Inking Troubleshooting Guides

14.) Symptom: Inker produces dots during "puff pulse," or ink flows out of the cartridge with the toggle switch in 'SETUP' (pneumatic inkers only)

Cause a): The air tubes from the controller to the inker are not connected properly.
Solution a): Connect RED AIR HOSE to the ink cartridge and BLUE AIR HOSE to the connection on the shuttle mechanism.

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15.) Symptom: Ink “backflows” out of the top of cartridge (filament inkers only)

Note: The causes of backflow are complex. Backflow problems are often caused by a combination of more than one of the factors listed below. For an instructive video of correct filament cartridge operation and use, click HERE (WMV 9Mb) Backflow Research Statement (PDF 21Kb)

Cause a): Overly aggressive priming of the ink cartridge
Solution a):  Reduce the amount of time spent priming the cartridge (as described in step #2 on the cartridge packaging). The purpose of cartridge priming is to force the ink into the needle and eliminate any entrapped air bubbles.  No more than 60 seconds should be required for this operation.

Cause b): The cartridge is being primed improperly, or opened and closed frequently. Any operation that repeatedly moves the cartridge main guide shaft from the open, inking position to the closed position may lead to increased backflow.
Solution b): 1) Prime cartridge correctly  - always perform step 2 of the priming operation with the notches on the cartridge body and main guide 180 degrees apart from each other. Never prime with the notches aligned. 
2) Avoid Frequent opening and closing - leave the cartridges open when not in use, or only close the cartridges if the inker down time will be very long (>12 hours).

Cause c): Plunger stop assembly is not being used (DM-1 5 mil cartridge applications).  The 5 mil application requires limited plunger travel to inhibit backflow and provide consistent performance. See Plunger Stop data sheet here.
Solution c): Purchase and install the plunger stop assembly and make sure that it is set at 1.25 turns from maximum to limit plunger travel.

Cause d): Ink temperature is too low.
Solution d): Increase the ambient temperature in the inking area. If backflow is a problem, Xandex recommends that the ambient temperature be no less than 70^o F (21^o C) in the inking area. If storing cartridges at below 70^o F, allow time for the cartridges to equilibrate to ambient temperature prior to inking.

Cause e): The inking speed is too fast.
Solution e): Reduce the inking speed. If possible, the inking speed should be less than 6 dots/second if backflow is a problem.

Cause f): Ink cartridge has been open and in use for longer than the Xandex recommended time interval for consistent flow.
Solution f): Do not use the cartridges for longer than the recommended time interval.

Related Information: Refer to the Ink section of the Cartridge Operations Manual (PDF) for cartridge priming instructions and recommended “open” time for consistent ink flow in regard to the specific ink type that you are using.

Related Information:  See Plunger Stop Assembly data sheet.

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16.) Symptom: ”Halo” around ink dot

Cause a): The time interval between inking the wafer and heat curing is too long (Markem 699x-series inks only).
Solution a): Xandex recommends curing inked wafers of 699x inks within 2 hours after inking. Under some conditions of high air flow or high temperature, even two hours between inking and curing may be too long.

Cause b): Ink was partially cured at low temperature (somewhere between ambient and 50 C) prior to oven curing at a higher temperature.  Under certain conditions, only the edges of the dots will cure at the low temperature. When the partially cured dots are placed in the oven, the uncured middle portion of the dot contracts as it cures and causes a “halo”.
Solution b): Reduce (or increase) the amount of time that the wafers are exposed to the lower temperature. If using a hot chuck, change the chuck temperature or do not use the hot chuck. Markem 699x inks are not recommended for use with a hot chuck.

Cause c): The surface of the substrate onto which the dots are being placed is porous/rough (on a microscopic scale). In some cases a capillary or chromatographic effect can pull solvents out of the main ink droplet, creating a “halo”.
Solution c): If possible, take steps to make the surface more uniform.

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Cause a): Ink dots were only partially cured before they were subjected to additional processing steps. The middle, uncured portion of the dots were removed leaving only the cured outer portion.
Solution a): Increase the ink cure time and/or temperature.

Cause b): The inker assembly Z-height is set too low, allowing the filament or needle tip to make contact with the wafer, deforming the ink dot as it is placed. 
Solution b): Raise the inker assembly Z height to the proper setting to produce round uniform dots.  See the Product Manuals Section of the website to locate the product manual for your inker assembly for setup instructions.

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Cause b): The rubber washer on the cartridge air hose connector is not installed (Pneumatic systems only).
Solution b): Install the washer.

Cause c): Ink cartridge is defective or was damaged by improper handling during the priming process.
Solution c): Replace with a fresh cartridge. Return the suspect cartridge to Xandex for test confirmation and possible warranty replacement.  

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