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Alfa Network CR6 Technical Manual

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Technical Manual
CR6
ORIGINAL INSTRUCTION
Code:
Year:
2023
Rev.:
04
www.alfadispenser.com

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Summary of Contents for Alfa Network CR6

  • Page 1 Technical Manual ORIGINAL INSTRUCTION Code: Year: 2023 Rev.: www.alfadispenser.com...
  • Page 2 Technical Manual – CR6 Page left intentionally blank...
  • Page 3 Technical Manual – CR6 ITALIANO Alfa Srl Via Caduti di Ustica, 28 - Calderara di Reno 40012 BOLOGNA – Italy Tel +39 051 0828494 Fax +39 051 0823283 © Copyright 2015 Tutti i diritti riservati © Copyright 2015 All rights reserved Total or partial reproduction, modification and translation of the present manual is forbidden without previous authorisation of Alfa Srl.

  • Page 4: Table Of Contents

    Technical Manual – CR6 Table of contents FOREWORD ..............................6 0.1. HOW TO USE THE MANUAL ........................6 0.1.1. IMPORTANCE OF THE MANUAL ...................... 6 0.1.2. HOW TO KEEP THE MANUAL ......................6 0.1.3. HOW TO CONSULT THE MANUAL ....................6 0.1.4.
  • Page 5 HANDLING THE MACHINE ........................... 53 5.1. MOVING THE MACHINE (CR2 VERSION) .................... 53 5.2. MOVING THE MACHINE (CR4 AND CR6 VERSIONS) ................. 53 ACCESS TO THE DIAGNOSTIC FUNCTIONS ..................... 54 6.1. CONTROL AND DIAGNOSTIC INTERFACE ..................54 CONNECTION DIAGRAMS ........................... 55...

  • Page 6: 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 product CR6. Further ordinary maintenance instructions are provided in the Operator Manual. Before performing any repair or extraordinary maintenance operation, carefully read this manual in all its parts, paying more attention to the paragraphs relating to precautions and safety alerts.

  • Page 7: Symbols Used In The Manual

    Technical 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: 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. 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: Ground Connection

    Technical Manual – CR6 GROUND CONNECTION Ground wire connection point. Always ensure that yellow-green ground leads are duly fastened to the ground point indicated by the symbol on the side. DO NOT REMOVE GROUND CONNECTIONS. In case of lead damage, switch machine off and immediately contact the technical service support.

  • Page 10: Residual Risks And Dangerous Areas

    Technical Manual – CR6 0.3.4. 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 11: Technical Specifications

    Technical Manual – CR6 0.3.5.1. GENERAL FIRST AID MEASURES In the event of eye contact: remove contact lenses, if present. Immediately rinse the eyes with running water for at least 15 minutes, holding the eyelids open. Consult a physician immediately.

  • Page 12: Description Of The Machine

    Technical Manual – CR6 1. DESCRIPTION OF THE MACHINE The paragraph describes the main external and internal components of the machine and their function. 1.1. MAIN COMPONENTS 1.1.1. MAIN COMPONENTS Colorant group cabinet Colorant group cabinet (extractable) Loading roller conveyor...

  • Page 13: 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 can be accessed by opening the relevant upper cover (1). The groups in the lower part of the machine, instead, can be accessed by extracting the relevant carriage (2).

  • Page 14: Loading And Unloading Roller Conveyors

    Technical Manual – CR6 1.1.4. 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 15: Auxiliary Functions

    Technical Manual – CR6 1.1.5. AUXILIARY FUNCTIONS In addition to the colorant turning table, each dispensing head contains a cleaning station (1), a roller conveyor for shuttle movement (2) and an electrical control panel (3) that provides some service functions, as described in more detail below.

  • Page 16: Electrical Control Panel

    Technical Manual – CR6 1.1.7. ELECTRICAL CONTROL PANEL It is located on the rear side of the machine and provides the main electrical connections of the system. On/off Switch Fuse holder 5x20mm T4A 250Vac Standard CT-120 Power Socket 100-240Vac 4 x standard C14 connector (200W MAX*) “0.100”: RJ45 socket for direct communication with...

