Rondo Rondostar 4000 User manual

Operating manual
Rondostar 4000
SFS6605
SFS6605C
SFS6607
SFS6607C
SFS6607H
SFS6607DD
SFI6607
SFI6607H
Edition BD406502
02.2014
Technical specications subject to change without notice
www.rondo-online.com

RONDO Burgdorf AG
Heimiswilstrasse 42
CH-3400 Burgdorf/Schweiz
Tel. [phone]
Fax [phone]
[email protected]
www.rondo-online.com
RONDO Schio s.r.l.
Via Lago di Albano, 86
I-36015 Schio (VI)
Tel. [phone]
Fax [phone]
[email protected]
RONDO GmbH & Co. KG
D-57299 Burbach
Hoorwaldstrasse 44
Tel. [phone]
Fax [phone]
[email protected]
RONDO S.à.r.l.
PAE «Les Pins»
F-67319 Wasselonne Cédex
Tel. [phone]
Fax [phone]
[e-mail]
RONDO Ltd.
Unit 7, Chessington Park
Lion Park Avenue
Chessington, Surrey KT9 1ST/GB
Tel. [phone]
Fax [phone]
[email protected]
RONDO Inc.
51, Joseph Street
Moonachie, N.J. 07074/USA
Tel. [phone]
Fax [phone]
[email protected]
RONDO Inc.
267 Canarctic Drive
Downsview, Ont. M3J 2N7/Canada
Tel. [phone]
Fax [phone]
[email protected]
OOO RONDO Rus
Dmitrovskoe Chaussée 157, Str. 4
RU-127411 Moskau/Russland
Tel. [phone]
Fax [phone]
[email protected]
RONDO Asia
A-2-21, Jalan Kuchai Maju 2
Kuchai Entrepreneurs Park
Off Jalan Kuchai Lama
58200 Kuala Lumpur/Malaysia
Tel. [phone]
Fax [phone]
[e-mail]
RONDO China
Unit 1511, 15F, South Tower
Fuli Yingli Bulding, No. 3
Hua Qiang Road
Guangzou P.R.C. 510623
China
Tel. [phone]
Fax [phone]
[email protected]
RONDO IBERIA
Ronda del Golf Este
Finca Doña María
Las Amapolas 8 -1b
29630 Benalmádena-Costa, Malaga
España
Tel. [phone]
Fax [phone]
[email protected]

Index
Edition BD406502
02.2014
Rondostar 4000
Operating manual 7
1 Safety information 10
1.1 Explanation of symbols 10
1.2 Explanation of warning signs 10
1.3 Safety elements 10
1.3.1 Safety guard 10
1.4 Safety instructions and information which must be followed 11
2 Transporting, setting up, connecting, dismounting and storing the machine 15
2.1 Machine delivery 15
2.2 Transportation 15
2.3 Unpacking the machine 16
2.4 Setting up the machine 16
2.4.1 Mounting the table supports to the support (model SFI) 16
2.4.2 Mounting the lower tables (model SFI) 17
2.4.3 Installing the machine tables 17
2.4.4 Mounting the forked supports 19
2.4.5 Mounting the pneumatic springs (model SFI) 21
2.4.6 Tightening the conveyor belts 22
2.4.6.1 The machine tables without fast tension release device for conveyor belt 22
2.4.6.2 The machine tables with fast tension release device for conveyor belt (option) 23
2.4.7 Mounting the dough catch pan 24
2.4.8 Mounting the automatic flour duster 24
2.4.9 Electrical connection of the automatic dough reeler (by models SFS 6607H / SFI 6607H) 26
2.4.10 Compound operation with a transfer table PTT150 / PTT250 27
2.4.11 Compound operation with a make-up line / donut line 27
2.5 Requirements for putting the machine into operation 27
2.5.1 Ground fault interrupter is actuated when inverter is started 28
2.6 Moving direction test 28
2.7 Moving the machine 28
3 General data about the machine 29
3.1 General information 29
3.1.1 Authorized use of the machine 29
3.1.2 Authorized use of the flour duster 29
3.1.3 Noise values 29
3.1.4 Temperatures 30
3.1.5 Ambient humidity 30
3.1.6 Machine weight 30
3.1.7 Operating personnel work area 30
3.2 Prerequisites 30

Index
Edition BD406502
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Rondostar 4000
Operating manual 8
3.3 Full view of the machine 31
3.4 Operating elements 33
3.4.1 Main switch 33
3.4.2 Safety guards 33
3.4.3 Push buttons 33
3.4.4 Display 33
3.4.5 Flour duster: dosing slides 33
