Software/Hardware: Fluxer Communication Board PK2230 / AVR2560
1. Problem Description
A customer reported inconsistent flux flow rate and flux volume readings on an wave soldering machine.
The problem was particularly noticeable after changing machine programs.
The reported symptoms included:
Flux flow rate readings fluctuating unexpectedly.
Flux volume measurements reading either too high or too low.
Inconsistent measurements following recipe or program changes.
Soft Stop alarms activating due to incorrect flux measurements.
Machine stopping production to prevent potentially defective boards from continuing through the process.
The customer had previously replaced the complete fluxer head, including its installation, but the problem continued.
2. Troubleshooting – Unstable Flux Flow Rate and Volume
When investigating inconsistent flux measurements, verify the following items:
A. Flux Tank Pressure
Verify that the flux tank has the correct operating pressure.
Confirm that the pressure is stable during operation.
Check that the pressure supply is functioning properly.
B. Flux Filter
Inspect the flux filter for contamination or blockage.
Verify that the filter is not clogged.
Clean or replace the filter if necessary.
C. Flux Lines
Inspect the flux supply lines for kinks or restrictions.
Verify that the lines are properly routed.
Check for anything that could restrict flux flow.
Important: Replacing the complete fluxer head does not necessarily eliminate flux flow measurement problems. Verify tank pressure, filter condition, and flux line routing before assuming the fluxer head is defective.
3. Fluxer Communication Board Upgrade – PK2230 to AVR2560
The customer also requested information about upgrading the existing fluxer communication system.
The machine was equipped with the older PK2230 communication board, and the customer wanted to upgrade to the newer AVR2560 board.
The customer had obtained the required upgrade components but did not have the newer Keyence flow meter.
The question was whether the existing older-style flow meter could be retained with the new AVR2560 communication board.
ITW EAE Technical Support confirmed that the older-style flow meter can be used with the AVR2560 board.
The new Keyence flow meter is not required for this configuration, provided the specified board switch settings are changed.
4. AVR2560 Board Switch Configuration
When installing the AVR2560 communication board and retaining the existing older-style flow meter, configure the board switches as follows:
Options Switch Block
Turn ON Switch 2.
Switch Block 2
Turn ON Switch 1.
Turn ON Switch 2.
These switch settings are required to enable N13 and N14 for the flow meter.
| Switch Location | Switch Number | Required Setting |
|---|---|---|
| Options Switch Block | 2 | ON |
| Switch Block 2 | 1 | ON |
| Switch Block 2 | 2 | ON |
Important: Verify the switch block identification and switch numbering on the actual AVR2560 board before making changes. Do not confuse the Options Switch Block with Switch Block 2.
5. Upgrade Compatibility
The following configuration was confirmed by ITW EAE Technical Support:
| Component | Configuration |
|---|---|
| Original communication board | PK2230 |
| Replacement communication board | AVR2560 |
| Existing flow meter | Older-style flow meter |
| New Keyence flow meter | Not required |
| Options Switch Block | Switch 2 ON |
| Switch Block 2 | Switches 1 and 2 ON |
| Flow meter inputs | N13 and N14 enabled |
The existing flow meter can be retained when upgrading to the AVR2560 board, provided the required switch settings are applied.
6. Recommended Troubleshooting Procedure
When responding to unstable flux flow rate or volume measurements:
Verify the flux tank pressure.
Inspect the flux filter for blockage.
Inspect all flux supply lines for kinks or restrictions.
Confirm whether the problem occurs primarily after changing programs.
Verify that the flow meter is operating correctly.
If the machine has been upgraded to an AVR2560 board, verify the required switch settings.
Confirm that Switch 2 on the Options Switch Block is ON.
Confirm that Switches 1 and 2 on Switch Block 2 are ON.
Verify that N13 and N14 are enabled for the flow meter.
Test flux flow rate and volume measurements following program changes.
7. Summary
Two separate concerns were addressed on the machine.
Unstable Flux Flow Rate and Volume
Inconsistent flux measurements, particularly after program changes, can cause Soft Stop alarms and interrupt production.
Technicians should verify flux tank pressure, filter condition, and flux line routing. These checks are recommended even when the complete fluxer head has previously been replaced.
AVR2560 Communication Board Compatibility
ITW EAE Technical Support confirmed that the older-style flow meter can be used with the newer AVR2560 communication board.
A new Keyence flow meter is not required, provided the following switches are configured:
Options Switch Block: Switch 2 ON.
Switch Block 2: Switches 1 and 2 ON.
These settings enable N13 and N14 for the existing flow meter.