Rondo SFS6115C, SFS6117H, SFS6117DD, SFI6117, SFI6117H User Manual

Service manual

Rondostar 3000

SFS6115, SFS6115C, SFS6117,
SFS6117C, SFS6117H, SFS6117DD
SFI6117, SFI6117H

Edition SD123402

T echnical specifications subject to change without notice

HEADQUARTERS
RONDO Burgdorf AG

Heimiswilstrasse 42
3400 Burgdorf
Switzerland
Phone [phone]
Fax [phone]
[e-mail]

COMPETENCE CENTRE SCHIO
RONDO Schio s.r.l.

Via Lago di Albano, 86
36015 Schio (VI)
Italy
Phone [phone]
Fax [phone]
[e-mail]

SUBSIDIARIES
RONDO GmbH & Co.KG

Hoorwaldstrasse 44
57299 Burbach
Germany
Phone [phone]
Fax [phone]
[e-mail]

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]
[e-mail]

RONDO Inc.

51 Joseph Street
Moonachie, N.J. 07074
USA
Phone [phone]
Fax [phone]
[e-mail]

RONDO Inc.

267 Canarctic Drive
Downsview, Ont. M3J 2N7
Canada
Phone [phone]
Fax [phone]
[e-mail]

RONDO S.r.l.

Via Lago di Albano, 86
36015 Schio (VI)
Italy
Phone [phone]
Fax [phone]
[e-mail]

OOO RONDO

Varschavskoge Chaussée, D 17, Str. 3
117105 Moskau
Russia
Phone [phone]
Fax [phone]
[e-mail]

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]

www.rondo-online.com

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

Index

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

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

7.4.3 Ground fault interrupter can be actuated when inverter is started

8. Part names, drawings

8.1 Machine 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

8.4.1 Machine base

8.4.2 Maschine base with support

8.4.3 Machine base SFI

8.5 Machine tables

8.5.1 Machine table Inox to Cutomat

8.5.2 Machine table Inox to support type

8.5.3 Machine table Inox to socle type

8.5.4 Flour catch pan

8.6 Cutting station / Machine table Cutomat

8.6.1 Adjustment of spring range

8.7 Flour duster

8.8 Automatic dough reeler

8.8.1 Convert the automatical dough reeler from the right to the left machine table

8.8.2 Reeler raise SFI61 17.E

8.9 Electrical box

8.10 Electrical box Cutomat

8.1 1 Front cover: Electrical equipment

9. Electro circuit diagrams

Unbedingt zu beachtende Sicherheitsvorschrif ten und -hinweise

Bei allen Reparatur-, Inst andhaltungs-, Reinigungs- und ähnlichen Arbeiten an Maschinen
sind vor Beginn die Netzstecker herauszuziehen und alle eventuell vorhandenen
Druckluftzuleitungen zu unterbrechen und zu entlüften!

Weiter sind sämtliche Sicherheitsvorschriften und -hinweise, gemäss Betriebsanleitung
Kapitel 1, zu beachten!

Prescriptions et conseils de sécurité à observer obligatoirement

Avant tout travail de rép aration, 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!

De plus, il faut observer toutes les prescriptions et conseils de sécurité selon chapitre 1
du mode d'emploi!

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!

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

2 Full View of the Machine

1

SFS6115

5

8

4

11

3

6

10

4

5

11

12

1

7

1 Dough Catch Pan
2 Flour Duster (Option)

9

8

3 Roller Head
4 Safety Guard
5 Machine T able
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

2

SFS6115C / SFS6117C

Edition: 04. 2005

14

SFS6117H

13

Service manual

SFI6117

16

17

SFI6117H

15

17

13

13 Automatical Dough Reeler (Option)
15 Support
16 Lower Table
17 Forked Supports

Edition: 04. 2005

Service manual

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

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

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

50607 Rippenband Tapis gouffré Ribbed belt
91339T05 Antriebsrolle Rouleau d'entraînement Drive roller
105467 Kunststoffband 640 x 3280 Tapis synthétique

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

121344T02 Kunststoffband 640 x 2680 Tapis synthétique

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

* = 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

Teilebezeichnung
Désignation
Part name

automatischem Haspel

automatischem Haspel

640 x 3280

Vérin à gaz 100N sans
enrouleur automatique

Vérin à gaz 200N avec
enrouleur automatique

640 x 3280

640 x 3570

640 x 2680

Tapis synthétique bleu
640 x 3280

Pneumatic spring 100N
without automatic reeler

Pneumatic spring 200N with
automatic reeler

Synthetic conveyor belt
640 x 3280

Synthetic conveyor belt
640 x 3570
Synthetic conveyor belt
640 x 2680

Synthetic conveyor belt blue
640 x 3280

3.2. Elektrische Ersatzteile / Pièces de rechange électriques /
Electrical spare parts

Bestell.Nr.
No commande
Ordering no.

