® ProMaster 2500 Integrated Production Programming System User Manual 981-0309-004
March 1997 981-0309-004 Data I/O has made every attempt to ensure that the information in this document is accurate and complete. Data I/O assumes no liability for errors or for any incidental, consequential, indirect, or special damages, including, without limitation, loss of use, loss or alteration of data, delays, or lost profits or savings, arising from the use of this document or the product which it accompanies.
Table of Contents Safety Summary ................................................................................................................................................. xv Preface Data I/O Customer Support.............................................................................................. xvii United States ................................................................................................................. xvii Canada .........................................................
Table of Contents TaskLink Software ............................................................................................................. 1-12 PC System Requirements ........................................................................................... 1-12 Modes of Operation .................................................................................................... 1-12 How to Use TaskLink Screens ...................................................................................
Table of Contents 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 ..............................................................................
Table of Contents 5. Preventive Maintenance Theory of Operation ............................................................................................................ 5-2 TaskLink ......................................................................................................................... 5-2 Device Processing .......................................................................................................... 5-2 Optics ...............................................................
Table of Contents 6. Troubleshooting Messages............................................................................................................................... 6-1 Troubleshooting Flow Charts............................................................................................. 6-6 7. Repair and Replacement Procedures Fuse Replacement ................................................................................................................
Table of Contents 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 ......................................................................................................................
Table of Contents E. Computer Remote Control Handler Computer Remote Control..................................................................................E-2 System Setup ..................................................................................................................E-2 Remote Mode Command Set .......................................................................................E-3 Handler CRC Error Codes ...............................................................................
Table of Contents Figure 2-8. Adjusting Plate Height .................................................................................... 2-9 Figure 2-9. Loading Labels in the Dot Matrix Printer................................................... 2-10 Figure 2-10. Installing the Labeler Ribbon Cassette in the Dot Matrix Printer ......... 2-12 Figure 2-11. Threading Labels in the Thermal Printer.................................................. 2-14 Figure 2-12. Threading a Ribbon in the Thermal Printer ....
Table of Contents Figure 4-11. Closeup View of Input Track with 8-pin 150-mil Device Keeper Bar Assembly Installed.......................................................................................................... 4-15 Figure 4-12. 8-pin 150-mil SOIC Device Keeper Bar Assembly Mounted in the Input Track ....................................................................................................................... 4-16 Figure 4-13. Chuck Selection Chart .......................................
Table of Contents Figure 5-28. Input and Output Track Funnel Adjustment........................................... 5-65 Figure 5-29. Adjusting the Track Width Cables............................................................. 5-66 Figure 6-1. Power-up Failures (page numbers are in parentheses) .............................. 6-7 Figure6-2.TheBeamDoesNotPickUptheDeviceCorrectly(pagenumbersareinparentheses) 6-8 Figure 6-3.
Table of Contents Figure C-2. ProMaster 2500 Handler Controller Board Layout (not to scale)............ C-3 Figure D-1. An Example of ASCII Binary Format .......................................................... D-5 Figure D-2. An Example of TI SDSMAC Format............................................................ D-7 Figure D-3. An Example of Formatted Binary Format ................................................ D-10 Figure D-4. An Example of Formatted Binary Format .................................
Table of Contents xiv ProMaster 2500 User Manual
Safety Summary General safety information for operating personnel is contained in this summary. In addition, specific WARNINGS and CAUTIONS appear throughout this manual where they apply and are not included in this summary. Antistatic Wrist Strap To avoid electric shock, the antistatic wrist strap must contain a 1 MΩ (minimum) to 10 MΩ (maximum) isolating resistor. Definitions WARNING statements identify conditions or practices that could result in personal injury or loss of life.
Safety Summary Symbol This symbol indicates that the user should consult the manual for further detail. V This symbol stands for Volts ac, for example: 120 V = 120 Vac. This symbol denotes a fuse rating for a user-replaceable fuse. This symbol denotes earth ground. An antistatic wrist strap with impedance of 1 MΩ (minimum) to 10 MΩ (maximum) can be attached to terminals designated for that function and marked with this symbol.
Preface The Preface includes details about contacting Data I/O for technical assistance and for repair and warranty services. The Preface also explains the Bulletin Board Service, typographic conventions and more. Data I/O Customer Support United States Note: After April 27, 1997, use area code 425 instead of 206 when placing a call to one of the phone or fax numbers listed in this Preface.
Preface Japan For technical assistance, repair, or warranty service, contact: Data I/O Japan Osaki CN Building 2F 5-10-10 Osaki Shinagawa-Ku Tokyo 141 Telephone: 3-3779-2152 Fax: 3-3779-2203 Germany For technical assistance, repair, or warranty service, contact: Data I/O GmbH Lochhamer Schlag 5a 82166 Gräfelfing Telephone: 089-858580 Fax: 089-8585810 Other European Countries Other Countries Worldwide For technical assistance, repair, or warranty service, contact your local Data I/O representative.
Preface Technical Assistance You can contact Data I/O for technical assistance by calling, sending a fax or electronic mail (e-mail), or using the Bulletin Board Service (BBS).
Preface Bulletin Board Service From the Data I/O Bulletin Board System (BBS) you can obtain a wide range of information on Data I/O products, including current product descriptions, new revision information, technical support information, application notes, and other miscellaneous information. Using the BBS, you can access device support information, request support for a particular device, and leave messages for the BBS system operator, Customer Support personnel, or other customers.
Preface Warranty Information Data I/O Corporation warrants this product to be free from defects in material and/or workmanship for a period of twelve months from the original date of shipment to the buyer. The warranty does not include normal wear or replacement components, programming sockets, drive belts, rollers, and socket contacts that contact devices being processed. This warranty shall apply only if the product fails to function properly under the normal intended use.
Preface Repair Service After the warranty period expires, repair services are available at Data I/O Service Centers on a time-and-materials basis, and through a fixed price annual agreement that covers all parts and labor needed to correct normal malfunctions. The annual agreement includes semiannual performance certification. For more information, call Data I/O Customer Resource Center at the numbers listed at the front of the Preface.
1 Introduction Product Description What Is the ProMaster 2500? ProMaster 2500 User Manual The Data I/O ProMaster™ 2500 is an automated, integrated circuit (IC) handler/programmer system. It transports, programs, tests, and labels devices and then sorts them in standard IC tubes. The system supports programmable integrated circuit (PIC) devices in a variety of package types, including dual in-line packages (DIP), plastic leaded chip carriers (PLCC), and small outline integrated circuits (SOIC).
Introduction Figure 1-1 ProMaster 2500 System 1825-2 The system is composed of two major parts: 1. ProMaster 2500 handler with programming electronics 2. TaskLink software operating on a personal computer (PC) 2500 Handler The 2500 handler is the hardware portion of the system. System firmware controls the transportation, programming, and labeling of a wide variety of IC device styles and packages.
Introduction General Features This section describes the major hardware components on the 2500. The components are divided into three broad categories: external features, features under the hood, and internal features. Note: Illustrations in this manual show the ProMaster 2500 with an E-stop button, hood interlock switch, labeler cover, and a modified hood with a handle. Handlers with the dot matrix labeler installed do not have these additional features.
Introduction Front Panel—The front panel includes an alphanumeric keyboard for text and data entry, and a 4-line, 160-character back-lit display for communicating prompts to the operator. This panel is used primarily for running diagnostics and invoking special handler/labeler firmware commands. (Refer to page 1-11 for more detailed information.) Output Tube Holders—By default, the right tube holder (tube 1) accepts all devices that have passed the programming/testing operation.
Introduction Figure 1-3 System Air Adjustment Knobs LOW PRESSURE 20-50 PSI HIGH PRESSURE 65-85 PSI HIGH PRESSURE ADJUSTMENT KNOB LOW PRESSURE ADJUSTMENT KNOB ON A J S SHIFT B K T DEL C L U D M V E F G H P Q N O Y Z W X SHIFT I R LOWER ENTER CASE 1 2 3 4 5 6 7 8 9 0 CAL RESET START STOP 1764-4 Back of 2500 AC Power Input and Power Switch—The system is factory configured to accept either 100/110 V or 220/240 V AC input.
Introduction RS-232 Ports—Two serial ports are used to connect the 2500 with the PC that is running TaskLink. A third port is available for running diagnostic tests. Figure 1-4 External Features on the ProMaster 2500 (rear view) AIR INPUT POWER SWITCH AC POWER INLET REMOTE RS232 PROGRAMMER RS232 HANDLER PORT 1759-2 Features Under the Hood The hood covers the primary transportation and configuration features on the 2500 as shown in Figure 1-5.
Introduction Input Tube Holder—The tube holder holds a tube of devices to be processed by the handler. It accepts most standard IC tubes without any adjustment. Track Sections—Three short sections of track provide the channel for devices to travel through the system. Devices are assisted in their travel down the track by the 18-degree slope of the track, orbital motors that gently vibrate the devices, and output track air.
Introduction . Figure 1-6 Dot Matrix Labeler Component Identification Drawing PLATEN PRESS BEARINGS APPLICATION PLATE (Raised) LABEL DRIVER ROLLER PRINT HEAD ADC OPTIC (1 of 2) PINCH ROLLER 2 PINCH ROLLER 1 SPRING CLIP (1 of 2) RIBBON CASSETTE LABEL ADVANCE KNOB RIBBON ADVANCE KNOB LABEL SENSING OPTIC LABEL REEL COVER LABELING STATION 1770-2 Label Application Area—The portion of the labeler where a printed label is applied to the device.
Introduction Figure 1-7 Beams and Programming Station Component Identification Drawing BEAM SOLENOID (1 of 4) BEAM ROTATE MOTOR LIMIT BAR CABLE HARNESS GUIDE BEAM DOWN OPTIC BEAM HOME OPTIC BEAM UP OPTIC SOLENOID LED (1 of 4) INPUT TUBE HOLDER FRONT CARRIAGE SHAFT LEAD SCREW TRACK AIR LINES CHUCK SPA PINS CHUCK TIP MODULE CLAMP (1 of 2) TRACK WIDTH ADJUSTMENT KNOB TRACK AIR ADJUSTMENT KNOB OUTPUT TUBE HOLDER 1 TRACK HEIGHT ADJUSTMENT SCREW DEVICES IN OUTPUT TUBE 1766-1 ProMaster 2500 User Manu
Introduction Beam—With a chuck on the beam head, a pick-and-place method is used to gently transport devices. Information in the Task instructs the beam to rotate the device so that programming and labeling are performed with the correct device orientation. The beam’s position is automatically calibrated each time the system is initialized. Chuck—Located on the end of the beam, the chuck achieves an air-tight seal on the device so the beam’s vacuum can pick up and release devices as they are processed.
Introduction Front Panel The primary features of the 2500’s front panel are described below (see Figure 1-8). Figure 1-8 The ProMaster 2500 Front Panel DISPLAY ARROW KEYS ON A J S ! B " _ K* $ , SHIFT T C # L : U ; D M V c = < DEL E % N ~ W > & F @ O X ? G ' P \ Y .
Introduction Display The 160-character, 4-line, back-lit display prompts you with menus during setup and diagnostic testing and for all operations in local mode. ON—A green LED behind this status indicator is on whenever the system is turned on. This is not a control key. Main Menu—The 2500 Main Menu is shown below.
Introduction TaskLink Software TaskLink software runs on a PC and coordinates device programming, testing, handling, labeling, and binning operations on the ProMaster 2500. TaskLink is available in a DOS version and a Windows™ version. The software procedures and instructions in this manual assume the use of TaskLink for DOS. If you are using the Windows version, refer to the TaskLink for Windows Getting Started Guide and the associated online Help for detailed information.
Introduction How to Use TaskLink Screens Figure 1-9 shows the TaskLink main screen for the system administrator. The Options pull-down menu has been selected. When you first enter TaskLink, the message line prompts you to press the ALT key on your PC keyboard. This highlights the Setup selection and a single letter on the other menu bar options. Press ↵ to select Setup or press the highlighted letter key for any displayed option you wish to select.
Introduction Figure 1-10 TaskLink General Parameters Dialog Box Push Buttons—Dialog boxes contain one or more push buttons. To select a push button, highlight it and press ↵, or select it using a mouse. < OK > and < Cancel > are examples of push buttons. Check Boxes [ X ]—Check boxes toggle an option on and off. Use the SPACE bar, or click on the check box with your mouse to toggle a selection on and off. Electronic ID is an example of a check box.
Introduction The table below summarizes the keys commonly used with TaskLink and the function they serve. PC Key(s) Description of Action TAB Moves the cursor to the next field (forward) in a dialog box. SHIFT + TAB Moves the cursor to the previous field (backward) in a dialog box. ↵ Accepts the current selections in a dialog box. In a multiple-line text entry field, this key moves the cursor to the next line or the beginning of the next field.
Introduction The 2500’s keyboard and display will be used by the system administrator and/or service technician when they want to: • Stop the handler during a job (Task), adjust a parameter, and then continue running the Task from the same point. (A complete list of the available STOP commands can be found in Appendix B.) • Run tests on the labeler using the Print Only mode. • Operate in Local mode to run system diagnostics.
Introduction Power Requirements Operating Voltages 100/110/220/240V ac ±10% Frequency Range 50 to 60 Hz ±5% Power Consumption 150 VA maximum 120 Watts maximum Fuse Rating 5 amp slow blow 3 amp slow blow 100V/120V ac (5A/120V/T) 220V/240V ac 93A/240V/T) Operating Requirements Input Air 80 PSI @ 1.0 CFM (5.5 Bar @ 0.0283 CMM) External Air Filter 10 micron (not provided with system) Physical and Environmental 1-18 Dimensions Width: 38 in (96.5 cm) Height: 26 in (66 cm) Depth: 19 in (48.
Introduction Safety (CE units only) The ProMaster 2500 meets essential health and safety requirements and conforms to the following European Community (CE) directives: • • • • Certificate of RFI/EMI Compliance (CE units) Machinery Directive 89/392/EEC Electromagnetic Compatibility Directive 89/336/EEC EN 292-1,2—Safety of Machinery EN 60204-1—Safety of Machinery (Electrical Equipment of Machines) Data I/O certifies that the ProMaster 2500 complies with the Radio Frequency Interference (RFI) and Electro
Introduction For More Information For technical assistance, call the Data I/O Customer Resource Center at 800-247-5700. (Press 2 on your touch-tone phone to bypass the operator or recorded message and speak to the first available Support Engineer.
Introduction ProMaster 2500 User Manual 3/97 1-21
2 Installation and Setup For Administrators This chapter describes how to install and start the ProMaster 2500 and is directed to system administrators. You should be familiar with the information described in Chapter 1 before performing the operations described in this chapter. System operators should skip Chapters 2 and 3 and read the daily operating procedures described in Chapter 4.
Installation and Setup Before You Install Before you install the ProMaster 2500, confirm that you have the following items ready in the area where it will be operating: • Room temperature between 50 and 100 degrees F (10 and 38 degrees C). • Clean, dry, oil-free factory air supply capable of supplying a constant volume of 1.0 CFM (cubic feet/minute) at 80 PSI (pounds/square inch) (5.5 Bar at 0.0283 CMM). • Air filter (rated at 10 microns) and regulator located between your compressor and the 2500.
Installation and Setup 1. Remove the eight screws (two on each vertical panel) that hold together the panels of the shipping crate (see Figure 2-2). Figure 2-2 The 2500 Shipping Crate TOP REAR FRONT PALET 2306-1 2. Carefully lift the top of the shipping crate and pull up the four vertical panels, and set them aside. 3. Carefully lift the 2500 (this will require two strong people) and set it on a clean, sturdy, stable surface.
Installation and Setup • An input air line (6 ft) with a male 1/4-inch NPT adapter on one end • Two male quick connects with female 1/4-inch NPT adapter on one end • Label roll • Chuck set • Spares Kit • Power cord • ProMaster 2500 User Manual with End User Registration Card • Customer letter Figure 2-3 System Contents PROMASTER 2500 DISKS PROGRAMMING MODULE LABEL ROLL aster TASKLINK DISK 2500 ProM SPARES KIT USER MANUAL 9 - 25 PIN CABLE CHUCK SET RS-232 CABLE (2) POWER CORD 1/4"
Installation and Setup 2. Pull the sliding knurled sleeve back and insert one of the male quick connects. 3. Release the knurled sleeve and check the connection to ensure that it is locked in place and seated correctly. Only one of the two male quick connects will seat correctly with the female connector you have on your source air line (see Figure 2-4). 4. Remove the male quick connect by pulling back the knurled sleeve.
Installation and Setup 5. The 2500’s high and low air pressure gauges will immediately display their current settings. Adjust these by performing the procedure on page 2-7.
Installation and Setup The line should come out easily, without any resistance. If it is difficult to remove, make sure that the collar is fully depressed against the 2500’s body before pulling on the air line (see Figure 2-5). Adjusting the High and Low Air Pressure After connecting the air line to the connector on the rear panel, set the high and low air pressure on the 2500. The air adjustment knobs (see Figure 2-6) are normally locked in position.
Installation and Setup Installing and Removing Chucks Figure 2-7 Chuck Selection Chart Three chucks are provided with the system. Each chuck has a different tip diameter that corresponds to the size and dimensions of different devices. Figure 2-7 shows the appropriate chuck for each supported package type.
Installation and Setup Setting Up the Dot Matrix Printer Checking the Application Plate Height The following sections describe the setup procedures that need to be checked and performed on the dot matrix printer before labels can be printed properly.
Installation and Setup Refer to Figure 2-9 and follow these steps to install a roll of labels: 1. Raise the application plate, and release rollers B and F by sliding them in the direction shown by the arrows in Figure 2-9. This prepares the path of the labels to be threaded through the labeler. 2. Remove the label reel cover (see Figure 2-9). Figure 2-9 Loading Labels in the Dot Matrix Printer PLATEN PRESS BEARINGS APPLICATION PLATE E D C F B G A LABEL REEL COVER 1851-2 3.
Installation and Setup 8. Thread the label liner across the platen and lower the application plate to hold it in position. 9. Route the liner to the left side of roller E and to the right of roller F. Allow the remaining liner to drape to the left of knob G. 10. Move roller F to the right until it snaps into position. Note: To ensure correct label printing and application, make sure both pinch rollers (B and F) are fully engaged.
Installation and Setup Installing the Dot Matrix Printer Ribbon Cassette Install the labeler ribbon cassette in the dot matrix printer by following this procedure (see Figure 2-10): 1. Rotate the knob on the new cassette in the direction indicated by the arrow (counter-clockwise) to pull the ribbon taut. 2. Guide the new cassette so the ribbon fits between the print head and the platen. 3.
Installation and Setup Setting Up the Thermal Printer Loading Labels Before labels can be printed and applied to processed devices, the label and ribbon material must first be loaded. The following sections cover the correct procedures for loading and calibrating labels and loading a new ribbon and repairing a torn ribbon. Threading labels on the thermal labeler is similar to threading labels on the dot matrix labeler (see Figure 2-11).
Installation and Setup Figure 2-11 Threading Labels in the Thermal Printer APPLICATION PLATE (raised) PLATEN PRINT HEAD (retracted position) LABEL ADC OPTIC LABEL DRIVE ROLLER (hidden) LABEL PINCH ROLLER PLATEN PINCH ROLLER LABEL ADVANCE KNOB LABEL ALIGNMENT ROLLER LABEL DETECTION OPTIC LABEL ROLL (cover removed) 2303-1 Calibrating Labels The label optic must be calibrated to detect and synchronize with the labels after you have finished any of the following operations: • Installing a new roll of
Installation and Setup Installing a New Ribbon Each new ribbon roll has a long leader to thread through the labeler. Follow the procedure below to install the new ribbon (refer to Figure 2-12). 1. Prepare the ribbon threading path by pushing the ribbon pinch roller to the right. 2. Install the ribbon take-up core (one empty core is supplied with the printer) on the ribbon take-up hub. After threading the ribbon, you will tape the ribbon’s leader to this cardboard core. 3.
