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.

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Edition: 06.2011 Service manual
When should the initialisation be carried out?
- Following the installation of a new processor in the machine
Full initialisation (FU 55)
- Where faults are suspected in the processor's control procedure (software errors)
In this case proceed as follows:
Initialise the parameters (FU 51) ---> then test the machine
- If the problems are not rectified
Full initialisation (FU 55) ---> then test the machine
This results in the loss of all sheeting programs
memorised by the customer!
- If only the customer programs are to be deleted
Initialise the programs (FU 53) ---> all sheeting programs are deleted
How to initialise?
Example: In order to initialise the parameters (FU 51) proceed as follows:
- Switch on working mode "Auto" LED "Auto" on continuously
- Press key "Flour Duster" for approx. 10 s Indication: FU 0 --
- Set "51" by turning knob Indication: FU 51 --
- Press key "OK" till Indication: FU 0 --
- Return to sheeting program Press the key "ESC"
4.3 Calibrating the roller gap
Calibration of the roller gap is imperative if:
- the processor has been changed
- changes are made to the absolute value sender (toothed belt, attachment of the sender,
etc.)
- the roller gap shown on the display does not coincide with the actual roller gap
The calibration of the roller gap takes place by a roller gap of 4,0 mm.
Proceed as follows:
- Switch off the machine at the main switch
- Set the roller gap to 4,0 mm, e.g. by turning the brake disk of the roller engagement
drive. Check the roller gap with e.g. a 4,0 mm large sheet.
- Switch on the machine at the main switch
- Press key "Flour duster" for approx. 10 s Indication: FU 0 --
- Set "67" by turning knob Indication: FU 67 XX,X-
- Press key "OK" till Indication: FU 67 4,0
Calibration is complete
Return to the sheeting program: Press the key "ESC"
XX,X = Numerical value
The calibration of the roller gap is not affected by initialisation and is not deleted.

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Edition: 06.2011 Service manual
4.4 Parameter
Key Funct. Param. Description Value Unity
OK 1 0 Entering data: Side end for folding not defined 0
Side end for folding right 1
Side end for folding left 2
1
OK 1 1 Entering data: Side end for man. reeling not defined 0
Side end for man. reeling right 1
Side end for man. reeling left 2
1
OK 1 2 Compound operation: Time band stop waiting postion 15 0,1 s
OK 1 3 Compound operation: Time for transfer 300 0,1 s
FD 10 10 Entering data: no Auto-reeler 0
Auto-reeler right 1
Auto-reeler left 2
0
FD 10 11 Entering data: no cutomat 0
Cutomat right 1
Coutomat left 2
0
FD 10 12 Time Auto-reeler finished
photocell free --> conveyor belt stop 15 (10) 0,1 s
FD 10 13 Time handreeler finished
photocell free --> conveyor belt stop 15 (10) 0,1 s
FD 10 14 Position of the dough handreeler placement
Dough in photocell --> conveyor belt stop 15 (10) 0,1 s
FD 10 15 Time conveyor belt stop for folding
photocell free --> conveyor belt stop 2 0,1 s
FD 10 16 Time conveyor belt stop for cutomat
photocell free --> conveyor belt stop 2 0,1 s
FD 10 17 Roller opening by cutting (Cutomat) 50 0,1 mm
FD 10 18 Time open Auto-reeler 12 0,1 s
D 10 19 Time close Auto-reeler 15 0,1 s
FD 10 20 max. dough thickness in mm for Auto-reeler 90 0,1 mm
FD 10 21 Delay time dough in photocell 2 0,1 s
FD 10 22 Indicator period 8 0,1 s
FD 10 23 Indicator break 2 0,1 s
FD 10 24 Cutomat: running time high speed at the start 10 0,1 s
FD 10 25 On delay-time for flour duster 8 0,1 s
FD 10 26 Time for changing the program-no. (Flashing of the program-no) 50 0,1 s
FD 10 27 Time press the key for selecting the program mode 30 0,1 s
FD 10 28 "long time" for key OK respectively flour duster for special
functions 100 0,1 s
FD 10 29 "short time" for key OK respectively flour duster for special
functions 30 0,1 s
FD 10 30 Compound operation:
no compound operation 0
compound left 1
compound right 2
compound operation left/right no passages without roller
adjustment (special) 3
compound operation left/right: for left machine place dough on
left side, for right machine place dough on right side 4
0
FD 10 31 Rondostar with table clutch 1
Rondostar with reversing gear 2
(Cutomat/Compound, machine delivery before August 1998)
1
FD 10 32 Light barrier wiper "above"
For new screen wiper on the roller, inactive 2
For old screen wiper with catch, function active 320
2
FD 10 33 Light barrier wiper "below"
For new screen wiper on the roller, inactive 450
For old screen wiper with catch, function active 120
450
Values in brackets are valid for short tables