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.

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

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

1. Stufe Teilebezeichnung
Echelon 1 Désignation
Variation 1 Part name

2. Stufe Teilebezeichnung
Echelon 2 Désignation
Variation 2 Part name

Embrayage électrique

Cutomat

Cutomat

Electrical clutch
Cutomat

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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

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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

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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

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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

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
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
FD 10 11 Entering data: no cutomat 0

Cutomat right 1

Coutomat left 2
FD 10 12 Time Auto-reeler finished

photocell free --> conveyor belt stop
FD 10 13 Time handreeler finished

photocell free --> conveyor belt stop
FD 10 14 Position of the dough handreeler placement

Dough in photocell --> conveyor belt stop
FD 10 15 Time conveyor belt stop for folding

photocell free --> conveyor belt stop
FD 10 16 Time conveyor belt stop for cutomat

photocell free --> conveyor belt stop
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
FD 10 29 "short time" for key OK respectively flour duster for special

functions
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
FD 10 31 Rondostar with table clutch 1

Rondostar with reversing gear 2

(Cutomat/Compound, machine delivery before August 1998)
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
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

Values in brackets are valid for short tables

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Edition: 06.2011

Service manual

1

1

0

0

15
(10)
15
(10)
15
(10)
2 0,1 s

2 0,1 s

100 0,1 s
30 0,1 s
0

1

2

450

0,1 s
0,1 s
0,1 s

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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

Parameters: The parameters are selected with the turning knob and confirmed with "OK"

technical service (no notes in the operating manual).

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

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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 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 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

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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

A0 Supervision processor

A2 Table drive:Conveyor-

A11 Table drive:Conveyor-

A5 Table clutches

A6 Roller adjustment

A10 Roller adjustment

A7 Roller adjustment
A9 Flour duster
A8 Direction of rotation flour

A4 Selection between

A3 Auto reeler, table

A1 Reeler

Function by
mains right rotating field
LED No. 9 dark

(watch-dog)

belt runs to the left

belt runs to the right

0 = left clutch
1 = right clutch
Cutomat:
1 = small number of
revolutions

1 = drive ON
0 = upward

1 = downward
1 = Brake ON
1 = Flour duster ON
duster 0 by right rotating

field
0 = reeler

1 = table clutch /
Cutomat clutch

clutches, Cutomat clutch
1 = ON

0 = Open reeler
1 = Close reeler

Function by
mains left rotating field
LED No. 9 illuminates

Supervision processor
(watch-dog)

Table drive:
Conveyor-belt runs to the
right
Table drive:
Conveyor-belt runs to the
left
Table clutches
0 = left clutch
1 = right clutch
Cutomat:
1 = small number of
revolutions
Roller adjustment
1 = drive ON
Roller adjustment
0 = downward
1 = upward
Roller adjustment
1 = Brake ON
Flour duster
1 = Flour duster ON
Direction of rotation flour
duster 1 by left rotating
field
Selection between
0 = reeler
1 = table clutch /
Cutomat clutch
Auto reeler, table
clutches, Cutomat clutch
1 = ON
Reeler
0 = Open reeler
1 = Close reeler

Relay

contactor

K8 Cannot be switched on

K9/K2M

F-inverter

K10/K3MF

-inverter
K13 Rondostar with table

K1/ K2

K5

K7

K3 / K4

K6

K14

K12 Switch on / off

K11

Remarks

or off
processor fault A1=0
By Cutomat:
Conveyor-belt runs
always to the left
By Cutomat:
Conveyor-belt runs
always to the right

clutches

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

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5.3.5 Testing the reeler

The motor of the reeler drive is equipped with limit switches which automatically interrupt the
electricity supply in the end position.

To check the reeler in the diagnostic program proceed as follows:

Switch on diagnostic program as described under 4.5.1

Switch on reeler

- Set d = 3 by turning knob Indication: d 3** 0

- Reeler ON by key "OK" Indication: d 3** 1
The reeler is now switched on

Open / close reeler

- Set d = 1 by turning knob Indication: d 1** 0 (1)
The reeler can now be opened and closed by the key "OK".

- Press key "OK": Close reeler, wait until the reeler
is closed completely Indication: d 1** 1

- Press key "OK": Open reeler, wait until the reeler
is opened completely Indication: d 1** 0

** = Indication is flashing

Warning: Do not change the direction of rotation while the reeler is moving.

