Siemens ProLINE-RoadRunner ProLINE-RoadRunner - User Manual

4 ProLINE-RoadRunner Operator’s Guide A 1. Power and Air Connections 2. Power Switch 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. Ele...

5 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

6 ProLINE-RoadRunner Operator’s Guide A Control Panel Lights 1. Blue - Stop Indicator. User intervention is required, or the unit is paused. (Do not 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: ...

7 ProLINE-RoadRunner Operator’s Guide A 1. Start - start or resume the chosen job. 2. Menu - exit to the previous menu, —or show the next message (deleting the current one), —or deselect an item. 3. Up and Down Arrows - move through menu items. 4. Select - select menu items. 5. Pause - interrupt the...

8 ProLINE-RoadRunner Operator’s Guide A Operator Menus are visible on the RoadRunner control panel, and can be navigated by using the Up Arrow and Down Arrow 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. Job...

9 ProLINE-RoadRunner Operator’s Guide A View the Supervisor Menus by inserting a PCMCIA card with supervisor authority.(The menus on this page and the next two pages are in addition to the Operator Menus.) Supervisor (Administrator) authorization is set in TaskLink. For more information, refer to th...

1 0 ProLINE-RoadRunner Operator’s Guide A Refer to the previous page for the main menu. NOTE: Programmer Diags are only available with a Diagnostic Adapter Board. R o b o t D i a g s Robot: Enabled Run Mode: Job/Dry Run Belt Move:Fwd/BkwPick Sensor: 0Speed: 400 ± 10Measure DeviceAdjust Device Sensor...

1 2 ProLINE-RoadRunner Operator’s Guide A Warnings and Cautions Compressed Air Point air hoses away from body. Always wear approved eye protection. Loud Noise Sound pressure levels may exceed 85db. Hearing protection is recommended for prolonged exposure at this level. High Voltage Turn power off be...

1 3 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

1 4 ProLINE-RoadRunner Operator’s Guide A 2 To mount RoadRunner on an assembly machine: 1. With the feeder table pulled out, slide the supplied hook around a pin on the assembly machine feeder table. 2. Secure the hook to the table by tightening the thumbscrew. NOTE: A black hook must be used on tal...

1 5 ProLINE-RoadRunner Operator’s Guide A 3. Slide RoadRunner under the 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...

1 6 ProLINE-RoadRunner Operator’s Guide A To connect the power and the air: 1. Turn the RoadRunner power switch to the Off (0) position. 2. Grasp the air hose behind the “quick connect” collar and push it firmly onto the male fitting. The collar must be allowed to move back as it goes onto the fitti...

1 7 ProLINE-RoadRunner Operator’s Guide A 3. Connect to a grounded power source using a cable with a standard IEC 320 plug. RoadRunner accepts power between 100 and 240 VAC, 50/60Hz. NOTE: To disconnect the air hose, grasp the collar on the connector and pull back. The air line is equipped with a “q...

1 8 ProLINE-RoadRunner Operator’s Guide A 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

1 9 ProLINE-RoadRunner Operator’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

2 0 ProLINE-RoadRunner Operator’s Guide A To run the Self-Test: 1. Turn the power switch On (I). All the control panel indicator lights will come on. When the Self-Test finishes, the blue light will remain on and the version number will display. If all the indicator lights start blinking, a serious ...

2 1 ProLINE-RoadRunner Operator’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...

2 2 ProLINE-RoadRunner Operator’s Guide To run a job, insert a TaskLink job card in the PCMCIA card slot. Use only TYPE I or TYPE II PCMCIA cards. To insert a job card: 1. If the power switch is on, make sure the blue lamp is lit. Inserting a Job Card Electrostatic Discharge May Cause Damage. Discha...

2 3 ProLINE-RoadRunner Operator’s Guide A NOTE: When 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 PCMCI...

2 4 ProLINE-RoadRunner Operator’s Guide To change the precisor: 1. Select Job , then End , wait for the blue lamp to light and turn the power Off (0). 2. Lift off the Robotics Cover. 3. Starting at one end, pull the precisor down off the magnet, and then pull the other end off. The PNP Head Cover ca...

2 5 ProLINE-RoadRunner Operator’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

2 6 ProLINE-RoadRunner Operator’s Guide To change the Actuator Plate: 1. Select Job , then End , wait for the blue lamp to light and turn the power Off (0). 2. Lift off the Robotics Cover. Once power is off, the PNP Head can be moved by hand to allow access to the Actuator Plate. PNP Head Changing t...

2 7 ProLINE-RoadRunner Operator’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

2 8 ProLINE-RoadRunner Operator’s Guide To change the Socket Adapter (with the Actuator Plate removed): 1. Make sure the power is Off (0). 2. Unscrew the two captive screws and lift the adapter bracket. 2 2 Changing the Socket Adapter Caution: Warning: Electrostatic Discharge May Cause Damage. Disch...

2 9 ProLINE-RoadRunner Operator’s Guide A 3. Without touching the gold contact surfaces on the bottom of the adapter, lift the adapter free. 4. Insert the correct adapter, making sure that it seats on the dowel pins. NOTE: Each type of device may have its own Socket Adapter. 5. Tighten the screws an...

3 0 ProLINE-RoadRunner Operator’s Guide If you have an Adjustable Tape-In Module, you may need to adjust the tape width. 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...