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Edition: 06.2011 Service manual
Notes
Key: Select special functions with the key "OK" or with the key "flour duster"
The customer has the option, to change parameter 0, 1, 2 and 3.
See description in the operating manual.
Function: The function is selected with the turning knob.
Function 10 and the associated parameters are exclusively intended for the
technical service (no notes in the operating manual).
Parameters: The parameters are selected with the turning knob and confirmed with "OK"
Value: The figures given in the column "value" are loaded into the working memory from
the EPROM during initialisation and may subsequently be changed.
Attention: By the software version V1.02 it was as follows:
- Parameter 31: Time for transfer in the compound operation
- Parameter 32: Time band stop waiting position in the compound operation
There were no parameters for the light barrier wipers.
Changing the parameters:
Example: The time to switch to "programming" is to be changed from 3 s to 5 s.
Use function (FU) 10 to change parameter (PA) 27 from 30 to 50
- Switch on working mode "Auto" LED "AUTO" on continuously
-Press key "flour duster" during 10 s Indication: FU 0 --
-Set "10" by turning knob Indication: FU 10 --
-Press key "OK" till Indication: PA 10** (0)
-Set parameter "27" by turning knob Indication: PA 27** 30
-Press key "OK" till Indication: PA 27 30**
-Set value "50" by turning knob Indication: PA 27 50**
-Press key "OK" Indication: PA 28** XX,X
return to the sheeting program: Press key "ESC" twice
XX,X = Numerical value ** = Indication is flashing
4.5 Diagnostic program
The Rondostar is fitted with an automatic direction of rotation control, i.e. after switching on
the electricity supply (mains switch), when a sheeting program is started for the first time, the
direction of rotation of the mains is checked. The drives are subsequently controlled in
accordance with the direction of rotation of the mains.
Before using the diagnostic program, the machine is briefly started in a sheeting program or in
the working mode "manual" (direction of rotation check). As soon as the conveyor belts start to
move, the machine can be stopped and the program may be aborted using "ESC". The turning
direction of the net will be indicated with LED 9 (see chapter 4.5.2)