5.3.6 Testing the roller adjustment drive brake

In order to test the brake of the roller adjustment drive in the diagnostic program, proceed
as follows:

- Switch on the diagnosic program as described under 4.5.1

- Set d = 7 by turning knob Indication: d 7** 0

- Brake ON by key "OK" Indication: d 7** 1

- Brake OFF by key "OK" Indication: d 7** 0

** = Indication is flashing

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5.3.7 Testing the Cutomat

For the operation Cutomat the Cutomat clutch (outputs A3 and A4 = 1) as well as the slow
speed (output A5 = 1) have to be switched on.

For testing the function Cutomat, set a simple auto-program with Cutomat in program 1,
3 positions:

Initial roller gap 10 mm
Final roller gap 6 mm
Roller reduction curve 5

Function Cutomat:

Now the program will start in the final test (See 5.4). If the endthickness is reached, start
the machine with the black push button.
Now the rollers open about 5 mm and the machine starts with the Cutomat speed. The
table on the infeed side has to run exactly as fast as the table on the outfeed side. A click
of the driving wheels in the front housing is audible (normal).

5.4 Final control test

For the final control test an automatic sheeting program (without dough) is used in a
continuous way. The running time for the table drive in either direction of operation is
approx. 3 s.

Warning:
Continuous operation is only possible using programs with the functions "Stop for
folding" or "automatic reeling".

- Switch on working mode "Auto" LED "AUTO" on continuously

- Press key "flour duster" during approx. 10 s Indication: FU 0 --

- Set "20" by turning knob Indication: FU 20 --

- Press key "OK" till Indication: FU 0 --

- Press key "OK", program no. 1 is displayed Indication: 01** XX,X XX,X

- Select desired testing program by turning knob
Start machine with black push button, stop machine with red push button or safety

guard.
Return to normal sheeting mode: Press key "ESC"
XX,X = Numerical value ** = Indication is flashing

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6. Compound operation

The Rondostar SFS6117 is also qualified for compound operation with a transfer table
(dough transfer with sheeting speed).

The Rondostar SFS6117DD is qualified for compound operation with a make-up line or a
donut line. The variable speed for the dough transfer is approx. 1,5 - 7,5 m/min for make-up
lines and approx. 15 - 25 m/min for donut lines.

6.1 General comments

In compound operation with make-up lines respectively donut lines, the Rondostar can be used
together with one or two lines. The following operating modes are possible (parameter 30):

- Make-up line / donut line to the left of the Rondostar

- Make-up line / donut line to the right of the Rondostar

- One make-up line / donut line on each side of the Rondostar

Compound operation with make-up lines respectively donut lines is only possible with the
Rondostar SFS6117DD. The Rondostar SFS6117DD can also be used like a standard
machine (Function Cutomat not possible). Special processor parameters, see chapter 6.3.

The compound operation with a transfer table is possible with a normal Rondostar
(without variable speed). The release for transfer takes place by the transfer table (high
speed).

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6.2 Function

6.2.1 Compound operation with one make-up line respectively donut line

For compound operation a program containing the final function "Cutomat" mus t
always be produced.
Sheeting takes place as for a normal sheeting program. The dough band is stopped in the
same position as for "place manual reeler". The dough position can be set by
parameter 2.
The dough transfer starts, if the release is given by the line (input E6).
The dough band is transferred at reduced speed. The time for transfer can be set by
parameter 3. When the transfer time is run down the sheeting program is finished (The rollers
revert to the initial roller gap).

Transfer speed:

Adjustable on the potentiometer as by Cutomat. The time for the transfer of the dough depends
on the speed! The time can be set by parameter 3.

6.2.2 Positioning the dough

During compound operation with one line (parameter 30 = 1 or 2) the dough piece can
be positioned on the left or right table.
During compound operation with two lines, sheeting takes place corresponding the
selected parameter 30.

- Parameter 30 = 3: without a passage without roller adjustment. The number of
sheeting passages (even/uneven) therefore determines the side on which for the left
respectively right line the dough must be positioned. By sheeting a dough piece it is
possible to determine the allocation of the side "position dough" to the left or right
line.

- Parameter 30 = 4: Side to place the dough is defined as follows:
for left machine place dough on the left side
for right machine place dough on the right side

6.2.3 Release signal for transfer

The release signal for transfer is given by the make-up line by means of a floating
contact.
Contact closed = release
Contact open = no release respectively stop during the transfer
In special circumstances the release signal can be given by operating the black push
button (the release is given as long as the black push button is operated).

6.3 Special parameters for compound operation

The following parameters have to be set on the processor for compound operation.

