Siemens ProLINE-RoadRunner, Operator'S Manual

Page 1: ...Overview Installation Job Setup Operation Maintenance Troubleshooting ProLINE RoadRunner E n g l i s h PN 096 0226 002 Operator s Guide for Siemens CONTENTS ...

Page 2: ...es 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 Data I O is a registered trademark of Data I O Corporation TaskLink is a trademark of Data I O Corporation ProLINE RoadRunner is a trademark of Data I O Corporation Data I O Corporation acknowledges the trademarks of other organi...

Page 3: ... ProLINE RoadRunner for Siemens 2 Jobs and Statistics 3 External View 4 Internal Components 5 Control Panel Lights 6 Control Panel Buttons 7 Operator Menus 8 Supervisor Menus 9 Warnings and Cautions 12 Technical Support 55 Chapter 1 Overview ...

Page 4: ... for high volume programming of electronic products The ProLINE RoadRunner 1 Takes programmable devices from a reel 2 Places them in sockets and programs them with your data 3 Places them on a conveyor belt 4 Delivers them to the pick point of your assembly machine 1 2 3 4 The ProLINE RoadRunner for Siemens ...

Page 5: ... ProLINE RoadRunner TaskLink allows you to create and manage a job database and it analyzes job statistics PCMCIA cards are used to transfer jobs and statistics between TaskLink and RoadRunner For more information on TaskLink see the TaskLink Help Menu Programming Jobs Statistics Jobs and Statistics ...

Page 6: ...tch 3 Handhold for lifting 4 PCMCIA Card Slot and Eject button 5 Control Panel 6 Conveyor Belt with Dust Cover 7 Mechanical Interface to Assembly Machine 8 Robotics Cover 9 Communications Cable optional 10 Electronics Enclosure External View Front Back 1 2 9 7 6 4 10 5 8 hidden 3 ...

Page 7: ... ProLINE RoadRunner Operator s Guide A 1 Cover Tape Take Up Reel 2 Tape In Module 3 PNP Probes Precisor and Cover 4 Reject Bin 5 Socket Adapter Actuator Plate and Programmer 1 2 3 4 5 Internal Components ...

Page 8: ...t remove PCMCIA card unless blue lamp is lit 2 Yellow Caution Indicator Correct a problem or the machine will stop 3 Green Run Indicator Lit A job is running Blinking Programmed devices are not yet at the SMT pick point 4 Emergency Stop Press to stop the robot motors in an emergency To resume motion twist the button and press Start 1 2 3 4 ...

Page 9: ...e chosen job 2 Menu exit to the previous menu or show the next message deleting the current one or deselect an item 3 Up and Down Arrows move through menu items 4 Select select menu items 5 Pause interrupt the job without cancelling it Control Panel Buttons 3 1 4 2 5 ...

Page 10: ...ed Socket 4 Enabled Adapter Statistics Reset Clean 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 same as 1 Socket 3 same as 1 Socket 4 same as 1 Job View Job Name Device E28F320 Checksum 3FC00000 Mfg INTEL Adapter PA G021 Prec 621 0086 005 Act 644 0016 0...

Page 11: ...cket Home Operation System Robot Diagnostics Programmer Diags Event Log Job View Job Name Device E28F320 Checksum 3FC00000 Mfg INTEL Adapter PA G021 Prec 621 0086 005 Act 644 0016 001 Results Passed 992 Failed 4 System Yld 98 7 Prgrmr Yld 99 6 Handler Yld 99 5 Parts Hour 255 MCBI 201 Skt 1 Yld 99 9 Skt 2 Yld 100 Skt 3 Yld 100 Skt 4 Yld 100 Skt Cycles 249 End Select X Job 1 yJob 2 End of List Socke...

Page 12: ... 1 Socket State Up Actuate 0 Act Duration 1501 Probe 1 4 Position Up Vacuum Enabled Puff Enabled Vac Sense 1 Speed 135 5 Head Position Head 0 Light gray shaded fields cannot be changed Programmer Diags 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...

Page 13: ... 166 Belt 180 Restore Defaults System Time Hour 4 Minute 55 Month 9 Day 23 Year 2002 Odometer Hours 469 92 Devices 24742 Timekeeping OFF Erase 0 0s Blankcheck 0 0s Program 0 0s Verify 0 0s Update Software Network Network Parm NVRAM Status Enabled PGM Fred sRR2 IP 139 138 16 215 Prog Port 7596 SUB 255 255 248 GTW 139 138 16 1 SNS 0 0 0 0 Network cont SNS Port 7500 HST rr215 nt data io DOM nt data i...

