunctioning.
• Adjust the conveyor End-of-Belt
Sensor optic. See “Adjusting the
End-of-Belt Sensor” in the Service Manual.
Inspect the optic connection.
Replace the Conveyor Module or
Contact Data I/O Customer Service.
Emergency Stop release causes
RoadRunner to emit a high pitch
squeal.
The PNP head has been moved a
long distance from its position prior
to pushing the E-Stop and cannot
recover.
• Push the E-Stop again and return
the head to its previous position,
then release the E-Stop, or
turn the power switch Off [0] and
then back On.
Error message “Device pick failure
on probe X at input” is displayed
when the pocket is empty.
The probe vacuum sensors are not
properly adjusted.
• Adjust the probe vacuum sensor.
See “Adjusting Probe Vacuum
Sensors” in the Service Manual.
6
6—18
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Troubleshooting • Problems, but no Error Message •• –
Symptom
Possible Cause
Corrective Action
PNP Head fails to transport devices.
A cylinder is stuck or spring is broken.
• Replace the PNP Head. See
“Removing the PNP Head” in the
Service Manual.
Pneumatic tubes leaking or disconnected.
• Inspect and repair.
Malfunctioning pneumatic valve or
insufficient air flow.
• Replace pneumatic filters.
Inspect or replace the Pneumatic
Module or Contact Data I/O Customer Service.
A vacuum pressure switch is out of
adjustment or malfunctioning.
• See “Adjusting Probe Vacuum
Sensors” in the Service Manual.
Replace the Pneumatic Module;
see “Removing the Pneumatic
Module” in the Service Manual.
Damaged or worn probe tip.
• Replace probe tip.
Excessive puff (blow-off) air.
• Contact Data I/O Customer Service.
Incorrect Precisor installed.
• Replace Precisor.
The Precisor does not locate device
center within tolerance.
• Contact Data I/O Customer Service.
Values for probe pick, place puff or
travel delay are out of adjustment.
• See “Resetting the Pick Delay and
Travel Delay Times” in the Service Manual.
Robot I/O Board malfunction.
• Replace Robot I/O Board or Contact Data I/O Customer Service.
6
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
6—19
Troubleshooting • Problems, but no Error Message •• –
6
Symptom
Possible Cause
Corrective Action
PNP Head position accuracy suffers.
Positions for Tape, socket, reject,
and belt are programmed incorrectly.
• Reteach the head positions. See
“Setting Operational Parameters”
on page 3-27.
PNP Head limit switches are malfunctioning.
• Contact Data I/O Customer Service.
The Sensor Flag is out of adjustment.
• Adjust. The Limit Sensor Flag is
on top of the head.
The Linear Stage Encoder is loose or
malfunctioning.
• Inspect connection. Replace
Robot I/O Board or Contact
Data I/O Customer Service.
Linear Stage Motor malfunction.
• Replace Robot I/O Board or Contact Data I/O Customer Service.
Motion Controller Board malfunction.
• Contact Data I/O Customer Service.
Main Controller Board to Motion
Controller Board cable is damaged
or disconnected.
• Inspect cable and connection.
Contact Data I/O Customer Service.
Linear Stage Motor or sensor cables
are damaged or disconnected.
• Inspect cables and connection.
Replace or Contact Data I/O Customer Service.
Linear Stage Motor stalls.
• Check for excessive drag. Contact
Data I/O Customer Service.
Power up fails —After turning
power On, the display is blank
and/or the machine emits a highpitch tone.
Bad Socket Adapter
• Turn power Off. Remove the
Socket Adapter. Turn the power
On.
• Contact Data I/O Customer Service.
Probe does not extend fully when
placing devices on the belt
The probe is not straight on the PNP
Head.
• Contact Data I/O Customer Service.
The precisor is not in place accurately.
• Check the precisor position.
Probe speed is too slow.
• Adjust probe speed. See “Adjusting and Balancing Probe Speed”
in the Service Manual.
Conveyor height is too low.
• Adjust the conveyor height. See
“Reinstalling the Conveyor Module” in the Service Manual.
6—20
Bad programmer
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Troubleshooting • Problems, but no Error Message •• –
Symptom
Possible Cause
Corrective Action
Dirty or worn Socket Adapter.
• See “Device continuity error” in
the “Error Messages” chart in the
Blue Lamp section.
