Siemens ProLINE-RoadRunner ProLINE-RoadRunner manual

Overview Installation Job Setup Operation Maintenance Troubleshooting ProLINE-RoadRunner English PN 096-0226-0 02 Operator ’ s Guide for Siemens ™ CONTENTS[...]

Data I/O has made a conscientiou s effort to ensure that the information in this document is accurate and complete. Data I/O assumes no liability for errors, or for any incidental, consequential, indirect, or spec ial damages, including, without limitation, loss of use, loss or alteration of data, delays, or lost profits or savi ngs, arising from t[...]

1 ProLINE-Road Runner Opera tor’s Guide A ProLINE-RoadRunner for Siemens........... 2 Jobs and S t atistics........... 3 External V iew ........... 4 Internal Component s........... 5 Control Panel Light s........... 6 Control Panel Bu ttons........... 7 Operator Menus........... 8 Supervisor Menus........... 9 W arnings and Ca utions......... 12[...]

2 ProLINE-Road Runner Opera tor’s Guide A Dat a I/O is proud to introduce a revolutionary new inline solution for high-volume programming of electronic product s. The ProLINE-RoadRunner: 1. T ak es programmable devices from a reel... 2. Places them in sockets and programs them with your dat a... 3. Places them on a conveyor belt... 4. Delivers th[...]

3 ProLINE-Road Runner Opera tor’s Guide A T askLink™ for Windows ® is required to process devices on the ProLINE-RoadRunner . T askLink allows you to create and manage a job dat abase and it analyzes job st atist ics. PCMCIA cards are used to transfer jobs and statistics between T askLink and RoadRunner . For more information on T askLink, see[...]

4 ProLINE-Road Runner Opera tor’s Guide A 1. Power and Air Connections 2. Power Switch 3. Handhold for lif ting 4. PCMCIA Card Slot and Eject button 5. Control Panel 6. Conveyor Belt with Dust Cover 7. Mechanical Interface to Assembly Mach ine 8. Robotics Cover 9. Communications Cable (optional) 10. Electronics Enclosure  External V iew Front [...]

5 ProLINE-Road Runner Opera tor’s Guide A 1. Cover T ape T ake-Up Reel 2. T ape-In Module 3. PNP Probes, Precisor , and Cover 4. Reject Bin 5. Socket Adapter , Actuator Plate, and Programmer  1 2 3 4 5 Internal Component s[...]

6 ProLINE-Road Runner Opera tor’s Guide A Control Panel Light s 1. Blue - Stop Indicator . User intervention is required, or the unit is p aused. (Do not remove PCMCIA card unless blue lamp is li t.) 2. Y ellow - Caution Indicator . Correct a problem or the machine will stop. 3. Green - Run Indicator . Lit: A job is running. Blinking: Programmed [...]

7 ProLINE-Road Runner Opera tor’s Guide A 1. Star t - s t art or resume the chosen job. 2. Menu - exit to the previous menu, —or show the next message (deleting the current one), —or deselect an item. 3. Up and Down Ar rows - move through menu items. 4. Select - select menu items. 5. Pau se - interrupt the job without cancelling it.  Contr[...]

8 ProLINE-Road Runner Opera tor’s Guide A Operator Menus are visible on the RoadRunner control p anel, and can be navigated by using the Up Ar r ow and Down Ar row buttons. Pressing the Menu button displays the menu that is one level up. If you are at the main menu , pressing menu will have no effect. Jo b is the first item in the main menu. NOTE[...]

9 ProLINE-Road Runner Opera tor’s Guide A View th e Supervisor Menus by inserting a PCMCIA c ard with supervisor authority . (The menus on this p age and the next two pages are in addition to the Operator Menus.) Supervisor (Administrator) authorization is set in T askLink. For more information, refer to the T askLink Help Menu. V ersion 5.1 1.00[...]