  • Page 17: Parts Removal And Replacement

    Technical Manual – CR6 2. PARTS REMOVAL AND REPLACEMENT 2.0. SAFETY REGULATIONS ON MAINTENANCE 2.0.1. AUTHORISED PERSONNEL The operations described in this chapter must be carried out in dangerous service areas RESERVED TO TRAINED AND AUTHORISED TECHNICAL PERSONNEL. 2.0.2. MACHINE SWITCHING OFF In order to switch off the machine, turn the main switch to its “O”...

  • Page 18: Panel Disassembly

    Technical Manual – CR6 2.1. PANEL DISASSEMBLY To reach the product groups and the turning 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 For each cabinet present in the machine configuration: •...

  • Page 19: Front Panel

    Technical Manual – CR6 2.1.2. FRONT PANEL To remove the front panel, which allows reaching and removing the groups, proceed as follows. • Loosen the 2 fixing screws (1) on the upper part of the panel using an appropriate Allen wrench.

  • Page 20: Product Circuit Removal

    Technical Manual – CR6 2.3. PRODUCT CIRCUIT REMOVAL To replace the product group proceed as follows: • Make sure the machine is disconnected from the power supply as described in para. 2.0.3. • Identify the product group to be replaced.

  • Page 21: Strainer Cleaning

    Technical Manual – CR6 • Slightly pull the group 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 colorant group to be replaced until it is removed from its seat.

  • Page 22: Replacing The Auxiliary Actuators And Sensors

    Technical Manual – CR6 2.4. REPLACING THE AUXILIARY ACTUATORS AND SENSORS 2.4.1. SENSOR REPLACEMENT • To remove the sensor from the bracket (1), loosen the fixing nut (2). • Disconnect the sensor by loosening the ring nut on wiring (3) and tighten the new sensor.

  • Page 23: Dispensing/Recirculation Motor Maintenance

    Technical Manual – CR6 2.4.4. DISPENSING/RECIRCULATION MOTOR MAINTENANCE If the dispensing and recirculation operations become noisy over time, the dispensing motor must be disassembled and greased. To disassemble the dispensing motor: • Move the underlying sensor support (2) by removing the two screws (1).

  • Page 24: 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 relevant support plate (3);...

  • Page 25: Replacing The Turning Table Rotation Home Photocell

    Technical Manual – CR6 2.4.6. REPLACING THE TURNING TABLE ROTATION HOME PHOTOCELL To replace the turning table rotation home photocell, proceed as follows: • Loosen the two M5 button head screws (1) underneath the colorant support base that hold the photocell holder plate (2), which can then be removed from below.

  • Page 26: Repair Interventions On The Colorant Turning Table

    Technical Manual – CR6 2.5. REPAIR INTERVENTIONS ON THE COLORANT TURNING TABLE 2.5.1. REPLACING/ADJUSTING THE TURNING TABLE ROTATION MOTOR Over time, the coupling between motor pinion and turning table toothed gear can show some backlash. To eliminate the backlash or to replace the motor, proceed as follows: •...
  • Page 27 Technical Manual – CR6 • In order to restore the correct tensioning of the new belt it is recommended to mark the position of the belt tensioner screws with a marker pen (1); • Then loosen the belt tensioners (2) by loosening the screws with a T20 torx driver and slide out the worn belt;...

  • Page 28: Removing The Turning Table, Replacing The Bearings And The Belt

    Technical Manual – CR6 2.5.3. REMOVING THE TURNING TABLE, REPLACING THE BEARINGS AND THE BELT Should it be necessary to replace the turning table bearings or the transmission belt of the stirring motion to the individual circuits, proceed as follows: •...

  • Page 29: Roller Conveyor Removal

    Technical Manual – CR6 2.6. ROLLER CONVEYOR REMOVAL 2.6.1. UPPER HEAD ROLLER CONVEYOR REMOVAL To remove upper head roller conveyor, proceed as follows: • Loosen the 2 fixing screws (1) • Disconnect the relevant connector (2) from its seat •...