Programming Errors; See Socket
Failure
Socket failure: sockets fail to program devices successfully (red light
on the Socket Adapter illuminates).
Waveform Board or Backplane
Board malfunction.
• Perform the DAB test. See “Diagnosing with the Adapter Board”
on page 5-5.
Incorrect programming parameters.
• Review the Job Statistics in
TaskLink to identify problem. For
example: if the wrong devices are
used for the selected job,
TaskLink will show an Electronic
ID Error.
Socket Actuator fails to open sockets properly due to low air pressure.
• Check the air regulator.
Socket Actuator position sensor is
loose or malfunctioning.
• Inspect sensor. Tighten or replace.
Figure 6-1—Socket Actuator
Sensor [Universal model
shown]
Sockets disabled or continuity errors
(excessive).
Malfunctioning Waveform Board,
Backplane Board, or CPU Board.
• Replace the Programmer Module.
See “Removing the Programmer
Module” in the Service Chapter.
Incompatible device data.
• Recreate the job in TaskLink
Faulty devices.
• Use new reel of device tape.
Dirty or worn Socket Adapter.
• Remove and clean the Socket
Adapter in an ultrasonic cleaning
tank.
Replace the Socket Adapter. See
“Changing the Socket Adapter”
on page 3-5.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
6—21
6
Troubleshooting • Schematics •• Pneumatic Schematic
Schematics
Pneumatic and electrical schematics are reproduced on labels inside the
RoadRunner as well as below.
Pneumatic Schematic
INTERFACE MANIFOLD
PICK HEAD
Vacuum Cup
PROBE
P
R
A
P
R
A
P
R
A
Socket
Actuation
A
P
R
A
2
3
3
4
4
Exhaust
Silencer
Exhaust
Silencer
Vacuum
Switch
Vacuum
Switch
2
7
±
5 4.0PSI
CFM
( .52 MPa)
( 2 dm 3/ s )
Supply
Valve
Breaking
Valve
P R
4
P R
Ejector
Ejector
Needle
Valve
Suction
Filter
Vacuum
Switch
Vacuum
Switch
Ejector
Ejector
Air Sensor
Air
Source
1
2
VACUUM MODULE
Exhaust
Silencer
P
R
1
Supply
Valve
P R
Suction
Filter
Needle
Valve
Suction
Filter
Breaking
Valve
3
P R
Supply
Valve
P R
Needle
Valve
Breaking
Valve
2
P R
Needle
Valve
Suction
Filter
Supply
Valve
P R
Breaking
Valve
1
P R
Figure 6-2—The pneumatic schematic: effective for production
RoadRunners shipped after June 2007.
The pneumatic system of the ProLINE-RoadRunner consists of a PNP Head,
Pneumatic Module, and an Interface Manifold. The pick head uses six pneumatic cylinders and compliant vacuum probes to move devices through the
unit. The electrically controlled Pneumatic Module creates a vacuum at the
pick head and pressurized air supplied at both the PNP Head and Programming Module. The Interface Manifold is a partition between the PNP Head
and Pneumatic Manifold providing flow control to the PNP Head cylinders.
6
6—22
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Troubleshooting • Schematics •• Electrical Schematic
Electrical Schematic
ProLINE-RoadRunner
Cable Interconnect
Max. Limit
Home
Min. Limit
User Interface Assy
E-Stop
J7A2 J7A2
Interlock
J7A3 J7A3
Tape Motor
J7A1 J7A1
PCMCIA socket
Gantry
Encoder
Lin. Stage
Motor
Tape
Broken
Tape Motor
J4B
J5B2
J5B1
J8B
J4B
J5B2
J5B1
J8B
Pneumatic
Module
Sprocket
Pulse
Power
Switch
Earth2
Reject
Optics
Programmer
Earth
Main
J7
Ethernet
J8
J9
Sockets
Open
J10
J11
J5C
J5
J1C
J1C
J3C
J3C
J2C
J2C
J16
Robot I/O PCB
J15
J3
J14
J2
J13
Motion
Controller
J12
Power
Supply
J1
J5C
J1C2 J1C2
J6
J4
Reject
Present
J3
J4
Power
Entry
Communication
PCB
J2
J15D J15D
Belt Motor
J1D
Belt Sensor
J1D
6
SMT
Communications
P/N 631-0145-006
Figure 6-3—Electrical Schematic for all RoadRunner Models
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
6—23
Troubleshooting • Schematics •• Electrical Schematic
6
6—24
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
GGlossary of Terms
Alphabetical List of Terms
This glossary defines terms and acronyms used in this
manual.
