Rondo Rondostar 3000 Series User manual

RONDOS.r.l.
Via Lago di Albano, 86
36015 Schio (VI)
Italy
Phone [phone]
Fax [phone]
[email protected]
Rondostar 3000
SFS6115, SFS6115C, SFS6117,
SFS6117C, SFS6117H, SFS6117DD
SFI6117, SFI6117H
Edition SD123402
Technical specifications subject to change without notice
HEADQUARTERS
RONDO GmbH & Co.KG
Hoorwaldstrasse 44
57299 Burbach
Germany
Phone [phone]
Fax [phone]
[email protected]
RONDO S.à.r.l.
PAE "Les Pins"
67319 Wasselonne cedex
France
Phone [phone]
Fax [phone]
[e-mail]
RONDO Ltd.
Unit 7, Chessington Park
Lion Park Avenue
Chessington, Surrey KT9 1ST
Great Britain
Phone [phone]
Fax [phone]
[email protected]
RONDOInc.
51 Joseph Street
Moonachie, N.J. 07074
USA
Phone [phone]
Fax [phone]
[email protected]
RONDOInc.
267 Canarctic Drive
Downsview, Ont. M3J 2N7
Canada
Phone [phone]
Fax [phone]
[email protected]
OOORONDO
Varschavskoge Chaussée, D 17, Str. 3
117105 Moskau
Russia
Phone [phone]
Fax [phone]
[email protected]
RONDO Asia
Regional Office
No. 14-1 Mezzanine Floor
Jalan 11/116B
Kuchai Entrepreneurs Park
Off Jalan Kuchai Lama
58200 Kuala Lumpur
Malaysia
Phone [phone]
Fax [phone]
[e-mail]
COMPETENCECENTRESCHIO
RONDO Burgdorf AG
Heimiswilstrasse 42
3400 Burgdorf
Switzerland
Phone [phone]
Fax [phone]
[email protected]
RONDO Schio s.r.l.
Via Lago di Albano, 86
36015 Schio (VI)
Italy
Phone [phone]
Fax [phone]
[email protected]
SUBSIDIARIES
www.rondo-online.com
Service manual

1. Safety regulations
2. Full view of the machine
3. Recommended spare parts
3.1 Mecanical spare parts
3.2 Electrical spare parts
4. Notes for the service
4.1 Important notes
4.1.1 Improvements on the Rondostar
4.1.2 Software changes
4.1.3 Usage of the new software
4.1.4 General view of the special functions
4.2 Initialisation
4.3 Calibrating the roller gap
4.4 Parameter
4.5 Diagnostic program
4.5.1 Selecting the diagnostic program
4.5.2 Checking the inputs
4.5.3 Allocation of the outputs
4.6 Operating hours counter
5. Important notes, testing the drives
5.1 Mains voltage, mains frequency
5.1.1 Modifying the machine for a different mains voltage
5.1.2 Modifying the machine for another frequency
5.2 Functions of the machine
5.2.1 Machine start function
5.2.2 Roller adjustment drive function
5.2.3 Turning knob
5.3 Testing the drives
5.3.1 Direction of rotation of the drives
5.3.2 Testing the table- and roller drive
5.3.3 Testing the roller adjustment drive
5.3.4 Testing the flour duster
5.3.5 Testing the reeler
5.3.6 Testing the roller adjustment drive brake
5.3.7 Testing the Cutomat
5.4 Final control test
Index

6. Compound operation
6.1 General comments
6.2 Function
6.2.1 Compound operation with one make-up line respectively donut line
6.2.2 Positioning the dough
6.2.3 Release signal for transfer
6.3 Special parameters for compound operation
7. Instructions for trouble shooting
7.1 Error messages
7.2 Construction of the control system
7.3 Checking the control system
7.3.1 Mains voltage
7.3.2 Control voltages
7.3.3 Control circuit main contactor K1M
7.3.4 Measure of the voltage on the plugs
7.4 Important notes to the frequency inverter
7.4.1 Types
7.4.2 Parameterization
7.4.3Groundfaultinterruptercanbeactuatedwheninverterisstarted
8. Part names, drawings
8.1Machine head front housing
8.1 Machine head front housing Cutomat / Compound
8.2 Machine head intermediate parts
8.3 Machine head rear housing
8.4 Machine bases
8.4.1Machine base
8.4.2Maschinebasewith support
8.4.3Machinebase SFI
8.5Machinetables
8.5.1MachinetableInoxtoCutomat
8.5.2MachinetableInoxtosupporttype
8.5.3MachinetableInoxtosocletype
8.5.4Flourcatchpan
8.6Cuttingstation/Machine table Cutomat
8.6.1Adjustment of spring range
8.7Flourduster
8.8Automatic dough reeler
8.8.1Converttheautomaticaldoughreelerfromtherighttotheleftmachinetable
8.8.2 Reeler raise SFI6117.E
8.9Electrical box
8.10Electricalbox Cutomat
8.11Frontcover:Electricalequipment
9. Electro circuit diagrams

