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Alfa Network CR6 Operator's Manual

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Operator Manual
CR6
ORIGINAL INSTRUCTION
Code:
Year:
2022
Rev.:
04
www.alfadispenser.com

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Summary of Contents for Alfa Network CR6

  • Page 1 Operator Manual ORIGINAL INSTRUCTION Code: Year: 2022 Rev.: www.alfadispenser.com...
  • Page 2 Operator Manual – CR6 ENGLISH Alfa Srl Via Caduti di Ustica, 28 - Calderara di Reno 40012 BOLOGNA – Italy Tel +39 051 0828494 Fax +39 051 0823283 © Copyright 2015 All rights reserved © Copyright 2015 All rights reserved Reproductions, full or partial modifications and translations of this manual are strictly forbidden without the written approval of Alfa Srl.
  • Page 3 Operator Manual – CR6 Page left intentionally blank...

  • Page 4: Table Of Contents

    1.7.4. EC / UKCA DECLARATIONS ......................22 UNPACKING ..............................24 2.1. GENERAL RECOMMENDATIONS ......................24 2.1.1. DIMENSIONS OF THE PACKAGE ....................24 2.2. UNPACKING ............................25 2.3. OPENING PACKAGE AND CHECKING THE CONTENT ..............26 2.4. MOVING THE MACHINE (CR2 VERSION) ....................27 2.5. MOVING THE MACHINE (CR4 AND CR6 VERSIONS) .................27...
  • Page 5 Operator Manual – CR6 INSTALLATION ............................. 28 3.1. CHOOSING THE ROOM ......................... 28 3.2. PRODUCT LABEL AND ELECTRICAL CONNECTION ................. 28 3.3. COMMISSIONING ........................... 29 3.3.1. PANEL DISASSEMBLY ........................29 3.3.2. REMOVING THE MECHANICAL AND PARKING RETAINERS ............30 3.3.3. CARRIAGE EXTRACTION ....................... 31 3.3.4.

  • Page 6: Foreword

    0.1. HOW TO USE THE MANUAL 0.1.1. IMPORTANCE OF THE MANUAL The manual contains instructions and advice for the commissioning and use of the CR6 product. Before installing and commissioning the system, carefully read this manual in all its parts and in particular the chapters “GENERAL INFORMATION”, “INSTALLATION”...

  • Page 7: Symbols Used In The Manual

    Operator Manual – CR6 0.1.4. SYMBOLS USED IN THE MANUAL The safety and advice symbols used in this manual are used to draw the reader’s attention to warnings concerning safety or indicating good working practices. The same symbols are also placed on the machine to indicate dangerous areas and refer to the relevant safety notes in the manual.

  • Page 8: Instructions For Original Spare Part And Consumable Order

    86/188/EEC regulations. 0.3.2. GENERAL SAFETY WARNINGS CR6 is compliant with all the safety requirements of the main European and extra-European Standards and Institutions. Despite that, it is suggested to read carefully the information contained in this chapter and in the next pages since they show the possible dangerous situations and the necessary precautions to take.

  • Page 9: Users And Access Levels

    Operator Manual – CR6 Flammable parts - Risk of fire The machine is made from materials which do not propagate fire in order to minimise fire risk. Nevertheless, the machine must be installed in a duly ventilated room, complying with the manufacturer's installation requirements.

  • Page 10: General Information

    Operator Manual – CR6 1. GENERAL INFORMATION 1.1. INTRODUCTION The CR6 is a dispenser intended for the production of paint for bodywork and CarRefinishing sectors, able to produce both small quantities (e.g. 50ml) for touch-ups or colour tests, and the quantities required to paint a complete car (max.

  • Page 11: Colorant Turning Table Configurations

    Operator Manual – CR6 1.1.2. COLORANT TURNING TABLE CONFIGURATIONS Each turning table can contain a maximum of 16 products and can be made up as follows: • 16 1.5 l canisters, or • 16 2.5 l canisters, or • 12 1.5 l canisters + 4 3 l canisters Each circuit is equipped with its own 0.25 l/min pump...