A
Actuator Plate
~ A plate that opens a socket(s) for loading a device(s).
algorithm
~ A software file containing specific step-by-step calculations required by the programmer
to program a device.
Allen Wrench
~ Hex Key
ATA
~ Advanced Technology Attachment. The specification for a disk drive interface standard
based on the IBM PC ISA 16-bit bus interface.
ATA flash card
~ A read/writable card with flash memory that uses the ATA interface.
B
Backplane Board
~ A printed circuit board that connects the Waveform Board to the Socket Adapter Board.
bit
~ The smallest unit of storage that can take one of two values, such as true and false or 0
and 1.
boot
~ To load and initialize the operating system on a computer.
bus
~ A set of connections for connecting various functional units in a computer.
C
CAN Network
~ A serial bus network that can handle communication between many pieces of equipment.
CFM
~ Cubic Feet per Minute, a volume/time measure of the rate of air flow.
One CFM = 28.32 liters per minute.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated 10Jul08]
Glossary—1
Glossary of Terms • D
checksum
~ A computed value which is transmitted or stored along with the data in order to detect
corruption of the data.
chip
~ See Device.
communication
parameters
~ The various settings that determine the I/O characteristics of your equipment. The parameters include baud rate, stop bits, data bits, handshaking, and others.
Communications
Module Interface
Board
~ A circuit board that allows communication with the host handler.
contacts
~ The electrically conductive metal leads on a socket module which conduct programming
signals from the programmer to the pins on the device in the socket.
continuity check
~ A preprogramming test that checks the device for electrical connections to the socket.
(No electrical connection to the die). Not all pins are checked during this test.
CPLD
~ Complex Programmable Logic Device
CPU
~ Central Processing Unit
D
DAB
~ Diagnostic Adapter Board
DAC
~ Digital to Analog Converter.
device
~ A programmable integrated circuit. You may have heard other terms such as chip, microchip, semiconductor device, PROM, or DUT (Device Under Test).
device package
~ The protective container or housing for an electronic device with external terminals to
provide electrical access to the components inside.
device tape
~ The device pocket tape, the devices, and the cover tape before they are separated.
Diagnostic Adaptor
~ A circuit board that replaces the Socket Adapter Board for performing programmer hardware diagnostics.
DIP
~ Dual Inline Package.
dm3/s
~ cubic decimeter per second
DRAM
~ Dynamic Random Access Memory
dry run
~ A state or action in which the RoadRunner will operate without all the necessary information or devices to run. Synonymous with trial run.
DUT
~ Device Under Test, referring to the device that will be programmed or verified.
E
ESD
G
Ethernet
Glossary—2
Electrostatic Discharge. ESD can damage programmable devices and other static sensitive electronic components.
~ The most popular type of local area network, which sends its communications through
radio frequency signals carried by a coaxial cable. Software protocols used by Ethernet
systems vary, but include Novell Netware and TCP/IP.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated 10Jul08]
Glossary of Terms • F
F
FC II
~ FlashCORE II is the name of the second generation of FlashCORE programmers with
more flexibility and supports more microcontrollers.
FC III
~ FlashCORE III is the name of the third generation of FlashCORE programmers (Jan.
2010) with faster file download speeds and support for files greater than 4 GBytes (up to
32 Gbits).
FEPROM
~ Flash Erasable Programmable Read Only Memory. Similar to EEPROM but erasing can
be done in blocks or to the whole chip.
firmware
~ Software stored in ROM or PROM; essential programs that remain even when the system
is turned off.
FLASH
~ See FEPROM.
G
gantry
~ The ball screw that supports the pick and place head and moves it horizontally (in the X
direction only in this case).
GND
~ Ground
graphical user
interface (GUI)
~ All the predefined on-screen elements (for example, dialog boxes, menus, icons, buttons,
fields) used to interact with the system software.
H
Hex Key
~ Allen Wrench.
HIC Socket
Adapters
~ Socket Adapters with High Insertion Count sockets.
I
I/O
~ Input/Output.