Installation and Setup Repairing a Torn Ribbon 5. Guide the pinch roller back into its operating position against the drive roller. 6. Use the tape supplied on the end of the leader (or a DIP label) to attach the leader to the take-up cardboard core. 7. When you install a new ribbon, remove the old ribbon’s cardboard core and install it on the take-up hub as the new ribbon take-up core. 8.
Installation and Setup 3. Connect one end of the second serial cable to the COM2 serial port on the back of your PC. TaskLink uses COM2 as the default Remote port. It does not use any other COM ports other than 1 and 2. If you plan to use a mouse with TaskLink, it must be a bus mouse; or you can set a COM port to 3 or 4 and use an interrupt other than IRQ 3 or 4. 4. Connect the other end of this COM2 cable to the connector labeled Remote RS-232 on the back of the 2500. 5.
Installation and Setup Starting TaskLink TaskLink operates in two different modes: Administrator and Operator. Administrator mode allows access to all parameters so that Tasks can be created. Operator mode (the default) is used during a production run when streamlined operation and high throughput are most important. From the DOS prompt, start TaskLink in Administrator mode by entering tl a on the PC. (Enter tl to start TaskLink in Operator mode.) The main TaskLink screen is displayed.
Installation and Setup Note: The 2500’s power-up self-test takes approximately two minutes to complete. Checking System Communication 3. Confirm that the high air pressure gauge on the 2500 is reading 75 PSI (see page 2-7). When the adjustment is correct, push the adjustment knob in toward the back of the handler to lock its position. 4. Confirm that the low air pressure gauge is reading 25 PSI.
Installation and Setup Switching Between Local and Remote Modes As discussed in Chapter 1, the 2500 uses two methods to communicate with the operator. Ninety-five per cent of the interaction will be through the TaskLink screens and PC keyboard. The remaining five per cent of the interaction is through the 2500’s keyboard and display. When the system is initially shipped from the factory, it is configured to communicate with TaskLink. There are two key points to remember about these modes: 1.
Installation and Setup General 2500 Setup Remote and Programmer Port Baud Rates The following procedures describe changing the system’s serial port baud rates and enabling or disabling the audible alarm. You must put the 2500 in local mode before performing these steps. Other 2500 front panel commands are described in Chapter 6 and Appendix F. The default baud rate of the remote and programmer ports is 9600. To change either baud rate follow the procedure below. 1.
Installation and Setup Adjusting Print Quality and Label Position This section describes several parameters that affect the appearance of characters on the label. Some of these labeling parameters are changed by entering commands on the 2500’s front panel while it is in the local mode. Others parameters are accessible in the middle of a Task after you press STOP on the 2500’s keyboard and then enter a specific key sequence.
Installation and Setup 4. With the cursor pointing to the Temporary file, press ENTER to select it. The 2500 displays: PRINT LABEL TEMPORARY FILE AUTO-SEL 26 CPI 26 CPI S 20 CPI 18 CPI 16 CPI T 12 CPI T MOVE TO SELECTION THEN PRESS ENTER Use the ← , ↑ , → , ↓ to point to one of the fonts. 5. Press ENTER to select that font. The 2500 displays: TTTT HHHH 6. | | | | Use the keyboard to enter label text. Press STOP when text entry is complete.
Installation and Setup 2. Press 2 to select LABELER. The 2500 displays this menu: * * * LABELER SETUP MENU * * * 1 - LABEL CALIBRATION 4 - SETUP MENU 2 - LABEL PLACEMENT 3 - LABEL ADJUST Label Calibration Label calibration determines the distance between the edge of the label and the first printed character. This value is set at the factory and does not usually need to be changed.
Installation and Setup The label calibration value can also be changed while the 2500 is processing devices using the STOP command. Press STOP on the 2500’s keyboard and then LOWER CASE + C. The 2500 displays: PROGRAM/TEST LABEL ENTER LABEL CALIBRATION VALUE (X):_ where X represents the current setting. Enter a new value (between 0 and 255) on the 2500’s keyboard. Press ENTER to save the value. Press CAL to run the ADC optic’s label calibration.
Installation and Setup Label Adjust This is a fine-tune adjustment of the label placement value when it is set to “autocenter.” To change the value when the 2500 is in the local mode, press 3 from the LABELER SETUP MENU. * * * LABELER SETUP MENU * * * 1 - LABEL CALIBRATION 4 - SETUP MENU 2 - LABEL PLACEMENT 3 - LABEL ADJUST The 2500 displays: ENTER LABEL ADJUST VALUE (X): _ Use the 2500’s keyboard to change the displayed value.
Installation and Setup 4. Enter a new value from the 2500’s keyboard and press ENTER to save the new dot split value. 5. Press START to print and examine the next sample label. 6. Closely examine the vertical stroke on the letter E to see if it is clear and formed from a single column of dots (see Figure 2-17). Repeat this process until you are satisfied with the quality of the printed character.
Installation and Setup Figure 2-19 Label Calibration (affects horizontal position) NORMAL HIGHER VALUE 2177-1 Print Shift Label Calibration Change this value using the STOP command described in the following procedure. 1. Press STOP to pause the 2500 while a Task is running. 2. Press LOWER CASE + P. The display on the 2500 prompts you to enter a new value. 3. Press ↑ and ↓ to enter a new print shift value between 0 and 16.
Installation and Setup Adjusting the Print Intensity of the Thermal Printer You can change the factory default setting for print intensity by using the STOP command while the 2500 is processing devices. Note: The print head uses more energy when the intensity value is increased. The life expectancy for the print head is shorter when this setting is set to a high value. Select a print intensity value that produces a legible label while not creating excessive wear. The range for intensity is from 1 to 21.
Installation and Setup Installing a 2500 Firmware Update The 2500 firmware will be updated periodically to add new operating features. The update replaces the EPROM in location U15 and/or U43 on the handler controller board. CAUTION: To avoid possible damage to the system components, this procedure should be performed only by a qualified service technician. Observe all antistatic precautions while performing this operation. Follow these steps to install a firmware update to the 2500.
Installation and Setup Figure 2-20 Location of Firmware EPROMs on the Main Controller Board CR51 CR87 CR63 CR111 CR75 CR99 CR52 CR88 CR64 CR112 CR76 CR100 CR53 CR89 CR65 CR113 CR77 CR101 CR54 CR90 CR66 CR114 CR78 CR102 +5V -12V +12V +36V U43 EPROM S4 S2 S3 S1 +24V S8 S7 +90V U15 EPROM S5 S6 1955-2 8. Install the device shield, lower the main plate, and then tighten the corner screws. 9. Plug in the power cord and turn on the 2500. 10.
Installation and Setup 2-32 ProMaster 2500 User Manual
3 Tasks and Kits For Administrators This chapter, which is directed to system administrators, describes how to set up Tasks and Kits in TaskLink after installation and setup are complete, as described in Chapter 2. System operators should skip this chapter and read the daily operating procedures described in Chapter 4. A Task, which is used by system operators to program, test, and label devices, is the cornerstone of the 2500 system’s daily operation.
Tasks and Kits What Is a Task? A Task is a job setup containing all the information necessary to process a set of devices. A Task records all the parameters of the job setup including the device type, the data file to be used, and the label text to print and place on the programmed device. The Task is created once and saved on disk so that it is available whenever that programming/labeling job needs to be run.
Tasks and Kits Figure 3-1 Overview of the Steps Involved in Creating Tasks 1 2 3 4 5 ProMaster 2500 User Manual 3-3
Tasks and Kits Creating a Task for a Logic Device This section describes how to create a Task for a logic device and describes the necessary parameters. The area on the screen in which you enter or select each parameter is referred to in this manual as the parameter entry field or, simply, field. Not all of the TaskLink parameter fields must be changed from their default values. You may accept the default settings on many fields while creating your Tasks.
Tasks and Kits Use the arrow keys (or pressA) to highlight the Add Task option, and press ↵ to select it. The Add Task dialog box appears (see Figure 3-3) with the cursor in the Name entry field. The Tasks and Kits available in the current Task/Kit database file (shown in the Task/Kit Database entry field at the top of the dialog box) are listed in the Task/Kit list box. Figure 3-3 Add Task Dialog Box Selecting Database Files TaskLink stores all Tasks and Kits in a database file with a .tsk extension.
Tasks and Kits You may also wish to enter such handler setup parameters as blank check number, programming module and configuration, label size, and sumcheck (for example, AMD 22V10/4 20R-2 0906K S/C 0000). Figure 3-4 Edit Task Dialog Box Selecting a Device From the Edit Task dialog box, create a list of devices that operators choose from when they run the Task. A maximum of five devices can be selected for each Task.
Tasks and Kits Selecting the Data Source Select the Data Source field to choose where the 2500 will retrieve the data to be programmed in the device. When you select PC Disk File, two additional fields allow you to select a data translation format and a data file name. These additional entry fields are: • Data File • Translation Format If you select Master Device as the data source, TaskLink will prompt the operator to insert a master device into the input track section.
Tasks and Kits For logic devices, the primary choices are two JEDEC formats (full and kernel) and Altera POF. Selecting a Process The Process(es) check box area of the Edit Task dialog box lists the operations that can be performed on a device. The three columns of check boxes allow you to configure three different combinations of operations, or process(es), within the Task.
Tasks and Kits • Selecting Handling/ Labeling Parameters Label—Select this parameter to label the devices. Devices do not have to be programmed (or verified) and labeled in the same process. They can be programmed and placed in tubes to be labeled by the 2500 later. The 2500 default configuration will not label devices that have failed the programming operation. (The 2500 can be configured to label both passed and failed devices. Refer to the Binning command in local mode in Appendix F.
Tasks and Kits Note: Your company should establish a standard orientation for each device package type (DIP, square PLCC, 32-pin PLCC, SOIC) so that all operators insert devices correctly. All devices are inserted and handled upside-down (also known as “dead bug”) on the 2500. The arrows on the TaskLink screen point to the four sides of the device (see Figure 3-7). Move the cursor using the ↑ and ↓ keys. Press TAB when you have the correct orientation highlighted for the Output track.
Tasks and Kits Figure 3-8 Recommended Device Orientation in Input Device INPUT TUBE HOLDER SQUARE PLCC DEVICES TUBE INSERTED WITH DEVICE CONTACTS FACING UP INPUT TUBE HOLDER DIP/SOIC DEVICES TUBE INSERTED WITH DEVICE CONTACTS FACING UP PIN 1 NOTCHED CORNER PIN 1 1854-3 Entering Label Text Enter Text to appear on the label. The TaskLink screen may allow you to enter more characters than will fit on the label you are using.
Tasks and Kits The Placement parameter (Label placement) controls the location of the label on the device. TaskLink’s default is Autocenter (numeric value of 255 in this field), which instructs the 2500 to position the label in the center of the device package. A placement value of 0 (zero) places the left end on the label on the left end of the device’s leading edge. Increasing the placement value by one moves the label 0.010 inch away from the leading edge of the device.
Tasks and Kits TaskLink displays the Logic Device Parameters dialog box with these main options: Verify Options — Select one option from the three offered. • Fuse verify only — Compares the fuses programmed in the logic device with the pattern in the 2500’s RAM. No structured test vectors are applied to the device even if they were downloaded in the JEDEC data file. • Functional test only — Verifies the programmed device using the structured test vectors downloaded with the JEDEC data file.
Tasks and Kits • • Data Sumcheck Serial Vector Test — The 2500 applies test vectors to the device inputs in parallel. If the PLD design requires certain input pins to be applied before others, the JEDEC standard states that the test vectors must be written to enforce that particular order. When this option has been selected, the 2500 applies the vector inputs starting with device pin 1 and continuing in numeric order to the last input.
Tasks and Kits Selecting a Translation Format Selecting the translation format requires matching the data file format on your PC disk with one of the more than 35 formats supported by the 2500. Refer to the list of formats on the TaskLink screen by pressing F2 from the Translation Format field on the Edit Task dialog box (see Figure 3-10). Note: Consider high-speed download compatibility when you choose a format.
Tasks and Kits There is one situation when the word width value would be changed. This occurs if you are trying to program 16-bit RAM data into two 8-bit memory devices. Assume that the 2500 loads a file intended to program 16-bit data into two 8-bit devices. The low order bytes of each 16-bit word are saved to all even address in RAM beginning with RAM address 0 (zero). The high order bytes for each word would be stored at RAM address 1 and all odd address locations.
Tasks and Kits The value of YYYY YYYY is the address where the byte of data is stored in the 2500’s RAM. Relative Addressing Under most circumstances the I/O Offset is left at its default value of FFFFFFFF. By default, the 2500 assumes that the first byte of data it receives should be located at RAM address 0 and all other data bytes received will be located in RAM at addresses relative to the address of the first byte.
Tasks and Kits Automatic RAM Fill When a Task is run and it calls for a data file to be downloaded into RAM, the 2500 will fill RAM with a specific data pattern depending on how this field is set. • None —RAM is not changed from its current state. The file will download and write over the current contents. • Default —RAM is initialized to the unprogrammed state for the device type selected.
Tasks and Kits Figure 3-12 Commands Available under Setup ProMaster 2500 User Manual 3-19
Tasks and Kits Logging Programming Statistics Figure 3-13 Log File Format Compared to Task Statistics Screen Use the Session Data Logging... feature to automatically record statistics for each Task run in a file with a file_name.log extension. From the TaskLink main screen, press Alt and S to select the Setup pull-down menu. Highlight Session Data Logging... and press ↵.
Tasks and Kits Remote Control commands in Appendix E. For example, you might use these commands if you want to program a device but disable the verify option. The Edit Task dialog box does not allow you to select this combination. From that box, Verify is automatically enabled when Program is selected. Use the 023] command to disable the verify operation.
Tasks and Kits Serializing Devices You may want to program a serial number into the devices and/or print the number on the label. TaskLink’s Serialization... option offers an opportunity to do this in software. A sample serialization program called serializ.exe is provided with TaskLink. For detailed information on the serialization program, refer to the External Serialization Program section on page 3-25 and to the online help topic “Writing a Serialization Program” under TaskLink’s General Help Index.
Tasks and Kits Figure 3-15 Serialization Parameters Dialog Box Serialization Method — select File when operating with an ESP. (The Memory Buffer selection is offered to maintain compatibility with a previous product and should not be used to create a new ESP.) RAM Serialization — select On when you want the serial number to be programmed in the device.
Tasks and Kits Figure 3-16 The Serialization Process TASKLINK SERIALIZATION PARAMETERS DIALOG BOX Operator provides TaskLink with "ESP" program name. PC HARD DRIVE 2 Calls "ESP" and passes parameters 1 "PROCESS DEVICES" Task runs -a -f -i -l -h -o -s -t skLink looks for "ser 4 Ta ial.d at" EXTERNAL SERIALIZATION PROGRAM (ESP) Written by user. Generates a serial number. Creates an ASCII file called "serial.dat." "serializ.exe" is a sample of a basic external serialization program.
Tasks and Kits Serialization Parameters TaskLink supplies a sample ESP called “serializ.exe” to use as a template for developing your program. The source code (named “serializ.c”) for this program is included with TaskLink. Figure 3-15 shows the Serialization Parameters dialog box. To use serializ.exe to place a serial number in programmer RAM, set the parameters as follows: Parameter Setting Serialization Method File RAM Serialization On Program serializ.
Tasks and Kits The following example gives these sample values for the parameters: a 10-character ASCII hexadecimal serial number at address 12345 (hexadecimal), increase the serial number by an increment of 2 for each device programmed, and print each serial number on the device label (in hexadecimal). The Program entry field in the Setup/Serialization dialog box might look like this: serializ.exe –l10 –fh –a12345 –i2 –h 3-26 Parameter Description –a Address of serial number.
Tasks and Kits Parameter Description –s Sumcheck calculation flag. Used to provide a new sumcheck for display on the TaskLink screen as new serial numbers are generated. This does not affect device data. –t Label text format. Defines how the serial number will be printed on the label. The options are either decimal or hexadecimal. –td = decimal –th = hexadecimal Default: Decimal (–td) –w Warning limit.
Tasks and Kits Programmer Interface — When this command is selected, TaskLink automatically displays a new set of menus so you can run diagnostic tests on the programming electronics. Refer to Chapter 5 for more information on running diagnostics on the programming electronics. Figure 3-17 Utilities Pull-down Menu VT100 on Programmer Port — Select this command when you update the Algorithm/System disk(s).
Tasks and Kits Options Pull-down Menu Many of the commands and options displayed on this menu are intended to be used with other products supported by TaskLink. To get information on these commands in TaskLink’s online Help, press F1. Only the commands used with the 2500 are described below. Figure 3-18 Commands Available from the Options Pull-down Menu Programmer Type and Handler Type Handler Sorting Selecting 2500 Text or Graphics automatically selects Handler type.
Tasks and Kits Programmer Port... and ProMaster Port... These screens allow you to change the configuration on the two RS-232C ports on the PC, which are configured for the Programmer Port on COM 1 and the Handler port on COM 2 using no parity, 8 data bits, and 1 stop bit. These settings should not need to be changed under normal operation. If you do change the configuration, you must exit TaskLink to save the new settings. Set Message Editor...
Tasks and Kits 3. Multiple User/Password Mode—In this mode, each user has a password and must enter it before TaskLink will display the main screen. Users are assigned an authorization level as either an administrator or operator (see Figure 3-20). Depending on the security level selected, you can configure TaskLink to require operators and administrators to enter their user name and password before the main screen is displayed (see Figure 3-20).
Tasks and Kits Set Preferences... This set of check boxes allows you to configure some of TaskLink’s optional system prompts and operating preferences. Press F1 to invoke TaskLink’s online Help for more information on the choices presented. Figure 3-21 Configuring Operating Preferences Two of the options that are particularly useful with the ProMaster 2500 are described in the following sections.
Tasks and Kits Introduction to Kits Kits are Tasks that have been daisy-chained together so several can be run as one large job. The most common use for Kits is to string together the separate Tasks used to program all the devices for a single board. In Figure 3-23 there are four devices that must be programmed and labeled for the sample board. Each device has one Task that controls the process for producing that device. The Kit acts like a super-Task.
Tasks and Kits Figure 3-23 Kits are a Series of Tasks in a Single Job Run Kit Specify • • • • • Task 1 Perform all Tasks in Kit Number of Kits to Build Session I.D.
Tasks and Kits Describing a Kit When TaskLink enters this dialog box the cursor is in the Description entry field. Enter a description of up to 40 printable characters. Figure 3-24 Edit Kit Screen Specify Source Database The Source Database is the xxxx.tsk file containing all the Tasks you include in the Kit you are creating. A Kit can only access one Source Database.
Tasks and Kits Set Number of Devices to be Processed Set Message Number Press TAB to move the cursor to the Quantity per Kit entry field. In most cases you will leave this at the default value of one, which means that one device with this data will be placed on each board. Move to the Message number entry field and enter a four-digit number corresponding to a screen message you will create.
Tasks and Kits Type the message you want TaskLink to display on the screen to prompt the system operator before the start of the next Task. Part of a sample tl.msg text file showing the ~0001 message that would be displayed before Task 2 is shown below, as it would appear in the unformatted file. ~0001 1. Change 2500 setup to program 32-pin DIP devices. -----> REMEMBER: This is a DIP device so Pin 1 goes to the right. 2. Change and calibrate labels. 3. Adjust track width. 4.
Tasks and Kits The requirements for user-created messages are described below: Creating Task/Kit Batch Files • Message file must be an ASCII text file. Save the file as an unformatted text file. • Message file must be called tl.msg. TaskLink looks for a file with this name. The maximum line length in this file is 66 characters. • Each message number must begin with a tilde (~), followed by four digits as in the following example: ~0023.
Tasks and Kits To run a batch file in operator mode, enter: tl -bBatchfile_name where -b starts the batch file mode and batchfile_name is any valid DOS file name. TaskLink does not require any specific file extension for batch files.
4 Operation For System Operators and Administrators Before you read this chapter, be familiar with the information in Chapter 1, especially the major components on the 2500. Chapter 1 has detailed drawings of the beam, track sections, and labeler that identify parts that will be referred to in this chapter. Chapter 1 also introduces TaskLink concepts and describes how to move around between items on the screen.
