Pneumatic Controller Diagnostic Tests

Pneumatic Controller Maintenance and Diagnostics 

Standard Controller Diagnostics and Logic Board
Auto-Z Controller Diagnostics and Logic Board
Motorized-Z Controller Diagnostics and Logic Board

Controller Sequence of Operation (applies to all controllers)
To initiate an ink dot, the Prober sends a 12-60 V (AC/DC unregulated) active-low signal to the Controller. After receipt of the signal, the microcontroller performs various checks of system status prior to firing the pneumatic valves.

Upon completion of the status checks, a 22.47ms pulse is sent to the Shuttle Valve, while at the same time a 6.4-24.8ms pulse (depending on position of Dot Size knob) is sent to the Cartridge Valve. 

Note:  In the X5200 Series Inkers the valves are part of the Valve/Manifold Assembly 231-0071 on the Inker Base and not contained inside the controller.  Sequence of operation is identical to the standard controller.

As the shuttle extends to the lower position, the air pulse from the Cartridge Valve forces ink out of the cartridge barrel and forms a drop at the end of the needle tip. When the shuttle is at its lowest position, the drop makes contact with the wafer surface and forms a dot. The shuttle then returns to the normal position.

At the completion of each dot, a small amount of vacuum is developed in the cartridge by the closure of the valve, preventing dripping. If another dot sequence is not initiated within 10 seconds, a short "puff" pulse equal to 1/2 the dot size duration (10-20ms) is sent to the cartridge to displace a small amount of ink back into the Teflon tube to aid in maintaining proper dot size after a long delay between dots.

Standard Controller Diagnostics
There are a few internal diagnostic tests available for testing the Controller. To enter the Diagnostics mode, apply power to the Controller with the "RESET" button to the right of the thumbwheels depressed.

The following tests are available:

Test Thumbwheels

1. Place the toggle switch on the front panel to SET-UP, set the thumbwheels to 12345, then reset the LCD Counter.

2. Press the RESET button and verify that the counter increments 15 counts.

3. Place the toggle switch to RUN, set the thumbwheels to all 1’s, reset the LCD Counter, and press RESET. The counter should increment one count.

4. Repeat the procedure for the rest of the digits (2 through 9). With the thumbwheels set for 00000, the counter increments 10 counts.

Test Dot Size Potentiometer

1. Place the toggle switch to DISABLE, set the HOURS thumbwheels to 01, then reset the LCD Counter.

2. With the Dot Size knob set at the minimum position, press the RESET button and verify that the LCD Counter does not increment.

3. Set the knob to 50% and press RESET. The Counter should display approximately 130 counts. (Variations in Dot Size knob alignment to scale may occur. An increment of ± 10 is not significant in this case.)

4. Reset the LCD Counter, adjust the knob to maximum, and press RESET. The Counter should display 255 counts.

Test Cartridge Valve

To test fire the Cartridge Valve 20 times:

1. Set the HOURS thumbwheels to 02

2. Place the toggle switch to DISABLE

3. Reset the LCD Counter

4. Press RESET. The cartridge valve fires 20 times, each time incrementing the LCD Counter.

Test Shuttle Valve

To test fire the Shuttle Valve 20 times:

1. Set the HOURS thumbwheels to 03

2. Place the toggle switch to DISABLE

3. Reset the LCD Counter

4. Press RESET.

The shuttle valve fires 20 times, each time incrementing the LCD Counter.

Life Test

This test will continuously fire the Cartridge and Shuttle valves for a predetermined number of cycles as set on the thumbwheels.

1. Place the toggle switch to DISABLE.

2. Set the HOURS thumbwheels to 10.

3. Set the DOTS X1000 thumbwheels for the desired number of cycles X1000 (i.e., 250 Equals 250,000 cycles).

4. Reset the LCD Counter.

5. Press RESET.

The Controller begins continuous firing, incrementing the Counter each cycle. To discontinue the Life Test prior to reaching the set amount, remove power.

Internal Maintenance

CAUTION: Use appropriate ESD precautions when working inside of the Controller!

