Joystick Repair Non-responsive A5200 Buttons

Transcription

1 Joystick Repair Non-responsive A5200 Buttons The Atari 5200 joystick controllers were innovative and unique in their time. However, Atari wasn t known for their quality materials. This is most evident in the carbon rubber pads or dots used on their user buttons in the 5200 joystick controller. This brief guide will explain how to fix non-responsive buttons using a very cheap and easy fix. Tools/Supplies Needed: Small Flat Bladed Screwdriver #1 Phillips or Cross-tip Screwdriver Sharp Scissors 3 of double sided sticky clear tape (1/2 width) 1 square of thin foil tape Pencil eraser (Pink Pearl recommended) Sheet of 8.5 x11 paper or cardstock Joystick Disassembly: NOTE: It is important that you work in a clean work area large enough to layout the pieces as you work on the controller. This is especially true when working with the foil tape. 1. Begin by inserting a small flat bladed screwdriver between the rubber of the Start or Reset buttons and under the lip of the bezel on the top row of buttons. 2. Gently pry in an upward motion to lift one side of the top bezel to be removed and set aside. (Figure 1) Fig. 1 Detail showing removal of top bezel NOTE! Failure to remove the top bezel and flex membrane will result in damage to the flex membrane which is not serviceable and would have to be replaced!

2 3. Pick up and set aside the rubber section of top row buttons. 4. Carefully lift the right side of the top row button s flex membrane and lift it so that is stands in an upright position to the left. NOTE! It is very important that you not crease the flex while handling it. Doing so is likely to create small fractures in the flex traces and render sections of the flex membrane permanently inoperable! 5. Turn the joystick over and locate the 3 cover retaining screws. Use the Phillips screwdriver to remove the 3 screws and set them aside with the other parts. (Figure 2) Fig. 2 Detail of bottom cover retaining screws 6. Turn joystick upright and carefully pull apart the upper section from the lower section of the joystick housing. Top row flex membrane will slide through a slot on the left side and remain attached to the lower half of the joystick assembly. Lay the top half aside with the other pieces. (Figure 3) Fig 3

3 7. Lift, remove, and set aside the following: Rubber Numeric Keypad Left and Right Rubber Fire button pads 8. Remove the rubber fire button pads from their plastic retaining frames and set aside. 9. You now have the 5200 joystick controller disassembled and ready for cleaning and repair. (Figure 4) Fig 4 The disassembled 5200 joystick controller

4 Joystick Cleaning/Repair: The main cause of non-responsive buttons is both dirty flex contacts and worn out carbon pads on the buttons. This next section will explain the process used to clean the flex membrane circuit of the 5200 controller and repair the carbon pads on the buttons to bring new longer lasting life to the 5200 joystick controller. It is important to note that there are two primary types of flex membrane circuits used on the 5200 joystick controller. The most common feature very thin metal aluminum traces. Most of these flex membranes will be labeled as REV 6, 7, or 8 as can be noted in the lower right hand corner of the flex membrane in the numeric keypad area. The other type of flex circuit feature carbon traces and only require a light cleaning of denatured alcohol with a Q-tip swap. Carbon traced flex membranes are usually labeled as REV 9. NOTE! The process below for cleaning the flex membrane pertains only to those REV versions that contain metal traces! Do not use an eraser to clean carbon based traces as the eraser will literally erase the carbon traces! Flex membrane circuit removal - 1. The flex membrane contacts can become discolored due to carbon residue from the button pads and tarnish from age. The picture below shows what this looks like on most 5200 metal flex membranes. (Figure 5) Fig 5 NOTE: Discoloration of contacts due to corrosion and carbon residue 2. Carefully pull the side fire button membranes away from the upper left and right of the lower assembly.

5 3. The flex membrane is attached by a single edge connector in the middle of the lower controller section. Carefully unplug the flex membrane circuit from this connector and set aside. (Figures 6 & 7) Fig 6 Detail showing the middle edge connector the flex membrane is plugged into Fig 7 The flex circuit membrane removed. Notice the top row flex portion is attached 4. With the flex removed, use a pencil eraser and rub off the residue and corrosion from the exposed traces. Also clean the connector traces that plug into the edge connector of the lower controller section. 5. Use a Q-tip and a light wetting of denatured alcohol to clean and remove the pencil eraser residue.