Page 14: ... protection is recommended for prolonged exposure at this level High Voltage Turn power off before removing electronics cover Heavy Object This equipment weighs approximately 15Kg 35 lbs Do not drop Mount only with approved hardware Moving Parts Pinch warning Keep hands away from moving parts Electrostatic Discharge Electrostatic Discharge ESD may cause damage Discharge static against a common gro...

Page 15: ...13 ProLINE RoadRunner Operator s Guide A Mounting on the Assembly Machine 12 Connecting Power and Air 16 Connecting the Communications Cable optional 18 Running the Self Test 20 Installation Chapter 2 ...

Page 16: ...nd a pin on the assembly machine feeder table 2 Secure the hook to the table by tightening the thumbscrew NOTE A black hook must be used on taller RoadRunners a silver hook on older models The label on the conveyor indicates which hook to use Mounting on the Assembly Machine 1 Heavy 16 kg 35 lbs Do Not Drop Mount Only With Approved Hardware Warning ...

Page 17: ...e hook so that its centering teeth engage the pin next to the hook 4 Lower RoadRunner allowing the feeder table dowels to mate up with the bushings in the RoadRunner housing 5 Verify that RoadRunner is secure before moving the feeder table back into the SMT machine 4 3 ...

Page 18: ...Grasp the air hose behind the quick connect collar and push it firmly onto the male fitting The collar must be allowed to move back as it goes onto the fitting NOTE Compressed air must be clean and dry at approximately 5 25 kgf cm2 75 psi Connecting Power and Air 2 1 Warning Point Air Hoses Away From Body Wear Approved Eye Protection ...

Page 19: ...ource using a cable with a standard IEC 320 plug RoadRunner accepts power between 100 and 240 VAC 50 60Hz NOTE To disconnect the air hose grasp the collar on the connector and pull back The air line is equipped with a quick connect that will stop airflow when disconnected 3 ...

Page 20: ...To connect the Communications 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 table Connecting the Communications Cable Red Dot 1 ...

Page 21: ...ator s Guide A 2 Similarly orient and plug the other end of the cable into the SMT feeder table Use the socket that corresponds with the track that RoadRunner is mounted on To unplug the cable pull back on the connector collar 2 ...

Page 22: ...t finishes the blue light will remain on and the version number will display If all the indicator lights start blinking a serious error has occurred Turn the unit off then on again If the error continues have the unit serviced 2 If no errors display RoadRunner is operation ready Running the Self Test 1 ProLINE RoadRunner Data I O Corporation Version 02 00 00 B ...

Page 23: ... s Guide A Inserting a Job Card 22 Changing the Precisor 24 Changing the Actuator Plate 26 Changing the Socket Adapter 28 Adjusting the Tape In Module 30 Loading a Reel of Devices 32 Aligning the Tape Pockets 34 Job Setup Chapter 3 ...

Page 24: ...ly TYPE I or TYPE II PCMCIA cards To insert a job card 1 If the power switch is on make sure the blue lamp is lit Inserting a Job Card Electrostatic Discharge May Cause Damage Discharge Static Against Common Ground Prior to Inserting Job Card Caution 1 ProLINE RoadRunner Data I O Corporation Version 02 00 00 B ...

Page 25: ...n fully inserted the job card extends slightly from the PCMCIA card slot 3 The Card Eject button can be pushed to remove the card Do not eject the card unless the blue lamp is lit or the power is off 2 3 2 Slide the job card into the PCMCIA card slot ...

Page 26: ...mp to light and turn the power Off 0 2 Lift off the Robotics Cover 3 Starting at one end pull the precisor down off the magnet and then pull the other end off The PNP Head Cover can be removed for easier access Changing the Precisor 3 PNP Head Cover Pinch Warning Keep Hands Away From Moving Parts Warning ...

Page 27: ...uide 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 ...

Page 28: ...b then End wait for the blue lamp to light and turn the power Off 0 2 Lift off the Robotics Cover Once power is off the PNP Head can be moved by hand to allow access to the Actuator Plate PNP Head Changing the Actuator Plate Warning Pinch Warning Keep Hands Away From Moving Parts ...