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Edition: 06.2011 Service manual
4.5.1 Selecting the diagnostic program
- Switch on working mode "Auto" LED "AUTO" on continuously
-Press key "flour duster" during 10 s Indication: FU 0 --
-Set function "30" by turning knob Indication: FU 30 --
- Press key "OK" till Indication: d. 1** 0
- Return to the sheeting program: Press key "ESC" twice
** = Indication is flashing
4.5.2 Checking the inputs
The statuses (On/Off) of the inputs are displayed on the LED of the roller reduction steps,
whereby they are numbered 1 - 9 from left to right.
LED No. 1 Control voltage processor Control voltage OK = 1
LED No. 2 General control voltage Control voltage OK = 1
LED No. 3 Right push button Right push button operated = 1
LED No. 4 Left push button Left push button operated = 1
LED No. 5 Main contactor K1M Main contactor engaged = 1
LED No. 6 Frequency inverter, Frequency inverter and
contactor K2M contactor K2M ON = 1
LED No. 7 Turning knob Slow turning of turning knob = 0/1
LED No. 8 Photocell Photocell covered = 1
Photocell free = 0
LED No. 9 Direction of rotation of mainsRight rotating field = 0
Left rotating field = 1
"1" indicates that the corresponding LED illuminates
"0/1" indicates that the LED switches on and off when the turning knob is turned.
"0" indicates that the corresponding LED is switched off
If all inputs should be tested, proceed as follows:
Select the diagnostic program (FU30)
Safety guard open illuminate: LED1, LED2
These two LED have to illuminate always.
Close safety guard
Press right push button illuminate: LED3 LED5 LED6
Push button no longer pressed illuminate: LED5 LED6
Press left push button illuminate: LED4 LED5 LED6
Push button no longer pressed illuminate: LED5 LED6
Open safety guard LED5 has to switch off imediately
LED6 has to switch off with approx 1 s delay
Turn turning knob slowly LED7 has to illuminate
Photocell LED8 illuminates when photocell is covered
LED8 doesn't illuminate when photocell is free

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Edition: 06.2011 Service manual
4.5.3 Allocation of the outputs
After leaving the diagnostic program, all outputs are automatically returned to their former status.
Functions of the processor outputs
Output
processor Function by mains right rotating field
LED No. 9 dark
Function by
mains left rotating field
LED No. 9 illuminates
Relay
contactor Remarks
A0 Supervision processor
(watch-dog) Supervision processor (watch-dog) K8 Cannot be switched on or off
processor fault A1=0
A2 Table drive:Conveyor-
belt runs to the left Table drive: Conveyor-belt runs to the
right
K9/K2M
F-inverter By Cutomat: Conveyor-belt runs
always to the left
A11 Table drive:Conveyor-
belt runs to the right Table drive: Conveyor-belt runs to the
left
K10/K3MF
-inverter By Cutomat: Conveyor-belt runs
always to the right
A5 Table clutches
0 = left clutch
1 = right clutch
Cutomat:
1 = small number of
revolutions
Table clutches
0 = left clutch
1 = right clutch
Cutomat:
1 = small number of
revolutions
K13 Rondostar with table
clutches
A6 Roller adjustment
1 = drive ON Roller adjustment 1 = drive ON K1/ K2
A10 Roller adjustment
0 = upward
1 = downward
Roller adjustment
0 = downward
1 = upward
K5
A7 Roller adjustment
1 = Brake ON Roller adjustment 1 = Brake ON K7
A9 Flour duster
1 = Flour duster ON Flour duster 1 = Flour duster ON K3 / K4
A8 Direction of rotation flour
duster 0 by right rotating
field
Direction of rotation flour
duster 1 by left rotating
field
K6
A4 Selection between
0 = reeler
1 = table clutch /
Cutomat clutch
Selection between
0 = reeler
1 = table clutch /
Cutomat clutch
K14
A3 Auto reeler, table
clutches, Cutomat clutch
1 = ON
Auto reeler, table
clutches, Cutomat clutch
1 = ON
K12 Switch on / off
A1 Reeler
0 = Open reeler
1 = Close reeler
Reeler
0 = Open reeler
1 = Close reeler
K11
Note:
The drives for roller adjustment and reeler each have:
- 1 relay for drive ON/OFF
- 1 relay for the direction of movement up/down respectively open/close
With outputs A2, A8, A10, A11 the function changes when the direction of rotation of the
mains changes.
Output A2: SFS Contactor K2M motor main drive, direction dough to left/right
depends of mains direction of rotation.
SFS Cutomat Signal to frequency inverter, direction dough to the left
Output A11: SFS Contactor K3M motor main drive, direction dough to the
left/right depends of mains direction of rotation
SFS Cutomat Signal to frequency inverter, direction dough to the right