4 Starting the machine 34
4.1 Preparing for operational readiness 34
4.2 Starting/Stopping the machine 35
4.3 Conveyor belt 36
4.3.1 Fast tension release device for conveyor belt (option) 36
5 Operation 37
5.1 General operation description for RONDOSTAR 4000 37
5.2 Operating elements / Display 37
5.3 Switch on the machine, initial screen 38
5.4 Sheeting by hand 39
5.4.1 Selecting working mode "Sheeting by hand" 39
5.4.2 Sheeting with photocell 40
5.4.3 Sheeting without photocell 41
5.5 Sheeting with existing programs 41
5.5.1 Select working mode "Sheeting" 41
5.5.2 Select and open program 42
5.5.3 Open program directly 42
5.5.4 Program method 43
5.5.5 Sheeting dough 45
5.5.6 Working mode "Compound operation with a transfer table" 46
5.5.7 Working mode "Compound operation with a make-up line / donut line" 46
5.5.8 Compound operation 47
5.5.9 Switching flour duster on/off 47
5.5.10 Pre-sheeting to width 47
5.5.11 Daily corrections 48
5.5.12 Selecting other program 48
5.5.13 Displaying and changing programs in table form 48
5.6 Programming 51
5.6.1 Selecting the programming mode 51
5.6.2 Creating a new program 52
5.6.3 Replacing an existing program 53

Index
Edition BD406502
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Rondostar 4000
Operating manual 9
5.6.4 Copying an existing program 53
5.6.5 Entering program parameters 54
5.6.6 Sheeting program with standard reduction curve 55
5.6.6.1 Multi- program (2 – 5 loops) 59
5.6.7 Sheeting program with manual entering of the reduction curve (Teach-in) 61
5.6.7.1 Multi- program (2 – 5 loops) 65
5.6.8 Shortcrust pastry program 66
5.6.9 Calibrating program 67
5.6.10 Continuous program without photocell 69
5.7 Special functions 71
5.7.1 Adjusting parameters 71
5.8 Flour duster 74
5.9 Automatic reeler unit 75
5.10 Cutting device 77
6 Cleaning 82
6.1 Cleaning 82
6.1.1 General information 82
6.1.2 Care 87
7 Maintenance 88
7.1 General information for maintenance of the machine 88
7.2 Maintenance list 88
7.3 Replacement parts list 89
8 Trouble shooting 90
8.1 List of possible errors 90
8.2 Error messages, shown on display 93
8.3 Checking the inputs 94
9 Technical data 95
9.1 Technical data Rondostar 4000 95
9.2 Additional information 99
Hint for operating manual: The numbers of the illustrations
(Ex. 1) are numbered chapterwise.

Safety information
Edition BD406502
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Rondostar 4000
Operating manual 10
1 Safety information
1.1 Explanation of symbols
All the sections in this operating manual containing safety instructions
which absolutely must be observed are marked with this symbol and
with a number.
All the sections in this operating manual containing information which
absolutely must be observed are marked with this symbol.
1.2 Explanation of warning signs
Sign indicating prohibited activity
Reaching under the safety guard is prohibited!
Instruction and information signs
Make sure to disconnect the mains plug before opening!
Danger warning sign
Danger Warning
High-voltage warning sign
Warning against electrical shock
Disconnect mains plug before opening.
1.3 Safety elements
1.3.1 Safety guard
Operation
The safety guards fulfil a dual purpose:
1. They protect the operator from inadvertent contact with the rollers
and the cutting rollers.
2. By lifting up the safety guard the machine stops immediately.
Raising the safety guard even just slightly will stop the machine
from continuing to operate. By closing the safety guard the
machine mustn't start by oneself.