Operation What Is a Task? A Task is a job setup containing all the information necessary for programming and/or testing a particular part. A Task records all the parameters of the job setup from the device type and data file used to the label text printed and placed on the device. Once a Task has been selected, TaskLink performs most of the system setup automatically and prompts the operator to insert devices to begin processing.
Operation Figure 4-1 Overview of the Procedure for Starting a Task 3 1 7a 11b 2 6b 7b 5 4 11a 6a 8 12 Type "t l " on the PC keyboard 9 10 (Insert Screen) (Insert Screen) 1950-3 ProMaster 2500 User Manual 4-3
Operation Antistatic Precautions The devices that you will be handling and programming on the 2500 are sensitive to static and can be damaged by accidental and unintended electrostatic discharge while you are handling them. To minimize possible damage to devices, wear your wrist strap and plug the end into the ground strap connector in the lower left corner of the 2500 (see Figure 1-2).
Operation Starting the 2500 System The system has been configured to power up in remote mode, ready to communicate with TaskLink. To start the system, follow this brief procedure: 1. Turn on the 2500. The 2500 will power up in remote mode. 2. On your PC, move to the directory where TaskLink is installed. 3. On your PC keyboard from the DOS prompt enter tl The main TaskLink screen is displayed.
Operation Entering Your Password The system administrator may configure your ProMaster 2500 for a security level that requires you to enter a password before you see the main TaskLink screen. If your system is configured in this way, the first screen you see after starting TaskLink is a security screen (see Figure 4-3). Figure 4-3 Enter Your Name on the Security Screen Enter your username as the system administrator has defined it for the 2500. Press ↵.
Operation If you forget your password, the system administrator will have to remove your name from the list of users and then re-enter it. This allows you to start again with the default password. Checking TaskLink Communication with the 2500 To confirm that communication between TaskLink and the 2500’s programming electronics has been established, press CTRL + F1 on the PC keyboard. Note: The 2500’s power-up self-test takes approximately two minutes to complete.
Operation • Is a new label type needed? • If you changed label type, did you calibrate the labels? • Have you inserted the input tubes with the correct orientation for device pin 1? Descriptions for each of these adjustments are presented in the same order in the following sections. Configuring the Programming Module To support the widest variety of devices, the 2500’s programming modules are jumper configurable so they can support faster, higher density devices.
Operation Removing Modules or Moving Configuration Blocks This section describes the typical steps involved in checking and changing the configuration of your module. 1. Select the device—On the Device List disk, find the device you want to program in the left-hand columns. The module configuration for that device is listed in the column labeled “Base.” Sample lines from the Device List disk are shown below: Mfr. Part Number Programmer Menu Name Pins Package Type Footnotes Base Prod. Vers.
Operation Figure 4-7 Configuration Box Lid—Optional Configurations for 28-pin Module. X1 X2 X1 X4 X2 28A X3 X4 28A X3 PLCC 28-1 28A X1 X1 PLCC 28-2 X2 28B X4 28A X2 X4 X3 X3 28A PLCC 28-3 PLCC 28-4 PLCC 28-5 28C X1 X2 28D X4 28B X3 28E = NO CONFIGURATION BLOCK 1670-1 Figure 4-7 shows that the PLCC-28-4 requires two configuration blocks marked “28A” installed in connectors X1 and X3 on the programming module.
Operation Table 4-1 ProMaster Programming Module Configuration Chart Programming Module Type Pin Count Connector X1 Connector X2 Connector X3 Connector X4 PLCC-20-1 20 Open Open Open Open PLCC-20-2 20 Open 20A Open 20A PLCC-28-1 28 Open Open Open Open PLCC-28-2 28 Open 28A Open 28A PLCC-28-3 28 Open 28B Open 28A PLCC-28-4 28 28A Open 28A Open PLCC-28-5 28 28C 28D 28E 28B PLCC-32-1 32 Open Open Open Open PLCC-32-2 32 Open 32A Open 32A PLCC-44-1 44
Operation Installing a Programming Module Install the new programming module with the silk-screened X4 to the right (toward the input track). Guide pins on the 2500 will not allow you to install the module backwards. If the beam is centered over the programming station, insert the module at an angle into position as shown in Figure 4-8.
Operation 1. Remove devices from all three track sections. 2. Turn the track width adjustment knob counterclockwise until the track is at its narrowest setting. This step is important because it prepares the three track sections to be adjusted together and uniformly. Figure 4-9 Adjusting the Track Width — Turning the knob clockwise opens all three track sections together. DEVICE INDENT TRACK WIDTH ADJUSTMENT KNOB 1856-2 3. Begin opening (widening) the track. 4.
Operation Figure 4-10 Final Track Adjustment OPTIC STOP GUIDE DEVICE 1855-1 Note: Insert square PLCC devices in the input track with pin 1 oriented toward the back of the 2500. Insert rectangular PLCC devices (32 pin), DIP and SOIC devices in the track with pin 1 toward the input tube. 5. Slowly turn the track adjustment knob clockwise to widen the track until the device just drops into place on the track floor.
Operation Figure 4-11 Closeup View of Input Track with 8-pin 150-mil Device Keeper Bar Assembly Installed 2500-1 The device keeper bar assembly attaches to the mounting block with a pin that has a detent ball on the tapered end and a handle ring on the other end (see Figure 4-12). This allows the device keeper bar assembly to be installed easily and when processing 150 mil SOIC devices, and removed easily when processing other devices.
Operation Figure 4-12 8-pin 150-mil SOIC Device Keeper Bar Assembly Mounted in the Input Track 2501-1 Removing and Installing Chucks When you change to a new device package, select the appropriate chuck as shown in the chuck selection chart (see Figure 4-13). CAUTION: Chucks are released from the beam suddenly. If the beam is positioned over the SPA pins or input track, the sudden release may damage those areas. Change the chuck with the beam directly over one of the two main plate recesses.
Operation Replacing a Chuck Tip Remove the chuck from the beam and remove the old tip. The new tip should extend slightly beyond the metal end of the chuck so an airtight seal can be made. After it is on, lightly chalk the end of the tip before processing devices. Chalking decreases the possibility of a device sticking to the tip due to an accumulation of oils from being handled.
Operation Loading Labels The 2500 labeler prints using either a 24-wire in-line dot matrix printer or a thermal printer. Labels usually need to be changed each time a new device package type or different pin count is required by the Task you are going to run. Labels are positioned on a non-adhesive liner material so they will peel easily as they advance around the label platen’s point. The label part number and date code are written on a label attached to the inside of the label roll.
Operation Figure 4-15 Threading New Labels in the Dot Matrix Printer APPLICATION PLATE PLATEN PRESS BEARINGS E D C F B G A LABEL REEL COVER 1851-2 6. Unroll approximately two feet of liner. Thread it around the left of roller B, between C and D, and between the platen and press bearings. 7. Move roller B to the left so it pinches the label liner and holds it in position. Ensure that the labels are fully aligned between the underside of the platen and above C and D. 8.
Operation To calibrate labels, do the following: Loading Labels in the Thermal Printer 1. Place your finger next to the press bearings to “catch” the two or three labels that are advanced during the calibration process. 2. Press CAL on the 2500’s keyboard. 3. When the labels stop advancing, calibration is complete. Threading labels on the thermal printer/labeler is similar to threading labels on the dot matrix printer/labeler (see Figure 4-16).
Operation 10. Make certain that the label liner is flat against the underside of the platen. 11. Feed the liner back over the top of the platen and through the gap between the platen and the track. 12. Thread it between the label drive roller and the label pinch roller (see Figure 4-16). 13. Thread the liner between it and the drive roller. Guide the springloaded pinch roller back into its operating position against the drive roller. Make certain that there is no slack in the liner. 14.
Operation Calibrating Labels in the Thermal Printer The label optic must be calibrated to detect and synchronize with the labels after you have finished either one of the following operations: • Installing a new roll of labels • Changing the ribbon • Adjusting the ADC reference value • Manually moving the labels Perform the following steps to calibrate the labels. Installing Devices in the Input Track 1. Put your finger near the label application point (the right edge of the application plate).
Operation Figure 4-17 Installing Devices in the Tube Holder INPUT TUBE HOLDER SQUARE PLCC DEVICES TUBE INSERTED WITH DEVICE CONTACTS FACING UP INPUT TUBE HOLDER DIP/SOIC DEVICES TUBE INSERTED WITH DEVICE CONTACTS FACING UP PIN 1 NOTCHED CORNER PIN 1 1854-3 Running a Task Start TaskLink at the DOS prompt in the directory where TaskLink is installed. Type: tl After a few seconds, the Run Task/Kit list box appears (similar to the one shown in Figure 4-2).
Operation Selecting a Task Selecting a Database File To select a Task from the list presented on the screen, press TAB to move the cursor to the Task/Kit list box. Use the ↑ + ↓ to highlight a specific Task name. Press ↵ to start that Task. If the Task you are looking for is not displayed, it may be located in a different Task database file. To select a different Task/Kit database file, highlight the Task/Kit Database entry line and press F2.
Operation Sumcheck Status Box Depending on how the administrator configured the Task, this box may appear if you download your device programming data from a file or load a master device. The recorded sumcheck may be displayed (depending on how the Task was written) so you can confirm the number with your paper documentation. Press ↵ to continue or ESC to abort the Task if there is an error.
Operation If you start a Task with an incorrect number in the Parts/tube field, press STOP and then LOWER CASE + T. Enter the correct number. Press ENTER and then START to continue running the Task. This screen also indicates where TaskLink expects device pin 1 to be located when the device is in the input track. This is critical for correct device handling and insertion in the programming module socket. Make certain that your device matches this positioning.
Operation Aligning a Device to a PLCC Programming Module Whenever you run a new TaskLink Task or Kit using a PLCC device, the display on the 2500 prompts you to align the beam. Follow the procedure below to adjust the position of the beam so that it picks the device at its center and inserts the device into the programming module correctly. Failure to perform the alignment and cleaning procedures may cause premature wear of the module’s contacts and an eventual decrease in programming yield.
Operation 4. Press ← and → to center the chuck over the device (left-to-right). Pressing the arrow key once moves the beam one small step in that direction. Figure 4-22 Aligning Beam to the Device FRONT PANEL ARROW KEYS 1857-1 Note: You can change beam alignment while a Task is running. When the beam hesitates above the device, press STOP and use the front panel arrow keys. 5. Press and hold D on the 2500’s keyboard to lower the beam and check the position of the chuck on the device.
Operation 8. Press and hold D on the 2500’s keyboard to lower the device into the programming block so you can check the alignment. You may also lower the beam with your hand by pushing on either side of the beam’s limit bar (see Figure 1-7). Pushing on the beam head or any other part of the beam might distort the alignment.
Operation Check Front-to-back Position 9. After the device is centered right-to-left, check its front-to-back position by looking at the device and programming module from over the input track. Figure 4-24 Checking the Front-to-Back Alignment (looking from the perspective of the input track) FRONT OF 2500 X1 X3 X4 1859-2 10. If the device is centered over the programming module in the frontto-back axis, press START to resume operation.
Operation 4. Press START. The beam rotates the device 90° and moves it over the programming module. Push the beam down manually (on either side of the beam limit bar), and ensure that the device moves into the center of the programming module’s block. When the alignment is correct, press and hold D on the 2500 keyboard to check the device’s insertion. Repeat steps 1 through 4 until the device moves into the center of the programming module and does not rub one set of contacts more than another. 5.
Operation Aligning a Device to a DIP/SOIC/32-pin PLCC Programming Module When you process a device with a rectangular shaped body (DIP, SOIC, or 32-pin PLCC), the 2500 prompts you to align the first device in the job run. Follow these steps to align the beam to a device in the input track. The track width should be adjusted for the device before you begin this procedure (see page 4-12).
Operation Figure 4-27 DIP Device Alignment 1945-2 If the device is not aligned properly, release the D key, use the arrow keys to change the position, and lower the beam into the programming module to check it again. When you are satisfied with the left-to-right alignment, check the front-to-back alignment. See if the device is pushing either the front or the back contact set much more than the other. 7.
Operation 3. If the device was too close to the front of the programming module, press ↑ on the 2500’s keyboard once or twice. If the device was too close to the back of the programming module, press ↓ once or twice. 4. Press START. The beam moves the device over the programming module and stops. 5. Press and hold D on the 2500 keyboard to make certain that the device is equidistant between the front and back contact sets.
Operation Task Summary Screen The Task summary screen shows the programming yield in terms of the number of devices that passed and the number that failed for each specific error. Press ↵ to continue running the Task, or press TAB to select and ↵ to stop the Task and return to the main TaskLink screen. Figure 4-29 Task Session Summary Screen Exiting TaskLink ProMaster 2500 User Manual From the main TaskLink screen, press TAB to select and then press ↵.
Operation Introduction to Kits Kits are like super-Tasks. They are simply individual Tasks that have been joined together to make one large Task. Kits are used most often to organize the individual Tasks used to program all the devices on one board. In Figure 4-30, there are four devices that must be programmed and labeled for the sample board. Each Task controls the process for one device on the board.
Operation For example, assume that 60 boards need to be built. When the Kit for these boards is run, Task 1 processes 60 devices and then TaskLink displays a message prompting the system operator to change devices for the second Task. After the operator inserts the new devices for Task 2 and presses ↵, TaskLink starts Task 2 and another 60 devices for that Task are programmed. This process continues for Task 3 and Task 4.
Operation Running a Kit Kits operate very much like Tasks. If you are familiar with running a Task, you will find that the steps required to run a Kit are almost the same. The process of running a Kit is outlined in the steps below. Refer to Figure 4-31 to see the TaskLink screens associated with these steps. 1. Select a Kit from the Run Task/Kit list box. Kit names are displayed on the screen with bold characters, Tasks appear as normal characters. 2.
Operation Figure 4-31 Overview: Running a Kit (the number by each screen refers to the number of the step describing it on the previous page.
Operation Adjusting Track Air When you switch between devices of different sizes, to make sure that the devices advance smoothly down the track into the output tube, you may need to adjust the track air. See Figure 4-32 for the location of the track air adjustment knob.
5 Preventive Maintenance This chapter describes ProMaster 2500 theory of operation, diagnostics, and preventive maintenance procedures. Diagnostic tests are described for the motors, solenoids, optics, switches, and programming electronics. The information in this chapter is presented in the following order: Theory of Operation................................................................................ 5-2 Conditions Requiring Corrective Action ...........................................
Preventive Maintenance Theory of Operation This section describes the operation of each of the ProMaster 2500’s major components. TaskLink You will normally operate the 2500 under the system control of the TaskLink software program, running on a personal computer (PC). TaskLink uses a set of computer remote control commands to communicate with the 2500. These commands control the programming, handling, labeling, and binning operations of the 2500.
Preventive Maintenance Figure 5-1 Optic and Microswitch Locations 17 3 4 19 1 15 (Under main plate) 2 22 13 11 14 23 12 16 (Under main plate) 20 (Output tube 1) 21 (Output tube 2) 1939-1 3. The tube is shaken by the input orbital assembly to help devices slide from the tube onto the input track. The base of the input tube clamp is mounted to a plate. The orbital disk mounting shaft is drilled offcenter and acts as a cam against the plate.
Preventive Maintenance Device Is Inserted into Programming Module Device Is Programmed 4. A device, positioned against the programming station stop guide, blocks the beam of the part detect optic. The handler detects the blocked optic and advances the beam until it is centered over the device (the location is determined by the pre-defined package size downloaded by TaskLink). The handler’s firmware stores the package dimensions for all supported package types.
Preventive Maintenance • Security fuse check—Some devices have a security fuse feature that, when programmed, prevents the reading of the main fuse pattern. Some semiconductor manufacturers allow the programmer to check the fuse before trying to program the fuses in the main array. If the security fuse is blown, the device cannot be read or programmed and TaskLink displays SECURITY FUSE VIOLATION. • Check silicon ID—Many devices have internal identification numbers (an electronic I.D.
Preventive Maintenance If the device programs without errors, the PE goes to a verify cycle. Most semiconductor manufacturers specify setting the device VCC to two different levels during the device verify cycle, one above and the other below the nominal operating VCC. All fuses in the device are verified at each level. This tests the device to make certain that the correct data is read when the device’s VCC pin is set slightly below and above the nominal VCC level.
Preventive Maintenance Optics Optics detect and monitor the location of devices, the movement and position of the beam, labeler movement, orbital motor positions, label position on the liner (the translucent label backing material), and position of the ribbon and ribbon pinch roller in the thermal printer (25 and 26 in Figure 5-1). The optics are mounted in pairs at various places on the handler.
Preventive Maintenance The beam has a traverse motor (with an encoder) that moves the beam along the lead screw in its horizontal (left-to-right) travel. The encoder counts the number of steps the beam travels from the home position and sends that information to the main board. The beam assembly also has a beam rotate motor that controls the rotation of the device on the chuck. The 2500 has three additional stepper motors.
Preventive Maintenance System Air Flow Low Air Pressure Beam Up/down Air enters the 2500 through a 1/4-inch air connector on the rear and branches through a Y connection to the low and high air pressure regulators (see Figure 5-2). The air exits each regulator in two ways: to the gauge (to display the PSI) and through the 2500 as described below. Low air pressure should be set to 30 PSI, and high air pressure should be set to 85 PSI.
Preventive Maintenance When the beam lowers, it is driven down by low pressure air routed through hole 12. This air enters the hi/low valve assembly through hole 19 and pushes the ball bearing up, sealing off hole 21 and creating a path to hole 20. From hole 20, the low pressure air is forced to hole 18, pushing down on the fixed piston and lowering the beam. This air is vented through exhaust holes on the bottom of the beam assembly.
Preventive Maintenance Figure 5-3 Beam Air Holes 16 17 4 11 12 21 5 18 20 19 21 17 20 18 BEAM AIR CYLINDER 19 2387-1 Label Application When solenoid 3 is selected (see Figure 5-15), low pressure air is passed to the beam assembly. When the 2500 prepares to apply a label on a device, the beam lowers (with low air pressure) the device on the application plate, and then solenoid 3 is turned off to bleed the low pressure line.
Preventive Maintenance High Air Pressure Beam High pressure air is routed from the high pressure regulator to a Y connection and is divided into beam high pressure and programming module clamp assembly air pressure. The beam high pressure air is routed to the beam by a black air line that passes through the beam and into a straight-in air fitting on the back right side of the beam.
Preventive Maintenance The Controller Board The components of the controller board are listed below. • LEDs—Used for a quick visual check on the status of various power supplies, solenoids, and certain logic signals. • Connectors— Route control signals to optics, microswitch, motors, solenoids, and other components of the handler.
Preventive Maintenance Figure 5-4 Power Supplies PROGRAMMING ELECTRONICS CONTROLLER BOARD +15V GND (TO BEAM TRAVERSE MOTOR) (TO BEAM) NC GND +5V SOLENOID CLAMP (TO SOLENOIDS 2 AND 3) MAIN PLATE (Underside) TB2 BACK OF BASE +15V 1 J1 GND 1 J2 NC 1 120Vac 1 97Vac 120V GND AC IN 220 120 100 J3 J4 MOTORS ** 1 +24V +24V GND J24 NC J2 NC +5V GND +12V NC -12V J27 BOTTOM OF BASE CONTROLLER BOARD J25 J25 1 NC NC +24V 1 +36V GND +36V J11 * DISK DRIVE 0 24 0 24 24 24 J24 J2 +90V
Preventive Maintenance Dot Matrix Label Printer The dot matrix label printer (also simply referred to as labeler) uses a 2 x 12-wire, in-line dot matrix print head to print labels. The labels are on a roll of label liner that is threaded through the labeler assembly from a label supply reel. The labeler can print a maximum of three lines of text on a label. The label drive motor is the second motor mounted behind the labeler assembly plate.
