Adamatic ALPHA User Manual

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Store this document safely and ensure it is available at all times.

Non-availability may affect the service / repair you’re your machine.

OPERATING AND MAINTENANCE MANUAL

for the

ALPHA DEPOSITOR

FOR PROGRAMMING INSTRUCTIONS – SEE SEPARATE MANUAL

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CONTENTS

1.0 - INTRODUCTION page5

2.0 - DIMENSIONS page5

3.0 - SPECIFICATIONS (SOFT DOUGH)page6

4.0 - SAFETY page7

5.0 - INSTALLATION page8

6.0 - ISOLATION page8

7.0 - CLEANING INSTRUCTIONS page8

8.0 - OPERATING CONDITIONS page11

9.0 - OPERATING INSTRUCTIONS page11

10.0 - CONTROL PANEL LAYOUT page13

11.0 - CONTROL KEY FUNCTIONS page13

12.0 - OPERATIONAL CONTROLS page16

13.0 - PREPARING FOR OPERATION page17

14.0 -

MACHINE / PRODUCT PROGRAMMING page17

15.0 - MAINTENANCE page18

16.0 - SPARES AND SERVICE page19

17.0 - RECOMMENDED SPARES LIST page20

18.0 - ELECTRICAL INFORMATION page24

SECTION “A” BASIC MACHINE

SECTION “B” WIRECUT VERSION

SECTION “C” ROTORY VERSION

SECTION “D” ROTORY & WIRECUT VERSION

19.0 - FAULT ANALYSIS CHARTS

 DISPOSAL

Failure to adhere to the cleaning and maintenance

instructions detailed in this booklet could affect the

warranty of this machine.

CARE SHOULD BE TAKEN WHEN THE MACHINE COMES TO THE END

OF ITS WORKING LIFE. ALL PARTS SHOULD BE DISPOSED OF IN THE

APPROPRIATE PLACE, EITHER BY RECYCLING OR OTHER MEANS OF

DISPOSAL THAT COMPLIES WITH LOCAL REGULATIONS.

(IN UK, ENVIRONMENTAL PROTECTION ACT 1990 APPLIES)

As it is our policy to improve our machines continuously, we reserve the right to change

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specifications without prior notice.

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1.0 INTRODUCTION

MONO’s ALPHA depositor is designed for ease of use to produce a wide range of

confectionery products. Its exceptional accuracy, repeatability, versatility and user friendly approach lends itself to quick high volume production.

The ALPHA depositor is a compact, high specification machine, operated off a single-phase electric supply and capable of being moved through a single door.

Product creation requires programming of the ALPHA’s controller via its menu driven interface screen situated on a swivel pod to the side of the machine. Product programs can be stored into the controller’s memory for future retrieval, with the ability to store up to 99 programs - each program requiring unique identification using alpha and/or numeric characters.

Subsequent deletion of created programs is only possible via a password-protected screen. Mechanically, the ALPHA is configured with the tray conveyor capable of vertical movement and the deposit head in a fixed height position. Vertical movement is controlled by a manual control, with a fixed jog height. In order to achieve smooth production and optimum performance, it is recommended that the information given in this manual be studied before any operation is carried out.

2.0 DIMENSIONS

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3.0 SPECIFICATIONS (SOFT DOUGH)

MODEL 40 45

(nom. hopper width (cm))

Weight: 270 272 (Kg)

Max. deposit rate: 26 30 (litre/min)

Standard hopper capacity: 36 41

(litre)

Power: 2.5Kw single phase fused at 20A anti-surge or 20A type d MCB.

Min distance between trays = 50mm Noise level = Less than 85dB Electronics = All microprocessor Controlled

NOTE:

The minimum deposit that can be made depends on several factors - recipe, mixing method, template size and deposit speed.

As a guide the following is the minimum that should be attempted:

Macaroons 6g, Meringues 3g, Choux Paste 5g, Viennese 4g, Sponge Drops 4g.

However, consult Mono Equipment if intended product falls outside the above general machine specification to determine the ALPHA’s exact capabilities with any specific product.

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4.0 SAFETY

1 Never use a machine in a faulty condition and always report any damage.

2 Only trained engineers may remove any part from this machine that requires a tool

to do so.

3 Always ensure hands are dry before touching any electrical appliance (including

cable, switch and plug).

4 All operatives must be fully trained.

5 People undergoing training on the machine must be under direct supervision.

6 Do not operate the machine with any panels or guards removed.

7 No loose clothing or jewellery should be worn while operating the machine.

8 Switch off power at the mains isolator when machine is not in use and before

carrying out any cleaning or maintenance.

ALL CLEANING AND MAINTENANCE OPERATIONS MUST BE MADE WITH

MACHINE DISCONNECTED FROM THE POWER SUPPLY.

9 The bakery manager or the bakery supervisor must carry out daily safety checks on

the machine.

10 Do not operate machine without hopper template fitted correctly.

10 HOPPER TEMPLATE FITTED

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5.0 INSTALLATION

1 Ensure that the depositor is connected to correct electric supply as specified on the

serial number plate on the rear of the machine.

2 Ensure that the correct fuse rating is fitted in the electrical supply to the ALPHA - a

13A single-phase supply fused at 20A anti surge or 20A type D MCB is required.

6.0 ISOLATION

1 In an emergency, switch off at the mains wall isolator, or the machines emergency

stop button. To release the emergency stop button, turn clockwise.

7.0 CLEANING INSTRUCTIONS

NOTE:

- Cleaning must be carried out by fully trained personnel only.

- Isolate machine from mains supply before carrying out any cleaning.

- Do not steam clean or use a jet of water.

All the outer surfaces of the machine should be daily wiped over with warm soapy water.

a. BETWEEN PRODUCT MIX CHANGES 1 The hopper, hopper pump, template, nozzles etc. should be removed from the

2 Slacken template clamp strip nuts and remove fitted template from hopper pump

Do not use any form of caustic detergent or abrasive.

machine and dismantled for thorough cleaning.

assembly by sliding out to avoid subsequent damage.

Clamp Strip Nut

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8

3 To reduce weight and bulk, separate and remove hopper body from hopper pump

assembly whilst still on machine. Unscrew the nuts holding the hopper body to the hopper pump to reveal the ’O’ sealing ring. Ensure seal is not damaged during cleaning.

3

4 Unscrew the nuts holding the pump end cap to the hopper. Ensure that the nuts are

placed where they will not be lost.

5 Withdraw the end cap with the pump gears, if still attached. Ensure that the ‘O’

sealing ring on the inside of the endplate is not damaged during cleaning.

5

6 Remove the hopper-locking clamp from the end of the hopper bar and slide off

hopper pump casting.

NOTE: Use only warm soapy water to clean these parts that should be rinsed and thoroughly dried before re-assembly. The greatest care must be taken not to drop the hopper, or leave any components in the hopper.

b. CLEANING OF HARD DOUGH HOPPER

1 Remove hopper from hopper body assembly by removing the wing nut at either end.

2 Lift off both upper bronze end caps

Remove both gears from the assembly; ensure that the hopper has been disengaged from the drive, to enable removal.

NOTE: The main hopper construction should be lifted off by at least two people.

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c. TABLE REMOVAL AND CLEANING

1 Removal of the table from the machine for cleaning is not necessary, however, if

required, unscrew the two securing screws from the side of the table. Disconnect the three sockets from the main bulkhead and slide the table off the support bars.

1

To replace, follow reverse procedure.

2 In normal use clean the table’s external surfaces and belts with warm soapy water

and rinse and thoroughly dry before use.

3 The table’s conveyor belts can be disengaged from their drive rollers by slackening

the adjusting screws on the underside of the table. However, for belt replacement first remove the table from machine as in 7.c.1 above.

3

d. WIRECUT REMOVAL AND CLEANING

1 To remove wirecut frame, lift out drop arm pins and slide frame out backwards.

2 Clean with warm soapy water, rinse and thoroughly dry and replace.

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8.0 OPERATING CONDITIONS

Make sure the depositor is used on a level floor to achieve best results. Ensure flat trays of consistent length, width, material and edge dimensions are used to obtain the best product results and consistent operating from the ALPHA.

9.0 OPERATING INSTRUCTIONS

FITTING THE HOPPER

CAUTION SHOULD BE TAKEN WHEN FITTING HOPPER PUMP AS WEIGHT

EXCEEDS 20KGS.

1 To reduce weight and bulk, fit the complete hopper assembly in two stages - first

the hopper pump assembly, then the hopper body with its detachable top guard.

2 Align hopper pump drive gear with drive shaft and slide hopper on support bars

until fully up against locating boss.

3 Ensure hopper-locking clamp is replaced on hopper bars.

2

DO NOT OPERATE MACHINE WITHOUT TEMPLATE FITTED

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FITTING A TEMPLATE

1 Select template and nozzles required.

2 Screw nozzles into threaded nozzle tube on templates.

3 Slide template into matching recess at base of hopper pump until the stop engages.

4 Tighten nuts on clamp strip, on underside of hopper pump, to secure template.

Leakage of mix will occur if the nuts are not securely tightened.

FITTING WIRECUT FINGERS

1 Select wirecut fingers that suit the chosen template i.e. the correct number of dies

across the template.

2 Remove drop arm pins and insert finger frame into arms. Ensure the follower arm

roller is positioned on the cam track, replace pins.

3 Replace drop arm pins.

4 Remove motor release handle and push fingers forward in order to line up the wire

with the dies.

5 Adjust individual finger bolts to raise the wire to touch the bottom surface of the die. Or adjust cam follower arm to raise or lower all fingers together.

REPLACEMENT WIRE

1 Remove broken wire

2 Feed wire through eye on its end, to make a loop.

3 Place loop around fixing screw and tighten

4 Feed wire through eyeholes in the end of the fingers.

5 Feed wire through hole in tensioning screw and tighten until wire is taught.

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10 CONTROL PANEL LAYOUT

11.0 DESCRIPTION OF CONTROL PANEL - KEY FUNCTIONS

DRG REF. FUNCTION DESCRIPTION

A PRIME

This button activates the hopper pump for as long as it is pressed, providing either a product creation or run menus are on screen, and all safety guards are properly closed. It fulfils two functions: -

a.To prime the hopper pump and nozzles with product mix.

b.Aids the engagement of the hopper drive

gear into the drive shaft.

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B MANUAL Runs product program for one tray only, then

returns tray to operator and stops. If a tray is already under the deposit pump, by pressing “manual” the tray will be returned to you.

C AUTOMATIC Activates an automatic machine cycle

provided a tray is on the table and positioned correctly. At the end of the cycle the tray conveyor will continue running to displace full tray from machine and introduce empty tray to deposit start position

NOTE If two trays are placed too close to

each other the machine will interpret this as one long continuous tray and will continue feeding both trays through the machine until a gap at the rear of the following tray is detected.

D STOP BUTTON Stop button for either the manual or automatic

modes. Stops machine cycle but does not cut power to drives.

E START BUTTON Pressed once will power up controller screen.

Pressed a second time will activate all power

electric circuits. All machine facilities can be used once pressed provided all safety guards are properly closed and emergency stop button is released.

F EMERGENCY STOP Immediately isolates all power circuits. To release - turn clockwise.

G NUMERIC/DIRECTION Whilst key (I) is being held down these

BUTTON keys will allow entry of numerical values. If pressed by themselves they can be used for cursor movement and command activation.

H CONTRAST If pressed simultaneously with key (I) and then

released, by using keys (I) and (H) the contrast of the screen can be changed Five seconds after release the new setting will

be fixed.

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I SHIFT BUTTON If used in conjunction with (G) keys will allow

numerical entry. Used for adjusting contrast (as above).

J SINGLE DEPOSIT When in a program creation menu BUTTON pressing this will run program to do a single row on a tray, then return the tray.

K ESCAPE Enables exit from menus to higher levels and exit from current on screen operations.

L POWER INDICATOR When illuminated all electric circuits have

been activated.

M DROP PRODUCT MENU Selects screen menu for creation of drop

products i.e. products with no length.

N STRIP PRODUCT MENU Selects screen menu for creation of strip products i.e. products with length.

O TRAY MENU Selects screen menu to enter values for positioning of product on tray.

