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Alfa Network CR6 Technical Manual

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Technical Manual
CR6
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
Code:
Year:
2021
Rev.:
02
www.alfadispenser.com

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  • Page 1 Technical Manual TRANSLATION OF THE ORIGINAL INSTRUCTIONS Code: Year: 2021 Rev.: www.alfadispenser.com...
  • Page 2 Technical Manual – CR6 "#!
  • Page 3 Technical Manual – CR6 ENGLISH Page left intentionally blank "#!
  • Page 4 Technical Manual – CR6 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 This manual may not be reproduced or modified, either wholly or partially, or translated without the prior authorisation of Alfa Srl.

  • Page 5: Table Of Contents

    Technical Manual – CR6 Table of contents FOREWORD ..............................7 0.1. HOW TO USE THE MANUAL ........................7 0.1.1. IMPORTANCE OF THE MANUAL ..................... 7 0.1.2. HOW TO KEEP THE MANUAL ......................7 0.1.3. HOW TO CONSULT THE MANUAL ....................7 0.1.4.
  • Page 6 Technical Manual – CR6 ELECTRICAL REPAIR PROCEDURES ....................... 37 3.1. DESCRIPTION OF ELECTRONIC PARTS AND DIAGNOSTICS ............37 3.1.1. PC BOARD ............................37 3.1.2. MMT BOARD ............................ 38 3.1.3. HUTTS BOARD ..........................39 3.2. CHECKING AND REPLACING THE NETWORK FUSES ..............39 3.3.

  • Page 7: Foreword

    0.1. HOW TO USE THE MANUAL 0.1.1. IMPORTANCE OF THE MANUAL This manual provides instructions on the ordinary and extraordinary maintenance of the product CR6. Further ordinary maintenance instructions are provided in the Operator Manual. Before performing any repair or extraordinary maintenance operations, carefully read this manual in all its parts, paying particular attention to the paragraphs relating to precautions and safety alerts.

  • Page 8: Symbols Used In The Manual

    Technical Manual – CR6 0.1.4. SYMBOLS USED IN THE MANUAL The purpose of the safety and information symbols used in this manual is 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 9: Safety Information

    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. Nevertheless, it is recommended that you read carefully the information contained in the following pages, since it illustrates the potential hazard situations and the necessary precautions to take.

  • Page 10: Users And Access Levels

    Technical Manual – CR6 EARTH CONNECTION Earth conductor connection point. Always ensure that yellow-green earth leads are securely fastened to the earth point indicated by the symbol on the left. DO NOT REMOVE THE EARTH CONNECTIONS FOR ANY REASON. In the event of damage to the conductors, switch the machine off and immediately contact the technical service support.

  • Page 11: Residual Risks And Hazardous Areas

    Technical Manual – CR6 0.3.4. RESIDUAL RISKS AND HAZARDOUS AREAS USER AND MAINTENANCE OPERATOR The potentially dangerous areas associated with mechanical moving parts: Colourant table movement*; the rotary movement of the colourant support base rotation during dispensing or refill operations does not give rise to any risks that are not immediately obvious;...

  • Page 12: Technical Specifications

    Technical Manual – CR6 0.4. TECHNICAL SPECIFICATIONS 0.4.1. ELECTRICAL SPECIFICATIONS Power supply 220Vac ±10% 60Hz or 230Vac ±10% 50Hz Max current 8.0A Maximum power consumption 1000W max (+200W AUX panel + 100W internal AUX) Fuses 5X20 mm T8.0A-250V Q.ty 2cs...

  • Page 13: Description Of The Machine

    Technical Manual – CR6 1. DESCRIPTION OF THE MACHINE This paragraph illustrates the main internal and external machine components are describes their respective functions. 1.1. MAIN COMPONENTS 1.1.1. MAIN COMPONENTS • Colourant groups cabinet • Colourant groups cabinet (extractable) •...