  • Page 12: Colorant Turning Table

    Operator Manual – CR6 1.3.2. COLORANT TURNING TABLE Each dispensing head can house up to 16 product groups. Circuits are placed on a turning table, which allows dispensing from the various circuits sequentially. Each product group can be equipped with one 1.5, 2.5 or 3 l canister and is provided with its own dispensing unit.

  • Page 13: Loading And Unloading Roller Conveyors

    Operator Manual – CR6 1.3.4. LOADING AND UNLOADING ROLLER CONVEYORS On the left side of the machine there are can input (1) and output (2) roller conveyors, as well as the output tunnel (3). Cans can be transported in the machine only by using the proper shuttles.

  • Page 14: Lifters

    Operator Manual – CR6 A heater (9) is present in the lower part of carriages. This element is automatically activated when the temperature drops below a programmable threshold, in order to keep the product temperature above the minimum values specified by the manufacturer.

  • Page 15: Control Interface

    Operator Manual – CR6 1.3.8. CONTROL INTERFACE The machine is equipped with a touch display used as User Interface for the operator, on which the machine supervisor software runs. For details on the functions of the machine supervisor software, refer to chap.4.

  • Page 16: Alarms

    Operator Manual – CR6 1.4.3. ALARMS The interface installed on the machine, which can be viewed using a Web Browser (e.g. Google Chrome), shows in real time any critical machine alarms requiring immediate operator intervention and preventing the use of the machine, as well as non-critical alarms, reminding the operator of (even not immediately) required service operation(s).

  • Page 17: Working Cycle

    Operator Manual – CR6 1.4.6. WORKING CYCLE When the colour production input is sent, the machine performs the following work phases: 1. CAN LOADING ON SHUTTLE 2. BARCODE READING AND CONSISTENCY CHECK BETWEEN CAN CAPACITY AND VOLUME TO BE DISPENSED 3.

  • Page 18: Dimensions And Weights

    Operator Manual – CR6 1.5.4. DIMENSIONS AND WEIGHTS MODEL Height (mm) 1620 1620 1620 Width (mm) 1980 2780 3580 Depth (mm) Unladen weight (kg) The unladen weight of every single module, without lifters and without input and output roller conveyors, is approx.

  • Page 19: Residual Risks And Dangerous Areas

    Operator Manual – CR6 1.6. RESIDUAL RISKS AND DANGEROUS AREAS USER AND MAINTENANCE OPERATOR The potentially dangerous areas associated with mechanical moving parts: − Colorant turning table movement: the support base rotation during dispensing or refill operations does not present any risk that is not obvious; however, it is advisable to be careful and not to approach the parts with hands, arms, hair or clothes during operation.

  • Page 20: Contact With Paints And Components

    Operator Manual – CR6 1.6.1. CONTACT WITH PAINTS AND COMPONENTS Always beware of any product leaks from the machine or circuits during production, as well as during cleaning and maintenance operations. Contact with the components (coloured bases) can cause irritations or injuries if not properly treated.

  • Page 21: Certifications

    All handling procedures must be carried out using an industrial truck or a transpallet of right capacity. 1.7.2. FCC The manufacturer Alfa Srl - Via Farini 4 - 40124 - Bologna – Italy, declares under its own responsibility that the CR6 system is compliant with the main international standards and regulations and in particular that: For the equipment supplied with power at 100-120V, 60 Hz, Alfa declare that: CR6 complies with part 15 of the FCC regulations, Sub-chapters A and B - sections 15.107 (b) (e)

  • Page 22: Ec / Ukca Declarations

    Operator Manual – CR6 1.7.4. EC / UKCA DECLARATIONS The equipment complies with the following European Directives: 2006/42/EC, 2014/35/EU, 2014/30/EU, 2011/65/EU as well as the relevant English transpositions in force from 2021. GENERAL INFORMATION...
  • Page 23 Operator Manual – CR6 GENERAL INFORMATION...