P FILE MENU Selects screen menu to save, retrieve and delete programs.

Q FUNCTION MENU Selects screen menu to enter edit/create menu and machine set-up menus.

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12.0 OPERATIONAL CONTROLS

(See Fig 10)

Emergency stop button (F)

Isolates all electric circuits immediately. To release the emergency stop button, turn clockwise.

NOTE: ONLY USE IN AN EMERGENCY

To stop the machine when in use only use stop button (D).

Start button (E)

Activates all electric circuits. This must be pressed to start machine initially or on restarting machine after emergency stop button has been depressed, or if safety guard displaced, and subsequently replaced.

Stop button (D)

Will stop the machine cycle immediately in either AUTOMATIC or MANUAL modes. When the machine is started again in either of these modes, it will begin to deposit at the start of a deposit cycle, no matter at what stage of the cycle the machine was stopped.

If pressed when conveyor table is too close to the depositing head to remove the tray, then manual button (B) must be pressed in order to reset and lower table and eject tray that is currently on the table.

Prime button (A)

Primes the pump gears and nozzles with product after the hopper has been loaded with mix and the hopper guards have been closed. The conveyor will drop, take in a tray and then the deposit motor will run for as long as the button is pressed. The prime button can also be used to aid the engagement of hopper gears to the drive shaft. Prime button will only function in a product creation menu or the run menu.

Auto button (C) This automatic operation is activated by the tray sensor on the table and allows the machine to be constantly fed with trays without the operator having to touch the control panel. The machine will operate when a tray is placed on the table and will stop cycling when each tray of deposit is completed. A minimum space of 50mm between trays allows for correct tray positioning. To halt the automatic cycle, press the stop button.

Manual button (B) This initiates the machine to cycle for one tray only. On completion of the tray, it is returned to the front of the machine and stopped ready to accept the next tray that should be placed on the table and the above procedure repeated. To halt the manual cycle,

press the stop button.

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13.0 PREPARING FOR OPERATION

1 Fill hopper with mix and close hopper guard. It is recommended that when heavy

mixes are used, the inside of the hopper should be coated with vegetable oil; for lighter mixes such as meringue, dampen with water. The oil or water will help the mix to settle down the hopper walls and prevent air being sucked in.

2 Turn on isolator switch.

Isolator switch

3 Press start button to turn on controller screen.

4 Select an existing or new program.

5 Press start button again to turn on all electric circuits.

6 Press prime button and place tray on table; hold down button until mix is deposited

equally across all nozzles. Then release prime button. Press manual to return tray.

7 The machine is now ready for operation

14.0 MACHINE / PRODUCT PROGRAMMING

Please see controller operational manual for programming instructions

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15.0 MAINTENANCE

WARNING: Isolate machine from mains supply before carrying out any

maintenance procedures. Refer to sections 7.0, 8.0 and 9.0

WARNING: DO NOT UNDER ANY CIRCUMSTANCES USE A WATER HOSE TO

CLEAN MACHINE.

RESETTABLE MINIATURE CONTACT BREAKERS.

A

These are located on the electrical bracket in the base of the machine. If a circuit breaker trips out more than once in a short period of time, contact a qualified electrician immediately.

AIR FILTER REPLACEMENT

B

Replacement of the ALPHA’s air filter must take place on a 3 monthly basis as otherwise, excessive restriction to air flow may result causing insufficient cooling of internal components and electrics. The air filter is mounted within its housing on the inside of the back removable panel.

TABLE HEIGHT ADJUSTMENT YOKE

C

For smooth operation and prolonged life the thread within the table adjustment yoke should be re-greased on a 6 monthly basis.

DRIVE SHAFT CHAIN MECHANISM / E JOG CHAIN

D

For smooth operation and prolonged life the jog chain and the drive shaft chain mechanism within the casting should be re-greased on a 6 monthly basis.

LINEAR BEARINGS

F

For smooth operation and prolonged life the drive shaft chain mechanism within the casting should be re-greased on a 6 monthly basis.

A B

D

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C

F

E

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16.0 SPARES AND SERVICE

If a fault arises, please do not hesitate to contact the MONO Customer Service Department.

MONO Equipment.

Queensway Swansea Industrial Estate Swansea SA5 4EB UK

Tel. 01792 561234 Fax. 01792 561016

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17.0 Recommended spares list

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ELECTRICAL SPARES LIST

Spares Item Description Mono Part No. Qty Req. per M/C

Pour through guard safety switch assy M077-25-00400 1 Tray sensor assy 077-25-01500 1 Jog position sensor assy 077-25-01400 1 Transformer B726-31-003 1 Control panel assy B728-93-010 1 PCB interconnect card B728-93-009 1 Deposit motor servo amplifier B739-80-002 1 Tray motor servo amplifier B739-80-002 1 Rack for servo amplifiers B739-09-002 1 Deposit motor assy 077-25-01900 1 Tray motor assy B912-74-021 1 Deposit motor encoder B742-99-001 1 Stop button B801-12-003 1 Start button B801-12-029 1 Start button contact block B801-14-001 1 Stop button contact block B801-14-002 1 Varistor B842-48-002 1 Filter unit B842-48-009 1 Contactor B859-08-044 1 Auxiliary contact block B859-14-088 1 Suppresser diode B859-48-002 1 Circuit breaker 110VAC supply B872-22-002 1 Circuit breaker 18-0-18VAC supply B872-22-075 1 Circuit breaker 72VAC supply B872-22-098 1 Inverter unit B807-80-001 1 ROTARY HEAD INVERTER(B807-80-001) 11/05 ONWARDS B801-80-010 1 Rotary motor/gearbox B912-74-019 1

Wirecut motor B912-74-025 1 Wirecut sensor B819-99-002 1

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BASE MACHINE SPARES LIST

Spares Item Description Mono Part No. Qty Req. per M/C

Flexible bellow 077-01-02600 2 Castor locked A900-20-043 2 Castor A900-20-044 2 Air filter A900-30-001 1 H.D Drive shaft 077-02-00400 1 S.D Drive shaft 077-02-00500 1 Drive gear chain A900-08-056 1 Drive gear chain link A900-08-055 1 Main deposit gearbox A900-11-082 1 Damper A900-29-013 1 Clutch 077-04-02100 1 (UP TO JUNE ’99 077-04-00100) Jog keeper pin 077-04-00400 1 Link pivot pin 077-04-01100 1 Jog control sleeve 077-04-01200 1 Jog control shaft 077-04-01300 1 Jog chain assy 077-04-02000 1 Jog sensor trigger plate 077-04-01900 1 Table adjuster shaft 077-05-00100 Yoke 077-05-00200 Yoke pin 077-05-00300 2 Upper sprocket pin 077-05-00500 1 Lower sprocket pin 077-05-00600 1 Fixed sprocket pin 077-05-010** 1 Jog sprocket 077-05-01100 3 Table drive roller shaft 077-06-00600 1 Table drive roller shaft (

motor in side position) 077-22-00100 1

Table idler shaft 077-06-00700 1 Table motor drive shaft 077-06-00800 1 Table bearings 077-06-01700 2

Table drive belt (old machines) A900-21-079 1

Conveyor belt A900-22-101 2 Rotary drive gear 077-09-00500 1 Rotary drive shaft 077-09-00100 1 Cutting wire (wirecut) A900-25-285 1

077-05-01200 (matched set)

1

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HOPPER SPARES LIST

• HOPPER 400mm WIDE

Spares Item Description Mono Part No. Qty Req. per M/C

Template clamp strip 073-09-00400 1 End cap - drive side 073-09-00500 1 End cap - non drive end 073-09-00502 1 End cap bush 073-09-00600 4 Template clamp stud 073-09-01000 4 End cap stud 073-09-01100 4 Hopper stud 073-09-01200 2 End cap ‘O’ ring A900-12-074 2 Hopper seal A900-12-083 1 Clamp strip nut 072-07-20902 4

• HOPPER 450mm WIDE

Spares Item Description Mono Part No. Qty Req. per M/C

Template clamp strip 073-09-00402 1 End cap - drive side 073-09-00500 1 End cap - non drive end 073-09-00502 1 End cap bush 073-09-00600 4 Template clamp stud 073-09-01000 4 End cap stud 073-09-01100 4 Hopper stud 073-09-01200 2 End cap ‘O’ ring A900-12-074 2 Hopper seal A900-12-084 1 Clamp strip nut 072-07-20902 4

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18.0 ELECTRICAL INFORMATION

SECTION “A” - BASIC MACHINE

SECTION “B” - WIRECUT VERSION

SECTION “C” - ROTARY VERSION

SECTION “D” - ROTARY & WIRECUT VERSION

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SECTION “A”

BASIC MACHINE

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ELECTRICAL COMPONENT LAYOUT PARTS LIST

MONO DRAWING PART PT-Ref DESCRIPTION NUMBER

PT-1 SLEEVE B842-48-008 PT-2 VARISTOR B842-48-002 PT-3 FILTER UNIT B842-48-009 PT-5a MAIN CONTACTOR N’ 1 B859-08-048 PT-5b AUXILIARY CONTACT BLOCK B859-14-011 PT-5c AUXILIARY CONTACT BLOCK B859-14-015 PT-6 DEPOSIT CONTROLLER 72 VAC SUPPLY M.C.B. B872-22-098 PT-7 DEPOSIT CONTROLLER 18-0-18 VAC BUS SUPPLY M.C.B. B872-22-075 PT-9 FAN POWER SUPPLY M.C.B. B872-22-002 PT-11 TRANSFORMER B726-31-003 PT-14 CONTROLLER UNIT ENCLOSURE & POWER SUPPLY UNIT B739-09-002 PT-15 DEPOSIT MOTOR CONTROLLER B739-80-002 PT-16 TRAY TRAVEL MOTOR CONTROLLER B739-80-002 PT-18 INTERFACE P.C.B. UNIT B728-93-009 PT-19a COMPUTER DISPLAY UNIT B728-93-010 PT-19b 25 WAY RIBBON LEAD B728-63-002 PT-19c 37 WAY RIBBON LEAD B728-63-004 PT-20a DEPOSIT DRIVE MOTOR. B741-74-001 PT-20b DEPOSIT DRIVE MOTOR GEARBOX A900-11-076 PT-20c DEPOSIT MOTOR ENCODER B742-99-001 PT-21a TRAY TRAVEL DRIVE MOTOR. B912-74-021 PT-23 TRAY SENSOR UNIT B735-99-001 PT-27 JOG POSITION SENSOR B842-99-001 PT-28 HOPPER SAFETY SWITCH B818-07-010 PT-29a STOP BUTTON B801-12-003 PT-29b STOP BUTTON CONTACT BLOCK B801-14-002 PT-30a START BUTTON B801-12-029 PT-30b START BUTTON CONTACT BLOCK B801-14-004 PT31a TRANSFORMER SUPPRESSOR CAPACITOR B900-48-003 PT-31b TRANSFORMER SUPPRESSOR V.D.R. B842-48-002 PT-32 FAN MOTOR SUPPRESSOR CAPACITOR B900-48-002 PT-33a TRAY TRAVEL ENCODER PLUG B900-06-004 PT-33b TRAY TRAVEL ENCODER SOCKET B900-25-004 PT-34a TRAY TRAVEL MOTOR PLUG HOOD B715-25-011 PT-34a TRAY TRAVEL MOTOR PLUG INSERT B715-25-006 PT-34b TRAY TRAVEL MOTOR SOCKET MOUNTING BASE B715-06-001 PT-34b TRAY TRAVEL MOTOR SOCKET INSERT B715-06-005 PT-35a TRAY SENSOR PLUG B900-06-003 PT-35b TRAY SENSOR SOCKET B900-25-003 PT-37 MAIN ROTARY ISOLATOR SWITCH B748-03-002 PT-37 MAIN ROTARY ISOLATOR SWITCH (AMERICAN) B748-03-003

PT-38 SURGE SUPPRESSOR RESISTOR B842-59-014

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COMPONENT LAYOUT PARTS LIST

MONO

DRAWING PART

PT-Ref DESCRIPTION NUMBER

PT 39 MAIN CONTACTOR N’ 2 B859-08-055 PT 40 WIRECUT MOTOR FUSE ON INERFACE PCB B842-85-026 PT 41 WIRECUT ONE TURN SENSOR B919-99-002 PT 42 WIRECUT MOTOR UNIT B912-74-025 PT 43 FRONT ACCESS COVER SAFETY SWITCH B818-07-010

