Operating Instructions, complete - W. Gantenbein GmbH

Operating Instructions 

BUFALO Rondofix V3.0 

BUFALO RONDOFIX 

� 1 Operatings Instructions Edition 22. November 2007 

Bufalo Rondofix V3.0



Index 

1. Preface.................................................................................................................................................... 6 

1.1. Safety precautions .............................................................................................................................. 7 

2. Description of equipment ........................................................................................................................ 8 

2.1. Pupose ................................................................................................................................................ 8 

2.1.1. General view ................................................................................................................................ 8 

2.1.2. Intended purpose ......................................................................................................................... 9 

2.1.3. Responsabilities........................................................................................................................... 9 

2.2. Technical data................................................................................................................................... 10 

2.2.1. Dimensions ................................................................................................................................10 

2.2.2. Weight........................................................................................................................................ 11 

2.2.3. Electrical data ............................................................................................................................ 11 

2.2.4. Oils, lubricants ........................................................................................................................... 11 

2.2.5. Noise emission........................................................................................................................... 11 

2.2.6. Ambient conditions..................................................................................................................... 11 

2.3. Accessories....................................................................................................................................... 12 

3. Security ................................................................................................................................................. 13 

3.1. Mandatory reading ............................................................................................................................ 13 

3.1.1. Responsibilities .......................................................................................................................... 13 

3.1.2. Safety references....................................................................................................................... 13 

3.1.3.......................................................................................................................................................... 13 

3.1.4. References................................................................................................................................. 14 

3.1.5. Meaning of the symbols ............................................................................................................. 14 

3.2. Personal classification....................................................................................................................... 15 

3.2.1. Operating personnel (instructed in control)................................................................................ 15 

3.2.2. Operating personnel (not instructed in control).......................................................................... 15 

3.2.3. Maintenance personnel.............................................................................................................. 15 

3.2.4. Service personnel ...................................................................................................................... 15 

3.3. Danger zones.................................................................................................................................... 16 

3.3.1. Danger zone 1: Delivery station................................................................................................. 16 

3.3.2. Danger zone 2: Gluing unit ........................................................................................................ 16 

3.3.3. Gefahrenzone 3: Electrics cabinet............................................................................................. 17 

3.3.4. Danger zone 4: Cutting station .................................................................................................. 17 

3.3.5. Danger zone 5: Paper infeed..................................................................................................... 17 

3.4. Positions of the emergency stop switches ........................................................................................ 18 

3.5. General safety rules .......................................................................................................................... 19 

4. Layout and function .............................................................................................................................. 21 

4.1. General layout................................................................................................................................... 21 

4.2. Functional principle ........................................................................................................................... 21 

4.3. Subassemblies.................................................................................................................................. 22 

4.3.1. Infeed station ............................................................................................................................. 22 

4.3.2. Cutting station ............................................................................................................................ 23 

4.3.3. Fixing station.............................................................................................................................. 24 

4.3.4. Gluing station ............................................................................................................................. 25 

4.3.5. Pressing station ......................................................................................................................... 26 

4.3.6. Conveying system...................................................................................................................... 27 

4.3.7. Delivery station .......................................................................................................................... 28 

4.3.8. Paper gripper ............................................................................................................................. 29 

4.3.9. Dust bag..................................................................................................................................... 30 

4.3.10. Controls .................................................................................................................................. 31 

4.3.11. Control unit ............................................................................................................................. 32 





5. Controls and operating modes.............................................................................................................. 33 

5.1. Commissioning the control system ................................................................................................... 33 

5.1.1. Turning-on the main switch........................................................................................................ 33 

5.1.2. Turning-on the main switch ................................................................................................... 34 

5.1.3. Switching-on the drives.............................................................................................................. 34 

5.2. Control unit........................................................................................................................................ 35 

5.3. Operating modes............................................................................................................................... 36 

5.3.1. Manual operation ....................................................................................................................... 36 

5.3.2. Semiautomatic operation ........................................................................................................... 36 

5.3.3. Automatic operation................................................................................................................... 36 

5.4. Emergency stopping ......................................................................................................................... 37 

5.4.1. Linking other equipment............................................................................................................. 37 

6. Commissioning ..................................................................................................................................... 38 

6.1. Introduction........................................................................................................................................ 38 

6.1.1. Personnel, qualification.............................................................................................................. 38 

6.1.2. Technical documentation........................................................................................................... 38 

6.1.3. Technical documentation........................................................................................................... 38 

6.2. Erecting and testing the machine...................................................................................................... 39 

6.2.1. Putting the machine into operation ............................................................................................ 39 

6.2.2. Testing the function.................................................................................................................... 39 

6.2.3. Acceptance certificate................................................................................................................ 39 

7. Operation .............................................................................................................................................. 40 

7.1. Control Panel Description ................................................................................................................. 40 

7.1.1. „Advance Reverse“ button ......................................................................................................... 40 

7.1.2. „Advance Forward“ button ......................................................................................................... 40 

7.1.3. „Fixer Forward“ button“ .............................................................................................................. 40 

7.1.4. „Fixer Reverse“ button ............................................................................................................... 41 

7.1.5. „Raise Press“ Button.................................................................................................................. 41 

7.1.6. „Lower Press“ Button ................................................................................................................. 41 

7.1.7. „Insert Lining or Cover“ Button................................................................................................... 41 

7.1.8. „No Lining or Cover“ Button ....................................................................................................... 41 

7.1.9. „Pusher“ Button.......................................................................................................................... 41 

7.1.10. „Programme Input“ Button...................................................................................................... 41 

7.1.11. „Mode Type Select“ Button .................................................................................................... 41 

7.1.12. „Start“ Button .......................................................................................................................... 42 

7.2. Switching On the Control System ..................................................................................................... 42 

7.3. Operational Mode Selection.............................................................................................................. 43 

7.3.1. Manual Operation ...................................................................................................................... 43 

7.3.2. Semi or Full Automatic Operation.............................................................................................. 44 

7.4. Programme Input .............................................................................................................................. 46 

7.4.1. System Settings ......................................................................................................................... 46 

7.4.2. Operational Parameters for Prod............................................................................................... 48 

7.5. Mechanical adjustments.................................................................................................................... 50 

7.5.1. Adjusting the book and glue thickness of the side gluing rollers ............................................... 50 

7.5.2. Adjusting the press stroke.......................................................................................................... 52 

7.5.3. Paper gripper ............................................................................................................................. 53 

7.5.4. Magnetic pusher ........................................................................................................................ 53 

7.5.5. Fitting the gauzing station.......................................................................................................... 54 

7.5.6. Feed adjustment for gauze or folding station............................................................................. 55 

7.5.7. Changing plates for cold and hot glue ....................................................................................... 56 

7.6. Error Messages and their Correction ................................................................................................ 57 

7.6.1. Control Voltage miss.................................................................................................................. 57 

7.6.2. Set V-min ................................................................................................................................... 57 

7.6.3. Programme Number .................................................................................................................. 58 

7.6.4. Hydraulics and Motors ............................................................................................................... 58 

� 3 Operatings Instructions 

Bufalo Rondofix V3.0 

Edition 22. November 2007



7.6.5. Advance Front............................................................................................................................ 58 

7.6.6. Advance Rear ............................................................................................................................ 59 

7.6.7. Fixer Front.................................................................................................................................. 59 

7.6.8. Fixer Rear .................................................................................................................................. 59 

7.6.9. Press Down................................................................................................................................60 

7.6.10. Safety Shear Cutter................................................................................................................ 60 

7.6.11. Safety Glue Unit & Press........................................................................................................ 60 

7.6.12. Safety Delivery Station ........................................................................................................... 61 

7.6.13. Cover Control ......................................................................................................................... 61 

7.6.14. Cover Missing......................................................................................................................... 61 

7.6.15. Ejection................................................................................................................................... 62 

7.6.16. Delivery Station ...................................................................................................................... 62 

7.6.17. Light curtain............................................................................................................................ 63 

7.6.18. Safety ejection........................................................................................................................ 63 

8. Maintenance ......................................................................................................................................... 65 

8.1. Introduction........................................................................................................................................ 65 

8.2. Oils, lubricants................................................................................................................................... 65 

8.2.1. Oils, lubricants ........................................................................................................................... 65 

8.3. Maintenance schedule ...................................................................................................................... 66 

8.3.1. Cleaning shafts for gluing rollers ............................................................................................... 66 

8.3.2. Lubricating the Cardan shaft...................................................................................................... 67 

9. Servicing ............................................................................................................................................... 68 

9.1. Adjusting cutter clearance................................................................................................................. 68 

9.1.1. Clearance from plate.................................................................................................................. 68 

9.1.2. Clearance from back rest........................................................................................................... 69 

9.2. Cleaning the cooler ........................................................................................................................... 70 

9.3. Adjusting limit switches ..................................................................................................................... 71 

9.3.1. Right-hand limit switch ............................................................................................................... 71 

9.3.2. Left-hand limit switch ................................................................................................................. 72 

9.4. Adjusting the chain tensioner............................................................................................................ 73 

