Rondo Rondostar 5000 User manual

EN
Operating manual
Rondostar 5000
Expert
SSH673*.A
SSH673*.C
SSH673*H.A
SSH673*H.A
Cutomat
SSH672*C.A
SSH672*C.C
SSH672*HC.A
SSH672*HC.C
SSH673*C.A
SSH673*C.C
SSH673*HC.A
SSH673*HC.C
Pro
SSH672*.A
SSH672*.C
SSH672*H.A
SSH672*H.C
Basic
SSH670*.A
SSH670*.C
SSH670*H.A
SSH670*H.C
* = See EC declaration for exact machine type
Translation of the original manual
Edition BE210202
03.2022

Addresses
Edition BE210202
03.2022
Rondostar 5000
Operating manual 3
RONDO Burgdorf AG
Heimiswilstrasse 42
3400 Burgdorf / Switzerland
Tel. [phone]
[email protected]
www.rondo-online.com
RONDO Schio s.r.l.
Via Lago di Albano, 86
36015 Schio (VI) / Italy
Tel. [phone]
[email protected]
RONDO GmbH & Co. KG
Hoorwaldstrasse 44
57299 Burbach / Germany
Tel. [phone]
[email protected]
RONDO S.à.r.l.
PAE „Les Pins “
67319 Wasselonne Cédex / France
Tel. [phone]
[email protected]
RONDO Ltd.
Unit 7, Chessington Park
Lion Park Avenue
Chessington, Surrey KT9 1ST / UK
Tel. [phone]
[email protected]
RONDO Inc.
100 State Street
Moonachie, N.J. 07074 / USA
USA
Tel. [phone]
[email protected]
Canada
Tel. [phone]
[email protected]
OOO RONDO Rus
Dmitrovskoye Chaussee, 163A, b. 2
Office 18.5 / Business Center SK Plaza
127495 Moscow / Russia
Tel. [phone]
[email protected]
RONDO Asia Sdn. Bhd.
A-2-21, Jalan Kuchai Maju 2
Kuchai Entrepreneurs Park
58200 Kuala Lumpur / Malaysia
Tel. [phone]
Tel. [phone]
[email protected]
RONDO China
Room 2830, Guangzhou International
Gang Hang Center
No. 983 Huangpu Avenue East.
Huangpu District
Guangzhou City P.C 510700
Guangdong Province / China
Tel. [phone]
[email protected]
RONDO México
Ote. 180 No. 378
Col. Moctezuma
2da sección
C.P. 15530 México D.F. / Mexico
Tel. [phone]
[email protected]

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EC Declaration of conformity for machinery
(Machinery Directive 2006/42/EC, Annex II., sub. A)
Manufacturer RONDO Burgdorf AG
Address Heimiswilstrasse 42, 3400 Burgdorf, Switzerland
Name (see signature) and address of the person authorised to compile the technical file:
RONDO Burgdorf AG, Heimiswilstrasse 42, 3400 Burgdorf, Switzerland
Herewith we declare that the dough processing machine:
Dough sheeter Rondostar 5000 Basic SSH670*.A / SSH670*H.A
SSH670*.C / SSH670*H.C
Rondostar 5000 Pro SSH672*.A / SSH672*H.A
SSH672*.C / SSH672*H.C
Rondostar 5000 Expert SSH673*.A / SSH673*H.A
SSH673*.C / SSH673*H.C
Rondostar-Cutomat 5000 SSH672*C.A / SSH672*HC.A /
SSH673*C.A / SSH673*HC.A
SSH672*C.C / SSH672*HC.C /
SSH673*C.C / SSH673*HC.C
●is in conformity with the relevant provisions of the Machinery Directive (2006/42/EC)
●is in conformity with the provisions of the following other European Directive:
○2014/30/EU Directive EMC
○EC 1935/2004 Materials, intended to come into contact with food
○EC 2023/2006 Good manufacturing practice for materials and articles intended to
come into contact with food
○EU 10/2011 Plastic materials and articles intended to come into contact with food
And furthermore, we declare that
●the following (parts/clauses of) European harmonised standards have been used:
○EN 1674 Food processing machines – Safety and Hygiene requirements
○EN 60204-1 Safety of machinery – Electrical equipment – Part 1
○EN ISO 12100 Safety of machinery – General principles