  • Page 14: Accessing The Groups

    Technical Manual – CR6 1.1.3. ACCESSING THE GROUPS The canisters of the groups housed in the upper part of the machine may be accessed by opening the upper lid (1). To access the groups in the lower part of the machine it is necessary to extract the respective carriages (2).

  • Page 15: Loading And Unloading Roller Conveyors

    Technical Manual – CR6 1.1.4. LOADING AND UNLOADING ROLLER CONVEYORS The container infeed (1) and outfeed (2) roller conveyors are located on the left hand side of the machine, together with the outfeed tunnel (3). The containers may only fed into the machine by means of the respective shuttles.

  • Page 16: Auxiliary Functions

    Technical Manual – CR6 1.1.5. AUXILIARY FUNCTIONS In addition to the rotating colourant table, each head includes a cleaning station (1), a roller conveyor for moving the shuttle (2) and an electrical panel (3) that is provides access to a series of service functions, as described below.

  • Page 17: Electrical Control Panel

    Technical Manual – CR6 1.1.7. ELECTRICAL CONTROL PANEL This panel is located on the side of the machine and houses the main system electrical connections. On/off Switch Fuse holder 5x20 mm T8 A 250 Vac IEC standard CT-120 power socket 4 x standard C14 connector (200 W MAX*) “192.168.0.100”:...

  • Page 18: Removal And Replacement Of Parts

    Technical Manual – CR6 2. REMOVAL AND REPLACEMENT OF PARTS 2.0. SAFETY REGULATIONS FOR MAINTENANCE 2.0.1. AUTHORISED PERSONNEL The operations described in this chapter require access to hazardous service areas AND MAY BE CARRIED OUT BY TRAINED AND AUTHORISED TECHNICAL PERSONNEL ONLY.

  • Page 19: Removing Panels

    Technical Manual – CR6 2.1. REMOVING PANELS To access the colourant groups, the rotating table and stirring movement mechanisms, it is necessary to remove the covers of the machine as described in this paragraph. 2.1.1. SIDE AND REAR PANELS On each of the cabinets present in the machine configuration: •...

  • Page 20: Front Panel

    Technical Manual – CR6 2.1.2. FRONT PANEL To remove the front panel, in order to access and remove the groups, proceed as follows: • Unscrew the 2 retaining screws (1) at the top of the panel using a suitable Allen key;...

  • Page 21: Removing Component Circuits

    Technical Manual – CR6 2.3. REMOVING COMPONENT CIRCUITS To replace the component group proceed as follows: • Make sure the machine is disconnected from the power supply as described in para. 2.0.3. • Identify the colourant group to be replaced.

  • Page 22: Cleaning The Filters

    Technical Manual – CR6 • Pull the group slightly outwards so that the lower metal sheet is pulled out from underneath the fixed locking pin (2). • When the metal sheet is free, gently lift the colourant group to be replaced until it is removed from its housing.

  • Page 23: Replacing The Auxiliary Actuators And Sensors

    Technical Manual – CR6 2.4. REPLACING THE AUXILIARY ACTUATORS AND SENSORS 2.4.1. REPLACING A SENSOR • To remove the sensor from the bracket (1), unscrew the retaining nut (2). • Disconnect the sensor by loosening the wiring ring nut on (3) and screw the new sensor into place.

  • Page 24: Replacing The Heater

    Technical Manual – CR6 2.4.3. REPLACING THE HEATER • To remove the heater, open the carriage where it is housed, and then loosen the 2 M6 screws that secure it to the support feet (1) and disconnect the electrical wiring (2).

  • Page 25: Servicing The Dispensing/Recirculation Motor

    Technical Manual – CR6 2.4.4. SERVICING THE DISPENSING/RECIRCULATION MOTOR If the dispensing and recirculation operations become noisy over time, the dispensing motor must be removed and lubricated with grease. To remove the dispensing motor: • Move the sensor support (2) located underneath it by removing the two screws (1).