Unbedingt zu beachtende Sicherheitsvorschriften und -hinweise
Bei allen Reparatur-, Instandhaltungs-, Reinigungs- und ähnlichen Arbeiten an Maschinen
sind vor Beginn die Netzstecker herauszuziehen und alle eventuell vorhandenen
Druckluftzuleitungen zu unterbrechen und zu entlüften!
Prescriptions et conseils de sécurité à observer obligatoirement
Avant tout travail de réparation, d'entretien, de nettoyage et de travail analogue à la
machine retirer la fiche de contact et, le cas échéant, arrêter et purger tout
approvisionnement d'air comprimé!
Safety instructions and information which must be followed
Before beginning any repair, maintenance, cleaning or similar work on the machine
disconnect the mains plug and interrupt and deaerate all possible existing feeding pipes
of compressed air!
Weiter sind sämtliche Sicherheitsvorschriften und -hinweise, gemäss Betriebsanleitung
Kapitel 1, zu beachten!
De plus, il faut observer toutes les prescriptions et conseils de sécurité selon chapitre 1
du mode d'emploi!
In addition, follow all safety instructions and information according to chapter 1 of the
operating manual!

Service manual
Edition: 04. 2005
2 Full View of the Machine
1 Dough Catch Pan
2 Flour Duster (Option)
3 Roller Head
4 Safety Guard
5 Machine Table
6 Machine Base
7 Main Switch
8 Black Push Button for Starting
9 Control Panel
10 Red Push Button for Stopping
11 Forked Support
12 Turning knob for data input
13 Automatical Dough Reeler (Option)
14 Cutting Station (Option)
SFS6117
SFS6115C / SFS6117C SFS6117H
SFS6115
1 1
34
45
5
11 67
11
2
9
10
8
8
12
13
14

Service manual
Edition: 04. 2005
SFI6117
15
16 17 17
13
SFI6117H
13 Automatical Dough Reeler (Option)
15 Support
16 Lower Table
17 Forked Supports