I/O Module
~ An input or output (I/O) unit which presents unprogrammed devices to the system (input)
or collects devices after they have been programmed and marked (output).
IDE
~ Integrated Drive Electronics. An interface for connecting additional hard drives to a computer.
ISA
~ Industry Standard Architecture. A bus standard for IBM compatibles.
J
JEDEC
~ Joint Electron Device Engineering Council.
job
~ A set of instructions, used by the RoadRunner, containing all the device programming
parameters required to set up and program a specific set of semiconductor devices. Used
interchangeably with task.
JTAG
~ Joint Test Action Group
K
kit
~ A collection of RoadRunner tasks that are run successively.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Glossary—3
G
Glossary of Terms • L
kgf/cm2
~ kilograms force per square centimeter.
L
laptop
~ A portable computer.
LCA
~ Logic Configure-able Array. A logic device using RAM for programming.
LCD
~ Liquid Crystal Display
lead
~ The connection legs that extend from the body of a device.
LED
~ Light Emitting Diode.
M
mA
~ milliampere
MB
~ Megabyte; 1,048,576 bytes (1,024 x 1,024, or 10242).
MCBI
~ Mean Count Between Interruption
μBGA
~ Micro Ball Grid Array. Sometimes written as MBGA.
menu
~ A screen display that lists available command choices.
Motion Controller
Board
~ A printed circuit board that controls the gantry motor for pick and place movement. It
interfaces with the PC Controller Board and the Robot I/O Board.
N
NVM
~ Non-Volatile Memory
NVRAM
~ Non-Volatile Random Access Memory
O
G
odometer
~ Meters hours and devices—information used for calculating yields.
OEM
~ Original Equipment Manufacturer.
open collector
outputs
~ Outputs can be wire OR'ed—only one logic level.
operation
parameters
~ Parameters that a supervisor sets to restrict the operations of the RoadRunner.
operational
statistics
~ Statistics for a specific operation.
P
PC
~ Personal Computer.
PCI
~ Peripheral Component Interconnect. A standard for connecting peripherals to a personal
computer.
Glossary—4
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated 10Jul08]
Glossary of Terms • Q
PCMCIA card
~ Personal Computer Memory Card International Association card. A lightweight, removable module about the size of a credit card. It is a plug and play module which uses a 16bit socket and a 68-pin connector.
pick position
~ The physical position where the pick-and-place head picks up devices.
Pick and Place
Head
~ The mechanism that supports the probe that picks up and places devices.
pindriver
~ Waveform Board circuitry that determines the function of the contact pins.
PLCC
~ Plastic Leaded Chip Connector.
PNP
~ Pick and Place head. Also referred to as P&P.
pocket parameters
~ The pitch of the device tape pockets. The pocket tape pitch is the number of sprocket
holes between the pocket centers.
pocket tape
~ The pocketed film that carries the devices. This term usually implies that the cover tape
has been removed. Also called device pocket tape.
precisor
~ A mechanical part that attaches to the pick-and-place head to align parts as they are taken
from tape.
probe
~ A device attached to the pick and place head that picks up, carries, and releases devices.
Each probe has a rubber tip on the end that allows it to create a good vacuum seal on the
device.
programming
~ The process of electronically writing data into a device. (Burning is another term used to
describe this operation.) “Input devices” are usually blank or un-programmed; “output
devices” are usually programmed devices.
programming
module
~ Module that contains the programming electronic circuit boards required to program a
device in the socket.
PSI
~ Pounds per Square Inch; a measurement of pressure. One PSI = 0.07031 kg per cm2.
Puff
~ A surge of air through the pick and place probes to release a device.
Q
QFP
~ Quad Flat Pack.
R
register
~ A high-speed memory location in a computer's CPU.
Robot I/O Board
~ A printed circuit board that provides an interface between the Waveform Board and the
Motion Controller Board and robot sensors. It controls power distribution.
S
SCFM
~ Standard Cubic Feet per Minute, a measurement of flow.
SCSI Interface
~ Small Computer System Interface. A processor-independent standard for system-level
interfacing between a computer and intelligent devices.
semiconductor
~ A programmable integrated circuit. Also called “devices,” they are made of a material
whose electrical conductivity is between that of a conductor and that of an insulator.