9.5. Limiting the press plate opening ....................................................................................................... 74 

9.6. Plate adjustment ............................................................................................................................... 75 

9.7. Adjusting the feed piston................................................................................................................... 76 

9.8. Ejector speed .................................................................................................................................... 77 

9.9. Brake adjustment .............................................................................................................................. 78 

9.10. Height adjustment of the gluing unit.................................................................................................. 79 

9.11. Interlocking........................................................................................................................................ 80 

10. Decommissioning, storage ................................................................................................................... 81 

10.1. Introduction........................................................................................................................................ 81 

10.1.1. Personnel, qualification .......................................................................................................... 81 

10.1.2. Storage conditions.................................................................................................................. 81 

10.2. Storage lasting more than six months............................................................................................... 81 

10.2.1. Preparations ........................................................................................................................... 81 

10.2.2. Maintenance during storage................................................................................................... 81 

11. Packing and transport........................................................................................................................... 82 

11.1. Preparations...................................................................................................................................... 82 

11.2. Packing.............................................................................................................................................. 82 

11.3. Transport........................................................................................................................................... 83 

11.3.1. Data for transportation............................................................................................................ 83 

11.3.2. Fixing points ........................................................................................................................... 83 

11.3.3. Transport by fork-lift ............................................................................................................... 84 





12. Disposal ................................................................................................................................................ 85 

12.1. Introduction........................................................................................................................................ 85 

12.1.1. Personnel, qualification .......................................................................................................... 85 

12.2. Preparations for disposal .................................................................................................................. 86 





1. Preface 

These operating instructions were issued in September 1998 

Updating status 

Section Title Date 

1 Preface 1 st edition 9/1998 

2 Description of equipment 1 st edition 9/1998 

3 Security 1 st edition 9/1998 

4 Layout and function 1 st edition 9/1998 

5 Controls and operating modes 2 st edition 3/2001 

6 Installation and commissioning 2 st edition 3/2001 

7 Operation 2 st edition 3/2001 

8 Maintenance 1 st edition 9/1998 

9 Servicing 1 st edition 9/1998 

10 Storage 1 st edition 9/1998 

11 Transport and packing 1 st edition 9/1998 

12 Disposal 1 st edition 9/1998 

Copyright © W. Gantenbein Maschinenbau GmbH 

Subject to technical alterations without notification. 

No part of this documentation may be stored electronically, transferred or duplicated in any way 

without the prior approval in writing of W. Gantenbein Maschinenbau GmbH. This applies also to 

photocopying, photographing, and recording on magnetic or other data carriers, though it is not 

restricted to the aforenamed reproduction methods. Non-compliance will entail liability for damages. 





1.1. Safety precautions 

The BUFALO RONDOFIX may be operated, maintained and serviced only by instructed 

personnel possessing the necessary technical qualifications. 

The operator is responsible for all persons involved being appropriately trained.. Further 

details is situated in the chapters 2. 

The firm of W. Gantenbein Maschinenbau GmbH declines all liability for any damage resulting 

from failure to fulfill these conditions. 

Before commissioning the BUFALO-RONDOFIX, Section 3 and the security instructions 

contained in it must have been read and understood. 





2. Description of equipment 

2.1. Pupose 

Brief description: This section defines the intended purpose of the equipment and 

provides an overview of the performance scope, technical data and accessories of the 

BUFALO RONDOFIX. 

2.1.1. General view 

9 

8 

Fig. 1 General view 

1 

2 

1. Infeed station 

2. Cutting station 

3. Fixing station 

4. Control unit 

5. Gluing station 

6. Pressing station (optionally with folding station/gauzing station/cover station) 

7. Delivery station 

8. Circulating containers 

9. Dust bag 



3 

4 

5 

6 

7



2.1.2. Intended purpose 

The BUFALO RONDOFIX is intended for casing-in, i.e. folding or gauzing books 

brochures, blocks and other pressed, stacked or bound materials. 

Indication 

If the machine is used for any other than the purpose defined here without the 

written approval of the maker, or if it is operated outside its technical limits (see 

Technical Data), the maker will accept no liability for any damage or injury resulting 

therefrom. 

2.1.3. Responsabilities 

• Personnel 

It is the operator's responsibility that everyone charged with the operation, 

maintenance or servicing of the BUFALO RONDOFIX has read and understood 

the relevant parts of these operating instructions. 

• Instruction and training 

The BUFALO RONDOFIX may be operated, maintained and serviced only by 

instructed personnel having the necessary technical qualifications. The operator is 

responsible for organizing and holding the necessary instruction courses. 

• Security 

The BUFALO RONDOFIX is equipped with the necessary interlocks and safety 

devices in accordance with international regulations. Nevertheless the machine 

may present dangers if the safety precautions set out in Section 3 are not followed. 

These precautions and the safety-relevant instructions in the individual sections 

must be observed meticulously by the operator and the users. In particular the 

machine operator is responsible for the protection of persons and the prevention of 

material damage. 





2.2. Technical data 

2.2.1. Dimensions 

2020 

730 



5110 

3410 

Fig.2 Dimensions of the BUFALO RONDOFIX 

650 

3000 

Fig. 3 Dimensions of the dust bag 

770



2.2.2. Weight 

Machine ca. 2100 kg 

Dust bag ca. 25 kg (empty) 

2.2.3. Electrical data 

Power supply Total 17 KW, 40 A 

Voltage 3 x 400 V 

Connecting leads L1, L2, L3, N, PE 

Frequency 50 Hz 

Current (fused by customer) 40 A 

Power max. 20 KW 

2.2.4. Oils, lubricants 

Oil BP Bartran SHF-S 46 / Blaser HVLP 46 

2.2.5. Noise emission 

The noise level ranges up to 75 dBA 

2.2.6. Ambient conditions 

Ambient temperature 10 - 40°C 

Air humidity 0 - 90 % 





2.3. Accessories 

>25 kg 

Gauzing or folding station 

Suction feeder 

Accessory parts weighing more than 25 kg or of bulky shape must be fitted 

by two persons. 

The gauzing and folding station accessories and the suction feeder each 

weigh more than 25 kg. 





3. Security 

Brief description: This section explains the safety concept of the BUFALO 

RONDOFIX. It defines the responsibilities of the operator and the security 

directives stated in these instructions. 

3.1. Mandatory reading 

Section 3 must be read by all persons involved in the installation, operation, maintenance and 

servicing of thr BUFALO RONDOFIX. 

3.1.1. Responsibilities 

The operator is responsible that all persons charged with the operation, maintenance 

or servicing of the BUFALO RONDOFIX have read and understood the relevant parts 

of these operating instructions 

The BUFALO RONDOFIX may be operated, maintained and serviced only by 

instructed personnel having the necessary technical qualifications. The operator is 

responsible for organizing and holding the necessary instruction courses. 

The operator is in addition responsible for: 

• keeping unauthorized persons away from the BUFALO RONDOFIX; 

• instructing the personnel about the potential risks and dangers when installing, 

operating, maintaining or servicing the BUFALO RONDOFIX as described in these 

instructions; 

• the strict observance of the technical specifications and safety instructions set out 

in Section 2.2 (Technical Data). 

3.1.2. Safety references 

3.1.3. 

The safety references that follow draw attention to the various danger levels and 

important technical requirements in the individual sections. 

Dangers possibly causing serious injuries or death. 

Dangers likely to cause light to medium injuries, substantial material 

damage or environmental offence. 





3.1.4. References 

References in the form shown below draw attention to technical requirements and tips 

in the individual sections. 

3.1.5. Meaning of the symbols 

Indication 

Instructions on handling or use. Failure to follow them may lead to 

troubles or minor material damage. 

The following symbols are used in the operating instructions and on the machine. 

They mean: 

Warning: dangerous voltage 

Warning: hot surface 

Warning: injury to hands 

Warning: strong noise emission 





3.2. Personal classification 

Depending on its training and authorization the personnel is classified as operational, 

maintenance and servicing. The operating personnel is subdivided into two categories: 

3.2.1. Operating personnel (instructed in control) 

The operating personnel may operate the BUFALO RONDOFIX in the automatic 

mode, which involves the following activities: 

• feeding the machine with unbound materials and removing the bound materials; 

• setting stops; 

• using the control system in the operating mode (switching-on, starting, program 

selection etc.); 

• cleaning 

3.2.2. Operating personnel (not instructed in control) 

The operating personnel may operate the BUFALO RONDOFIX in the automatic 

mode, involving the following activities: 

• feeding the machine with unbound materials and removing the bound materials; 

• cleaning. 

3.2.3. Maintenance personnel 

The maintenance personnel may operate the BUFALO RONDOFIX in the normal 

mode and in addition perform maintenance tasks necessary to ensure trouble-free 

operation. Maintenance includes the following tasks among others: 

• lubricating chains and Cardan shaft 

• checking the oil level. 

• all tasks described in the section on maintenance. 

To be able to maintain the BUFALO RONDOFIX the maintenance personnel must 

have been instructed by a co-worker or an experienced and responsible employee of 

the plant operator. 

3.2.4. Service personnel 

The service personnel may operate the BUFALO RONDOFIX in the normal mode and 

perform maintenance and servicing work. 

• All activities described in the section on servicing. 

The BUFALO RONDOFIX may be serviced only by trained employees of W. Gantenbein 

Maschinenbau GmbH, a representative of this firm or trained employees of the 

plant operator with equivalent proficiency. 

For working on electrical components a training as master electrician or equivalent is 

necessary. 





3.3. Danger zones 

The critical danger zones are shown in the illustration below. 

Fig. 4 Danger zones 

3.3.1. Danger zone 1: Delivery station 

• Danger from moving mechanical parts. 

3.3.2. Danger zone 2: Gluing unit 

5 



4 

Danger from moving mechanical parts. 

Do not reach under the protective hood. 

Danger from glue temperature up to 200°C. 

Do not reach into the gluing unit during operation. 

3 

2 

1



Danger from possible vapours. 

3.3.3. Gefahrenzone 3: Electrics cabinet 

Read and note the safety instructions of the glue supplier. 

Suctioning or other precautions may be necessary to avoid possible 

danger to health. 

Warning: Voltage 

3.3.4. Danger zone 4: Cutting station 

3.3.5. Danger zone 5: Paper infeed 

Turn off the main switch before working on the electrical installation. 

Considerable noise is set up when cutting and roughening the book 

spines. 

Always wear hearing protection while working. 

Warning: Paper gripper moves down. 

Do not reach into the path of the downcoming gripper. 





3.4. Positions of the emergency stop switches 

The positions of the emergency stop switches are shown in the illustration below. 

Fig. 5 Emergency stop switches 

1. Emergency stop switch at infeed station 

2. Emergency stop switch on control unit 

2 



1



3.5. General safety rules 

The following rules must be strictly observed. 

• Use as intended 

See subsection 2.1.2 

• Maker's specifications 

The application specifications include also the observance of the regulations for 

commissioning, maintaining and servicing the BUFALO RONDOFIX. 

• Personnel training 

The BUFALO RONDOFIX may be installed, operated (commissioned), maintained and 

serviced only by trained personnel. These people must have been instructed about the 

dangers associated with the machine. 

• Delimitation of responsibility 

The responsibilities and competences must be established clearly prior to installation, 

operation, maintenance or servicing work, and they must be adhered to under all 

Circumstances. 

• Misuse 

It is absolutely wrong to operate the BUFALO RONDOFIX in such a way that injury to 

persons or material damage may ensue. 

• Inaccessibility for unauthorized or untrained persons 

It is the operator's responsibility that the BUFALO RONDOFIX can be used only by trained 

persons. 

• Impermissible modifications 

Modifications or design alterations detrimental to the security or reliability of the BUFALO 

RONDOFIX are not allowed. W. Gantenbein Maschinenbau GmbH must be contacted 

before attempting any modifications. 

• Registration of modifications 

The operator is under obligation to notify W. Gantenbein Maschinenbau GmbH at once of 

modifications to the BUFALO RONDOFIX, especially if the security or reliability of the 

machine might be affected. 

• Maintenance obligation 

The operator must ensure that the BUFALO RONDOFIX is operated only under admissible 

conditions and in perfect state. 

• Working area 

The operator must ensure that the BUFALO RONDOFIX is freely accessible on all sides for 

all necessary work. 





• Transport and installation 

The BUFALO RONDOFIX may be transported only in its original packing and lifted only by 

the points provided. Installation must be performed exclusively by technically qualified 

personnel. The relevant installation instructions must be followed strictly. 

• Switching-off 

The BUFALO RONDOFIX must be switched off completely for all maintenance and 

servicing work, to ensure that all parts of it are dead whilst working. 

• Removing safety devices 

Safety devices may be removed only when the machine is switched off and its power 

supply cut off. The safety devices must be properly fitted again before restoring the power 

supply. 

• Checks after maintenance or servicing 

After any installation, maintenance or servicing work all safety circuits (e.g. interlocks) must 

be checked to ensure that they function properly. Above all, after electrical installation or 

servicing the safety provisions must be tested (e.g. earthing, insulation resistance etc.). The 

BUFALO RONDOFIX may be put back into operation only after successful checking. 

• Connections to the BUFALO RONDOFIX 

Electrical connecting leads must be protected against all kinds of mechanical damage. The 

leads must affect neither the security nor the reliability of the machine, nor working on it. 

• Organizational measures 

These operating instructions must be kept accessible at all times at a place near to the 


• Specific safety regulations 

Local regulations and specific safety regulations applying to industrial equipment must 

likewise be observed when operating the BUFALO RONDOFIX. 





4. Layout and function 

4.1. General layout 




The BUFALO RONDOFIX consists essentially of two associated subsystems: 

• Production machine 

• Dust bag 

9 

8 

1 

2 

Fig. 6 Overall view 

1. Infeed station 

2. Cutting station 

3. Fixing station 


5. Gluing station 

6. Pressing station (optionally with folding station/gauzing station/cover station) 

7. Delivery station 

8. Circulating container 

9. Dust bag 

4.2. Functional principle 

The unbound book block or unbound brochure is led to the gripping jaws, thereby actuating a 

contact that triggers in the correct sequence all motions needed for the working operation. 

After inserting the first brochure the start key must then be pressed, likewise after the 

economy circuit responds. 



3 

4 

5 

6 

7



6 

4.3. Subassemblies 

4.3.1. Infeed station 

At this station the paper to be bound is placed in the paper gripper. 

59 57 55 53 51 49 47 45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 9 7 

5 

4 

Fig. 7 Infeed station 



3 

1. Start trigger 4. Inclination adjustment 

2. Emergency stop switch 5. Cutting depth adjustment 

3. Infeed table 6. Fixing lever 

6 

5 

4 

Abbildung 8 Cutting depth adjustment 

1 

Infeed table with sensor-controlled start triggering. At this station the cutting depth is 

adjusted from 0 mm to 5.6 mm for stitched book blocks, and the inclination is adjusted 

too. 

2



4.3.2. Cutting station 

At this station the book or brochure spines are routed off to the preadjusted height. 

4 

Fig. 9 Cutting station 

1. Adjusting screw 

2. Cover plate 

3. Grinding wheel 

4. Cutter 

5. Cutter cover 

3 

The spine cutter consists of a hard metal cutter blade with overarm. The fold is cut 

away and then roughened by the grinding wheel and the fibres felted. 



2 

5 

1



4.3.3. Fixing station 

The spine and end piece of the book or brochure to be bound are provided with 

regular, crosswise dovetail cuts in the fixing unit. 

59 57 55 53 51 49 47 45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 9 

Fig 10 Fixing station 

1. Cutter 

2. Height adjustment 

3. Cover plate 

3 

2 



1 

The fixing unit cuts crosswise grooves .8 mm wide into the spine, adjustable in depth 

up to 1 mm, into which the glue penetrates like a thread. This gives a strengthened 

binding. 

7



4.3.4. Gluing station 

The gluing station serves to apply glue onto the spine of the book or brochure. 

12 

11 

1 2 3 4 5 6 7 

Fig. 11 Gluing station 

1. Glue thickness adjustment for gluing roller 1 

2. Gluing roller 1 

3. Glue thickness adjustment for gluing roller 2 

4. Gluing roller 2 

5. Glue wiper adjustment 

6. Height adjustment for gluing unit 

7. Height adjustment for side gluing 

8. Side gluing roller 

9. Gluing wheel 

10. Heating for hot glue (optional) 

11. Lifting device for glue pot 

12. Thermostat for glue pot (for hot glue heating) 

• Cold gluing 

The glue is applied by two rollers for the spine and two side gluing rollers. 

• Hot gluing 

There is a choice between a one-piece and a two-piece glue pot. With two-piece 

glue pots it is possible to use different glues simultaneously for the spine and 

sides. The glue is kept at the right temperature by thermostats. 



8 

9 

10



4.3.5. Pressing station 

The pressing station serves to press the books or brochures being produced 

(pressing-on the covers). 

3 

2 

59 57 55 53 51 49 47 45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 9 

Fig. 12 Pressing station 

1. Front pressing plate 

2. Rear pressing plate 

3. Pressing table 

1 

7 

On the standard BUFALO RONDOFIX the covers are fed in manually and pressed on 

from below and the side by a hydraulic press. Pressing time may be varied between 

0.5 and 5 seconds by the control system. Thanks to the high pressing force of 100 kg, 

covers weighing up to 300 g can be handled without scoring. 

To press on a cover, first the lower pressing plate moves up and presses the cover 

against the spine. Then the front and rear pressing plates move together, pressing the 

cover against the side glue. 





4.3.6. Conveying system 

The conveying system takes the finished books and brochures to the delivery station. 

3 

Fig. 13 Conveying system 

1. Hand wheel 

2. Conveying system 

3. Conveyor belt 

2 

59 57 55 53 51 49 47 45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 9 7 

With the hand wheel the spacing of the conveying system is matched to the book 

width. 

The station has an ejection sensor that stops the machine if there is still a book in the 

paper gripper after passing the ejection. 



1



4.3.7. Delivery station 

The delivery station serves to dry the books or brochures. 

59 57 55 53 51 49 47 45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 9 7 

4 3 

Fig. 14 Delivery station 

1. Heatable delivery (for cold glue only) 

2. Ejector 

3. Valve for heated delivery 

4. Counter (optical sensor)) 

5. Safety hood 

On their way to the heated delivery the books are counted eelctronically. They are 

then positioned for drying standing on their spines. 

Fig. 15 Delivery station 



2 

1 

5 

In Fig. 10 the valve [3] is shown in the 

heating position for cold glue.



4.3.8. Paper gripper 

The circulating paper grippers take up the paper to bring it to the working stations. 

59 57 55 53 51 49 47 45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 9 

1 

4 

Fig. 16 Paper gripper 

1. Gripper spacing adjustment 

2. Support 

3. Scale 

4. Spine length stop 

3 

7 

2 



1



4.3.9. Dust bag 

The dust bag takes up the suctioned paper wastes (shavings, dust etc.) 

3 

2 

1 

Abbildung 17 Suction hose 

1. Stand 

2. Waste bag 

3. Filter bag 

4. Suction hose 



4



4.3.10. Controls 

The controls shown below control and regulate all functions of the machine. 

1 2 3 4 5 6 7 

7 8 9 

ALARM 

SYST 

4 5 6 

SYST 

1 2 3 

Start 

ALARM 

+/– 0 . 



DEL 

ESC +1 MENU 

MOD 

SHIFT -1 ENTER 

Fig. 18 Controls 

1. Advance speed 

2. Main switch 

3. Control voltage switch-on/off 


5. Counter 

6. Emergency stop switch 

7. Thermostat control for hot gluing (optional) 

MAGELiS 

Stop



4.3.11. Control unit 

The control unit accommodates the display, operating and controls for the BUFALO 

RNDOFIX. 

ALARM 

ESC 

SHIFT 

+1 

SYST 

MOD 

-1 



MENU 

ALARM 

ENTER 

DEL 

7 

8 9 

4 5 6 

1 2 3 

+/– 0 . 

5 4 

3 

Fig. 19 Control unit 

1. Display 

2. Control key 

3. Numeric keypad 

4. Function keys 

5. Manual operation keys 

SYST 

1 

Start 

MAGELiS 

2 

Stop



5. Controls and operating modes 




5.1. Commissioning the control system 

1 2 3 4 5 

DEL 

ESC +1 MENU 

MOD 

SHIFT -1 ENTER 

ALARM 

SYST 

SYST 

ALARM 

MAGELiS 

7 8 9 

4 5 6 

1 2 3 

Start 

+/– 0 . 

Fig. 20 Control console 

1. Main switch 

2. Control voltage switch-on/off 


4. Counter 

5. Emergency stop switch 

The machine has a lockable main switch. 

Stop 

The main switch can be secured in the OFF position for servicing purposes, using up 

to 3 padlocks. 

5.1.1. Turning-on the main switch 

To put the machine into operation the main switch must be turned on. If it is secured 

with more than one padlock, these must be removed by the people who attached 

them. 

The main switch is turned on by turning it clockwise. 





5.1.2. Turning-on the main switch 

After turning on the main switch the control voltage can be switched on by pressing 

the green button [2], though this is possible only if no emergency stop switch has been 

operated and the covering over the cutter is closed. Emergency stop switches once 

pressed are released by turning them. 

The green button [2] lights when the control voltage is switched on. 

5.1.3. Switching-on the drives 

Upon switching-on the control voltage the motors driving the various subunits are put 

into operation automatically. 

These drives are switched off automatically after running more than 5 minutes without 

load. 

The drives are switched on again automatically by operating a button or switch for 

manual or automatic operation on the control unit [3]. 





5.2. Control unit 

ALARM 

ESC 

SHIFT 

+1 

SYST 

MOD 

-1 

MENU 

ALARM 

ENTER 



DEL 

7 

8 9 

4 5 6 

1 2 3 

+/– 0 . 

5 4 

3 

SYST 

Fig. 21 Control unit 

1. Display 

2. Control keys 

3. Numeric keys 

4. Function keys 

5. Manual operation keys 

1 

Start 

MAGELiS 

For a full description of the functions see subsection 7.1: Control Unit. 

2 

Stop



5.3. Operating modes 

5.3.1. Manual operation 

In manual operation all subassemblies of the BUFALO RONDOFIX can be operated 

singly with the function keys [4] and manual operation keys[5] (for full details see 

Section 7). 

5.3.2. Semiautomatic operation 

In semiautomatic operation each movement of the machine must be triggered by 

pressing the starting key. In this way the machine cycle can be run through stepwise 

(for more details see Section 7). 

5.3.3. Automatic operation 

In automatic operation only the first cycle must be started by pressing the starting key 

after inserting the book. The next cycle is started automatically by inserting the second 

book. Readiness is signalled by the diode lighting in the starting key (for fully 

description see Section 7). 





5.4. Emergency stopping 

Indication 

The emergency stop switch is effective in every operating mode. It serves to 

shut down the machine in dangerous situations. Every an emergency stop all 

subunits are without power. 

Operating the emergency stop switch cuts out the control voltage. This must be 

restored again after releasing the emergency stop switch by pressing the ON key. 

Opening the safety covers over the fixing station will also trigger an emergency stop. 

After closing the covers the control voltage must be switched on again. 

5.4.1. Linking other equipment 

If the EMERGENCY STOP circuit of other equipment is to be linked with the safety 

circuit of the BUFALO RONDOFIX, terminals have been provided for this. The 

connections are shown in the electrical diagram. 

The control system of the BUFALO RONDOFIX gives a pulse signal to other 

equipment. 





6. Commissioning 

6.1. Introduction 

Brief description: This section provides information for successfully installing and 

commissioning. It deals with the erection, assembly and the first commissioning of the 


It is the operator's responsibility that everyone involved in the installation of the BUFALO 

RONDOFIX has read and understood these operating instructions. 

The following personnel and technical qualifications are required for erecting, assembling and 

commissioning the machine. 

6.1.1. Personnel, qualification 

The work described in this section may be carried out only by authorized skilled 

personnel who have had appropriate technical training and can draw upon the 

necessary experience, or who have been suitably instructed by the operator. 

6.1.2. Technical documentation 

This equipment may pose dangers if the safety rules are not 

followed. See Section 3: Security. 

The following technical documentation is needed for erecting, assembling and 

commissioning the machine: 

• electrical diagram 

This may be found in your technical documentation. 

6.1.3. Technical documentation 

The following technical documentation is needed for erecting, assembling and 

commissioning the machine: 

• electrical diagram 

This may be found in your technical documentation. 





6.2. Erecting and testing the machine 

Check the following points before commissioning: 

• Is the power cable intact and properly connected? 

Indication 

Check the rotation of the motors. The gluing rollers may be used for this. If 

they will not turn, the motor rotation needs reversing. 

• Has the power cable been laid covered and secured? 

• Are there no foreign materials on or at the machine'? 

• Check whether the paper grippers run properly and unobstructed. 

• Check whether the infeed station functions faultlessly and unobstructed. 

• Check whether the cutting station functions faultlessly and unobstructed. 

• Check whether the fixing station functions faultlessly and unobstructed. 

• Check whether the gluing station and gluing rollers function faultlessly and unobstructed. 

• Check whether the pressing station functions faultlessly and unobstructed. 

• Check whether the delivery station functions faultlessly and unobstructed. 

• If one of the stations malfunctions, see Section 7.6 Trouble Shooting and rectify the fault as 

instructed therein. 

6.2.1. Putting the machine into operation 

To commission the machine proceed as follows: 

• Schalten Sie den Hauptschalter ein. 

• Check the emergency stop switches and release them if necessary (see 

subsection 3.4). 

• Switch the machine on (see Section 5). 

• Switch the machine over to manual operation (see Section 7). 

• Test the door interlock circuit of the cutter/fixer and gluing station/press by opening 

the doors singly and closing them again. When any of these doors is opened the 

control must cut out and a fault must be signalled. 

6.2.2. Testing the function 

Check all functions according to Section 5 before considering the commissioning 

completed and handing the machine over for normal operation. 

6.2.3. Acceptance certificate 

The acceptance certificate must be copied. Do not write on the original. See appendix. 





7. Operation 

Brief description: This section shows by means of example how the BUFALO 

RONDOFIX is operated. All routine steps for production are described in detail.. 

7.1. Control Panel Description 

Fig. 22 Control Panel 

ALARM 

ESC 

SHIFT 

+1 

SYST 

MOD 

7.1.1. „Advance Reverse“ button 

Button for manual operation. 

-1 



SYST 

MENU 

ALARM 

ENTER 

DEL 

7 

8 9 

4 5 6 

1 2 3 

+/– 0 . 

Start 

MAGELiS 

Pressing this key makes the press stroke up as long as the key is pressed. If the cover 

is open it will function only if the dual-palm buttons on the press are pressed 

simultaneously. 

7.1.2. „Advance Forward“ button 


Press this button and keep it depressed to run the advance forwards. The 

speed selector must be set to minimum, otherwise an error message will 

appear. 

7.1.3. „Fixer Forward“ button“ 


Press this button and keep it depressed to run the fixer forwards. 

Stop



7.1.4. „Fixer Reverse“ button 

Button for manual operation 


Press this button and keep it depressed to run the fixer in reverse. 

7.1.5. „Raise Press“ Button 


Press this button and keep it depressed to raise the press. If the glue unit safety cover 

is open, this button only functions if the "two-hand button" under this safety cover is 

pressed simultaneously. 

7.1.6. „Lower Press“ Button 


Press this button and keep it depressed to lower the press. 

7.1.7. „Insert Lining or Cover“ Button 

Button for all operational modes. 

Press this button to start the lining advance, or to insert a cover. 

7.1.8. „No Lining or Cover“ Button 

Button for semi and fully automatic operational modes. 

Press this button to stop the next lining advance, or to stop the insert of another cover. 

This function is automatically reset. 

When the function is active, the built-in diode in the button lights 

7.1.9. „Pusher“ Button 

Button for all operational modes. 

Press this button to actuate the pusher for a cycle. In semi and fully automatic 

operational modes, this button only functions when the machine is not operating. 

7.1.10. „Programme Input“ Button 

Press this button to enter programme input mode. This command is only 

accepted while the machine is not in operation. During programming the machine 

cannot be operated, neither in manual nor in an automatic mode. 

7.1.11. „Mode Type Select“ Button 

Press this button to select the operational mode type, between manual, 

semi and fully automatic operational modes. 

In manual operation mode, the milling cutter, fixer and glue unit can be switched on 

and off. 

In semi and fully automatic operational modes, only the desired programme number 

can be entered. 





7.1.12. „Start“ Button 

Button for all operational modes 

In semi and fully automatic operational modes, pressing this button starts the 

automatic cycle, or the semi-automatic cycle will be advanced one step. 

7.2. Switching On the Control System 

To put the machine into operation, first switch on the main switch on the control panel. 

Then actuate the control system by pressing the green luminous button. The control system is 

only active provided no emergency cut-off button has been pressed, and the milling cutter 

safety cover is closed. The emergency cut-off button can be disengaged by rotating it. 

The green luminous button lights when the control system is active. 

In cases of danger one of the emergency cut-off buttons must be pressed. After the 

malfunction has been eliminated, the pressed emergency cut-off button must be disengaged, 

and the open milling cutter cover closed, to allow the control system to be reactivated by 

pressing the green luminous button. 

When the main switch is engaged and the control system is not actuated, the blinking error 

message "No control voltage" appears on the control panel. This error message does not 

require any action at this point: it disappears automatically when the control system is 

actuated. 

Indication 

The first machine cycle must be made at minimum speed for operational 

reasons. Therefore, set the speed selector to minimum until the machine has 

completed its first cycle. If this is forgotten, the machine will not carry out any 

forward advance, but instead the message "Set V-min" will be displayed. This 

error message does not require any action at this point: it disappears 

automatically when the start button, or the button which releases the forward 

advance, is released. 

If a forward advance is not completed while in manual operation, the speed 

selector must be reset to minimum again. 

Indication 

After switching-on the control voltage the motors driving the various units are 

automatically started in staggered sequence. 

These drives are switched off automatically after running without load more 

than 5 minutes. 

The drives are switched on again automatically by operating a key or switch 

for manual or automatic operation. 





7.3. Operational Mode Selection 

After the main switch is engaged, the control system returns to the same operational mode in 

which it was before it was switched off. 

To change the operational mode, press the "Operational Mode Select" button. The 

following is displayed: 

Manual Semi Auto 

← ↓ → 

Select the desired operational mode by pressing the corresponding arrow key. 

7.3.1. Manual Operation 

After manual operational mode is selected (see above), the following is displayed: 

Milling Cutter ON 0 

The cutter can now be actuated by pressing the "MOD" button and then inputting 0 or 

1 (on or off). The input must be concluded by pressing "Enter", to advance the 

programme and the following is displayed: 

Fixer ON 0 

The fixer can now be switched on or off like the milling cutter. 

The display then displays the following: 

Glue heater 

Off ← On ↓ Auto → 

The glue heater can now be switched off in manual operational mode (cold gluing) or 

left on continuously, or switched on and off according to the timer programme. 

At the same time, the programme advances and displays: 

Tip Glue Unit 

The glue unit can be held in the desired position by pressing the manual button. If the 

manual button is held for more than 1 sec, the glue unit remains in position after the 

manual button is released. Pressing the manual button again restarts the glue unit 

Indication 

To stop the glue unit completely, use an emergency cut-off button. 

To exit this mode, press the "Enter" button. The following is now displayed: 





Manual Operation 

In manual operation, all machine movements can be carried out individually and 

independently by pressing the corresponding buttons on the terminal. 

I no action is made for 5 minutes, the motors switch off automatically, and the machine 

goes into "Sleep mode". The following is displayed: 

Date XXXX 

Time XX.XX 

Before an action can be started, one of the function buttons must be pressed. This 

ends the "Sleep mode", and the motors restart automatically. 

7.3.2. Semi or Full Automatic Operation 

After selection of Semi of Full Automatic Operation (see above), the following is 

displayed: 

Progr. Number XXXX 

To enter the desired programme number, press the "MOD" button, type in the desired 

programme number, and confirm with "Enter". This loads the relative programme from 

the memory into the work register. Programme numbers must be numbers between 1 

and 20. An input of a programme outside this range will result in an error message, 

which must be exited by pressing "Enter", and the procedure repeated. 

The final step is to exit the "Select Operational Mode" function. 

In semi or full automatic operational mode, the glue heating unit will be switched on 

and off automatically in accordance with the "Glue: hot/cold" programme. If hot glue 

has been programmed, the heating turns on automatically. In this case, the glue heatup 

time must be waited before the machine is ready for operation. The following is 

displayed: 

Heat-Up XXXX 

The figure displayed refers to the remaining time left till the start of the glue unit. 

The heat-up time can be stopped immediately by pressing the "Enter" button within 10 

seconds. 

The display then shows the following: 

or 

Semi-Auto 

Automatik 

In semi automatic operational mode, every action of the machine must be released by 

pressing the start button. In this way, the machine cycle can be run through step by 

step. 

In automatic operational mode, only the first cycle needs to be started by pressing the 

start button after inserting a book. The next cycle will start automatically when the next 

book is in position. The readiness of the book is signalled by the diode integrated in 

the start button lighting up. 





If no second book is put in the ready position for more than 5 minutes, the diode goes 

out, the motors switch off automatically, and the machine goes into "Sleep mode". The 

following is displayed: 

Date XX.XX 

Time XX.XX 

The next start must be released by pressing the start button twice, to switch off the 

"Sleep mode". After the first press, the motors start automatically, and after the 

second the motors are brought up to working speed, and the cycle starts. 

Extension of heating time: The heating system, controlled by the clock, operate only 

in the semi- or automatic function. 

The heating time ends in semi- or automatic function at 

expiration of the programmed heating time and expiration 

of the follow up timer. The follow up timer is set for 30 

minutes. 

As long as one works on the machine, the follow up timer 

is always put back. The heater with as switched off after 

the programmed end of the heating time only 30 minutes 

after the last manipulation of the machine. 





7.4. Programme Input 

Programme input mode is entered by pressing the "Programme Input" button. In this 

mode, system configurations such as day of the week, time, start and stop times for 

glue unit heating, etc., as well as operational parameters for each product, can be 

entered. 

Programme input follows the following sequence: 

Program Number: Inp. Range 0 - 20 

Year: Inp. Range 1900 - 2099 

Month: Inp. Range 1 - 12 

Time: Inp. Range 00.00 - 23.59 

h 

Day of the Week: Inp. Range 1 - 7 (Mon =1) 

Glue Heat. ON: Inp. Range 00.00 - 

23.59 h 

Glue Heat. OFF: Inp. Range 00.00 - 23.59 

h 

Saturday: Inp. Range 0 or 1 

Sunday: Inp. Range 0 or 1 

Glue Cold/Hot: Inp. Range 0 or 1 

Milling Cut. ON/OFF: Inp. Range 0 or 1 

Fixer ON/Off: Inp. Range 0 or 1 

Without/Lining/ 

Cover: Inp. Range 0 - 2 

Start Delay: Inp. Range 0.0 - 999.9 s 

Press Delay: Inp. Range 0.0 - 999.9 s 

Press Duration: Inp. Range 0.0 - 999.9 s 

Pusher Delay: Inp. Range 0.0 - 999.9 s 

Pusher Duration: Inp. Range 0.0 - 999.9 s 

To change the displayed value press the "MOD" 

button. Then enter the new value with the 

numerical keyboard, and confirm with the "Enter" 

key. 

If the displayed value does not need to be 

changed, press the "Enter" key only. 

If the above input range limits are not maintained, in particular for data and time inputs, 

incorrect values can be stored. If you are unsure whether the input values are correct, repeat 

the input procedure. 

If a programme number outside the given range is entered, an error message will be given. 

This can be exited by pressing "Enter", and then the programme input can be restarted. 

7.4.1. System Settings 

When the following display appears, enter 0 (zero): 

Progr.Number X 

Press first the "MOD" key, Then enter 0 (zero). Confirm by pressing "Enter". 





The display now changes to the following: 

Set Date 

Year XXXX 

Press the "MOD" key, then enter the current year. Confirm the input by pressing 

"Enter". The display now changes to the following: 

Set Date 

Day/Month XX.XX 

Enter the current date in the same way. Attention! Separate the day and month with a 

point (.).The display now changes to the following: 

Set Time 

Hour/Minute XX.XX 

Enter the current time in the same way. Attention! Separate the hour and minutes with 

a point (.). The display now changes to the following: 

Week Day X 

1=Monday, 7=Sunday 

Enter the numeral which corresponds to the current day of the week. The control 

system is now able to interpret the following inputs for Saturday and Sunday correctly. 

After confirming the input, the display now changes to the following: 

Glue Heather ON 

Stunde/Minute XX.XX 

Geben Sie nun, wie oben beschrieben, die gewünschte Startzeit für die Leimheizung 

ein. Achtung! Die Stunde und die Minute sind durch einen (.) Punkt zu trennen. Das 

Display wechselt nun zu folgender Anzeige: 

Glue Heather OFF 

Hour/Minute XX.XX 

Enter the desired stop time for glue heating in the same way. Attention! Separate the 

hour and minutes with a point (.). The display now changes to the following: 

Saturday X 

Is Saturday a workday? If yes, then enter 1 (one) here, otherwise enter 0 (zero) and 

confirm with "Enter". This allows you to control whether the glue heating should 

automatically start on Saturday or not. The display now changes to the following: 

Sunday X 

Is Sunday a workday? If yes, then enter 1 (one) here, otherwise enter 0 (zero) and 

confirm with "Enter". This allows you to control whether the glue heating should 

automatically start on Sunday or not. The system set up is now complete, and the 

display shows the current operational mode. 





7.4.2. Operational Parameters for Prod. 

Enter a number from 1 to 20 in the following display field. This allows frequently used 

operational parameter sets for specific products to be stored for repeated application. 

Progr. Number X 

First press the "MOD" key. The desired figure can now be entered. Confirm with 

"Enter". The display changes to the following: 

Glue: Cold/Hot X 

Following the procedure as described above, enter 0 (zero) for cold glue or 1 (one) for 

hot glue, and confirm the input with "Enter". The display changes to the following: 

Milling Cutter ON X 

If you wish to work on the product with the milling cutter, enter a 1 here, otherwise 

enter a 0. The display changes to the following: 

Fixer ON X 

If you wish to work on the product with the fixer, enter a 1 here, otherwise enter a 0. 

The display changes to the following: 

0=without, 1=Cover 

2=Lining X 

If you wish to work on the product without lining or cover, enter a 0, for cover a 1, and 

for lining (gauze) a 2. This command instructs the lining advancer, the cover unit and 

press correspondingly, and actuates or switches off the cover monitor as required. 

The display changes to the following: 

Start Retardation 

sec XXXX 

Here you can stipulate how long the machine should wait, after the book is positioned 

at the infeed, till the start. The input can be in steps of tenths of a second. To do this, 

type in a decimal point. Example: an input of 15.3 corresponds to 15.3 sec delay 

before start. The display changes to the following: 

Press Raise Retardation 

sec XXXX 

Here you can stipulate how long the press is delayed till the start. For a large cover or 

lining, a relatively long delay time must be entered. The input can be in steps of tenths 

of a second. To do this, type in a decimal point. Example: an input of 15.3 

corresponds to 15.3 sec delay before start. The display changes to the following: 

Press Duration 

sec XXXX 

Here, the minimum necessary press time for the product needs to be programmed. 

The input can be in steps of tenths of a second. To do this, type in a decimal point. 

Example: an input of 15.3 corresponds to 15.3 sec delay before start. The display 

changes to the following: 





Pusher Retardation 

sec XXXX 

The pusher must be actuated earlier or later to match the advance speed. The entered 

time must be long enough so that the book is entirely under the book delivery station 

before the pusher engages. The input can be in steps of tenths of a second. To do 

this, type in a decimal point. Example: an input of 15.3 corresponds to 15.3 sec delay 

before start. The display changes to the following: 

Pusher Duration 

sec XXXX 

In this case the time that needs to be entered depends on the width of the back of the 

book and set speed of the pusher. The pusher path length should be a little longer 

than the width of the back of the book. 

The parameter input is now complete, and the current operational mode is displayed. 

We recommend to make a note of all the settings and the corresponding programme 

numbers that you have allocated for each product. This allows you to change the 

machine settings rapidly for a new product. 

To check the settings, the whole procedure can be repeated, and changes made or 

the present values confirmed by pressing "Enter". 

Indication 

The work register is automatically updated if the same programme is 

used as that which is already loaded into the work register by selecting 

the operational mode. 





7.5. Mechanical adjustments 

For producing different product formats there are mechanical adjustments to be made in 

addition to the parameter entry. 

7.5.1. Adjusting the book and glue thickness of the side gluing rollers 

4 

Fig. 23 Adjusting the book thickness 

1. Allen screw 

2. Setting ring for side gluing flow control 

3. Glue wiper 

4. Allen screw 

Adjusting the book thickness: 

1. Remove the protection covering the shaft, on which the setting ring [2] rests. 

2. The adjustment is performed in manual operation. 

3. Turn the gluing disk into a position that allows the Allen screw to be unfastened. 

Tilt the gluing unit 

By pressing the manual key the gluing unit can stopped in the desired position. If the 

key is pressed longer than 1 second, the gluing unit remains stationary even after 

releasing the start key. The gluing unit is started again by pressing the start key once 

more. 

4. Unfasten the Allen screws [1] and [4] and push the gluing disk into the desired 

position with the wiper 



1 

2 

3



5. Tighten the Allen screws again. 

Indication 

To stop the gluing unit for sure an emergency stop switch must be 

operated finally. 

Adjusting the glue thickness 

1. Turning the setting ring [2] clockwise increases the gap between the gluing wheel 

and the wiper. More glue is applied. 

2. Turning the setting ring [2] counterclockwise narrows the gap between gluing 

wheel and wiper. Less glue is applied. 





7.5.2. Adjusting the press stroke 

Fig. 24 Adjusting the stroke 

If the press action is too strong or insufficient, it is possible to alter the stroke. This 

may be necessary to accommodate widely differing cover thicknesses for example. 

Adjusting the press stroke is done in the following steps: 

1. Open the door below the pressing station. 

2. Unfasten the knurled nut [3]. 

3. Turn the screw [2] clockwise to shorten the stroke (weaker pressing) or 

counterclockwise to lengthen the stroke (stronger pressing). 

Indication 

Do not turn the screw in or out more than 1/8th of a turn when adjusting. 





7.5.3. Paper gripper 

The circulating paper grippers serve to take up the paper and bring it to the working 

stations. 

59 57 55 53 51 49 47 45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 9 

1 

Fig. 25 Paper gripper 

1. Gripper spacing adjustment 

2. Support 

3. Scale 

4. Spine length stop 

7.5.4. Magnetic pusher 

4 

3 



7 

2 

The stop and the glue wiper switch must be set to the spine length of the infed paper 

(the adjustments must be the same. 

Fig. 26 Magnetic pusher 

Magnetic pusher 

1



7.5.5. Fitting the gauzing station 

1. Withdraw supporting rods [1] 

2. Fit shears 

3. Push in supporting rods [1] 

4. Attach unrolling device 

5. Connect control cable 

2 

3 

1 

Fig. 27 Right-hand supporting rod 

1 

Fig. 28 Left-hand supporting rod 

Indication 

Make sure that the supporting rods are withdrawn when fitting the gauzing 

station. 





7.5.6. Feed adjustment for gauze or folding station 

(Only if this optional equipment is provided) 

1. Unfasten the fixing screw with the Allen wrench included in the tool set provided 

(see picture of fixing screw. 

Fig. 29 Fixing screw 

2. Insert the Allen wrench through the slot in the casing into the adjusting screw. 

Adjust the feed to the desired amount. 

3. Tighten the adjusting screw. 

Fig. 30 Adjusting screw 





7.5.7. Changing plates for cold and hot glue 

1 2 3 4 

Fig. 31 Plate changing 

1. The rear plate has phases for hot glue [1] and cold glue [2]. It is screwed and 

pinned and must be unscrewed and turned when changing glues. 

2. The front plate [4] has a ledge [3] which must be changed also when changing 

glue. 





7.6. Error Messages and their Correction 

Error messages are displayed with blinking text. The standard procedure is first to correct 

errors, then reset by pressing "Enter". Exceptions to this rule are described in detail in the 

following. 

7.6.1. Control Voltage miss 

The following is displayed: 

Control Voltage miss 

Possible causes: 

• The control system was actuated by switching on the main switch. 

• An emergency cut-off button has been pushed. 

• The milling cutter cover is open. 

Correction: 

• Connect the control system power by pressing the green luminous button. Before 

doing this, make sure that any emergency buttons which were pressed are 

unlocked, and that the cover is closed. 

Exit: 

• No exit required. 

7.6.2. Set V-min 


Causes: 

Set V-min 

• The control system has not been initialised yet, and the control valve for advance 

speed is not at minimum. 

• An emergency cut-off has been pressed. 

• The advance feed in manual operation only operates when the control valve for 

advance speed is at minimum. 

Correction: 

• Turn the control valve to the advance speed required. Turn the control valve to the 

advance speed required. 

Exit: 

• No exit required. 





7.6.3. Programme Number 


Causes: 

Program/-Number 

• A programme number outside the limits has been entered. The highest programme 

number is 20. Refer to Programme Input. 

Correction: 

• This error message must first be exited by pressing the "Enter" key on the terminal, 

and the correct programme number entered. 

7.6.4. Hydraulics and Motors 


Causes: 

Hydraulic & Motors 

• The hydraulic oil is too hot, or the drive motor for the hydraulic pump is overloaded. 

• A motor or overload protection of the other drives or glue heater has switched off. 

Correction: 

• Switch on the non-active monitoring or drive component. 

Exit: 

• Press the "Enter" key on the terminal. 

7.6.5. Advance Front 


Causes: 

Advance Front 

• The feed advance cylinder has not reached the front limit switch (right) in 

automatic mode. The timeout has expired. Possibly the end limit switch is set 

incorrectly or is defect. 

Correction: 

• This error message must first be exited by pressing the "Enter" key on the terminal. 

Then switch the machine to manual operational mode. Advance the cylinder 

forwards. Correct or exchange end limit switch. 





7.6.6. Advance Rear 


Causes: 

Advance Rear 

• The feed advance cylinder has not reached the rear limit switch (left) in automatic 

mode. The timeout has expired. Possibly the end limit switch is set incorrectly or is 

defect. 

Correction: 


Then switch the machine to manual operational mode. Move the cylinder back. 

Correct or exchange end limit switch. 

7.6.7. Fixer Front 


Causes: 

Fixer Front 

• The drive cylinder has not reached the front limit switch (operator side) in 

automatic mode. The timeout has expired. Possibly the end limit switch is set 

incorrectly or is defect. 

Correction: 


Then switch the machine to manual operational mode. Advance the cylinder 

forwards. Correct or exchange end limit switch. 

7.6.8. Fixer Rear 


Causes: 

Fixer Rear 

• The drive cylinder has not reached the rear limit switch (rear side) in automatic 

mode. The timeout has expired. Possibly the end limit switch is set incorrectly or is 

defect. 

Correction: 


Then switch the machine to manual operational mode. Move the cylinder to the 

rear. Correct or exchange end limit switch. 

Exit: 






7.6.9. Press Down 


Causes: 

Press Down 

• The press has not reached the lower limit switch or has not left the lower limit 

switch in automatic mode. The timeout has expired. Possibly the end limit switch is 

set incorrectly or is defect. 

Correction: 


Then switch the machine to manual operational mode. Drive the press down. 

Correct or exchange end limit switch. 

7.6.10. Safety Shear Cutter 


Causes: 

Safety Shear Cutter 

• An attempt was made to raise the press when the forward advance had not been 

completed. Alternatively, the end limit switch S100.42 is possibly defect. 

Correction: 


Then advance the forward feed to the end. The press can now be raised. 

7.6.11. Safety Glue Unit & Press 


Causes: 

Safety Glue Unit & Press 

• The cover over the glue unit and the press was opened while in automatic 

operational mode. 

Correction: 


Then the resetting or cleaning work can be carried out on the glue unit or press. 





Indication 

»When the covering is opened the press can be raised only in the 

manual mode, by simultaneously pressing the button on the terminal and 

the one under the covering (dual-palm control). 

• The covering must be closed again after completing the work. 

7.6.12. Safety Delivery Station 


Causes: 

Safety Delivery Station 

• The cover over the delivery station was opened. 

Correction: 

• Close cover. 

Exit: 


7.6.13. Cover Control 


Causes: 

Cover Control 

• A lining or cover was detected in the machine before the start of a new cycle while 

in automatic mode. 

Correction: 

• Remove lining or cover. While there is no lining or cover in machine, clean the 

optics of the lining and cover control. Readjust the switching unit as required. 

Exit: 


7.6.14. Cover Missing 


Causes: 

Cover Missing 

• The machine in automatic mode is waiting for a lining or cover. 

Correction: 

• Check cover infeed or lining unit, and switch on cover infeed or lining unit. 





Exit: 


7.6.15. Ejection 


Causes: 

Ejection 

• A book in the delivery station has not been ejected, or the optics of the ejector 

control unit are not set correctly. 

Correction: 

• Remove book or readjust optics. 

Exit: 


7.6.16. Delivery Station 


Causes: 

Delivery Station 

• The last ejected book did not pass the control and counter sensor between the 

book ejector and delivery station. 

• The counter sensor is defect. 

Correction: 

• The book that was perhaps removed by hand should be replaced on the conveyor 

before the counter sensor. 

• Readjust the counter sensor or exchange. 

Exit: 


Indication 

If troubles occur frequently there may a serious defect. In such cases our 

service representative should be informed. 





7.6.17. Light curtain 

The display shows: 

• Cause: 

Light grating 

• The light grating has been interrupted during the feed advance, stopping the feed 

at once and causing the above fault message. 

Remedy: 

Indication 

Place material in the book inset only if the green lamp above the book 

inset is lit. In manual operation do not reach into the book inset zone 

during the feed movement. Do not place material in this zone. 

• Take hands or material out of the light grating range. 

• Acknowledgement: 

• Press «Enter»-key on terminal, then throttle feed speed to the minimum and start 

procedure anew. 

7.6.18. Safety ejection 

The display shows: 

Cause: 

Safety ejection 

• The cover over the ejection has been opened. 

Remedy: 

• Close the cover again. 

Indication 

No acknowledgement is necessary, but in manual operation the feed 

speed must be throttled down to minimum before ending the feed 

movement, otherwise the fault "Adjust minimum feed" will be displayed 

and the feed will not function. 





Frequently occurring errors could indicate a serious fault. In this case, please contact 

the servicing department of the company. 

W. Gantenbein Maschinenbau GmbH 

Im Riet 7 

CH-8308 Illnau 

Tel. +41 52-343 21 21 

Fax +41 52-343 21 24 

Mail info@bufalo.ch 





8. Maintenance 

Brief description: this section gives a maintenance schedule describing the 

maintenance tasks to be performed on the BUFALO RONDOFIX.. 


• The maintenance tasks should be performed only by qualified personnel in accordance 

with the maintenance schedule. This schedule distinguishes between work to be carried 

out by a machine operator (B), by a service mechanic (S) or by a technician from W. 

Gantenbein Maschinenbau GmbH (T). 

• Safety instructions in Section 3 are to be strictly observed. Additional safety directives are 

in Section 8 before the individual working steps, and these too must be followed without 

fail. 

• All maintenance tasks must be carried out as they fall due according to the maintenance 

schedule and in the sequence prescribed, observing the safety instructions. Operating 

troubles must be expected if this neglected. 

8.2. Oils, lubricants 

8.2.1. Oils, lubricants 

The following oils and lubricants are needed for giving maintenance: 

• Oil for the hydraulics is supplied in the tank. 

Oil grade: BP Bartran SHF-S 46 or Blaser HVLP 46 

• Axle grease for the gluing rollers: Blasolube 304 high-temperature grease. 





8.3. Maintenance schedule 

N 

o. 

B = operator d = daily 

S = service mechanic m = monthly 

T = technician 

W. Gantenbein 

h = half-yearly 

y = yearly 

c = customerspecific 

Task to be performed d m h y c Remarks 

1 Plate adjustment B/S See Section 9 

2 Brake check B/S See Section 9 

3 Cardan shaft lubrication B/S 

4 Lubricate chains B/S 

5 Clean away glue and paper B 

6 Check dust bag B 

7 Tension the gluing station chain S 

8 Check hydraulic oil B/S 

9 Check vacuum pump S See separate instructions 

10 Replace PLC buffer battery S See separate instructions 

11 Check functions of safety devices S 

8.3.1. Cleaning shafts for gluing rollers 

WARNUNG WARNUNG WARNUNG 

Depending on the hot glue used the temperature will range up to 

200°C. Contact with the glue may cause burns. 

Wear gloves or leave the equipment long enough to cool down. 

Every time the rollers are changed or the gluing station is cleaned, make sure that the 

gluing roller support is greased with Blasolube 304 high-temperature grease after 

cleaning. 





8.3.2. Lubricating the Cardan shaft 

The Cardan shaft is mounted underneath the casing of the pressing station. Its joints 

should be lubricated monthly at least. 





9. Servicing 

Brief description: this section describes the necessary procedure for servicing the 


9.1. Adjusting cutter clearance 

9.1.1. Clearance from plate 

Fig. 32 Clearance from plate 

The plate clearance is adjusted in the following steps: 

1. Dismantle grinding wheel 

2. Remove Seeger circlip 

3. Remove bottom washer 

4. Correct the position of the cutter with the three Allen screws now accessible. 

Clearance from the plate should be 0.2 mm. The gap should be checked with a 

feeler gauge or paper 0.2 mm thick. 





9.1.2. Clearance from back rest 

Fig. 33 Clearance from back rest 

The clearance from the back rest is adjusted in the following steps: 

1. Unscrew the cover 

2. Slacken the screws of the back rest a little 

3. Put on the cover. 

4. Adjust clearance with 0.2 mm feeler gauge or equivalent piece of paper 

5. Remove cover and screw back rest secure 

6. Put on cover and screw secure 





9.2. Cleaning the cooler 

Fig. 34 Cooler 

The cooler should be cleaned periodically with compressed air, or with a brush if this is not 

available. 





9.3. Adjusting limit switches 

9.3.1. Right-hand limit switch 

Fig. 35 Right limit switch (rear) 

If the stop at the end position of the sensor is not detected (LED does not light), the 

sensor position must be corrected. 

1. Unfasten the sensor a little and shift it 1 to 2 mm towards the middle of the 

machine till the LED lights. 

2. Tighten the sensor secure. 

3. The distance from sensor [1] to counterpiece [2] should be 1-2 mm, maximum 2.5 

mm. 



1 

2



9.3.2. Left-hand limit switch 

1 

Fig. 36 Left limit switch (front) 

If the stop at the end position of the sensor is not detected (LED does not light), the 

sensor position must be detected. 

1. Unfasten the sensor a little and shift it 1 to 2 mm towards the middle of the middle 

till the LED lights. 

2. Tighten the sensor secure. 





9.4. Adjusting the chain tensioner 

Fig. 37 Chain tensioner 

To retention the chain proceed as follows: 

1. Unfasten lock nut [2]. 

2. Turn screw [1] clockwise to increase tension. 

3. Tighten lock nut [2]. 

Indication 

Caution: do not tension the chain excessively. 





9.5. Limiting the press plate opening 

Fig. 38 Limiting the opening of the press plate 

Adjusting the opening travel 

1. Unfasten lock nut [3]. 

Indication 

The limiter may be fitted only in the folding mode. 



5 

2. Adjust desired travel between stop [1] and screw head [2]. (More travel gives wider slipfold 

at front) 

3. Tighten lock nut [3]. 

Dismantling the limiter 

1. Unfasten screw [5] and pull limiter from pin [4]. 

4 

1 

2 

3



9.6. Plate adjustment 

Fig. 39 Plate adjustment 

Fig. 40 Adjusting screw 

0.5 



1 

With the adjusting screw [1] the plate should be adjusted so that the rear plate projects 0.5 

mm beyond the inner edge of the paper gripper.



9.7. Adjusting the feed piston 

1 2 3 

Fig.41 Cylinder adjustment 

1. Switch the control over to manual operation and press the "Feed advance" key till the 

cylinder is stroked out to the full. 

2. Press the "Feed back" till the cylinder is stroked in fully. When the lock engages, the paper 

gripper should still tend to advance. If it travels more than 1/2 mm the clearance must be 

adjusted. To do this, unfasten the lock nut [1] and turn the screw out a little (not more than 

1/8th of a turn) till the paper gripper no longer moves forward. Tighten the lock nut again. If 

the paper gripper moves backward, unfasten the lock nut and turn the screw in a little (not 

more than 1/8th of a turn) till the paper gripper no longer moves back. Tighten the lock nut 

again. 





9.8. Ejector speed 

Fig. 42 Adjusting the ejector speed 

To alter the ejector speed, turn the slotted screw 1. 

1. Faster: turn the screw clockwise 

2. Slower: turn the screw counterclockwise 





9.9. Brake adjustment 

Fig. 43 Adjusting the brake 

The brake should be adjusted so that no impact noises are heard. The brake is adjusted by 

tightening the screw [1]. 

Indication 

Be careful not to tighten the brake excessively, otherwise the paper grippers will 

not reach their end positions. 





9.10. Height adjustment of the gluing unit 

1 

Fig. 44 Height adjustment right Fig.45 Height adjustment left 

The height adjustment of the gluing unit can be altered by means of two screws. 

1. The screw beside the arrow [1] in Fig. 44 adjusts the height of the right-hand side. 

2. The screw beside the arrow in Fig. 45 adjusts the height of the left side. To get at the lefthand 

height adjustment the casing on the back of the gluing unit must be removed. 





9.11. Interlocking 

2 

Fig. 46 Changing the catch 

1 

When changing the catch [2] or replacing a broken spring [1], make sure that the hose is 

pushed over the screw again. 





10. Decommissioning, storage 


Brief description: this section describes the measures required when taking the 

BUFALO RONDOFIX out of production or putting it into storage. 

The term "storage" as used in this section means shutting down the BUFALO RONDOFIX 

completely for more than 6 months. Regular interruptions of production and idleness lasting 

less than 6 months do not call for any storage measures. 


The BUFALO RONDOFIX may be put into storage only by authorized and instructed 

personnel. 

10.1.2. Storage conditions 

This equipment may be dangerous if the safety instructions are not 


The BUFALO RONDOFIX and its subassemblies must be stored in a dry room. 

Ambient conditions 

• Minimum storage temperature:10°C 

• Maximum storage temperature:70°C 

• Minimum air humidity: 0% 

• Maximum air humidity: 60% 

10.2. Storage lasting more than six months 

10.2.1. Preparations 

The following preparatory work is necessary: 

• Close all covers. 

• Remove the connecting cable. 

10.2.2. Maintenance during storage 

No maintenance is necessary during storage. 





11. Packing and transport 

11.1. Preparations 

Brief description: this section gives information on preparations and packing. 

All the preparations set out in Section 10 (Storage) must have been completed. 

11.2. Packing 

Indication 

The BUFALO RONDOFIX may be packed and transported only in its original 

packing. 

The BUFALO RONDOFIX is supplied as one packing unit. 

• For air transport the machine is fixed on a pallet. 

• For sea transport it is packed in a closed case. 





11.3. Transport 

11.3.1. Data for transportation 

Outside dimensions Gross weight Nett weight 

Machine 2940 kp 

Dust bag Incl. machine 

11.3.2. Fixing points 

When the machine is lifted and moved with a crane there is a danger of 

it swinging to and fro. 

Do not stand immediately beside it or underneath it. 

There is a considerable risk of injury. 

2 3 

Fig. 47 Fixing points 

1. Front fixing point 

2. Rear left fixing point 

3. Rear right fixing point 



1 

The front fixing point is welded on underneath the cover plate before the fixing station 

on the machine frame. The two rear fixing points are screwed onto the machine frame 

and should be unscrewed after transportation.



11.3.3. Transport by fork-lift 

High inertia forces are set up when the machine is moved. 

Drive slowly and do not go down ramps. 

The machine could slip off, attended by considerably risk of injury. 

Indication 

Run under the middle of the machine if possible, taking care not to 

damage its feet. 





12. Disposal 


Brief description: this section deals with the special tasks and the disposal and 

environment protection rules pertaining to the particular industry and location when 

disposing of the machine. 

The operator is responsible for the proper disposal of the BUFALO RONDOFIX as well as all 

oils, lubricants, cleansing agents etc. 

The disposal and environment protection rules applicable in the particular industry and 

location must be complied with when disposing of the various materials. 


The work described in this section may be performed only by persons who have 

received suitable technical instruction and have gathered the necessary experience, 

or who have been trained appropriately by the operator. 

Dismantling and disposal of the BUFALO RONDOFIX may be entrusted only to 

authorized and instructed personnel. Training and instruction may be given on a 

contract basis or as needed. Mechanical disassembly should be performed by a 

mechanic, disassembly of the electrical equipment by an electrician. 

This machine may pose dangers if the safety instructions are not 






12.2. Preparations for disposal 

• Turn off the main switch and disconnect the power supply. 

Danger from electric current. 

Make sure that all electrical connections are interrupted and have been 

removed before starting to dismantle the machine. 

• Drain off and dispose of all oils and lubricants etc. from their tanks. 

• Dispose suitably of all mechanical and electrical components such as valves, sensors, 

drives etc. after disassembling them. 

• Disassemble electrical components from the electrics cubicle and dispose of them suitably. 

• Remove the lithium battery from the PLC power pack and dispose of it suitably: see 

separate operating instructions. 

Indication 

If you need more information about disposal or if special problems arise, 

you should request the necessary information or support from your local 

representative or from W. Gantenbein Maschinenbau GmbH direct.

Operating Instructions, complete - W. Gantenbein GmbH

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