  • Page 24: Unpacking

    The dimensions of the package depend on the machine configuration. For shipment of versions with several modules (CR4 and CR6), each vertical module, containing two turning tables, is packed and shipped separately. Accessories, spare parts and removable parts are packed separately and placed inside the main packages.

  • Page 25: Unpacking

    Operator Manual – CR6 2.2. UNPACKING The unpacking procedure described in this paragraph is conceptually valid for all the individual packages, regardless of the configuration. • Using a cutter, carefully remove the straps. • Lift the wooden cover (1), remove it and place it on the ground close to the machine.

  • Page 26: Opening Package And Checking The Content

    Operator Manual – CR6 2.3. OPENING PACKAGE AND CHECKING THE CONTENT After unpacking, make sure all products are in place and that the machine does not show any internal or external damage or evident fault. All the supplied products and accessories are housed inside the packaging.

  • Page 27: Moving The Machine (Cr2 Version)

    For small movements, it is possible to lift the support feet and push the machine using its wheels. If movements are not possible by pushing by hand, the modules that make up CR4 or CR6 must be separated and moved individually.

  • Page 28: Installation

    Always make sure that the voltage output from the mains is compatible with the nameplate specifications. * maximum absorbed current in case of use of CR6 at full load and one IEC320 socket (see chap.1 – AUXILIARY FUNCTIONS) with load of 100W.

  • Page 29: Commissioning

    Operator Manual – CR6 3.3. COMMISSIONING 3.3.1. PANEL DISASSEMBLY To complete the installation, first disassemble the panels to access all the internal mechanical and electric parts. WARNING: all the installation operations described below can be carried out by specialised and authorised technicians only.

  • Page 30: Removing The Mechanical And Parking Retainers

    Operator Manual – CR6 3.3.2. REMOVING THE MECHANICAL AND PARKING RETAINERS During transport, each carriage is mechanically locked to the cabinet. To release the carriage and allow its opening, remove the screws and brackets (1) using a 4mm Allen wrench.

  • Page 31: Carriage Extraction

    Operator Manual – CR6 For CR4 or CR6 versions, lock the modules together using the 8x60 screws already present on the central cabinet: Insert the final part of the screw into the strut of the adjacent module, then lock the module with the nut supplied.

  • Page 32: Assembling The Supervisor Panel

    Operator Manual – CR6 3.3.4. ASSEMBLING THE SUPERVISOR PANEL • Recover the supervisor panel and the relevant support from the packaging; • Fix the support to the left cabinet using two M6 TCEI screws (1), with 5mm Allen wrench, and the M8 TE screw (2), with 13mm wrench;...

  • Page 33: Input And Output Roller Conveyor Installation

    Operator Manual – CR6 3.3.5. INPUT AND OUTPUT ROLLER CONVEYOR INSTALLATION • Recover the input roller conveyor group from the relevant packaging; • Fit the barcode support (1) on the side guide (2) of the input roller conveyor as shown in the figure;...
  • Page 34 Operator Manual – CR6 • To allow group assembly, remove the plastic panel (6) that closes the left lifter by unscrewing the 6 countersunk head screws with 2.5mm Allen wrench. • Position the group by inserting the input roller conveyor inside the input tunnel over the lifter.

  • Page 35: Canister Opening

    Operator Manual – CR6 3.3.6. CANISTER OPENING • Remove the roll on canister lids. 3.3.7. RESTORING ELECTRICAL CONNECTIONS BETWEEN MODULES In case of CR4 or CR6 configuration, it is necessary to restore electrical connections between various modules. • Identify the PW OUT wiring tied inside the modules...

  • Page 36: Panel Reassembly

    NOTE: The CR6 is provided with a board whose aim, among other things, is to maintain the PC board power supply for the time required to safely shut down the board. Any voltage interruptions or dips with a shorter duration do not cause machine switching off by the PC.

