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Troubleshoo ting ProM aster 25 00 User Manua l 6-3 ELECTRONIC ID ERROR The internal electronic ID of the device t hat is being programmed did not match the ID that the 2500 expected. C heck that the correct devices are b…

Troubleshooting

6-2 ProMaster 2500 User Manual

ALGORITHM-SPECIFIC ERROR

A few devices have special internal features or programming

requirements not used by any other devices. When the 2500 detects an

error while trying to access one of these unique features, it issues this

generic error code. Record the part number on the device, the device part

number in the Task, and contact Data I/O Support (phone numbers listed

in the Preface) for additional assistance.

BEAM OPTIC MALFUNCTION

The beam reference optic is not operating correctly.

Run the diagnostic tests. Clean, adjust, or replace the optics (emitter or

collector) as needed.

Check the optics and harness wiring.

CAPACITOR CONFIGURATION

ERROR

The programming module’s configuration jumpers are not located in the

correct positions for the device being programmed. Refer to page 4-8 for

the configuration procedure.

CATEGORY X BIN NOT

AVAILABLE

The system does not recognize an output tube in the output tube holder.

Insert an output tube and the operation should continue. If it still fails,

check the microswitch by performing the output tube Optic test.

Check the switch and harness wiring.

DEVICE ALGORITHM NOT

FOUND

The device defined in the Task was not found. This error occurs if an

algorithm update was installed without updating the device list.

If a new Algorithm disk or disks have recently been installed, run the

Task Database Device Check

utility to check for any name mismatches.

DEVICE ON THE BEAM WAS

DROPPED. CAREFULLY

REPLACE THE DEVICE ON

CHUCK OR REMOVE FROM

SYSTEM AND PRESS START

This message appears if the beam fails to correctly pick up a device.

If possible, place the device on the chuck correctly. When it is properly

replaced, the 2500 displays:

Press

START

to continue the operation.

If the beam fails to pick up the device and you cannot replace it on the

chuck properly, remove the device and press

START

Check the vacuum in diagnostics. Check for leaks in the beam or hoses.

Ensure that the air pressure is at the correct setting.

DEVICE OVERCURRENT

The device in the programming module drew excessive current. The

device may be defective. Inspect the programming module for excessive

wear to the block or deformed module contacts. Replace as required.

DEVICE ERROR CLEARED, PRESS START

Troubleshooting

ProMaster 2500 User Manual 6-3

ELECTRONIC ID ERROR

The internal electronic ID of the device that is being programmed did not

match the ID that the 2500 expected. Check that the correct devices are

being used for this Task.

ERROR CLEARED, PRESS

START

This message is displayed when the

DEVICE WAS DROPPED, PRESS START

error condition was corrected.

HARDWARE DID NOT PASS

SELF-TEST

Error occurs when a device-related operation has been attempted for the

first time after turning the 2500 on. A critical assembly in the

programming electronics has failed. Run the programming electronics

self-test as described on page 5-50.

HOOD UP

The hood was up when you started a handler operation. Lower the hood

and press

START

ILLEGAL BIT

A device has a bit programmed and the 2500’s RAM indicates that it

should be blank (unprogrammed). If the devices are not erasable, the

device cannot be programmed. If the devices are erasable, try erasing and

reprogramming.

LABEL JAM, PRESS START

The labels did not move properly.

Make sure the label advance rollers are clean, the pinch rollers are

engaged, and the label detection optics are functioning properly. Make

sure the label motor is operating and that the drive belt is properly

installed. Check the pulley for loose set screws.

Make sure that the label reel has labels.

LABELS NOT CALIBRATED,

PRESS START

The labels did not calibrate properly.

Make sure the label advance rollers are clean, the pinch rollers are fully

engaged, and the ADC optics are functioning properly. Check the ADC

optic value in the Optics test.

Make sure that the label advance motor is operating.

Make sure that the label reel has labels.

Make sure that the label stock is not sticking to the liner.

NON-BLANK

The 2500 has detected bits in the device that are not in their

unprogrammed message state and are not illegal bits. The devices are

probably programmable, but will not be programmed and will be sent to

the fail output tube when Blank Check has been selected as a Task

process. The 2500 will try to program a non-blank device if Blank Check

is not selected in the Task’s process.

PROGRAM FAIL

The 2500 has applied the maximum number of programming pulses

according to the device manufacturer’s specifications and the device is

not programmed. The device should be discarded.

Troubleshooting

6-4 ProMaster 2500 User Manual

RIBBON LATCH NOT ENGAGED

The ribbon pinch roller in the thermal printer is not in place against the

ribbon drive roller.

RIBBON NOT DETECTED

The thermal printer ribbon optic detected that the ribbon roll is empty or

the ribbon is torn.

SECURITY FUSE VIOLATION

The device security fuse has been programmed. A load, program, or

verify operation will give this error.

SUMCHECK ERROR

The data sumcheck calculated by the 2500 during the file download did

not match the sumcheck written in the data file. This problem could be

caused by an incorrect device selection.

UNABLE TO LOWER BEAM

The beam will not move down, or the beam is lowering and the beam

down optic is not operating correctly.

Run the Optics diagnostic test to check the beam down optic. Clean,

adjust or replace the optics based on the test results.

Low air pressure may be too low. Confirm that it is set to 40 PSI.

Ensure that no object is blocking the beam’s complete vertical movement.

Ensure that the beam up solenoid (4) and cutoff solenoid (3) are

functioning properly.

UNABLE TO PICK UP DEVICE,

PRESS START

Vacuum is not being achieved.

High air pressure may be too low. Confirm that it is set to 75 PSI.

The device is not positioned on the chuck properly. Check the track

width adjustment and the beam alignment to the device.

The chuck you are using may be dirty or may not be the correct type for

the device package. Check the chuck and replace it with the correct one.

Clean or replace the chuck tip.

The vacuum generator may not be operating correctly; it may be leaking,

or its filter may be clogged. Run the Optic diagnostics test to check its

operation.

The vacuum switch or the circuitry on the controller board (or connector)

may be faulty. Check the LED on solenoid 7. Check the 24V supply used

for the vacuum generator solenoid on the controller board at J1.

The solenoid for the vacuum generator may not be operating correctly.

Check the Solenoid diagnostics test.

The chuck or vacuum line may be leaking.

UNABLE TO RAISE BEAM

The beam will not move up. Check optic tests and run solenoid test 4.

Low air pressure may be too low. Confirm that it is set to 40 PSI.

Check to see if an object is blocking the beam’s vertical movement.

Lubricate the beam shafts.