Preface

Documentation
RA-160007

CUSTOMER:

BRB CABLE INDUSTRIES LTD.

BSCIC Industrial Estate
7000 Kushtia
Bangladesh

ORDER NUMBER: RA-160007

LINE/MACHINE:

Combined SZ-Stranding and

Sheating Line RN-K

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Preface

Documentation
RA-160007

Preface
The present Operating Instructions form an integral part of the scope of delivery
provided by the cable production lines and machines manufactured by Rosendahl
Co. Nevertheless, it will, in no case, have any effect on the purchase contract!
These Instructions include the description of the line/machine, instructions for the
correct commissioning and operation as well as for the execution of maintenance and
repair work.
Hints on the prevention of accidents and damage done to the line must be observed!
For reasons of clarity, not all the details on all the models of the line/machine or any
conceivable case of installation, operation and maintenance are considered in the
documentation.
In order to guarantee a perfect function of the line/machine, the prescribed
maintenance of the single machine must absolutely be observed
see Maintenance Instructions.
As a rule, wear parts of the individual machines (the co. Rosendahl) are stated in a
separated manner in the respective operating instruction - these parts are to be
exchanged depending on application in different working time;
no guarantee applies to wearing parts to a specific working life.
In case of questions (relating to the single machines) or in case of problems to be
eliminated, the engineers of ROSENDAHL Co. will always be at your disposal.
The documentation of the line/machine must be kept carefully and must be available
for being viewed at any time!

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Preface

Rosendahl Nextrom GmbH

Schachen 57
Postfach 42
A-8212 Pischelsdorf-Austria
Phone (++43) 03113 / 5100-0
Fax (++43) 03113 / 5100-59
email: office@rosendahlaustria.com
Registered office in: A-8212 Pischelsdorf
Firmenbuch Nr. 74318 t Landesgericht Graz
DVR: 0417408 ARA LizenzNr.3376 ATU 19111805
All the drawings and descriptions (of this documentation) are intellectual property of
ROSENDAHL Co. and must neither be duplicated nor communicated to third parties
without the consent of ROSENDAHL Co.

Hints relating to Documentation:

Hints referring to the protection or the operating personnel and/or the line/machine
are particularly emphasized.
CAUTION

refers to operations that must be kept accurately in order to exclude

the imperilment of persons.

ATTENTION refers to operations that must absolutely be kept in order to avoid

damage done to the line/machine and the destruction of the
line/machine.

Hints relating to the Line/Machine:

Attention:
These Operating Instructions must be read before unpacking and
commissioning the line/machine and the directives must be strictly observed!

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Preface

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RA-160007

The delivered line/machine must be checked for completeness and transport damage
prior to installation nonconformities must be immediately reported to Rosendahl
Co.!
Subsequent complaints can no longer be taken into account!
Attention:
The appropriate use of each machine (of a line) is stated in the Operating
Instructions of the machine. The line/machine may only be operated, maintained and
repaired by persons that are familiar with the Operating Instructions or have been
trained for this line/machine.
Caution:
As for all the safety hints (sticker with text part) of the line/machine, the
operator of the line must make sure that they are understood by the employed
personnel.
If necessary, the operator will have to place additional stickers, which are
understood by the personnel, beside the existing stickers.
Attention:
The operation of the extrusion unit (extruder and extrusion head) as
well as sparktester and colour signator (if available) is only
permissible with a corresponding suction of the pollutions.
The local regulations about pollutant load and all the other
impairments due to operating materials of the facility will have to be
kept!
Attention:
Operating the line and/or enter the danger area is only admissible
when wearing protective glasses!
Danger for the eyes caused by product ends flying around.

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Documentation
RA-160007

Plant-Documentation

Plant-Documentation
This is a combined SZ-Stranding and Sheathing line RN-K.

Product Data:
General
Insulation mode:
Conductor material*
Conductor shape*
Cross section of the conductor
Diameter of conductor round
Insulation thickness
Diameter over insulation
Insulation material

copper stranded (class 2)

copper flexible (class 5)
round
1 - 35 mm
1.3 7.6 mm
0.7 1.2 mm
2.7 - 10 mm
PVC

SZ-stranding-sheathing mode:
Conductor:
PVC Insulated conductor (class 2 & class 5)
Pre-stranded cable core (with DSH pay-off )
Number of stranding elements:
24
Product range:
2 x 1.0 to 4 x 16 mm
Cross section of the conductor:
1.0 16.0 mm
Wall thickness filler
0.5 1.0 mm
Diameter over filler
8 - 19 mm
Filling material
PVC, HFFR
Wall thickness sheath
1.0 1.8 mm
Diameter over sheath
6 23 mm
Sheathing material
PVC, HFFR

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Plant-Documentation

General line data:

Line geared for
at barrel diameter
Height of cable passage over floor

max. 300 m/min

400 mm
1000 mm

Reel data
Pay-off stand AUF 5.18
Flange diameter
Width over hubs
Max. reel weight

800 - 1800 mm
500 - 1500 mm
5.000 kg

Single flyer pay-off EAB 1250

Flange diameter
Barrel diameter
Width over hubs
Diameter of mandrel
Maximum reel weight
Diameter of mandrel
Maximum reel weight

Take-up stand AUF 5.22

Flange diameter
Width over hubs
Max. reel weight

800 - 1250 mm
at least half of flange diameter
475 - 950 mm
80 mm
2.500 kg
127 mm
4000 kg
(with mandrel diameter 127 mm)

800 - 2240 mm
700 - 1700 mm
5.000 kg

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Documentation
RA-160007

Table of contents
R-CE ............................................ Rosendahl Declaration of conformity (CE Erklrungen)
A

General prevention of accidents............. General Prevention of Accidents 4.3_E

Information to mount the machines

Files:
Installation Instructions ........................................... Installation Instructions 6.7_E
Coolants .................................................................................... A 210.000_R7_E
Compressed air ......................................................................... A 220.000_R1_E
Operating conditions ............................................................... A 300.100_R2_ED
Heat expansion of extruders .................................................. AP 000.01_R3_ED
Drawings:
Installation plan ........................................... Drawing no.: APRA160007_00B_RNK
Rail plan DTSZ ................................................... Drawing no.: RA16000712010_00

010 Portal pay-off stand AUF 5.18 .............................. AUF 5.18 RA-160007-010_ED
020 Traverse fork VG with EN .............................................. VG RA-160007-020_ED
030 Double guide roller RFR 150 D ................................................. UR02A01100_03
040 Control pulleys accumulator TRS 500 V ............ TRS 500 V RA-160007-040_ED
050 Single flyer pay-off EAB 1250 ...................... EAB 1250 RA-160007-050-080_ED
060 Single flyer pay-off EAB 1250 .................................................... see RA-160007-050
070 Single flyer pay-off EAB 1250 .................................................... see RA-160007-050
080 Single flyer pay-off EAB 1250 .................................................... see RA-160007-050
090 Deflection pulley system RDPS 315.................................... DPV031A050000_01
100 Deflection pulley UR 315 ........................................................... UR04A14100_02
110 Capstan unit SSA 630 ........................................... SSA 630 RA-160007-110_ED
120 SZ-strander DTSZ 55 ............................................ DTSZ 55 RA-160007-120_ED
130 V-shaped pulley on stand -movable ................................................. S013A04000
140 V-shaped pulley on stand -movable ........................................... see RA-160007-130
150 Torsion lock TTSP 1200 .................................... TTSP 1200 RA-160007-150_ED

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160 Talcum Applicator ECC 701-3 ............................................................... NORDSON

170 Extruder ROEX 120.24 ................................. ROEX 120.24 RA-160007-170_ED
180 Temperature control unit TT-168 E .................................................... TOOL-TEMP
190 Vacuum hopper loader SVR 100............................................................. LABOTEK
200 Extrusion crosshead RX 25 M.1.0. ................... RX 25 M.1.0 RA-160007-200_ED
210 Dual axis diameter gauge LASER 2030 XY .............................................. SIKORA
220 Cooling through KS 35/8A ........................................... KS35 RA-160007-220_ED
230 Talcum applicator ........................................................................... Customer supply
240 Extruder ROEX 120.24 ................................. ROEX 120.24 RA-160007-240_ED
250 Temperature control unit TT-168 E ................. (see pos. RA-160007-180) TOOL-TEMP
260 Dosing unit Plasticolor PC 2500/- G251 ............................................... WOYWOOD
270 Vacuum hopper loader SVR 100......................... (see pos. RA-160007-190) LABOTEK
280 Extruder ROEX 45.24 ..................................... ROEX 45.24 RA-160007-280_ED
290 Dosing unit Plasticolor PC 1500/- G251 ........... (see pos. RA-160007-260) WOYWOOD
300 Vacuum hopper loader SVR 8............................. (see pos. RA-160007-190) LABOTEK
310 Extrusion crosshead RX 25 V.1.1. ................... RX 25 V.1.1 RA-160007-310_ED
320 Vacuum pump RVP 40 S ..................................... RVP 40 S RA-160007-320_ED
330 Dual axis diameter gauge LASER 2030 XY .............................................. SIKORA
340 Cooling through KS 35/8A KSU35/140/800 ..........................................................
.................................................................... KS35 + KSU35 RA-160007-340_ED
350 Dual axis diameter gauge LASER 2030 XY .............................................. SIKORA
360 Length measuring gauge - LASERSPEED 9000........................................... BETA
370 Control pulley accumulator TRS 800 H .............. TRS 800 H RA-160007-370_ED
380 Double guide roller RFR 150 D ..........................................(see pos. RA-160007-030)
390 Portal take-up stand AUF 5.22 ..................... AUF 5.22 AUF RA-160007-390_ED
400 RA-160007-400 Line control RIO
440 Deflection pulley system RDPS 315...................................(see pos. RA-160007-090)
450 Deflection pulley system RDPS 315...................................(see pos. RA-160007-090)
460 Deflection pulley system RDPS 315...................................(see pos. RA-160007-090)
470 Belt type caterpillar ROCA 1220 ...................... ROCA 1220 RA-160007-470_ED