Note: Making any modifications to the controller circuitry or components other than Xandex recommended maintenance procedures may void your controller warranty. These instructions are provided for replacement of the microcontroller for upgrade purposes and to enable/disable the audible alarm only.

With Power and Main Air removed:

1. Remove the cover of the controller.

2. Disconnect the connectors from J2-J5 on the controller logic board. See wiring diagram 260-0019 on the Drawings CD supplied with this manual.

3. Push back both locking devices on the card guides to unlock position, then lift the logic board from the mounting location.

4. Disconnect connector from J1 on the logic board.

5. Disconnect connector from J1 on the logic board. Place the logic board on ESD protective surface or store in ESD protective anti-static bag.

Reverse this procedure for installation of logic board.

Removal/Replacement of Microcontroller With the Logic Board removed:

1. Carefully remove the microcontroller from the J1 and J2 headers on daughter card 250-1160, using the appropriate IC removal tool. Reference Drawing 250-1160 on the Drawings CD supplied with this manual. Do not attempt to remove the 250-1160 daughter card from the logic board.

2. Use caution when removing the Microcontroller to prevent damage to the leads.

3. Place the microcontroller on anti-static foam, then in ESD protective anti-static bag for storage.

To re-install:

1. Match pin one markings on microcontroller and the 250-1160 daughter card, line up component leads with J1 and J2 sockets (verify correct orientation of microcontroller per Schematic 950-1001 on the Drawings CD supplied with this manual) and gently press to install, using caution to prevent bending or damage to the leads.

2. Visually inspect the socket and microcontroller to insure the integrity of the installation prior to re-installation of logic board.

3. After installing the microcontroller, re-install the logic board by reversing the procedure outlined in the “Controller Logic Board Removal” above.

There are five internal diagnostic tests available for testing the Auto-Z Controller. To enter the Diagnostics mode, apply power to the Controller with the “RESET” button to the right of the thumbwheels depressed. All references to “mode switch” in the following tests refer to the top mode (toggle) switch. The bottom mode switch should be set to RUN during testing.

Test Thumbwheels

1. Place the mode switch on the front panel to SETUP, set the DOTS X1000 thumbwheels to 12345, then reset the LCD Counter.
2. Press the RESET button and verify that the counter increments 15 counts.
3. Place the toggle switch to RUN, set the thumbwheels to all 1’s, reset the LCD Counter, and press RESET. The counter should increment one count.
4. Repeat the procedure for the rest of the digits (2 through 9). With the thumbwheels set for 00000, the counter increments 10 counts.

Test Cartridge Valve
To test fire the Cartridge Valve 20 times:

1. Set the DOT SIZE thumbwheels to 02
2. Place the mode switch to CALIBRATE
3. Reset the LCD Counter
4. Press RESET.

The cartridge valve fires 20 times, each time incrementing the LCD Counter.

Test Shuttle Valve
To test fire the Shuttle Valve 20 times:

1. Set the DOT SIZE thumbwheels to 03
2. Place the mode switch to CALIBRATE
3. Reset the LCD Counter
4. Press RESET.

The shuttle valve fires 20 times, each time incrementing the LCD Counter.

Test Sensor Valve
To test fire the Sensor Valve 20 times:

1. Set the DOT SIZE thumbwheels to 09
2. Place the mode switch to CALIBRATE
3. Reset the LCD Counter
4. Press RESET.

The sensor valve fires 20 times, each time incrementing the LCD Counter.

Life Test
This test will continuously fire the Cartridge and Shuttle valves for a predetermined number of cycles as set on the thumbwheels.

1. Place the mode switch to CALIBRATE
2. Set the DOTS X1000 thumbwheels for the desired number of cycles X1000 (i.e.: 250 Equals 250,000 cycles).
3. Reset the LCD Counter.
4. Press RESET.

The Controller begins continuous firing, incrementing the Counter each cycle. To discontinue the Life Test prior to reaching the set amount, remove power.
 

