Inking Troubleshooting Guides

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Specialized troubleshooting for the Motorized-Z inking system
1) Motorized-Z function is not working (up and down buttons do not move the shuttle)
2) Irregular size or skipping dots using small dot function
3) Audible alarm does not sound, is too loud or not loud enough

Specialized troubleshooting for the Auto-Z inking system
1) Up and down push buttons do not move the shuttle 
2) Auto Z function does not initiate or stalls
3)When Auto Z function is initiated, the inker moves up and stops and the STATUS light starts to flash. 
4) Auto Z function moves the shuttle but does not return the cartridge tip to the same place when a cartridge is replaced

X5200 for TEL P8
1) Inker does not ink in the center of the die

Symptom: State Symptom
Cause a): State Cause A for Symptom 
Solution a): State solution(s) for Cause A
Cause b): State Cause B for Symptom
Solution b): State solution(s) for Cause B (continue with Cause:Solution as required)
Related Information: Included if there is related information/referral to other causes, for example: "See pneumatic shuttle maintenance procedure"

1) Symptom: Dots too large or too small
Cause a): Dot size setting on the controller is adjusted too high (large dots) or too low (small dots). 
Solution a): Adjust the controller dot size setting.

Cause b): b) Main Air pressure supply to pneumatic controller is too high (large dots) or too low (small dots). 
Solution b): Verify setting at 70 ± 10 PSI for all inkers except Motorized-Z inker, which should receive air at 80 ± 5 PSI.

Cause c): Wrong cartridge type (A5, A6, A8) is being used for dot size range desired.
Solution c): Change to a cartridge type with dot size range appropriate to desired dot size.
Related Information: See pneumatic cartridge dot size specifications (PDF 66kb )

Cause d): Controller dot size potentiometer or thumbwheel module is defective.
Solution d): Run Diagnostics test B described in controller diagnostics. If test results are not within parameters, contact Xandex Customer Service.

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Cause b): If the chuck moves the wafer Z up during an inking cycle, AND the prober allows this inking height to be adjusted, the chuck inking Z height is set out of range. 
Solution b): Consult the prober documentation and re-set the chuck inking Z height so that it is within the range of the inkers Z adjustment capability.

Cause c):  Prober ring carrier (head plate) is set too high.
Solution c):  Occasionally, depending on previous inker setup, the ring carrier (head plate) will need to be lowered (or raised) to accommodate the Motor-Z inker.  Adjust the ring carrier height so that it is within range of the inkers Z adjustment capability.  Planarize ring carrier after adjustment and repeat inker setup.

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Cause b):  Prober chuck was not set to "Z up" (inking) position when the inker was initially setup. When the chuck moves up into inking/test position, the cartridge crashes into the wafer surface.
Solution b):   Replace cartridge and repeat inker setup with chuck in correct inking position. 

Cause c):  Prober ring carrier (head plate) is set too low.
Solution c):  Occasionally, depending on previous inker setup, the ring carrier (head plate) will need to be raised (or lowered) to accommodate the Motor-Z inker.  Adjust the ring carrier height so that it is within range of the inkers Z adjustment capability.  Planarize ring carrier after adjustment, replace cartridge and repeat setup.

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Cause b): The controller-to-shuttle air tubing is connected but air flow to the shuttle and cartridge is restricted
Solution b): Verify that the controller-to-shuttle air tubing is not kinked, clogged or pinched closed. Correct any air restriction discovered. If the tubing or connector is damaged, replace the controller-to-shuttle tube assembly.

Cause c): The controller-to-shuttle air tubing is connected but the air pressure supply to the controller is NOT connected or is adjusted improperly.
Solution c): Verify air pressure setting at the regulator is 70 ± 10 PSI for all inkers except Motorized-Z inker, which should receive air at 80 ± 5 PSI.

Cause d): An unlikely combination of causes:  the shuttle is frozen due to lack of maintenance/lubrication AND the cartridge is empty, not primed correctly, is clogged or has a damaged teflon tube that restricts ink flow.
Solution d): Perform recommended shuttle maintenance to restore shuttle function and re-prime or replace the ink cartridge.

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Cause b): The cartridge is empty, not primed correctly, or has a damaged teflon tube that restricts ink flow.
Solution b): Verify cartridge priming, insuring that the needle collar is flush with the cartridge neck and the internal membrane is broken. If the cartridge is empty, clogged or damaged, replace the cartridge.

