RONDO RONDOSTAR 3000 SFS6117 (01) PDF MANUAL

RONDO RONDOSTAR 3000 SFS6117 (01) PDF SUMMARY:

What safety instructions and information must be followed before beginning any repair, maintenance, cleaning, or similar work on the machine?

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! In addition, follow all safety instructions and information according to chapter 1 of the operating manual!

---

Where are Rondo headquarters located?

RONDO GmbH & Co.KG is located at Hoorwaldstrasse 44 57299 Burbach Germany. RONDO S.r.l. is located Via Lago di Albano, 86 36015 Schio (VI) Italy. RONDO S.à.r.l. is located at PAE “Les Pins” 67319 Wasselonne cedex France. RONDO Ltd. is located at Unit 7, Chessington Park Lion Park Avenue Chessington, Surrey KT9 1ST Great Britain. RONDO Inc. is located at 51 Joseph Street Moonachie, N.J. 07074 USA. RONDO Inc. is located at 267 Canarctic Drive Downsview, Ont. M3J 2N7 Canada. OOO RONDO is located at Varschavskoge Chaussée, D 17, Str. 3 117105 Moskau Russia. RONDO Asia Regional Office is located at No. 14-1 Mezzanine Floor Jalan 11/116B Kuchai Entrepreneurs Park Off Jalan Kuchai Lama 58200 Kuala Lumpur Malaysia. RONDO Burgdorf AG is located at Heimiswilstrasse 42 3400 Burgdorf Switzerland. RONDO Schio s.r.l. is located at Via Lago di Albano, 86 36015 Schio (VI) Italy.

---

What are the part names in relation to the full view of the machine?

The part names are: Dough Catch Pan, Flour Duster (Option), Roller Head, Safety Guard, Machine Table, Machine Base, Main Switch, Black Push Button for Starting, Control Panel, Red Push Button for Stopping, Forked Support, Turning knob for data input, Automatical Dough Reeler (Option), Cutting Station (Option), Support, Lower Table, Forked Supports.

---

What are some recommended mechanical spare parts?

Some recommended mechanical spare parts include: Toothed belt GT, Retaining ring, Toothed belt HTD, Pneumatic spring 100N without automatic reeler, Toothed belt GT, Clutch, Toothed belt, Pneumatic spring 200N with automatic reeler, Ribbed belt, Drive roller, Synthetic conveyor belt 640 x 3280, Eccentric lever, Segment, Compression spring, Dough retaining hoop, Synthetic conveyor belt 640 x 3570, Synthetic conveyor belt 640 x 2680, Scraper blade, Gearwheel Z = 22, Gearwheel Z = 15, Gearwheel Z = 18, Gearwheel Z = 16, Gearwheel Z = 15, Ribbed V-belt pulley, Ribbed V-belt pulley, Ribbed V-belt pulley, Spring, Scraper complete, Spring bar, Ductor, Wiper arm, Scraper blade, Scraper complete blue, Synthetic conveyor belt blue 640 x 3280, O-Ring, Gearwheel Z = 10, Gearwheel Z = 12, Gearwheel Z = 13, Motor with cable Linak.

---

What are some recommended electrical spare parts?

Some recommended electrical spare parts include: Fuse 2,0A slow, Limit switch, Receiver head, Transmitter head, Modul basic, Handwheel compl., Rotary encoder, Turning knob, Fuse 0,63A slow, Microprocessor unit, Cable for light barrier, Cable for light barrier, Frequency inverter 230 V, Frequency inverter 400 V, Motor three-phase 0.09 kW, Motor with brake, El. magnetic brake, Contact component auxiliary, Contactor miniature, Contactor miniature, Ribbon cable, 20 pol., Electrical clutch Cutomat, Motor 1,1 kW 50/60 Hz, Time relais, Push button black, Push button red, Contact block auxiliary 2S, Contact block auxiliary 10, Motor 1,1 kW 60 Hz, UL.

---

What improvements have been made 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.

---

What software changes have been made?

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.

---

What should you pay attention to when using the new software V1.10 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.

---

What special functions is the software for the RONDOSTAR equipped with to assist the technical service?

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.

---

How do you allocate the function codes?

The allocation of the function codes is as follows:

• “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.

---

What happens when the processor is initialized and when should the initialization be carried out?