Preventive Maintenance Table 5-1 ProMaster 2500 Label Print Guide (Dot Matrix Printer) Label Model Number & Dimensions 12 CPI Tall 16 CPI Tall 18 CPI 20 CPI 26 CPI 26 CPI* Short 300 MIL DIP (14-20 PIN) QF-06-20 3/16” X 5/8” (.187” X .625”) 7 (L=1) 10 (L=1) 11 (L=2) 11 (L=2) 15 (L=2) 15 (L=3) 300 MIL DIP (20-28 PIN) QF-06-24 3/16” X 3/4” (.187” X .750”) 8 (L=1) 12 (L=1) 13 (L=2) 14 (L=2) 18 (L=2) 18 (L=3) 300 MIL DIP (24-28 PIN) QF-06-26 3/16” X 13/16” (.187” X .
Preventive Maintenance Thermal Label Printer The thermal label printer (also referred to simply as the labeler) uses a thermal print head to print labels. The labels are supplied on a roll of label liner that is threaded through the labeler assembly from a label supply reel. The number of lines that the labeler can print on a label is determined by the size of the font selected. The label drive motor is the only motor mounted behind the labeler assembly plate.
Preventive Maintenance Table 5-2 ProMaster 2500 Label Print Guide (Thermal Printer) Label Model Number & Dimensions 11 CPI 16 CPI 19 CPI 22 CPI 28 CPI 28 CPI* Short 300 MIL DIP (14-20 PIN) QF-06-20 3/16” X 5/8” (.187” X .625”) 6 (L=1) 10 (L=1 ) 11 (L=2) 13 (L=2) 17 (L=2) 17 (L=3) 300 MIL DIP (20-28 PIN) QF-06-24 3/16” X 3/4” (.187” X .750”) 8 (L=1) 12 (L=1) 14 (L=2) 16 (L=2) 20 (L=2) 21 (L=3) 300 MIL DIP (24-28 PIN) QF-06-26 3/16” X 13/16” (.187” X .
Preventive Maintenance Programming Electronics Boards and Assemblies The PE is composed of two main units that are mounted on the underside of the handler’s main plate at the programming station. The PE’s major assemblies are described in the following section. • Power Supply—The input AC generates +15V DC that is routed to the controller/waveform board’s internal power supply circuits. • Controller/waveform Board—Uses +15V (from the power supply) to generate a precise +10V reference.
Preventive Maintenance Self-calibration • Pin Driver Board(s)—Internally generated supply voltages serve as inputs to the pin driver circuits from the waveform section of the controller/waveform board. Control signals from the PCU coprocessor on the controller/waveform board are also received and used by the pin driver circuitry on the board to shape programming waveforms.
Preventive Maintenance TaskLink also allows you to download device data from a file on your PC. TaskLink sends the PE information on the data file format and then downloads the file. The PE translates the formatting information in the file, discards all formatting characters and stores the data in RAM. The PE signals TaskLink when it completes writing the file data into RAM. TaskLink then sends the “program” command to the PE and the device is programmed.
Preventive Maintenance Faulty Printing Printing Is Too Light The ribbon is worn or broken, the print head is worn, or the print head gap is too great. Replace ribbon, or print head. Adjust the print head gap (see page 5-24). Characters Too Close Together Labels are loaded incorrectly, the rollers are dirty, or the motor or drive circuitry is not operating properly. Load the labels correctly, clean the rollers, and make sure the pinch rollers are engaged (see page 2-9).
Preventive Maintenance Chuck Is Handling Devices Incorrectly The chuck does not work correctly with the devices you are using. Ensure that you are using the correct chuck size for the devices you are processing. Refer to the chuck selection chart on page 4-16. Replace the rubber chuck tip. Confirm that high and low air pressure gauges are set to the correct levels. Make sure there are no air leaks.
Preventive Maintenance Corrective Adjustments Changing Dot Matrix Printer Ribbon Cassette Refer to the procedure on page 5-57. Changing Thermal Printer Ribbon Refer to the procedure on page 5-59. Adjusting Dot Matrix Print Head Gap The print head gap is set at the factory and will not usually need to be changed. If there are substantial changes in the thickness of the label or label backing, however, you may need to make an adjustment.
Preventive Maintenance Adjusting Position of Print on Label (Dot Matrix Printer) Figure 5-6 Adjusting Label Calibration The left-to-right position of characters on the label is determined by label calibration. NORMAL HIGHER VALUE 1944-1 You can change the label calibration setting during a Task run by pressing STOP and then LOWER CASE + C. The 2500 displays: ENTER LABEL CALIBRATION VALUE (X): The X represents the current setting. The default setting places the first column of print within 0.
Preventive Maintenance Adjusting Press Bearings Make sure the dot matrix printer’s application plate is aligned correctly by holding a device in your fingers and sliding it across the application plate, over the press bearings, and onto the bearing plate (see Figure 2-8). The device should move smoothly across the press bearings.
Preventive Maintenance Label Calibration Change the label calibration value using the STOP command described in the following procedure. 1. Press STOP to pause the 2500 while a Task is running. 2. Press LOWER CASE + C. The 2500 displays: PROGRAM/TEST LABEL SLAVE MODE PART TOTAL: 251 LABEL CAL: (XXX) PART TYPE: DIP 24-.3 PART LENGTH: 1.250 where XXX represents a numeric value for the current setting. Label Advance 3. Press ↑ or ↓ to change the label calibration value (the range is from 0 to 255).
Preventive Maintenance 5. If necessary, remove the two screws that hold the guard in place. Loosen the collar and remove the ribbon drive roller assembly from the printer. Hold the roller with one hand and turn it with the other. If more than a small amount of friction is felt, adjust the collar counterclockwise until only a slight amount of friction is felt.
Preventive Maintenance Figure 5-9 Thermal Printer Ribbon Path PLATEN APPLICATION AREA PRINT HEAD (Retracted position) 4 RIBBON ALIGNMENT ROLLER 2 RIBBON PINCH ROLLER 5 6 RIBBON DRIVE ROLLER RIBBON ALIGNMENT ROLLER 1 RIBBON DETECT OPTIC RIBBON TAKE-UP ROLL 8 RIBBON ROLL 1 2 3 2304-2 ProMaster 2500 User Manual 5-29
Preventive Maintenance Diagnostics The Diagnostics option allows you to run the diagnostic tests. Refer to Figure 5-10 for the Diagnostic command tree and refer to Appendix C for the 2500 wiring diagram and a diagram of the handler controller board layout.
Preventive Maintenance Figure 5-11 Inserting the Hood Interlock Switch 2516-1 Hood Interlock Key A hood interlock key is provided with each handler to allow service personnel to simulate a closed hood in order to run diagnostic tests. When the key is in position, the 2500 detects a lowered hood and will perform the solenoid and motor tests while the hood is raised. The hood cannot be lowered fully into its operating position while the key is installed.
Preventive Maintenance Optic Test The optic test verifies that the optics and microswitches are working correctly. To access the optic test, press 1 from the Diagnostics menu. The 2500 displays: OPTIC TEST - ADC = 200 - VAC = XX 11100000001111101111111100 ENC = 13107 | | | | | U15 REV X.XX 5 10 15 20 25 U43 REV X.XX where ADC represents the value when the label or liner is present, VAC represents the amount of beam vacuum, ENC is the traverse beam motor encoder position, U15 REV X.XX and U43 REV X.
Preventive Maintenance Figure 5-12 Optic and Microswitch Locations 17 3 4 19 1 15 (Under main plate) 2 22 13 11 14 23 12 16 (Under main plate) 20 (Output tube 1) 21 (Output tube 2) 1939-1 ProMaster 2500 User Manual • Tests 1 and 2, and 11 through 14—Trigger these optics by blocking them with an opaque object. • Tests 3 and 4—Push straight down on the beam head to perform these two tests.
Preventive Maintenance Adjusting the ADC (Label Detecting) Optic on the Dot Matrix Printer • Test 25—Lift the main plate. • VAC—Press V to toggle the vacuum generator on and off. When the vacuum generator is on, place your finger over the end of the chuck to seal the opening and the VAC value should be greater than or equal to 140. You may need to adjust the ADC optic if you have trouble with label calibration, label position, or location of printed text, especially if you have just changed labels.
Preventive Maintenance Figure 5-13 Adjusting the Dot Matrix Printer ADC Optic During Calibration PLATEN PRESS BEARINGS APPLICATION PLATE (Raised) LABEL DRIVER ROLLER PRINT HEAD ADC OPTIC (1 of 2) PINCH ROLLER 2 PINCH ROLLER 1 SPRING CLIP (1 of 2) RIBBON CASSETTE LABEL ADVANCE KNOB RIBBON ADVANCE KNOB LABEL SENSING OPTIC LABEL REEL COVER LABELING STATION 1770-2 Adjusting the ADC Optic on the Thermal Printer The ADC optic detects the leading edge of the label on the liner.
Preventive Maintenance Always calibrate the labels (refer to the procedure on page 5-25) after performing either one of the following operations: • Installing a new roll of labels • Changing the ribbon • Adjusting the ADC reference value • Manually moving the labels To check and manually adjust the ADC value, follow the steps below: 1. Put the 2500 in local mode. 2. Select OPTIC TEST from the DIAGNOSTIC MENU and load labels. 3.
Preventive Maintenance Figure 5-14 Thermal Printer, Front View, Showing the ADC Label Optic APPLICATION PLATE (raised) LABEL ADC OPTIC PLATEN PRINT HEAD (retracted position) LABEL DRIVE ROLLER (hidden) LABEL PINCH ROLLER PLATEN PINCH ROLLER LABEL ADVANCE KNOB LABEL ALIGNMENT ROLLER LABEL DETECTION OPTIC LABEL ROLL (cover removed) 2303-1 ProMaster 2500 User Manual 5-37
Preventive Maintenance Solenoid Test Run this test to evaluate the operation of the solenoids. Note: You can also manually test each solenoid by pressing on the actuator button on the side of each solenoid. WARNING: Performing these diagnostic procedures will expose you to harmful high voltage. Only a service technician trained on electromechanical equipment should perform the diagnostic tests described in this manual.
Preventive Maintenance Figure 5-16 Solenoids on the Beam (test numbers shown) 7 6 5 4 1940-1 To see the LEDs on this board (located in the 2500’s base), loosen the two corner screws that hold the main plate in position on the base and raise the main plate. Figure 5-19 shows the location of the board. An LED on that board illuminates when the solenoid control circuitry is sending a signal to activate the solenoid.
Preventive Maintenance The solenoids perform the following operations (confirm that LEDs on the solenoids turn on for the duration of each test): • Blower — Turns on low air pressure to the output tracks. There is no air on the input track. • Cutoff — Turns low air pressure to the beam on and off. If you are running all tests, perform the cutoff test first when you enter the diagnostic tests. At the start of the diagnostic tests, the beam should be up.
Preventive Maintenance Figure 5-17 Location of the Motors (3) BEAM ROTATE (5) TUBE OUTPUT (4) TUBE INPUT (1 + 2) BEAM TRAVERSE (6) LABELER (Hidden) MOTOR ENCODER 1942-2 Test No. Motor Description 1 Beam Forward 2 Beam Reverse 3 Beam (Head) Rotate 4 Tube Input (Orbital) 5 Tube Output (Orbital) 6 Label Drive Note: The beam traverse motor (tests 1 and 2) may appear to stall or fail. This could be caused by a dirty or dry lead screw.
Preventive Maintenance Cycle Parts This option inserts devices into the programming module without programming them. It differs from the diagnostic tests because it allows you to assess the following system operations under operating conditions without having to program devices: • Beam movement • Vacuum generator functionality • High and low air pressure • Applying labels to devices To select Cycle Parts, press 4 from the Diagnostic menu.
Preventive Maintenance Enter a new number, or accept the default, and press ENTER. The 2500 displays: CYCLE PARTS PART TYPE: PLCC 20 PART LENGTH: .390 PRESS START TO BEGIN Press START and the 2500 displays: CYCLE PARTS COMM: NO INTERFACE PARTS PER TUBE: 5 PART TOTAL = 0 PART TYPE: PLCC 20 PART LENGTH: .390 PROGRAM TARGET: INF When you are finished with the test, press RESET. To Label Devices If you want to label devices, press Y at the DO YOU WANT TO LABEL? display.
Preventive Maintenance To select a custom device for which you determine the length, move the cursor to CUSTOM, and press ENTER. The 2500 displays: PROGRAM/TEST LABEL TEMPORARY FILE ENTER PART LENGTH: _ EXAMPLE: 1.234 OR .28 OR 1 Type the length of your device in inches, up to three decimal places and under 2.250 inches. Press ENTER. If you type an invalid number, the 2500 displays: PROGRAM/TEST LABEL TEMPORARY FILE ENTER PART LENGTH: _ LENGTH CAN NOT EXCEED 2.250 Type a valid number and press ENTER.
Preventive Maintenance Figure 5-18 Recommended Orientation of Pin 1 for DIP and PLCC Devices FRONT PANEL DISPLAY IN INPUT TUBE 1 SQUARE PLCC DIP, SOIC 32-PIN PLCC 1 1256-2 Text Rotation The 2500 displays: 1 TXT TEMPORARY FILE SELECT POSITION OF PIN 1 IN RELATION TO THE TEXT. USE ARROW KEYS THEN PRESS ENTER. Select a text rotation value and press ENTER. Device Orientation in Receiving Tube The 2500 displays: 1 <------- TEMPORARY FILE SELECT POSITION OF PIN 1 AS IT WILL GO INTO THE TUBE.
Preventive Maintenance Up to three lines of text with 25 characters per line are available, but the number of lines and characters that will fit on a device is limited by the size of the device, and type (font). See the charts on pages 5-15 and 5-17. Three lines is the maximum number currently available. Enter the text you want on the label. Existing text is overwritten. To delete a character, move the cursor one space to the right of the character you want to delete, and press DEL.
Preventive Maintenance Figure 5-19 Interior View of the 2500’s Base MAIN PLATE CONTROLLER BOARD 1931-2 Figure 5-20 Print Head LEDs on Handler Controller Board CR51 CR87 CR63 CR111 CR75 CR99 CR52 CR88 CR64 CR112 CR76 CR100 CR53 CR89 CR65 CR113 CR77 CR101 CR54 CR90 CR66 CR114 CR78 CR102 +5V -12V +12V +36V U43 EPROM S4 S2 S3 S1 +24V S8 S7 +90V U15 EPROM S5 S6 1955-2 ProMaster 2500 User Manual 5-47
Preventive Maintenance Key/Display Test This test verifies that the keypad keys and the display dot matrixes are operating correctly. To select the Key/Display test, press 6 from the Diagnostic menu. The 2500 displays: PRESS 1 FOR KEY TEST, 2 FOR DISPLAY TEST Testing the Keys Press 1 and the 2500 displays: PRESS KEYS TO TEST, STOP TO ABORT Press the keys you want to check. The characters for these keys appear on the display, in the first column of the second row.
Preventive Maintenance During the test, the 2500 displays: EEPROM TEST IN PROGRESS PRESS ANY KEY TO ABORT If an EEPROM memory error is found, the test is stopped. The 2500 displays: EEPROM TEST - PRESS ANY KEY TO START EEPROM ERROR AT LOCATION XXX Press any key, except RESET, to return to the Diagnostics menu. (Pressing RESET returns you to the Main Menu.) Replace the EEPROM if it fails this test.
Preventive Maintenance Press a key on the terminal keyboard. If the port is operating properly, the character you typed appears on the terminal display. If random characters are displayed, the baud rates may not match, or there may be a problem in the handler or terminal port. Press any key to end the test and return to the Communications Diagnostic menu.
Preventive Maintenance Checking the Reference Points The programming electronics (PE) assembly in the ProMaster 2500 has no service calibration potentiometers that need to be adjusted. The procedure described below explains how you can confirm the critical reference levels that must be present for the programming electronics assembly to run its performance verification and self-test accurately.
Preventive Maintenance 2. Check the 8 MHz programming electronics clock frequency by placing the ground probe of your scope (or frequency counter) on pin 1 (ground) and the input probe on pin 28 (see Figure 5-22). The clock frequency should read between the minimum and maximum values shown below: 3. Minimum Nominal Maximum 7.999 MHz 8.000 MHz 8.001 MHz Check the +10V precision reference by reading pin 78 (+10V) using your digital multimeter (see Figure 5-14).
Preventive Maintenance Figure 5-22 Test Points on the MSM 78-pin Connector 40 39 PIN 28 (8MHz) PIN 24 (+15V) PIN 72 (Plugged) PIN 78 (+10V) PIN 1 (Ground) 78 1 2143-1 4. Check the +15 reference by reading pin 24 (+15V) on the connector block (see Figure 5-14). The +15V signal should read between the minimum and maximum values shown below: Minimum Nominal Maximum +14.25V +15.00V +15.75V This completes the performance verification for the programming electronics assembly.
Preventive Maintenance 4. Press F1. If you are prompted to select a new terminal type, press ↵ to accept the default. 5. Select M (More Commands) and S (Self-test) to get to the Self-test screen. 6. Select the One Pass mode to perform all the displayed tests once. 7. Move the cursor to the Test Mode field and press SPACE. You may stop the test by pressing CTRL + Z. There may be a delay before the system responds to the CTRL-Z if you are testing system RAM.
Preventive Maintenance Note: A programming module must be installed to run the programming module/relays test. To install and clamp a programming module a Set any programming module in the programming station. b Put the 2500 in local mode and start the Optic diagnostics test (see page 5-32). c Press C to toggle the programming module clamps closed. d Run the programming electronics self tests. When the testing is complete, press C to open the clamps, and remove the module. 9. Mass Storage Module 10.
Preventive Maintenance Daily Procedures System Self-check The 2500 performs a self-check and system performance verification each time you turn it on. The software sets specific output levels for the power supplies and then reads these values to confirm that they are within internal the correct operation ranges. We recommend that you cycle the system power once every 3 months so that these self-checks are performed.
Preventive Maintenance Programming Module Dot Matrix Printer Label Path Remove the programming module from the 2500, and blow compressed air into the programming module before the start of every Task or after every 1,000 devices, whichever occurs first. To ensure continued proper functioning of the dot matrix printer, you must keep the label path clean. An accumulation of dirt and debris along the label path can lead to jams at the print head and a decline in print quality.
Preventive Maintenance Figure 5-23 Removing the Ribbon Cassette SPRING CLIP (1 of 2) RIBBON CASSETTE 2296-1 2. Rotate the knob on the new cassette in the direction indicated by the arrow (counterclockwise) to pull the ribbon taut. 3. Guide the new cassette so the ribbon fits between the print head and the platen. Figure 5-24 Installing a New Dot Matrix Printer Ribbon Cassette PRINT HEAD SPRING CLIP (1 of 2) RIBBON CASSETTE RIBBON ADVANCE KNOB 1852-2 5-58 4.
Preventive Maintenance Replacing a Thermal Printer Ribbon When the ribbon roll runs out install a new roll to replace it. Each new ribbon roll has a long leader to thread through the labeler. Follow the procedure below to install the new ribbon (refer to Figure 5-25). 1. Prepare the ribbon threading path by pushing the ribbon pinch roller to the right. 2. Install the ribbon take-up core (one empty core is supplied with the printer) on the ribbon take-up hub.
Preventive Maintenance Repairing a Torn Thermal Printer Ribbon 5. Guide the pinch roller back into its operating position against the drive roller. 6. Use the tape supplied on the end of the leader (or a DIP label) to attach the leader to the take-up cardboard core. 7. When you install a new ribbon, remove the old ribbon’s cardboard core and install it on the take-up hub as the new ribbon take-up core. 8.
Preventive Maintenance Cleaning Guidelines Cleaning the Beam Follow the steps below to clean and lubricate the beam. CAUTION: This procedure should be performed only by a qualified service technician or by the system administrator. Replacing the Beam Filter 1. Turn off the 2500 and remove the power cord. 2. With a clean, dry cloth, wipe the center connecting rod and the two outer beam guide posts until no lubricant or dirt remains. 3.