  • Page 30: Lower Head Roller Conveyor Removal

    Technical Manual – CR6 2.6.2. LOWER HEAD ROLLER CONVEYOR REMOVAL To remove lower head roller conveyor, proceed as follows: • Extract the lower carriage (1) • Loosen the two fixing screws (2) (see par. 2.6.1.) • Disconnect the relevant connector (3) from its seat •...

  • Page 31: Input And Output Roller Conveyor Removal

    Technical Manual – CR6 2.6.3. INPUT AND OUTPUT ROLLER CONVEYOR REMOVAL Output roller conveyor • Loose the 4 M4 TCEI screws (3) with a 3mm Allen wrench and the M6 TCEI screw (4) with a 5mm Allen wrench. Accessible in the output tunnel.

  • Page 32: Roller Conveyor O-Ring Replacement

    Technical Manual – CR6 2.6.4. ROLLER CONVEYOR O-RING REPLACEMENT To remove roller conveyor O-rings, proceed as follows: • Loosen the four fixing screws (1) of the guard (2) and remove it • Loosen the screw with steel bushing from its seat (3)

  • Page 33: Central O-Ring Replacement

    Technical Manual – CR6 • Loosen the screw (4) from the opposite side by pivoting with its roller • Loosen the screw (5) of the adjacent roller and loosen the screw (6) • Lifting the two rollers, remove the O-ring (7) from the two sides and replace it with a new one.

  • Page 34: Lifter Adjustments

    Technical Manual – CR6 2.7. LIFTER ADJUSTMENTS 2.7.1. LIMIT SWITCH ADJUSTMENT The “high” and “low” positions of the lifters are defined by means of microswitches. To adjust the microswitches proceed as follows: • Loosen the 2 M4 screws (1) that secure the rear panel with a 2.5mm Allen wrench.

  • Page 35: Roller Conveyor Transmission Belt Tensioning

    Technical Manual – CR6 Check each level a few times by repeatedly moving the lifter up and down. Once the correct position has been found, adjust the mechanical limit switch by unscrewing the fixing screw (4) and bringing the stop into contact with the lifter trolley.

  • Page 36: Electric Repairing Operations

    Technical Manual – CR6 3. ELECTRIC REPAIRING OPERATIONS 3.1. DIAGNOSIS AND ELECTRONIC PART DESCRIPTION 3.1.1. PC BOARD The machine is provided with a PC board (Raspberry Pi) on which the high-level machine software is memorised. 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 37: Mmt Board

    Technical Manual – CR6 3.1.2. MMT BOARD MMT is the Main board on which machine management firmware is saved. 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 38: Checking And Replacing The Network Fuses

    Technical Manual – CR6 3.2. CHECKING AND REPLACING THE NETWORK FUSES In case of mains malfunction or problems, the safety fuses could blow and cut power. Fuses are located in the fuse holder built in the plug with switch on the back panel.

  • Page 39: Replacing The Power Supply Units

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

  • Page 40: Replacing The Hutts Board

    Technical Manual – CR6 3.6. REPLACING THE HUTTS BOARD The board is located inside the cabinet, fixed on the back of the colorant support base. To change the board, remove the top rear panel as described in Chap. 2 - REMOVING THE EXTERNAL COVERS, then: •...
  • Page 41 Technical Manual – CR6 • Save file containing credentials C:/programs/OpenVPN/Config • Make sure you save it as an “.opvn” file. • On Windows Toolbar, click the arrow icon “show hidden icons” (3) then find the icon “OpenVPN” (4) in the pop-up.

  • Page 42: Connection Via Vpn Client From Android Devices

    Technical Manual – CR6 • To connect to the machine, open your internet browser. • In the address bar, enter the IP address of the machine you wish to establish connection with, usually indicated on the LTE router. • Enter the login credentials given by Alfa.
  • Page 43 Technical Manual – CR6 • Run the app OpenVPN (2) previously installed. • Press symbol “+” present on the bar at top right of the app screen. • Press “Import” (3). • Select the “.ovpn” file previously downloaded; ELECTRIC REPAIRING OPERATIONS...
  • Page 44 Technical Manual – CR6 • Press on the check mark in the top right corner; • Press on the just-added file (4). • Press OK (5) on the next window. ELECTRIC REPAIRING OPERATIONS...
  • Page 45 Technical Manual – CR6 • Now the VPN status must be “Connected” (6). • To connect to the machine, open your internet browser. • In the address bar, enter the IP address of the machine you wish to establish connection with, usually indicated on the LTE router.