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Burgdorf, 11.07.2022
Christoph Albrecht
Manager Machine Safety

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Rondostar 5000 Basic
SSH6703.A
SSH6703H.A
SSH6704.A
SSH6704H.A
SSH6705.A
SSH6705H.A
SSH6706.A
SSH6706H.A
SSH6707.A SSH6707H.A
SSH6708.A SSH6708H.A
SSH6709.A
SSH6709H.A
SSH6703.C
SSH6703H.C
SSH6704.C
SSH6704H.C
SSH6705.C SSH6705H.C
SSH6706.C SSH6706H.C
SSH6707.C
SSH6707H.C
SSH6708.C
SSH6708H.C
SSH6709.C
SSH6709H.C
Rondostar 5000 Pro
SSH6723.A
SSH6723H.A
SSH6724.A
SSH6724H.A
SSH6725.A
SSH6725H.A
SSH6726.A
SSH6726H.A
SSH6727.A SSH6727H.A
SSH6728.A SSH6728H.A
SSH6729.A
SSH6729H.A
SSH6723.C
SSH6723H.C
SSH6724.C
SSH6724H.C
SSH6725.C SSH6725H.C
SSH6726.C SSH6726H.C
SSH6727.C
SSH6727H.C
SSH6728.C
SSH6728H.C
SSH6729.C
SSH6729H.C
SSH6723.A
SSH6723H.A
Rondostar 5000 Expert
SSH6733.A
SSH6733H.A
SSH6734.A
SSH6734H.A
SSH6735.A
SSH6735H.A
SSH6736.A SSH6736H.A
SSH6737.A SSH6737H.A
SSH6738.A
SSH6738H.A
SSH6739.A
SSH6739H.A
SSH6733.C
SSH6733H.C
SSH6734.C SSH6734H.C
SSH6735.C SSH6735H.C
SSH6736.C
SSH6736H.C
SSH6737.C
SSH6737H.C
SSH6738.C
SSH6738H.C
SSH6739.C
SSH6739H.C
Rondostar
-
Cutomat 5000
SSH6723C.A
SSH6723HC.A
SSH6733C.A
SSH6733HC.A
SSH6724C.A
SSH6724HC.A
SSH6734C.A
SSH6734HC.A
SSH6725C.A
SSH6725HC.A
SSH6735C.A
SSH6735HC.A
SSH6726C.A SSH6726HC.A SSH6736C.A SSH6736HC.A
SSH6727C.A SSH6727HC.A SSH6737C.A SSH6737HC.A
SSH6728C.A
SSH6728HC.A
SSH6738C.A
SSH6738HC.A
SSH6729C.A
SSH6729HC.A
SSH6739C.A
SSH6739HC.A
SSH6723C.C
SSH6723HC.C
SSH6733C.C
SSH6733HC.C
SSH6724C.C SSH6724HC.C SSH6734C.C SSH6734HC.C
SSH6725C.C SSH6725HC.C SSH6735C.C SSH6735HC.C
SSH6726C.C
SSH6726HC.C
SSH6736C.C
SSH6736HC.C
SSH6727C.C
SSH6727HC.C
SSH6737C.C
SSH6737HC.C
SSH6728C.C
SSH6728HC.C
SSH6738C.C
SSH6738HC.C
SSH6729C.C
SSH6729HC.C
SSH6739C.C
SSH6739HC.C