Cause c): Ink has dried at the cartridge tip and is restricting ink flow.
Solution c): Clean the tip of the cartridge with a lint free swab and DieMark ink remover to remove the dried ink. See Ink Curing and removal section of the Xandex website for more information.

Cause d): The rubber washer is not present on the cartridge air fitting or it is damaged allowing air to leak at this connection point and decreasing air signal to the cartridge.
Solution d): Verify that the rubber washer is present and replace the washer if it is damaged. 

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Cause b):  The shuttle air supply tubing (blue side of the twin blue/red tubing) is cut or blocked preventing air signal from reaching the shuttle.
Solution b):  Inspect the shuttle air supply tubing (blue tubing) and verify that it is not cut, pinched or clogged and correct as necessary.

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• RED AIR TUBING connects to the ink cartridge and to the barbed fitting that is closest to the center of the controller connector.
• BLUE AIR TUBING connects to the shuttle connection on the shuttle mechanism and to the barbed fitting that is closest to the outside edge of the controller connector.

Related Information: See Shuttle Maintenance and Training section of the Xandex website.

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Cause b):  Shuttle is sticking due to lack of maintenance
Solution b):  Perform recommended shuttle maintenance.
Related Information: See Shuttle Maintenance section of the Xandex website here.

Cause c):  The cartridge valve and/or the shuttle valve in the pneumatic controller are worn and have not been replaced at the recommended intervals, causing inconsistent performance.
Solution c):  Perform recommended controller maintenance.
Related Information: See Controller Maintenance section of the Xandex website here.

ALL CAUSES: See related information in the Ink and Cartridge Troubleshooting section here

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Cause b):  The cartridge was not placed in the cartridge preparation tool correctly when the cartridge was primed, causing the needle to be inserted into the cartridge body at an angle.
Solution b):  Replace the cartridge with a correctly primed cartridge.  The cartridge needle should be straight (inline with the centerline of the cartridge body) and the needle collar should be flush with the cartridge neck.

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MOTORIZED Z INKER

Cause b):  Motor cable is not plugged into the controller
Solution b): Verify that the inker stepper motor is plugged into the "MOTOR" connection on the back of the Controller.

Cause c):  Pins on the motor cable connector are bent or broken, causing faulty connection of the motor to the controller.
Solution c): Xandex recommends returning the inker base to the factory for replacement of the connector.  If a technician with fine soldering skills is available to complete the repair, a new connector can be ordered by contacting Xandex Customer Service or by ordering online. Order part number 158-0008, 7 pin quick disconnect plug. 

Cause d):  Stepper motor mount has loosened or detached from the inker body. 
Solution d):  The motor is secured to the inker base via two screws.  If they have only loosened slightly, it may be possible to re-tighten the screws to restore motorized Z  function.  If the motor has loosened significantly, Xandex recommends returning the inker base to the factory for service and alignment.
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Cause e):  Stepper motor wires have become disconnected from the motor.
Solution e):  Return the inker base to Xandex for service.

Cause f):  Guideway pins are bent causing the inker Z stage to bind.
Solution f):  The guideway pins that align the Z movement of the inker Z stage can become bent if the unit is dropped, causing the Z stage to bind as the motor attempts to move the stage up and down.  If you can feel the motor actuate when the UP and DOWN buttons are pressed but the inker does not move, this is probably the cause.  The inker should be returned to Xandex for repair.

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Cause b):  The internal air pressure regulator that governs the small dot air signal is not adjusted correctly.
Solution b):  Download the Motorized-Z user manual (PDF 750Kb) by clicking here.  Follow the instructions in the Maintenance and Troubleshooting section for re-setting the internal regulator.

Cause c):  Ring carrier is set too low. 
Solution c):  Depending on the chuck Z setup range, it may be necessary to raise (and planarize) the ring carrier to position the inker high enough for full Z adjustment range to be effective.

Cause d):  Prober chuck is not planar.
Solution d):  Verify chuck planarity and adjust as required.  Perform inker setup again after chuck is planarized. 