When the processor is initialized, the basic data (parameters, sheeting programs) are loaded from the program EPROM into the processor’s working memory.

When initializing, all previously entered data such as customer programs, special parameters, etc. are overwritten by the basic data.

When should the initialization be carried out?

• Following the installation of a new processor in the machine, do a full initialization (FU 55)

• Where faults are suspected in the processor’s control procedure (software errors)

  • In this case proceed as follows: Initialize the parameters (FU 51) —> then test the machine
  • If the problems are not rectified, do a full initialization (FU 55) —> then test the machine, This results in the loss of all sheeting programs memorized by the customer!

• If only the customer programs are to be deleted, initialize the programs (FU 53) —> all sheeting programs are deleted

---

How do you initialize the parameters?

Example: In order to initialize 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”

---

When is calibration of the roller gap imperative and how does the calibration of the roller gap take place?

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 initialization and is not deleted.

---

What are the parameter descriptions and values?

The parameter descriptions and values are:

• Entering data: Side end for folding not defined 0, Side end for folding right 1, Side end for folding left 2
• Entering data: Side end for man. reeling not defined 0, Side end for man. reeling right 1, Side end for man. reeling left 2
• Compound operation: Time band stop waiting position 15 0,1 s
• Compound operation: Time for transfer 300 0,1 s
• Entering data: no Auto-reeler 0, Auto-reeler right 1, Auto-reeler left 2
• Entering data: no cutomat 0, Cutomat right 1, Coutomat left 2
• Time Auto-reeler finished photocell free –> conveyor belt stop 15 (10) 0,1 s
• Time handreeler finished photocell free –> conveyor belt stop 15 (10) 0,1 s
• Position of the dough handreeler placement Dough in photocell –> conveyor belt stop 15 (10) 0,1 s
• Time conveyor belt stop for folding photocell free –> conveyor belt stop 2 0,1 s
• Time conveyor belt stop for cutomat photocell free –> conveyor belt stop 2 0,1 s
• Roller opening by cutting (Cutomat) 50 0,1 mm
• Time open Auto-reeler 12 0,1 s
• Time close Auto-reeler 15 0,1 s
• max. dough thickness in mm for Auto-reeler 90 0,1 mm
• Delay time dough in photocell 2 0,1 s
• Indicator period 8 0,1 s
• Indicator break 2 0,1 s
• Cutomat: running time high speed at the start 10 0,1 s
• On delay-time for flour duster 8 0,1 s
• Time for changing the program-no. (Flashing of the program-no) 50 0,1 s
• Time press the key for selecting the program mode 30 0,1 s
• “long time” for key OK respectively flour duster for special functions 100 0,1 s
• “short time” for key OK respectively flour duster for special functions 30 0,1 s
• 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
• Rondostar with table clutch 1 Rondostar with reversing gear 2 (Cutomat/Compound, machine delivery before August 1998)
• Light barrier wiper “above” For new screen wiper on the roller, inactive 2 For old screen wiper with catch, function active 320
• Light barrier wiper “below” For new screen wiper on the roller, inactive 450 For old screen wiper with catch, function active 120

Values in brackets are valid for short tables.

---

What are some notes in relation to the parameters?

Some notes in relation to the parameters include:

• 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 initialization 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.

---

How do you change 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

---

How does the diagnostic program work?

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.

---

How do you select 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

---

How do you check 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, contactor K2M, Frequency inverter and 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 mains Right 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 immediately, 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

---

What is the 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

---

How can the individual outputs be switched on and off?

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.

---

How do you read the 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

---

What are some notes in relation to testing the drives?

Some notes in relation to testing the drives include:

• 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.

---

What must coincide with the data given on the machine specification plate?

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.

---

How do you modify 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.

---

How do you modify the machine for another frequency?

The following parts depend of the value of the frequency:

50 Hz	60 Hz
motor 50400	motor 50421
V-belt pulley 124128	V-belt pulley 124138
V-belt 50401	V-belt 50403

Attention: Rondostar with Cutomat (variable speed) can be operated with 50 or 60 Hz without a change.

---

How does the 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.

---

How does the 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.

---

What does the turning knob consist of and what is it used for?

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.

---

How do you test the 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.

---

How do you test the table and roller 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”

---

How do you test 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

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