PT 44 REAR ACCESS COVER SAFETY SWITCH B818-07-010 PT 45 WIRECUT TEMPLATE SENSOR B819-99-002 PT 46 ROTARY HEAD MOTOR MCB B872-22-064 PT 47 ROTARY HEAD INVERTER (B807-80-001) 11/05 ONWARDS B801-80-010 PT 48 ROTARY HEAD MOTOR B912-74-019

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SECTION “B”

WIRECUT VERSION

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ELECTRICAL COMPONENT LAYOUT PARTS LIST

MONO DRAWING PART PT-Ref DESCRIPTION NUMBER

PT-1 SLEEVE B842-48-008 PT-2 VARISTOR B842-48-002 PT-3 FILTER UNIT B842-48-009 PT-5a MAIN CONTACTOR N’ 1 B859-08-048 PT-5b AUXILIARY CONTACT BLOCK B859-14-011 PT-5c AUXILIARY CONTACT BLOCK B859-14-015 PT-6 DEPOSIT CONTROLLER 72 VAC SUPPLY M.C.B. B872-22-098 PT-7 DEPOSIT CONTROLLER 18-0-18 VAC BUS SUPPLY M.C.B. B872-22-075 PT-9 FAN POWER SUPPLY M.C.B. B872-22-002 PT-11 TRANSFORMER B726-31-003 PT-14 CONTROLLER UNIT ENCLOSURE & POWER SUPPLY UNIT B739-09-002 PT-15 DEPOSIT MOTOR CONTROLLER B739-80-002 PT-16 TRAY TRAVEL MOTOR CONTROLLER B739-80-002 PT-18 INTERFACE P.C.B. UNIT B728-93-009 PT-19a COMPUTER DISPLAY UNIT B728-93-010 PT-19b 25 WAY RIBBON LEAD B728-63-002 PT-19c 37 WAY RIBBON LEAD B728-63-004 PT-20a DEPOSIT DRIVE MOTOR. B741-74-001 PT-20b DEPOSIT DRIVE MOTOR GEARBOX A900-11-076 PT-20c DEPOSIT MOTOR ENCODER B742-99-001 PT-21a TRAY TRAVEL DRIVE MOTOR. B912-74-021 PT-23 TRAY SENSOR UNIT B735-99-001 PT-27 JOG POSITION SENSOR B842-99-001 PT-28 HOPPER SAFETY SWITCH B818-07-010 PT-29a STOP BUTTON B801-12-003 PT-29b STOP BUTTON CONTACT BLOCK B801-14-002 PT-30a START BUTTON B801-12-029 PT-30b START BUTTON CONTACT BLOCK B801-14-004 PT31a TRANSFORMER SUPPRESSOR CAPACITOR B900-48-003 PT-31b TRANSFORMER SUPPRESSOR V.D.R. B842-48-002 PT-32 FAN MOTOR SUPPRESSOR CAPACITOR B900-48-002 PT-33a TRAY TRAVEL ENCODER PLUG B900-06-004 PT-33b TRAY TRAVEL ENCODER SOCKET B900-25-004 PT-34a TRAY TRAVEL MOTOR PLUG HOOD B715-25-011 PT-34a TRAY TRAVEL MOTOR PLUG INSERT B715-25-006 PT-34b TRAY TRAVEL MOTOR SOCKET MOUNTING BASE B715-06-001 PT-34b TRAY TRAVEL MOTOR SOCKET INSERT B715-06-005 PT-35a TRAY SENSOR PLUG B900-06-003 PT-35b TRAY SENSOR SOCKET B900-25-003 PT-37 MAIN ROTARY ISOLATOR SWITCH B748-03-002 PT-37 MAIN ROTARY ISOLATOR SWITCH (AMERICAN) B748-03-003

PT-38 SURGE SUPPRESSOR RESISTOR B842-59-014

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40

COMPONENT LAYOUT PARTS LIST

MONO

DRAWING PART

PT-Ref DESCRIPTION NUMBER

PT 39 MAIN CONTACTOR N’ 2 B859-08-055 PT 40 WIRECUT MOTOR FUSE ON INERFACE PCB B842-85-026 PT 41 WIRECUT ONE TURN SENSOR B919-99-002 PT 42 WIRECUT MOTOR UNIT B912-74-025 PT 43 FRONT ACCESS COVER SAFETY SWITCH B818-07-010

PT 44 REAR ACCESS COVER SAFETY SWITCH B818-07-010 PT 45 WIRECUT TEMPLATE SENSOR B819-99-002 PT 46 ROTARY HEAD MOTOR MCB B872-22-064 PT 47 ROTARY HEAD INVERTER (B807-80-001) 11/05 ONWARDS B801-80-010 PT 48 ROTARY HEAD MOTOR B912-74-019

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41

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42

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46

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SECTION “C”

ROTARY VERSION

47

ELECTRICAL COMPONENT LAYOUT PARTS LIST

MONO DRAWING PART PT-Ref DESCRIPTION NUMBER

PT-1 SLEEVE B842-48-008 PT-2 VARISTOR B842-48-002 PT-3 FILTER UNIT B842-48-009 PT-5a MAIN CONTACTOR N’ 1 B859-08-048 PT-5b AUXILIARY CONTACT BLOCK B859-14-011 PT-5c AUXILIARY CONTACT BLOCK B859-14-015 PT-6 DEPOSIT CONTROLLER 72 VAC SUPPLY M.C.B. B872-22-098 PT-7 DEPOSIT CONTROLLER 18-0-18 VAC BUS SUPPLY M.C.B. B872-22-075 PT-9 FAN POWER SUPPLY M.C.B. B872-22-002 PT-11 TRANSFORMER B726-31-003 PT-14 CONTROLLER UNIT ENCLOSURE & POWER SUPPLY UNIT B739-09-002 PT-15 DEPOSIT MOTOR CONTROLLER B739-80-002 PT-16 TRAY TRAVEL MOTOR CONTROLLER B739-80-002 PT-18 INTERFACE P.C.B. UNIT B728-93-009 PT-19a COMPUTER DISPLAY UNIT B728-93-010 PT-19b 25 WAY RIBBON LEAD B728-63-002 PT-19c 37 WAY RIBBON LEAD B728-63-004 PT-20a DEPOSIT DRIVE MOTOR. B741-74-001 PT-20b DEPOSIT DRIVE MOTOR GEARBOX A900-11-076 PT-20c DEPOSIT MOTOR ENCODER B742-99-001 PT-21a TRAY TRAVEL DRIVE MOTOR. B912-74-021 PT-23 TRAY SENSOR UNIT B735-99-001 PT-27 JOG POSITION SENSOR B842-99-001 PT-28 HOPPER SAFETY SWITCH B818-07-010 PT-29a STOP BUTTON B801-12-003 PT-29b STOP BUTTON CONTACT BLOCK B801-14-002 PT-30a START BUTTON B801-12-029 PT-30b START BUTTON CONTACT BLOCK B801-14-004 PT31a TRANSFORMER SUPPRESSOR CAPACITOR B900-48-003 PT-31b TRANSFORMER SUPPRESSOR V.D.R. B842-48-002 PT-32 FAN MOTOR SUPPRESSOR CAPACITOR B900-48-002 PT-33a TRAY TRAVEL ENCODER PLUG B900-06-004 PT-33b TRAY TRAVEL ENCODER SOCKET B900-25-004 PT-34a TRAY TRAVEL MOTOR PLUG HOOD B715-25-011 PT-34a TRAY TRAVEL MOTOR PLUG INSERT B715-25-006 PT-34b TRAY TRAVEL MOTOR SOCKET MOUNTING BASE B715-06-001 PT-34b TRAY TRAVEL MOTOR SOCKET INSERT B715-06-005 PT-35a TRAY SENSOR PLUG B900-06-003 PT-35b TRAY SENSOR SOCKET B900-25-003 PT-37 MAIN ROTARY ISOLATOR SWITCH B748-03-002 PT-37 MAIN ROTARY ISOLATOR SWITCH (AMERICAN) B748-03-003

PT-38 SURGE SUPPRESSOR RESISTOR B842-59-014

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48

COMPONENT LAYOUT PARTS LIST

MONO

DRAWING PART

PT-Ref DESCRIPTION NUMBER

PT 39 MAIN CONTACTOR N’ 2 B859-08-055 PT 40 WIRECUT MOTOR FUSE ON INERFACE PCB B842-85-026 PT 41 WIRECUT ONE TURN SENSOR B919-99-002 PT 42 WIRECUT MOTOR UNIT B912-74-025 PT 43 FRONT ACCESS COVER SAFETY SWITCH B818-07-010

PT 44 REAR ACCESS COVER SAFETY SWITCH B818-07-010 PT 45 WIRECUT TEMPLATE SENSOR B819-99-002 PT 46 ROTARY HEAD MOTOR MCB B872-22-064 PT 47 ROTARY HEAD INVERTER (B807-80-001) 11/05 ONWARDS B801-80-010 PT 48 ROTARY HEAD MOTOR B912-74-019

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52

SECTION “D”

ROTORY AND WIRECUT VERSION

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53

ELECTRICAL COMPONENT LAYOUT PARTS LIST

MONO DRAWING PART PT-Ref DESCRIPTION NUMBER

PT-1 SLEEVE B842-48-008 PT-2 VARISTOR B842-48-002 PT-3 FILTER UNIT B842-48-009 PT-5a MAIN CONTACTOR N’ 1 B859-08-048 PT-5b AUXILIARY CONTACT BLOCK B859-14-011 PT-5c AUXILIARY CONTACT BLOCK B859-14-015 PT-6 DEPOSIT CONTROLLER 72 VAC SUPPLY M.C.B. B872-22-098 PT-7 DEPOSIT CONTROLLER 18-0-18 VAC BUS SUPPLY M.C.B. B872-22-075 PT-9 FAN POWER SUPPLY M.C.B. B872-22-002 PT-11 TRANSFORMER B726-31-003 PT-14 CONTROLLER UNIT ENCLOSURE & POWER SUPPLY UNIT B739-09-002 PT-15 DEPOSIT MOTOR CONTROLLER B739-80-002 PT-16 TRAY TRAVEL MOTOR CONTROLLER B739-80-002 PT-18 INTERFACE P.C.B. UNIT B728-93-009 PT-19a COMPUTER DISPLAY UNIT B728-93-010 PT-19b 25 WAY RIBBON LEAD B728-63-002 PT-19c 37 WAY RIBBON LEAD B728-63-004 PT-20a DEPOSIT DRIVE MOTOR. B741-74-001 PT-20b DEPOSIT DRIVE MOTOR GEARBOX A900-11-076 PT-20c DEPOSIT MOTOR ENCODER B742-99-001 PT-21a TRAY TRAVEL DRIVE MOTOR. B912-74-021 PT-23 TRAY SENSOR UNIT B735-99-001 PT-27 JOG POSITION SENSOR B842-99-001 PT-28 HOPPER SAFETY SWITCH B818-07-010 PT-29a STOP BUTTON B801-12-003 PT-29b STOP BUTTON CONTACT BLOCK B801-14-002 PT-30a START BUTTON B801-12-029 PT-30b START BUTTON CONTACT BLOCK B801-14-004 PT31a TRANSFORMER SUPPRESSOR CAPACITOR B900-48-003 PT-31b TRANSFORMER SUPPRESSOR V.D.R. B842-48-002 PT-32 FAN MOTOR SUPPRESSOR CAPACITOR B900-48-002 PT-33a TRAY TRAVEL ENCODER PLUG B900-06-004 PT-33b TRAY TRAVEL ENCODER SOCKET B900-25-004 PT-34a TRAY TRAVEL MOTOR PLUG HOOD B715-25-011 PT-34a TRAY TRAVEL MOTOR PLUG INSERT B715-25-006 PT-34b TRAY TRAVEL MOTOR SOCKET MOUNTING BASE B715-06-001 PT-34b TRAY TRAVEL MOTOR SOCKET INSERT B715-06-005 PT-35a TRAY SENSOR PLUG B900-06-003 PT-35b TRAY SENSOR SOCKET B900-25-003 PT-37 MAIN ROTARY ISOLATOR SWITCH B748-03-002 PT-37 MAIN ROTARY ISOLATOR SWITCH (AMERICAN) B748-03-003

PT-38 SURGE SUPPRESSOR RESISTOR B842-59-014

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54

COMPONENT LAYOUT PARTS LIST

MONO

DRAWING PART

PT-Ref DESCRIPTION NUMBER

PT 39 MAIN CONTACTOR N’ 2 B859-08-055 PT 40 WIRECUT MOTOR FUSE ON INERFACE PCB B842-85-026 PT 41 WIRECUT ONE TURN SENSOR B919-99-002 PT 42 WIRECUT MOTOR UNIT B912-74-025 PT 43 FRONT ACCESS COVER SAFETY SWITCH B818-07-010

PT 44 REAR ACCESS COVER SAFETY SWITCH B818-07-010 PT 45 WIRECUT TEMPLATE SENSOR B819-99-002 PT 46 ROTARY HEAD MOTOR MCB B872-22-064 PT 47 ROTARY HEAD INVERTER (B807-80-001) 11/05 ONWARDS B801-80-010 PT 48 ROTARY HEAD MOTOR B912-74-019

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55

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56

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57

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58

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59

18.0 Fault Analysis Charts

FG077 – 04-05 RAC

60

ALPHA DEPOSITOR FAULT ANALYSIS FLOW CHART

START

PLUG IN MACHINE INTO

CUSTOMERS SUPPLY.THEN

ROTATE M AINS SW ITCH (PT-37)

HANDLE TO "ON" POSITION.

