Tecnolux RP3480 4W Service Manual
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Tecnolux RP3480 4W Service Manual

4w wheel washer machine
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4W WHEEL WASHER MACHINE
ARTICLE RP3480 4W
SERVICE MANUAL
- Rev01 -
Tecnolux S.r.l.
Via del Lavoro 12, Trevenzuolo (VR)

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  • Page 1 4W WHEEL WASHER MACHINE ARTICLE RP3480 4W SERVICE MANUAL - Rev01 - Tecnolux S.r.l. Via del Lavoro 12, Trevenzuolo (VR)

  • Page 2: Table Of Contents

    Wheel washer RP3480 4W CONTENTS 2/49 CONTENTS DESCRIPTION CONTENTS INTRODUCTION ............................4 1 PURPOSE OF THE SERVICE INSTRUCTION MANUAL................. 4 HOW TO READ THE INSTRUCTION MANUAL ................... 5 HOW TO KEEP THE INSTRUCTION MANUAL .................... 7 HOW TO UPDATE THE INSTRUCTION MANUAL ..................7 WASHING PARAMETER SETTINGS ....................
  • Page 3 Wheel washer RP3480 4W CONTENTS 3/49 Revision table for the manual and its parts Part of manual Revision Contents Chapter Date Dec. 2017 Signature...

  • Page 4: Introduction

    Wheel washer RP 3480 4W 4/49 SERVICE MANUAL INTRODUCTION DESCRIPTION 1 PURPOSE OF THE SERVICE INSTRUCTION MANUAL This instruction manual is an addition to the use and maintenance manual and its purpose is to provide all the information required to: •...

  • Page 5: How To Read The Instruction Manual

    Wheel washer RP 3480 4W 5/49 SERVICE MANUAL INTRODUCTION DESCRIPTION HOW TO READ THE INSTRUCTION MANUAL The Manual has been divided into chapters each of which corresponds to a specific operator (INSTALLER, MACHINE OPERATOR, AND MAINTENANCE TECHNICIAN).The necessary skills for each operator to safely operate the machine have been defined.
  • Page 6 Wheel washer RP 3480 4W 6/49 SERVICE MANUAL FIGURE NUMBERING Each figure is consecutively numbered. The numbering is composed as follows: Chapter 0.2.1 0-2.1 Progressive number Paragraph TABLE NUMBERING Each table is consecutively numbered. At each different section numbering starts from “1”. The numbering is composed as follows: Chapter 0-2.1...

  • Page 7: How To Keep The Instruction Manual

    Wheel washer RP 3480 4W 7/49 SERVICE MANUAL INTRODUCTION DESCRIPTION HOW TO KEEP THE INSTRUCTION MANUAL This Instruction Manual must be kept with care and accompany the machine in any transfers of ownership that may take place during its lifetime. The Manual must be preserved by handling it with care, with clean hands and by not placing it on dirty surfaces.

  • Page 8: Washing Parameter Settings

    Wheel washer RP 3480 4W 8/49 SERVICE MANUAL WASHING PARAMETER SETTINGS DESCRIPTION DESCRIPTION OF THE WASHING PROGRAMS AND STAGES This paragraph describes the washing programs and the stages that make up the individual cycles. You can select different programs according to the result you want. Each washing cycle consists of several washing stages, and you can set the duration of each one as required.
  • Page 9 Wheel washer RP 3480 4W 9/49 SERVICE MANUAL The following washing cycles are available: Tab. 1-1.2 PROGRAM DESCRIPTION DISPLAY SYMBOL WASHING IS PERFORMED BASIC DETERGENT USING BASIC DETERGENT ONLY. WASHING IS PERFORMED USING THE RINSE AID ONLY. RINSE AID USE THIS TO IMPROVE THE WASHING RESULT.
  • Page 10 Wheel washer RP 3480 4W 10/49 SERVICE MANUAL There are six different washing programs in total. The stages that make them up are listed below. Tab. 1-1.4 BASIC DETERGENT STAGES ACID DETERGENT STAGES WASHING PROGRAM...