10 ProLINE-Road Runner Opera tor’s Guide A Refer to the previous pa ge for the main menu. NOTE: Programmer Diags are only available with a Diagnostic Adapter Board. Robot Diags Robot: Enabled Run Mode: Job/Dry Ru n Belt Move:Fwd/Bkw Pick Sensor: 0 Speed: 400 ± 10 Measure D evice Adjust Device Sensors T ape Sprocket: 0 T ape Broken: 0 Reject Full[...]

11 ProLINE-Road Runner Opera tor’s Guide A Refer to the main Supervisor Menu (2 pages back) for orient ation. 1 Actuation duration is set by the Soc ket Adapter . For more information about menu commands, see Chapter 3 of the ProLINE-RoadRunner Owner ’s Manual.  • Light gra y shaded fields cannot be changed. Opera tion Job Pick Retrie s: 2[...]

12 ProLINE-Road Runner Opera tor’s Guide A W arnings and Cautions Compressed Air Point air hoses away from body . Always wear ap proved eye protectio n. Loud Noise Sound pressure levels may excee d 85db. Hearing prote ction is recommended for prol onged exposure at this level. High Vo l t a g e T urn power off before removing electron ics cover .[...]

13 ProLINE -RoadRunner Operator’s Guid e A Mounting on the Assembly Machine...... 12 Connecting Power and Air ...... 16 Connecting th e Communica tions Cable (optiona l) .......18 Running the Self-T est ...... 20 Installation Chapter 2[...]

14 ProLINE-Road Runner Opera tor’s Guide A 2 T o mount RoadRunner on an assembly machine: 1. With the feeder t able pulled out, slide the supplied hook around a pin on the assembly machine feeder t able. 2. Secure the hook to the t able by tightening the thumbscrew . NOTE: A black hook must be used on taller RoadR unners; a silver hook on older m[...]

15 ProLINE -RoadRunner Operator’s Guid e A 3. Slide RoadRunner under the hook so that it s centering teeth engage the pin next to the hook. 4. Lower RoadRunner allowing the feeder t able dowels to mate up with the bushings in the RoadRunner housing. 5. V erify that RoadRunner is secure before moving the feeder t able back into the SMT machine. ?[...]

16 ProLINE-Road Runner Opera tor’s Guide A T o connect the power and the air: 1. T urn the RoadRunner power switch to the Off (0) position. 2. Grasp the air hose behind the “quick connect” collar and push it firmly onto th e male fitting. The collar must be allowed to move back as it goes onto the fitting. NOTE: Compressed air must be clean a[...]

17 ProLINE -RoadRunner Operator’s Guid e A 3. Connect to a grounded power source using a cable with a st andard IEC 320 plug. RoadRunner accept s power between 100 and 240 V AC, 50/60Hz. NOTE: T o disconnect the air hose, grasp the collar on the connector and pull back. The air line is equipped with a “quick connect” that will stop airflow wh[...]

18 ProLINE-Road Runner Opera tor’s Guide A T o connect the Communicat ions Cable (option): 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 t able. Connecting the Communications Cable Red Dot 1[...]

19 ProLINE -RoadRunner Operator’s Guid e A 2. Similarly orient and plug the other end of the cable into the SMT feeder t able. Use the socket that corresponds with the track that RoadRunner is mounted on. T o unplug the cable, pull back on the connector collar .  2[...]

20 ProLINE-Road Runner Opera tor’s Guide A T o run the Self-T est: 1. T urn the pow er switch On (I). All the control p anel indicator light s will come on. When the Self-T es t finishes, the blue light will remain on and the version number will display . If all the indicator light s start blinking, a serious error has occurred. T urn the unit of[...]

21 ProLINE-Road Runner Opera tor’s Guide A Inserting a Job Card ..... 22 Changing the Precisor ..... 24 Changing the Actuator P late..... 26 Changing the Socket Adapter..... 28 Adjusting the T ape-In Module ..... 30 Loading a Reel of Devices ..... 32 Aligning the T ape Pockets ..... 34 Job Setup Chapter 3[...]