WILL HAN DLE REM AIN IN THIS

"ON" POSITION.

YES

NO

CHECK UNDERVOLTAGE

COIL WIRES FROM

TERMINALS D1 & D2 TO

TERMINALS 1 & 3 ARE

SECURE. CHECK

CUSTOMERS SUPPLY TO

DEPOSITOR SOCKET FOR

MACHINE.

CHECK BLACK WIRES

N'2 & N'7 FROM J18 TO

TB3 N'1 & N'2 ON

TRANSFORMER PANEL, AND RED & WHITE WIRE FROM

TB3 N'1 & N'2 TO

START BUTTON PT-30

CONTACT BLOCK ON

START BUTTON.

WHEN START

BUTTON PT-30 IS

FIRST PRESSED

WILL P.C.B.

DISPLAY

ILLU MINATE AND I/O

RED LED

ILLUMINATE.

IS THERE 240V AC

ACROSS " L & N "

OFF THE MAINS

INPU T TER MIN AL

NO

YES

CORRECT FUSE/

CIRCUIT BREAKER

FOR SUPPLY TO

MACHINE. WILL

BLOCK TB-2.

NO

CHECK FOR

DEPOSITOR,

SWITCH ON

FUSE BLOW .

REMOVE J18

WHEN START

BUTTON PT-30 IS

NO

YES YES

FIRST PRESSED

WILL RELAY RLY1

ON INTERFACE

P.C.B. PT-18

ENERGISE.

YES

IS THERE 240V AC

ACROSS

TERMINALS 6 ON

PT5A & "N" ON

MAINS INPUT

TERMINAL BLOCK

TB-2

NO

CHECK SURGE

RESISTOR(PT38) IS

O.K. RESISTANCE

SHOULD BE 10

OHM .IF O PEN

CIRCUIT REPLACE

AND RETRY.

YES

NO

IS THERE 240V

AC ACROS S

TERMINALS 0 &

240V ON TB1

TRANSFORMER

TERM INAL

BLOCK.

CHECK WIRES

BETWEEN

TRANSFORMER

TERMINAL BLOCK

TB1 AND M AINS

INPUT TER MINAL

BLOCK VIA FILTER

UNIT (PT-3).

CONNECTOR FROM

INTERFACE P.C.B. PT-18. IS THERE 0

OHMS ACROSS

BLACK WIRES N'2 &

N'7 WHEN START

BUTTON PT-30 IS

PRESSED.

NO

IS THERE 18V

AC ACROS S

TERMINALS 0-18

ON TB1

TRANSFORMER

TERM INAL

BLOCK.

NO

FAULTY 0-18V AC

WINDING ON

TRANSFORMER

PT-11 OR LOOSE

WIRES ON 0-18

TERMINALS

ON TB1

TRANSFORMER

TERMINAL BLOCK.

YES

1

FG077 – 04-05 RAC

YES

2 3

PAGE 1

61

ALPHA DEPOSITOR FAULT ANALYSIS FLOW CHART

1

YES

2

REPLACE

VARISTOR PT-2

AND RET RY

MACHINE.

REPLACE

FILTER UNIT

PT-3 AND

RETRY

MACHINE.

3

YES

DISCONNECT VARISTOR

NO

YES

PT-2 ACROSS L&N ON

MAIN S INPUT TERM INAL

BLOCK. WILL FUSE BLOW

IF M ACHIN E SWITCHE D O N.

YES

DISCONNECT LEADS ON

OUTPUT TERMINALS

( LOAD SIDE ) OF FILTER

UNIT PT-3. W IL L FU SE

BLO W IF M ACHINE

SWITCHED ON.

YES

NO

RECONNECT LEADS ON

REPLACE

SUPPRESSER

UNIT PT-31 AND

RETRY

MACHINE.

1

2

NO

OUTPUT TERMINALS OF FILTER

UNIT ( LOAD SIDE ) PT-3, BUT

REMOVE SUPPRESSER UNIT

PT-31 ACROSS OUTPUT OF

FILTER TERMINALS. WILL FUSE

BLO W IF M ACHINE S WITCHE D

ON.

FG077 – 04-05 RAC

PAGE 2

62

ALPHA DEPOSITOR FAULT ANALYSIS FLOW CHART

1

2

YES

IS THERE 18V AC

ACROSS TERMINALS

N'8(BROWN) &

N'9(BLUE) ON J1

CONNECTOR ON

INTERFACE P.C.B.

PT-18

NO

CHECK CRIMP

TERM INALS ON J1

CONNECTOR N' 8&9, AND

CONTINUITY OF WIRES

BACK TO 0-18V ON

TRANSFO RMER

TERMINAL BLOCK TB1.

CLEAR ANY

SHORTS OF

WIRES AND

RETRY.

YES

REPLACE FUSE

FS2. DISCONNECT

J15 37 W AY

D CONNECTOR

AND RETRY. WILL

FUSE BLOW .

IS FU SE

FS2-6.3A TYPE T

(18VAC) OK ON

INTE RF ACE

P.C.B. PT-18

NO

REPLACE

FUSE FS2.

RETRY. WILL

FUSE BLOW ?.

YES

NO

REPLACE

INTE RF ACE

P.C.B PT-18.

IS FUSE

FS3-2A

(12V DC ) O.K .

ON INTERFAC E P.C.B. PT-18

NO

REPLACE

FUSE FS3.

RETRY, WILL

FUSE BLOW ?.

YES

ARE ALL W IR ES ON

SKT3 37WAY

"D"CONNECTOR

MAIN P.C.B CLEAR

OF SHORT CIRCUIT

OF WIRES.

REPLACE

MAIN

P.C.B.

UNIT PT-19

NO

YES

NO

REPLACE

FUSE FS3 ON

INTE RF ACE

P.C.B.(PT-38).

YES

IS THERE 24VDC

ACROSS TERMINALS

N' 1 & N'2 ON 37 WAY D

CONNECTOR THAT

PL UG S INTO M AIN P.C .B.

SOCKET N'3 ON PT-19.

NO

CHECK FOR BREAK IN

CABLES FROM SKT3

ON MAIN P.C.B. P T-19

TO J15 37 W AY D CONNECTOR ON

INTERFACE P.C.B. PT-

18

YES

DISCONNECT ALL

ENCODERS J2,J3 PLUGS

ON INTERFACE P.C.B. &

TRAY SENS OR-J8,

RECONNECT ONE BY

ONE AND TRY WHEN

FUSE BLOW S LAST

CONNECTED PLUG IS

THE FAULTY UNIT.

WILL FUSE BLOW EVEN

IF ALL CONNECTORS

DISCONNECTED

1

FG077 – 04-05 RAC

PAGE 3

63

1

YES

WHE N IN ANY

PROGRAM MENU

(EXCEPT PROGRAM

SELECT MENU).

WHEN START

BUTTON PT-30 IS

PRESSED WILL

MAIN CONTACTO R

PT-5A ENERGIZE.

ALPHA DEPOSITOR FAULT ANALYSIS FLOW CHART

ARE HOPPER SAFETY SWITCH WIRES

RED & BLUE ON J12 , AND WIRE LINK ON

J13 SECURE, AND ACROSS RED & BLUE

WIRES INDICATE 0 OHMS, INDICATING

THAT SWITCH CONTACTS ARE CLOSED.

IF FITTED WITH WIRE CUT SYSTEM

NO

ARE FRONT & REAR ACCESS SAFETY

SWITCH W IRES RED & BLUE ON J11 , SWITCH W IRES RED & BLUE ON J13 ,

AND ACROSS RED & BLUE WIRES OFF

FRONT & REAR ACCESS SAFETY

SWITC HES INDICATE 0 OHMS,

INDICATING THAT SWITCH CONTACTS

ARE CLO SED.

NO

IS THERE OV DC ACROSS

TERMINALS N'3 & N'4 ON

CONNECTOR J12, J13, ON

INTERFACE P.C.B PT18.

IF FITTED W ITH WIRE C UT SYSTEM

IS THERE OV DC ACROSS

TERMINALS N'3 & N'4 ON

CONNECTOR J11, J13, ON

INTERFACE P.C.B PT18.

YES

CHECK

CONTINUITY

FROM ONE

SOCKET END TO

OTHER, IF OPEN

CIRCUIT REPLACE

RIBBON LEAD

ELSE REPLACE

MAIN P.C.B.

IS EMERGENCY

STOP BUTTON

PT-29

PRESSED.

YES

IS LEAD BETW EEN CONNECTOR J15 O N INTERFACE P.C.B. &

YES

SOCKET 3 ON MAIN

P.C.B. PT-19a SECURE

AND NOT DAMAGED

NO

YES

IS FUSE FS1-1.5A

(24V DC) ON

INTERFACE P.C.B.

PT-18 O.K.

NO

CHECK IF MAGNET IS ATTACHED TO

REMOVABLE HOPPER GUARD AND

ALIGNS TO HO PPER SWITCH.

IF FITTED W ITH WIRE CUT SYSTEM

IF FRONT & REAR ACCESS COVERS

ARE CLOSED AND MAGNETS ALIGNS

TO SAFETY SW ITCH AND

ARE IN THE CORRECT POSITION.

CHECK J1

CONNECTOR,

AND

TERMINALS

N'4 & N'1

IS THERE 24VDC

ACROSS TERMINAL

YES

A2 ON PT-5A MAIN

CONTACTOR & TB3

TERMINAL BLOCK N'5

(BROWN WIRE).

NO

1

FG077 – 04-05 RAC

TWIST TO RELEASE BUTTON, AND PRESS START

BUTTON AGAIN. WILL MESSAGE

DISAPPEAR.

YES

2

NO

YES

3

PAGE 4

64

ALPHA DEPOSITOR FAULT ANALYSIS FLOW CHART

1

YES

2

REPLACE FUSE AND

DISCONNECT WHITE WIRE

ON TER M INAL A1 ON

MAIN CONTACTOR PT-5A.

RETRY. WILL FS1 BLOW

WHEN " START " B UTTON

PT-30 IS PRESSED.

3

NO

FAULTY

MAIN

CONTACTOR

PT-5A.

