Alfa Network CR6 User manual

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

Operator Manual –CR6
2
Engl
ish
ENGLISH
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
Reproductions, full or partial modifications and translations of this manual are strictly forbidden without the written
approval of Alfa Srl.
IMPORTANT:
Alfa Srl shall not be held responsible for any technical and print errors or incomplete content in this manual.
IMPORTANT:
Alfa shall not be held responsible for errors or damages caused by the use of accessories or spare parts not approved
or guaranteed by Alfa Srl.

Operator Manual –CR6
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Operator Manual –CR6
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EN
Table of contents
0. 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. SYMBOLS USED IN THE MANUAL ...................................................................................................7
0.1.5. UPDATING THE MANUAL IN CASE OF MODIFICATIONS TO MACHINE.......................................7
0.1.6. OTHER INFORMATION SUPPORTS.................................................................................................7
0.2. INSTRUCTIONS FOR ORIGINAL SPARE PART AND CONSUMABLE ORDER....................................8
0.3. SAFETY INFORMATION...........................................................................................................................8
0.3.1. PRECAUTIONS AND USAGE REGULATIONS .................................................................................8
0.3.2. GENERAL SAFETY WARNINGS........................................................................................................8
0.3.3. USERS AND ACCESS LEVELS.........................................................................................................9
1. GENERAL INFORMATION............................................................................................................................10
1.1. INTRODUCTION .....................................................................................................................................10
1.1.1. MODELS AND VERSIONS...............................................................................................................10
1.1.2. COLORANT TURNING TABLE CONFIGURATIONS.......................................................................11
1.2. INTENDED AND UNINTENDED USE.....................................................................................................11
1.3. DESCRIPTION OF THE MACHINE ........................................................................................................11
1.3.1. MAIN COMPONENTS.......................................................................................................................11
1.3.2. COLORANT TURNING TABLE.........................................................................................................12
1.3.3. ACCESSING THE GROUPS.............................................................................................................12
1.3.4. LOADING AND UNLOADING ROLLER CONVEYORS....................................................................13
1.3.5. AUXILIARY FUNCTIONS..................................................................................................................13
1.3.6. LIFTERS............................................................................................................................................14
1.3.7. ELECTRICAL CONTROL PANEL.....................................................................................................14
1.3.8. CONTROL INTERFACE....................................................................................................................15
1.4. WORK CYCLE.........................................................................................................................................15
1.4.1. SWITCH-ON - RESET.......................................................................................................................15
1.4.2. OPERATOR INTERFACE AND MAINTENANCE INTERFACE .......................................................15
1.4.3. ALARMS............................................................................................................................................16
1.4.4. STAND-BY.........................................................................................................................................16
1.4.5. PRODUCT STIRRING AND RECIRCULATION ...............................................................................16
1.4.6. WORKING CYCLE............................................................................................................................17
1.5. TECHNICAL SPECIFICATIONS .............................................................................................................17
1.5.1. ELECTRICAL SPECIFICATIONS .....................................................................................................17
1.5.2. EQUIPMENT CLASSIFICATION AND REFERENCE STANDARDS ...............................................17
1.5.3. OPERATING CONDITIONS..............................................................................................................17
1.5.4. DIMENSIONS AND WEIGHTS .........................................................................................................18
1.5.5. PRODUCTION CAPABILITY AND TECHNICAL SPECIFICATIONS ...............................................18
1.5.6. CONSUMABLE STORAGE...............................................................................................................18
1.6. RESIDUAL RISKS AND DANGEROUS AREAS.....................................................................................19
1.6.1. CONTACT WITH PAINTS AND COMPONENTS .............................................................................20
1.6.2. GENERAL FIRST AID MEASURES..................................................................................................20
1.7. CERTIFICATIONS...................................................................................................................................21
1.7.1. END OF LIFE TREATMENT - WEEE DIRECTIVE ...........................................................................21
1.7.2. FCC ...................................................................................................................................................21
1.7.3. ROHS CHINA DECLARATION .........................................................................................................21
1.7.4. EC / UKCA DECLARATIONS............................................................................................................22
2. 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

