Equipment: Electrovert Wave Vectra ES2
Subject: Correcting external fluxer license configuration and conveyor operation after PC replacement
1. Condition
Following replacement of the machine's PC, the Vectra ES2 experienced software configuration and operating issues, including:
The machine software was not configured for the installed external fluxer.
The conveyor operated correctly in manual mode but did not operate correctly in automatic mode.
In automatic mode, the conveyor speed feedback remained at 0.00, causing the conveyor to run at full speed and eventually generate an error because the commanded setpoint was not being reached.
The machine configuration was set for motorized (automatic) conveyor-width adjustment, even though the machine had manual conveyor-width adjustment.
2. Cause
Two configuration issues were identified:
A. Incorrect software license
The replacement PC initially had a software license intended for a machine equipped with an internal fluxer. The machine required the external ServoSpray fluxer license.
B. Incorrect conveyor-width configuration
The machine was configured for automatic motorized conveyor-width adjustment even though the conveyor width was adjusted manually. This configuration mismatch caused the control system to attempt automatic width adjustment when that function was not installed.
3. Corrective Action
A. Install the correct external fluxer license
The machine must have the software license that matches its installed fluxer configuration.
Obtain the correct external fluxer license files from Electrovert Technical Support.
Copy the supplied license package to a USB flash drive, following the instructions provided by Technical Support.
Exit the machine software.
Log in to Windows using an authorized administrator account.
Run the supplied machine-specific registry license file.
Approve the Windows security prompt and the Registry Editor confirmation.
Restart the PC.
Launch the machine software and verify that the external fluxer is recognized and configured correctly.
Important: License files are machine-specific. Do not use a license file from another machine or substitute an internal-fluxer license for an external-fluxer license. Contact Electrovert Technical Support for the correct license package.
B. Disable automatic conveyor-width adjustment
If the machine has manual conveyor-width adjustment, verify that the software is not configured for motorized width adjustment.
Place the machine in Stop Mode.
Open the Configuration Menu.
Select the Conveyor tab.
Locate Motorized Conveyor Width.
Uncheck the box next to this option.
Click OK to save the configuration.
Return to the machine operating screen and test conveyor operation.
Important: Only disable this option when the machine is equipped with manual conveyor-width adjustment. Machines equipped with motorized width adjustment should retain the appropriate configuration.
4. Verification and Testing
After completing the corrections:
Restart the machine PC after installing the correct license.
Verify that the software recognizes the installed external fluxer.
Confirm that the conveyor-width configuration matches the machine's actual hardware.
Test conveyor operation in manual mode.
Test conveyor operation in automatic mode.
Verify that conveyor speed feedback responds appropriately to the commanded setpoint.
Confirm that the conveyor operates without the previously reported speed-control error.
If the conveyor still does not provide feedback in automatic mode, further troubleshooting may be required.
5. Additional Troubleshooting Information
The service investigation also reviewed the conveyor rotary encoder feedback.
The encoder signal is routed through the Timer Counter Card. The card supplies 5 VDC to the encoder, and the encoder returns a pulsed signal to the card.
If the conveyor operates in manual mode but does not provide feedback in automatic mode after the configuration has been corrected, Technical Support may need to investigate the encoder signal, Timer Counter Card, and machine configuration.
Do not bypass safety inputs or force I/O signals to make the machine run. Investigate and correct the underlying configuration or hardware issue.
6. Summary
When replacing a PC on a Wave Vectra ES2, verify that the installed software license and machine configuration match the actual machine hardware.
For machines equipped with an external ServoSpray fluxer, the correct external-fluxer license must be installed. For machines with manual conveyor-width adjustment, the Motorized Conveyor Width option must be unchecked.
Correcting these configuration items addressed the issues documented in this service case.