  • Page 11: Setting The Washing Parameters

    Wheel washer RP 3480 4W 11/49 SERVICE MANUAL WASHING PARAMETER SETTINGS DESCRIPTION SETTING THE WASHING PARAMETERS This paragraph described the procedures for editing the default washing parameters in the machine. To open the parameter setting menu, switch on the machine and wait for the screen shown in figure 1-1.1 to appear on the display.
  • Page 12 Wheel washer RP 3480 4W 12/49 SERVICE MANUAL Press the button to open the washing parameter settings. The screen shown in figure 1.1-3 will appear. Fig. 2-1.3 SETTING THE DURATION OF STAGES 4 AND 5 Any user can access the screen shown in figure 2-1.3 to set the duration of stages 4 and 5 (see tab.1-1.1).
  • Page 13 Wheel washer RP 3480 4W 13/49 SERVICE MANUAL You can vary the duration of the stage within the preset limits. Once you have set the duration you want, press the button to save the changes. To change SETTING THE DURATION OF STAGES 1, 2 AND 3 Only personnel with the safety password may change the duration of stages 1, 2 and 3.
  • Page 14 Wheel washer RP 3480 4W 14/49 SERVICE MANUAL Fig. 2-1.6 Fig. 2-1.7 There are three setting screens, and you can move from one screen to another by pressing the screen identification button...
  • Page 15 Wheel washer RP 3480 4W 15/49 SERVICE MANUAL You can change the settings as described above for stages 4 and 5. You can also change stages 4 and 5 from these three password protected screens. To restore the default stage durations, press the button, and then press the button to save the change...

  • Page 16: Pneumatic Circuit Settings

    Wheel washer RP 3480 4W 16/49 SERVICE MANUAL PNEUMATIC CIRCUIT SETTINGS DESCRIPTION SETTING THE VALVE FLOW AND PRESSURE REGULATORS This paragraph describes the procedures and parameters for setting the flow and pressure regulators of the solenoid valves and pneumatic cylinders used to automate the machine. The first step is to make sure that the inlet pressure at the machine is set to 7 bar.
  • Page 17 Wheel washer RP 3480 4W 17/49 SERVICE MANUAL Fig. 3-1.2 Fig. 3-1.3 Tab. 3-1.1 REGULATOR L (mm) VALVE FUNCTION Door opening Tipping the wheel from the trolley to the washing compartment Tipping the wheel from the trolley to the washing compartment Wheel loading-unloading Wheel loading-unloading...

  • Page 18: Positioning The Sensors On The Movement Cylinders

    Wheel washer RP 3480 4W 18/49 SERVICE MANUAL Unloading the wheel from the washing compartment Forward movement of the trolley Forward movement of the trolley 2 PNEUMATIC CIRCUIT SETTINGS DESCRIPTION POSITIONING THE SENSORS ON THE MOVEMENT CYLINDERS Fig. 2-2.1 LOADING- UNLOADING CYLINDER UNLOADING...
  • Page 19 Wheel washer RP 3480 4W 19/49 SERVICE MANUAL To ensure that the machine operates correctly, it is important that the sensors are positioned correctly on the cylinders. Below there is a description of the sensor positions on the cylinders. Ensure that the sensors are oriented correctly and positioned at the correct distance.
  • Page 20 Wheel washer RP 3480 4W 20/49 SERVICE MANUAL Fig. 2-2.4 FORWARD CYLINDER Fig. 2-2.5 TIPPING CYLINDER 3B16 3B14 3B15 Fig. 2-2.6 DOOR CYLINDER...
  • Page 21 Wheel washer RP 3480 4W 21/49 SERVICE MANUAL Fig. 2-2.7 STOP CYLINDER 3B10 Fig. 2-2.8 LOCKING CYLINDER...