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Operating manual 11
1.4 Safety instructions and information which must be followed
Before putting the machine into operation the operating manual
must be read!
RONDO's dough sheeters are built for the food industry exclusively for
sheeting, booking, final sheeting and cutting (Cutomat) of dough.
RONDO's flour duster is made exclusively for continuous dusting of
dough sheets with flour.
Any other use of these units is not in accordance with the purpose for
which they are built. Therefore, the manufacturer will not be liable for
any accidents or damage resulting from unauthorized use; the risk in
any such instance will be borne solely by the user.
Authorized use also means that the user must follow all instructions
prescribed by the manufacturer in respect of operation, maintenance
and service.
Any work on the electrical components of the machine, in particular the
correct professional mounting of the mains plug, may only be carried
out by qualified personnel who are familiar with the relevant safety in-
structions.
Defective cables and main plugs must be immediately replaced by
qualified personnel.
Protective covers over the electrical controls and the mechanical mov-
ing parts may only be removed by professionally qualified personnel
and must be remounted before the machine is put back into operation.
Any unauthorized changes made to the machine, and in particular, to
the safety devices on the machine will automatically exclude any liabil-
ity on the part of the manufacturer for accidents or damage sustained
as a result of such changes.
The machine may only be connected to the mains using the mains
plug! No permanent electrical installation may be made using, for ex-
ample, terminal screws. The mains plug serves as a mains isolation
device. It has to be clearly visible at all times and freely accessible.
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Operating manual 12
The machine may only be connected to the mains once it has been
fully assembled.
In particular, operation with removed machine tables is prohibited.
Before beginning any repair, service or cleaning work on the machine,
the electricity supply to the machine must be disconnected (pull out
mains plug).
Safety devices on the machine may not be adjusted, by-passed or
expanded.
Operation of the machine when any of the safety devices is out of order
is prohibited.
Defective safety devices must be immediately replaced with new origi-
nal parts from RONDO.
Machine parts located in the areas in which the dough is being pro-
cessed, and whose surface coating becomes worn (e.g. chromium-
plate worn off), must be replaced.
When transporting the machine, it may not be lifted on the machine
base. The machine should be fastened on a pallet without table for
transport. Fasten the safety guard in the upper position.
Reaching under the closed safety guard is prohibited!
Never reach in the delivery roller of a moving flour duster with either
hands or any other object!
Do not deposit any loose objects such as knives, tools or articles of
clothing, etc. in the area where the dough is processed.
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Safety information
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Operating manual 13
In order to guard against respiratory tract difficulties and flour dust al-
lergies, we recommend to equip the machine with an automatic flour
duster. Limit the use of flour to a minimum.
The use of compressed air for cleaning the machine is not permissible.
The use of a dust extraction system in the bakehouse is recommend-
ed.
Check periodically to ensure that there are no loose screws in the area
where the dough is processed.
The machine may not be operated without its scrapers fitted in place.
The automatic reeler is a device starting automatically by the electrical
control.
Attention when handling it!
Do not reach into the stationary or running device!
Cutting rollers must only be lowered with safety guards closed.
Cutomat: Due to the risk of injury at the sharp edges the replacement
of the cutting rollers must be carried out carefully and professionally. To
prevent injury, always wear suitable protective gloves. Cutting rollers
located outside the cutting area must be placed in the holding device
located underneath the machine table.
Any disposal of the installation must be carried out in accordance with
environmentally-accepted practices. The operators are fully responsi-
ble for ensuring that such practices are followed.
The machine must never be cleaned using spray water, high-pressure
cleaner, steam-cleaning machine or any similar cleaning methods.
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Safety information
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Operating manual 14
This machine is not designed to be used in explosive ambient.
Defective parts must be replaced with new original parts by RONDO.
Prior to the first starting-up, the complete machine must be thoroughly
cleaned.
All still existing protective foils on the machine must be removed.
Non-ionising radiation is not intentionally produced but only given off
for technical reasons by electric equipment (e.g by electric motors). In
addition the machine has no strong permanent magnets. By keeping a
safe distance (the distance from the source field to the implant)
of 30 cm, interference with active implants (e.g. pacemakers, defibrilla-
tors) can be excluded with a high degree of probability.