Table of contents
Edition BE210202
03.2022
Rondostar 5000
Operating manual 9
1 Safety information 15
1.1 Explanation of symbols 15
1.2 Explanation of symbols 16
1.3 Personnel 18
1.3.1 Personnel requirements 18
1.3.2 Unauthorised persons 18
1.3.3 Personal protective equipment 18
1.3.4 Conversion 19
1.4 Area of application 19
1.5 Safety elements 20
1.5.1 Safety guards 20
1.6 Safety instructions and information that must be observed 20
2 Transporting, setting up, connecting, dismounting and storing the device 27
2.1 Delivering the machine 27
2.2 Transporting the machine 27
2.3 Unpacking the machine 28
2.3.1 Unloading the pallet with a crane 29
2.3.2 Unloading the pallet with a forklift truck 29
2.3.3 Unloading the pallet with a manual pallet jack 30
2.4 Space requirement 35
2.5 Setting up the machine 36
2.5.1 Mounting the undertables [SSH673***.*] 36
2.5.2 Mounting the machine tables 37
2.5.3 Mounting gas springs: rigid substructure [SSH673***.*] 38
2.5.4 Mounting the table supports [SSH670**.*, SSH672***.*] 39
2.5.5 Tensioning the conveyor belts: Belt release [variant] 41
2.5.6 Tensioning the conveyor belts: Quick-release belt [variant] 42
2.5.7 Mounting the dough catch pans 43
2.5.8 Folding up the machine table [SSH670*.*/ SSH672*.* / SSH672*C.*] 43
2.5.9 Folding up the machine table: Cutomat [SSH672**C.* / SSH673**C.* ] 43
2.5.10 Folding down the machine table: Cutomat [SSH672**C.* / SSH673**C.* ] 44
2.5.11 Mounting the flour container [variant SSH670**.*] 44
2.5.12 Mounting the automatic flour duster
[variant SSH670**.*][standard SSH672***.*, SSH673***.*] 45
2.5.13 Mounting the automatic reeling device [SSH67* 7H*.*] 46
2.5.14 Interconnected operation with PTT150/PTT250 transfer table 47
2.5.15 Interconnected operation with make-up line/donut line 47
2.5.16 Moving the machine 48
2.5.17 Mounting the ship feet [option SSH670**.*, SSH672***.*] 48

Table of contents
Edition BE210202
03.2022
Rondostar 5000
Operating manual 10
2.6 Storing the machine 49
2.7 Requirements for commissioning the machine 50
3 General information on the machine 52
3.1 General information 52
3.1.1 Authorised use of the basic version 52
3.1.2 Authorised use of the automatic reeling device
[SSH67* 7H*.*] 53
3.1.3 Authorised use of the flour container [variant SSH670**.*] 53
3.1.4 Authorised use of the Cutomat [SSH67***C.*] 53
3.1.5 Authorised use of the automatic flour duster
[variant SSH670**.*][standard SSH672**.*, SSH673**.*] 54
3.1.6 Authorised use of the ship feet [option SSH670**.*, SSH672**.*] 54
3.2 Technical information 55
3.2.1 Noise values 55
3.2.2 Temperatures 55
3.2.3 Ambient humidity 55
3.3 Full view of the machine 56
3.3.1 Rondostar 5000 Basic / Rondostar 5000 Pro 56
3.3.2 Rondostar 5000 Expert 57
3.3.3 Rondostar-Cutomat 5000 58
3.3.4 Type plate 59
3.4 Machine configurations 60
3.4.1 Overview 60
3.4.2 Machine type nomenclature 61
3.5 Individual components 62
3.5.1 Complete housing (housing covers include basic structure) 62
3.5.2 Scraper 62
3.5.3 Dough catch pans 63
3.5.4 Conveyor belts 63
3.5.5 Machine tables 64
3.5.6 Substructure 65
3.5.7 Flour catch sheets [option SSH670**.*, SSH672***.*] 66
3.5.8 Belt release [variant] 66
3.5.9 Quick-release belt [variant] 66
3.5.10 Flour container [variant SSH670**.*] 67
3.5.11 Automatic flour duster
[variant SSH670**.*][standard SSH672***.*, SSH673***.*] 67
3.5.12 Dough reeler 68
3.5.13 Automatic reeling device [SSH67*7H*.*] 68

