Troubleshooting Guides

Pneumatic Controller Troubleshooting

STANDARD PNEUMATIC CONTROLLER MODEL 350-0002

Cause a): The outlet the controller is plugged into does not have power.
Solution a): Make sure that the controller is plugged into a live outlet. The requirement is 100/120/220/240 volts.

Cause b): The controller fuse is bad.

Solution b): Check controller fuse to be sure it is good and has the right ratings.

Related Information: Go to the product manuals section of the Xandex website and download the appropriate user manual. Review the Voltage Selection and Fuse Replacement information contained in the manual. If you have an older controller model, review the Voltage Selection and Fuse Replacement information contained in the Pneumatic Controller Power Module History application note.

Cause a): The prober to controller cable is not connected to the controller or it is not connected to the prober, or both.
Solution a): Verify prober to controller cable is plugged into the "PROBER" input on the controller and the probers inker output signal jack.

Cause b): The prober to controller cable is shorted.
Solution b): Check the continuity of each cable pin and repair or replace the cable as necessary.

Cause c): The controller has sustained internal damage.
Solution c): The controller is subject to internal damage such as a cracked Printed Circuit Assembly (PCA) if it is dropped. Perform system diagnostics procedure as documented in the controller maintenance section the Operation Manual to verify controller operation. Xandex recommends returning the controller to the factory for service if internal damage is suspected.

Cause d): Prober's inker signal is outside the controller's input range.

Solution: d) The controller input circuit responds to an unregulated 12 to 59 VDC input signal. If the prober's output signal is not within this range, the controller is not able to respond. Verify that the prober's inker output signal is within the controllers input range.

Cause a): The controller is not in operating mode.
Solution a): Place the toggle switch on the front of the controller into the RUN position.

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.

Cause c): Place top mode switch to SETUP. The shuttle should extend. If it does not, and all air hose connections are correct, the problem may be that the shuttle mechanism is binding.
Solution c): Perform shuttle maintenance. Shuttle maintenance kits are available from Xandex. See the Shuttle Maintenance section of the Xandex web site for more information.

Cause d): The controller shuttle valve is defective.
Solution d): c) Perform Shuttle Valve diagnostic test as documented in the controller maintenance section of the Xandex website. If the valve requires replacement, a maintenance kit is available from Xandex. See the Controller Maintenance section of the Xandex website for more information.

Cause a): The blue and red twin air tubing that supply the cartridge and shuttle with air have been switched.
Solution a): Verify that the air hoses from the controller to the inker are connected properly:

  • 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.

Cause b): Dot Size Potentiometer is defective.
Solution b): Run diagnostic test "B." Dot Size Potentiometer Test described in the controller maintenance section of the Operations Manual for your inker. If test results are not within parameters, contact Xandex Customer Service.

Cause c): If the dot size changes, but does not change sufficiently, the cartridge type is not correct.
Solution c): Three cartridge types are available for Xandex pneumatic inkers. You must select the cartridge type based on the inker model, ink type and dot size required. Cartridge types are A5, A6, and A8. Each has a different size Teflon tube and therefore, a different dot size range. Type A5 is capable of creating the smallest ink dots and type A8 the largest. For more information see Pneumatic Inking System Dot Size Specifications (PDF) to select a cartridge type to fit your requirements.

Cause d): Dot size knob set screw is loose, allowing the knob to turn without changing the dot size setting.
Solution d): Loosen the set screw sufficiently to remove the dot size knob from the potentiometer shaft. Turn the potentiometer shaft counterclockwise until it stops. Replace the dot size knob with the knob indicator set at MIN on the controller scale and tighten down the set screw. Perform potentiometer diagnostics as documented in the controller maintenance section of the Operations manual for your inker to verify potentiometer operation.

Maintenance for the Standard Pneumatic Controller requires regular replacement of the internal pneumatic valves. For a description, maintenance schedule, maintenance kits available and detailed instructions see the controller maintenance section of this website.

MOTORIZED-Z PNEUMATIC CONTROLLER MODEL 350-0018

All causes and solutions listed under Standard Controller apply.

All causes and solutions listed under Standard Controller apply.

All causes and solutions listed under Standard Controller apply.

Cause a): The controller is not connected to an air supply.
Solution a): Verify that the Motorized-Z controller is connected to a continuous 80 ± 5 PSI air supply.