  • Page 22: Pneumatic Connection Diagrams

    Wheel washer RP 3480 4W 22/49 SERVICE MANUAL 2 PNEUMATIC CIRCUIT SETTINGS DESCRIPTION PNEUMATIC CONNECTION DIAGRAMS UNLOADING CYLINDER Fig. 2-3.1 3Y12...
  • Page 23 Wheel washer RP 3480 4W 23/49 SERVICE MANUAL LOADING-UNLOADING CYLINDER Fig. 2-3.2 T7-2 T8-2 T7-1 T8-1 3Y1-2-3-4...
  • Page 24 Wheel washer RP 3480 4W 24/49 SERVICE MANUAL TIPPING CYLINDER Fig. 2-3.3 T9-2 T10-2 T9-1 T10-1 3Y1-2-3-4...
  • Page 25 Wheel washer RP 3480 4W 25/49 SERVICE MANUAL FORWARD CYLINDER Fig. 2-3.4 3Y15 3Y11...
  • Page 26 Wheel washer RP 3480 4W 26/49 SERVICE MANUAL DOOR CYLINDER Fig. 2-3.5 3Y10 36 mm...
  • Page 27 Wheel washer RP 3480 4W 27/49 SERVICE MANUAL STOP CYLINDER Fig. 2-3.6 3Y14...
  • Page 28 Wheel washer RP 3480 4W 28/49 SERVICE MANUAL LOCKING CYLINDER Fig. 2-3.7 3Y13...
  • Page 29 Wheel washer RP 3480 4W 29/49 SERVICE MANUAL T10-2 T9-2 338D-015-02 358-015-02 T9-2 368-011-02 T10- 368-011-02 358-015-02 T7-2 358-015-02 T8-2 378-011-02 358- 015-02 T7-2 T8-2...
  • Page 30 Wheel washer RP 3480 4W 30/49 SERVICE MANUAL T9-2 T8-2 T7-2 T10-2 T10-1 T9-1 T7-1 T8-1 3Y1-2-3-4...
  • Page 31 Wheel washer RP 3480 4W 31/49 SERVICE MANUAL...
  • Page 32 Wheel washer RP 3480 4W 32/49 SERVICE MANUAL TROLLEY FORWARD WHEEL UNLOADING TROLLEY LOCKING LOCK FORWARD UNLOAD 3Y11 3Y15 3Y12 3Y13...
  • Page 33 Wheel washer RP 3480 4W 33/49 SERVICE MANUAL WHEEL IN-OUT WHEEL TROLLEY IN TIPPER LOAD-UNLOAD T9-1 T10-1 T7-1 T8-1 3Y1-2-3-4 3Y1-2-3-4 3Y1-2-3-4 3Y1-2-3-4 T10-2 T8-2 T9-2 T7-2...
  • Page 34 Wheel washer RP 3480 4W 34/49 SERVICE MANUAL TROLLEY STOP BAR DOOR OPEN-CLOSE STOP DOOR UP 3Y14 3Y10...

  • Page 35: Updating Procedure

    Wheel washer RP 3480 4W 35/49 SERVICE MANUAL 3 UPDATING PROCEDURE DESCRIPTION UPDATE TYPE The machine firmware may be updated at two different levels: 1) SLAVE board level 2) MASTER board (or display board) level A USB flash drive is used to update the SLAVE board, while a PC connected to the machine with an RS-232 cable is used to update the MASTER board.

  • Page 36: Updating The Slave Board

    Wheel washer RP 3480 4W 36/49 SERVICE MANUAL 3 UPDATING PROCEDURE DESCRIPTION UPDATING THE SLAVE BOARD Updating the SLAVE board It is necessary to update both Slave boards, one of which controls the washing system, while the other controls the moving parts. They are located in the corresponding electrical panels.
  • Page 37 Wheel washer RP 3480 4W 37/49 SERVICE MANUAL To update the Washing Board, carry out the following procedure: 3) Get a USB flash drive with a capacity of at least 2 GB 4) Makes sure that the flash drive is empty 5) Save the file UPMAGIG_PLUS_X.XXL on the flash drive (where X.XX is the firmware version) 6) Rename the file you have just saved to UPMAGIC...
  • Page 38 Wheel washer RP 3480 4W 38/49 SERVICE MANUAL To update the Automation Board, carry out the following procedure: 16) Get a USB flash drive with a capacity of at least 2 GB 17) Makes sure that the flash drive is empty 18) Save the file UPMAGIG_AUTOM_X.XXA on the flash drive (where X.XX is the firmware version) 19) Rename the file you have just saved to UPMAGIC...
  • Page 39 Wheel washer RP 3480 4W 39/49 SERVICE MANUAL CAUTION !! Do not swap the automation firmware with the washing firmware or vice versa. When switching on for the first time after updating the firmware on the boards, open the information menu (Fig. 2-3.2) to make sure that the firmware versions are correct.

