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Table of Conte nts viii ProM ast er 2500 User Manu al A. Glossary B. Firmware Keys and STOP Commands STOP Commands ....................... ............ ................. ................. ................ ...............…

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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
Table of Contents
ProMaster 2500 User Manual ix
E. Computer Remote Control
Handler Computer Remote Control..................................................................................E-2
System Setup ..................................................................................................................E-2
Remote Mode Command Set .......................................................................................E-3
Handler CRC Error Codes .........................................................................................E-10
Hex Label Format...............................................................................................................E-11
Label Record Content .................................................................................................E-11
Label Record Types .....................................................................................................E-11
Creating Hex Label Records ......................................................................................E-14
Source Code of LABEL.C Program ...........................................................................E-16
Programming Electronics Computer Remote Control.................................................E-17
System Setup ................................................................................................................E-17
Programming Electronics CRC Commands ............................................................E-18
CRC Error Codes................................................................................................................E-22
F. Local Mode
Switching Between Local and Remote Modes.................................................................F-1
System Configuration..........................................................................................................F-1
The Main Menu Commands...............................................................................................F-2
Operations Menu ...........................................................................................................F-2
File Utilities Menu .........................................................................................................F-6
System Setup Menu .......................................................................................................F-9
Index
Keep Current Subscription Service
System Requirements..............................................................................................................1
Version Compatibility ......................................................................................................2
Using Keep Current.................................................................................................................2
Accessing the BBS ..............................................................................................................2
Using a Text-based FTP Program ...................................................................................4
Using a Web Browser ........................................................................................................4
Sample Keep Current Scenario ..............................................................................................5
List of Figures
Figure 1-1. ProMaster 2500 System....................................................................................1-2
Figure 1-2. External Features of the 2500..........................................................................1-3
Figure 1-3. System Air Adjustment Knobs.......................................................................1-5
Figure 1-4. External Features on the ProMaster 2500 (rear view).................................1-5
Figure 1-5. Major Features Under the Hood....................................................................1-6
Figure 1-6. Dot Matrix Labeler Component Identification Drawing............................1-7
Figure 1-7. Beams and Programming Station Component Identification Drawing...1-8
Figure 1-8. The ProMaster 2500 Front Panel..................................................................1-10
Figure 1-9. TaskLink Main Screen: Options Pull-Down Menu Selected....................1-13
Figure 1-10. TaskLink General Parameters Dialog Box................................................1-14
Figure 2-1. Connecting the Air Line from the External Source to the 2500.................2-2
Figure 2-2. The 2500 Shipping Crate .................................................................................2-3
Figure 2-3. System Contents...............................................................................................2-4
Figure 2-4. Selecting the Correct Quick Connect.............................................................2-5
Figure 2-5. Connecting the External Air to the 2500.......................................................2-6
Figure 2-6. Adjusting High and Low Air Pressure .........................................................2-7
Figure 2-7. Chuck Selection Chart.....................................................................................2-8