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Glossary—5
G
Glossary of Terms • T
SMA
~ Surface Mount Assembly; An assembly or machine that utilizes technology for mounting
devices onto circuit boards by connecting leads on the surface of the board rather than
through a hole on the board.
SMD
~ Surface Mounted Device.
SMT
~ Surface Mount Technology.
SNS
~ Serial Number Server
socket adapter
~ A part that allows a socket to fit the programmer.
Socket Adapter
Board
~ A printed circuit board that connects to the Backplane Board to supply the electrical connections for programming devices.
socket module
~ The device-specific part of the programmer that holds a device in place so that it can be
programmed.
SRAM
~ Static Random Access Memory
system parameters
~ System-wide parameters that are metered are real clock time and odometer information.
T
Tape In Module
~ The subassembly on the RoadRunner that controls the feed rate of the pocket tape.
TaskLink
~ Data I/O’s software for creating programming jobs for RoadRunner (as well as
FlashPAK, FLX500, Sprint™ Family Programmers and UniSite™ family Programmers).
It is a Windows based program that simplifies task management.
teach
~ To communicate your directives to the RoadRunner.
throughput
~ The rate at which correctly-programmed devices are produced.
tip
~ A rubber fitting inserted onto the end of a probe that allows it to achieve the vacuum seal
required to pick and hold a device.
TPn
~ Test Point [number].
TSOP
~ Thin Small Outline Package.
V
G
vacuum chamber
block
~ The toric shaped metal at the end of each probe. The vacuum chamber block aids the precisor in centering a device.
vacuum tool
~ A hand tool that uses suction to manipulate objects. “Handy-Vac” is such a tool.
VCC DAC
~ Voltage Collector Common Digital to Analog Converter. Used to generate the supply
power for the devices to be programmed or verified.
VDC
~ Volts (of) Direct Current
verify
~ A device operation that compares data in a programmed device with data in RAM or in a
disk file. With logic devices, verifying can also include functional testing.
VPP DAC
~ Voltage Programming Power Digital to Analog Converter. A DAC that controls the programming power supply for devices.
Glossary—6
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated 10Jul08]
Glossary of Terms • X
X
XLF
~ Acronym for eXtra-Large-Format. XLF model RoadRunners program devices up to
32 mm x 32 mm (44 mm tape width).
G
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated Mar2010]
Glossary—7
Glossary of Terms • X
blank page
G
Glossary—8
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240 [updated 10Jul08]
Remember to check
the Service Manual
index for items not
found here.
GIndex
Alphabetical Index Listing
A
Actuator Plate
actuate duration 3-36
adjusting 3-8
changing 3-8
description 3-8
for HIC adapters 3-8
verify correct one 3-9
Adapter Alarm 3-32
Adapter Clean Count 3-32
Adapter, see Socket Adapter
Adjustable Actuator Plate 3-8
Adjusting GTP Tape-In Module 3-11
Adptr. Life 6-4
Air
Also see Pneumatic
connection 2-26
filter requirement 2-26
requirements 2-26
saving 3-30
Algorithm updates 3-34
Aligning device tape 3-17
B
Ball Screw, description 1-7
Ball Screw, lubricating 5-3 to 5-5
Belt Offset 3-35
Belt position 3-29
Belt Settings 3-31
Black Hook 2-17
Blue light 2-31, 6-1
C
Card
Network 2-31
operator 3-3
PCMCIA 1-11
supervisor 3-24
Carrier Tape. See device tape.
Change-over steps 3-1
Checksum 3-10
Clean Alert 6-5
Clean Count 3-32, 6-5
Cleaning
chassis 5-2
conveyor belt 5-2
probe tips 5-2
sockets 5-2
Clock, setting 3-31
Communication 2-28
Communications Cable 2-28
Config 3-34
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240
Index—1
Index • D+
Configure RoadRunner 2-31
Connections. See Facilities.