YES

IS THERE 24 VDC

ACROSS TERMINAL

A2 ON PT -5A AND

TB3 TERM INAL N'6

(BLUE WIRE)

YES

NO

CHECK IF

EMERGENCY STOP

BUTTON PT-29 IS

PRESSED, CHECK

FOR LOOSE W IRES

ON CONTACT

BLOCK TERMINALS

N'1 & N'2

YES

IS THERE 24 VDC

ACROSS TERMINAL

A2 ON PT -5A AND

TERMINAL N'34 ON

PT-5 B O N M AIN

CONTACTOR

CHECK IF MAGNET IS ATTACHED TO

REMOVABLE HOPPER GUARD AND

ALIG NS TO H OP PE R S W ITCH ARE IN

ARE HOPPER SAFETY SWITCH WIRES

RED & BLUE ON J12 SECURE, AND

AND ACROSS RED & BLUE WIRES

INDICATE 0 OHMS, INDICATING THAT

SWITCH CONTACTS ARE CLOSED.

ALS O IF J11,AN D J 13 NNECTORS

ARE SECURE AND LINK IS FITTED

CHECK IF MAGNET IS ATTACHED TO

REMOVABLE HOPPER GUARD AND

ALIG NS TO H OP PE R S W ITCH ARE IN

NO

POSITION.

CO

ACROSS TERMINALS 1 & 2.

POSITION.

1

FG077 – 04-05 RAC

2

PAGE 5

65

ALPHA DEPOSITOR FAULT ANALYSIS FLOW CHART

1

YES

2

WHEN " START "

BUTTON PT-30 IS

RELEASED WILL MAIN

CONTACTOR PT-5A

REMAIN ENERGISED

NO

CHECK MAIN CONTACTOR AUXILIARY CONTACT BLOCK PT-5B

CONTACTS N'73 & N'74 AND WIRES ON THESE

CONTACTS.

CHECK THAT THERE

ARE 2 RED WIRES

ON EACH CONTACT

OF L3 & N'6 O N M AIN

CONTACTOR PT-5A,

AND THAT THER E IS

A CIRCUIT ACROSS

L3 & N'6 WHEN

CONTACTOR IS

ENERGIZED

IS TH ER E 24VD C

ACROSS TERMINAL A1

YES

CHECK AUXILIARY

CONTACT BLOCK

PT-5B CONTACT TERMINALS N'83 & N'84 ARE CLOSED

WHEN CONTACTOR

IS E NE RG ISED.

& A2 ON PT-5A (MAIN

CONTACTOR) WHEN "

START " BUTTO N PT-30

CHECK WIRES ON

TERMINALS N'34 ARE

SECURE ON PT-5B AND

CHECK WIRE FROM

TER M INAL N '73 T O

TER M INAL A1 ON

NO

IS PRESSED.

NO

PT-5A.

YES

CHECK CONTINUITY OF WIRE N'3 FROM

TERMINAL N'3

ON

4 WAY J11

CONNECTOR TO

TERMINAL N'84

ON

PT-5B.

IS THERE 24VDC

ACROSS A2 ON PT-5A

MAIN CONTACTOR &

TERMINAL N'73 ON

PT-5 B O N M AIN

CONTACTOR WHEN

" START " BUTTO N PT-30 IS PRESSED.

NO

CHECK BLACK

AND GREY

WIRES ON " START "

BUTTON PT-30

CHECK

CONTINUITY FROM

ONE SOCKET END

TO OTHER, IF

OPEN CIRCUIT

REPLACE RIBBON

LEAD ELSE

REPLACE MAIN

P.C .B. IF NOT

REPLACE

INTERFACE P.C.B.

PT-18

NO

WHEN START

BUTTON PT-30 IS

PRESSED WILL

DISPLAYS

REMAIN

LLUMINATED

AND MAIN

CIONTACTOR

PT-5A

ENERGISED

YES

NO

CHECK

AUX ILIARY

CONTACT BLOCK

PT-5B CONTACT

TERMINALS N'83

& N'84 ARE CLOSED WHEN CONTACTOR IS

ENERGISED.

YES

NO

IS THERE 0 VDC

ACROSS A2 ON

PT-5A MAIN

CONTACTOR &

TERMINAL N'3 ON

4 WAY J11

CONNECTOR ON

INTE RF ACE

P.C.B. PT-18

WHEN

" START "

BUTTON

PT-30 IS

PRESSED.

YES

NO

IS RIBBON LEAD

BETWEEN

CONNECTOR J16

ON INTE RF ACE

P.C.B. & SOCKET 2

ON MAIN P.C.B.

SECURE AND NOT

DAMAGED

1

PAGE 6

FG077 – 04-05 RAC

66

1

YES

ALPHA DEPOSITOR FAULT ANALYSIS FLOW CHART

IS THERE 72V AC ACROSS

THE 0-72V AC W IRES O N TB1

TRANSFO RMER TERM INAL

BLOCK.

YES

IS TH ER E 72V AC

ACROSS TERMINALS

N'2 & N'4 ON MAIN

CONTACTOR PT-5A

FAULTY POWER

YES

PT-14, REPLACE

SUPPLY UNIT

AND RETRY.

NO

CHECK FOR LOOSE WIRES ON

TB1 TRANSFORMER TERM INAL

BLOCK, OR REPLACE MAIN

TRANSFORMER PT-11 IF FAULTY

IS THERE 72V AC

ACROSS TERMINALS

L1 & L2 O N M AIN

CONTACTOR PT-5A

YES

FAULTY CONTACTS ON

MAIN CONTACTOR

PT-5A. CHANGE

CONTACTOR.

RECONNECT THE TWO RED W IRES

TO R EC TIFIE R, T HEN IN TUR N

DISCONNECT THE BUSS SUPPLY

YES

TO ALL AM P LIFIE RS PT-1 5, PT-16,

ON TB1 CONNECTOR TERMINALS

N'1 & N'2. RETRY, WILL 20 AMP DOUBLE POLE M.C.B. PT-6 TRIP

OUT.

NO

RECONNECT ONE AT A TIME TB1

TERMINALS N'1 & N'2 CONNECTOR

TO EACH AM PL IFIER UN IT W H EN 2 0

AMP DOUBLE POLE M.C.B. PT-6

TRIP S THAT AM PLIFIE R U NIT IS

FAULTY. REPLACE FAULTY UNIT

AND RETRY MACHINE.

NO

IS THERE 72V AC ACROSS (INPUT)

TERM INALS ON

20AMP DOUBLE POLE

M.C.B. PT-6

NO

YES

CHECK IF 20 AMP DOUBLE

POLE M.C.B. HAS TRIPPED.

RESET AND RETRY. WILL

M.C.B. T RIP

YES

DISCONNECT THE TWO RED

W IRE S (2.5 mm ) O N

RECTIF IER TER MINALS IN MAIN CONTROLLER UNIT BOX PT-14. RETRY MACHINE. WILL 20 AMP DOUBLE POLE M.C.B.

PT-6 TRIP .

YES

THERE IS A SHORT

CIRCUIT BETWEEN THE

TWO RED W IRES

BETWEEN CONTROLLER

BOX AND

20 AMP DOUBLE POLE

M.C.B. PT-6 ON

TRANSFORMER PANEL.

IS TH ER E 36V AC ACR OS S

18--18 OF 18-0-18

TER M INALS, AND 18V AC

ACROSS BOTH 0-18 WIRES

ON TB1 TRANSFORMER

TERMINAL BLOCK

YES

1

FG077 – 04-05 RAC

NO

CHECK FOR LOOSE W IRES

ON TB1 TRANSFORMER

TERMINAL BLOCK, OR

REPLACE MAIN

TRANSFO RMER PT-11 IF

FAULTY

PAGE 7

67

1

YES

ALPHA DEPOSITOR FAULT ANALYSIS FLOW CHART

IS THERE 36V AC

ACROSS TOP(INPUT)

TERMINALS (WHITE

WIRES) ON 4 AMP

DOUBLE POLE M.C.B.

PT-7

NO

IS THERE 36V AC

ACROSS TERMINALS

N'13 ON PT-5C &

TER M INAL 63 O N

PT-5 B O N M AIN

CONTACTOR PT-5A

NO

CHECK 2 WHITE WIRES BETWEEN 2 POLE 4 AMP M.C.B.

PT-7 BOTTOM

(OU TPUT)

TER M INAL S TO PT 5C

TER M INALS N'13 &

PT-5B TERMINAL 63.

CHECK 2 WHITE WIRES FROM

TOP(INPUT) TER MINALS O N

4 AMP DOUBLE POLE M.C.B.

PT-7 TO 18V & 18V TERM INALS

ON TB1 TRANSFORMER

TERMINAL BLOCK

NO

YES

CONTACT 13-14 ON PT-5C,

OR FAULTY AUXILIARY

CONTACT 63-64 ON PT-5B

ON MAIN CONTACTOR PT-

5A.CHECK WHICH CONTACT

IS OPEN CIRCUIT WHEN

CONTACTOR IS ENERGIZED.

CH ECK IF 4 AMP DOUBLE POLE M.C.B. HAS TRIPPED. RESET

AND R ETR Y. W ILL

M.C.B. TRIP.

IS THERE 36V AC

ACROSS TERMINALS

N'14 ON PT-5C &

TER M INAL 64 O N

PT-5 B O N M AIN

CONTACTOR PT-5A

NO

YES

FAULTY AUXILIARY

YES

FAULTY POWER

SUPPLY UNIT

PT-14, REPLACE

AND R ETR Y.

RECONNECT TB2 ON PT-14 IN

MAIN CONTROL BOX, THEN

DISCONNECT TERMINAL BLOCK

TB2 ON ALL AMP LIFIER U NIT S

PT-15, PT-16, AND RETRY. W ILL

4 AMP DOUBLE POLE M.C.B. PT-7

TRIP.

YES

NO

RECO NNEC T ONE AT A TIME TB2

CONNECTOR TO EACH AMPLIFIER

UN IT W HE N M .C .B. PT-7 TR IPS THAT

AMPLIFIER UNIT IS FAULTY.

REPLACE FAULTY UNIT AND RETRY

MACHINE.

NO

REMOVE TB2 CONNECTOR

ON POWER SUPPLY UNIT

PT-1 4 IN M AIN CO NTROL

BOX. RETRY MACHINE

WILL 4 AMP DOUBLE POLE

M.C.B. PT-7 TRIP.

YES

THERE IS A SHORT

CIRCUIT BETWEEN THE

WHITE/BLUE WIRES

BETWEEN CONTROLLER

BOX AND 4 AMP DOUBLE

PO LE M.C .B. P T-7 O N

TRANSFORMER PANEL.

1

FG077 – 04-05 RAC

2

PAGE 8

68

ALPHA DEPOSITOR FAULT ANALYSIS FLOW CHART

1

YES

2

YES

IS THERE 36V AC ACROSS

TERMINALS N'3 & N'5 AND 18V

AC ACROSS TERMINALS

N'3 & N'4 AND TERMINALS

N'5 N'4 ON TB2 ON PT-14

PO W ER S UP PLY UNIT IN M AIN

CONTROL PANEL.

NO

CHECK FOR LOOSE W IRES OF 2

WHITE WIRES FROM PT-5A

TERMINALS N'8 & PT5B

TER MINAL 64, TO

PT14-TB2 TERM INALS N'3 & N'5,

AND BLACK WIRE FROM 0V OF 18-0-18 ON TB1 TRANSFORMER TERMINAL BLOCK TO PT14-TB2

TER MINAL N '4.

YES

NO

IS THERE 24V+ DC ACROSS

PT14-TB1 TERMINALS

BLACK(0V) & RED(+V) WIRES

AND 24V- DC

ACROSS PT14-TB1

TERMINALS BLACK(0V) &

BLUE(-V) WIRES

NO

YES

CHECK FUSES ON PT-14

POWER SUPPLY UNIT.

IF BLOWN CHANGE.

RETRY.

WILL FUSES BLOW

IS TH ERE 110V AC ACRO SS

0-110 TERMINALS ON TB1 TRANSFORMER TERM INAL

BLOCK

REPLACE FUSES ON PT-14

POWER SUPPLY UNIT. DISCONNECT ALL TB2

TERMINAL BLOCKS ON ALL

AMPLIF IER U NITS PT -15,

RETRY. WILL FUSES BLOW.

PT-16.

YES

FAULTY POWER

SUPPLY UNIT

PT-14, REPLACE

AND RET RY.