  • Page 37: Commissioning - Preparation

    Operator Manual – CR6 3.6. COMMISSIONING - PREPARATION 3.6.1. PRODUCT LOADING Modules and circuits, when present, are always numbered in sequence as shown in the figure. Each product group is matched to a hardware address. By convention, group order is as shown in the figure.

  • Page 38: Circuit Triggering And Recirculation

    Operator Manual – CR6 3.6.2. CIRCUIT TRIGGERING AND RECIRCULATION Before using the machine, trigger circuits and leave them in recirculation mode. Once the circuits are full, it is recommended to perform some purge cycles and leave the machine in stand by mode for at least 12 hours, a period of time usually sufficient to remove the residual air from the circuits.
  • Page 39 Operator Manual – CR6 The page consists of 3 main sections: • Top part (1): a section is shown with the main dispenser status information; • Central part (2): there is a list of dispenser maintenance commands. • Bottom part (3): the information about the circuits present on the dispenser with the relevant product levels and service operations are shown;...
  • Page 40 The refill command of the chosen circuit can be sent. The quantity of product to be added/removed is expressed in CC. If the dispenser is equipped with a REFILL turntable (Thor or CR6 model), the command to rotate the table will be executed to set it to the refill position. INTELLIGENT...

  • Page 41: How To Produce A Colour

    Operator Manual – CR6 4. HOW TO PRODUCE A COLOUR 4.1. MACHINE STATUSES The machine synoptic diagram always shows the status of every single head (1). Following are the possible statuses of each head: STANDBY: machine ready, waiting for controls...

  • Page 42: Loading The Shuttle

    Operator Manual – CR6 4.2.3. LOADING THE SHUTTLE Apply the barcode labels to the cans with suitable capacity, paying attention that the barcode is fully visible when inserted into the shuttle. Insert the container of desired volume into the shuttle with...

  • Page 43: Ordinary Maintenance And Adjustments

    Operator Manual – CR6 5. ORDINARY MAINTENANCE AND ADJUSTMENTS 5.1. INTRODUCTION The following paragraphs describe the circuit top-up operations as well as the instructions for simple adjustments that can be performed by the operator. Namely: • Product canister top-up Please refer to Chapter 6 for lubrication and cleaning of the machine.

  • Page 44: Recording The Operation

    5.5. ADJUSTING MINIMUM LEVELS CR6 is not provided with minimum level sensors. Levels are only software controlled. To change the parameters, access the Service page, then press HOME, Machine Data, Pipe. 5.6. PRODUCT DISPOSAL During maintenance or repair, it may be necessary to empty the circuits from the products they contain.

  • Page 45: Ordinary Maintenance And Cleaning

    Operator Manual – CR6 6. ORDINARY MAINTENANCE AND CLEANING 6.1. SCHEDULED MAINTENANCE The following table indicates the scheduled maintenance recommended by Alfa. SERVICE OPERATION INTERVAL Lubrication none Cleaning Loading and unloading weekly Purge daily Machine external cleaning monthly Machine internal cleaning...

  • Page 46: Service Equipment

    Operator Manual – CR6 6.2. SERVICE EQUIPMENT Below is a list of the required equipment for the service operations. Blotting paper, clean cloth/sponge Plastic spatula Thin metal wire or clip (to clean circuit nozzles, where required) Thin tip tool or 2.5 mm flat screwdriver (for...

  • Page 47: Lubrication

    Operator Manual – CR6 6.3. LUBRICATION The machine requires no scheduled lubrication by the MAINTENANCE OPERATOR. However, it is advisable that the machine is overhauled on a yearly basis by a specialised TECHNICIAN, who can perform scheduled maintenance operations, including table lubrication in the bearings area.

  • Page 48: Manual Controls

    Operator Manual – CR6 6.7. MANUAL CONTROLS Access to controls is carried out through the supervisor synoptic panel. Press the open wrench symbols (1) to access the manual control page of the relevant machine section. Press the “Home” symbol (2) to go back to home screen.
  • Page 49 Operator Manual – CR6 Right lifter START ROLLER CONVEYOR IN CW DIRECTION = starts the roller conveyor clockwise (load inside the lifter); START ROLLER CONVEYOR DIRECTION = starts the roller conveyor counter- clockwise (unload from the lifter); STOP ROLLER CONVEYOR = stops the roller conveyor;...

