Alfa Network CR6 User manual

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

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ENGLISH
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Alfa Srl
Via Caduti di Ustica, 28 - Calderara di Reno
40012 BOLOGNA – Italy
Tel [phone] Fax [phone]
© 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.
IMPORTANT:
Alfa Srl may not be held liable for technical or editorial errors or omissions contained herein.
IMPORTANT:
Alfa Srl may not be held responsible for any errors or damage caused by the use of accessories or spare parts not
specifically approved or guaranteed by Alfa Srl.

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Table of contents
0. 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. SYMBOLS USED IN THE MANUAL .................................................................................................. 8
0.1.5. PROCEDURE FOR UPDATING THE MANUAL IN CASE OF MODIFICATIONS TO MACHINE ...... 8
0.2. INSTRUCTIONS FOR ORDERING ORIGINAL SPARE PART AND CONSUMABLES .......................... 8
0.3. SAFETY INFORMATION ......................................................................................................................... 9
0.3.1. PRECAUTIONS AND USAGE REGULATIONS ................................................................................ 9
0.3.2. GENERAL SAFETY WARNINGS ...................................................................................................... 9
0.3.3. USERS AND ACCESS LEVELS ...................................................................................................... 10
0.3.4. RESIDUAL RISKS AND HAZARDOUS AREAS .............................................................................. 11
0.3.5. CONTACT WITH COLOURANTS .................................................................................................... 11
0.3.5.1. GENERAL FIRST AID MEASURES ................................................................................................. 11
0.4. TECHNICAL SPECIFICATIONS ............................................................................................................ 12
0.4.1. ELECTRICAL SPECIFICATIONS .................................................................................................... 12
0.4.2. EQUIPMENT CLASSIFICATION AND REFERENCE STANDARDS ............................................... 12
0.4.3. OPERATING CONDITIONS ............................................................................................................. 12
1. DESCRIPTION OF THE MACHINE .............................................................................................................. 13
1.1. MAIN COMPONENTS ............................................................................................................................ 13
1.1.1. MAIN COMPONENTS ...................................................................................................................... 13
1.1.2. ROTATING COLOURANT TABLE ................................................................................................... 13
1.1.3. ACCESSING THE GROUPS ........................................................................................................... 14
1.1.4. LOADING AND UNLOADING ROLLER CONVEYORS ................................................................... 15
1.1.5. AUXILIARY FUNCTIONS ................................................................................................................. 16
1.1.6. LIFTERS ........................................................................................................................................... 16
1.1.7. ELECTRICAL CONTROL PANEL .................................................................................................... 17
2. REMOVAL AND REPLACEMENT OF PARTS ............................................................................................ 18
2.0. SAFETY REGULATIONS FOR MAINTENANCE ................................................................................... 18
2.0.1. AUTHORISED PERSONNEL ........................................................................................................... 18
2.0.2. SWITCHING THE MACHINE OFF ................................................................................................... 18
2.0.3. ACCESSING THE REPAIR AND MAINTENANCE OPERATIONS ................................................. 18
2.0.4. RESTORING NORMAL MACHINE OPERATION FOLLOWING MAINTENANCE .......................... 18
2.0.5. DISPOSAL OF PRODUCTS ............................................................................................................ 18
2.1. REMOVING PANELS ............................................................................................................................. 19
2.1.1. SIDE AND REAR PANELS .............................................................................................................. 19
2.1.2. FRONT PANEL ................................................................................................................................ 20
2.2. ACCESSING THE ELECTRICAL PARTS .............................................................................................. 20
2.3. REMOVING COMPONENT CIRCUITS .................................................................................................. 21
2.3.1. CLEANING THE FILTERS ............................................................................................................... 22
2.4. REPLACING THE AUXILIARY ACTUATORS AND SENSORS ............................................................ 23
2.4.1. REPLACING A SENSOR ................................................................................................................. 23
2.4.2. SERVICING/CLEANING THE NOZZLE CLEANING UNIT .............................................................. 23
2.4.3. REPLACING THE HEATER ............................................................................................................. 24
2.4.4. SERVICING THE DISPENSING/RECIRCULATION MOTOR .......................................................... 25
2.4.5. REPLACING THE CERAMIC VALVE DRIVE MOTOR .................................................................... 26
2.4.6. REPLACING THE ROTATING TABLE ROTATION HOME PHOTOCELL ...................................... 27
2.4.7. REPLACING THE DOOR SENSORS .............................................................................................. 27
2.5. REPAIR PROCEDURES ON THE COLOURANT ROTATING TABLE .................................................. 28
2.5.1. REPLACING/ADJUSTING THE ROTATING TABLE MOTOR ......................................................... 28
2.5.2. REPLACING THE STIRRING BELT AND/OR THE DRIVE COUPLING ......................................... 28
2.5.3. REMOVING THE ROTATING TABLE, REPLACING THE BEARINGS AND THE BELT ................ 30
2.7. LIFTER ADJUSTMENTS ........................................................................................................................ 35
2.7.1 LIMIT SWITCH ADJUSTMENT ........................................................................................................ 35
2.7.2 ROLLER CONVEYOR TRANSMISSION O-RING TENSIONING .................................................... 36