  • Page 26: Replacing The Ceramic Valve Drive Motor

    Technical Manual – CR6 2.4.5. REPLACING THE CERAMIC VALVE DRIVE MOTOR To remove the ceramic valve drive motor, proceed as follows: • Disconnect the motor and photocell connectors (1); • Loosen the 4 M6 countersunk head screws (2) and remove the motor with the respective support plate (3);...

  • Page 27: Replacing The Rotating Table Rotation Home Photocell

    Technical Manual – CR6 2.4.6. REPLACING THE ROTATING TABLE ROTATION HOME PHOTOCELL To replace the rotating table rotation home photocell, proceed as follows: • Loosen the two M5 button head screws (1) underneath the colourant support base that support the photocell holder plate (3), which can then be removed from below.

  • Page 28: Repair Procedures On The Colourant Rotating Table

    Technical Manual – CR6 2.5. REPAIR PROCEDURES ON THE COLOURANT ROTATING TABLE 2.5.1. REPLACING/ADJUSTING THE ROTATING TABLE MOTOR Over time, the coupling between the motor pinion and rotating table toothed gear may become subject to backlash. To eliminate backlash, or replace the motor, proceed as follows: •...
  • Page 29 Technical Manual – CR6 • In order to ensure the new belt is tensioned correctly, we recommend marking the position of the belt tensioner screws with a marker pen (1); • Next, loosen the belt tensioners (2) by loosening the screws with a T20 torx driver and slide out the worn belt;...

  • Page 30: Removing The Rotating Table, Replacing The Bearings And The Belt

    Technical Manual – CR6 2.5.3. REMOVING THE ROTATING TABLE, REPLACING THE BEARINGS AND THE BELT If it is necessary to replace the rotating table bearings or the belt that transmits the stirring motion to the individual circuits, proceed as follows: •...
  • Page 31 Technical Manual – CR6 2.6. REMOVING THE ROLLER CONVEYORS 2.6.1. REMOVING THE UPPER HEAD ROLLER CONVEYOR To remove the upper head roller conveyor, proceed as follows: • Unscrew the 2 retaining screws (1) • Disconnect the respective connector (2) from its socket •...
  • Page 32 Technical Manual – CR6 2.6.2. REMOVING THE LOWER HEAD ROLLER CONVEYOR To remove the lower head roller conveyor, proceed as follows: • Extract the lower carriage (1) • Unscrew the two retaining screws (2) (see para. 2.6.1). • Disconnect the respective connector (3) from its socket •...
  • Page 33 Technical Manual – CR6 2.6.3. REMOVING THE INFEED AND OUTFEED ROLLER CONVEYOR Outfeed roller conveyor • Unscrew the 4 M4 cyl. head hex. socket screws (3) using a 3 mm Allen key, and the M6 cyl. head hex. socket screw (4) using a 5 mm Allen key.
  • Page 34 Technical Manual – CR6 2.6.4. REPLACING THE ROLLER CONVEYOR O-RINGS To remove the o-rings from the roller conveyors, proceed as follows: • Unscrew the four retaining screws (1) from the safety guard (2) and remove it. • Unscrew the screw with the iron bushing from its housing (2).

  • Page 35: Lifter Adjustments

    Technical Manual – CR6 2.6.5. REPLACING THE CENTRAL O-RINGS To remove the central o-rings (motor zone) • Unscrew the screws (1) to release the motor pulley support (3) and remove it • To replace the o-rings on the rollers (4) or (5), unscrew the screws (2) and follow the procedure described in para.

  • Page 36: Roller Conveyor Transmission O-Ring Tensioning

    Technical Manual – CR6 • Using 2.5mm Allen wrench loosen microswitch fixing screws; • Move or tilt the microswitch to lower or raise the stop position as required. • After changing the position of the microswitch, use the manual controls to move the lifter and check that the stop level is correct.

