ProLINE-RoadRunner ™
Operator’s Guide
for Fuji MFU:
QP242, QP351 ,IP3
Troubleshooting
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Warnings and Cautions......... 12
Technical Support......... 53
Overview
1
ProLINE-RoadRunner Operator’s Guide A
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The ProLINE-RoadRunner for Fuji
Data I/O is proud to introduce a
revolutionary new inline solution for
high-volume programming of
electronic products.
3
4
2
ProLINE-RoadRunner:
1. Takes programmable devices
from a reel...
2. Places them in sockets and
programs them with your data...
1
3. Places them on a conveyor
belt...
4. Delivers them to the pick point
of your assembly machine. „
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Jobs and Statistics
TaskLink™ for Windows® is
required to process devices on
ProLINE-RoadRunner.
Programming Jobs
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. „
Statistics
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External View
1. SMT Communications
Connection
7
6
Back
2. Power and Air Connections
3. Power Switch
5
4
4. Handhold for lifting
5. PCMCIA Card Slot
6. Control Panel
8
9
3
7. Conveyor Belt
10
8. Mechanical Interface to the
Multi-Feeder Unit
2
1
Front
Cables not shown
9. Electronics Enclosure
10. Robotics Cover „
4
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Internal Components
1. Cover Tape Take-Up Reel
2. Tape-In Module
3
4
2
3. PNP Probes, Precisor, and
Cover
4. Reject Bin
1
5. Socket Adapter, Actuator Plate,
and Programmer „
5
5
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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.)
4
2. Yellow - Caution Indicator.
Correct a problem or the
machine will stop.
1
2
3
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. „
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Control Panel Buttons
1. Start - start or resume the
chosen job.
1
2
2. Menu - exit to the previous
menu, —or show the next
message (deleting the current
one), —or deselect an item.
3
3. Up and Down Arrows - move
through menu items.
4. Select - select menu items.
5. Pause - interrupt the job
without cancelling it. „
5
4
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Operator Menus
Operator Menus are visible on the
RoadRunner control panel, and can
be navigated by using the Up
Socket
Main Menu
Job
Job
View
Job Name
Socket 1: Enabled
Socket 2: Enabled
Socket 3: Enabled
Socket 4: Enabled
Advance Pocket
Align Pocket
Purge
Device: E28F320
Checksum: 3FC00000
Mfg: INTEL
Adapter: PA-G021
Prec: 621-0086-005
Act: 644-0016-001
Passed: 992
Arrow and Down Arrow buttons.
Socket
Adapter Statistics
Reset Clean
Clean Count
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 is the
first item in the main menu.
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
Results
• Light gray
shaded fields
cannot be
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
changed.
• For Advance
Pocket, Align
Pocket, and
Purge, see
Chapter 3 in
the Owner’s
Manual.
NOTE: To change languages
press Menu while pressing the
Select button. Arrow Down to
the desired language and press
Menu twice.
Fail: 2
Yield: 99.8
End
Version 5.14.00 menus shown. „
Socket 2 [same as 1]
Socket 3 [same as 1]
Socket 4 [same as 1]
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Supervisor Menus
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.)
Main Menu
Job
Advance Pocket
Align Pocket
Purge
Socket
Home
Operation*
System*
Robot Diagnostics^
Programmer Diags^
Event Log^
Job
View
Socket
Socket 1: Enabled
Socket 2: Enabled
Socket 3: Enabled
Socket 4: Enabled
Job Name
Device: E28F320
Checksum: 3FC00000
Mfg: INTEL
Adapter: PA-G021
Prec: 621-0086-005
Act: 644-0016-001
Passed: 992
Reset Clean Count
Clean Count
Adapter Statistics
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]
Results
Supervisor (Administrator)
authorization is set in TaskLink. For
more information, refer to the
TaskLink Help Menu.
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
* See next page
^ Next odd page
Version 5.14.00 menus shown.
• HOME sends the
PNP Head to the
Home position.
• Light gray shaded
fields cannot be
changed.
A (• ) indicates the currently
selected item.
End
Select
A (X) indicates the current cursor
position.
X Job 1
y
Job 2
End of List
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Supervisor Menus, continued
Refer to the previous page for the
main menu.
O p e r a t i o n
System
Time
System
Network
(cont.)
Pick Retries: 2
Job
Hour: 4
SNS Port: 7500
Error Retries: 3
Pocket Pitch: 4
Pocket Advance: 3
Velocity: 250
Accel: 700
Minute: 55
Month: 9
Day: 23
HST: rr215.nt.data-io
DOM: nt.data-io.com
DNS: 888.888.88.888
DTS: 888.888.88.88
EAddr:
Year: 2002
Head
Note that many of the values
shown, such as the Teach and
Network menus, are for example
only.