Preventive Maintenance Follow the steps below to clean the PLCC module’s contacts. CAUTION: This procedure should be performed only by a qualified service technician or by the system administrator. 1. Blow compressed air into the top of the programming module to remove any device package debris. Use a rotating motion with the air nozzle to ensure that you reach all areas. 2. Use the DeoxIT pen to apply conditioner directly to the module’s contacts.
Preventive Maintenance Cleaning and Lubricating the Beam Lead Screw Lubricate the lead screw, beam shaft, and carriage shafts (see Figure 5-26) approximately every three months or as needed. CAUTION: This procedure should be performed only by a qualified service technician or the system administrator. 1. Turn off the 2500 and remove the power cord. 2. With a clean cloth, wipe the lead screw and the front and rear beam carriage shafts until no lubricant or dirt remains.
Preventive Maintenance Track Adjustments Adjusting Track Height You may have to adjust the track height to compensate for the varying thickness of different device tubes. Use a 50-mil hex wrench to raise or lower the height of the track. Follow the steps below. 1. Insert the 50-mil hex wrench into one of the track height adjustment screws (see Figure 5-27). 2. Turn the track height adjustment screw clockwise to raise the track height, or counterclockwise to lower the track height.
Preventive Maintenance Figure 5-28 Input and Output Track Funnel Adjustment TRACK ENTRANCE (Make wider by .010") TRACK ENTRANCE (Make wider by .010") INPUT TRACK OUTPUT TRACK 2284-2 Adjusting the Track Width Cables All three tracks should have the same track width and be adjusted equally. If one of the tracks is out of adjustment with the others, you may have to perform the track width adjustment procedure. To perform the track adjustment procedure, follow the steps below.
Preventive Maintenance Figure 5-29 Adjusting the Track Width Cables PUSHING THESE CABLES WILL NARROW THE TRACK or PULLING THE CABLES WILL WIDEN THE TRACK INPUT TRACK * OUTPUT TRACK 1 * (Right track) OUTPUT TRACK 2 * (Left track) * Turn clockwise to make tracks wider Turn counter-clockwise to make tracks narrower SET SCREW (1 of 4) CABLE PINCH BLOCK 2285-1 5-66 5.
Preventive Maintenance Maintenance Intervals Interval Component 2500 Operator 2500 Service Every Day Programming module Track Beam chuck tips Optic holes Beam-to-programming module alignment Label path Clean with air Clean Inspect/clean Inspect/clean Inspect Clean – – – – – – Every Week Programming module contacts – Clean with DeoxIT Every Month Dust guards Operator’s maintenance (see page 5-55) Keyboard and display Beam chuck tips Labeler ribbon Label platen area Programming module contacts L
Preventive Maintenance 5-68 ProMaster 2500 User Manual
6 Troubleshooting This chapter describes ProMaster 2500 messages and contains troubleshooting flow charts. Use the flow charts to help determine the likely cause of problems you may experience while operating the 2500. Some of the items listed in the flow chart refer to repair and replacement procedures that should be performed by trained service technicians. These repair and replacement procedures are described in Chapter 7. The information in this chapter is presented in the following order: Messages.....
Troubleshooting 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.
Troubleshooting 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.
Troubleshooting 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.
Troubleshooting Check to see if the beam up solenoid (4) is functioning properly. Check the red LED on the solenoid itself (see Figure 5-16) to see if it turns on during the test. Use a small hex wrench to depress the manual test button on the side of the solenoid to see if the beam rises. If it does not move up, check the air pressure or check for leaks in the air line. Replace the solenoid if necessary. UNABLE TO RELEASE DEVICE, PRESS START Low air pressure may be too low.
Troubleshooting Troubleshooting Flow Charts These troubleshooting flow charts help you do the following: • Isolate the area where the problem is occurring. • Determine whether a malfunctioning component or assembly requires cleaning, adjusting, or replacement. • Go to the page in the manual that describes the appropriate procedure. The following flow charts are included on the following pages: Power-up Failures .........................................................................................
Troubleshooting The beam moves quickly. To avoid injury, keep your hands, hair, and loose clothing away from the path of the beam.
Troubleshooting Figure 6-1 Power-up Failures (page numbers are in parentheses) Start Does 2500 power up in remote or local mode? No Does 2500 display handler message? No Check main fuse (7-2) Check Toroid & controller board power supplies (5-13) Yes Yes Go to Start Record message & try to solve problem. If unsuccessful, call Customer Support.
Troubleshooting ProMaster 2500 User Manual 6-9
Troubleshooting Figure 6-2 The Beam Does Not Pick Up the Device Correctly (page numbers are in parentheses) Start Is device in correct position at pickup point? No Yes Does device exit tube? No Adjust track width (4-12) Adjust track height (5-64) No Adjust track width (4-12) Check tube input motor test (5-32) Check devices for residue Yes Does device get to pick-up point? Yes Is beam over pick-up point? No Yes Does beam move along lead screw? No Check +90V beam voltage (5-13) Check motor
Troubleshooting ProMaster 2500 User Manual 6-11
Troubleshooting Figure 6-3 The Beam Does Not Insert the Device Correctly into the Programming Module (page numbers are in parentheses) Start Is beam over programming socket? No Yes Does beam move smoothly & align above socket ? No Yes Check +90V beam voltage (5-13) Check motor fuses F5 to F8 (schematic) Check motor driver circuit U25 to U27 and Q1 to Q4 (schematic) Check flex coupler (7-21) Check for mechanical obstructions Clean & lubricate lead screw (5-63) Reduce beam motor speed (B-3) Check wir
Troubleshooting ProMaster 2500 User Manual 6-13
Troubleshooting Figure 6-4 Programming Failures (page numbers are in parentheses) Start Acceptable continuity/device insertion failure rate? No Try another programming module & check alignment (4-27) Clean programming module contacts (5-61) Replace programming module contacts (7-28) or block (7-36) Yes Acceptable program/verify failure rate? Go to Start No Check PE reference voltage (5-51) Run PE self test (5-50) Try another programming module & check alignment (4-27) Clean programming module cont
Troubleshooting ProMaster 2500 User Manual 6-15
Troubleshooting Figure 6-5 Label Printing Problems, Dot Matrix Printer (page numbers are in parentheses) Start Does labeler print anything? No Run Print Test (5-46) Check labeler power supply (5-13) Check cables Replace ribbon (5-57) Yes Are all dots in characters printed? No Run Print Test (5-46) Check +24V labeler power supply (5-13) Replace print head (7-12) Check/swap cable Check label supply Replace ribbon (5-57) Yes Are all characters printed on label? No Run label calibration (2-11) Chec
Troubleshooting ProMaster 2500 User Manual 6-17
Troubleshooting Figure 6-6 Label Application Problems, Dot Matrix Printer (page numbers are in parentheses) Start Does beam hold device? No See Figure 6-2 (6-8) Yes Does device align over labeling station? No Does beam move along lead screw? No Check +90V beam voltage (5-13) Check motor fuses F5 to F8 (schematic) Check motor driver circuit U25 to U27 and Q1 to Q4 (schematic) Check flex coupler (7-21) Check beam obstruction Check wiring & connectors Yes Yes Does beam move smoothly & align over la
Troubleshooting ProMaster 2500 User Manual 6-19
Troubleshooting Figure 6-6 (continued) Label Application Problems, Dot Matrix Printer (page numbers are in parentheses) A Does part of label extend over edge of device? Yes Clean ADC optic hole (5-56) Adjust ADC optic value (5-34) Adjust advance label value (B-2) Clean label path (5-57) Clean pinch rollers (5-57) Check & adjust height of application plate (2-9) Check label stock No Does beam hold device during labeling? Go to Start No Check & adjust bearing plate (2-9) Check chuck size (2-8) Check
Troubleshooting ProMaster 2500 User Manual 6-21
Troubleshooting Figure 6-7 The Beam Does Not Deliver the Device Correctly (page numbers are in parentheses) Start Does the device arrive at the output track? Check for mechanical obstructions Check +90V beam voltage (5-13) Check flex coupler (7-21) Clean & lubricate lead screw (5-63) Reduce beam motor speed (B-3) Check wiring & connectors No Yes Does beam lower to output track ? No Does an object block beam? No Check low pressure air (2-7) Check beam up/down solenoid (5-38) Check beam down optic t
7 Repair and Replacement Procedures This chapter contains instructions for replacing failed components. These component replacement procedures should be performed by qualified service personnel only. Please refer to Chapter 6, “Troubleshooting,” to determine which ProMaster 2500 component may be malfunctioning and may require replacement. The flow chart in Chapter 6 will help you identify a specific component failure and direct you to the appropriate cleaning, adjustment, or replacement procedure.
Repair and Replacement Procedures Fuse Replacement The main fuse is located behind the power cord input assembly. Perform the following procedure to replace the main fuse. CAUTION: For continued protection against the possibility of fire, replace the blown fuse only with a fuse of the same voltage, current, and type. 1. Turn off the 2500 and remove the power cord. 2. Use the edge of a flat-blade screwdriver to pry open the door covering the fuse holder, as shown in Figure 7-1.
Repair and Replacement Procedures 5. Insert the fuse holder into its slot with the arrow pointing in the same direction as the arrows on the door and snap the door closed. Programming Electronics Assembly Replacement Removing the PE Follow the steps below to remove the PE assembly from the 2500. The PE assembly is mounted on the underside of the 2500’s main plate. You will need to raise the main plate and use a 7/64-inch hex wrench to complete the removal procedure.
Repair and Replacement Procedures 5. 7-4 Disconnect the red and black power cable from the connector on the left side of the controller/waveform board. (Figure 7-4 shows the location and polarity of this cable.
Repair and Replacement Procedures Figure 7-4 Polarity of the Cables on the Programming Electronics Assembly TO MAIN CONTROLLER BOARD TO TERMINAL PORT TERMINAL REMOTE RED AND BLACK POWER CABLE R R B B CONTROLLER/ WAVEFORM BOARD BL R SYSTEM FAN (TOP) R R R B B B PROGRAMMING ELECTRONICS POWER SUPPLY (BOTTOM) DISK DRIVE 2056-2 6. Locate the wide ribbon cable that connects the controller/waveform board with the disk drive.
Repair and Replacement Procedures Figure 7-5 Remove the Module Clamp Assembly Screws SCREW LOCATION (1 of 6) 2313-1 10. Holding the programming electronics from the bottom, remove the last two screws. Lower the programming module clamp assembly and let it rest on the black protective shield. Note: Hold the programming module clamp assembly in place (from below the main plate) when you remove the assembly from the main plate. 11. Disconnect the two optic cables (S-24 and C-25).
Repair and Replacement Procedures Figure 7-6 Lower the Clamp Assembly and Remove the Retaining Bar RETAINING BAR PROGRAMMING MODULE CLAMP ASSEMBLY PROGRAMMING ELECTRONICS ASSEMBLY HEX HEAD SCREW MAIN PLATE (Underside) A J S SHIFT B K T DEL C L U D M V E F G H Q P N O Z Y W X SHIFT I R LOW ENTER CASE 1 2 3 6 4 5 9 7 8 0 CAL RESET START STOP 2070-2 14. Carefully slide the programming electronics assembly away from the clamp assembly.
Repair and Replacement Procedures Installing the PE Assembly Follow the steps below to install the programming electronics assembly in the 2500. 1. Turn off the 2500 and remove the power cord. CAUTION: Pins in the pin block are delicate and could be damaged if they hit components mounted on the underside of the main plate. The pin block cover ensures that these pins are not damaged while you are removing or reinstalling the PE assembly. 2. Carefully slide the PE assembly onto the clamp assembly.
Repair and Replacement Procedures 4. Remove the two 3/32-inch hex screws that hold the rear orbital alignment block to the underside of the main plate. Slide the rear orbital alignment block off the dowel pin, and let the block dangle from the cables. 5. From above the main plate, remove the two 3/32-inch hex screws that hold the front orbital alignment block to the main plate. Remove the front orbital retaining block from the underside of the main plate.
Repair and Replacement Procedures 10. Remove the orbital cam from the motor shaft. Now you are ready to remove the input orbital motor. 11. Unplug the Molex motor cable J-12. The end of this connector is located under the main plate and will not fit through the main plate hole. Remove the four pins in the connector to free the cable. Note the wire colors and positions in the connector (see Figure 7-9). Figure 7-9 Note the Wire Colors and Positions POINT GREEN BLACK FLAT END BLUE RED 2286-1 12.
Repair and Replacement Procedures 23. Rotate the orbital cam to make sure it spins freely and does not rub against the underside of the main plate. If you feel or hear the cam rubbing against something, grasp the outer edge of the cam and gently pull it approximately 3/32 of an inch away from the underside of the main plate and recheck it again. 24. Install the collar over the cam spindle. The slit in the collar must be aligned with the slit in the spindle (see Figure 7-10). 25.
Repair and Replacement Procedures 10. Follow the same procedure to remove the left orbital alignment block. 11. Support the assembly with one hand while you remove the two 7/64inch hex retaining screws (with the white plastic standoff) on the tube clamp support braces. 12. Carefully slide the back end of the orbital assembly off the orbital cam spindle. Be careful that the white bushing between these two is not lost or damaged. 13.
Repair and Replacement Procedures Replacing the Print Drive Motor Follow the steps below to replace the print drive motor. 1. Turn off the 2500 and remove the power cord. 2. Unplug the motor cable from the motor power supply. 3. Push down on the belt tension wheel and remove the drive belt. 4. Loosen the 5/64-labeler knob set screw (two screws are used on the thermal printer) and pull the knob off the motor shaft. 5.
Repair and Replacement Procedures Figure 7-12 Removing the Print Head PRINT HEAD MOUNTING BLOCK (1 of 2) SCREW (1 of 2) 2390-1 Replacing the Thermal Print Head The thermal print head is mounted on a small printed circuit board (PCB). Do not attempt to remove the print head from the PCB. The new print head is mounted on a new board, which should be installed as one assembly. 1. Turn off the 2500 and remove the power cord. 2.
Repair and Replacement Procedures Replacing the Beam Head Rotation Motor Follow the steps below to replace the beam head rotation motor. 1. Turn off the 2500, remove the power cord, and disconnect the motor cable. 2. Remove the two 3/32-inch set screws in the shaft pulley of the rotation motor. 3. Remove the single 3/32-inch hex mounting screw in the beam head pulley. 4. Loosen the four motor mounting screws using a 1/16-inch hex wrench. 5.
Repair and Replacement Procedures Mechanical Assembly Removal Replacing the Input Orbital Tube Clamp If the tube clamp on the input orbital tube clamp assembly is too loose, does not close, or produces too much tension, follow the steps below to replace it. 1. Turn off the 2500 and remove the power cord. 2. Remove the PE assembly, as described on page 7-3. 3. Lift the main plate and locate the round input orbital motor collar on the cam spindle. Loosen the set screw and remove the motor collar. 4.
Repair and Replacement Procedures 11. Carefully pull the input orbital assembly off the motor spindle and then slide the assembly to the left, until the right side of the assembly is free. 12. Install the repaired input orbital assembly and re-assemble all of the disconnected cables and components. Replacing the Output Orbital Tube Clamp If an orbital tube clamp on the output orbital tube clamp assembly needs to be repaired, follow the steps below to remove and reinstall it. 1.
Repair and Replacement Procedures Replacing the Programming Module Clamp Air Cylinder If the programming module clamp air cylinder fails, follow the steps below to replace it. 1. Turn off the 2500 and remove the power cord. 2. From above the main plate, remove four of the six 7/64-inch hex screws (two front ones and two back ones) holding the programming module clamp assembly to the main plate. 3. Holding the PE from the bottom (below the main plate), remove the other two screws.
Repair and Replacement Procedures Figure 7-15 Removing the Air Cylinder AIR CYLINDER NUT AIR CYLINDER 2312-1 Solenoid Replacement This procedure describes the steps required to remove and replace a solenoid. You can use this procedure to replace any of the solenoids in the 2500. Replacing a Solenoid If a solenoid fails, follow the steps below to replace it. 1. Turn off the 2500 and remove the power cord. 2.
Repair and Replacement Procedures Replacing the PE Power Supply Replacing the Toroid Transformer Replacing the Toroid PCB Replacing the Controller Power Supply 7-20 If the programming electronics power supply fails, follow the steps below to replace it. 1. Turn off the 2500 and remove the power cord. 2. Disconnect the two cable connectors. 3. Remove the four 1/4-inch hex nuts at the corners of the assembly. 4. Carefully lift out the PE power supply assembly. 5.
Repair and Replacement Procedures Replacing the Labeler Power Supply If the labeler power supply fails, follow the steps below to replace it. Be sure to note the direction of rotation before you remove the fan so that you can reinstall it correctly. 1. Turn off the 2500 and remove the power cord. 2. Disconnect the three AC input cables on the right side of the power supply assembly. 3. Disconnect the two output cables on the left side of the power supply assembly. 4.
Repair and Replacement Procedures CAUTION: Cover the power supply assemblies in the base of the 2500 with a large sheet of paper to catch any mounting hardware (screws, washers, and nuts) that might otherwise fall onto the power supply assemblies as you work. If a piece of mounting hardware is not accounted for when you install the new controller board, do not turn on the 2500 until you have located the missing piece of mounting hardware.
Repair and Replacement Procedures 6. Reinstall the traverse motor and attach the new flex coupler to the lead screw. Tighten with a torque wrench and a left-side screw using 24 inch-pounds of torque. Note: After you have reinstalled the flex coupler, make sure it does not drag on the enclosed (right) side of the bracket. Leave a 1/8-inch clearance (approximately). Replacing the Right Lead Screw Bearing Assembly If the right lead screw bearing assembly fails, follow the steps below to replace it. 1.
Repair and Replacement Procedures 9. The right lead screw bearing assembly will come away from the right end plate with the lead screw. Remove the bearing assembly and replace it with a new bearing assembly. 10. Reverse the procedure to reinstall all of the components. Replacing the Left Lead Screw Bearing Assembly If the left lead screw bearing assembly fails, follow the steps below to replace it. 1. Turn off the 2500 and remove the power cord.
Repair and Replacement Procedures 6. Use a 9/64-inch hex wrench to loosen the four hex screws holding the front and rear carriage shafts to the left end plate. Note: Have an assistant hold the lead screw and shafts during the next steps. 7. Loosen the two main plate corner screws and lift the main plate. 8. Use a hex wrench to remove the two screws holding the left end plate to the main plate. 9. Lower the main plate and slide the end plate off the shafts and lead screw. 10.
Repair and Replacement Procedures 9. Apply a small amount of purple Loctite on the outer surface of the new nut where it contacts the carriage during operation. 10. Twist the new anti-backlash nut into place and carefully re-assemble all of the disconnected components. Replacing the Beam Gasket If there are air leaks in the beam, follow the steps below to replace the beam air channel gasket. 1. Turn off the 2500, remove the power cord, and disconnect the air supply. 2.
Repair and Replacement Procedures Figure 7-17 Beam Cable and Switch Locations LIMIT BAR CABLE HARNESS GUIDE BEARING COVER PLATE BEAM TRAVERSE MOUNTING BLOCK VACUUM SENSOR CABLE VACUUM SENSOR SWITCH AIR CYLINDER PIN SCREW (1 on each side) RIGHT END PLATE FRONT COVER SHAFT REAR CARRIAGE SHAFT 2287-1 10. Use a 6/64-inch hex wrench to remove the two screws that hold the air cylinder pin in place. 11.
Repair and Replacement Procedures 24. Place the baffle plate back on the beam and then reinstall all of the screws in the order shown in Figure 7-18. 25. Carefully re-assemble all of the disconnected cables and components.
Repair and Replacement Procedures Keyboard/Display Assembly Replacement This procedure describes the steps required to remove and replace the keyboard/display assembly. Replacing the Keyboard/Display Assembly If the keyboard/display assembly fails, follow the steps below to replace it. 1. Turn off the 2500 and remove the power cord. 2.