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Consider: - What do I want to switch on?
- Which output must be switched?
- Is the correct output selected?
The drives can only be started when the safety guards have been closed.
The individual outputs can be switched on and off as follows:
- Switch on working mode "Auto" LED "AUTO" on
continuously
-Press key "flour duster" during approx 10 s Indication: FU 0 --
-Set function "30" by turning knob Indication: FU 30 --
- Press key "OK" till Indication: d. 1** 0
-Select output (for example A7) by turning knob Indication: d. 7** 0
-Switch on output by key "OK" Indication: d. 7 1
-Switch off output by key "OK" Indication: d. 7 0
- Return to the sheeting program: Press key "ESC" twice
** = Indication is flashing
In order to test the drives a number of special test programs are available.
Testing of the individual drives is described in detail in chapter 5.3.
4.6 Operating hours counter
The processor is fitted with an operating hours counter. The counter reading can be called up
using function 70.
The display is given in hours.
In order to read the operating hours counter, proceed as follows:
- Switch on working mode "Auto" LED "AUTO" on continuously
-Press key "flour duster" during 10 s Indication: FU 0 --
-Set "70" by turning knob Indication: FU 70 --
-Press key "OK" (10 s) till Indication: h 000 045
(45 hours)
- Return to the sheeting program: Press key "ESC" twice

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5. Important notes, testing the drives
Notes:
Rondostar without Cutomat:
The drive motor for tables and rollers is supplied directly from the mains.
Rondostar with Cutomat (variable speed):
The drive motor for tables and rollers is supplied by a frequency inverter during the sheeting and
also during the cutting process.
Attention:
For the operating voltages 200 - 230 V and 380 - 460 V different types of frequency inverters and
mains filters are necessary.
5.1 Mains voltage, mains frequency
The mains voltage and mains frequency must coincide with the data given on the machine
specification plate.
The specification plate is to be found on the substructure where the mains cable input is
located.
The prescribed maximum fusing must be observed.
5.1.1 Modifying the machine for a different mains voltage
Motors: Table drive motor, roller adjustment motor, flour duster motor
200 - 230 V Motors delta-connected
380 - 460 V Motors star-connected
Attention: Rondostar with Cutomat (variable speed) cannot be switched over
from 200 - 230 V to 380 - 460 V. (Different frequency inverters!)
Transformer:
The transformer in the basic module must be switched to the new voltage.
5.1.2 Modifying the machine for another frequency
The following parts depend of the value of the frequency:
50 Hz 60 Hz
motor 50400 50421
V-belt pulley 124128 124138
V-belt 50401 50403
Attention: Rondostar with Cutomat (variable speed) can be operated with 50 or 60 Hz
without a change.

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5.2 Functions of the machine
5.2.1 Machine start function
When the machine is started, the following control process runs automatically:
1. One of the black push buttons is operated.
Here the black push buttons have a dual function.
On the one hand they switch on the main contactor, on the other hand they issue the
command for the direction of rotation of the conveyor belt to the processor.
2. Main contactor K1M engages.
3. At the time of the first start after switching on the mains, the direction of rotation of the
mains is checked automatically as follows:
The roller drive is briefly switched on and the direction of rotation of the motor is
checked. If the roller rises when given the command "close" (wrong direction), the
direction of rotation of the table, roller adjustment and flour duster drives is
automatically changed.
4. The roller adjustment drive starts and the roller moves to the roller gap shown in the
display. At the same time the automatic reeler is opened if it is not already in the upper
end position.
5. The table drive starts automatically when the roller end position is reached.
5.2.2 Roller adjustment drive function
The position of the roller gap is measured with an absolute value sender. With an angle of
rotation of 360°(roller gap 45.0 - 0.2 mm), the absolute value sender has 256 positions. A
specific roller gap is allocated to each of these 256 positions in the software.
Here the correct calibration of the absolute value sender at a roller gap of 4.0 mm is
paramount. (See chapter 4.3)
The direction of rotation of the mains is checked using the roller adjustment drive. The
controls of the table drive and the flour duster are dependent on the direction of rotation of
the roller adjustment drive.
5.2.3 Turning knob
The turning knob consists of an impulse sender with 128 impulses per revolution.
The turning knob is used to input the data during programming, when selecting the program
and during diagnostic work, etc.