3. Empfohlene Ersatzteile / Pièces de rechange recommandes /
Recommended spare parts
3.1 Mechanische Ersatzteile / Pièces de rechange mécaniques /
Mecanical spare parts
Bestell-Nr.
No commande
Ordering no
Teilebezeichnung
Désignation
Part name
50284 * Zahnriemen GT Courroie dentée GT Toothed belt GT
11532 Haltering Anneau de blocage Retaining ring
11935 Zahnriemen HTD Courroie dentée HTD Toothed belt HTD
11936 Zahnriemen HTD Courroie dentée HTD Toothed belt HTD
50048 Gasfeder 100N ohne
automatischem Haspel
Vérin à gaz 100N sans
enrouleur automatique
Pneumatic spring 100N
without automatic reeler
50283 Zahnriemen GT Courroie dentée GT Toothed belt GT
50453 Kupplung Dispositif d'accouplement Clutch
50474 Zahnriemen Courroie dentée Toothed belt
50485 Gasfeder 200N mit
automatischem Haspel
Vérin à gaz 200N avec
enrouleur automatique
Pneumatic spring 200N with
automatic reeler
50607 Rippenband Tapis gouffré Ribbed belt
91339T05 Antriebsrolle Rouleau d'entraînement Drive roller
105467 Kunststoffband 640 x 3280 Tapis synthétique
640 x 3280
Synthetic conveyor belt
640 x 3280
106570 Exzenterhebel Levier excentrique Eccentric lever
106593 Schaltsegment Segment Segment
108241 Schraubendruckfeder Ressort à pression Compression spring
121093 Teigrückhaltebügel Archet de retenue de pâte Dough retaining hoop
121344 Kunststoffband 640 x 3570 Tapis synthétique
640 x 3570
Synthetic conveyor belt
640 x 3570
121344T02 Kunststoffband 640 x 2680 Tapis synthétique
640 x 2680
Synthetic conveyor belt
640 x 2680
122775T03 Abstreifermesser Lame de racleur Scraper blade
123568 Zahnrad Z = 22 Roue dentée Z = 22 Gearwheel Z = 22
123570 Zahnrad Z = 15 Roue dentée Z = 15 Gearwheel Z = 15
124107 Zahnrad Z = 18 Roue dentée Z = 18 Gearwheel Z = 18
124108 Zahnrad Z = 16 Roue dentée Z = 16 Gearwheel Z = 16
124802 Zahnrad Z = 15 Roue dentée Z = 15 Gearwheel Z = 15
125908 Rippenbandscheibe Poulie courroie striée Ribbed V-belt pulley
125909 Rippenbandscheibe Poulie courroie striée Ribbed V-belt pulley
125910 Rippenbandscheibe Poulie courroie striée Ribbed V-belt pulley
125953 Feder Ressort Spring
125954 Abstreifer komplett Racleur complet Scraper complete
126055 Federstab Barre pour ressort Spring bar
126084 Rakel Racle Ductor
126088 Wischer Bras de monture d'essuie Wiper arm
133577T03 Abstreifermesser Lame de racleur Scraper blade
134823 Abstreifer komplett blau Racleur complet bleu Scraper complete blue
135341 Kunststoffband blau
640 x 3280
Tapis synthétique bleu
640 x 3280
Synthetic conveyor belt blue
640 x 3280
* = Ausführung Cutomat/Version Cutomat/Type Cutomat
Automatischer Teighaspel / Enrouleur automatique de pâte / Automatic dough reeler
50466 O-Ring O-Anneau O-Ring
130530 Antriebsrad Z = 10 Roue dentée Z = 10 Gearwheel Z = 10
130531 Antriebsrad Z = 12 Roue dentée Z = 12 Gearwheel Z = 12
130532 Antriebsrad Z = 13 Roue dentée Z = 13 Gearwheel Z = 13
124595 Motor mit Kabel Linak Moteur avec câble Linak Motor with cable Linak

3.2. Elektrische Ersatzteile / Pièces de rechange électriques /
Electrical spare parts
Bestell.Nr.
No commande
Ordering no.
1. Stufe Teilebezeichnung
Echelon 1 Désignation
Variation 1 Part name
8935 Feinsicherung 2,0A träg Fusible 2,0A lent Fuse 2,0A slow
9371 Endschalter Interrupteur fin de course Limit switch
11334 Empfängerkopf Tête de récepteur Receiver head
11335 Senderkopf Tête de transmetteur Transmitter head
50477 Grundmodul Module de base Modul basic
50481 Handrad komplett Roue à main compl. Handwheel compl.
50482 Absolutwertgeber Codeur en valeur absolue Rotary encoder
50483 Drehknopf Bouton tournant Turning knob
50495 Feinsicherung 0,63A träg Fusible 0,63A lent Fuse 0,63A slow
50587 Prozessoreinheit Unité microprocesseur Microprocessor unit
106111 Lichtschrankenkabel Câble pour cell. photoélectr. Cable for light barrier
106112 Lichtschrankenkabel Câble pour cell. photoélectr. Cable for light barrier
135202 *** Frequenzumrichter 230 V Variateur de fréquenze 230 V Frequency inverter 230 V
135203 *** Frequenzumrichter 400 V Variateur de fréquenze 400 V Frequency inverter 400 V
Bestell.Nr.
No commande
Ordering no.
2. Stufe Teilebezeichnung
Echelon 2 Désignation
Variation 2 Part name
12061 Drehstrommotor 0,09 kW Moteur triphasé 0.09 kW Motor three-phase 0.09 kW
35493 Motor mit Bremse Moteur avec freinage Motor with brake
50044 El. magnetische Bremse El. freinage magnétique El. magnetic brake
50359 *** Hilfskontaktblock Module de contacts auxiliaires Contact component auxiliary
50361 Kleinleistungschütz Contacteur de petit calibre Contactor miniature
50362 Kleinleistungsschütz Contacteur de petit calibre Contactor miniature
50484 Flachbandkabel 20-pol. Câble plat, 20 pol. Ribbon cable, 20 pol.
50588 *** Elektrische Kupplung
Cutomat
Embrayage électrique
Cutomat
Electrical clutch
Cutomat
50603 Motor 1,1 kW 50/60 Hz Moteur 1,1 kW 50/60 Hz Motor 1,1 kW 50/60 Hz
50604 *** Zeitrelais Relais temporisé Time relais
50925 Pilztaster schwarz Bouton poussoir noir Push button black
50926 Pilztaster rot Bouton poussoir rouge Push button red
50927 Hilfsschalterblock 2S Bloc de contacts auxiliaires Contact block auxiliary 2S
50928 Hilfsschalterblock 10 Bloc de contacts auxiliaires Contact block auxiliary 10
51309 Motor 1,1 kW 60 Hz, UL Moteur 1,1 kW 60 Hz, UL Motor 1,1 kW 60 Hz, UL
*** Nur für Cutomat