NO

CHECK FOR LOOSE WIRES

TERMINAL BLOCK 0-110, OR

YES

RECONNECT ONE AT A TIME TB2

CONNECTOR TO EACH AMPLIFIER

NO

ON TB1 TR ANSFORM ER

REPLACE MAIN

TRANSFORMER PT-11 IF

FAULTY

UNIT W HEN M .C.B. PT-7 TRIPS THAT

REPLACE FAULTY UNIT AND RETRY

AMP LIF IER UNIT IS FAU LTY .

MACHINE.

YES

1

FG077 – 04-05 RAC

PAGE 9

69

1

YES

IS TH E C OO LING FAN IN THE M AIN

CONTROL BOX

PT-14 RUNNING.

ALPHA DEPOSITOR FAULT ANALYSIS FLOW CHART

IS THERE 110V AC

IS THERE 110V

NO

CHECK RED & BLUE

1.0mm WIRE FROM TERMINALS N'10 &

N'11 BACK TO MAIN

TRANSFORMER

CONTROL PANEL

110VAC ON TB1 TRANSFORMER

CHECK FOR LOOSE

WIRES ON 0-110V

TERM INALS ON TB1

TRANSFORMER

TER MINAL B LO CK, IF

WIRES CORRECT

THEN FAULTY MAIN

TRANSFORMER PT-11.

AC ACR OSS

0v AND

YES

TERM INAL

BLOCK.

NO

REPLACE.

ACROSS 0v OF

0-110VAC ON TRANSFORMER TERM INAL TB1,

AND TOP(INPU T) SIDE OF SINGLE

POLE 2AMP M.C.B.

PT-9.

NO

CHECK BROWN

WIRE BETWEEN

SINGLE POLE 2 AMP

M.C.B. TOP (INPUT)

SIDE TO 0V OF 110V

AC TE RM INAL ON

TB1 TRANSFO RME R

TERMINAL BLOCK.

YES

IS THERE 110V AC

ACROSS 0v OF

0-110VAC ON TB1

TRANSFORMER

TERMINAL BLOCK,

AND TERMINALS N'53

ON MAIN

CONTACTOR

AUXIL IARY CONTACT

BLOCK PT-5B

NO

CHECK IF 2 AM P

SINGLE POLE M.C.B.

PT-9 HAS TRIPPED,

RESET M.C.B. AND

CHECK BROWN W IRE

BETWEEN M.C.B.

BOTTOM (OUTPUT)

SIDE TO PT-5B

TER MINAL N '13. RETR Y.

WILL M.C.B. TRIP.

NO

YES

1

NO

IS THERE 110V AC

ACROSS TB 2

TERM INAL BLOCK N'10 & N'11 IN M AIN CONTROLLER BOX

WHERE FAN IS

PLUG IN .

YES

FAULTY

COOLING FAN

IN M AIN

CONTROL BOX.

REPLACE AND

RETRY.

CHECK BROWN AND

BLUE WIRES FOR

SHOR TS BETW EEN TRANSFORMER PANEL AND AMPLIFIER PANEL

PT-14.

IS TH ER E 11 0V AC

ACROSS 0v OF

YES

0-110VAC ON TB1

TRANSFORMER

TERMINAL BLOCK,

AND TERMINALS N'4

CHECK BROWN WIRE

IN TB3-N'3 AND CHECK

SHORTING LINK

TB3-N'3 & N'4, AND

ALSO CHECK BLACK

WIRE RED WIRE TO

FAN ON TB3 TERMINAL

N'4 ARE SECURE.

ON TB3

NO

BETWEEN

NO

YES

IS TH ER E 110V AC

ACROSS 0v OF

0-110VAC ON TB1

TRANSFORMER

TERMINAL BLOCK, AND

TER MINALS N'54 ON MAIN

CONTACTOR AUXILIARY CONTACT BLOCK PT-5B

NO

FAULTY CONTACT

ON MAIN

CONTACTOR

AUXIL IARY CONTACT

BLOCK PT-5B.

REPLACE AUXILIARY

CONTACT BLOCK.

DISCONNECT CONTROL

BOX COOLING FAN BY

UNPLUGGING FAN FROM TB2 TERMINAL BLOCK N'10 & N'11 IN

MAIN CONTROLLER

BOX. RETRY. WILL

SINGLE PO LE M.C .B

PT-9. TRIP OUT.

YES

FG077 – 04-05 RAC

PAGE 10

70

1

YES

IS WIRE CUT

WORKING

CORRECTLY

ALPHA DEPOSITOR FAULT ANALYSIS FLOW CHART

WIRE CUT FAULT LOCATION CHART(IF FITTED)

IS M AIN

CONTACTOR N'2

PT-39

ENERGIZED

NO

YES

NO

IS PROGRAM

SET FOR WIRE

CUT

NO

YES

IS THERE 230V AC

BETWEEN TB1

NEUTRAL (BLUE

WIRE) AND

TERMINAL N'2(T2)

ON MAIN RELAY N'2

(PT-3 9) W HE N

ENERGIZED

NO

IF W IRE CU T IS R EQ UIRED F OR PROGRAM SET APPROPIATE VALUES. IF CANNOT SET CHECK WIRECUT TEMPLATE SENS OR PT-45 IS POSITIONED CORRECTLY. IS THERE 24V DC ACROSS BROWN & BLUE WIRE OFF WIRECUT TEMPLATE SENSOR CONNECTOR J5 ON INTERFACE P.C.B.-(PT -18). (IF N O, F AULTY INT ERFACE P.C.B. IS THERE 24V DC ACROSS BROWN & BLACK WIRE OFF WIRECUT TEMPLATE SENSOR CONNECTOR J5 ON INTERFACE P.C.B.(IF NO, FAULTY WIRECUT TEMPLATE SENS OR.

IS W IRE CU T

CONTINUALLY WORKING AND NOT STOPPING

AFTER ONE TURN.

YES

CHECK ONE TURN

WIRE CUT SENSOR

PT-4 1 IS S ET

CLOSE TO THE

ROTATING ARM TO

SENSE SENSOR AND STOP WIRE

CUT MOTOR,

IS WIRE CUT FUSE

NO

3.15AMP TYPE T ON INTE RFACE

REPLACE WIRE CUT

MOTOR FUSE PT-40

FS1 3.15 TYPE T

FUSE AND RETRY

CHECK WIRES TO MAIN CONTACTOR

N'2 (PT-39) ON TER MINALS A1 & A2 HAVE 24V DC WHEN

MAIN CONTACTOR N'1 IS ENERG IZE D

(PT-40) FS-4

P.C.B. BLOWN.

YES

MACHINE

NO

FAULTY CONTACT

1(L1) -2(L 2).

CHANGE MAIN

CONTACTOR N'2 (PT-39)

AND RETRY MACHINE

YES

(BLUE WIRE) AND ONE

OF THE TERMINALS ON

TERMINAL N'1(L1) ON

IS TH ER E 23 0V AC

BETW EEN TB1

NEUTRAL

INTERFACE PCB

CONNECTOR J19

NO

CHECK WIRE

BETWEEN

MAIN

CONTACTOR

N'2 (PT-39)

TERMINAL N' 2

TO J19

IS THERE 230V AC

BETWEEN TB1

NEUTRAL

(BLUE W IR E) AND

MAIN RE LAY N '2

(PT-39).

YES

END OF

CHART

FG077 – 04-05 RAC

IS THERE 12V DC ACROSS

BROWN & BLUE W IRES

OFF SENSOR WIRE

CONNECTOR J9 WHEN

CONNECTED TO

INTERFACE P.C.B.(PT-18)

NO

FAULTY

INTERFACE P.C.B,

PT-18. REPLACE

AND RETRY

MACHINE.

YES

PAGE 11

71

WH EN ROTATING ARM IS

INFRONT OF ONE TURN

SENSOR IS THERE 12V DC

ACROSS BROWN & BLACK

OF SENSOR WIRE

CONNECTOR J9 WHEN

CONNECTED TO INTERFACE

P.C.B.(PT-18)

NO

FAULTY ONE TURN

WIRE CUT SENSOR

(PT-4 1). RE PLACE AN D

RETRY MACHINE.

1

YES

IS ROTARY

HEAD

WORKING

CORRECTLY

ALPHA DEPOSITOR FAULT ANALYSIS FLOW CHART

ROTARY HEAD FAULT LOCATION CHART(IF FITTED)

IS M AIN

CONTACTOR N'2

PT-39

ENERGIZED

NO

YES

NO

IS P RO GR AM

SET FOR

ROTARY HEAD

OPERATION

NO

YES

IS TH ER E 230V AC

BETWEEN TB1

NEUTRAL (BLUE

WIRE) AND

TERMINAL N'4(T2)

ON MAIN RELAY N'2

(PT-3 9) W HE N

ENERGIZED

NO

YES

IF ROTARY HEAD IS

IS THERE A DC VOLTAGE

BETW EEN 0-10 VOLTS

ACROSS TERMINALS

11 & 12 O N IN VE RTE R

(PT-4 7) W HE N IT IS

REQUIRED TO RUN.

IS THERE 0-10 V DC

VOLTAGE ACROSS

J20 TERM INALS N'3 &

YES

N'4 ON INTERFACE

P.C.B.(PT-18) WHEN

ROTARY HEAD IS

REQUIRED TO RUN.

RE QU IRED FO R

PROGRAM SET

APP ROPIATE

VALUES.

NO

YES

INTERFACE P.C.B.

NO

(PT-18) AND

RETRY R OTARY

REPLACE

HEAD.

CHECK WIRES TO

MAIN CONTACTOR

N'2 (PT-39) ON TER M INALS A1 & A2 HAVE 24V DC WHEN

MAIN CONTACTOR

N'1 IS EN ER GIZ ED

CHECK IF ROTARY HEAD

M.C.B. (PT- 46) HAS

TRIPPED OUT. RESET

IS THE INVERTER

(PT-4 7) DIS PL AY

ILLUMINATED

NO

REPLACE

ROTARY

HEAD

INVERTER

(PT-4 7)

NO

AND RETRY.

ACROSS " L " & " N " ON

YES

IS TH ER E 230V AC

BETWEEN TB1

NEUTRAL

(BLUE W IR E) AN D

TERMINAL N'3(L2) ON

MAIN RELAY N'2

(PT-3 9).

IS TH ER E 230V AC

ROTARY HEAD

INVERTER (PT-47)

NO

CHECK SUPPLY

WIRE BETWEEN

INVERTER AND

TRANSFO RMER

PANEL

YES

END OF

CHART

FG077 – 04-05 RAC

REMOVE THE GREEN & YELLOW FROM

TERMINALS CM & FWD ON INVERTER.

THEN FIT LINK ACROSS TERMINALS CM

& FWD ON ROTARY HEAD INVERTER

(PT-47).

WILL ROTARY HEAD RUN WHEN

REQUIRED TO.

NO

FAULTY ROTARY HEAD

INV ER TER DR IVE (PT-47).

REPLACE AND RETRY.

72

YES

PAGE 12

CHECK ROTARY INTERFACE LEAD

CONNECTOR ON J20 OF INTERFACE

PCB(PT-18). IF CONNECTOR IS O.K. THEN

CHECK EACH WIRE FROM J20

CONNECTOR TO INVERTER FOR

CONTINUITY, IF NO CONTINUITY FROM

ONE END OF WIRE TO THE OPPOSITE

END REPLACE IROTARY HEAD

INTE RF ACE LEAD. IF O .K. THEN RE PL ACE

INTERFACE P.C.B.

As it is our policy to improve our machines continuously, we reserve the right to change specifications without prior notice.

As it is our policy to improve our machines continuously, we reserve the right to change

FG077 – 04-05 RAC

The equipment mentioned in this manual has CE accreditation.

MONO Equipment.

Queensway Swansea Industrial Estate Swansea SA5 4EB UK

Tel. 01792 561234 Fax. 01792 561016

specifications without prior notice.

73

Enter Serial No. here. In the event of an enquiry please quote this serial number.

Store this document safely and ensure it is available at all times.

Non-availability may affect the service / repair of your machine.