  • Page 37: Electrical Repair Procedures

    Technical Manual – CR6 3. ELECTRICAL REPAIR PROCEDURES 3.1. DESCRIPTION OF ELECTRONIC PARTS AND DIAGNOSTICS 3.1.1. PC BOARD The machine is provided with a PC board (Raspberry Pi) on which the high-level machine software is stored. The PC board receives the Ethernet connection from the outside (LAN1 port) and is internally connected to the Main board (refer to next paragraph) via RS-232.

  • Page 38: Mmt Board

    Technical Manual – CR6 3.1.2. MMT BOARD MMT is the Main board on which machine management firmware is stored. The orders sent by the high-level software are managed at MMT level. This board organises the machine cycle by interrogating and sending orders via RS-485 to the slave boards of the single circuits.

  • Page 39: Hutts Board

    Technical Manual – CR6 3.1.3. HUTTS BOARD The HUT_TS board (1) is the board that supports the temperature sensor TC72 used to monitor the temperature of the products (colourants and bases). The board is located inside the cabinet, mounted on the rear of the colourant support base.

  • Page 40: Replacing The Secondary Circuit Fuses (Internal Terminal Boards)

    Technical Manual – CR6 3.3. REPLACING THE SECONDARY CIRCUIT FUSES (INTERNAL TERMINAL BOARDS) In case of malfunction or faults, the safety fuses may interrupt the output power supply of the terminal boards. The fuses are located on the terminal boards, located inside the rear electric compartment (see chapter 2 - ACCESSING THE ELECTRIC PARTS).

  • Page 41: Replacing Power Supplies

    Technical Manual – CR6 3.4. REPLACING POWER SUPPLIES In case of an electric fault in one or more power supply units of the machine, proceed as follows to replace them: • To access the power supply unit compartment, remove the rear panel as described in chapter 2 - REMOVING THE EXTERNAL COVER.

  • Page 42: Replacing The Hutts Board

    Technical Manual – CR6 3.6. REPLACING THE HUTTS BOARD The board is located inside the cabinet, mounted on the rear of the colourant support base. To replace the board, remove the top rear panel as described in Chap. 2 REMOVING THE EXTERNAL COVERS, and then: •...

  • Page 43: Connection Via Vpn Client On Windows 7 And 10

    Technical Manual – CR6 3.6.1. CONNECTION VIA VPN CLIENT ON WINDOWS 7 AND 10 To install the VPN Client, proceed as follows: • Open the following address in an internet browser https://openvpn.net/index.php/open- source/downloads.html • Click “openvpn-install-2.4.4-I601.exe” download the file. •...
  • Page 44 Technical Manual – CR6 • Save the file containing the credentials to C:/programs/OpenVPN/Config • Make sure you save it as an “.opvn” file. • On the Windows Toolbar, click the arrow icon “show hidden icons” (3) then locate the icon “OpenVPN” (4) in the pop-up.

  • Page 45: Connection Via Vpn Client From Android Devices

    Technical Manual – CR6 • To connect to the machine, open your internet browser. • Enter the IP address of the machine you wish to establish connection with in the address bar; this is usually indicated on the LTE router.
  • Page 46 Technical Manual – CR6 • Run the app OpenVPN (2) installed previously. • Press the “+” symbol present on the bar at top right of the app screen. • Press “Import” (3). • Select the “.ovpn” file downloaded previously; "2"*-&+*02!&",0+&!,&%*"(3&")!
  • Page 47 Technical Manual – CR6 • Press on the check mark in the top right corner; • Press on the file that has just been added (4). • Press OK (5) on the next window. • At this point, the VPN status should be “Connected”...
  • Page 48 Technical Manual – CR6 • To connect to the machine, open your internet browser. • Enter the IP address of the machine you wish to establish connection with in the address bar; this is usually indicated on the LTE router.

  • Page 49: Programming The Electrical Circuit Boards

    Technical Manual – CR6 4. PROGRAMMING THE ELECTRICAL CIRCUIT BOARDS Depending on the version, two different methods may be used to program the boards: Boards without bootloader (programming through PICkit / ICD3). Boards with bootloader. Alfa products are delivered with the Bootloader loaded on all boards.