22 ProLINE-RoadR unner Operat or’s Guide T o run a job, insert a T askLink job card in the P CMCIA c ard slot. Use only TYPE I or TYPE II PCMCIA cards. T o inse rt a job card: 1. If the power switch is on, make sure the blue lamp is lit. Inserting a Job Card Electrostati c Discharge Ma y Cause Damage . Discharge St atic Agains t Comm on Groun d P[...]

23 ProLINE-Road Runner Opera tor’s Guide A NOTE: When fully inserted, the job card extends slightly from the PCMCIA card slot. 3. The Car d Eject button can be pushed to remove the card. Do not eject the card unless the blue lamp is lit (or the power is off).  2 3 2. Slide the job card into the PCMCIA card slot.[...]

24 ProLINE-RoadR unner Operat or’s Guide T o change the precisor: 1. Select Jo b , then End , wait for the blue lamp to light and turn the power Off (0). 2. Lif t off the Robotics Cover . 3. St arting at one end, pull the precisor down off the magnet, and then pull the other end off. The PNP Head Cover can be removed for easier access. Changing t[...]

25 ProLINE-Road Runner Operato r’s Guide A 4. When inserting the new precisor , make sure that the part number faces up and that the small holes near the precisor edge fit over the dowel pins on the PNP head. There should be no visible gap between the precisor and the head.  4[...]

26 ProLINE-RoadR unner Operat or’s Guide T o change the Act uator Plate: 1. Select Jo b , then End , wait for the blue lamp to light and turn the power Off (0). 2. Lif t off the Robotics Cover . Once power is off, the PNP Head can be moved by hand to allow access to the A ctuator Plate. PNP Head Changing the Actuator Plate Warning: Pinch Warning.[...]

27 ProLINE-Road Runner Operato r’s Guide A 3. Pull the Actuator Plate to slide it out of the grooved brackets. NOTE: The Actuator Plate must be out to access or change the Socket Adapter . T o change the Soc ket Adapter , see the procedure on the following pa g e .  3[...]

28 ProLINE-RoadR unner Operat or’s Guide T o change the Socket Adapter (with the Actuator Plate removed): 1. Make sure the power is Off (0). 2. Unscrew the two captive scre ws and lift the adapter bracket. 2 2 Changing the Socket Adapter Caution: Warning: Electrostatic Di scharge May C ause Damage . Discharge Stati c Against Com mon Grou nd. Pinc[...]

29 ProLINE-Road Runner Operato r’s Guide A 3. Without touch ing the gold cont act surfaces on the bottom of the adapter , lif t the adapter free. 4. Insert the correct adapter , making sure that it seats on the dowel pins. NOTE: Each type of device may have its own Socket Adapter . 5. Tighten the screws and replace the Actuator Plate.  3[...]

30 ProLINE-RoadR unner Operat or’s Guide If you have an Adjust able T ape-In Module, you may need to adjust the ta p e w i dt h . Adjust able T ape-In Module only— If the etched number on the 3-Position Sp acer does not match your t ape wid th dimension (mm): 1. With the power off (0), move the PNP Head out of the way . 2. Loosen the Position L[...]

31 ProLINE-Road Runner Operato r’s Guide A 3. Rota te the 3-Position Sp acer with your finger until you read 16, 24 or 32, corresponding to your t ape width. 4. Retighten the Position Locking Screw . 5. Rot ate the Peel Bar counterclockwise 180 degrees to the up position. 6. Lif t and move the magnetic Front T rack to the position that f i ts y o[...]

32 ProLINE-RoadR unner Operat or’s Guide T o load a reel of de vices: 1. Make sure the reel is correctly inst alled in the rack of the assembly machine. NOTE: A reel axle is required. 2. Insert the t ape into the T ape-In Module and onto the sprocket. 3. Select Advance Poc ket fro m the Operator Menu, then press the Up Ar r ow button. 4. When the[...]