  • Page 50: External Cleaning

    Operator Manual – CR6 Output roller conveyor START ROLLER CONVEYOR = starts the roller conveyor; STOP ROLLER CONVEYOR = stops the roller conveyor; START STEP 12 = starts the roller conveyor for a defined time and then automatically stops. On the right side there are some status indicators related to the sensors of this section: input photocell (FTC10).

  • Page 51: Check Of The Correct Operation Of The Door Control Sensors

    Operator Manual – CR6 6.12. CHECK OF THE CORRECT OPERATION OF THE DOOR CONTROL SENSORS Periodically, at least once a week, check the correct operation of the door opening and trolley extraction sensors. To carry out the check: − open the upper door;...

  • Page 52: Extraordinary Maintenance

    Operator Manual – CR6 7. EXTRAORDINARY MAINTENANCE The extraordinary maintenance operations require access to the service areas and area reserved for specialised technicians. ALWAYS ENTRUST THE SPECIAL MAINTENANCE INTERVENTIONS TO AN AUTHORISED SUPPORT CENTRE. THE MACHINE POWER CABLE MUST BE UNPLUGGED FROM THE MAINS BEFORE ACCESSING THE SERVICE AREA AND BEFORE PERFORMING ANY REPLACEMENT/REPAIR OPERATIONS.

  • Page 53: Trouble Shooting

    Operator Manual – CR6 8. TROUBLE SHOOTING Error code Error detected Error description Resolution of the problem Check for the absence of parameters in the case of MMT replacement. Load the EEPROM_COLOR_CIRC_PARAM_CRC Circuit parameter CRC fault bases/colorants circuit parameters onto...
  • Page 54 Operator Manual – CR6 Error code Error detected Error description Resolution of the problem Verify the correct operation of the Error in the HOMING procedure photocell, that there is at least one flag on TINTING_TABLE_HOME_POS_ERROR of the Tinting Turning Table...
  • Page 55 Operator Manual – CR6 Error code Error detected Error description Resolution of the problem Overcurrent or overtemperature in the driver that controls the Check the connection and wiring of the ROLLER_DRV_OVER_CURR_TEMP_E Loading or Unloading Lifter or in Loading or Unloading Lifter or Loading...
  • Page 56 Operator Manual – CR6 Error code Error detected Error description Resolution of the problem Verify the set parameters and send the Incorrect parameters in TINTING_BAD_PERIPH_PARAM_ERRO command to set the Peripheral units peripheral setting command again Possible absence of Brush parameters.
  • Page 57 Operator Manual – CR6 Error code Error detected Error description Resolution of the problem Current circulating in the Air Heater is higher than the Verify the connections and wiring of the TINTING_AIR_HEATER_OVERCURREN threshold set in the MMT board Air Heater on the MMT board...
  • Page 58 Operator Manual – CR6 Error code Error detected Error description Resolution of the problem The Brush HOME photocell is not engaged during movements Check operation of photocell, brush DC TINTING_BRUSH_READ_LIGHT_ERRO for machine Reset, or during a motor and the motor wiring on MMT...
  • Page 59 Operator Manual – CR6 Error code Error detected Error description Resolution of the problem The Tinting Pump Coupling photocell is in a wrong status: it Verify Pump and Pump Stepper coupling C”X”_ is not engaged when it should photocell operation. Verify the Pump...
  • Page 60 Alfa Srl Timbro rivenditore Sales Mark Headquarters: Via Caduti di Ustica, 28 I-40012 – Calderara di Reno (BO), Italy Tel. +39 (0)51 0828494 Fax +39 (0)51 0823283 Registered Office: Via Farini, 4 I- 40124 – Bologna, Italy VAT: IT-03364471205 – REA BO: 513367 Shared Capital €...

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