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Table of Conte nts vi P roMas te r 2500 User Ma nual 5. Preventive Maintenance Theory of Operation ............. ................. ................. ................. ................ ................. ........... 5-2 Ta…
Table of Contents
ProMaster 2500 User Manual v
3. Tasks and Kits
What Is a Task?.....................................................................................................................3-2
Overview: Creating a Task ...........................................................................................3-2
Creating a Task for a Logic Device....................................................................................3-4
Adding a Task ................................................................................................................3-4
Selecting Database Files ................................................................................................3-5
Naming a Task/Kit .......................................................................................................3-5
Entering a Task Description .........................................................................................3-5
Selecting a Device ..........................................................................................................3-6
Selecting the Data Source .............................................................................................3-7
Selecting a Process .........................................................................................................3-8
Selecting Handling/Labeling Parameters .................................................................3-9
Saving the Task ............................................................................................................3-12
Other Logic Parameters ..............................................................................................3-12
Creating a Task for a Memory Device ............................................................................3-14
Selecting a Translation Format ..................................................................................3-15
Other Memory Parameters ........................................................................................3-15
Other TaskLink Parameters..............................................................................................3-18
Setup Menu Options ...................................................................................................3-18
Data and Program Pull-down Menus ......................................................................3-26
Utilities Pull-down Menu ...........................................................................................3-26
Options Pull-down Menu ..........................................................................................3-28
Introduction to Kits............................................................................................................3-32
Selecting Kit Parameters .............................................................................................3-32
Creating Task/Kit Batch Files ...................................................................................3-37
4. Operation
What Is a Task?.....................................................................................................................4-2
Overview: Starting a New Task.........................................................................................4-2
Antistatic Precautions ...................................................................................................4-4
Raising the Hood While a Task is Running ...............................................................4-4
Operating Noise Level ..................................................................................................4-4
Starting the 2500 System ...............................................................................................4-5
Entering Your Password ..............................................................................................4-6
Reconfiguring the System for a New Device ............................................................4-7
Configuring the Programming Module .....................................................................4-8
Installing a Programming Module ............................................................................4-12
Adjusting the Track Width ........................................................................................4-12
Removing and Installing Chucks ..............................................................................4-16
Adjusting High and Low Air Pressure ....................................................................4-17
Loading Labels .............................................................................................................4-18
Installing Devices in the Input Track .......................................................................4-22
Running a Task...................................................................................................................4-23
Selecting a Task ............................................................................................................4-24
Selecting a Database File ............................................................................................4-24
Select Process ...............................................................................................................4-24
Other Prompts ..............................................................................................................4-24
Aligning a Device to a PLCC Programming Module...................................................4-27
Aligning a Device to a DIP/SOIC/32-pin PLCC Programming Module..................4-31
System Status Box ........................................................................................................4-33
Exiting TaskLink ..........................................................................................................4-34
Introduction to Kits............................................................................................................4-35
Running a Kit ...............................................................................................................4-36
Adjusting Track Air...........................................................................................................4-38
Table of Contents
vi ProMaster 2500 User Manual
5. Preventive Maintenance
Theory of Operation ............................................................................................................5-2
TaskLink .........................................................................................................................5-2
Device Processing ..........................................................................................................5-2
Optics ..............................................................................................................................5-7
Switches ..........................................................................................................................5-7
Motors .............................................................................................................................5-7
Solenoids .........................................................................................................................5-8
Beam and Chucks ..........................................................................................................5-8
System Air Flow ............................................................................................................5-9
The Controller Board ..................................................................................................5-13
Power Supplies ............................................................................................................5-13
Dot Matrix Label Printer ............................................................................................5-15
Thermal Label Printer .................................................................................................5-17
Programming Electronics Boards and Assemblies .................................................5-19
Conditions Requiring Corrective Action........................................................................5-21
Device Jams ..................................................................................................................5-21
Faulty Printing .............................................................................................................5-22
Miscellaneous ...............................................................................................................5-22
Corrective Adjustments ....................................................................................................5-24
Changing Dot Matrix Printer Ribbon Cassette .......................................................5-24