RONDO will not accept liability when any of the above safety in-
structions / notes have not been complied with!
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Transporting, setting up, connecting, dismounting and storing the machine
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Operating manual 15
2 Transporting, setting up, connecting, dismounting and
storing the machine
2.1 Machine delivery
The machine is delivered in its original packaging.
• Report any claims for damage caused as a result of transportation
directly to the freight handlers
(see the packaging: the delivery documentations are contained on
the outside of the packaging)
2.2 Transportation
When transporting the machine must be packed in the original packag-
ing or in accordance with the instructions of the manufacturer to guar-
antee stability.
The machine must be fastened on a pallet. The tables must be dis-
mounted and the safety guards fixed in the upper position.
The machine must not be tipped over.
(For machine weight, see 9.1 Technical data Rondostar 4000)
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Transporting, setting up, connecting, dismounting and storing the machine
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Operating manual 16
2.3 Unpacking the machine
The machine must be set up on a level, even floor surface.
For further information regarding the ambient conditions required for
the machine, see 3.1 General information
• Unpack table and attachments
• Check all items received against the delivery slip for completness
Dismount the supports from the machine base (model SFI)
If machine doesn't pass through small passages (doors), the support
(3) has to be dismounted from the machine base (5) as follows:
• Dismount two screws (A) on each side (front and rear) and one
screw (B) (left and right) on the machine base
• Lift off the machine base from the support
(2 persons required)
Caution when lifting by crane (danger of tipping)
Remount it in reverse order.
2.4 Setting up the machine
Two people are required to set up the machine.
2.4.1 Mounting the table supports to the support (model SFI)
• Mount the table supports (1) using a hexagon screw (2A) (each
support) to the support (3)
Do not yet tighten the hexagon screws (2A), after mounting the
table supports.
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Transporting, setting up, connecting, dismounting and storing the machine
Edition BD406502
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Operating manual 17
2.4.2 Mounting the lower tables (model SFI)
• Lay the lower tables (4) on the machine base (5) and the table
supports
• Mount the lower tables to the machine base using three hexagon
screws (2B) (each lower table)
• Mount the lower tables to the table supports using two screws
(2C) (each lower table)
• Do not yet tighten screws (2A/B/C)!
• Adjust the lower table
• Tighten all the screws of the mentioned connections:
• Machine base - Lower tables
• Lower tables - Table supports
• Table supports - Support
2.4.3 Installing the machine tables
• Remove all protective foil on the stainless steel sections of the
machine
• Lift the machine table with the aid of a second person
• Guide the centre of the machine table's driving roller
to the spring bolt (6) at the rear of the housing (7)
• Push the table towards the rear, use pressure
2B 42C
1
2A
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Transporting, setting up, connecting, dismounting and storing the machine
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Operating manual 18
• Centre the catch of the machine table's driving roller in the
receiver (8) in the front section of the housing
In order to snap the machine table into place, proceed as follows:
• Tug lightly on the conveyor belt until the catch snaps into place
• Hinge down the table bolt (9) (it is used to prevent the uninten-
tional unhinge of the table)
A: Position by mounting/dismounting
B: Position by operation
• Lift the table up
• When lifting up the table, either push in or remove the dough
catch pan
• Attach table hook (10)
The machine table is now secured.
8
Pos. A 9 Pos. B
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Edition BD406502
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Operating manual 19
2.4.4 Mounting the forked supports
• Push forked support (11) into the support guide (12)
• Fix the forked support (11) by the hexagon bolt
• Fit the second washer on both sides on the inside, afterwards
screw down the lock nut (13b)
Attention: The conveyor belt has to be placed below the lock nut.
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Transporting, setting up, connecting, dismounting and storing the machine
Edition BD406502
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Operating manual 20
Position of the forked support (11) when the machine table is hinged
down.
What to watch out for when mounting the forked supports on ma-
chines equipped with the "Cutomat" cutting device:
The feet (14) of the forked support must be set in such a manner that
the table stands level. This is the only way to ensure optimal function-
ing of the safety guard.
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