Table of contents
Edition BE210202
03.2022
Rondostar 5000
Operating manual 11
3.5.14 Ship feet [option SSH670**.*, SSH672***.*] 68
3.5.15 Transferring [option] 69
3.5.16 Cutomat [SSH672**C.*] 69
3.6 Operating and display elements 70
3.6.1 Switches – buttons – displays 70
3.6.1.1 main switch 70
3.6.1.2 Black mushroom button 70
3.6.1.3 Red mushroom button 70
3.6.1.4 Touch screen 71
3.6.1.5 Automatic flour duster: Dosing slides
[variant SSH670**.*][standard SSH672**.*, SSH673**.*] 71
3.6.1.6 Cutomat: Tension lever / stop lever [SSH67***C.*] 71
3.6.2 Safety elements 72
3.6.2.1 Safety guards 72
3.6.2.2 Gas spring 72
3.6.2.3 Warning label 73
3.6.2.4 Cutomat: Locking lever [SSH67***C.*] 73
4 Putting into operation 74
4.1 Preparing for standby 74
4.2 Switching the machine on / off 75
4.3 Registering the machine 75
4.4 Starting / stopping the machine 77
5 Operation 78
5.1 General functional description 78
5.2 Explanatory texts 78
5.3 User 79
5.3.1 User levels 79
5.3.2 Create new user [foreman or higher] 80
5.3.3 Manage users [foreman or higher] 80
5.4 Programs 81
5.4.1 Create new program: Swipe-programming [foreman or higher] 81
5.4.2 Create new program: Program wizard [foreman or higher] 82
5.4.3 Copy program [foreman or higher] 83
5.4.4 Permanently change program [foreman or higher] 83
5.4.5 Delete program [foreman or higher] 83
5.4.6 Preparing the USB stick [foreman or higher] 84
5.4.7 Saving a program on the USB stick [foreman or higher] 85
5.4.8 Load program from USB stick [foreman or higher] 85
5.4.9 Load product image / portrait from USB stick [foreman or higher] 86

Table of contents
Edition BE210202
03.2022
Rondostar 5000
Operating manual 12
5.5 Sheeting 87
5.5.1 Working in production mode 87
5.5.1.1 Re-entering the sequence from a defined program step 87
5.5.1.2 Performing daily corrections 88
5.6 Settings 89
5.6.1 Set parameters: Dough processing [foreman or higher] 89
5.6.2 Set parameters: End function [foreman or higher] 89
5.7 Process know-how 90
5.7.1 Automatic width monitoring system: At roller gap 90
5.7.2 End function 90
5.7.2.1 Manual reeling 90
5.7.2.2 Automatic reeling 90
5.7.2.3 Transferring to downstream machine 90
5.7.3 Dough retention arm 90
5.8 Automatic flour duster
[variant SSH670**.*][standard SSH672***.*, SSH673***.*] 91
5.9 Automatic reeling device [SSH67*7H*.*] 92
5.10 Cutomat with cutting station [SSH67***C.*] 93
5.10.1 Cutting roller types 94
5.10.2 Inserting the cutting rollers 95
5.10.3 Lowering the cutting rollers 96
5.10.4 Lifting the cutting rollers 96
5.10.5 Cutting 97
5.11 RONDOconnect [Technician or higher] 98
5.11.1 Establishing the basic requirements 99
5.11.2 Connecting a machine to the WIFI 100
5.11.3 Registering the machine for RONDOconnect 101
5.11.4 Displaying the customer dashboard: via WIFI 102
5.11.5 Using the customer dashboard 103
5.11.5.1 Operating elements 103
5.11.5.2 Recipe history 104
5.11.5.3 Cleaning history 104
5.11.5.4 Machine data 105
5.11.5.5 Customer data 105
5.11.5.6 Chart production 106
5.11.5.7 Error statistics 107
5.11.5.8 Operating hours counter and machine state 108