  • Page 50: Installing The "Bootloaderapp

    Technical Manual – CR6 4.2.2. INSTALLING THE “BOOTLOADERAPP” If a version of the application is already present on the PC, you must first remove it before installing a new version. this case, installation software , select the “Remove ALFA Boot Manager”...

  • Page 51: Starting The Bootloader

    Technical Manual – CR6 4.2.3. STARTING THE BOOTLOADER Run the BootloaderApp on the PC (the application is in the folder selected in step 2 of the installation procedure). The following window will open. 4.2.4. UPDATING THE MAB FIRMWARE • Not used on CR6 4.2.5.

  • Page 52: Moving And Handling The Machine

    When moving the machine over small distances, it is possible to raise the support feet and push it along on its wheels. If it is not possible to move the machine simply by pushing it, the modules that make up the CR4 and CR6 versions must be dismantled and moved separately.

  • Page 53: Accessing The Diagnostic Functions

    Technical Manual – Thor 6. ACCESSING THE DIAGNOSTIC FUNCTIONS 6.1. CONTROL AND DIAGNOSTIC INTERFACE The essential diagnostic functions are indicated in the user manual. For more information, contact Alfa customer assistance "#! 0**"))+#4!-."!(+04#%)-+*!$3#*-+%#)!

  • Page 54: Connection Diagrams

    Technical Manual – CR6 7. CONNECTION DIAGRAMS *%##"*-+%#!(+04&0/)! "#!
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  • Page 71: Diagnostics

    Technical Manual – CR6 8. DIAGNOSTICS 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 _FAULT...
  • Page 72 Technical Manual – CR6 Error code Error detected Error description Resolution of the problem Verify the correct operation of the 2 Error in the HOMING procedure photocells and the correct movement of TINTING_VALVE_HOME_POS_ERROR of the Tinting Valve the stepper Verify the correct operation of the...
  • Page 73 Technical Manual – CR6 Error code Error detected Error description Resolution of the problem Logic error in the process statuses of the Roller Conveyors Request a Firmware update ROLLER_SOFTWARE_ERROR and Lifters Overcurrent or overtemperature in the driver that controls the...
  • Page 74 Technical Manual – CR6 Error code Error detected Error description Resolution of the problem Possible absence of Pump parameters. In case of MMT board replacement, load Tinting table parameter CRC the Tinting Pump parameters with EEPROM_TABLE_PARAM_CRC_FAULT fault “UPDATE_TINTING_TABLE_SETTINGS ” command...
  • Page 75 Technical Manual – CR6 Error code Error detected Error description Resolution of the problem Current circulating in the Brush is higher than the threshold set Check the connection and wiring of the TINTING_BRUSH_OVERCURRENT_TH in the MMT board driver, or brush on the output reserved on MMT...
  • Page 76 Technical Manual – CR6 Error code Error detected Error description Resolution of the problem The Tinting Table photocell is not engaged when it should be TINTING_TABLE_PHOTO_READ_LIGHT Verify Tinting Table Photocell operation engaged in various machine _ERROR processes Generic error in Tinting Table...
  • Page 77 Technical Manual – CR6 Error code Error detected Error description Resolution of the problem The circuits detected at the end of the Tinting Table Homing do not coincide with those found by the Self-Learning and stored in the MMT board EEPROM, or the...
  • Page 78 Technical Manual – CR6 Error code Error detected Error description Resolution of the problem In Recirculation or Dosing processes that involve the “x” Check operation of the Open Valve C”X”_ 1136-1159 circuit, the Open Valve photocell photocell and the Valve stepper motor...
  • Page 79 Technical Manual – CR6 "#! (+04#%)-+*)!
  • Page 80 Alfa Srl Distributor’s stamp 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 – BO Business Register: 513367 Fully paid up share capital €...

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