Pneumatic Controller Preventive Maintenance

The two solenoid driven air valves used in Xandex pneumatic controllers to drive the Pneumatic Shuttle and Ink Cartridge are identical. Valve one (V1) supplies air to the ink cartridge, and is also referred to as the Cartridge Valve. Valve two (V2) supplies air to the pneumatic shuttle and is also called the Shuttle Valve.

Xandex Auto Z and Motorized Z controllers contain a third valve (V3) that is identical to the Shuttle and Cartridge valves. The Auto Z controller uses this valve only when the Auto Z function is engaged. The Motorized Z uses this valve to change the air pressure supplied to the cartridge valve when inking in small dot mode. In normal operation, the third valve (V3) in either the Auto Z or Motorized Z controller will not need replacement for the life of the unit.

Preventive maintenance for Xandex pneumatic controllers requires replacement of just the Cartridge Valve, or of both the Cartridge and Shuttle valves at the intervals specified below.

Controller Model	Replace	Interval
All Models	Cartridge Valve	12 million cycles
All Models	Cartridge Valve, Shuttle Valve and internal tubing	Every 24 months

Two valve replacement kits are available from Xandex to facilitate controller preventive maintenance.

Cartridge Valve Kit, containing a single valve assembly, electrical connectors and replacement instructions. This kit is used for the 12 million cycle controller preventive maintenance. Order part number 370-0100. Online Training Now Available

Dual Valve Kit containing two valve assemblies, electrical connectors, adequate tubing to replace all internal controller pneumatic routes in all Xandex pneumatic controllers and replacement instructions. Replacement of the polyurethane tubing is recommended as the internal operating temperature within the controller enclosure can cause the tubing to shrink slightly over time. This can result in leaking connections at the valve and coupling connections. This kit is used for the 24 month controller preventive maintenance. Order part number 370-0101. Online Training Now Available

Valve Replacement Kit Instructions

For more information or to order pneumatic controller PM kits, contact Xandex Customer Service at (707) 763-7799, (800) 767-9543 (toll free in the US), FAX (707) 763-2631; email info@xandex.com or order online at www.xandex.com.

Pneumatic Controller Valve Replacement (all models) Current Build Pre-June 1999

Applications Note: Controller units manufactured before June, 1999 used a soldered wire splice covered by heat shrink tubing for valve electrical connections, instead of the snap plug connectors used in the current build. The replacement valve assembly P/N 240-0261 is shipped with post-end snap plug connectors. To order crimp on receptacle connectors to retrofit an older controller unit, contact Xandex Customer Service and order snap on receptacle connector P/N 519-0031. Receptacles are supplied with Valve Replacement Kits.

If you do not wish to update your controller to current build, order replacement valve 160-0001 and follow the pre-June 1999 instructions.

Current Build Cartridge (V1) or Shuttle (V2) Valve Replacement

This procedure is to be used for replacement of either valve, as they are identical. For detailed, illustrated instructions, follow this link to the Valve Replacement Kit Instructions.

With Power and Main Air removed:

Remove the four (4) cover screws from each side of the controller and remove the controller cover.
Disconnect the input and output pneumatic hoses from the defective valve by depressing the colored fitting collar and pulling on the pneumatic hose simultaneously.
Disconnect the two snap in connectors that connect the valve wires to the controller.
Remove the two Phillips mounting screws securing the valve to the Controller base and remove the valve.

Installation:

Remove appropriate fittings from old valve and install on new valve assembly using Teflon thread sealant tape (not supplied).
Install the replacement valve assembly (P/N 240-0261) in the controller base, securing with the two Phillips screws previously removed.
Connect the two snap in connectors on the valve wires to the receptacle connectors on the controller. Polarity does not matter.
Install the pneumatic lines accordingly, insuring that each hose is firmly seated in the valve fitting. Apply power and main air.
Perform appropriate valve functional and diagnostic tests. See Controller Maintenance and Diagnostics and use tests for your specific controller (standard, Auto-Z or Motorized-Z).
Re-install the controller cover.

Pre-June 1999 build Cartridge (V1) or Shuttle (V2) Valve Replacement

This procedure is to be used for replacement of all valves, as they are identical.

With Power and Main Air removed:

Remove the four (4) cover screws from each side of the controller and remove the controller cover.
Disconnect the input and output pneumatic hoses from the defective valve by depressing the colored fitting collar and pulling on the pneumatic hose simultaneously.
Using diagonal cutters, cut the two wires from the valve at the splice.
Remove the two Phillips mounting screws securing the valve to the Controller base and remove the valve.

Prepare the new valve for installation by:

Trimming the two wires to 2.0" nominal.

Strip and tin the wires accordingly.

Installation:

Install the replacement valve (P/N 160-0001) in the controller base, securing with the two Phillips screws previously removed.
Strip and tin the existing wires. (Install shrink tubing as required.)
Make connections.
Install the pneumatic lines accordingly, insuring that each hose is firmly seated in the valve fitting.
Apply power and main air.
Perform appropriate valve functional and diagnostic tests. See Controller Maintenance and Diagnostics and use tests for your specific controller (standard, Auto-Z or Motorized-Z).
Re-install the controller cover.