RoboLabs ROBOPOP 60, Operating Manual

Page 1: ...OPERATING MANUAL ROBOPOP 60 VPM RM4 CAUTION READ THE INSTRUCTIONS BEFORE USING THE MACHINE PDF version of this manual is available on www robolabs pro ...

Page 2: ... settings 14 2 5 Operation indicators 17 2 6 Display notifications 18 2 7 Popcorn quality 20 3 Technical maintenance 22 3 1 Cleaning guide 22 3 2 Light bulb replacement 24 3 3 Preservation 24 4 Troubleshooting 25 5 Transportation and storage 26 6 Acceptance certificate 26 7 Warranty obligations 27 8 Manufacturer details 27 Annex A Electric component list 28 Annex B Safety temperature regulator set...

Page 3: ...ED PERSONNEL ARE ALLOWED TO OPERATE THE MACHINE IT IS PROHIBITED TO USE MACHINE FOR PROCESSING OTHER KERNELS THAN CORN DO NOT LEAVE RUNNING MACHINE UNATTENDED ALL SWIVEL CASTERS MUST BE LOCKED WHILE IN OPERATION BEWARE MOVING PARTS SOME PARTS ARE HOT WHILE IN OPERATION BURN HAZARD ...

Page 4: ...reserved since popcorn doesn t spend more time than necessary in hot chamber 1 2 Technical Specifications Throughput1 up to 28 kg h Ampacity 25 A Rated voltage 3 N PE AC 230 400 V 50 60 Hz Rated power 11 3 kW Machine dimensions LхWхH 1430х600х1700 mm Shipping dimensions LхWхH 1800х1530х800 mm Net weight 250 kg Shipping weight 400 kg Ingress protection IP22 1 3 Delivery Set Popper 1 pc Cleaning scr...

Page 5: ...res and ground connection of the machine periodically In case of faults found an electrician must be called It is allowed to turn the machine on only after all the issues are resolved 1 5 Ambient Conditions The equipment must be operated at the ambient temperature between 5 and 40 C 41 F to 104 F relative humidity not more than 45 at 40 C 104 F Altitude above sea level should not exceed 1000 m Whi...

Page 6: ...close to heating elements In case of overheating safety temperature regulator will turn off the contactor that runs heating elements so they will be de energized and temperature won t rise further The main PLC controls actual turbine rotation speed in the beginning of operation If the speed is below 40 Hz for more than 30 sec then operation will be stopped and an error message will appear on the s...

Page 7: ...shaft Rotational speed is controlled by the main PLC Chamber This is where popping happens Airflow circulates through the chamber air is being heated by heating elements In the chamber s lower part there is a bowl with special shaped holes that causes air vortex During machine operation corn kernels are being fed into the chamber kernels are being heated up and finally immediately blown away from ...

Page 8: ...pper alert message will appear on the screen Sifter and scrap tray Sifter is a rotating drum that screens un popped kernels old maids partly popped popcorn and other small fractions into scrap tray located under the sifter Scrap tray is easily removable Controls There are following controls on the front panel START push button Turns machine on SIFTER push button Operates sifter OIL WARMER switch T...

Page 9: ...larm will be given If no action is taken the machine will stop popping process and will be switched to the pause mode 1 8 Getting Started 2 Carefully unpack the machine check delivery set and remove protective film from all surfaces 3 Once machine in dedicated position lock all four swivel casters 4 Plug machine into the mains see section 1 4 5 Assemble both carts provided in the delivery set 6 Tu...

Page 10: ...urning off popper must be cooled down In cooling mode heating elements are completely de energized turbine keeps running cooling down the machine Once temperature drops low enough popper is turned off automatically Testing mode This mode is used for testing popper components See Annex D for more details 2 2 Quick Operation Guide DO NOT LEAVE MACHINE UNATTENDED ALWAYS FILL CORN HOPPER TO THE TOP Ma...

Page 11: ...g 3 Program settings screen If nothing is pressed heating stage will start in 10 seconds automatically Heating will take 15 20 minutes depending on ambient conditions and settings Once heating is completed machine will be switched in popping mode automatically Popping mode screen will appear Fig 4 Popping mode screen ...

Page 12: ...f the screen see Fig 5 Parameters screen will appear To adjust parameters press MODIFY button enter password 2325 by default and press ENTER Use up and down arrow buttons to adjust parameters Press BACK for return if not pressed the settings will be saved and machine returns back to popping mode screen automatically shortly Refilling ingredients If less than 5 kg approx of corn left in a hopper Lo...