Table of contents
Edition BE210202
03.2022
Rondostar 5000
Operating manual 13
6 Cleaning 109
6.1 Cleaning 109
6.1.1 Care 111
6.1.1.1 Machine body and substructure 112
6.1.1.2 Safety guards 112
6.1.1.3 Light barrier / sensor wiper 112
6.1.1.4 Scrapers / Rollers 113
6.1.1.5 Conveyor belts: Top 114
6.1.1.6 Conveyor belts: underside / machine table / drive roller / idle roller 114
6.1.1.7 Table supports 115
6.1.1.8 Flour catch sheets 115
6.1.1.9 Dough catch pans 115
6.1.1.10 Touch screen 115
6.1.1.11 Automatic flour duster
[variant SSH670**.*][standard SSH672***.*, SSH673***.*] 115
6.1.1.12 Automatic reeling device [SSH67*7H*.*] 117
6.1.1.13 Cutting rollers [SSH67***C.*] 117
7 Maintenance 118
7.1 General information for machine maintenance 118
7.2 Software updates 120
7.3 Maintenance list 121
7.4 Replacement kit 122
7.4.1 Checking and replacing the sensor wiper 123
7.4.2 Lubricating the sensor wiper 123
7.4.3 Check and replace gas spring: Safety guards 124
7.4.4 Checking and replacing the gas springs: rigid substructure [SSH673***.*] 125
7.4.5 Checking the safety guards trigger point 126
7.4.6 Replacing the scrapers 126
7.4.6.1 Removing the scrapers 126
7.4.6.2 Replacing the scraper blade 127
7.4.6.3 Mounting the scraper 128
7.4.7 Conveyor belt 128
7.4.7.1 Checking for wear 128
7.4.8 Automatic reeling device: Check seal rings
[SSH67*7H*.*] 128
7.4.9 Automatic flour duster: Adjusting the brush
[variant SSH670**.*][standard SSH672***.*, SSH673***.*] 129
7.4.10 Cutomat: Replacing the guideway [SSH67***C.*] 129

Table of contents
Edition BE210202
03.2022
Rondostar 5000
Operating manual 14
7.4.11 Check warning labels 130
7.4.11.1 Warning label: Complete housing: ISO
[SSH67****.A] 130
7.4.11.2 Warning label: Automatic flour duster: ISO
[variant SSH670**.A][standard SSH672***.A, SSH673***.A] 131
7.4.11.3 Warning label: Automatic reeling device: ISO
[SSH67*7H*.A] 132
7.4.11.4 Warning label: Cutomat: ISO
[SSH67***C.A] 133
7.4.11.5 Warning label: Complete housing: ANSI
[SSH67****.C] 134
7.4.11.6 Warning label: Automatic flour duster: ANSI
[variant SSH670**.C][standard SSH672***.C, SSH673***.C] 135
7.4.11.7 Warning label: Automatic reeling device: ANSI
[SSH67*7H*.C] 136
7.4.11.8 Warning label: Cutomat: ANSI
[SSH67***C.C] 137
8 Troubleshooting 138
8.1 List of errors 138
8.2 Checking the inputs and outputs 141
9 Technical data 142
9.1 Technical data 142
9.1.1 Technical data for Rondostar 5000 Basic / Rondostar 5000 Pro 142
9.1.2 Technical data for Rondostar 5000 Expert 143
9.1.3 Technical data for Rondostar-Cutomat 5000 144
9.2 Supplementary information 145
9.3 Dismantling, dismounting and disposal 146
Note for operating manual:
The image position numbers (e.g. 1) are sequentially numbered,
chapter by chapter.

Safety information
Edition BE210202
03.2022
Rondostar 5000
Operating manual 15
1 Safety information
In the following sections, the term “installation” refers to RONDO instal-
lations.
1.1 Explanation of symbols
All sections in this operating manual containing safety instructions
which absolutely must be observed are marked with this symbol and
with a number.
All sections in this operating manual containing instructions which ab-
solutely must be observed are marked with this symbol.