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5.3 Testing the drives
5.3.1 Direction of rotation of the drives
The machine automatically tests the direction of rotation of the mains and controls the
machine accordingly.
The roller adjustment drive always depends directly on the direction of rotation of the
mains.
If the direction of movement of the table drive or of the flour duster is incorrect, proceed as
follows:
Flour duster: Switch 2 phases on the motor terminals
Table drive: First check if the black push buttons are correctly connected.
(See checking the inputs, chapter 4.5.2, LED 3 and LED 4)
Are the push buttons correctly connected, switch 2 phases of the
motor cable on contactor K2M.
5.3.2 Testing the table- and roller drive
Testing the drive
Testing the drive is best not carried out in the diagnostics program but directly in the working
mode "Manual".
Proceed as follows:
- Select "Manual" working mode
- Operate left push button conveyor belt must run to the right
Stop by using red push button
- Leave the program with "ESC"
- Operate right push button conveyor belt must run to the left
Stop by using red push button
- Leave the program with "ESC"
Testing the clutches table drive
Note: The clutch of the infeed belt is always switched on.
The infeed belt only runs when the clutch is switched on!
For testing the clutches in the diagnostic program, proceed as follows:
Switch on diagnostic program as described under 4.5.1
Testing the left clutch:
- Set d = 4 by turning knob Indication: d 4** 0
- Switch on by key "OK" Indication: d 4** 1
- Set d = 3 by turning knob Indication: d 3** 0
- Switch on clutch by key "OK" Indication: d 3** 1
** = Indication is flashing

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Testing the right clutch:
- Set d = 4 by turning knob Indication: d 4** 0
- Switch on by key "OK" Indication: d 4** 1
- Set d = 5 by turning knob Indication: d 5** 0
- Switch on by key "OK" Indication: d 5** 1
- Set d = 3 by turning knob Indication: d 3** 0
- Switch on clutch by key "OK" Indication: d 3** 1
** = Indication is flashing
5.3.3 Testing the roller adjustment drive
In order to test the roller adjustment drive, a special test program "Test roller
adjustment" is available. Proceed as follows:
- Switch on working mode "Auto" LED "AUTO" on continuously
-Press key "flour duster" during 10 s Indication: FU 0 --
-Set "40" by turning knob Indication: FU 40 --
-Press key "OK" till Indication: d. XX,X 45,0**
- Set roller gap (example 35 mm) by turning knob Indication: d. XX,X 35,0**
- Close safety guard
Start of the roller adjustment drive by black push button
Roller moves to the selected roller gap Indication: d. 35,0 35,0**
XX,X = Numerical value
** = Indication is flashing
5.3.4 Testing the flour duster
The correct direction of rotation for the flour duster has been determined by the automatic
check on the direction of rotation of the mains. (Do not change output A8).
To check the flour duster, switch on the diagnostic program as described under 4.5.1
- Switch on working mode "Auto" LED "AUTO" on
continuously
-Press key "flour duster" during approx. 10 s Indication: FU 0 --
-Set function "30" by turning knob Indication: FU 30 --
- Press key "OK" till Indication: d. 1** 0
Now the diagnostic program is switched on
** = Indication is flashing
Processor output 9, flour duster On / Off
- Close safety guard, press the black push button briefly
- Set d = 9 by turning knob Indication: d 9** 0
- Flour duster ON by key "OK" Indication: d 9** 1
- Flour duster OFF by key "OK" Indication: d 9** 0
** = Indication is flashing