Cause e):  Inker shuttle is binding due to lack of maintenance.  Regular shuttle preventive maintenance is especially critical when the inker is used continuously (24/7) over long periods of time.
Solution e):  Perform shuttle maintenance. Shuttle maintenance kits and instructions are available from Xandex.  See the Shuttle Maintenance section of the Xandex web site here for details.

Cause f):  Controller Cartridge valve needs to be replaced.  Regular cartridge valve replacement is especially critical when the inker is used continuously (24/7) over long periods of time in small dot mode. 
Solution f):  Perform cartridge valve replacement. Valve maintenance kits and instructions are available from Xandex. See Controller Maintenance section of the Xandex web site here for details. 
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Cause a):  Audible alarm has been disabled or volume needs adjustment.  
Solution a):  When enabled, the audible alarm sounds when the Hours X10 or Dots X1000 set points programmed into the controller are reached.  See the Alarm Volume Adjustment instructions in the Motorized Z user manual here (PDF 750Kb) to enable/disable and set the volume for the audible alarm. 

AUTO Z INKER

1) Up and down push buttons do not move the shuttle
Solution a):  See possible causes and solutions listed at "Motorized-Z function is not working (up and down buttons do not move the shuttle)" under Motorized Z inker section.

Cause a): Sensor nozzle air tubing is not connected to the controller 
Solution a):  Connect the sensor nozzle tubing to the port on the rear of the controller labeled "sensor"

Cause b):  Sensor nozzle is clogged or tubing is pinched or cut restricting air flow to the sensor nozzle.
Solution b):  Inspect the sensor nozzle tip and clean if necessary.  Inspect sensor air tubing (clear tube) for cuts and make sure it is not pinched so that air flow to the sensor nozzle is restricted.

Cause c): Sensor nozzle is loose in retaining bracket.
Solution c):  Download the Auto-Z user manual here (PDF xxxKb) and review the procedure in the maintenance and troubleshooting section for adjusting the sensor nozzle position on the bracket.  

Cause d):  When the Auto-Z function is initiated and the sensor nozzle is within 0.10 inches (0.254 cm) of the wafer surface, the sensor will move up slightly and then down to the set position, giving the appearance that the Auto-Z function is not initiating.
Solution d):  This is a programmed function of the controller.  When the sensor is completely out of range of the wafer surface, the inker will move up to its topmost range of travel before moving down to the set point.  When the Auto-Z function is activated with the sensor in range of the wafer surface (within 0.10 inches/0.254 cm) the inker moves up slightly until it is out of range (instead of moving completely up to the top or travel position) and then begins downward movement to the set point.  This range of movement is small enough to go unnoticed unless the unit is being closely observed.

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Cause a):  If the Auto-Z function is initiated without air connected to the controller OR without the air sensor tubing connected to the controller, the unit is programmed to move up to the top end of its range of travel and stop.  The STATUS light begins to flash as a warning that the sensor is without air flow.
Solution a):  Verify that the controller is connected to a 70 ± 10 PSI air supply and that the sensor tubing is connected to the port on the controller labeled "SENSOR"

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Cause a): Auto Z function is working correctly, however, slight cartridge manufacturing variations OR inconsistent priming (variation from cartridge to cartridge in needle penetration into the cartridge body at priming) may require additional manual fine tuning using the UP and DOWN buttons on the controller.

Solution a):  Download the X4105, X4205 Auto-Z Pneumatic Inker (PDF 816 KB) and review the inker setup procedure for instructions on how to fine tune cartridge placement.  If the cartridge preparation tool is damaged, dirty or worn, inconsistent exposed needle length may result at priming.  Replacement cartridge preparation tools can be ordered by contacting Xandex customer service.  Order part number 200-0001.

Cause b): Sensor nozzle is loose in retaining bracket on the inker.
Solution b):  Download the X4105, X4205 Auto-Z Pneumatic Inker (PDF 816 KB) and review the procedure in the maintenance and troubleshooting section for adjusting the sensor nozzle on the bracket.  

Cause c):  Controller has not been calibrated to the Inker assembly. 
Solution c):  Each Auto-Z inker assembly/controller pair must be calibrated to work together. Download the X4105, X4205 Auto-Z Pneumatic Inker (PDF 816 KB) and perform the procedure in the maintenance and troubleshooting section for calibrating the controller with the inker.  

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X5200 for TEL P8