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3. 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. ASSEMBLING THE SUPERVISOR PANEL .....................................................................................32
3.3.5. INPUT AND OUTPUT ROLLER CONVEYOR INSTALLATION .......................................................33
3.3.6. CANISTER OPENING.......................................................................................................................35
3.3.7. RESTORING ELECTRICAL CONNECTIONS BETWEEN MODULES ............................................35
3.3.8. FIELD WIRING CONNECTION.........................................................................................................35
3.3.9. PANEL REASSEMBLY .....................................................................................................................36
3.4. SWITCH-ON AND INITIALISATION .......................................................................................................36
3.5. SWITCH-OFF..........................................................................................................................................36
3.6. COMMISSIONING - PREPARATION .....................................................................................................37
3.6.1. PRODUCT LOADING........................................................................................................................37
3.6.2. CIRCUIT TRIGGERING AND RECIRCULATION.............................................................................38
3.6.3. SETUP OF CIRCUITS.......................................................................................................................38
3.7. ALFA40 SERVICE OVERVIEW ..............................................................................................................38
4. HOW TO PRODUCE A COLOUR..................................................................................................................41
4.1. MACHINE STATUSES............................................................................................................................41
4.2. PRODUCTION OF A COLOUR...............................................................................................................41
4.2.1. LOADING SHUTTLES ......................................................................................................................41
4.2.2. SELECTING FORMULA AND QUANTITY .......................................................................................41
4.2.3. LOADING THE SHUTTLE.................................................................................................................42
4.2.4. STARTING THE PRODUCTION PROCESS....................................................................................42
5. ORDINARY MAINTENANCE AND ADJUSTMENTS....................................................................................43
5.1. INTRODUCTION.....................................................................................................................................43
5.2. CANISTER TOPPING UP.......................................................................................................................43
5.3. RECORDING THE OPERATION............................................................................................................44
5.4. MINIMUM AND RESERVE LEVEL .........................................................................................................44
5.5. ADJUSTING MINIMUM LEVELS ............................................................................................................44
5.6. PRODUCT DISPOSAL............................................................................................................................44
6. ORDINARY MAINTENANCE AND CLEANING............................................................................................45
6.1. SCHEDULED MAINTENANCE...............................................................................................................45
6.2. SERVICE EQUIPMENT ..........................................................................................................................46
6.3. LUBRICATION ........................................................................................................................................47
6.4. ROLLER CONVEYOR CLEANING.........................................................................................................47
6.5. CLEANING GROUP MAINTENANCE.....................................................................................................47
6.6. PURGE....................................................................................................................................................47
6.7. MANUAL CONTROLS.............................................................................................................................48
6.8. EXTERNAL CLEANING..........................................................................................................................50
6.9. INTERNAL CLEANING ...........................................................................................................................50
6.10. COMPONENT SPILLING........................................................................................................................50
6.11. REPLACING THE FUSES.......................................................................................................................50
6.12. CHECK OF THE CORRECT OPERATION OF THE DOOR CONTROL SENSORS.............................51
7. EXTRAORDINARY MAINTENANCE.............................................................................................................52
8. TROUBLE SHOOTING..................................................................................................................................53

Operator Manual –CR6
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FOREWORD
EN
0. 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” and “HOW TO PRODUCE A COLOUR”, paying more attention to the
paragraphs related to precautions and safety alerts.
In case problems or difficulties should arise, the TECHNICAL SERVICE SUPPORT of Alfa Srl is always available to
provide the right support, advice, explanation and assistance.
Alfa Srl reserves the right to make modifications for improving its own products without prior notification.
The 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, rewrite 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 comprises:
•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 CONTENTS to find the list of CHAPTERS and PARAGRAPHS contained in the manual and their subjects.
The INSTRUCTIONS AND/OR NOTES ON THE PRODUCT define the safe working practices and advice on the
correct procedures and the skills required to correctly operate and maintain the system.
Some images of this manual having been enclosed for easier identification of the described parts may not be exactly
the same as the ones in your System.