Safety information
Edition BE210202
03.2022
Rondostar 5000
Operating manual 16
1.2 Explanation of symbols
Earthing point
Reaching under the closed safety guard is prohibited!
Ensure that the mains plug is disconnected before opening!
Pay attention to the centre of gravity!
Secure the machine with a padlock to prevent restarting!
Turn the main switch off!
Danger due to general causes.
Danger due to hazardous electrical supply voltage.
Danger due to pinch points on bands, belts and chains.
Danger due to pinch points on gearwheels.

Safety information
Edition BE210202
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Operating manual 17
Danger due to contact points and pinch points.
Danger due to automatic starting.
Danger due to pinch points on rotating parts.
Danger due to sharp parts.
Danger due to heat.
Wear safety shoes.

Safety information
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Rondostar 5000
Operating manual 18
1.3 Personnel
1.3.1 Personnel requirements
Only those persons who can reliably work on the installation and whose
reactions are not impaired (e.g. due to medicines, alcohol or drugs) are
approved as personnel.
Unqualified personnel cannot identify risks and are therefore exposed
to increased dangers.
• Only instruct technically qualified personnel who have been
trained by RONDO, to perform the tasks described in this operat-
ing manual.
• Ensure that the personnel adhere to locally valid rules and regula-
tions for safe and hazard-aware working.
• Specify responsibilities for activities and make sure these are
known. Only give assigned personnel the keys and passwords.
• Work on/with the machine requires personnel to have been
instructed and be a minimum of 16 years of age.
1.3.2 Unauthorised persons
Unauthorised persons who do not fulfil the requirements described
here and are not aware of the dangers in the work area. Unauthorised
persons must be kept away from the work area. Work must be inter-
rupted for as long as unauthorised persons are in the work area.
1.3.3 Personal protective equipment
Protective equipment Use
Safety gloves Wear safety gloves when working with sharp parts, e.g. scrapers.
Mask Wear a mask to prevent breathing difficulties and flour dust allergies.
Safety shoes To prevent severe slipping or falling accidents, wear safety shoes.
Protective clothing Suitable protective clothing is close-fitting work clothing with low
resistance to tearing, narrow sleeves and without protruding parts. It serves primarily
as protection from entanglement in moving machine parts. Do not wear rings,
necklaces or other jewellery. Wear a hair net if you have long hair.

Safety information
Edition BE210202
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Rondostar 5000
Operating manual 19
1.3.4 Conversion
The machine may only be converted by trained and instructed RONDO
personnel.
1.4 Area of application
The machine is designed solely for industrial and commercial use.
The machine may only be used in a dry environment protected from
sunshine. This means that the machine can only be operated in a
closed room.

Safety information
Edition BE210202
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Rondostar 5000
Operating manual 20
1.5 Safety elements
Safety elements (e.g. safety guards and similar) are designed to
protect the operator and to shut down the installation safely and
as quickly as possible in an emergency situation.
It is not permitted to use safety elements instead of the “STOP”
mushroom button to stop the installation. Stopping the installa-
tion incorrectly may cause production defects.
1.5.1 Safety guards
• Safety guards protect the operator from accidentally touching
dangerous areas.
• If a safety guard is lifted, the installation stops.
• After the installation has been stopped by lifting a safety guard,
the installation must then be restarted.
• The gas spring protects the operator against the safety guard
dropping.
1.6 Safety instructions and information that must be observed
Read the operating manual before putting the machine into oper-
ation.
This RONDO machine is exclusively designed for sheeting, laminating
and finish-rolling doughs (dough and marzipan sheets) for the food in-
dustry.
The RONDO automatic flour duster is exclusively designed for contin-
uously dusting dough and marzipan bands with flour.
However, the machine is not suitable for the processing of other prod-
ucts (e.g. modelling clay or other types of mouldable masses which are
not dough products).
Any other use of this machine is not in accordance with the purpose for
which it was built. Therefore, the manufacturer will not be liable for any
accidents or damage resulting from unauthorised use; the risk will be
borne solely by the user.
1
2