- Parameter 30: Definition of compound operation (left, right, both sides)

- Parameter 2: Stop position on the table end if the dough cannot be transferred.

- Parameter 3: Running time for the dough transfer (depends on the transfer speed).
The parameters 2 and 3 can also be set by the customer (operating manual)

Parameterization of the frequency inverter, see chapter 7.4.2

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7. Instructions for trouble shooting

7.1 Error messages

The following error messages are indicated on the display:

Indication Error Causes

Err 1 Supervision of the control - Mains voltage to small
voltage of the microprocessor - Control voltage to small, replace
the basic modul

- Error processor (Input)
Err 2 Supervision of the control - Check control voltage

voltage, Error input E2 - Check fuse F2 in the basic
module

Err 3 Time-out roller adjustment - Motor runs only with 2 phases
drive, i. e. adjusting the roller - Mechanism of the roller
takes too long adjustment jams.

Err 4 No reaction of the sender, - Roller adjustment motor doesn't
if roller adjustment drive turn
is switched on. - The roller jams in the upper or
the lower final position.

- Sender defective.

- Sender cable is not plugged into
the processor

- Ribbon cable from the processor to
the basic module isn't plugged
in.

Err 5 Target value for roller gap, i. e. - Brake doesn't function
divergence between set point - The transmitter doesn't work
and actual value of roller gap properly (positions are partially
is too big missing

Err 6 The main contactor K1M is By switching on the main switch
welded. the contactor K1M is already
tightened.

Attention:
The black push button may only be
operated if the indications on the
display are illuminating, i. e. if the
processor is ready for working

Err 7 Error frequency inverter or - Check the frequency inverter
contactor K2M doesn't switch on. Switch of the mains switch for at
(Input E4) least 30 s.

- Check contactor K2M

- Check time relay K3T

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Indication Error Causes

Err 8 Error frequency inverter or - Check the frequency inverter
contactor K2M switchs off to (See also Error 7)
early (Input E4) - Check the adjustment of the
time relay K3T (1,0 s with
off-delay)

Err 9 Contactor K2M doesn't - Check contactor K2M
switch off - Check the adjustment of the
time relay K3T

The errors can be eleminated by switching off the mains switch.
The mains has to be switched off for at least 30 s, by machines with a frequency
inverter (Cutomat).

7.2 Construction of the control system

The electrical control consists basically of the following parts:

Processor with display

The machine is controled by the processor.

Basic module (fitted in electrical box)

The basic module contains:

- Power-pack consists of the transformer and the rectifier for the control voltages
24 VDC and 15 VDC.

- Relays for the control of the roller adjustment drive including the brake.

- Relays for the control of the flour duster.

- Relays for the control of the reeler.

- Contactors for the control of the roller drive / table drive

Contactor control system

The main contactor K1M carries out a safety function. When opening the safety guard
or pressing the red push button, all drives are disconnected.
The table drive is controled by the contactors K2M and K3M.

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7.3 Checking the control system

7.3.1 Mains voltage

Switch on mains switch and measure all 3 phases on contactor K1M, terminals 2, 4, 6.
(by Cutomat terminals L1, L2, L3)

7.3.2 Control voltages

Attention: The connections of the control voltage transformer (fitted in the basic
module) have to coincide with the phase voltage of the net!

Control voltage 15 VDC

Control voltage for the processor.
Measure the voltage at plug X5 on the processor (Terminals 4 and 5).
Check fuse F1 (0,63 AT) in the basic module.

Control voltage 24 VDC

Control voltage for contactor control system, in- and outputs of the processor etc.
Measure the voltage at plug X5 on the processor (Terminals 1 and 2).
Check fuse F2 (2,0 AT) in the basic module.

The control voltages can also be checked at the basic modul on the terminals TP1 - TP6
(Close to the fuses)

TP1: +24V TP3: +15V TP5: 26VAC
TP2: G24V TP4: G15V TP6: 26VAC

Voltage 24 VDC for reeler drive (Up / Down)

Measure the voltage at plug X10-1 / X10-2.
Check fuse F3 (2,0 AT) in the basic module.

7.3.3 Control circuit main contactor K1M

The release of the control voltage is done by the relay K8 in the basic module.

(See circuit diagram 500680, side 3, path 1 respectively 500681 side 3, path 1)
Relay K8 switches on as soon as the processor works faultless.
If the processor doesn't run (Error in the processor), the red LED in the basic module is
illuminated.