Repair and Replacement Procedures Figure 7-19 Removing the DIP Module from the Circuit Board PRINTED CIRCUIT BOARD 1927-1 Figure 7-20 Removing the Retaining Block 3. Turn the module so the underside is facing you. 4. Use a 1/16-inch hex wrench to remove the two screws (on the sides of the module) that hold the retaining block in place (see Figure 7-20). Remove the retaining bar and set it aside. 5.
Repair and Replacement Procedures Figure 7-21 Removing or installing the Contact Set VIEW FROM BELOW CROSS SECTION CONTACT SET CROSS SECTION PLANE RETAINING BLOCK (1 of 2) SCREW (2 per side) TILT CONTACT SET BEFORE REMOVING OR INSERTING Replacing Contacts on a PLCC Module 1929-1 6. Gently feed the new contact set through the underside of the module into its operating position. The contact set has a notch that fits the ridge in the module to set the correct alignment.
Repair and Replacement Procedures When you have determined that the contacts need replacing, perform the operations described in the steps below. You will need the following items to complete this procedure: • 1/16-inch hex driver • 0.050-inch hex driver • Four new contact sets 1. Remove the configuration blocks from all four sides (see Figure 7-22).
Repair and Replacement Procedures 4. The device ejector pin and ejector spring are loose and will drop out into your hand when you turn the block upright (see Figure 7-24). Set these aside; you will reinstall them later. Figure 7-24 Removing the Device Ejector Pin and Spring PROGRAMMING BLOCK ASSEMBLY GOLD PIN DEVICE EJECTOR PIN DEVICE EJECTOR SPRING 1681-2 5. Use a 1/16-inch hex driver to remove the two screws holding the contact set in place. 6.
Repair and Replacement Procedures 9. When the contact set is in position, insert and tighten the two hex screws that hold it in place.The programming block consists of two pieces: a top and a base. The contact set screws hold the top and base together. Keep at least one contact set installed so the top does not separate from the base. If the top and base come apart, refer to page 7-38, step 9 for instructions on reassembling the programming block. 10.
Repair and Replacement Procedures Figure 7-26 Replacing the Defective Pins PRINTED CIRCUIT BOARD 1930-1 Replacing the Pin Insulation Block 2. Using the needle nose pliers, insert the replacement pin in the same hole in the block. 3. To ensure that the pin is seated correctly, use the pliers (or flat end of a flat-blade screwdriver) to press down on the spring-loaded pin until it is flush with the block. Do not use any object to push the pin farther down the hole. 4.
Repair and Replacement Procedures The pin insulation block is symmetrical so no specific polarity orientation is required; it may be inserted into the programming block either way. 6. Carefully plug the programming block onto the circuit board using the block’s alignment pins as guides. The programming block is symmetrical so no specific polarity orientation is required; the block may be inserted on the circuit board either way.
Repair and Replacement Procedures 10. Test the module by running a device-related operation using the module. Replacing the Programming Block on a PLCC Module After a period of time, the protective coating on the programming block (see Figure 7-28) may wear to the point that you begin to see a higher number of device-related errors.
Repair and Replacement Procedures When you have determined that the block needs to be replaced, follow the steps listed below. This procedure describes how to completely disassemble the programming module so you can replace the top of the programming block (see Figure 7-28).
Repair and Replacement Procedures 1. Remove the configuration blocks from all four sides (see Figure 7-22). 2. Turn the board upside-down and use the 0.050-inch hex driver to remove the two screws holding the programming block to the printed circuit board. Be careful not to strip the screws. 3. Hold the module in the upside-down position and gently pull the board from the programming block assembly (see Figure 7-23). 4. Turn the block right-side up.
Repair and Replacement Procedures Assembly Drawings 7-40 ProMaster 2500 User Manual
Repair and Replacement Procedures Figure 7-29 Test Site Clamp Assembly ProMaster 2500 User Manual 7-41
Repair and Replacement Procedures 7-42 Item No. 1 2 3 4 5 6 7 8 9 Part Number 250-0125-004 220-0113-002 234-0009-002 220-0207-002 265-0030-625 220-0005-911 210-5624-901 210-0640-901 280-0018-901 10 280-0014-904 11 12 13 14 15 16 17 18 19 20 21 22 24 27 284-2290-901 234-0015-906 290-1836-901 287-5500-902 284-5530-901 604-0058-001 604-0059-001 604-0060-001 614-0021-001 617-0019-001 665-0008-001 641-0025-001 815-1989-001 665-0007-001 Description # 6 spacer, .140” i.d., .250” o.d.
Repair and Replacement Procedures Figure 7-30 Carriage Assembly ProMaster 2500 User Manual 7-43
Repair and Replacement Procedures 7-44 Item No. 1 2 3 4 5 6 7 9 11 12 Part Number 249-0316-901 220-1375-221 220-0113-002 220-0412-911 234-0004-901 622-1305-001 234-0002-901 220-0317-921 220-0100-331 280-0014-904 13 280-0034-901 14 15 16 17 18 21 22 210-4375-902 604-0055-001 604-0057-001 636-0071-001 641-0026-001 251-1350-901 815-1991-001 Description Quantity O-ring 2 Screw, 10-24 x 3/8, socket head 4 Screw, 4-40 x 3/8, cap head 5 Screw, 10-24 x 1/2, cap head 2 # 4 flat washer, .125” i.d., .281” o.d.
Repair and Replacement Procedures Figure 7-31 Input Assembly ProMaster 2500 User Manual 7-45
Repair and Replacement Procedures 7-46 ProMaster 2500 User Manual
Repair and Replacement Procedures ProMaster 2500 User Manual 7-47
Repair and Replacement Procedures 7-48 ProMaster 2500 User Manual
Repair and Replacement Procedures Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Part No.
Repair and Replacement Procedures Figure 7-32 Output Tube Clamp Assembly 7-50 ProMaster 2500 User Manual
Repair and Replacement Procedures Item No.
Repair and Replacement Procedures Figure 7-33 Beam Assembly 7-52 ProMaster 2500 User Manual
Repair and Replacement Procedures ProMaster 2500 User Manual 7-53
Repair and Replacement Procedures 7-54 ProMaster 2500 User Manual
Repair and Replacement Procedures ProMaster 2500 User Manual Item No.
Repair and Replacement Procedures Item No.
Repair and Replacement Procedures Figure 7-34 Main Plate Assembly ProMaster 2500 User Manual 7-57
Repair and Replacement Procedures 7-58 ProMaster 2500 User Manual
Repair and Replacement Procedures ProMaster 2500 User Manual Item No.
Repair and Replacement Procedures Item No.
Repair and Replacement Procedures Figure 7-35 Thermal Printer Assembly ProMaster 2500 User Manual 7-61
Repair and Replacement Procedures 7-62 ProMaster 2500 User Manual
Repair and Replacement Procedures ProMaster 2500 User Manual Item No.
Repair and Replacement Procedures 7-64 Item No.
Repair and Replacement Procedures ProMaster 2500 User Manual Item No.
Repair and Replacement Procedures ProMaster 2500 Thermal Printer Standard Spares Kit (Part Number: 952-0156-002) Description Part Number Quantity Air cylinder, shutter/thermal 298-5500-901 1 Air cylinder, programming module site clamp 287-5500-902 1 Ball bearing, high/low valve 280-0180-901 1 Bearing, 3/8” i.d., 1/2” o.d., 1/2” t. 280-0200-901 1 Bearing, 3/8” i.d., 9/16” o.d., .14” t.
Repair and Replacement Procedures Description Part Number Quantity Seal, beam cylinder 265-8880-902 2 Seal, beam shaft 265-8880-901 1 Solenoid valve 289-0024-901 1 Solenoid, 4-way, 2500 289-0524-901 1 Standoff, tube guide 250-0612-902 3 Spring, .625” free length, .156” o.d. 265-2500-901 2 Spring, .875” free length, .312” o.d. 265-4415-901 3 Spring, .965” free length, .343” o.d. 265-4067-901 1 Spring, 1.468” free length, .375” o.d. 265-4420-901 1 Spring, 47/64” free length, .
Repair and Replacement Procedures ProMaster 2500 Advanced Spares Kit (Part Number: 952-0133-003) Description Part Number Board assembly, main logic/controller, CE handler 701-2531-005 1 Board assembly, main logic/controller, non-CE handler 701-2531-004 1 Carriage motor assembly, with encoder 815-2056-001 1 Keyboard electronics assembly 850-0077-001 1 Power supply 701-2530-001 1 Power supply, 12–15V 806-0080-001 1 Power supply, 24V 806-2400-901 1 Power supply, 5V (controller board) 8
A Glossary Action Symbol Found in various locations on the TaskLink screen depending on the operation being performed. The action symbol rotates to indicate that the 2500 is performing an operation. ADC Optic A special function optic pair that uses a light emitter and collector to detect the leading edge of labels. The optics detect the change in the level of light passing through the combined label and liner versus light passing through the liner alone.
Glossary Blank Check A device check that checks a device for programmed bits. If no programmed bits are found, the device is considered blank. Block Size The number of bytes (display as a hexadecimal number on the TaskLink screen) to be transferred in a data transfer. The beginning of the block is defined by a begin address, and the end of the block is the sum of the block size and the begin address minus one.
Glossary Device Term referring specifically to the programmable IC that is to be processed through the ProMaster 2500 system. This is the part that will be programmed and labeled by the 2500. Device Block Size The size of device data to be used in device operations. Device Operation A term that usually refers to any electronic operation performed on the device while it is in the programming module.
Glossary Fuse Verification A type of post-programming device check that checks the fuse pattern programmed into a logic device against the pattern in user memory. Fusemap The fuse-level description portion of a programmable integrated circuit. Fusemaps are typically files in JEDEC Standard # 3A format and are downloaded to PLD programmers for programming or verifying a device.
Glossary Logic Verification After programming a device, you can select test vector verification, fuse verification, or both types of verification. Main Plate The metal plate on which the tracks, beam, tube holders, and beam carriage assemblies are mounted. The hood rests on the main plate when it is closed. Mass Storage Module (MSM) The hard disk drive contained in the programmer that stores the system startup and TaskLink software, programming algorithms, and device programming database files.
Glossary PLD An acronym for Programmable Logic Device. A particular type of programmable integrated circuit. Architectures range from being very simple to very complex. Most PLDs contain two levels of logic: an AND array followed by an OR array. PROM An acronym for programmable read-only memory. A device with fixed AND and programmable OR arrays. This is a slightly different architecture from an FPLA or a PAL. Process A series of device related operations are combined to form a process for each Task.
Glossary Serial Vector Test A device test that applies test vector input states serially, starting with pin one and stepping through the remaining pins. This test is a diagnostic tool designed to help debug and classify test vector failures. Specifically, this test is designed to isolate test vectors that are sequence dependent.
Glossary Wildcard A global search character used to speed the search for a specific device name or file name in TaskLink. When entering filenames, a wildcard represents one or more characters in a filename. For example, 27*.dat represents both 27512.dat and 27128.dat. Yield The percentage of successfully programmed devices.
B Firmware Keys and STOP Commands The ProMaster 2500 is normally operated in remote mode using the TaskLink software. Some of the firmware key commands listed in this Appendix are active only while the handler is in local mode. To execute a firmware key command from one of the handler menus, perform the following steps: 1. Put the handler into local mode by pressing the LOWER CASE + L keys. 2. Go to the appropriate menu and press the key sequence to access the display. 3.
Firmware Keys and STOP Commands Function Keys to Press Description LOWER CASE + L Changes the 2500 from remote mode to local mode. Select this mode to run operations such as diagnostics tests and firmware keys. Remote mode LOWER CASE + R Changes the 2500 from local mode to remote mode. Display intensity ↓↑ Adjust the intensity of the display. Advance label LOWER CASE + A Advances the label’s position for application on the device. The nominal range is 35 to 60.
Firmware Keys and STOP Commands Function Keys to Press Description From the Diagnostics/Motor Menu Changes beam & input/output motor speed LOWER CASE + M Allows changes to the speed for the beam motor, input track shake motor, and output track shake motor. Increasing the motor value on the display lowers the speed and increases the motor’s torque. If the beam is stalling, the lead screw should be cleaned and lubricated.
Firmware Keys and STOP Commands STOP Commands Use the STOP commands to pause and change parameters from the middle of a Task (job). By using these convenient commands, you can suspend a running Task and continue later from the same point without having to exit and restart. Unlike the firmware keys, STOP commands do not need to be called from a specific 2500 menu. To use this set of commands perform the following steps: 1. Pause the 2500’s Task processing by pressing STOP. 2. Select a parameter. 3.
Firmware Keys and STOP Commands Function Press STOP, Then press Description Label advance (Thermal Printer) LOWER CASE + W The label advance value defines how far a label is extended above the application plate just before it is applied. Increasing the numeric value advances the label farther above the application plate. Print intensity (Thermal Printer) LOWER CASE + I The print intensity ranges from 0 (lightest) to 21 (darkest).
Firmware Keys and STOP Commands B-6 ProMaster 2500 User Manual
C Wiring Diagram The wiring diagram and handler controller board layout are included in this section.
GRN GRN WHT WHT C-2 +24V DC 1 GRN BLK WHT ORN YEL RED VIOL J1 TOROIDAL TRANSFORMER 1 NC 1 1 BLK WHT WHT BRN BLK BLUE GRAY 1 RED VIOL YEL ORN HANDLER CONTROLLER BOARD 1 RED YEL BLUE BLK J27 TB - 1 GND AC (L) AC (N) 1 GRN WHT BLK PROGRAMMING ELECTRONICS ASSEMBLY FAN J3 J2 J1 J11 J2 MOTOR POWER SUPPLY BOARD 1 J4 1 GRN WHT BLK BLUE YEL RED RED GRN BLUE BLUE BLK BLK DISK DRIVE 1 J2 BLK RED BLK RED RED RED BLK BLK NC NC NC NC 1 8 AC IN BLK RED BLK RED FAN BLK WH
1 1 J15 Keyboard J14 Display ProMaster 2500 User Manual 1 J27 S5 S6 S7 S8 1 1 Device blow off (LP) High pressure (HP) Vacuum (HP) Prog.
Wiring Diagram C-4 ProMaster 2500 User Manual
D Translation Formats Translation formats are different ways of encoding the data in a data file. A data file contains the information to be programmed into a device. The data file could contain the fuse pattern and test vectors for a logic device or the data for a memory device. Generally, the data, such as the fuse pattern for a logic device, are created on a development platform and are then stored in a particular data translation format.
Translation Formats Below you will find a list, in ascending numerical order, of all the translation formats supported by the programmer. Following the list is a description and, in most cases, an example of each translation format, presented in order by format number.
Translation Formats Instrument Control Codes The instrument control code is a 1-digit number that signals or controls data transfers. Specifically, the instrument control code can be used to implement a form of remote control that provides peripherals with flow control beyond that provided by software handshaking. When using computer remote control, the instrument control code is sent immediately preceding the 2-digit format code.
Translation Formats General Notes Some information about data translation is listed below: Compatibility When translating data, you may use any remote source that produces formats compatible with the descriptions listed in this section. Formats with Limited Address Some formats are not defined for use with address fields greater than Fields 64K.
Translation Formats ASCII Binary Format, Codes 01, 02, and 03(or 05, 06, and 07) In these formats, bytes are recorded in ASCII codes with binary digits represented by Ns and Ps, Ls and Hs, or 1s and 0s, respectively. See Figure D-1. The ASCII Binary formats do not have addresses. Figure D-1 shows sample data bytes coded in each of the three ASCII Binary formats. Incoming bytes are stored in RAM sequentially starting at the first RAM address.
Translation Formats Note: Data without a start or end code may be input to or output from the programmer by use of alternate data translation format codes. These are ASCII-BNPF, 05; ASCII-BHLF, 06; ASCII-B10F, 07. A single data byte can be aborted if the programmer receives an E character between B and F characters. Data will continue to be stored in sequential RAM addresses. Data are output in 4-byte lines with a space between bytes.
Translation Formats Texas Instruments SDSMAC Format (320), Code 04 Data files in the SDSMAC (320) format consist of a start-of-file record, data records, and an end-of-file record. See Figure D-2. The format is used for Texas Instruments’ 320 line of processors.
Translation Formats The record ends with a checksum field initiated by the tag character 7 or 8, a 4-character checksum, and the tag character F. The checksum is the two’s complement of the sum of the 8-bit ASCII values of the characters, beginning with the first tag character and ending with the checksum tag character (7 or 8). Data records follow the same format as the start-of-file record but do not contain a file header. The end-of-file record consists of a colon (:) only.
Translation Formats The 5-Level BNPF Format, Codes 08 or 09 Except for the start and end codes, the same character set and specifications are used for the ASCII-BNPF and 5-level BNPF formats. Data for input to the programmer are punched on 5-hole Telex paper tapes to be read by any paper tape reader that has an adjustable tape guide. The reader reads the tape as it would an 8-level tape, recording the 5 holes that are on the tape as 5 bits of data.
Translation Formats Formatted Binary Format, Code 10 Data transfer in the Formatted Binary format consists of a stream of 8-bit data bytes preceded by a byte count and followed by a sumcheck, as shown in Figure D-3. The Formatted Binary format does not have addresses.
Translation Formats A paper tape generated by a programmer contains a 5-byte, arrowshaped header followed by a null and a 4-nibble byte count. The start code, an 8-bit rubout, follows the byte count. The end of data is signaled by two nulls and a 2-byte sumcheck of the data field. Refer to Figure D-4. If the data output has a byte count GREATER than or equal to 64K, an alternate arrow-shaped header is used.
Translation Formats Spectrum Format, Codes 12 or 13 In this format, bytes are recorded in ASCII codes with binary digits represented by 1s and 0s. During output, each byte is preceded by a decimal address. Figure D-5 shows sample data bytes coded in the Spectrum format. Bytes are sandwiched between the space and carriage return characters and are normally separated by line feeds. The start code is a nonprintable STX, CTRL-B (or hex 02), and the end code is a nonprintable ETX, CTRL-C (or hex 03).
Translation Formats POF (Programmer Object File) Format, Code 14 The POF (Programmer Object File) format provides a highly compact data format to enable translation of high bit count logic devices efficiently. This format currently applies to MAX™ devices, such as the Altera 5032. The information contained in the file is grouped into “packets.” Each packet contains a “tag,” identifying what sort of data the package contains plus the data itself.
Translation Formats Comment_Text tag=3 Read This packet contains a text string which may consist of comments related to the POF. This text may be displayed to the operator when the file is read. The string may include multiple lines of text, separated by appropriate new line characters. Tag_Reserved tag=4 Skipped Security_Bit tag=5 Used This packet declares whether security mode should be enabled on the target device.
Translation Formats Logical_Address_and_ Data_32 ProMaster 2500 User Manual tag=17 Read This packet defines a group of logical addresses in the target device and associates logical data with these addresses. The addresses comprise a linear region in the logical address space, bounded on the low end by the starting address and extending upward by the address count specified in the packet. The starting address and address count are each specified by 4-byte fields (32 bits).
Translation Formats Absolute Binary Format, Code 16 Absolute Binary format is a literal representation of the data to be transferred and no translation of the data takes place during the transfer. There are no overhead characters added to the data (i.e. no address record, start code, end code, nulls, or checksum). Every byte transferred represents the user’s data. This format can be used to download unformatted data such as an “.exe” file to the programmer.
Translation Formats LOF Format, Code 17 The Link Object Format (LOF) is an extension of the standard JEDEC data translation format and is used to transfer fuse and test vector data between the programmer and a host computer. LOF is designed to support the Quicklogic QL8x12A family of FPGAs. An LOF data file is stored as an imploded ZIP file, which yields data compression approaching 95%. Note: You must have PKZIP version 1.0 to use this format.