Changing Thermal Printer Ribbon ...........................................................................5-24
Adjusting Dot Matrix Print Head Gap .....................................................................5-24
Adjusting Position of Print on Label (Dot Matrix Printer) ....................................5-25
Adjusting Position of Label on Device (Dot Matrix Printer) .................................5-25
Adjusting Press Bearings ............................................................................................5-26
Adjusting Print Position on the Label (Thermal Printer) ......................................5-26
Adjusting the Thermal Printer ..................................................................................5-27
Diagnostics..........................................................................................................................5-30
Running Diagnostic Tests with the Hood Up .........................................................5-30
Optic Test ......................................................................................................................5-31
Solenoid Test ................................................................................................................5-37
Motor Test ....................................................................................................................5-40
Cycle Parts ....................................................................................................................5-42
Print Test (Dot Matrix Printer) ..................................................................................5-46
Key/Display Test ........................................................................................................5-48
EEPROM Test ...............................................................................................................5-48
Communications Test .................................................................................................5-49
Programming Electronics Self-test ............................................................................5-50
Preventive Maintenance Procedures For Operators.....................................................5-55
Daily Procedures .........................................................................................................5-56
Periodic Cleaning ........................................................................................................5-56
Replacing the Dot Matrix Printer Ribbon Cassette ................................................5-57
Replacing a Thermal Printer Ribbon ........................................................................5-59
Repairing a Torn Thermal Printer Ribbon ...............................................................5-60
Preventive Maintenance Procedures For Service Technicians....................................5-60
Cleaning Guidelines ....................................................................................................5-61
Track Adjustments ......................................................................................................5-64
Maintenance Intervals.......................................................................................................5-67
Table of Contents
ProMaster 2500 User Manual vii
6. Troubleshooting
Messages...............................................................................................................................6-1
Troubleshooting Flow Charts.............................................................................................6-6
7. Repair and Replacement Procedures
Fuse Replacement ................................................................................................................7-2
Programming Electronics Assembly Replacement.........................................................7-3
Removing the PE ...........................................................................................................7-3
Installing the PE Assembly ..........................................................................................7-7
Motor Replacement..............................................................................................................7-7
Replacing the Input Orbital Motor .............................................................................7-7
Replacing the Output Orbital Motor ........................................................................7-10
Replacing the Print Drive Motor ...............................................................................7-11
Replacing the Dot Matrix Print Head .......................................................................7-12
Replacing the Thermal Print Head ...........................................................................7-13
Replacing the Beam Head Rotation Motor ..............................................................7-14
Replacing the Beam Traverse Motor ........................................................................7-14
Mechanical Assembly Removal.......................................................................................7-15
Replacing the Input Orbital Tube Clamp ................................................................7-15
Replacing the Output Orbital Tube Clamp .............................................................7-16
Replacing the Programming Module Clamp Air Cylinder ...................................7-17
Solenoid Replacement.......................................................................................................7-18
Replacing a Solenoid ...................................................................................................7-18
Power Supply Replacement..............................................................................................7-18
Replacing the PE Power Supply ................................................................................7-19
Replacing the Toroid Transformer ............................................................................7-19
Replacing the Toroid PCB ..........................................................................................7-19
Replacing the Controller Power Supply ..................................................................7-19
Replacing the Labeler Power Supply .......................................................................7-20
System Fan Replacement..................................................................................................7-20
Replacing the System Fan ..........................................................................................7-20
Controller Board Replacement.........................................................................................7-20
Replacing the Controller Board .................................................................................7-20
Beam Assembly Component Replacement....................................................................7-21
Replacing the Flex Coupler ........................................................................................7-21
Replacing the Right Lead Screw Bearing Assembly ..............................................7-22
Replacing the Left Lead Screw Bearing Assembly .................................................7-23
Replacing the Lead Screw ..........................................................................................7-23
Replacing the Anti-backlash Nut ..............................................................................7-24
Replacing the Beam Gasket ........................................................................................7-25
Disk Drive Replacement....................................................................................................7-27
Replacing the Disk Drive ............................................................................................7-27
Keyboard/Display Assembly Replacement...................................................................7-28
Replacing the Keyboard/Display Assembly ...........................................................7-28
Programming Module Components Replacement.......................................................7-28
Replacing Contacts on a DIP Module .......................................................................7-28
Replacing Contacts on a PLCC Module ...................................................................7-30
Replacing Pins on a SOIC Programming Module ..................................................7-33
Replacing the Pin Insulation Block ...........................................................................7-34
Replacing the Programming Block on a PLCC Module ........................................7-36
Assembly Drawings...........................................................................................................7-39
ProMaster 2500 Thermal Printer Standard Spares Kit..................................................7-64
ProMaster 2500 Advanced Spares Kit.............................................................................7-66