Odome-
ter
Hours: 469.92
Puff: 50
Pick: 200
Probes
Devices: 24742
Timekeeping: OFF
Erase: 0.0s
Blankcheck: 0.0s
Program: 0.0s
Verify: 0.0s
0010EC002211
Clear NetParms
Place: 100
Configu-
ration
Travel: 250
Tape: 40.0
Firmware Version
Teach
Ver 05.11.00.C
Installed Boards
Bkpln Brd Id: 2
Cntrl Brd Id: 1
Wvfrm Brd Id: 1
Adptr Brd Id: 3
Hardware Config
HwCfgIds 1, 3, 4
Model: name (-uC)
Skt 1: -26.85
Reject: -166
Belt: -180
Update
Software
Network
Restore Defaults
Network Parm:Card
Status: Enabled
PGM: Fred’sRR2
IP: 888.888.88.888
Prog Port: 7596
• Light gray shaded fields
cannot be changed.
SUB: 255.255.248
GTW: 139.138.16.1
SNS: 0.0.0.0
10
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Supervisor Menus, continued
Robot Diags
Refer to the main Supervisor Menu
(2 pages back) for orientation.
Programmer
Diags
Enabled
Robot:
Run Mode:
Belt
Programr: Enabled
Exercise Display
Test Cycles: 3
Test All: PASS
Bus Test: PASS
Job/Dry Run
Move:Fwd/Bkw
Pick Sensor: 0
Speed: 400 ± 10
Measure Device
Offset: 0.00
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
NOTE: Programmer Diags are only
available with a Diagnostic
Adapter Board.
Programmer
Diagnostic
tests require a
Diagnostic
Adapter
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:
Sensors
1
Board for all
items below
this line.
Actuation duration is set by the Socket
Adapter.
For more information about menu
commands, see Chapter 3 of the
ProLINE-RoadRunner Owner’s
Manual. „
Continuity Loop: 3
Socket
Event Log
View
Clear
1
Act.Duration:150
Position: Up
Probe 1– 4
Vacuum: Enabled
Puff: Enabled
Vac Sense: 1
• Light gray shaded fields cannot be changed.
Speed: 135 ± 5
Head: 0
Head Position
11
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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 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 ground.
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Mounting on the
Connecting Power and Air ...... 16
Running the Self-Test ...... 18
Installation
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Mounting on the Feeder Bank
To mount RoadRunner onto an
MFU:
1. Align and push the communica-
tions cable into the MFU.
3
NOTE: To allows access to
RoadRunner, do not use the ten
right-most slot positions on the
MFU.
2
2. While holding RoadRunner at a
slight nose-down angle, let the
nose rest on the MFU. Ensure
that it settles into a slot.
1
Warning:
Heavy. 15 kg (31 lb). Do not drop.
Mount only on approved units.
14
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3. Still holding it at an angle, slide
it forward as far as it will go.
(The nose will fit under the lip on
the MFU.)
4
4. Lower RoadRunner and jiggle it
to ensure that the angle bracket
has settled into the spring
clamp on the MFU.
NOTE: The assembly machine
pick point will correspond with the
MFU slot number that is inline with
the conveyor belt.
Make sure the communication
socket number corresponds with
that slot number. „
Warning
Heavy. 15 kg. Do not drop. Turn off
RoadRunner and disconnect facilities
before removing it from a feeder bank.
15
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Connecting Power and Air
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
fitting.
1
NOTE: Compressed air must be
clean and dry at approximately
5.25 kgf/cm (75 psi).
2
2
Warning:
Point air hoses away from body.
Wear approved eye protection.
16
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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.
Pull Collar
3
4. Align and push the
communications cable end into
the RoadRunner connector. (The
other end should already be
connected to the MFU.)
4
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. „
17
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Running the Self-Test
To run the Self-Test:
1. Turn the power switch On (I).
1
All the control panel indicator
lamps light up. When the Self-
Test finishes, the blue lamp will
remain on and the version
number will display.
If all the indicator lamps start
blinking, a serious error has
occurred. Turn the unit off then
on again. If the error continues,
have the unit serviced.
ProLINE-RoadRunner
Data I/O Corporation
Version: 05.14.00.C
2. If no errors display, RoadRunner
is operation ready. „
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Inserting a Job Card ..... 20
Changing the Precisor ..... 22
Changing the
Actuator Plate..... 24
Changing the
Loading a Reel of Devices ..... 30
Aligning the Tape Pockets ..... 32
Job Setup
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Inserting a Job Card
To run a job, insert a TaskLink job
card into the PCMCIA card slot. Use
only TYPE I or TYPE II PCMCIA
cards.
1
To insert a job card:
1. If the power switch is on, make
sure the blue lamp is lit.
ProLINE-RoadRunner
Data I/O Corporation
Version 02.00.00.B
Caution:
Electrostatic discharge may cause damage.