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xx

Purchase parts general

consists of:
C Boards ......................................................... Rosendahl & different deliverers
D

SIEMENS General ...................................................... only on CD Siemens

SIEMENS Simatic ....................................................... only on CD Siemens

Line control system RIO Intouch

Line control system HARDWARE-MANUALS .. Listing - Line control RA-160007_ED
see special RIO-Folder
Manual - RIO ............................................................................... see special CD-ROM

The line control system (manual) consists of:

Install ............................................................................................................ Install-Intouch V3.0_E
GUI Graphic User Interface ............................................................................ GUI-Intouch V3.0_E
PCS Process Control System ....................................................................... PCS-Intouch V3.0_E
AMS Alarm Management System ................................................................. AMS-Intouch V3.0_E
RMS Recipe Management System ...............................................................RMS-Intouch V3.0_E
FTS Flexible Trend System ............................................................................ FTS-Intouch V3.0_E
RSM Remote Services Management ............................................................RSM-Intouch V3.0_E

Hint:
The corrected electric documentation will be delivered to you after the
commissioning of the line.

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RA-160007

Short Instructions for the present Documentation

Structure of the Entire Documentation:
(in addition to this overview)
General Part with the Pos. No. "A" and "B".
This part includes the "General Prevention of Accidents" and all the "Installation
Documents".
Machine Documentation with the Pos. No. "010" to ""
These Pos. No. are always identical with the Pos. No. of the Installation Plan
and can thus have gaps.
Customer-supplied machines are also mentioned in the Table of Contents (but
they carry the hint "machine from the customer and therefore do not include
any documentation of Rosendahl Co.).
As for machines manufactured by Rosendahl Co., the file name is stated in the
respective position in the Table of Contents.
As for purchased machines, the manufacturer is stated in the respective
position in the Table of Contents.
Documentations for purchased parts which are applicable to
several machines:
These documentations have the Pos. Nos. "C" to "Y" and are, for example,
descriptions of control boxes, motherboards, etc.
Documentation for the Line Control
This documentation will always be in a separate folder;
it has the Pos. No. "Z" and includes descriptions for the RIO Control, SPC, etc.

Structure of the Machine Documentation:

(for machines manufactured by Rosendahl Co.)
Each machine description has a survey giving the following information:
Technical Data
Operating and Maintenance Instructions
Parts list/list of drawings
Purchased parts/descriptions
The individual files (Technical Data, Operating and Maintenance Instructions, ...),
drawings and descriptions of purchased parts (the documentation can partly also be
delivered in digital form) are filed according to the cover sheet for each machine
documentation.

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Plant-Documentation

Arrangement table
SI units to other customary units
Length units:
1m =
39,37 inch (in)
3,281 foot (ft)
1,094 yard (yd)

1 mm = 0,0394 inch
1 inch = 25,40 mm

Face units:
1 m2 =
1550 inch2 (in2)
10,76 food2 (ft2)
1,196 yard2 (yd2)
Volume units:
1 Litre = 61,02
0,0353
0,2642
0,22

inch3 (in3)
food3 (ft3)
gallon (US)
gallon (UK)

1 m3 =

61023
35,31
264,2
220

inch3 (in3)
food3 (ft3)
gallon (US)
Gallon (UK)

Mass units:
1 kg =
35,27 ounce (oz)
2,205 pound (lb)
0,157 stone
Force units:
1N =
0,102 kp (Kilopond)
0,157 lbf (pound-force)
Pressure units:
1 bar = 100000 Pa
= 0,1 MPa
1,02 kp/cm2 bzw. at
0,987 atm
750 Torr
14,505 lbf/in2 (psi)
1 at =
10 m WS (bei 4C)
1 Torr = 1/760 atm = 1 mm Hg (bei 0C)
1 bar = 1 dyn/cm2

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Documentation
RA-160007

Power unit:
1 kW = 101,972 kpm/s
1,36 PS
1,341 hp (horsepower)
Temperature units:
1C =
1,8 degF

0C = 32degF

Improvements of the Documentation

Dear customer,
Our machine documentation is continuously being updated and improved.
By making your proposals for improval, you help us to make it more and more
user friendly.
You are requested to make your proposals as follows:
Fax:
(++43) 03113 / 5100-50
email:
johannes.jantscher@rosendahlnextrom.com

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