Operator Manual –CR6
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FOREWORD
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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.
MEANING OF THE SYMBOLS
WARNING! GENERAL DANGER
WARNING! HIGH VOLTAGE
WARNING! RISK OF CRUSHING.
WARNING! LASER RADIATION DANGER
GROUND CABLES
THIS SYMBOL INDICATES GROUND REFERENCE POINT.
0.1.5. UPDATING THE MANUAL IN CASE OF MODIFICATIONS TO MACHINE
If the MACHINE or MANUAL is MODIFIED in any way, an UPDATE could be sent for insertion into the printed Manual.
0.1.6. OTHER INFORMATION SUPPORTS
Several QR codes are present on the machine.
Each QR code allows accessing a web page containing
instructions and/or videos concerning the function shown
below the QR code.
Scan the barcode with an application suitable to open its
content.

Operator Manual –CR6
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FOREWORD
EN
0.2. INSTRUCTIONS FOR ORIGINAL SPARE PART AND CONSUMABLE ORDER
To provide a fast and efficient service, always specify the following information when ordering replacement and
consumable parts:
−Machine type: as indicated on nameplate.
−Serial number: as indicated on nameplate.
−Quantity of each item required.
−Code of required part.
−Description of required part.
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 perfectly level flooring.
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 can be exceeded in certain work environments.
If the noise to which the operator is exposed on a daily basis is presumably greater than 85 DB,
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. 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.
The machine is provided with doors and guards that prevent the operator from getting 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 part is accessible from the User area. All the high voltage circuits are contained into
enclosed areas and protected by fixed guards. The high-voltage internal parts are accessible to the
maintenance operator and are protected against direct contact with dangerous parts by means of IP
2X or higher class protection. Dangerous parts are marked by the symbol indicated on the side.
Dangerous mechanical parts - Risk of crushing or trapping.
Internal moving parts are accessible only to technical personnel. Do not put your hands into the
machine working areas. Tie hair to avoid the risk that it can be trapped in the machine.
For the same reason, keep away of the machine or avoid wearing any hanging objects such as ties,
necklaces, pendants or other similar items.
High-temperature parts - Risk of scalds
The machine includes no components or areas that may reach so high temperature as to become
dangerous for the user, the maintenance operator or the technician. The areas where this risk can
occur, under faulty conditions, are marked by the symbol indicated on the side.

Operator Manual –CR6
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FOREWORD
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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.
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 machine's internal an external protections. Contact Alfa's Technical
Support Service if necessary.
Alfa Srl shall bear no responsibility 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.
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.
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 routine maintenance operations, such as canister
filling and autocap moisturising.
−TECHNICIAN: an expert operator authorised to access the machine's 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 OPERATOR AREA: the area inside the machine, which can be accessed by opening the doors,
where ordinary maintenance operations are usually performed; extraordinary maintenance operations require the
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 can not be accessed using
a single key, but with other tools (circuits electrical cabinets);

Operator Manual –CR6
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GENERAL INFORMATION
EN
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. 1 litre per package).
The machine can be configured with a variable number of
circuits and canisters having different capacity, as
described in more detail below.
Each circuit can dispense a different product (products for
bodyworks).
Thanks to the accuracy and high resolution of the cutting-
edge dispensing systems designed and patented by Alfa,
the machine can reproduce any colour with exceptional
precision and absolute repeatability.
1.1.1. MODELS AND VERSIONS
This dispenser is available in three different configurations:
−CR6 (three modules, for a total of six product
dispensing heads and max. 96 total circuits);
−CR4 (two modules, for a total of four product
dispensing heads and max. 64 total circuits);
−CR2 (one module, for a total of two product dispensing
heads and max. 32 total circuits);
Each dispensing head consists of a rotary turning table
where up to 16 independent canisters can be housed.
Each dispensing head is equipped with one single
dispensing station.