Auto-Z Controller Logic Board Removal

With Power and Main Air removed:

1. Remove the cover of the Controller.
2. Disconnect the Molex connectors (P2 through P7) from the top of the controller logic board. (See wiring diagram 350-0006 on the Drawings CD included with the product manual)
3. Push back both locking devices on the card guides to unlock position, then lift the logic board from the mounting location.
4. Disconnect the P1 connector from the logic board and remove the logic board from the controller.
5. Place the logic board on ESD protective surface or store in ESD protective anti-static bag.
6. Reverse this procedure for installation of logic board.

Removal/Replacement of Microcontroller

With the Logic Board removed:

1. Carefully remove the microcontroller from the J1 and J2 headers on daughter card 250-1160, using the appropriate IC removal tool. Reference Drawing 250-1160 on the Drawings CD supplied with the product manual.
2. Do not attempt to remove the 250-1160 daughter card from the logic board.Use caution when removing the Microcontroller to prevent damage to the leads.
3. Place the microcontroller on anti-static foam, then in ESD protective anti-static bag for storage.

To re-install:

1. Match pin one markings on microcontroller and the 250-1160 daughter card, line up component leads with J1 and J2 sockets (verify correct orientation of microcontroller per Schematic 950-1003 on the Drawings CD supplied with the product manual) and gently press to install, using caution to prevent bending or damage to the leads.
2. Visually inspect the socket and microcontroller to insure the integrity of the installation prior to re-installation of logic board.
3. After installing the microcontroller, re-install the logic board by reversing the procedure outlined in the “Controller Logic Board Removal” above.

Turn Audible Alarm ON/OFF

Auto-Z controller units (P/N 350-0006) with serial numbers higher than 3000 are equipped with an audible alarm feature. When enabled, an audio alarm will sound (in addition to the STATUS LED illuminating) when the programmed number of dots, or number of hours set point is reached. The controller is shipped with the audio alarm feature disabled.

With the logic board removed:

1. Locate JP2 on the 250-1160 daughter card mounted on the 250-1001 printed circuit board. In the default factory condition, JP2 is populated with a jumper on pin 1 only. This is the default audio alarm disabled condition.
2. To enable the audio alarm remove the jumper from pin 1 on JP2 and install the jumper onto pins 1 and 2. This is the audio enabled condition.
3. After enabling/disabling the alarm, re-install the logic board by reversing the procedure outlined in the “Controller Logic Board Removal” above.

Before returning the unit to service:

Install the cover, apply power and main air, and perform controller diagnostics, as documented in this chapter, to verify operation. If problems are noted, review the installation of the microcontroller or audio alarm jumper to insure installation is correct, none of the component leads are bent, and verify connection of P1 through P7 connectors on the logic board.

There are six internal diagnostic tests available for testing the Controller. To enter the Diagnostics mode, apply power to the Controller with the “RESET” button to the right of the thumbwheels depressed. All references to “mode switch” in the following tests refer to the top mode (toggle) switch. The bottom mode switch should be set to RUN during testing.

Test Thumbwheels

1. Place the mode switch on the front panel to SETUP, set the DOTS X1000 thumbwheels to 12345, then reset the LCD Counter.
2. Press the RESET button and verify that the counter increments 15 counts.
3. Place the toggle switch to RUN, set the thumbwheels to all 1’s, reset the LCD Counter, and press RESET. The counter should increment one count.
4. Repeat the procedure for the rest of the digits (2 through 9). With the thumbwheels set for 00000, the counter increments 10 counts.

Test Cartridge Valve

To test fire the Cartridge Valve 20 times:

1. Set the DOT SIZE thumbwheels to 02
2. Place the mode switch to DISABLE
3. Reset the LCD Counter
4. Press RESET.

The cartridge valve fires 20 times, each time incrementing the LCD Counter.

Test Shuttle Valve

To test fire the Shuttle Valve 20 times:

1. Set the DOT SIZE thumbwheels to 03
2. Place the mode switch to DISABLE
3. Reset the LCD Counter
4. Press RESET.

The shuttle valve fires 20 times, each time incrementing the LCD Counter.