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Edition: 06.2011 Service manual
4. Notes for the service
4.1 Important notes
4.1.1 Improvements on the Rondostar
In August 1998 the following changes have been made on the Rondostar.
Table drive:
Rondostar SFS611 is new equipped with clutches instead of the reversing gear (Like
Compas 3000).
Rondostar SFS611C (Cutomat, compound operation) is still equipped with the
reversing gear.
Light barrier wiper (screen wiper):
New light barrier wipers, mounted directly on the roller, as by Compas 3000.
Scraper:
New scraper system, consisting of 4 single scrapers instead of the pairs of scrapers.
4.1.2 Software changes
The following software changes have been made:
- Control system for the table clutches
- Changes in the control system of the screen wiper
- Modifications for compound operation with make-up lines and transfer table.
Previous software: 125921T01B V1.02
New software: 125921T01D V1.10
The EPROM is new marked as follows:
125921T01D / V1.10
125921T01D: Software identification by Seewer Rondo
V1.10: Software version, which is indicated below parameter 99 on the
display
The software version is new also indicated on the processor beside the mark of the
serial number.
4.1.3 Usage of the new software
The new software V1.10 can be used for all previous Rondostar.
In doing so pay attention to:
- Table drive: Table clutches Parameter 31 = 1
Reversing gear Parameter 31 = 0
- Light barrier cleaning: new system on the roller Parameter 32 = 2
Parameter 33 = 450
old system with catch Parameter 32 = 320
Parameter 33 = 120
By delivery of the processors the parameters for clutches and for the new light
barrier wipers are set.

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______________________________________________________________________________________________________________________________________________________________________________________________________
Edition: 06.2011 Service manual
4.1.4 General view of the special functions
The software for the RONDOSTAR is equipped with special functions to assist the technical
service.
Functions 1, 2: Access by the customer is possible (see operating manual)
For entering press the key "OK".
Other functions: For entering press the key "flour duster". The information on these
functions is not contained in the operating manual.
The individual functions must be selected using a function code.
Allocation of the function codes:
with key function
code FU Description of the function See chapter
"OK" 1 Parameters, access for customer possible ##
"OK" 2 Diagnosis for customer, inputs indicated,
access to outputs is not possible ##
Flour duster 10 Parameters, for technical service 4.4
Flour duster 20 Final control test 5.4
Flour duster 30 Diagnosis for technical service 4.5
Flour duster 40 Test roller adjustment 5.3.3
Flour duster 51 Initialisation of the parameters 4.2
Flour duster 53 Initialisation of the programs 4.2
Flour duster 55 Full initialisation (parameters and programs) 4.2
Flour duster 67 Calibration of roller gap 4.3
Flour duster 70 Display operating hours counter 4.6
Flour duster 99 Indication of the software version -----
## For description of the functions see the operating manual
The functions listed above are described in detail in the following chapters.
Warning
Changing the functions requires great care and forethought.
4.2 Initialisation
Function
When the processor is initialised, the basic data (parameters, sheeting programs) are loaded
from the program EPROM into the processor's working memory.
When initialisating, all previously entered data such as customer programs, special parameters,
etc. are overwritten by the basic data.