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3. 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. REPLACING THE SECONDARY CIRCUIT FUSES (INTERNAL TERMINAL BOARDS) ...................... 40
3.4. REPLACING POWER SUPPLIES .......................................................................................................... 41
3.5. REPLACING THE PC AND MAIN BOARDS .......................................................................................... 41
3.6. REPLACING THE HUTTS BOARD ........................................................................................................ 42
3.6.1. CONNECTION VIA VPN CLIENT ON WINDOWS 7 AND 10 .......................................................... 43
3.6.2. CONNECTION VIA VPN CLIENT FROM ANDROID DEVICES ...................................................... 45
4. PROGRAMMING THE ELECTRICAL CIRCUIT BOARDS .......................................................................... 49
4.1. PROGRAMMING BOARDS WITHOUT BOOTLOADER ........................................................................ 49
4.2. PROGRAMMING BOARDS WITH BOOTLOADER ............................................................................... 49
4.2.1. “BOOTLOADERAPP” SOFTWARE .................................................................................................. 49
4.2.2. INSTALLING THE “BOOTLOADERAPP” ......................................................................................... 50
4.2.3. STARTING THE BOOTLOADER ..................................................................................................... 51
4.2.4. UPDATING THE MAB FIRMWARE ................................................................................................. 51
4.2.5. UPDATING THE MMT FIRMWARE ................................................................................................. 51
5. MOVING AND HANDLING THE MACHINE ................................................................................................. 52
6. ACCESSING THE DIAGNOSTIC FUNCTIONS ........................................................................................... 53
6.1. CONTROL AND DIAGNOSTIC INTERFACE ......................................................................................... 53
7. CONNECTION DIAGRAMS .......................................................................................................................... 54
8. DIAGNOSTICS .............................................................................................................................................. 71

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0. 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.
If problems or difficulties should arise, the Alfa Srl TECHNICAL SERVICE SUPPORT is always available to provide the
appropriate support, advice, explanation and assistance.
Alfa Srl reserves the right to make modifications to its products, with the purpose of improving their performance, without
prior notification.
Incorrect use of the system can lead to loss of warranty in all its forms and terms.
0.1.2. HOW TO KEEP THE MANUAL
Do not remove, modify or rewrite the contents of this manual for any reason.
Keep the manual in a safe place, protected from heat and humidity.
0.1.3. HOW TO CONSULT THE MANUAL
This manual consists of:
• COVER PAGE IDENTIFYING THE TYPE OF PRODUCT
• TABLE OF CONTENTS
• INSTRUCTIONS AND/OR NOTES ON THE PRODUCT
The COVER PAGE identifies the product described in this manual.
Use the TABLE OF CONTENTS to find the list of CHAPTERS and PARAGRAPHS contained in the manual and the
corresponding topics.
The INSTRUCTIONS AND/OR NOTES ON THE PRODUCT define the safe working practices and advice on the correct
procedures and the skills required to operate the system correctly and maintain it.
Some images of this manual, which have been included for easier identification of the described parts, may not be
exactly the same as the ones in your System.

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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.
MEANING OF THE SYMBOLS
ATTENTION! GENERIC HAZARD
ATTENTION! HAZARDOUS VOLTAGE
ATTENTION! CRUSHING RISK.
ATTENTION! LASER RADIATION HAZARD
CABLES WITH EARTH CONNECTION
THIS SYMBOL IDENTIFIES THE EARTH CONNECTION REFERENCE POINT.
0.1.5. PROCEDURE FOR UPDATING THE MANUAL IN CASE OF MODIFICATIONS TO MACHINE
If the MACHINE or MANUAL is MODIFIED in any way, an UPDATE may be sent for insertion into the printed Manual.
0.2. INSTRUCTIONS FOR ORDERING ORIGINAL SPARE PART AND CONSUMABLES
To ensure you obtain the correct items as rapidly as possible, please include the following information when placing
your order:
- Machine type: as indicated on nameplate.
- Serial number: as indicated on nameplate.
- Quantity of each item required.
- Part number of required part.
- Description of required part.