The control voltage can be checked as follows:

- Measure against ground, e. g. earth terminal

- Terminal X1-1: Voltage existing if released off processor (Relay K8)

- Terminal X1-2: Voltage existing if safety guard OK

- Terminal X1-6: Voltage existing if red push button OK

- Terminal X1-5: Voltage existing if one of the black push buttons is operated

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7.3.4 Measure of the voltage on the plugs

All connections to the basic module are plugable and allow a quick and faultless exchange.
The following picture shows the numbering of the plug connections. Based on these, in
combination with the diagram, the output voltage on the basic module can be
measured.

7.4 Important notes to the frequency inverter

7.4.1 Types

For 200 - 230 V and 380 - 460 V different types of frequency inverters and mains
filters are used.

7.4.2 Parameterization

The frequency inverters delivered by RONDO Burgdorf AG, CH are already
parameterized. The inverters can be used without a change for the sheeting
machine Compas SFA612.

Important: All other parameters must not be changed.

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7.4.3 Ground fault interrupter can be actuated when inverter is started
Leakage current flows through the inverter.

The inverter performs internal switching. Therefore, a leakage current flows through the
inverter. This leakage current may actuate the ground fault interrupter, shutting the power
off.

Use a ground fault interrupter with a high leakage-current detection value (sensitivity
amperage of 200mA or more, operating time of 0,1 s or more) or one with high-frequency
countermeasures for inverter use.

In addition, remember that a leakage current increases in proportion to the cable length.
Normally, approximately 5 mA of leakage current is generated for each meter of cable.

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8. Teilebezeichnungen, Zeichnungen / Désignations des pièces,
dessins / Part names, drawings

8.1 Maschinenkörper vorderes Gehäuse Corps de la machine carter avant 125895 Machine head front housing

Bestell-Nr.
No commande
Ordering no.

7153 Federkeil 8x25 Clavette 8x25 Key 8x25
7159 Federkeil 5x5x20 Clavette 5x5x20 Key 5x5x20
7249 Rillenkugellager Roulement à billes Ball bearing
7251 Rillenkugellager Roulement à billes Ball bearing
7272 Rillenkugellager Roulement à billes Ball bearing
7286 Rillenkugellager Roulement à billes Ball bearing
8102 Rillenkugellager Roulement à billes Ball bearing
10404 Gewindestift M4x4 Vis sans tête Set screw
11301 Kugellager Freilauf Roulement à billes libre Free wheeling with ball bearing
11335 Senderkopf Tête de transmetteur Transmitter head
11901 Distanzscheibe Rondelle d'espacement Spacing washer
11903 Lagerbüchse Coussinet Bearing bush
50044 El. Magnetbremse Frainage Brake
50283 Zahnriemen GT Courroie dentée GT Toothed belt GT
50284 Zahnriemen GT Courroie dentée GT Toothed belt GT
50451 Federkeil 4x4x14 Clavette 4x4x14 Key 4x4x14
50452 Lagerbüchse mit Bund Coussinet Bearing bush
50453 Wellenkupplung Dispositif d'accouplement Clutch
50474 Zahnriemen HTD Courroie dentée HTD Toothed belt HTD
50482 Absolutwertgeber mit

105444 Druckfeder Ressort à pression Compression spring
106112 Lichtschrankenkabel Câble pour cellule

106114T01 Kupplung mit Kabel Embrayage avec câble Clutch with cable
106814 Verstellschwinge Levier basculant Adjusting lever
106815 Exzenter Excentrique Eccentric
106817 Dichtteller Disque de joint Seal cover plate
122421 Kupplungswelle links Arbre d'embrayage à gauche Clutch shaft left
122422 Kupplungswelle rechts Arbre d'embrayage à droite Clutch shaft right
122423 Riemenscheibe Z=34 Poulie Z=34 Pulley Z=34
122425 Riemenscheibe Z=38/Z=44 Poulie Z=38/Z=44 Pulley Z=38/Z=44
122427 Riemenscheibe Z=46 Poulie Z=46 Pulley Z=46
122428 Distanzbolzen Bouton d'écartement Distance bolt
122431 Lagerbrille Plaque de palier Bearing plate
124110 Spindel Broche Spindle
124111 Mutter Ecrou Nut
124113 Spindellager Logement du broche Spindle bearing
124115 Hebel Levier Lever
124118 Riemenscheibe Z=21 Poulie Z=21 Pulley Z=21
124119 Riemenscheibe Z=65 Poulie Z=65 Pulley Z=65
124608 Motor für Walzenzustellung Moteur pour approche des

126050 Lager Palier Bearing
126063 Spindelhalterung Broche d'appui Holding device

Teilebezeichnung
Désignation
Part name

Stecker

Codeur en valeur absolue
avec prise mâle

photoélectrique.

cylindres

Rotary encoder with plug

Cable for light barrier

Motor for roller adjustment