SERVICE BULLETIN
Subject: External Fluxer Restricted Flow Detected Alarm
Equipment: Electrovert EVT-Electra with OA ServoJet Fluxer
Applicable Configuration: Dual-head, dual-tank ServoJet systems
Bulletin Type: Troubleshooting / Configuration Correction
1. CONDITION
Some Electrovert EVT-Electra machines equipped with an OA ServoJet fluxer may display the following alarm when the fluxer is turned on:
“External Fluxer Restricted Flow Detected”
The alarm may occur repeatedly during fluxer startup.
2. CAUSE
The investigation identified an incorrect deep-switch/DIP-switch configuration in the flux module.
In the documented case, the flux module had been configured using settings and documentation from an older machine. The incorrect switch configuration resulted in the restricted-flow alarm being generated even though the fluxer was otherwise capable of operating.
3. CORRECTION
Verify the Flux Module Switch Settings
Place the machine in a safe condition and follow all applicable machine lockout/tagout and service procedures.
Access the flux module according to the machine's current service documentation.
Locate the deep switches/DIP switches associated with the flux module.
Verify that the switches are configured according to the current machine-specific configuration.
Do not use switch settings or documentation from an older machine as the configuration reference.
Correct any incorrectly positioned switches.
Restore the machine to normal operating condition.
Turn on the fluxer and verify that the “External Fluxer Restricted Flow Detected” alarm no longer occurs.
IMPORTANT: The original service record confirms that the deep switches were incorrectly set, but it does not record the individual switch positions. Therefore, the exact ON/OFF switch pattern should be obtained from the current approved machine documentation or ITW EAE Technical Support rather than inferred from this bulletin.
4. INITIAL TROUBLESHOOTING
If the alarm is present and the correct flux-module switch configuration has not yet been verified, the following checks may be performed:
Verify the flux module's deep-switch/DIP-switch configuration.
Confirm that the current machine configuration documentation is being used.
If appropriate, perform the fluxer auto purge during initial startup to ensure that flux is present in the line. This was suggested by the fluxer OEM during the original investigation.
If the alarm remains after the switch configuration is corrected, investigate the flux-flow circuit for restrictions.
Potential restriction points identified during the investigation include:
Tank fittings
Filters
Solenoids
Quick disconnects
Tubing
Tubing connections
Flow meters
Connections between the tank and the nozzles
The ServoJet design uses tank pressure to push flux through the solenoid and tubing to the nozzles. The system contains duplicate components, which can be useful for troubleshooting by comparison or component substitution.
5. TROUBLESHOOTING FLOW
Alarm appears when fluxer is turned on
↓
Verify flux-module deep-switch/DIP-switch settings
↓
Are the settings correct for the current machine configuration?
NO: Correct the switch settings and retest.
YES: Continue troubleshooting the flux-flow circuit.
↓
Run the fluxer auto purge, if applicable
↓
Alarm still present?
Inspect the flux path for restrictions, including the tank fittings, filter, solenoids, quick disconnects, tubing, connections and flow meters.
6. RELATED FLOW SYMPTOMS
A related machine may exhibit unequal flux levels or nozzle-flow differences even when the tank pressure is the same. In the documented case, the customer reported different flux levels between tanks and unequal nozzle flow on one tank. The tubing was inspected and no bent tubing was found.
When troubleshooting unequal flow on a dual-tank system, use the duplicated components to isolate the problem. A recommended approach is to:
Swap the tanks and observe whether the problem follows the tank.
If the problem does not follow the tank, exchange the valves/solenoids as appropriate.
Continue isolating components in the flux path until the restriction or faulty component is identified.
This troubleshooting approach was recommended because the system contains duplicated components, including flow meters.
7. SERVICE HISTORY / LESSON LEARNED
The important lesson from this service event is:
Always verify flux-module deep-switch/DIP-switch settings against the current machine configuration.
Do not assume that settings or documentation from another or older machine are applicable.
In this case, the restricted-flow alarm was ultimately resolved after identifying that the flux-module deep switches had been incorrectly configured using old machine settings/documentation.
8. TECHNICAL SUPPORT
For Electrovert equipment technical support:
ITW EAE Technical Support
Phone: 1-800-737-8110, Option 3
Email: evtsupport@itweae.com
For service spare parts:
Phone: 1-800-737-8110, Option 4
Email: parts@itweae.com
Revision: A
Purpose: Customer troubleshooting reference
Source: Field service investigation – External Fluxer Restricted Flow Detected