Inking Troubleshooting Guides

20.) Symptom: Ink appears thicker than normaL

Cause a):  Dot size setting has been changed on the pneumatic controller (pneumatic systems only).
Solution a):  Adjust the dot size setting to your normal set point.

Cause b):  Air pressure to pneumatic controller is too low (pneumatic systems only).
Solution b):  Set the air pressure to the pneumatic controller at 70 ±10 psi on all controllers except Motorized Z controller which should be set to 80 ± 5 psi.

Cause c):  Dot size potentiometer is defective (pneumatic systems only). Run Diagnostics Test B described in Controller Diagnostics section of the Operations manual. If test results are not within specified parameters, contact Xandex Customer Service.
Solution c): Replace dot size potentiometer.

Cause d): Ink is being placed onto a surface with an unusually low surface energy.  Depending on the type of material, spreading behavior and size of the ink droplet may vary significantly.
Solution d): Switch to a different cartridge size and/or a lower viscosity ink. If using a DM-2 cartridge, increase the Dot Size Setting to compensate for the smaller dots.

Cause e): The ambient temperature in the inking area is lower than normal. Ink viscosity (thickness) is higher at lower temperatures. Higher viscosity leads to smaller ink dots. For best performance, inking temperatures should be between 67^o and  77^o F (19.5-25^o C).
Solution e): Increase the ambient inking temperature to the recommended range. If storing the cartridges at less than 67^o F (19.5^o C), allow time for the cartridges to equilibrate to room temperature prior to inking.

Cause f): Ink has risen above the specified viscosity range. This should not occur under normal conditions, as long as the cartridges are not past their expiration date. Some inks, however, will experience viscosity changes if exposed to temperature extremes during shipping.
Solution f): Return sample cartridges to Xandex for test confirmation and possible warranty replacement.

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Related Information: Refer to the appropriate Cartridge Preparation and Installation sections of the Cartridge Operations Manual (PDF) for detailed priming instructions.

Cause b): Inker has been fired multiple times without depositing ink. This can occur if the z-height is positioned too high during the initial installation and adjustment of a new cartridge. It can also occur in some cases if the edge sensor is not adjusted properly and causes the inker to fire when the cartridge is not positioned over the wafer.
Solution b): Carefully remove all the excess ink from the needle using a lint-free tissue or swab before continuing with inking operation.

Cause c): Ink cartridge is defective (pneumatic systems only). If the ink balling occurs multiple times and the causes listed above have been ruled out, the cartridge is probably defective. If the cartridge is defective, leakage is occurring between the Teflon and metal portions of the DM-2 needle.
Solution c): Replace with a fresh cartridge. Return the defective cartridge to Xandex for test confirmation and warranty replacement.  

Cause d): The Plunger Stop Assembly is not being used or is being used improperly (DM-1, 5 Mil cartridges only).
Solution d): Install a Plunger Stop Assembly and make sure that it is set at 1.25 turns from maximum. Carefully remove any excess ink from the needle using a lint-free tissue or swab before continuing with inking operation.

Related Information:  See Plunger Stop Assembly data sheet.

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Cause b): Air bubbles in the ink (pneumatic systems only). This sometimes occurs during the initial 1,000 ink dots from a new cartridge.
Solution b): Run 1,000 dots onto a test wafer. This should eliminate any bubbles that may have been present inside of the cartridge.

Cause c): The Teflon tubing (DM-2) or filament (DM-1) at the needle tip is worn or abraded. If burrs develop on the needle tip or filament, the cartridge can sometimes splatter ink.
Solution c): Replace with a fresh cartridge. Make sure that the Z-height setting is properly adjusted so that the needle tip or filament will not become abraded.

Cause d): Ink solvents have evaporated and partially cured the ink at the needle tip. If the splatter only occurs on re-start after long periods of down time, this may be the cause. Solvent evaporation changes the viscosity of the ink at the needle tip, making it more "sticky" and prone to splatter.
Solution d): Remove any excess ink from the needle tip using a tissue or swab saturated with DieMark Ink Remover or acetone prior to re-starting the inker after long periods of down time.

Cause e): 6993 ink used in hot chuck applications only. Condensation of ink solvent vapors on the needle tip can lead to solvent build-up and periodic deposition on the wafer under certain conditions.  This will only occur in low yield off-line applications where large numbers of ink dots are placed rapidly with a very close spacing.
 Solution e):  Xandex does not recommend the use of 69xx series inks with a hot chuck.  1)  Reduce the inking speed and/or change the chuck temperature.  2) Wipe off the needle tip with a lint free cloth or swab if any significant of accumulation of ink solvent is observed.  

Cause f): Ink backflow is occurring at the top of the cartridge (DM-1, DM-1.25 filament cartridges only).
Solution f): See causes and solutions for preventing ink backflow at item 15 here.

Cause g): (Pneumatic Only) Ink cartridge is not screwed into the cartridge connector properly.

Solution g): Check cartridge connection to inker.  Ensure that the connector is screwed firmly into the cartridge and that the cartridge threads are not stripped or damaged.  Replace cartridge if necessary.

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Cause b):  Air pressure to pneumatic controller is too high (pneumatic systems only).
Solution b):  Set the air pressure to the pneumatic controller at 70 ±10 psi on all controllers except Motorized Z controller which should be set to 80 ± 5 psi.

Cause c):  The cartridge size is too large.
Solution c):  Change to a smaller cartridge size.

Cause d):  Dot size potentiometer is defective (pneumatic systems only). Run Diagnostics Test B described in Controller Diagnostics section of the Operations manual. If test results are not within specified parameters, contact Xandex Customer Service.
Solution d): Replace dot size potentiometer.

Cause e): Ink is being placed onto a surface with an unusually high surface energy.  Depending on the type of material, spreading behavior and size of the ink droplet may vary significantly.
Solution e): Switch to a different cartridge size and/or a higher viscosity ink. If using a DM-2 cartridge, reduce the Dot Size Setting to compensate for the larger dots.

Cause f): The ambient temperature is higher than the recommended maximum temperature listed on the cartridge packaging (or higher than your normal operating temperature). Ink viscosity is lower at higher temperatures. Lower viscosity leads to larger ink dots. Storage and inking temperatures should be below 77^o F (25^o C) if possible.
Solution f): Reduce the cartridge storage and inking temperature to the recommended range: Storage = 50^o-77^o F (10-25^o C). Inking = 67^o-77^o F (19.5-25^o C).

Cause g): Ink has dropped below the specified viscosity range. This should not occur under normal conditions, as long as the cartridges are not past their expiration date and have been stored and used properly. Some inks, however, will experience viscosity changes if exposed to temperature extremes during shipping.
Solution g): Return sample cartridges to Xandex for testing and possible warranty replacement. 

Cause h): The die surface contains channels that are causing the ink to “wick” to the adjacent die via capillary action.
Solution h): Place the ink dot in a different location on the die. Reduce the ink dot size if possible (use a smaller cartridge and/or reduce dot size setting).

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