Page 29: ...rator 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 To change the Socket Adapter see the procedure on the following page 3 ...

Page 30: ...or Plate removed 1 Make sure the power is Off 0 2 Unscrew the two captive screws and lift the adapter bracket 2 2 Changing the Socket Adapter Caution Warning Electrostatic Discharge May Cause Damage Discharge Static Against Common Ground Pinch Warning Keep Hands Away From Moving Parts ...

Page 31: ... the gold contact surfaces on the bottom of the adapter lift the adapter free 4 Insert the correct adapter making sure that it seats on the dowel pins NOTE Each type of device may have its own Socket Adapter 5 Tighten the screws and replace the Actuator Plate 3 ...

Page 32: ...dth Adjustable Tape In Module only If the etched number on the 3 Position Spacer does not match your tape width dimension mm 1 With the power off 0 move the PNP Head out of the way 2 Loosen the Position Locking Screw using a 4 mm Allen wrench Adjusting the Tape In Module Non Adjustable Adjustable 2 Current Setting ...

Page 33: ...ntil you read 16 24 or 32 corresponding to your tape width 4 Retighten the Position Locking Screw 5 Rotate the Peel Bar counterclockwise 180 degrees to the up position 6 Lift and move the magnetic Front Track to the position that fits your tape width 7 Rotate the Peel Bar back down 3 4 5 6 6 ...

Page 34: ...ack of the assembly machine NOTE A reel axle is required 2 Insert the tape into the Tape In Module and onto the sprocket 3 Select Advance Pocket from the Operator Menu then press the Up Arrow button 4 When the tape is advanced past the peel bar separate the cover tape from the device tape 2 4 Loading a Reel of Devices ...

Page 35: ...path and attach it to the Cover Tape Take Up Reel Advance the tape as necessary NOTE A small piece of adhesive tape may be needed to stick the cover tape to the Take Up Reel 6 Turn the Take Up Reel to take up slack cover tape Align the tape pockets as described in the following procedure 5 5 ...

Page 36: ...e pocket center hole is approximately centered at the pick point alignment mark Do not advance devices past the pick point They may fall and jam the tape path Do not use the Down Arrow to align NOTE This aligning procedure must be performed each time power is applied such as after releasing the Emergency Stop Aligning the Tape Pockets 1 Job Advance Pocket Align Pocket Purge 2 ...

Page 37: ...roLINE RoadRunner Operator s Guide A Running a Job 36 Pausing or Stopping a Job 37 Ending a Job 38 Emptying the Reject Bin 40 Emptying Cover Tape 41 Shutting Down 42 Restarting a Job 44 Operation Chapter 4 ...

Page 38: ...slot 2 Clear the conveyor belt of any unneeded devices 3 Press Start The green lamp will start blinking When the programmed devices reach the assembly machine pick point the belt will pause and the green lamp will stay lit without blinking Running a Job 3 Job Advance Pocket Align Pocket Purge 1 ...

Page 39: ... Press Pause on the control panel To instantly stop in an emergency situation 2 Press the Emergency Stop button Pausing or Stopping a Job 1 Job Advance Pocket Align Pocket 2 Job Advance Pocket Align Pocket Warning Electrical shock hazard The E Stop does not stop electricity to RoadRunner ...

Page 40: ...current job To 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 from the tape Ending a Job 1 Job Advance Pocket Align Pocket 2 View Results End ...

Page 41: ...NE RoadRunner Operator s Guide A 3 Clear away excess devices from the conveyor belt 4 Empty the Reject Bin See next heading 5 Empty the Cover Tape Take Up Reel See Emptying Cover Tape ahead several pages 5 4 3 ...

Page 42: ... 2 Pull the Reject Bin out by grabbing the finger tab and then lift up and out When reinserting the Reject Bin be sure the bin is completely lowered so that the tab is positioned out of the path of the probes Emptying the Reject Bin 2 Warning Pinch Warning Keep Hands Away From Moving Parts ...

Page 43: ...slack to reattach 3 Pull the Take Up Reel straight out Reels with slots require rotating before pulling off 4 Unwind the used cover tape and discard it 5 Replace the Take Up Reel slide it on and rotate it to line up with the pins and push or twist Emptying Cover Tape Warning Pinch Warning Keep Hands Away From Moving Parts 3 4 5 ...