33 ProLINE-Road Runner Operato r’s Guide A 5. Thread the cover t ape up through the cover tape p ath and att ach it to the Cover T ape T ak e-Up Reel. Advance the tape as necessary . NOTE: A small piece of adhesive tape may be needed to stick the cover tape to the T ake-Up Reel. 6. T urn t he T ake-Up Reel to take up slack cover tape. Align the t[...]

34 ProLINE-RoadR unner Operat or’s Guide T o align the tape pocket s: 1. Select Align P ock et from the Operator Menu. 2. Press the Up Ar r ow button to advance the t ape until the next t ape pocket center hole is approximately centered at the pick point alignment mark. Do not advance devices p ast the pick point. They may fall and jam the t ape [...]

35 ProLINE-Road Runner Operato r’s Guide A Running a Job ........ . 36 Pausing or S topping a Job ......... 37 Ending a Job ......... 38 Emptying the Reject Bin ........ . 40 Emptying Cover T ape ......... 41 Shutting Down .. ....... 42 Rest arting a Job ......... 44 Operation Chapter 4[...]

36 ProLINE-Road Runner Operato r’s Guide A T o run a job: 1. Insert a job card in the PCMCIA card slot. 2. Clear the conveyor belt of any unneeded devices. 3. Press Start . The green lamp will st art blinking. When the programmed devices reach the assembly machine pick point, the belt will p a use and the green lamp will st ay lit without blinkin[...]

37 ProLINE-Road Runner Operato r’s Guide A T o pause at the end of the current operation: 1. Press Pause on the control pa n e l . T o instantly stop in an emergency situation: 2. Press the Emer gency Stop button.  Pausing or Stopping a Job 1 > Job Advance Po cket Align Pocket 2 > Job Advance Pocket Align Pocket Warning Electrical shock [...]

38 ProLINE-Road Runner Operato r’s Guide A Whenever you are going to change job cards, you must first end the current job. T o end the current job: 1. Press Pause button. 2. Choose End from the Job Menu. Job is in the main menu. The system will finish processing devices and place the devices on the belt, but no additional devices will get picked [...]

39 ProLINE-Road Runner Operato r’s Guide A 3. Clear away excess devic es from the conveyor belt. 4. Empty the Reject B in. (See next heading.) 5. Empty the Cover T ape T ak e-Up Reel. (See “Emptying Cover T ape” ahead several pages.)  5 4 3[...]

40 ProLINE-Road Runner Operato r’s Guide A T o empt y the Reject Bin: 1. Press the Pause button. 2. Pull the Reject Bin out by grabbing the finger t ab and then lif t up and out. When reinserting the R eject Bin, be sure the bin is comp letely lowered so that the t ab is positioned out of the path of the probes.  Emptying the Reject Bin 2 Warn[...]

41 ProLINE-Road Runner Operato r’s Guide A T o empt y the Cover T ape T ake-Up Reel: 1. Press Pause . 2. Cut the cover tape, leaving enough slack to reatt ach. 3. Pull the T ake- Up Reel straight out. (Reels with slot s require rot ating before pulling off.) 4. Unwind the used cover tape and discard it. 5. Replace the T ake-Up Reel—slide it on [...]

42 ProLINE-Road Runner Operato r’s Guide A T o shut down RoadRunner: 1. Press Pause . 2. Select End J ob from the Job Menu and wait for all devices to be placed on the belt. 3. T urn the pow er Off (0). 4. Remove devices from the conveyor belt. Shutting Down 1 > Job Advance Po cket Align Pocket 3[...]

43 ProLINE-Road Runner Operato r’s Guide A 5. Empty the Reject B in. 6. Remove and empty the T ake-Up Reel. (For more, see the previous heading.) 7. Remove the air hose or shut off the air flow . NOTE: When disconnecting the air hose, pull the connector collar back as you pull the connector off.  5 6[...]

44 ProLINE-Road Runner Operato r’s Guide A T o restart RoadRunner af ter a pause or an emergency stop: 1. T urn the Emer gency Stop button clockwise to release it, if needed. 2. Press Menu until the main level menu is displayed 3. Select Align P ock et. 4. Press the Up Ar row to advance the device t ape until the next pocket center hole lines up [...]