Page 13: ... you see Chamber is clogged with popcorn message then do the following DO NOT OPEN CHAMBER DOOR UNTIL MACHINE IS COOLED DOWN DO NOT USE FIRE EXTINGUISHERS 1 DO NOT panic and DO NOT use fire extinguishers 2 Patiently wait for machine cooling down 3 Once turbine is stopped turn the machine off To do this press and hold TURN OFF button 4 Machine is still hot Wait few hours to let machine cool down co...

Page 14: ...ture affects the way how popcorn pops its shape and size Too high values lead to smaller popcorn Too low values lead to reduced productivity improperly popped kernels and chamber clogging Common popping temperature for Butterfly is between 200 and 215 C for Mushroom between 210 and 225 C Due to constructive features it takes few minutes to see the result once the temperature has been changed Curre...

Page 15: ...irflow intensity can be reduced because of clogged mesh screen inside the chamber Keep the chamber clean see section 3 1 Corn auger speed Corn auger rate setting defines actual throughput rate amount of raw corn processed per hour The faster auger rotates the more corn kernels processed for the same time If low quality corn is used then corn auger rate should be decreased to avoid chamber clogging...

Page 16: ... sifter may affect proper scrap screening process and application of oil and salt Purge chamber every Defines operation cycle of automatic purge feature see below Corn sensor delay This one sets timer which is activated once corn sensor tripped upon timer expiring operator hears audible alarm Password change Password required for program parameters adjustment The main purpose is to avoid program p...

Page 17: ...y Chamber Cleaning Every parameter see above It helps to evacuate scrap from the chamber avoiding clogging PWR PWR ON economy mode switch While activated power consumption is decreased and machine draws not more than 30 Amps CAUTION Using this mode may affect productivity and or product quality in negative way DEFAULT Press and hold to reset all settings to default EN RU Press to change interface ...

Page 18: ...lied in the chamber This is just a reminder that oil and salt supply will start in certain time See Oil Turn On Delay setting Chamber is clogged with popcorn Machine chamber is equipped with chamber clogging sensor that watches what is happening in the chamber Based on the sensor s output machine can increase turbine spinning rate automatically in order to blow out excessive stuff out of the chamb...

Page 19: ...wn clean the chamber See section 3 1 Also this message can be seen upon turning the machine on To continue operation related indicator should be released See section 2 4 Motor turbine failure If the turbine speed is below 40 Hz for more than 30 sec in the beginning of heating stage the said message will appear Temperature sensor failure The temperature value coming from the temperature sensor is m...

Page 20: ... 1 5 Popcorn that just came out of the machine may have moisture content circa 4 5 as it is still losing moisture as cooling down It is recommended to establish proper environment and workflow at the site to be able to achieve top quality product Production capacity Unlike traditional kettle poppers Robopop has continuous operation workflow Corn is being fed into the chamber continuously constant ...

Page 21: ...ent doors must be kept closed all the time 3 Two oil canisters must be always kept in the compartment empty canister must be replaced in time The machine is intended for using with special salt only Using common salt or powders of other kind e g cheese or sugar may lead to salt applicator clogging and equipment failure While colored oil is used freshly made popcorn with oil and salt may have patch...

Page 22: ...LED DOWN BEFORE CLEANING Outer surface cleaning Clean outer surfaces of the machine by the means of dry and clean cloth it is allowed to use a cloth slightly damped with soap water It is convenient to clean the sifter by a scraper included in the delivery set To rotate the sifter press and hold SIFTER button on the front panel Sifter cleaning Sifter is not rigidly connected to the machine and can ...

Page 23: ... During long time operation certain amount of corn dust is accumulated in the chamber It is important to clean mesh screen Open the chamber There is a baffler in the center The mesh screen is behind the baffler Normally there is enough room to get access to the screen in order to clean it However if required baffler can be removed To do so remove two bolts that fix the baffler to sidewalls Then pu...

Page 24: ...b THE BULB MIGHT BE HOT BURN HAZARD 6 Spare lamp is included in the delivery set To replace the lamp take the spare one from the box but do not extract from the plastic wrap Do not touch the new lightbulb with bare fingers skin fat can cause bulb destruction during further operation If the bulb is greasy wipe it thoroughly with soft clean and dry cloth before putting it in 7 Take the bulb using th...