Discharge static against common ground
prior to inserting Job Card.
20
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2. Slide the job card into the
PCMCIA card slot.
NOTE: When fully inserted, the job
card extends slightly from the
PCMCIA card slot.
2
NOTE: Do not eject the card
unless the blue lamp is lit (or the
power is off).
3. The Card Eject button can be
pushed to remove the card
when the blue lamp is lit. „
3
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Changing the Precisor
To change the precisor:
PNP Head Cover
1. Select Job, then End, wait for
the blue lamp to light and turn
the power Off (0).
3
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.
3
The PNP Head Cover can be
removed for easier access.
Warning:
Pinch Warning. Keep hands
away from moving parts.
22
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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
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Changing the Actuator Plate
To change the Actuator Plate:
1. Select Job, then End, wait for
the blue lamp to light and turn
the power Off (0).
PNP Head
2. Lift off the Robotics Cover.
Once power is off, the PNP Head
can be moved by hand to allow
access to the Actuator Plate.
Warning:
Pinch Warning. Keep hands
away from moving parts.
24
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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
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Changing the Socket Adapter
To change the Socket Adapter (with
the Actuator Plate removed):
1. Make sure the power is Off (0).
2. Unscrew the two captive screws
and lift the adapter bracket.
2
2
Caution:
Electrostatic Discharge may cause damage.
Discharge static against common ground.
26
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3. Without touching the gold
contact surfaces on the bottom
of the adapter, lift the adapter
free.
4. Insert the correct adapter,
making sure that it seats on the
dowel pins.
NOTE: Each type of device may
have its own Socket Adapter.
5. Tighten the screws and replace
the Actuator Plate. „
3
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Adjusting the Tape-In Module
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):
Non-Adjustable
Adjustable
1. With the power off (0), move the
PNP Head out of the way.
Current
Setting
2. Loosen the Position Locking
Screw several turns using a
4 mm Allen wrench.
2
28
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3. Rotate the 3-Position Spacer
with your finger until you read
16, 24 or 32, corresponding to
your tape width.
3
4
5
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.
6
6
7. Rotate the Peel Bar back
down. „
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Loading a Reel of Devices
To load and thread device tape:
4
1. Place a reel onto the
RoadRunner spindle.
2
2. Lock the reel in place by rotating
the brass button on the spindle
end.
3. Insert the device tape into the
Tape-In Module and onto the
sprocket.
3
4. Select Advance Pocket from
the operator menu, then press
the Up Arrow button.
30
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5. When the tape is advanced past
the Peel Bar, separate the cover
tape from the device tape.
6
6. Thread the cover tape up
through the cover tape path and
attach it to the Cover Tape
Take-Up Reel. Advance the tape
as necessary.
NOTE: A small piece of adhesive
tape may be needed to stick the
cover tape to the Take-Up Reel.
7
6
7. Turn the Take-Up Reel to take up
slack cover tape.
5
8. Align the tape pockets as
described in the following
procedure. „
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Aligning the Tape Pockets
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
Job
Advance Pocket
> Align Pocket
Purge
2
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.
2
1
NOTE: This aligning procedure
must be performed each time
power is applied, such as after
releasing the Emergency
Stop. „
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Shutting Down ......... 40
Restarting a Job ......... 42
Operation
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Running a Job
To run a job:
1. Insert a job card into the
PCMCIA card slot.
2. Clear the conveyor belt of any
unneeded devices.
> Job
1
Advance Pocket
Align Pocket
Purge
3. Press Start.
The green lamp will start
blinking.
3
When the programmed devices
reach the assembly machine
pick point, the belt will pause
and the green lamp will stay lit
without blinking. „
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Pausing or Stopping a Job
To pause at the end of the current
operation:
2
1. Press Pause on the control
panel.
To instantly stop in an emergency
situation:
> Job
Advance Pocket
Align Pocket
> Job
Advance Pocket
Align Pocket
2. Press the Emergency Stop
(E-Stop) button.
The E-Stop does not stop the
assembly machine. „
1
Warning
Electrical shock hazard. The E-Stop does
not stop electricity to RoadRunner.
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Ending a Job
Whenever you are going to change
job cards, you must first end the
current job.
To end the current job:
1. Press Pause button.
> Job
Advance Pocket
Align Pocket
2. Select End from the Job Menu.
View
Job is in the main menu.
Results
2
> End
The system will finish
processing devices and place
the devices on the belt, but no
additional devices will get
picked from the tape.
1
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3. Clear away excess devices from
the conveyor belt.
4
5
4. Empty the Reject Bin. (See next
heading.)
5. Empty the Cover Tape Take-Up
Reel. (See “Emptying Cover
3
Tape” ahead several pages.) „
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Emptying the Reject Bin
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.