Translation Formats LOF Fields The following fields are included in Data I/O’s implementation of the LOF format: * Start of Data (ASCII Ctrl-B, 0x02 hex) C * Fuse Checksum K N Fuse data, followed by control words and pulse link cycles * Notes Field QB Number of bits per word QC Number of control words at the end of each K field QF Number of Fuses in Device (# of K fields) QM Number of macro cells in the data file QP * QS QV Number of Device Package Pins Number of Hex-ASCII words
Translation Formats ASCII Octal and Hex Formats, Codes 30-37 and 50-58 Each of these formats has a start and end code, and similar address and checksum specifications. Figure D-6 illustrates 4 data bytes coded in each of the 9 ASCII Octal and Hexadecimal formats. Data in these formats are organized into sequential bytes separated by the execute character (space, percent, apostrophe, or comma). Characters immediately preceding the execute character are interpreted as data.
Translation Formats Although each data byte has an address, most are implied. Data bytes are addressed sequentially unless an explicit address is included in the data stream. This address is preceded by a $ and an A, must contain 2 to 8 hex or 3 to 11 octal characters, and must be followed by a comma, except for the ASCII-Hex (Comma) format, which uses a period. The programmer skips to the new address to store the next data byte; succeeding bytes are again stored sequentially.
Translation Formats RCA Cosmac Format, Code 70 Data in this format begin with a start record consisting of the start character (!M or ?M), an address field, and a space. See Figure D-7.
Translation Formats Fairchild Fairbug, Code 80 In the Fairbug format, input and output requirements are identical; both have 8-byte records and identical control characters. Figure D-8 shows a Fairbug data file. A file begins with a 5-character prefix and ends with a 1-character suffix. The start-of-file character is an S, followed by the address of the first data byte. Each data byte is represented by 2 hexadecimal characters. The programmer will ignore all characters received prior to the first S.
Translation Formats MOS Technology Format, Code 81 The data in each record are sandwiched between a 7-character prefix and a 4-character suffix. The number of data bytes in each record must be indicated by the byte count in the prefix. The input file can be divided into records of various lengths. Figure D-9 shows a series of valid data records. Each data record begins with a semicolon. The programmer will ignore all characters received prior to the first semicolon.
Translation Formats Motorola EXORciser Format, Code 82 Motorola EXORciser data files may begin with an optional sign-on record, which is initiated by the start characters S0. Valid data records start with an 8-character prefix and end with a 2-character suffix. Figure D-10 shows a series of valid Motorola data records.
Translation Formats Intel Intellec 8/MDS Format, Code 83 Intel data records begin with a 9-character prefix and end with a 2-character suffix. The byte count must equal the number of data bytes in the record. Figure D-11 simulates a series of valid data records. Each record begins with a colon, which is followed by a 2-character byte count. The 4 digits following the byte count give the address of the first data byte.
Translation Formats Signetics Absolute Object Format, Code 85 Figure D-12 shows the specifications of Signetics format files. The data in each record are sandwiched between a 9-character prefix and a 2-character suffix.
Translation Formats Tektronix Hexadecimal Format, Code 86 Figure D-13 illustrates a valid Tektronix data file. The data in each record are sandwiched between the start character (a slash) and a 2-character checksum. Following the start character, the next 4 characters of the prefix express the address of the first data byte. The address is followed by a byte count, which represents the number of data bytes in the record, and by a checksum of the address and byte count.
Translation Formats Motorola EXORmacs Format, Code 87 Motorola data files may begin with an optional sign-on record, initiated by the start characters S0. Data records start with an 8- or 10-character prefix and end with a 2-character suffix. Figure D-14 shows a series of Motorola EXORmacs data records.
Translation Formats Intel MCS-86 Hexadecimal Object, Code 88 The Intel 16-bit Hexadecimal Object file record format has a 9-character (4-field) prefix that defines the start of record, byte count, load address, and record type and a 2-character checksum suffix. Figure D-15 shows a sample record of this format.
Translation Formats Problem: Find the address for the first data byte for the following file. :02 0000 02 1230 BA :10 0045 00 55AA FF.....BC Solution: Step 1. Find the record address for the byte. The first data byte is 55. Its record address is 0045 from above. Step 2. Find the offset address. The offset address is 1230 from above. Step 3.
Translation Formats Hewlett-Packard 64000 Absolute Format, Code 89 Hewlett-Packard Absolute is a binary format with control and data-checking characters. See Figure D-16. Figure D-16 An Example of HP 64000 Absolute Format HIGH ORDER END-OF-FILE RECORD LOW ORDER End-of-File record consists only of a word count of 0. Checksum Third Byte MSB LSB Second Byte Data bytes 32-bit address is sent in this manner, in 4 groups of 8-bit bytes. ONE DATA RECORD Address where following data byte is to be stored.
Translation Formats The Data Bus Width represents the width of the target system’s bus (in bits). The Data Width Base represents the smallest addressable entity used by the target microprocessor. The Data Bus Width and Data Width Base are not used by the programmer during download. During upload, the Data Bus Width will be set to the current Data Word Width, and the Data Width Base will be set to 8. The Transfer Address is not used by the programmer. Data records follow the Start-of-file record.
Translation Formats Texas Instruments SDSMAC Format, Code 90 Data files in the SDSMAC format consist of a start-of-file record, data records, and an end-of-file record. See Figure D-17.
Translation Formats Data records follow the same format as the start-of-file record but do not contain a file header. The end-of-file record consists of a colon (:) only. The output translator sends a CTRL-S after the colon.
Translation Formats JEDEC Format, Codes 91 and 92 Introduction The JEDEC (Joint Electron Device Engineering Council) format is used to transfer fuse and test vector data between the programmer and a host computer. Code 91 is full format and includes all the data fields (such as note and test fields) described on the following pages. Code 92 is the Kernel, or shorter, format.
Translation Formats For example, in words the definition of a person’s name reads: The full name consists of an optional title followed by a first name, a middle name, and a last name. The person may not have a middle name, or may have several middle names. The titles consist of: Mr., Mrs., Ms., Miss, and Dr. The BNF definition for a person’s name is: :: = [] <f. name> {<m.name>} <l. name> <title> :: = ‘Mr.’ | ‘Mrs.’ | ‘Ms.’ | ‘Miss’ | ‘Dr.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-367.html>PAGE 367</a></h6><p>Translation Formats The Design Specification Field <design spec> ::= {<field character>}’*’ The first field sent in a JEDEC transmission is the design specification. Both the full and kernel JEDEC formats accept the design specification field. This field is mandatory and does not have an identifier (such as an asterisk) signaling its beginning. The design specification field consists of general device information.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-368.html>PAGE 368</a></h6><p>Translation Formats JEDEC Full Format, Code 91 The full JEDEC format consists of a start-of-text character (STX), various fields, an end-of-text character (ETX), and a transmission checksum. A sample JEDEC transmission sent in the full format is shown in Figure D-18. Each of the fields is described on the following pages. Figure D-18 An Example of JEDEC Full Format Vector Number D-38 Header ABEL(tm) Version 2.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-369.html>PAGE 369</a></h6><p>Translation Formats JEDEC Field Syntax <field> ::= [<delimiter>]<field identifier>{<field character>}’*’ <field identifier>::= ‘A’ | ‘C’ | ‘D’ | ‘F’ | ‘G’ | ‘K’ | ‘L’ | ‘N’ | ‘P’ | ‘Q’ | ‘R’ | ‘S’ | ‘T’ | ‘V’ | ‘X’ <reserved identifier>::= ‘B’ | ‘E’ | ‘H’ | ‘I’ | ‘J’ | ‘M’ | ‘O’ | ‘U’ | ‘W’ | ‘Y’ | ‘Z’ Following the design specification field in a JEDEC transmission can be any number of information fields. Each of the JEDEC fields begins with a character that identifies what type of field it is.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-370.html>PAGE 370</a></h6><p>Translation Formats Fuse Information Fields (L, K, F, C) <fuse information> :: = [<default state>] <fuse list> {<fuse list>} [<fuse checksum>] <fuse list> : = ‘L’ <number> <delimiter> {<binary-digit> [<delimiter>]} '*' <fuse list> :: = ‘K’ <number> <delimiter> {<hex-digit> [<delimiter>]} ‘*’ <default state> :: = ‘F’ <binary-digit> ‘* ‘ <fuse checksum> :: = ‘C’ <hex-digit>:4 ‘* ‘ Each fuse of a device is assigned a decimal number and has two possible states: zero, specifying a low-resistance link, or one,</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-371.html>PAGE 371</a></h6><p>Translation Formats The C field, the fuse information checksum field, is used to detect transmitting and receiving errors. The field contains a 16-bit sum (modulus 65535) computed by adding 8-bit words containing the fuse states for the entire device. The 8-bit words are formed as shown in the following figure. Unused bits in the final 8-bit word are set to zero before the checksum is calculated. Word 00 Fuse No. msb 7 6 5 4 3 2 1 lsb 0 Word 01 Fuse No.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-372.html>PAGE 372</a></h6><p>Translation Formats The P Field The P field remaps the device pinout and is used with the V (test vector) field. An asterisk terminates the field.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-373.html>PAGE 373</a></h6><p>Translation Formats • The U-field cells are not included in the C (fuse checksum) field. • The U field reads left to right to be consistent with the L (fuse list) and E fields. The syntax for the U field is as follows: <user data fuse list>::’U’<binary-digit(s)>’*’ The character U begins the U field and is followed by one binary digit for each U fuse.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-374.html>PAGE 374</a></h6><p>Translation Formats Test Field (V field) <function test> :: = [<pin list>] <test vector> {<test vector>} <pin number> :: = <delimiter> <number> N :: = number of pins on device <test vector> :: = ‘V’ <number> <delimiter> < test condition> :N ‘* ‘ <test condition> :: = <digit> ‘B’ | ‘C’ | ‘D’ | ‘F’ | ‘H’ | ‘K’ | ‘L’ | ‘N’ | ‘P’ | ‘U’ | ‘X’ | ‘Z’ <reserved condition> :: = ‘A’ | ‘E’ | ‘G’ | ‘I’ | ‘J’ | ‘M’ | ‘O’ | ‘Q’ | ‘R’ | ‘S’ | ‘T’ | ‘V’ | ‘W’ | ‘Y’ | ‘Z’ Functional test information is specified by test v</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-375.html>PAGE 375</a></h6><p>Translation Formats The following example uses the V field to specify functional test information for a device: V0001C01010101NHLLLHHLHLN* V0002C01011111NHLLHLLLHLN* V0003C10010111NZZZZZZZZZN* V0004C01010100NFLHHLFFLLN* ProMaster 2500 User Manual D-45</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-376.html>PAGE 376</a></h6><p>Translation Formats JEDEC Kernel Mode, Code 92 <kernel>::=<stx><design spec><min. fuse information><etx><xmit checksum> <design spec>::={<field character>}’*’ <min. fuse information>::=<fuse list>{<fuse list>} You may use the JEDEC kernel format if you wish to send only the minimum data necessary to program the logic device; for example, if you do not want to send any test vectors.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-377.html>PAGE 377</a></h6><p>Translation Formats Extended Tektronix Hexadecimal Format, Code 94 The Extended Tektronix Hexadecimal format has three types of records: data, symbol, and termination records. The data record contains the object code. Information about a program section is contained in the symbol record (the programmer ignores symbol records), and the termination record signifies the end of a module. The data record (see sample below) contains a header field, a load address, and the object code.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-378.html>PAGE 378</a></h6><p>Translation Formats The load address determines where the object code will be located. This is a variable length number that may contain up to 17 characters. The first number determines the address length, with a zero signifying a length of 16. The remaining characters of the data record contain the object code, 2 characters per byte. When you copy data to the port or to RAM, set the high-order address if the low-order is not at the default value.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-379.html>PAGE 379</a></h6><p>Translation Formats Motorola 32-Bit Format, Code 95 The Motorola 32-bit format closely resembles the Motorola EXORmacs format, the main difference being the addition of the S3 and S7 start characters. The S3 character is used to begin a record containing a 4-byte address. The S7 character is a termination record for a block of S3 records. The address field for an S7 record may optionally contain the 4-byte instruction address that identifies where control is to be passed and is ignored by the programmer.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-380.html>PAGE 380</a></h6><p>Translation Formats Hewlett-Packard UNIX Format, Code 96 This format divides the data file into data records, each with a maximum size of 250 bytes not including header information. An ID header is added to the beginning of the first record. Each subsequent record has its own header section. The section at the beginning of the file contains the following elements: the header 8004, filename, byte count for the processor information record, and the processor information record.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-381.html>PAGE 381</a></h6><p>Translation Formats The record length during upload is not affected by the upload record size parameter in the Configure/Edit/Communication screen. It is automatically set to transfer records using the maximum size (250 bytes) except for the last record. The size of the last record will be set according to the remaining number of data bytes.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-382.html>PAGE 382</a></h6><p>Translation Formats Intel OMF386 Format, Code 97 This data translation format is considered by Intel to be proprietary information. Contact your local Intel representative or call (408) 987-8080 for information about the structure of this format.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-383.html>PAGE 383</a></h6><p>Translation Formats Intel OMF286 Format, Code 98 The Intel OMF286 format is a dynamically allocatable file format. This format has three basic parts: the file header, data file module, and a 1-byte checksum. The file header is hexadecimal number (A2) that identifies this file as an Intel OMF 286 format file. See Figure D-23.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-384.html>PAGE 384</a></h6><p>Translation Formats Figure D-24 A Close-up of the Intel OMF286 Format INTEL OMF286 FORMAT, CODE 98 4 bytes Total Space 8 bytes 8 bytes Date 41 bytes Time Module Creator 2 bytes 4 bytes 4 bytes GDT Limit GDT Base 4 bytes IDT Limit IDT Base 2 bytes TSS Selector Data File Header 4 bytes ABSTXT Location File Header (A2 or 06 and 02) 4 bytes DEBTXT Location Data File Module Data File Header Checksum 1 byte 4 bytes 4 bytes Last Next Location Partition Table of Contents 75 bytes 2 bytes Length</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-385.html>PAGE 385</a></h6><p>Translation Formats Intel Hex-32, Code 99 The Intel 32-bit Hexadecimal Object file record format has a 9-character (4-field) prefix that defines the start of record, byte count, load address, and record type, and a 2-character checksum suffix. Figure D-25 illustrates the sample records of this format.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-386.html>PAGE 386</a></h6><p>Translation Formats Problem Find the address for the first data byte for the following file. :02 0000 04 0010 EA :02 0000 02 1230 BA :10 0045 00 55AA FF ..... BC Solution: Step 1. Find the extended linear address offset for the data record (0010 in the example). Step 2. Find the extended segment address offset for the data record (1230 in the example). Step 3. Find the address offset for the data from the data record (0045 in the example). Step 4.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-387.html>PAGE 387</a></h6><p>Translation Formats Highest I/O Addresses The following table shows the highest I/O addresses accepted for each Data Translation Format.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-388.html>PAGE 388</a></h6><p>Translation Formats D-58 ProMaster 2500 User Manual</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-389.html>PAGE 389</a></h6><p>E Computer Remote Control The Computer Remote Control (CRC) commands are used by TaskLink to control the operation of the 2500. This information is included in the manual to allow you to write a remote computer software program (referred to as a driver) to control the operation of the ProMaster 2500. The CRC driver issues commands in the format required by the 2500 and sends these commands to the 2500 to execute.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-390.html>PAGE 390</a></h6><p>Computer Remote Control Handler Computer Remote Control This section lists commands that specifically affect the device handling functions of the 2500. It includes the following information: System Setup • Handler Remote Command Set — Lists the available handler CRC commands. A command summary, which lists commands, descriptions, and the 2500’s response, precedes the complete list.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-391.html>PAGE 391</a></h6><p>Computer Remote Control Remote Mode Command Set All remote commands begin with an @ symbol followed by a two-digit number, with the exception of the reset command (!) and the devices labeled command (# ). After the command is issued, the 2500 responds with an R followed by two to four ASCII digits and a CR-LF, except in the case of the Exit Remote and Reset commands, when no response is returned. Note: CR-LF means Carriage Return and Line Feed (0D hex and 0A hex).</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-392.html>PAGE 392</a></h6><p>Computer Remote Control @@01XX Program and Label Parts - Continuous—where XX represents the maximum parts needed to fill a receiving tube. This is followed by a 2500 hex file. After the 2500 receives this command and upon detecting devices at the input, it begins to continuously program and label devices. To invoke a new command, you must send a ! (the reset command).</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-393.html>PAGE 393</a></h6><p>Computer Remote Control @@07XXYYY Y = Bin Assignment—Configures the bin map for the specified bin. XX represents the bin and YYY represents the bin configuration number. The bin number is a two-digit ASCII number from 01 to 04, representing the bin to be configured. The bin configuration number is a three-digit decimal number in ASCII which, when converted to binary, represents the category or categories to be routed to the bin specified.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-394.html>PAGE 394</a></h6><p>Computer Remote Control The changes you make with this command are retained until you send a new @08 command, make changes using the setup menu under BINNING, or turn off power. Sending an @08255 restores the label mapping settings to those currently defined in the BINNING setup menu. Response: R08 @@09XXX Serial Control Functions—where XXX represents serial control functions number. Note: Use this command only when you control the programming electronics (PE) through the handler firmware.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-395.html>PAGE 395</a></h6><p>Computer Remote Control @@11XX Label Only Devices - Continuous—Causes the 2500 to continuously label devices. XX represents the maximum parts needed to fill a receiving tube. This is followed by a 2500 hex file. After the command sequence is received, the 2500 begins labeling immediately upon detecting devices at the input. To invoke a new command, send a reset command “!” first.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-396.html>PAGE 396</a></h6><p>Computer Remote Control This command is used in conjunction with the command @13. When the 2500 sends the remote computer a : it waits indefinitely for an @14 command. The category number sent with command @14 is converted to a bin number using the binning map. If labeling is assigned to the bin, the device is labeled with information received from the label hex file then put into the assigned bin.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-397.html>PAGE 397</a></h6><p>Computer Remote Control Response: R16 (when rotation is completed) @@17X Define Pass Category — X represents category number 1 to 5. This command allows the remote computer to define the pass category. If this command is not sent, the 2500 assumes that all parts receiving a label are good. When a part is good, the “PART TOTAL” is incremented and compared to the “PROGRAM TARGET” to determine if the run is complete.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-398.html>PAGE 398</a></h6><p>Computer Remote Control Handler CRC Error Codes If the 2500 stops during operation due to an error, the audible alarm sounds, and one of the following messages is displayed. The 2500 sends an error code to the remote computer in the form of a # followed by a three-digit decimal between E00 and E99, followed by a CR-LF. In most cases, the operator must take some corrective action and press a key to restart the 2500. For example, # E07 indicates an UNABLE TO LOWER BEAM error.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-399.html>PAGE 399</a></h6><p>Computer Remote Control Hex Label Format The Hex Label format has been developed to encode data files in ASCII format to transfer between the Remote RS232C port on the 2500 and the attached computer system. Label Record Content Label records appear as character strings consisting of the following four fields: identifying record type, record length, data, and checksum.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-400.html>PAGE 400</a></h6><p>Computer Remote Control Q2 This record contains the index number in hex of the type of device to be handled. The following device types and their index numbers are available for handling: 01 – PLCC 20 02 – PLCC 28 03 – PLCC 32 04 – PLCC 44 05 – PLCC 52 06 – PLCC 68 07 – PLCC 84 08 – DIP 08 09 – DIP 14 10 – DIP 16 11 – DIP 18 12 – DIP 20 13 – DIP 22 14 – DIP 24 – 0.3” 15 – DIP 24– 0.6” 16 – DIP 28– 0.6” 17 – DIP 32 18 – DIP 28 – 0.