Expert faders send out flickering DMX values

[emoreth]

I've got an Expert console running Titan 6.1, and 2 of its playback faders have recently started sending out DMX values that cause the lights to flicker. Fortunately, they're only controlling intensity and not gobo selection or P/T, but it's still a serious problem.

What I'm seeing:
It's clear in the USB Expert panel that there are values coming from the fader panel that aren't related to where the fader is in its track. This ONLY happens when the fader is at FULL. Sometimes it'll even keep sending out varied values for a few seconds after you take your hand off it.
I've tested all the other faders by tapping my finger against the bottom of the handle when they're at full, and they don't flicker at all. The bad ones do -- sometimes sending out a value as low as 119 -- and they also flicker if you wiggle them side to side a bit (which the good ones don't). That suggests to me that they've become hyper-sensitive for some reason.
When attempting to repair USB drivers, it says there's an error opening "/system32/wdapi1100.dll" for writing. The file must be skipped to complete the repair.
HealthCheck comes up all green.

Previous experience:
We've had this issue twice before. The first time, we sent the console in and had the entire fader panel replaced. It came back in working order. The second time, I somehow managed to fix it myself. I don't remember what I did, though. It may have involved updating software, but like a fool, I didn't write anything down.
One thing I do know is that we've only had this problem since updating from Titan 5 to Titan 6.
Also, the problem is eventually contagious. In the past, it has started out on 1 or 2 faders, then slowly spread to others. I think the most we've had was 4 or 5 before we managed to get it fixed.

Things I've tested:
It's nothing to do with the cue loaded on the fader -- the issue sticks with that fader even if all cues are removed from it.
Dirt is not likely to be the problem. I opened up the fader panel and vacuumed out each fader track individually, but it didn't help.
Creating a new show with a DMX setting wipe doesn't fix it.
Repairing USB drivers doesn't fix it.

Conclusion (so far):
This seems like it might be a firmware problem, or perhaps a bug buried in the OS.

Has anyone else ever seen this problem? Do you have any solutions?

[niclights]

This is a hardware fault, almost certainly just worn-out faders. It's quite normal and seeing values jump around in Usb Expert, particularly when wiggling the fader at the end of its track is exactly what I would expect to see. Order some replacements and get the solder sucker and soldering iron out. It's an easy fix.

[emoreth]

It's normal for faders on an Avo console to wear out in less than a year? The thing doesn't even get used that heavily.

[niclights]

That doesn't sound normal, no. It is possible that environment or spillage has prematurely caused a failure, maybe on the PCB itself, although I think this is less likely particularly as it has already been replaced.
For sure fire off an email to service for an official diagnosis but given that you need to get this resolved ASAP I would go ahead and replace a fader as it is a cheap and easy thing to try. Hopefully you can get these parts quickly in the states. I notice that the distributor has changed so it's a good test for them. In the UK I would expect next working day.

If that fixes the issue then you will have got it working properly again with minimum delay and will have confirmed this was the fault. You can then investigate why they are failing prematurely in due course. If not then at least you have narrowed down the problem.

[illumn8r]

I had a similar issue with a pretty new console, no downtime to send the console in and not a good solder-er. It was suggested I try some fader lube, I got the correct kind (DeOxit F5) used just a little very carefully and it fixed my problem.

[Lite Monkey NJ]

I'm having a similar problem. How did you apply the lube? With the console assembled or not?

TIA!

[illumn8r]

Just stuck the little tube in the fader slot and did a tiny burst and ran the fader up and down, no dis-assembly required

[Lite Monkey NJ]

Thank you! - Ordered the spray today.