  • Page 40: Updating The Master Board

    Wheel washer RP 3480 4W 40/49 SERVICE MANUAL DESCRIPTION UPDATING THE MASTER BOARD To update the MASTER board, prepare a PC and RS-232 connection cable near the machine Configuring the PC Before continuing, correctly configure the PC that you are going to use for the update.
  • Page 41 Wheel washer RP 3480 4W 41/49 SERVICE MANUAL Fig. 2-3.3 Right-click the “prg ctf6 lavaruote” file in the USB flash drive and select “edit” 5) A window will open containing a line of text like the one shown below.
  • Page 42 Wheel washer RP 3480 4W 42/49 SERVICE MANUAL Replace the values in the line of text as shown in the following screen “?:\boot seriale CTF6\UPDISP.hex P24QP COM? Replace this value with the DRIVE letter assigned to the USB flash drive Replace this value with the COM port assigned to the RS-232 cable Select “File”...
  • Page 43 Wheel washer RP 3480 4W 43/49 SERVICE MANUAL 12) Close the DOS window...
  • Page 44 Wheel washer RP 3480 4W 44/49 SERVICE MANUAL Updating the MASTER board firmware Carry out the procedure described below: With the machine off, open the Control panel to access the back of the display. EMERGENCY STOP BUTTON CONTROL PANEL 2) Turn on the machine by turning the switch on the electrical panel and wait for the display to come on 3) Press the Settings button on the machine display...

  • Page 45: Test Mode

    Wheel washer RP 3480 4W 45/49 SERVICE MANUAL 8) The following screen will appear: 9) Connect the RS-232 cable to the serial port at the top of the box containing the display board 10) On the PC, double-click the file “prg ctf6 lavaruote” If the procedure has been carried out correctly, a DOS window will open with the message “connecting…”...

  • Page 46: Accessing And Using Test Mode

    Wheel washer RP 3480 4W 46/49 SERVICE MANUAL DESCRIPTION ACCESSING AND USING TEST MODE There may be cases in which it is necessary to actuate individual drive cylinders, motors or the pump, without running a washing program. For example, this may occur after replacing a movement cylinder, replacing a solenoid valve, to open/close the door, or for other reasons.
  • Page 47 Wheel washer RP 3480 4W 47/49 SERVICE MANUAL The “WASHING” and “AUTOMATION” buttons let you open the test screens for the corresponding components. At the centre of the screens there are buttons to actuate the individual components, while at the top there are two lines that show the input and output status of the individual components.
  • Page 48 Wheel washer RP 3480 4W 48/49 SERVICE MANUAL WASHING INPUT DESCRIPTION water present air present motor compartment pump circuit breaker motor circuit breaker (inverter) "Not used" INPUT DESCRIPTION speed 1 speed 2 RH rotation LH rotation PUMP MOTOR WHEEL LOCK (NOT USED) ROBOT MOVEMENT Detergent PUMP 1 (ALKALINE) Detergent PUMP 2 (ACIDIC)
  • Page 49 Wheel washer RP 3480 4W 49/49 SERVICE MANUAL AUTOMATION INPUT DESCRIPTION Forward (A1) Forward (A2) Forward (A3) Block (B1) Unloading (G1) Unloading (G3) Loading/Unloading (E1) Loading/Unloading (E2) Loading/Unloading (E3) Tipper (D1) Tipper (D2) Tipper (D3) Door (F1) Door (F2) Door (F3) Stop (C1) Trolley present INPUT DESCRIPTION...

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