Cause b): Unacceptable mode switch combination on the controller front panel.
Solution b): Review Motorized Z operation in Chapter 4 of the Motorized Z User Manual.

Cause a): The blue and red twin air tubing that supply the cartridge and shuttle with air have been switched.
Solution a): Verify that the air hoses from the controller to the inker are connected properly:

  1. RED AIR TUBING connects to the ink cartridge and to the barbed fitting that is closest to the center of the controller connector.
  2. 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.

Cause b): Ink cartridge tip is damaged or clogged.
Solution b): Clean the cartridge tip with DieMark Ink Remover and a clean lint free swab. If this does not enable dot size adjustment replace the ink cartridge with a new undamaged cartridge.

Cause c): If the dot size changes, but does not change sufficiently, the cartridge type is not correct.
Solution c): Three cartridge types are available for Xandex pneumatic inkers. You must select the cartridge type based on the inker model, ink type and dot size required. Cartridge types are A5, A6, and A8. Each has a different size Teflon tube and therefore, a different dot size range. Type A5 is capable of creating the smallest ink dots and type A8 the largest. For more information see Pneumatic Inking System Dot Size Specifications (PDF) to select a cartridge type to fit your requirements.

Cause d): Dot Size Thumbwheel module is defective
Solution d): b) Run diagnostic test "A." Dot Size Potentiometer Test described in the Motorized Z User Manual available for download from the Xandex website. If test results are not within parameters, contact Xandex Customer Service.

Maintenance for the Motorized Z Pneumatic Controller requires regular replacement of the internal pneumatic valves. For a description, maintenance schedule, maintenance kits available and detailed instructions see the controller maintenance section of the Xandex website.

AUTO-Z PNEUMATIC CONTROLLER MODEL 350-0006

All causes and solutions listed under Standard Controller apply.

All causes and solutions listed under Standard Controller apply.

All causes and solutions listed under Standard Controller apply.

Cause a): The blue and red twin air tubing that supply the cartridge and shuttle with air have been switched.
Solution a): Verify that the air hoses from the controller to the inker are connected properly:

  1. RED AIR TUBING connects to the ink cartridge and to the barbed fitting that is closest to the center of the controller connector.
  2. 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.

Cause b): Ink cartridge tip is damaged or clogged.
Solution b): Clean the cartridge tip with DieMark Ink Remover and a clean lint free swab. If this does not enable dot size adjustment replace the ink cartridge with a new undamaged cartridge.

Cause c): If the dot size changes, but does not change sufficiently, the cartridge type is not correct.
Solution c): Three cartridge types are available for Xandex pneumatic inkers. You must select the cartridge type based on the inker model, ink type and dot size required. Cartridge types are A5, A6, and A8. Each has a different size Teflon tube and therefore, a different dot size range. Type A5 is capable of creating the smallest ink dots and type A8 the largest. For more information see Pneumatic Inking System Dot Size Specifications (PDF) to select a cartridge type to fit your requirements.

Cause d): Dot Size Thumbwheel module is defective
Solution d): b) Run diagnostic test "A." Dot Size Potentiometer Test described in the AUTO-Z User Manual available for download from the Xandex website. If test results are not within parameters, contact Xandex Customer Service.

Maintenance for the AUTO-Z Pneumatic Controller requires regular replacement of the internal pneumatic valves. For a description, maintenance schedule, maintenance kits available and detailed instructions see the controller maintenance section of the Xandex website.

REMOTE VALVE PNEUMATIC CONTROLLER MODEL 350-0013

All causes and solutions listed under Standard Controller apply.

All causes and solutions listed under Standard Controller apply.

All causes and solutions listed under Standard Controller apply.

All causes and solutions listed under Standard Controller apply.

Maintenance for Xandex Pneumatic Controllers requires regular replacement of the internal pneumatic valves. The remove valve controller does not contain internal pneumatic valves. It relies instead on valves installed on the inker body (remote valve). Other than providing an optimum operating environment, and a clean filtered air supply, there is no regular maintenance required. A description of the operation of this controller and procedures for replacing the valve/manifold assembly located on the inker body, are contained in the X5200 Pneumatic Inker Installation and Operation manual (PDF).