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0.3. SAFETY INFORMATION
0.3.1. PRECAUTIONS AND USAGE REGULATIONS
The machine must be positioned in an enclosed area that complies with the environmental requirements set out in the
relevant paragraph.
Do not install the machine in a dusty environment.
Do not expose the machine to sources of heat, excessive cold, water, electromagnetic energy, or
sources of smoke.
The machine must be positioned on a completely level surface.
Always make sure that the power cable is intact and free of any cuts or cracks.
In case of cable damage, renew the cable using genuine spare parts.
The noise level generated by the machine is less than 70 DB (measured at a distance of 1 m and at a
height of 1.60 m from the floor).
This value may be exceeded in certain work environments.
If the operator is exposed noise levels potentially exceeding 85 DB on daily basis, effective hearing
protections must be used, as required by the 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.
The machine is provided with doors and guards that prevent the operator from coming in contact with
mechanical and electrical hazardous parts.
A periodical check on the safety devices must be performed according to the instructions provided by
this manual.
If the safety protection systems are damaged, turn off the machine and call the technical service.
High voltage parts - Risk of electric shock
No high voltage parts are accessible from the User area. All the high voltage circuits are housed within
enclosed areas and protected by fixed guards. The high-voltage internal parts are accessible to the
maintenance operator and are protected against direct contact by means of IP 2X or higher class
protection. Hazardous parts are marked by the symbol on the left.
Hazardous mechanical parts - Risk of crushing or entanglement.
Internal moving parts are accessible only to technical personnel. Do not put your hands into the machine
working areas. Tie hair to avoid it becoming entangled in the machine.
For the same reason, avoid wearing loose objects such as ties, necklaces, pendants or other similar
items when working on the machine.
High-temperature parts - Risk of scalding
The machine does not include any components or areas that may reach temperatures high enough to
pose a risk to the user, the maintenance operator or the technician. The areas where this risk could
occur, under fault conditions, are marked by the symbol on the left.
Inflammable parts - Fire risk
In order to minimise the fire risk, the machine is made from materials that do not propagate fire.
Nevertheless, the machine must be installed in a properly ventilated room, complying with the
manufacturer's installation requirements.
Never leave materials, fluid or foreign objects that might increase the risk and spread of a fire inside the
machine.
It is forbidden to modify the internal and external machine protections. If necessary, contact Alfa
Technical Service Support.
Alfa Srl may not be held responsible for any damage that may arise due to the failure to comply with the
above instructions.
In the event of a malfunction, contact the manufacturer's technical support service.

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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.
IF THE EQUIPMENT HAS BEEN USED IN A MANNER NOT SPECIFIED BY THE MANUFACTURER, THE
PROTECTION PROVIDED BY THE EQUIPMENT MAY BE IMPAIRED
0.3.3. USERS AND ACCESS LEVELS
The machine has three different user interfaces:
- USER: an operator who uses the machine for the purpose of producing a colour sample;
- MAINTENANCE OPERATOR: user in charge of performing ordinary maintenance operations, such as canister
filling, nozzle cleaning and autocap moisturising;
- TECHNICIAN: an expert operator authorised to access the machine special diagnostic, calibration, configuration,
troubleshooting, and extraordinary maintenance functions.
In order to identify the various areas of intervention, the following definitions must be taken into account:
- USER AREA: the area outside the machine that the user accesses in order to produce a colour sample and to
perform ordinary maintenance operations;
- MAINTENANCE AREA: the area inside the machine, which can be accessed using a key, and where ordinary
maintenance operations are usually performed (on Thor such operations are performed by the MAINTENANCE
OPERATOR); extraordinary maintenance operations require access to the SERVICE AREA and are performed by
the TECHNICIAN (replacement of dispensing units, circuits, electric parts);
SERVICE AREA (FOR USE BY TECHNICIANS): the internal areas of the machine that cannot be accessed
simply with a key but also require other tools (circuits, electrical cabinets);