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-401.html>PAGE 401</a></h6><p>Computer Remote Control Q6 This record contains print density information. It is allowed one data byte and is defined as follows: Dot Matrix Printer Thermal Printer 00 = Auto-Select 00 = Auto-Select 01 = 26 CPI 01 = 28 CPI 02 = 26 S CPI (Short) 02 = 28 S CPI (Short) 03 = 20 CPI 03 = 22 CPI 04 = 16 T CPI (Tall) 04 = 11 CPI 05 = 12 T CPI (Tall) 05 = 19 CPI 07 = 18 CPI 06 = 16 CPI To select a print density of 26 CPI for the dot matrix printer, the record would be Q60201FC.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-402.html>PAGE 402</a></h6><p>Computer Remote Control The following diagram illustrates an example of pin 1 orientations for the three locations: DIRECTION OF TRAVEL PIN 1 PIN 1 TXT PIN 1 INTO RECEIVING TUBE = 01 (1) LABEL ORIENTATION = 0 OUT OF INPUT TUBE = 11 (3) 1393-1 The rotation byte in binary is 00010011. Convert 00010011 binary to 13 hex. The record becomes Q70213EA. Q8 Reserved for future use. Q9 A termination record for a block of label records. There is no data field.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-403.html>PAGE 403</a></h6><p>Computer Remote Control Q1 0C Label record type — Q1 indicates a data record containing labeling information. The ASCII character CR (0D hex) forces a new line (may contain up to 8 lines). Record length — Indicates that 12 hex bytes follow in the record: 4C 41 42 45 4C 0D 54 45 58 54 0D 34 L A S E R cr T E X T cr Checksum The Q2 record consists of the following: Q2 02 01 FC Label record type — Q2 indicates a data record containing device type information.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-404.html>PAGE 404</a></h6><p>Computer Remote Control Source Code of LABEL.C Program ************************************************************************ * LABEL.C - Create Hex Label Format containing label info * * * * This program is written using only standard C file functions * * and can be compiled with any C compiler. * ************************************************************************* #include <stdio.h> FILE *fp; char lb[] = " "; .() { int i = 0; char l, c, d, chksum; fp = fopen("LABEL.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-405.html>PAGE 405</a></h6><p>Computer Remote Control Programming Electronics Computer Remote Control This section describes the CRC commands used for the ProMaster 2500’s programming electronics. It includes the following information: System Setup • System Setup—Explains how to set up the 2500 programming electronics for remote control operation. Includes information on entering and exiting CRC mode. • CRC Commands—lists the available CRC commands.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-406.html>PAGE 406</a></h6><p>Computer Remote Control CRC Default Settings When CRC mode is entered, certain defaults are set prior to accepting any commands.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-407.html>PAGE 407</a></h6><p>Computer Remote Control You send CRC commands to the 2500 programming electronics by typing the command and then pressing ↵. When the 2500 programming electronics receive a CRC command, the command is executed and a response character with a carriage return is sent back. Three responses from the 2500 are possible: F Indicates that an error occurred. The “X” CRC command prompts the 2500 to return a specific error code (listed later in this Appendix) that describes the error.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-408.html>PAGE 408</a></h6><p>Computer Remote Control Summary of Standard CRC Commands E-20 Command Description Response – hhhhhh: Invert RAM > Select device begin address > hhhhhh; Select memory block size > hhhhhh< Select memory begin address > nn= Select I/O timeout > fffppp@ or ffpp@ Select device type > cffA Enter translation format > B Blank check > C Compare to port > D Set odd parity > E Set even parity > F Error status inquiry HHHHHHHH> G Configuration inquiry DD> H No operation ></p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-409.html>PAGE 409</a></h6><p>Computer Remote Control Summary of Extended CRC Commands Command Description 01] nn02] n03] nn04] xxx...</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-410.html>PAGE 410</a></h6><p>Computer Remote Control Command Description 59] Enable/disable capacitor configuration test Display list of parameters Clear vector data Load system files for CM algorithm disk Write system files to CM disk Write algorithms to CM disk Select algorithm source drive for creating CM algorithms Get number of sectors Get sector configuration settings Set sector configuration settings Select device part number for CM (use xxx...</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-411.html>PAGE 411</a></h6><p>Computer Remote Control 27 End of user RAM exceeded 28 Fatal device-specific programming error 29 Non-fatal device-specific programming error 2A Device Insertion error Note: The two following errors have the same error code. For either error to appear, you must have previously selected command n23] - where n = 0, 1, or 2. If a 0 is chosen, there will be no error condition. (Select Verify Option). If 1 was specified as the variable, use the first description. If 2 was specified, use the second description.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-412.html>PAGE 412</a></h6><p>Computer Remote Control 9B Incompatible system/algorithm disks or incompatible device libraries 9C Invalid command for this mode 9D I/O address beyond range of data format selected A1 No Electronic ID A2 Electronic ID verify error AB Unable to load system file from system disk AC Security violation AE Keep Current algorithm disk not found.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-413.html>PAGE 413</a></h6><p>F Local Mode Local mode is an operating mode for the ProMaster 2500 where the operator is communicating using the 2500’s keyboard and display. This mode can be used for initial system setup, running diagnostic tests or cycling devices. This chapter describes the parameters that can be changed using the 2500’s keyboard. Switching Between Local and Remote Modes The 2500 normally operates with TaskLink in Remote mode. To switch to Local mode, press LOWER CASE + L (for Local) on the 2500’s keyboard.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-414.html>PAGE 414</a></h6><p>Local Mode 3. Press 2 to select the thermal printer. This reconfigures the 2500 so that it operates with a thermal printer installed. The Main Menu Commands The 2500 will display the following Main Menu: * * PROMASTER 2500 MAIN MENU * * ENTER THE NUMBER OF THE DESIRED FUNCTION 1 - OPERATIONS 3 - SYSTEM SETUP 2 - FILE UTILITIES 4 - DIAGNOSTICS Press the number key corresponding to the optional menu you wish to access and the 2500 will display the new menu.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-415.html>PAGE 415</a></h6><p>Local Mode 3. Select the file you want to use for this operation. Use the arrow keys to scroll through the filenames. Press ↓ to scroll down the list of filenames and press ↑ to back up. Use ← and → to move the cursor across the columns to the file you want to use and press ENTER. In most cases you will be running in this mode to perform some test on the 2500’s operation. If you want to create a test label file and do not want to save the file for later use, select TEMPORARY as your file.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-416.html>PAGE 416</a></h6><p>Local Mode Type Size After you have selected an existing device or entered a valid length for your custom device, the 2500 displays: PRINT LABEL TEMPORARY FILE AUTO-SEL 26 CPI 26 CPI S 20 CPI 16 CPI T 12 CPI T 18 CPI MOVE TO SELECTION THEN PRESS ENTER Select the font you want and press ENTER. The 2500 displays: 1 Device Orientation in Input Tube <------- TEMPORARY FILE SELECT POSITION OF PIN 1 AS IT COMES OUT OF THE TUBE. USE ARROW KEYS THEN PRESS ENTER.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-417.html>PAGE 417</a></h6><p>Local Mode Text Content The TEMPORARY text file is ready to edit when the 2500 displays: SAMPLE PROMASTER 2500 TEXT | | | | TEMPORARY FILE COLUMN X ROW X PRESS STOP WHEN EDITING IS COMPLETE. Any text on the left side of the display is from the last file edited and COLUMN X and ROW X refer to the position of the cursor.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-418.html>PAGE 418</a></h6><p>Local Mode Print Only The Print Only feature enables you to check the position of text on the label by printing a label without applying it to a device. To use this feature, perform the following procedure. 1. Press 1 from the Main Menu to select OPERATIONS. The 2500 displays: * * * OPERATIONS MENU * * * 1 - PROGRAM/TEST & LABEL 4 - LABEL ONLY 2 - LOAD MASTER 5 - PRINT ONLY 3 - PROGRAM/TEST ONLY 6 - PURGE 2. Press 5 to select PRINT ONLY.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-419.html>PAGE 419</a></h6><p>Local Mode Editing an Existing File To select a file, scroll to that filename and press ENTER, or type the name of a file and press ENTER. The filename is shown on the top line of the display: FILE EDIT MODE FILENAME: FILE5 CURRENT PART IS: CUSTOM LENGTH: .250 DO YOU WISH TO CHANGE? (Y OR N): To change the device package, press Y. Otherwise, press N or ENTER. The 2500 displays: FILE EDIT MODE FILENAME: FILE5 CURRENT FONT IS: xxxx LENGTH: .</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-420.html>PAGE 420</a></h6><p>Local Mode Type a filename not currently on the list of files or use the arrow keys to scroll to files not listed on the display. (Only eight filenames appear on the screen at one time.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-421.html>PAGE 421</a></h6><p>Local Mode System Setup Menu There are three submenus under System Setup. General Setup Menu General setup allows you to change the port settings and choose to turn the audible alarm on or off. The access these from the 2500 Main Menu, press 3 to select SYSTEM SETUP.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-422.html>PAGE 422</a></h6><p>Local Mode Labeler Setup Menu Label Calibration This menu allows you to alter parameters which affect the printing of characters on a label and the application of that label on a device. Label calibration determines the distance between the edge of the label and the first printed character. If characters are not being printed on the label with the correct spacing from the label’s edge, make sure that the following have been checked: • Labels have been calibrated.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-423.html>PAGE 423</a></h6><p>Local Mode The 2500 displays: ENTER LABEL PLACEMENT VALUE (X): ENTER "A" FOR AUTO CENTERING Enter a number from 0 to 254. Entering a “0” (zero) places the left end of the label on the leading edge of the device; each unit higher moves the label 0.010-inches away from the leading edge of the device. Press ENTER to accept the selection. This parameter can also be changed by the system administrator using TaskLink.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-424.html>PAGE 424</a></h6><p>Local Mode The 2500 displays: * * * HANDLER SETUP MENU 1 - BINNING 2 - CONTROL FUNCTIONS 3 - SETUP MENU * * * Press 1. The 2500 displays: BIN 1=C1-X BIN 2=C1- C2C2-X C3C3-X C4C4-X C5C5-X LABEL-X LABEL- The C in the displays represents the category signal sent by TaskLink (or any computer remote control driver program) to indicate the result of the last programming operation. In the example above, a C1 signal from TaskLink indicates that the device passed.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-425.html>PAGE 425</a></h6><p>Index A Absolute addressing, 3-17 Adapter, air connection, 2-4 ADC optic adjusting value, 5-34, B-2 adjusting, dot matrix printer, 5-34 adjusting, thermal printer, 5-35 label calibration, 5-7 positioning, 5-7 roller assembly, 5-15, 5-17 super optic collector, A-5 Adjusting ADC optic, dot matrix printer, 5-34 ADC optic, thermal printer, 5-35 ADC value, 5-34, B-2 dot matrix print head gap, 5-24 dot split, 2-26 label placement, 2-25, 5-25 label print position, 5-25 label print position, thermal printer, 5-26 l</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-426.html>PAGE 426</a></h6><p>Index B Baud rate changing 2500 ports, F-9 default, E-2 setting on 2500, 2-21 Beam aligning, 4-27 lead screw lubrication, 5-62 stall and motor speed, B-3 stalling described, 5-8 stalls, 5-22 theory of operation, 5-8 Beam gasket replacement, 7-25 Beam head rotation motor replacement, 7-14 Beam optic malfunction message, 6-2 Beam traverse motor replacement, 7-14 Bearing plate, checking the height, 2-9, 5-26 Blank check, 3-8, 5-5, 6-3 Board pin driver, 5-20 power supply, 5-19 relay, 5-19 Bulletin Board Servic</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-427.html>PAGE 427</a></h6><p>Index D Daily maintenance, 5-56 Data I/O addresses, xvii—xviii Bulletin Board Service, xx contacting via BBS, xx contacting via phone, xix Data source, 3-7 Data sumcheck parameter, 3-18 Database file, defined, 3-5 Default settings, 2-20 Default values, 1-11 Defaults, programming electronics, restoring, 3-26 Deleting a file, F-8 Device ID error, 5-5 programming, 5-4, 5-20 verifying, 5-6 Device algorithm not found message, 6-2 Device error cleared, press start message, 6-2 Device jams, 5-21 Device List, read</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-428.html>PAGE 428</a></h6><p>Index G J General help index, 1-14 General setup, 2-21 General Setup menu, F-9 Jams, device, 5-21 H Kapton labels, ADC value, 4-18 Keep Current algorithm, selecting, 3-6 subscription service, 1-19 Kernel circuit, 5-50 Keyboard, 1-11 Keyboard/Display assembly replacement, 7-28 Keyboard/display test, 5-48 Keystroke summary, TaskLink, 1-13 Halting an operation in CRC, E-17 Handler sorting, 3-28 Hardware did not pass self-test message, 6-3 Hardware handshaking, D-3, D-4 Help, online, 1-14 Hex Label Forma</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-429.html>PAGE 429</a></h6><p>Index Labels adjusting, 5-25 calibrating, thermal printer, 4-22 calibration, 2-24, 5-25 calibration value firmware key, B-4 compatibility, 4-18 delete files, B-2 loading, 4-18 loading, dot matrix printer, 2-9, 4-18 loading, thermal printer, 2-13, 4-20 part number location, 4-18 position on device, 2-25 print position, 2-24 Labels not calibrated, press start message, 6-3 LCD display, 1-11 Lead screw lubrication, 5-62 replacement, 7-23 Left lead screw bearing assembly, replacing, 7-23 Loading RAM from a mast</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-430.html>PAGE 430</a></h6><p>Index P Package type, selecting, 3-9 Parameter entry fields, 1-14 Parameters factory default, B-2 system and factory, B-3 Part number, labels, 4-18 Parts per tube, B-4 Parts, 2500, 2-2 PC connecting to 2500, 2-16 requirements, 1-12 PCU (Pin Control Unit) defined, 5-19 PE (Programming Electronics) self-calibration, 5-20 self-test, 5-50 Periodic cleaning, 5-56 Personal computer See PC Pico fuses, 5-13 Pin Control Unit (PCU) defined, 5-19 Pin driver board, 5-20 PLCC devices, alignment, 4-27 module contacts, r</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-431.html>PAGE 431</a></h6><p>Index Repairing torn ribbon (thermal printer), 2-16, 5-60 Replacing anti-backlash nut, 7-24 beam gasket, 7-25 beam head rotation motor, 7-14 chuck tip, 4-17 controller board, 7-20 controller power supply, 7-19 DIP module contacts, 7-28 disk drive, 7-27 dot matrix printer ribbon cassette, 5-57 flex coupler, 7-21 input orbital motor, 7-7 input orbital tube clamp, 7-15 keyboard/display assembly, 7-28 labeler power supply, 7-20 lead screw, 7-23 left lead screw bearing assembly, 7-23 main fuse, 7-2 output orbit</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-432.html>PAGE 432</a></h6><p>Index T Task adding, 3-4 defined, 3-2 Logic Task parameters, 3-4 Memory Task parameters, 3-14 naming, 3-5 saving, 3-12 selecting a data source, 3-7 selecting a device, 3-6 selecting data file, 3-7 selecting package type, 3-9 selecting the process, 3-8 translation format, 3-7 Task parameters data sumcheck, 3-18 memory devices, 3-14 TaskLink adding a task, 3-4 communication with 2500, 2-19 database file defined, 3-5 error messages, 6-1—6-5 exiting, 2-18 general description, 1-2, 1-12 installing, 2-17 load fr</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-433.html>PAGE 433</a></h6><p>Index U Unable to lower beam message, 6-4 Unable to pick up device, press start message, 6-4 Unable to raise beam message, 6-4 Unable to release device, press start message, 6-5 Unpacking and inspecting the 2500, 2-2 Updates, 1-19 User interface options, 1-14 User RAM, 1-16 V Vacuum generator on/off diagnostic test, B-2 power, 5-13 VAC, checking, 5-34 Vector translation, 3-14 ProMaster 2500 User Manual Verify fail message, 5-6 Verify fail, pass X message, 6-5 Verify options, logic device, 3-12 W Warran</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-434.html>PAGE 434</a></h6><p>Index Index-10 ProMaster 2500 User Manual</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-435.html>PAGE 435</a></h6><p>Keep Current Subscription Service The Keep Current™ subscription service keeps your programmer up-todate with the latest features and device support. You gain immediate access to new and improved programming algorithms via the Keep Current Library accessible through the Internet or via the Data I/O BBS. Semiconductor companies constantly introduce new devices and issue specification changes for existing devices.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-436.html>PAGE 436</a></h6><p>Keep Current Subscription Service Procedure Overview 2 Keep Current</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-437.html>PAGE 437</a></h6><p>Keep Current Subscription Service 1. Gather Device Information 2. Connect to Keep Current BBS Web Page 3. Find Device Algorithm 4. Download Algorithm 5.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-438.html>PAGE 438</a></h6><p>Keep Current Subscription Service 1. Gather Information Knowing the following information about the devices you will be programming will enable you to find the correct algorithm once you are connected. • Manufacturer (example: AMD) • Device name (example: 27c1024) • Package type (example: 48-pin PLCC) • Current version of the programmer software (example: 5.4) 2. Connect to Keep Current Using the BBS Use the following procedure to log on to the Keep Current BBS: 1. Modem: Call 206-882-3211.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-439.html>PAGE 439</a></h6><p>Keep Current Subscription Service 3. Find Device Algorithm Once you have reached the Keep Current Library, select the correct algorithm. Algorithms are arranged by programmer and system software version. Keep Current filenames are represented as follows: xVVddddd.exe Programmer Type u = UniSite r = 2900 s = 3900 a = AutoSite or ProMaster 2500 Version Number with which this algorithm will work.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-440.html>PAGE 440</a></h6><p>Keep Current Subscription Service 4. Download Algorithm Algorithms come in a self-extracting file format. Place the Keep Current file on a floppy disk and then expand the file by running it. The following files should be created: File Name xVVddddd.KCx xVVddddd.txt adapters. sys* devfnote.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-441.html>PAGE 441</a></h6><p>Keep Current Subscription Service Sample Keep Current Scenario The following example illustrates a typical Keep Current scenario: Keep Current 1. In May, you update your system software to version x.4. At the same time, you enroll in the Keep Current Subscription Service. 2. In June, Cruft Technologies announces a new device, the Cruft 1263. 3.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-442.html>PAGE 442</a></h6><p>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.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-443.html>PAGE 443</a></h6><p>Figure 3-18. Commands Available from the Options Pull-down Menu .. 328 Figure 3-19. Selecting Security Options..................................................... 3-29 Figure 3-20. Password Screen for System Operators............................... 3-30 Figure 3-21. Configuring Operating Preferences ..................................... 3-31 Figure 3-22. Selecting “Add Kit” from the Main Screen......................... 3-32 Figure 3-23. Kits are a Series of Tasks in a Single Job............................</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-444.html>PAGE 444</a></h6><p>Figure 5-3. Beam Air Holes ......................................................................... 5-11 Figure 5-4. Power Supplies.......................................................................... 5-14 Figure 5-5. Missing Character Dots in Label Printout............................. 5-22 Figure 5-6. Adjusting Label Calibration .................................................... 5-25 Figure 5-7. Print Shift (affects vertical position)....................................... 5-26 Figure 5-8.</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-445.html>PAGE 445</a></h6><p>Figure 7-8. Input and Output Orbital Assemblies ..................................... 7-8 Figure 7-9. Note the Wire Colors and Positions......................................... 7-9 Figure 7-10. Align the Slit in the Collar with the Slit in the Spindle ..... 7-10 Figure 7-11. Removing the Print Drive Motor (Dot Matrix Printer shown; Thermal Printer similar) .............................................................................. 7-12 Figure 7-12. Removing the Print Head ...............................</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-446.html>PAGE 446</a></h6><p>Figure D-22. Hewlett-Packard 64000 Unix Format................................. D-51 Figure D-23. A Sample of the Intel OMF286 Format.............................. D-53 Figure D-24. A Close-up of the Intel OMF286 Format ........................... D-54 Figure D-25. An Example of the Intel Hex-32 Format............................ D-55 Figure 1. Keep Current BBS Logon Screen .....................................................3 Figure 2. Keep Current Library Menu.............................................</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-447.html>PAGE 447</a></h6><p>vi Technical Review UniSite User Manual</p></li><li><h6><a class="text-decoration-none text-link fw-bold" href=/manual/data-technology/pro-master-2500/1-user-manual-english/page-448.html>PAGE 448</a></h6><p>Table 4-1. ProMaster Programming Module Configuration Chart . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11 Table 5-1. ProMaster 2500 Label Print Guide (Dot Matrix Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16 Table 5-2. 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