Continuity Error retries 3-30
Continuity Test 3-37
Control Panel
Layout 1-4
testing 3-37
Conveyor, overview 1-10
Cover Tape
loading 1-6
threading 3-16
Cover Tape Module
description 1-5
emptying 3-21
Customizing RoadRunner operation 3-30
D
DAB 5-5
Device
centering 3-35
off-centering, see Belt offset 3-35
Device Count, RoadRunner Total 3-31
Device tape
aligning 3-17
description 3-14
loading 3-14, 3-16
removing 3-22
Diagnostics
board 5-5
menu 3-25
programmer 3-36, 5-5
Robot 3-35
test 5-5
Disabling a Socket 3-20
Dry Run 3-35
Errors
blue lamp is on 6-7 to 6-14
informative 6-4
messages 6-1
no error message displayed 6-15
resolutions 6-4
types 6-1
viewing messages 6-2
yellow lamp is on 6-4 to 6-7
ESD. See Electrostatic Discharge
Event Log 3-25, 3-32, 3-37
Extra Large Format RR 1-1
F
Facilities, description 2-25
FC I 1-9
FC II 1-9, Glossary-3
FC III Glossary-3
Feeder Comm 3-34
FFI Communication 3-34
Filter
air 2-26
maintenance 5-3
moisture separator 2-26
Firmware update 3-33
FlashCORE 1-9
G
Gateway (GTW) command 3-25
Gradual Tape Path, see GTP
Green lamp 3-18
Grounding 1-14
GTP Tape-In Module 3-11
E
H
Electrical connection 2-25
Electrical power
requirements 2-25
turning off 3-22
turning on 3-2
Electrostatic Discharge 1-14
Emergency Stop
button 1-13
restoring power 1-13
safety precaution 2-26
Emptying cover tape reel 3-21
Enabling a Socket 3-20
Error Retries 3-30
Hardware configuration 3-34
Hardware, checking setup 3-9
Hazardous Mtrls, China 5-7
Head positions 3-27 to 3-29
HIC Socket Adapters 3-8
High Force Actuation 1-9
Hook 2-17
Hook, Siemens XLF 2-19
Hours, RoadRunner "on" time 3-31
HwCfgID 3-34
I
Index—2
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240
Index • I+
I
Interlocks 1-12
IP Address 3-25
IP command 3-25
J
Job
defining 3-5
menu 3-3
pausing 3-19
restarting 3-19
selecting 3-5
setting up 1-11
starting 3-18
statistics 1-9
stopping 3-19
Job card. See PCMCIA card.
K
Keypad
conventions used in manual 3-4
layout 3-4
operation 3-4
scrolling 3-4
selecting commands 3-4
L
Language, changing 3-3
LED 3-19
also see Socket Adapter
Linear Stage, description 1-7
Log file 3-26, 3-37 to 3-38
Lubrication 5-3 to 5-5
Lubrication sign-off chart 5-8
M
Maintenance
daily 5-2
every 3 months 5-2
preventive 5-2
sign-off charts 5-8
tools required 5-1
weekly 5-2
yearly 5-3
Measure Device 3-35
Memory card 1-11
Menu, language 3-3
Menus 3-3, 3-24
Model 3-34
Mounting RoadRunner 2-3
Assembleon ACM 2-4
Fuji NXT, AIM 2-10
Fuji QP242,QP351,IP3 2-8
MYDATA 2-6
Panasonic CM401,CM402,DT 2-12, 2-14
Panasonic MSF,MCF,MPA 2-11
Siemens 2-17
Siemens SIPLACE X 2-20
Universal 2-22
N
Network card 2-31
Network Setting/Parameters 3-25
Network Txt command 2-31
Networking 2-31
O
Odometer, viewing 3-31
Operation menu 3-24
Operational parameters
belt 3-29
reject 3-28
skt 1 3-28
tape 3-27
Operator menu 3-3
Operator steps 3-1
P
Part. See Device
Pass Limit 3-23
PCMCIA card, overview 1-4
PCMCIA memory requirement 1-11
Pick & Place Head, description 1-7
Pick attempts 3-30
Pick delay, see Service Manual
Pick devices 3-20
Pick failures 3-30
Pick point, see SMT pick point or RoadRunner
pick point
Pick retries 3-30
Pneumatic Cylinders 1-7
Pneumatic Regulator Kit 2-26 to 2-27
PNP Head. See Pick and Place Head
Pocket Advance 3-30
I
Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240
Index—3
Index • R+
Pocket Pitch, changing 3-30
Pocket Tape, jammed 6-2
Power requirements 2-25
Power Switch 2-30
Precisor Plate
changing 3-7
description 1-8
Probe
cycling 3-36
description 1-8
testing 3-36
Problems
conveyor 6-15
device tape 6-17
picking and placing 6-17 to 6-18
PNP Head 6-20
programming 6-21
with devices 6-17
Programmer Module
description 1-8
diagnostics 3-36, 5-5
Programmer Port command 3-25
Programmer Upgrade Kits 1-9
Programming Results 3-37
Programming times 3-32
ProLINE-RoadRunner System 1-1
Puff 1-8
Purge 3-20
Robotic System
description 1-6
precision 1-8
Running a Job. See Starting a Job
S
Safe Operation 1-14
Safety
about warnings 1-3
grounding 1-14
precautions 1-14
Safety Shields 1-12
Save Air 3-30
Save Network text parms 2-31
Schematic
electrical 6-23
pneumatic 6-22
Selecting a job 3-5, 3-18
Self-test 2-30, 5-8
Serial Number Server Settings 3-25
Session Data Log 3-38
Shipping Bracket, removing 2-2
Shock Indicator
description 2-2
photo 2-2
Shutting down 3-22
“I don’t see Ozone in here! It should be here.”