CONTROLLER OPERATION MANUAL

for the

ALPHA DEPOSITOR

(Programming Instructions)

INDEX

1.0 INTRODUCTION

2.0 USE OF KEY PAD -- Key functions

3.0 USE OF MENU SCREENS

1. Drop deposit menu …………………………………………….page 13

A) The creation and editing of product programs

Quantity

•

Deposit speed

•

Rotory speed

•

Jog delay

•

2. Strip deposit menu…………………………………………….page 15

Initial deposit

•

Product length

•

Product quantity

•

Final deposit

•

Deposit speed

•

Rotary speed

•

page 6

page 9

page 13

3. Tray set-up menu………………………………………………page 16

No. per tray

•

Distance to first

•

Product spacing

•

Tray length

•

Set height

•

Wirecut

•

4.Edit / Create menu……………………………………………..page 19

Move

•

Deposit pump (axis 0)

•

Tray conveyor (axis 1)

•

Speed

•

Wait

•

Delete

•

- 2 - FG 077 – 08-05 RAC

B) Memory facilities

1. Memory menu………………………………………………page 23

Save

•

Save new program

•

DELETE item

•

Sort

•

DELETE directory

•

2. Product select……………………………………………..page 26

Existing programs

•

New drop products

•

New strip products

•

Other new products

•

3. Run menu…………………………………………………..page 27

4. Delete menu………………………………………………..page 27

Clear counter

•

Delete product

•

C) Machine set-up & diagnosis

1. Speed set-up……………………………………………….page 28

Deposit speed

•

Table speed

•

Rotary speed

•

Initial tray velocity

•

Maximum acceleration limit

•

Jog down Acceleration

•

Jog up acceleration

•

2. Offset menu……………………………………………….page 30

Soft dough

•

Hard dough

•

- 3 - FG 077 – 08-05 RAC

3. Set-up and diagnostics…………………………….….page 30

Set time

•

Set date

•

Test DACS menu

•

Keypad test

•

Inputs test

•

Exit to operating system

•

Loading new program

•

4.Initial checks…………………………………………….page 34

5. Field set-up……………………………………………...page 35

Amplifier replacement

•

Inverter unit (rotary head)

•

6. PASSWORD set-up screen…………………………..page 37

7. Screen warnings……………………………………….page 37

CONVERSION FROM OPTIDRIVE TO ALTIVAR 11 INVERTER

4.0 NOZZLE IDENTIFICATION RECORD SHEET

Keep a record of I.D.no. and nozzle descriptions.

page 38

- 4 - FG 077 – 08-05 RAC

A

l

1.0 INTRODUCTION

This manual covers all functional aspects of the ALPHA depositor that can only be addressed through data entry into the electronic controller situated on its control pod. Such aspects include product creation, product program storage into memory and retrieval, program deletion, machine set-up and diagnostics display.

As such, this manual forms a necessary accompaniment to the ALPHA’s Operation and Maintenance Manual to impart the complete and necessary information to the user and maintenance engineer for successful and safe use of the ALPHA.

Data entry into the controller is via the membrane covered key switch keypad and the prompted menu-driven LCD screen display allowing word processor type entry.

ll menu screens are logically arranged in hierarchical order and by reference to Fig 1a

and 1b, the relative location of screens can be clearly seen.

Included in Fig1a and 1b are details of screens which the user will not require norma access to. These screens are made use of by MONO’s production and maintenance engineers and provide a convenient means of displaying information regarding machine set-up. They are consequently password protected for MONO use only.

Prior to taking delivery of the ALPHA depositor, all controller aspects regarding machine set-up will have been performed at MONO’s factory. Once commissioned, the ALPHA will be ready for use with all necessary adjustments made. From this point the user need mainly concern himself with the ALPHA’s functional aspects of creating and storage of a product library.

- 5 - FG 077 – 08-05 RAC

- 8 - FG 077 – 08-05 RAC

2.0 USE OF KEYPAD

Fig 2. Shows the ALPHA’s controller keypad and LCD screen.

The five keys immediately below the controller’s LCD screen are menu option keys. Selecting these will gain the user access to the relevant menus.

Data entry into the controller is by use of the directional / numerical keys (G), - key (R), and enter key . Selection of value to be entered is by use of directional keys, holding down the shift key (I) and pressing the numerical keys will enable the user to enter a figure. Exit to a higher screen is by use of the escape (K) key, generally in accordance with Figs.1a and 1b.

Fig 2.0 - ALPHA Control panel

DESCRIPTION OF CONTROL PANEL - KEY FUNCTIONS

DRG REF.

A PRIME

b.Aids the engagement of the hopper drive gear

B MANUAL Runs product program for one tray only, then

C AUTOMATIC Activates an automatic machine cycle provided

NOTE If two trays are placed too close to each

D

FUNCTION DESCRIPTION

This button activates the hopper pump for as

long as it is pressed, providing either a product

creation or run menu are on screen, and all

safety guards are properly closed. It fulfils two

functions: -

a.To prime the hopper pump and nozzles with

product mix.

into the drive shaft.

returns tray to operator and stops. If a tray is

already under the deposit pump, by pressing

“manual” the tray will be returned to you.

a tray is on the table and positioned correctly.

At the end of the cycle, the tray conveyor will

continue running to move the full tray from the

machine and introduce an empty tray to the

deposit start position

other, the machine will interpret this as one long

continuous tray and will continue feeding both

trays through the machine until a gap at the rear

of the following tray is detected.

STOP BUTTON Stop button for either the manual or automatic

modes. Stops machine cycle but does not cut

power to drives.

- 10 - FG 077 – 08-05 RAC

E START BUTTON Pressed once will power up controller screen.

Pressed a second time will activate all power

electric circuits. All machine facilities can be

used once pressed provided all safety guards

are properly closed and emergency stop button

is released.

F To release - turn clockwise.

G NUMERIC/DIRECTION Whilst key (I) is being held down these BUTTON

H CONTRAST If pressed simultaneously with key (I) and then

be fixed.

I SHIFT BUTTON If used in conjunction with (G) keys will allow

J SINGLE DEPOSIT When in a program creation menu

BUTTON pressing this will run program to do a single row on a tray, then return the tray.

K ESCAPE Enables exit from menus to higher levels and exit from current on screen operations.

L POWER INDICATOR When illuminated all electric circuits have been

M DROP PRODUCT MENU Selects screen menu for creation of drop

EMERGENCY STOP Immediately isolates all power circuits.

keys will allow entry of numerical values. If

pressed by themselves they can be used for

cursor movement and command activation.

released, by using keys (I) and (H)

the contrast of the screen can be changed

Five seconds after release the new setting will

numerical entry. Used for adjusting contrast (as

above).

activated.

products i.e. products with no length.

- 11 - FG 077 – 08-05 RAC

N STRIP PRODUCT MENU Selects screen menu for creation of strip products i.e. products with length.

O TRAY MENU Selects screen menu to enter values for positioning of product on tray.

P FILE MENU Selects screen menu to save, retrieve and delete programs.

Q FUNCTION MENU Selects screen menu to enter edit/create menu and machine set-up menus.

- 12 - FG 077 – 08-05 RAC

3.0 USE OF MENU SCREENS

Refer to Figs 1a and 1b. The controller functionality can be split up into three areas of machine use: -

a) The creation and editing of product programs

b) Memory facilities

c) Diagnostics and machine set-up.

a) CREATION AND EDITING OF A PRODUCT PROGRAM

When creating a new program, data entry into 2 separate menus has to be achieved – Tray set-up menu with either drop or strip and edit/create menu. Information contained within all these menus is stored in the controller’s memory for each product program. Upon switching on of the ALPHA depositor by means of the start button (E), the controller LCD screen will be displaying the program selection menu. To edit a program or simply run a program, selection must be made be means of the up and down arrow keys and entered.

1. DROP DEPOSIT MENU

A Drop product is a product that is considered to have no length e.g. no tray movement during a deposit. For creation of a new drop deposit, simply press the drop deposit menu key (M) when switching on the machine.

1. Drop deposit menu

2. Strip deposit menu

3. Tray set-up menu

4. Edit/Create menu

1. Memory menu

2. Product select menu

3. Run menu

4. Delete menu

Program selection menu

Drop deposit menu

- 13 - FG 077 – 08-05 RAC

• QUANTITY

Enter a positive numerical reading to achieve rotation of the deposit pump and a quantity of product mix extruded through the selected template assembly. The entered value is proportional to the amount of pump rotation but is, by necessity, uncalibrated in product mix quantity terms as any attempt to do so would be inaccurate should the template arrangement, product mix or pumping speed change. To increase the amount deposited move the cursor onto the value using the up and down arrow keys as appropriate, and enter a new value whilst holding down the shift key. If a zero value is entered the value will default to a minimum value.

• DEPOSIT SPEED

The speed command sets a maximum speed value to the motor driving the deposit head (up to a preset maximum) during prior, in between or after each of the deposited rows on the tray. If a value, which exceeds the motors maximum speed, is entered the machine will automatically enter the default value. The user chosen value, when entered, will represent a proportionate amount of the full speed value.

the product creation sequence of movements only, not

• ROTARY SPEED

When activated the rotary will start as soon as a tray is detected and will run continuously until the tray has been completed. With this speed command set to zero the rotary will be switched off rotary. The rotary speed value will default to zero when creating a new program i.e. with the rotary off. The rotary speed can be increased in small increments up to the default maximum. When using offset nozzles for creating rings for example, the product quantity must be varied simultaneously with the rotary speed in order to obtain the correct position for the beginning and end of the ring.

. Using a rotary template, entering a value for the speed will enable the

• JOG DELAY

When ‘on’ is selected, there will be a delay after each deposit, before the table jogs down. The rotary will continue during this delay in order to remove deposit tails when producing rings

Using < and > the jog delay can be toggled ON and OFF. A value can also be entered using the shift key; this can be done if a longer delay is required.

- 14 - FG 077 – 08-05 RAC

2. STRIP DEPOSIT MENU

A Strip product is a product that is considered to have length e.g. the tray will continue to move while depositing. For creation of a new strip product simply press the strip deposit. menu key upon switching on the machine. The creation of a strip product consists of three separate steps, an initial deposit, a strip deposit and a final deposit. The initial and final deposits can be varied to produce the type of product end you require.

Program selection menu

• INITIAL DEPOSIT

Enter a positive numerical Value along side the ’Initial deposit’ heading to achieve rotation of the deposit pump and a quantity of product mix extruded through the selected template assembly. The entered value is proportional to the amount of pump rotation but is, by necessity, uncalibrated in product mix quantity terms as any attempt to do so would be inaccurate should the template arrangement, product mix or pumping speed change.

To increase the amount deposited move the cursor onto the value using the up and down arrow keys as appropriate, and enter a new value whilst holding down the shift key.

The entered value will produce a single drop deposit at the beginning of the desired strip product. By means of increasing or decreasing this value the shape of the product end can be varied.

• PRODUCT LENGTH

Enter a positive numerical value to achieve horizontal movement of the tray conveyor in a direction away from the operator and control panel. The entered value is the length of the product, measured in millimetres.

Product length illustration

• PRODUCT QUANTITY

The entered value is proportional to the quantity of product mix extruded equally over the product length. To increase the amount deposited move the cursor onto the value using the up and down arrow keys as appropriate, and enter a new value whilst holding down the shift key.

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• FINAL DEPOSIT

The entered value will produce a single drop deposit at the end of the desired strip product. By means of increasing or decreasing this value the shape of the product end can be varied.

To increase the amount deposited move the cursor onto the value using the up and down arrow keys as appropriate, and enter a new value whilst holding down the shift key.

• DEPOSIT SPEED

The speed command sets a maximum speed value to the motor driving the deposit head (up to a preset maximum) during prior, in between or after each of the deposited rows on the tray. If a value, which exceeds the motors maximum speed, is entered the machine will automatically enter the default value. The user chosen value, when entered, will represent a proportionate amount of the full speed value.

the product creation sequence of movements only, not

• ROTARY SPEED

When activated the rotary will start as soon as a tray is detected and will run continuously until the tray has been completed. With this speed command set to zero the rotary will be switched off rotary. The rotary speed value will default to zero when creating a new program i.e. with the rotary off. The rotary speed can be increased in small increments up to the default maximum. . Within the Strip product menu, the rotary could be used for adding spiral affect to an éclair type product.

. Using a rotary template, entering a value for the speed will enable the

3. TRAY SET-UP MENU

Consideration needs to be given to the trays onto which the product(s) are to be deposited and the head and the table motion between each product on the tray. These relevant and important factors are all addressed in the Tray set-up menu.