45 ProLINE-Road Runner Operato r’s Guide A Cleaning with Air ......... . 46 Cleaning with Alcohol.......... 47 Running the Self-T est.......... 48 Maintenance Chapter 5[...]

46 ProLINE-Road Runner Operato r’s Guide A T o prevent dust accumulat ion, inject compressed air into the following component areas: 1. T ape-In Module (we ekly). 2. Socket s (daily). Socket s should be opened and closed by hand while air is injected. NOTE: Compressed air must be clean and dry .  Cleaning with Air 1 2 Warning: Point Air Hoses [...]

47 ProLINE-Road Runner Operato r’s Guide A T o prevent dust and oil accumulations, clean the following component areas with isopropyl alcohol on a lint-free cloth. 1. Chassis and Covers (every 3 months). 2. Conveyor belt (daily). See "Device Rot a tion" in the T roubleshooting chapter . NOTE: Dry the conveyor belt before rotating it. Th[...]

48 ProLINE-Road Runner Operato r’s Guide A Run the Self-T est procedure approximately once a week. T o run the Self-T est procedure: 1. Press Pause . 2. Clear all devices from the socket s and from the conveyor belt. 3. T oggle the power switch off and then back on. The Self-T est will run, checking the condition of the component s. 4. Check the [...]

49 ProLINE-Road Runner Operato r’s Guide A Viewing Errors.. .......... 50 Enabling a Socket........... . 52 Clearing Jammed T ape............ 53 Device Rot ation............ 54 T echnical Support............ 55 T roubleshooting Chapter 6[...]

50 ProLINE-Road Runner Operato r’s Guide A Viewing Errors T o vie w and correct errors: 1. Messages will appear in the keypad display . 2. Check the condition—t ape p ath, Reject Bin, etc.—implied by the message. If you cannot correct the error condition, cont act a service technician . 3. Press Menu to remove the message. If there are other [...]

51 ProLINE-Road Runner Operato r’s Guide A Sto p Caution Motor Cont roller not responding Some common error messages are listed below . For more information see “T roubleshooting” in the ProLINE-RoadRunner Owner ’s Manual . 1 Twist the Emerge ncy Stop butt on to releas e it.  Lamp Color Error Message No change in lamps Card not present Y[...]

52 ProLINE-Road Runner Operato r’s Guide A If a socket r epeatedly becomes disabled, RoadRunner should be serviced. T o re-ena ble a disabled socket: 1. Choose Soc k et from the top level menu. 2. Arrow down and select the disabled socket from the Socket menu. (A dot appears.) 3. Press the Up Ar r ow button to re-enable the socket. NOTE: T o disa[...]

53 ProLINE-Road Runner Operato r’s Guide A If the t ape jams, an error message displays and the blue lamp illuminates. T o cle ar the t ape p a th: 1. Press the Emer gency Stop button (to continue the job later) or select Job , then End , and turn the power off. 2. Unroll one turn of cover t ape and cut it near the T ake -Up Ree l. 3. Pull the t [...]

54 ProLINE-Road Runner Operato r’s Guide A Device Rot ation If devices rotate excessively on the conveyor belt: 1. Press Pause . W ait for all t he devices to get picked from the belt. 2. Press the Emer gency Stop . 3. Remove the D ust Cover and clean only the exposed surface of the conveyor belt with isopropyl alcohol on a lint-free cloth, then [...]

55 ProLINE-Road Runner Operato r’s Guide A Worldwide Data I/O Corporation Shippin g address: 10525 Willows Road N.E. Redmond, W A USA 98052 Mailing address: P .O. Box 97046 Redmond, W A USA 98073-9746 T ele pho ne : 425-867-6870 USA Only: 1-800-3 32-82 46 Fax: 425-882-1043 E-mail: s upport@da ta-io.com Y ou can also find answers by visiting our K[...]

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