Test Pressure Valve

To test fire the Pressure Valve 20 times:

1. Set the DOT SIZE thumbwheels to 09
2. Place the mode switch to DISABLE
3. Reset the LCD Counter
4. Press RESET.

The pressure valve fires 20 times, each time incrementing the LCD Counter.

Life Test

This test will continuously fire the Cartridge, Shuttle and Pressure valves for a predetermined number of cycles as set on the thumbwheels.

1. Set the DOT SIZE thumbwheels to 10
2. Place the mode switch to DISABLE
3. Set the DOTS X1000 thumbwheels for the desired number of cycles X1000 (i.e.: 250 Equals 250,000 cycles). If the thumbwheel count is zero, the valves cycle 6,553,600 times.]
4. Reset the LCD Counter.
5. Press RESET.

The Controller begins continuous firing, incrementing the LCD Counter each cycle. To discontinue the Life Test prior to reaching the set amount, remove power.

Alarm Test

Pressing the reset button will toggle the state of the alarm signal. This signal controls the red STATUS LED and the LOUD audio alarm.

1. Set the DOT SIZE thumbwheels to 06
2. Place the mode switch to DISABLE
3. Press RESET to change the state of the alarm.

Motorized-Z Logic Board Removal

Note: Making any modifications to the controller circuitry or components other than Xandex recommended maintenance procedures might void your controller warranty. These instructions are provided for replacement of the microcontroller for upgrade purposes and to enable/disable the audible alarm only.

With Power and Main Air removed:

1. Remove the cover of the Controller.
2. Disconnect the Molex connectors from J2 through J7 on the top of the controller logic board. (See controller drawing 350-0018 on the Drawings CD included with the product manual)
3. Push back both locking devices on the card guides to unlock position, then lift the logic board from the mounting location.
4. Disconnect the connector from J1 on the face of the logic board and remove the board from the controller.
5. Place the logic board on an ESD protective surface or store in ESD protective anti-static bag.

Reverse this procedure for installation of logic board.

Removal/Replacement of Microcontroller

With the Logic Board removed:

1. Carefully remove the microcontroller from the J1 and J2 headers on daughter card 250-1160, using the appropriate IC removal tool. Reference Drawing 250-1160 on the Drawings CD supplied with the product manual. Do not attempt to remove the 250-1160 daughter card from the logic board.
2. Use caution when removing the Microcontroller to prevent damage to the leads.
3. Place the microcontroller on anti-static foam, then in ESD protective anti-static bag for storage.

To re-install:

1. Match pin one markings on microcontroller and the 250-1160 daughter card, line up component leads with J1 and J2 sockets (verify correct orientation of microcontroller per Schematic 950-1003 on the Drawings CD supplied with the product manual) and gently press to install, using caution to prevent bending or damage to the leads.
2. Visually inspect the socket and microcontroller to insure the integrity of the installation prior to re-installation of logic board.
3. After installing the microcontroller, re-install the logic board by reversing the procedure outlined in the “Controller Logic Board Removal” above.

Turn Audible Alarm ON/OFF

Motor-Z controller units (P/N 350-0018) with serial numbers higher than 3000 are equipped with an audible alarm feature. When enabled, an audio alarm will sound (in addition to the STATUS LED illuminating) when the programmed number of dots, or number of hours set point is reached. The Motor-Z controller is shipped with the audio alarm feature enabled.

With the logic board removed:

1. Locate JP2 on the 250-1160 daughter card mounted on the 250-1003 printed circuit board. In the default factory condition, JP2 is populated with a jumper on pin 1 and pin 2. This is the default audio alarm enabled condition.
2. To disable the audio alarm remove the jumper from pin 1 and 2 on JP2 and install the jumper onto pin 1 only. This is the audio disabled condition.
3. After enabling/disabling the alarm, re-install the logic board by reversing the procedure outlined in the “Controller Logic Board Removal” above.

Before returning the unit to service:

Install the cover, apply power and main air, and perform controller diagnostics, as documented in this chapter, to verify operation. If problems are noted, review the installation of the microcontroller or audio alarm jumper to insure installation is correct, none of the component leads are bent, and verify connection of J1 through J7 connectors on the logic board.