6 6. Carefully plug the flex circuit back into the middle edge connector ensuring the pegs on the plastic plate line up properly with the holes in the flex membrane. (Figure 8) Fig 8 Flex membrane contacts cleaned. NOTE: Small pegs to the middle left and right to align flex on plastic tray 7. Cut 1 of double sided tape from your 3 strip and then cut this again in two halves. Stick these to the back of the fire button sections of the flex membrane. Align the fire button section of the flex with the notches on the flex and pegs on the lower controller assembly. (Figure 9) Fig 9 Detail showing double sided tape attached to back of right button section of flex membrane. Note the notch on bottom portion of flex for alignment. 8. Attach the remaining 2 of your double sided tape to the top half of the controller where the flex for the top tow buttons will lay. The tape is used to hold the flex membrane in place during play while still allowing the flex to be pulled away as needed for future maintenance. (Figure 10)

7 Fig 10 Detail showing double sided tape affixed to top row button section of upper joystick assembly. With the flex circuit membrane reinstalled we are now ready to clean and refurbish the joystick controller buttons. Cleaning Carbon Pads Dots : 1. Take out your sheet of paper or cardstock and lay it flat. 2. Take one of the rubber buttons and with carbon pad facing down, make 3 streaks of approximately 6 lengths. This is done to ensure that any grime and dirt from the carbon pads themselves is removed. It is important that the surface of the pads be clean for the next part. (Figure 11) Fig 11 Cleaning the carbon pads Dots Be sure to clean all the carbon pads from each button and the numeric keypad in this manner. Cardboard can also be used but is a bit rough and almost acts like sandpaper. Cardboard will also leave residue on the pads that must be wiped away.

8 Fixing the Carbon Pads: Foil tape can be purchased cheaply at most any auto parts stores. Look in the section where pinstripe tape and detailing chrome are found. Just make sure the foil tape you purchased is thin so as to be easily cut with scissors. 1. Using the scissors, cut small squares from the foil tape. These squares just need to be about the same size as the carbon pad of the buttons. 2. Carefully peel the backing off of a foil square and apply the foil directly to the carbon pad. Ensure the foil is on securely by pressing the foil onto the pad using a hard surface such as the top of a desk or counter top. 3. Repeat this process for each carbon pad of each button. (Figure 12) Fig 12 Carbon pads with new foil squares to provide a new surface. Note the small square of foil to still be applied to the carbon pad above it. This process is the most time consuming and will require a steady hand and patience. The 1 inch square of foil is more than enough for 1 joystick and should even be enough for 2 joysticks if used sparingly.

9 Joystick Reassembly: 1. Place the numeric keypad onto the flex circuit at the lower half of the bottom controller assembly. Take note to align the small pegs used to for the flex with the holes in the rubber numeric keypad. 2. Insert the rubber fire buttons back into their plastic retainers. And slide the fire button assemblies back into their places on the upper left and right half of the bottom controller assembly. 3. Carefully turn the potentiometers so that the top potentiometer is pointing in the 9 o clock position and the lower potentiometer is pointing straight down in the 6 o clock position. (Figure 13) Fig 13 Correct placement of potentiometers for reassembly 4. Now place the top controller assembly back onto the lower assembly making sure to carefully thread the top flex membrane back through the slot on the left of the upper controller. Also keep the joystick centered to ensure proper seating onto the potentiometers. It can be difficult to do this and keep the numeric pad in place. You can use the small flat bladed screwdriver to push the numeric pad from the sides if it requires additional alignment. 5. Lay the top row button flex membrane onto the double sided tape you applied earlier to hold it securely in place.

10 6. Lay the top row rubber buttons section onto the flex membrane and snap the bezel back in place. 7. Turn the joystick controller bottom side up and replace the 3 Phillips retaining screws to the lower controller housing. 8. Joystick assembly is now complete and ready for use. All Text and Images are 2005 J. Hardesty Do not reproduce without permission