Page 44: ...e A To shut down RoadRunner 1 Press Pause 2 Select End Job from the Job Menu and wait for all devices to be placed on the belt 3 Turn the power Off 0 4 Remove devices from the conveyor belt Shutting Down 1 Job Advance Pocket Align Pocket 3 ...

Page 45: ... 5 Empty the Reject Bin 6 Remove and empty the Take Up Reel For more see the previous heading 7 Remove the air hose or shut off the air flow NOTE When disconnecting the air hose pull the connector collar back as you pull the connector off 5 6 ...

Page 46: ...button clockwise to release it if needed 2 Press Menu until the main level menu is displayed 3 Select Align Pocket 4 Press the Up Arrow to advance the device tape until the next pocket center hole lines up with the alignment mark 5 Press Start The job will resume 1 Job Advance Pocket Align Pocket Purge 3 Restarting a Job 4 5 ...

Page 47: ...45 ProLINE RoadRunner Operator s Guide A Cleaning with Air 46 Cleaning with Alcohol 47 Running the Self Test 48 Maintenance Chapter 5 ...

Page 48: ...ressed air into the following component areas 1 Tape In Module weekly 2 Sockets daily Sockets should be opened and closed by hand while air is injected NOTE Compressed air must be clean and dry Cleaning with Air 1 2 Warning Point Air Hoses Away From Body Wear Approved Eye Protection ...

Page 49: ... component areas with isopropyl alcohol on a lint free cloth 1 Chassis and Covers every 3 months 2 Conveyor belt daily See Device Rotation in the Troubleshooting chapter NOTE Dry the conveyor belt before rotating it These intervals are based on running 40 000 devices weekly Cleaning with Alcohol 2 1 ...

Page 50: ...e Self Test procedure 1 Press Pause 2 Clear all devices from the sockets and from the conveyor belt 3 Toggle the power switch off and then back on The Self Test will run checking the condition of the components 4 Check the display for system errors Running the Self Test 1 Job Advance Pocket Align Pocket 3 ...

Page 51: ...49 ProLINE RoadRunner Operator s Guide A Viewing Errors 50 Enabling a Socket 52 Clearing Jammed Tape 53 Device Rotation 54 Technical Support 55 Troubleshooting Chapter 6 ...

Page 52: ... display 2 Check the condition tape path Reject Bin etc implied by the message If you cannot correct the error condition contact a service technician 3 Press Menu to remove the message If there are other error messages the next one will appear 1 Inadequate Air Pressure 3 U8 RevA ID27 Devices 800 Rejected 0 Parts Hr 567 ...

Page 53: ...elow For more information see Troubleshooting in the ProLINE RoadRunner Owner s Manual 1 Twist the Emergency Stop button to release it Lamp Color Error Message No change in lamps Card not present Yellow Reject Bin needs to be emptied Blue Cover tape broken Blue Emergency Stop is activated1 Blue Motor controller not responding ...

Page 54: ...ket from the top level menu 2 Arrow down and select the disabled socket from the Socket menu A dot appears 3 Press the Up Arrow button to re enable the socket NOTE To disable a probe disable the probe s corresponding socket Enabling a Socket 1 Advance Pocket Align Pocket Purge Socket 3 Socket 1 Disabled Socket 2 Enabled Socket 3 Enabled Socket 4 Enabled ...

Page 55: ... continue the job later or select Job then End and turn the power off 2 Unroll one turn of cover tape and cut it near the Take Up Reel 3 Pull the tape out backwards until the cover tape end is free 4 Cut the device tape 5 Pull the tape out where it exits to remove it from the machine 6 Trim away any flaws before reloading Cut Pckt Tape 4 2 3 2 Cut Cvr Clearing Jammed Tape ...

Page 56: ...picked from the belt 2 Press the Emergency Stop 3 Remove the Dust Cover and clean only the exposed surface of the conveyor belt with isopropyl alcohol on a lint free cloth then dry it Rotate the belt by hand and repeat until clean 4 To continue replace the Conveyor Dust Cover release the Emergency Stop button and press Start Dry 3 Rotate Repeat 3 3 Clean ...

Page 57: ...8073 9746 Telephone 425 867 6870 USA Only 1 800 332 8246 Fax 425 882 1043 E mail support data io com You can also find answers by visiting our Knowledge Base on our Web site at www dataio com then click Support then Knowledge Base Search Contact your local Data I O representative To find your local representative go to http www dataio com contact repsearch asp Technical Support ...

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