To enter a figure, move the cursor onto the value using the up and down arrow keys as appropriate, and enter a value whilst holding down the shift key.

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Tray set-up menu

• NO PER TRAY

The number of repeated rows of deposited product required along the tray’s length.

NOTE - this value does not correspond to the number of products deposited across the

tray, i.e. the number of nozzles on the template in use.

• DISTANCE TO FIRST

The distance in millimetres from the leading edge of the tray to the first deposited product row on the tray.

• PRODUCT SPACING

The distance in millimetres between each deposited product row.

• TRAY LENGTH

The length, in millimetres, of the tray being used for the depositing of products. Dimension of tray to be considered is that in the direction of tray conveyor travel.

IMPORTANT - No automatic tray length detector exists on the ALPHA and this programmed length value is stored in the controller’s memory for the particular product in question. Hence, it is imperative that no tray with a length shorter than the programmed value is used, otherwise damage to the machine may result and the controller will be unable to complete it’s full program. Use of longer trays than the programmed value will result in inefficient use of trays with the last deposit being positioned somewhat further away from the tray’s edge than its leading edge.

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Tray length illustration

• SET HEIGHT

g

The value entered here is a reminder value. The table height adjustment handle should be set to this height.

NOTE - The table height adjustment is a manual adjustment and therefore not being controlled by the controller. Care must be taken to set the table to the correct height before commencing operation of the machine, to prevent any damage being done to the tray’s being used. For creation of a new product table height should be set to it’s lowest position before running the machine, then table adjustment can be done while the machine is runnin

.

Table height adjuster

• WIRECUT

The operation of the wirecut mechanism can be selected, using the arrow keys to toggle between ON and OFF.

NOTE! IF WIRECUT IS SELECTED ON THEN THE WIRECUT MECHANISM WILL OPERATE AFTER EACH INDIVIDUAL DEPOSIT, BUT ONLY IF A WIRECUT TEMPLATE IS CORRECTLY FITTED.

WARNING! USE FLAT TRAYS WITH NO EDGES OR ENSURE TABLE HEIGHT IS SET TO A HEIGHT WHERE WIRECUT WILL NOT COLLIDE WITH ANY TRAY EDGES

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4. EDIT/CREATE MENU

The third product creation screen is the edit/create screen. This screen is used for the creation of slightly more complicated products that would not be possible to create in the drop or strip product menus.

With this screen consideration needs to be given to the product program.

The product program is the sequence of events and command instructions, imparted via the controller and the user written program necessary to describe the simultaneous and related movements of the ALPHA’s two axes to deposit one product row only.

Edit/create menu

The value programmed in the tray set-up menu then repeats the individual product program. Creating a product program requires the appropriate use of available commands along with numerical data entry to describe simultaneous machine movements as applicable to each of the drives.

The available machine movement commands are as follows: -

MOVE

SPEED

WAIT

DELETE

To invoke any of the above commands, use the function key once the edit/create menu is current. The available commands will appear on a pop up menu on the existing edit/create menu screen. Use the up and down arrow keys to move the curser onto the command required and press the enter key to select. The command will be inserted into the main program above the line that the curser is currently on, so the curser needs to be positioned correctly before the introduction of a new command into the program. To remove the pop up menu commands from the edit/create menu, position the curser on the line to be deleted and then select delete from the pop up menu. The rules for correct data entry and the effect of each of the commands are outlined next.

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• MOVE

A Move command will instruct each of the motors associated with the axes to start to move and to finish simultaneously. By appropriate programming each axis’s motor may also be made to remain stationary. The table drive can even be made to move in reverse to its normal forward movement when carrying out its move command.

SPECIAL NOTE - The very first move line on any product program is preceded by an unseen program line, which is automatically introduced by the ALPHA’s controller and is not printed out on screen. This line sets the start positions for all axes and obviates the need for the user to do so. All move start values are set to zero.

DEPOSIT PUMP (Axis 0)

– enter a positive numerical value under the ‘Dep qty’ column on the MOVE command line to achieve rotation of the deposit pump and a quantity of product mix extruded through the selected template assembly. The entered value is proportional to the amount of pump rotation but is, by necessity, uncalibrated in product mix quantity terms as any attempt to do so would be inaccurate should the template arrangement, product mix or either pumping speed change.

To increase the amount deposited at any particular stage in the product depositing sequence, move the cursor onto the value to be edited by using the up, down, left and right arrow keys as appropriate, and enter a new value.

TRAY CONVEYOR (Axis 1)

– enter a positive numerical value under the ‘Prod L’ column on the MOVE command line to achieve horizontal movement of the tray conveyor in a direction away from the operator and the control panel. The entered value is the horizontal position; measured in millimetres, relative to the initial start position for each product, which is regarded as position zero.

IMPORTANT - on a multi line product program consideration needs to be given to the value entered in the previous MOVE command line, as the tray will be progressed from this position to its new position as measured from position zero.

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• SPEED

The speed command sets maximum speed values, up to preset maximum values, to each of the motors linked to the ALPHA’S 3 axes during the product creation sequence of movements only, not prior, in between or after each of the deposited rows on a tray. The SPEED command is inserted into the product program just prior to the MOVE command that it is to ‘speed’ control and all other MOVE commands, unless superseded by another SPEED command at a later point in the product program. Consequently, the SPEED command will be the first command of a product program but it can be used repeatedly throughout any program. Upon initially invoking the SPEED command into the product program, the maximum allowable values to drive each axis at full speed are automatically entered and displayed. The user chosen value, when entered, will represent a proportionate amount of this fullspeed value.

When activated the rotary will start as soon as a tray is detected and will run continuously until the tray has been completed. With the rotary speed command set to zero the rotary will be switched off. Using a rotary template, entering a value for the speed will enable the rotary. The rotary speed value will default to zero when creating a new program i.e. with the rotary off. The rotary speed can be increased in small increments up to a default maximum.

NOTE! - Special consideration needs to be given to the application and effect of the SPEED command when more than one axis is moving. Since both of the two axes may be required to move simultaneously, then such axes must start and finish at the same time – the controller achieves this automatically. If the programmed value for any one of the moving axes represents a large amount of rotation for its motor compared to the other, then it is the motor with this large amount of rotation that will dominate events. The SPEED value entered for this dominant axis will be achieved and the other axes involved in the simultaneous movement being performed will have their speed automatically compensated for so that all axis movements start and finish together.

So to affect any control on the speed of events during product creation, the dominant axis must be identified and its SPEED value altered accordingly.

If no SPEED command is entered into the product program, then the controller will automatically use the default values as set in the ‘speed set up’ menu.

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• WAIT

The WAIT command allows the introduction of a period of inactivity (i.e. no movement) at any point during the product creation program. The command, allowing WAIT periods in increments of 1 second, can be used to allow the complete depositing of mix before continuation onto the next deposit.

• DELETE

The DELETE command permits editing of the product program by allowing deletion of any one of the above commands from the program one line at a time.

Prior to invoking the DELETE command the cursor must be on the command that is to be deleted.

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B) MEMORY FACILITIES

1. MEMORY MENU

Access to the controller’s memory facilities is via the ALPHA’S file menu key (P). Within this menu the ALPHA’S memory will allow you to do the following: -

• SAVE

• SAVE NEW PROGRAM

• DELETE ITEM

• SORT

• DELETE DIRECTORY

• SAVE

Enables the overwriting of an existing product program, it being replaced with an edited version of the original but saved under the same name.

Edited data contained within any of the menus that fully define the product program i.e. DROP and TRAY MENU, STRIP and TRAY MENU or EDIT/CREATE and TRAY MENU can be overwritten to the existing program.

Select SAVE by using the up and down arrow keys and then pressing enter will reveal the instruction’ Enter password’. To enter the password, use the numerical keypad while simultaneously pressing the SHIFT key. Upon entering the password a further check screen, which allows the overwrite operation to be aborted, is then invoked. Press the appropriate left or right arrow key to accept or prevent the procedure.

NOTE! - This procedure, as with others, is password protected to avoid accidental

use and misuse.

Memory Menu

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• SAVE NEW PROGRAM

Enables the addition of a new product program (item) to the controller’s existing directory.

Select SAVE NEW PROGRAM by using the up and down arrow keys and then pressing enter. This will reveal the prompt ‘Program name. Using the up and down arrow keys scroll through the alphabet to select the first letter of the program name to be used. Press the right arrow key to move to the second letter.

When program name is completed, pressing the enter key will reveal a prompt for ‘Template. Using the numerical keypad and the shift key simultaneously enter the number of the template being used and press enter.

’Nozzle type No””. Again using the numerical keypad and the shift key simultaneously enter the number that represents the nozzles being used and press enter.

To store information on whether the conveyor is jogging up and down in between each individual product, use the right arrow key to select ‘ON’ or ‘OFF’ when ‘jog selector’ is revealed.

To store information on whether a hard dough hopper or a soft dough hopper is being used, use the right arrow key to select ‘HD’ or ‘SD’ when ‘H/S HOPPER’ is revealed.

Upon entering the last line the program will automatically be saved with all its relevant information.

If an incorrect name, number or choice is made during the saving process, abort the saving of a new program at any time by pressing escape.

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• DELETE ITEM

Enables selected product programs to be deleted from the product program directory. This operation is also password protected to avoid misuse and mistakes.

Select DELETE ITEM by using the up and down arrow keys, and then press enter.

This will reveal the instruction’ Enter password’

To enter the password use the numerical keypad while simultaneously pressing the SHIFT key.

Upon entering the password a check screen, which allows the delete operation to be aborted, is then invoked.

Press the appropriate left or right arrow key.

A second check screen then ensures you have selected the correct product program to delete.

Press the appropriate left or right arrow key to

accept or prevent the procedure.

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• SORT

Enables the list of product programs to be sorted into alphabetical order if so desired. Select SORT by using the up and down arrow keys and then pressing enter to reveal another screen offering the choice of either accepting or refusing the option. Press the appropriate left or right arrow key to accept or prevent the procedure.

• DELETE DIRECTORY

•

WARNING! This cannot be undone. WARNING!

Enables the complete deletion of all product programs contained within the controller’s memory. This function also allows the clearance of all corrupt data from the memory banks of the controller should this occur and could be an essential requirement in this event. Select DELETE DIRECTORY by using the up and down arrow keys, and then pressing enter. This will reveal the instruction’ Enter password’. To enter the password, use the numerical keypad while simultaneously pressing the SHIFT key. Upon entering the password a check screen, which allows the delete operation to be aborted, is then invoked. Press the appropriate left or right arrow key to accept or prevent the procedure.

WARNING! This cannot be undone. WARNING!

2. PRODUCT SELECT MENU

Upon switching on the machine, this menu is automatically appears.

• EXISTING PROGRAMS

To select an existing program, use the up and down arrow keys to scroll through the product programs. Place the cursor over the required program; pressing enter will then recall the ‘RUN MENU’ with all the relevant information for this product program.

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• NEW DROP PRODUCTS

To create a new drop product program, access directly into the relevant menu can be selected by pressing the ‘DROP MENU’ key.

• NEW STRIP PRODUCTS

To create a new strip product program, access directly to the relevant menu can be selected by pressing the ‘STRIP MENU’ key.

• OTHER NEW PRODUCTS

To create other more complicated product programs, access directly to the relevant menu can be selected by pressing the ‘ FUNCTION ‘ key (Q) and then selecting the ‘EDIT/CREATE’ menu by using the up and down arrow keys.

3. RUN MENU

Enables the use of an existing product program without modification. Once made current, by selecting from the initial ‘ menu select menu’, the ALPHA operates in either ‘manual’ or ‘automatic’ mode. Once the ‘RUN MENU’ screen is evoked it displays, as a visual reminder, all the pertinent information to instruct on machine, template and tray set-up.

4. DELETE MENU

• CLEAR COUNTER

Selection of clear counter using the enter key will reset, to zero, the total number of deposits. The counter is visible on the bottom of the screen when the machine is running.

• DELETE PRODUCT

Selection of delete product will clear the product creation menus to enable a new program to be entered.

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Adamatic ALPHA User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual