System: Fluxer Actuator / Controller Assembly
Subject: Fluxer actuator alarm or abnormal operation that continues after actuator or controller-kit replacement
1. Symptom
The fluxer actuator reported an alarm during its return movement and did not operate correctly. Replacing the fluxer actuator did not eliminate the reported problem.
2. Findings from the Service Investigation
The troubleshooting history documented the following:
A replacement fluxer actuator produced the same error and behavior as the original actuator.
A replacement controller kit was installed, but the problem remained.
During isolation testing, power was applied to the board, the RS-232 connection to the computer, and the cable to the IAI controller.
The input and output connections were left unplugged during this test, but the problem continued.
The power supply was then suspected as a possible cause.
The customer later confirmed that replacing the power supply restored normal fluxer operation.
3. Probable Cause and Resolution
The final customer update confirmed that replacing the power supply resolved the fluxer problem.
Based on this service case, a defective or inadequate power supply was identified as the cause of the fluxer malfunction.
4. Power Supply Requirements
The service investigation identified the following power supply requirements:
Output voltage: 24 VDC
Power rating: 120 watts
Minimum current capacity: 5 amps
The original ITW EAE part number identified in the service ticket was:
2-6049-402-00-0 – PSU001
The part was reported as out of stock at the time of the service investigation.
Before installing a replacement power supply, verify that it meets the required electrical specifications and is compatible with the machine configuration.
5. Recommended Troubleshooting Procedure
Record the exact fluxer alarm and identify when it occurs, such as during actuator return.
Inspect the fluxer actuator and associated wiring/connectors for visible damage or loose connections.
If replacing the actuator does not change the symptom, do not assume the actuator is the root cause.
If replacing the controller kit does not resolve the symptom, continue troubleshooting the supporting electrical supply.
If authorized by the machine documentation, isolate the assembly as appropriate. In this service case, the board power, RS-232 connection to the computer, and IAI controller cable were connected while the input and output connections were unplugged. The problem remained.
Check the power supply output against the machine's specified voltage and current requirements. Follow appropriate electrical safety procedures.
If the power supply is found to be defective, replace it with an approved, electrically compatible unit.
Reconnect the wiring and test the fluxer.
6. Verification After Repair
After replacing the power supply:
Verify that the fluxer initializes correctly.
Verify that the actuator completes its commanded movement.
Confirm that the original alarm no longer occurs.
Run the fluxer through its normal operating cycle.
Confirm that the machine returns to normal operation.
Service Case Result: The customer confirmed that replacing the power supply restored fluxer operation.
Important: This bulletin is based on one documented EVT-Vectra service case. Although power supply replacement resolved the issue in this case, not every fluxer actuator alarm will necessarily have the same cause. Verify the power supply specifications and machine configuration before replacing components.