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Table of Content s ProM aster 25 00 User Manua l vii 6. Troubleshooting Messages .................... ................. ................. ................. ................. ................. ............. .... ..... 6-1…

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

Table of Contents

viii ProMaster 2500 User Manual

A. Glossary

B. Firmware Keys and STOP Commands

STOP Commands.................................................................................................................B-4

C. Wiring Diagram

D. Translation Formats

Instrument Control Codes.................................................................................................D-3

General Notes......................................................................................................................D-4

ASCII Binary Format, Codes 01, 02, and 03(or 05, 06, and 07).....................................D-5

Texas Instruments SDSMAC Format (320), Code 04.....................................................D-7

The 5-Level BNPF Format, Codes 08 or 09......................................................................D-9

Formatted Binary Format, Code 10................................................................................D-10

DEC Binary Format, Code 11..........................................................................................D-11

Spectrum Format, Codes 12 or 13...................................................................................D-12

POF (Programmer Object File) Format, Code 14..........................................................D-13

Absolute Binary Format, Code 16...................................................................................D-16

LOF Format, Code 17........................................................................................................D-17

LOF Field Syntax ........................................................................................................D-17

ASCII Octal and Hex Formats, Codes 30-37 and 50-58 ...............................................D-19

RCA Cosmac Format, Code 70........................................................................................D-21

Fairchild Fairbug, Code 80...............................................................................................D-22

MOS Technology Format, Code 81.................................................................................D-23

Motorola EXORciser Format, Code 82...........................................................................D-24

Intel Intellec 8/MDS Format, Code 83...........................................................................D-25

Signetics Absolute Object Format, Code 85...................................................................D-26

Tektronix Hexadecimal Format, Code 86......................................................................D-27

Motorola EXORmacs Format, Code 87..........................................................................D-28

Intel MCS-86 Hexadecimal Object, Code 88..................................................................D-29

Hewlett-Packard 64000 Absolute Format, Code 89 .....................................................D-31

Texas Instruments SDSMAC Format, Code 90.............................................................D-33

JEDEC Format, Codes 91 and 92.....................................................................................D-35

Introduction .................................................................................................................D-35

BNF Rules and Standard Definitions ......................................................................D-35

JEDEC Full Format, Code 91...........................................................................................D-38

JEDEC Field Syntax ....................................................................................................D-39

Field Identifiers ...........................................................................................................D-39

JEDEC U and E Fields ................................................................................................D-42

JEDEC Kernel Mode, Code 92.........................................................................................D-46

Extended Tektronix Hexadecimal Format, Code 94....................................................D-47

Motorola 32-Bit Format, Code 95....................................................................................D-49

Hewlett-Packard UNIX Format, Code 96......................................................................D-50

Intel OMF386 Format, Code 97.......................................................................................D-52

Intel OMF286 Format, Code 98.......................................................................................D-53

Intel Hex-32, Code 99........................................................................................................D-55

Highest I/O Addresses....................................................................................................D-57