2
When reinserting the Reject Bin,
be sure the bin is completely
lowered so that the tab is
positioned out of the path of the
probes. „
Warning:
Pinch Warning. Keep hands
away from moving parts.
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Emptying Cover Tape
To empty the Cover Tape Take-Up
Reel:
1. Press Pause.
2. Cut the cover tape, leaving
enough slack to reattach.
3. Pull the Take-Up Reel straight
out. (Reels with slots require
rotating before pulling off.)
4
4. Unwind the used cover tape and
discard it.
5
3
5. Replace the Take-Up Reel—slide
it on and rotate it to line up with
the pins, and push (or twist). „
5
Warning:
Pinch Warning. Keep hands
away from moving parts.
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Shutting Down
To shut down RoadRunner:
1. Press Pause.
3
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).
> Job
Advance Pocket
Align Pocket
Purge
4. Remove devices from the
conveyor belt.
1
Reel not shown
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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
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Restarting a Job
To restart RoadRunner after a pause
or an emergency stop:
1
Job
Advance Pocket
> Align Pocket
Purge
3
1. Turn the Emergency Stop
button clockwise to release it, if
needed.
4
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
5. Press Start.
The job will resume. „
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Cleaning with Alcohol.......... 45
Running the Self-Test.......... 46
Maintenance
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Cleaning with Air
To prevent dust accumulation,
inject compressed air into the
following component areas:
1. Tape-In Module (weekly).
2. Sockets (daily). Sockets should
be opened and closed by hand
while air is injected.
1
NOTE: Compressed air must be
clean and dry. „
2
Warning:
Point Air Hoses Away From Body.
Wear Approved Eye Protection.
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Cleaning with Alcohol
To prevent dust and oil
accumulations, clean the following
component areas with isopropyl
alcohol on a lint-free cloth.
•
Chassis and Covers
(every 3 months).
•
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. „
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Running the Self-Test
Run the Self-Test procedure
approximately once a week.
To run the Self-Test procedure:
3
1. Press Pause.
2. Clear all devices from the
sockets and from the conveyor
belt.
> Job
Advance Pocket
Align Pocket
3. Toggle the power switch off and
then back on.
The Self-Test will run, checking
the condition of the
components.
1
4. Check the display for system
errors. „
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Device Rotation............ 52
Technical Support............ 53
Troubleshooting
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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.
> U8 RevA ID27
Devices: 800
Rejected: 0
Inadequate Air Pressure
1
Parts/Hr: 567
3. Press Menu to remove the
3
message.
If there are other error
messages the next one will
appear.
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Some common error messages are
listed below. For more information
see “Troubleshooting” in the
ProLINE-RoadRunner Owner’s
Manual.
Stop
Lamp Color
Error Message
No change in
lamps
Card not present
Caution
Yellow
Reject Bin needs to be
emptied
Motor Controller not
responding
Blue
Blue
Cover tape broken
Emergency Stop is
activated
1
Blue
Motor controller not
responding
1
Twist the Emergency Stop button to release
it.
„
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Enabling a Socket
If a socket repeatedly becomes
disabled, RoadRunner should be
serviced.
To re-enable a disabled socket:
1. Select Socket from the top
level menu.
Advance Pocket
Align Pocket
Purge
•
Socket 1: Disabled
Socket 2: Enabled
Socket 3: Enabled
Socket 4: Enabled
2
2. Arrow down and select the
disabled socket from the Socket
menu. (A dot appears.)
> Socket
1
3. Press the Up Arrow button to
3
re-enable the socket.
NOTE: To disable a probe, disable
the probe’s corresponding
socket. „
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Clearing Jammed Tape
If the tape jams, an error message
displays and the blue lamp
illuminates. To clear the tape path:
3
2. Cut Cvr
Cut Tape
2
1. Press the Emergency Stop
button (to continue the job later)
or select Job, then End. Turn
the power off.
2. Unroll one turn of cover tape
and cut it near the Take-Up Reel.
4
3. Cut the device tape where it
exits the conveyor.
4. At the tape reel, pull the tape out
backwards until the end is free
from the tape path.
5. Trim away any flaws before
reloading. „
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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
3
isopropyl alcohol on a lint-free
cloth, then dry it. Rotate the belt
by hand and repeat until clean.
• Clean
• Dry
• Rotate Belt
• Repeat
4. To continue, replace the
Conveyor Dust Cover, release
the Emergency Stop button
and press Start. „
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Technical Support
Contact your local Data I/O representative.
Worldwide
Data I/O Corporation
To find your local representative, go to
Shipping address:
10525 Willows Road N.E.
Redmond, WA USA 98052
Mailing address:
P.O. Box 97046
Redmond, WA USA 98073-9746
Telephone: 425-867-6870 USA Only: 1-800-332-8246
Fax:
E-mail:
425-882-1043
You can also find answers by visiting the Knowledge
Support, then Knowledge Base Search.
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