I simulate pion showers in a hadronic sampling calorimeter. With the FTF_BIC physics list I got several times following error which causes Geant4 to exit:

G4BinaryCascade::GetIonMass() - invalid (A,Z) = (0,2)
G4BinaryCascade::GetIonMass() - giving up

This happened 6 times in approx. 2 million simulated events. (I simulate 10 different energies between 8 and 80 GeV, each 200k events)

Here is the list of invalid (A,Z) combinations:
G4BinaryCascade::GetIonMass() - invalid (A,Z) = (0,2)
G4BinaryCascade::GetIonMass() - invalid (A,Z) = (-1,-1)
G4BinaryCascade::GetIonMass() - invalid (A,Z) = (0,2)
G4BinaryCascade::GetIonMass() - invalid (A,Z) = (0,2)
G4BinaryCascade::GetIonMass() - invalid (A,Z) = (-1,-2) G4BinaryCascade::GetIonMass() - invalid (A,Z) = (-1,-1)

3 of the 6 occurrences were with 60GeV pi+. One each with 10GeV pi-, 30GeV pi+ and 50GeV pi+. 

The used Geant version is:
*************************************************************
 Geant4 version Name: geant4-09-03    (18-December-2009)
                      Copyright : Geant4 Collaboration
                      Reference : NIM A 506 (2003), 250-303
                            WWW : http://cern.ch/geant4
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