3 1 ProLINE-RoadRunner Operator’s Guide A 3. Rotate the 3-Position Spacer with your finger until you read 16, 24 or 32, corresponding to your tape width. 4. Retighten the Position Locking Screw. 5. Rotate the Peel Bar counterclockwise 180 degrees to the up position. 6. Lift and move the magnetic Fro...

3 2 ProLINE-RoadRunner Operator’s Guide To load a reel of devices: 1. Make sure the reel is correctly installed in the rack of the assembly machine. NOTE: A reel axle is required. 2. Insert the tape into the Tape-In Module and onto the sprocket. 3. Select Advance Pocket from the Operator Menu, then ...

3 3 ProLINE-RoadRunner Operator’s Guide A 5. Thread the cover tape up through the cover tape path and attach it to the Cover TapeTake-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 ta...

3 4 ProLINE-RoadRunner Operator’s Guide To align the tape pockets: 1. Select Align Pocket from the Operator Menu. 2. Press the Up Arrow button to advance the tape until the next tape pocket center hole is approximately centered at the pick point alignment mark. Do not advance devices past the pick p...

3 5 ProLINE-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 Chapt e r 4

3 6 ProLINE-RoadRunner Operator’s Guide A To 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 start blinking. When the programmed devices reach the assembly machine pick point, the belt will pause and th...

3 7 ProLINE-RoadRunner Operator’s Guide A To pause at the end of the current operation: 1. 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 PocketAlign Pocket 2 > Job Advance PocketAli...

3 8 ProLINE-RoadRunner Operator’s Guide A Whenever you are going to change job cards, you must first end the 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 be...

3 9 ProLINE-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

4 0 ProLINE-RoadRunner Operator’s Guide A To empty the Reject Bin: 1. Press the Pause button. 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 pr...

4 1 ProLINE-RoadRunner Operator’s Guide A To empty the Cover Tape Take-Up Reel: 1. Press Pause . 2. Cut the cover tape, leaving enough slack to reattach. 3. Pull the Take-Up Reel straight out. (Reels with slots require rotating before pulling off.) 4. Unwind the used cover tape and discard it. 5. Re...

4 2 ProLINE-RoadRunner Operator’s Guide 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 PocketAlign Pocket 3

4 3 ProLINE-RoadRunner Operator’s Guide A 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

4 4 ProLINE-RoadRunner Operator’s Guide A To restart RoadRunner after a pause or an emergency stop: 1. Turn the Emergency Stop 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 unti...

4 5 ProLINE-RoadRunner Operator’s Guide A Cleaning with Air.......... 46 Cleaning with Alcohol.......... 47 Running the Self-Test.......... 48 Maintenance Chapter 5

4 6 ProLINE-RoadRunner Operator’s Guide A To prevent dust accumulation, inject compressed air into the following component areas: 1. Tape-In Module (weekly). 2. Sockets (daily). Sockets should be opened and closed by hand while air is injected. NOTE: Compressed air must be clean and dry. „ Cleaning ...

4 7 ProLINE-RoadRunner Operator’s Guide A To prevent dust and oil accumulations, clean the following component areas with isopropyl alcohol on a lint-free cloth. 1. Chassis and Covers (every 3 months). 2. Conveyor belt (daily). See "Device Rotation" in the Troubleshooting chapter. NOTE: Dry ...

4 8 ProLINE-RoadRunner Operator’s Guide A Run the Self-Test procedure approximately once a week. To run the 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 co...

4 9 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

5 0 ProLINE-RoadRunner Operator’s Guide A Viewing Errors To view and correct errors: 1. Messages will appear in the keypad display. 2. Check the condition—tape path, Reject Bin, etc.—implied by the message. If you cannot correct the error condition, contact a service technician. 3. Press Menu to rem...

5 1 ProLINE-RoadRunner Operator’s Guide A Stop Caution Motor Controller not responding Some common error messages are listed below. For more information see “Troubleshooting” in the ProLINE-RoadRunner Owner’s Manual . 1 Twist the Emergency Stop button to release it. „ Lamp Color E r r o r M e s s a ...

5 2 ProLINE-RoadRunner Operator’s Guide A If a socket repeatedly becomes disabled, RoadRunner should be serviced. To re-enable a disabled socket: 1. Choose Socket from the top level menu. 2. Arrow down and select the disabled socket from the Socket menu. (A dot appears.) 3. Press the Up Arrow button...

5 3 ProLINE-RoadRunner Operator’s Guide A If the tape jams, an error message displays and the blue lamp illuminates. To clear the tape path: 1. Press the Emergency Stop button (to continue the job later) or select Job , then End , and turn the power off. 2. Unroll one turn of cover tape and cut it n...

5 4 ProLINE-RoadRunner Operator’s Guide A Device Rotation If devices rotate excessively on the conveyor belt: 1. Press Pause . Wait for all the devices to get 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 iso...

5 5 ProLINE-RoadRunner Operator’s Guide A Worldwide Data I/O Corporation Shipping address: 10525 Willows Road N.E.Redmond, WA USA 98052 Mailing address: P.O. Box 97046Redmond, WA USA 98073-9746 Telephone: 425-867-6870 USA Only: 1-800-332-8246 Fax: 425-882-1043 E-mail: [email protected] You can also ...