  • Page 46: Programming The Electronic Boards

    Technical Manual – CR6 4. PROGRAMMING THE ELECTRONIC BOARDS Depending on board version, programming can be carried out in either of two different methods: − Boards without bootloader (programming through PICkit / ICD3). − Boards with bootloader. Alfa products are delivered with the Bootloader loaded on all boards.

  • Page 47: Remote Update

    Technical Manual – CR6 4.2.1. REMOTE UPDATE The remote update service allows the user to update the firmware of the load driver boards (MMT, SCCB, MAB, HUTBRD) using only the browser. The service resides on the Linux board and can be reached at port 8070. Assuming the machine can be reached at the address 192.168.0.100, simply connect to the address http://192.168.0.100:8070/.
  • Page 48 Technical Manual – CR6 4.2.1.1. MACHINE UPDATE MODE When it becomes necessary to perform a complete update, Alfa Service will provide an archive in .zip format compatible with the machine. First, you need to save the .zip file in an easily accessible folder.

  • Page 49: Manual Mode

    Technical Manual – CR6 4.2.1.2. MANUAL MODE Manual mode allows each board to be updated/programmed individually, following its replacement. To enable manual mode, it is necessary to access the settings (see Chapter 4.2.1.) and flag the “Enable expert mode” field (2).

  • Page 50: Software "Bootloaderapp

    Technical Manual – CR6 Once successfully connected, the following operations can be performed: • Get Info (4). It is used to query the board and display the following data: the list of enabled slave boards; the bootloader version of the master and slave boards;...
  • Page 51 Technical Manual – CR6 4.2.2.1. INSTALLATION OF “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 and select option “Remove ALFA Boot Manager”, then press “Finish”.

  • Page 52: Starting The Bootloader

    Technical Manual – CR6 4.2.3. STARTING THE BOOTLOADER Run 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. MAB FIRMWARE UPDATE • Not used on CR6 4.2.5.

  • Page 53: Handling The Machine

    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 54: Access To The Diagnostic Functions

    Technical Manual – CR6 6. ACCESS TO THE DIAGNOSTIC FUNCTIONS 6.1. CONTROL AND DIAGNOSTIC INTERFACE Essential diagnostic functions are outlined in the operator's manual. For more details contact Alfa's service department ACCESS TO THE DIAGNOSTIC FUNCTIONS...

  • Page 55: Connection Diagrams

    Technical Manual – CR6 7. CONNECTION DIAGRAMS CONNECTION DIAGRAMS...
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  • Page 69: Trouble Shooting

    Technical 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 70 Technical 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 71 Technical Manual – CR6 Error code Error detected Error description Resolution of the problem Check connection of HUTTS Temperature Sensor housing board with Error in Temperature MMT board. If the problem persists, TEMPERATURE_ERROR measurement replace the board and/or the connection...
  • Page 72 Technical Manual – CR6 Error code Error detected Error description Resolution of the problem The Tinting Pump Home photocell is engaged while it should not be engaged during Verify Pump and Pump Stepper Home TINTING_PUMP_PHOTO_HOME_READ HOMING, or during photocell operation...
  • Page 73 Technical Manual – CR6 Error code Error detected Error description Resolution of the problem Shut off the machine, wait some minutes Tinting Pump stepper motor and turn in on again. If the problem TINTING_PUMP_MOTOR_THERMAL_S controller internal persists, verify the electric connections...
  • Page 74 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 75 Technical Manual – CR6 Error code Error detected Error description Resolution of the problem In Recirculation or Dosing processes that involve the “x” C”X”_ Check operation of the Open Valve 1136-1159 circuit, the Open Valve photocell photocell and the Valve stepper motor TINTING_VALVE_2_READ_LIGHT_ERR OR, where “X”...
  • Page 76 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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