Let us know about any items you can’t find by e-mailing:
[email protected]
R
Regional power 2-25
Reject Bin
emptying 3-21
position 3-28
Remaining devices 3-23
Restarting a paused job 3-19
Restarting a stopped job 3-19
Results 3-37
RoadRunner pick point
about
aligning 3-17
setting Tape parameter 3-27
Robot diagnostics menu 3-24, 3-35
SIPLACE Regulator Kit 2-26
SMT Models Supported 1-15 to 1-24
SMT pick point
about 1-10
adjusting 3-35
buffer 3-31
problems 6-15
teaching 3-27
SNS Settings 3-25
Socket
disabled 6-3
purging 3-20
re-enabling 6-3
wear 1-9
Socket 1 position 3-28
Socket Actuator Sensor 6-21
I
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Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240
Index • T+
Socket Adapter
changing 3-5
clean count 3-32
cleaning 5-2
errors 6-21
LED 6-21
life 3-32
statistics 3-37
Software update 3-33
Specifications 1-15 to 1-24
Starting a Job 3-18
Starting RoadRunner 2-30, 3-2
Statistics 1-9, 3-37
Steps for programming devices 3-1
Stopping a job 3-19
Subnet (SUB) command 3-25
Supervisor card 3-24
Supervisor menu 3-24, 3-36
Surface mount assembly machine, mounting RoadRunner onto 2-3 to 2-22
System menu 3-24
System parameter, setting 3-31
T
V
Version Number (firmware) 3-33
W
Warning
E-Stop button 1-13
fast robot 1-13
heavy object 2-1
mounting hook 2-19
Warning Lamps 6-1
Waveform Board, testing 5-5
X
XLF Model 1-1
X-series Siplace 3-34
Y
Yellow light 6-1
Yields 3-37
Tape Advance Motor 1-5
Tape position 3-27
Tape-In Module
adjusting 3-10 to 3-13
description 1-5
Task, defining 3-5
TaskLink
description 1-11
other information sources 1-11
overview 1-4
Teach function, head positions 3-27
Tests performed 1-9, 2-30
Threading Cover Tape 3-16
Timekeeping 3-32
Tools 5-1
Travel delay, see Service Manual
Troubleshooting
error message 6-4 to 6-14
no error message displayed 6-15 to 6-21
U
Unpacking 2-1
Update software 3-33
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Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240
Index—5
Index • Y+
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Data I/O • ProLINE-RoadRunner Owner’s Manual • 096-0240
Sales and Technical Support
World Wide
Data I/O Corporation
Redmond, WA USA 98052
Telephone: 425-881-6444
inside US 1-800-332-8246
Fax:
425-867-6972
E-mail:
[email protected]
Contact your local Data I/O representative or see the contacts below. To find your local representative on our Web site, go to http://www.dataio.com and click Contact Us (upper right), then click
Representative Search (left side). Then follow the instructions.
www.dataio.com
United States
www.dataio.cn
China
www.dataio.de
Germany
When calling or writing, please provide the following information:
•
•
•
•
•
•
RoadRunner Serial number
Software Version displayed on the keyboard screen at start-up (turn the power off and then on
again)
Detailed description of the problem you are experiencing (if any)
Error messages (if any)
Device manufacturer, part number, package style and number of pins (if device-related)
Name, telephone number and address