Page 25: ...ply is not stable machine operated by short 10 15 min sessions which is not enough for reaching stable operation mode oil temperature is not constant make sure the machine operates for longer periods without interruption avoid frequently activating pause mode and or to switch between programs frequently keep oil compartment closed all the time keep oil heater on all the time including night time r...

Page 26: ... The equipment may be transported by any kind of covered vehicle in accordance with transportation rules for this kind of vehicle Ambient temperature during the transportation and storage must be between minus 25 C and 55 C 13 F to 131 F 6 Acceptance certificate ACCEPTANCE CERTIFICATE _____________ Product Name _____________ Serial No The equipment is made with accordance to mandatory requirements...

Page 27: ...nged by manufacturer at any time due to improvements and or other reasons Technical specifications stated in this document are intended to act as a reference point which is necessary to evaluate suitability of the equipment for the customer s needs and are not the subject of warranty policy The information stated in this document has been thoroughly checked and considered as accurate one neverthel...

Page 28: ...0 W EK5 EK6 W type heat element 1GIK1Z159001 IRCA 230 V 600 W EL Halogen lamp 64684 ECO 230 V 48 W EMI 3 phase EMI filter DL 25EA3 400 V 25 А HL Contact block with LED BB 230 V HMI HMI operator panel MT4414T 24 V K1 K2 Electromagnetic relay G2RV SL700 DC24 24 V 4 A KM1 Contactor LC1D09M7 400 V 9 A KM2 Contactor LC1D32M7 400 V 32 A M1 AC Motor TN80A2 B5 400 V 3000 rpm M2 Stepping motor w gearbox FL...

Page 29: ...couple K type 250 Lower limit of set point 400 Upper limit of set point Relay control output Type of control ON OFF Alarm mode 10 Hysteresis alarm output 20 Temperature alarm output 20 Hysteresis Settings lock Set point SV is 370 С by default All parameters above must be set in order as they appear in the list above ...

Page 30: ... 4 Auto acceleration deceleration 02 00 3 Source of First Master Freq command RS 485 02 01 4 Source of First Operation command RS 485 STOP RESET disabled 02 07 1 UP DOWN mode based on accel decel time 02 11 40 00 Keypad frequency command 09 00 5 Communication address 1 09 04 1 Communication protocol ASCII 7 E 1 ...

Page 31: ...R_0 1st group of heating elements6 Y1 SN HEATER_1 2nd group of heating elements Y5 SN BUZZER Buzzer X0 Sensor Chamber chamber sensor condition X1 Button SIFTER SIFTER button condition X2 Button WARM OIL WARM switch condition X3 Sensor Corn Left left corn hopper sensor condition X4 Sensor Corn Right right corn hopper sensor condition X5 Sensor Bag cart sensor condition X6 Heater control AL1 signal ...

Page 32: ...er 1 Operation distance adjusting screw 2 Operation indicator Open the chamber and make sure that the sensor head is clean use a dry soft cloth if necessary Put a piece of paper or any suitable item inside the chamber in order to block sensor s sightline in the middle of the chamber see Fig 2 Use the adjustment screw on the amplifier to set the operating distance accordingly Use the operation indi...

Page 33: ...3 Annex E2 Corn hopper sensor setup Operating distance of each sensor can be adjusted with adjustment screw 2 coarse tuning and locking nut 3 fine tuning Use operating indicator to see the current status of the sensor ...

Page 34: ...tm2692 Jan 20 34 Annex F Parts list ...

Page 35: ...tm2692 Jan 20 35 ...

Page 36: ...protection cover sticker 4 2 3917 Optical sensor E3F1 DP12 2M 5 1 2242 HMI panel МТ4414Т 5 2 2393 Push button black B100DH 5 3 16121 2 pos switch В100SL20K 16490 Contact block with backlight ВВ 1301 Contact block B1 5 4 13585 Control panel sticker 5 5 496 Emergency stop button B200Е40 5 6 4068 STOP label ВЕТ60А 6 22036 Oil compartment door TM 2692 12 00 000 7 20565 Oil pump assembled ТМ 1672 01 06...

Page 37: ...ing tube ТМ 1672 01 10 300 13 4 20587 Salt feeder cover ТМ 1672 01 10 100 13 5 22039 Salt auger with clutch TM 2692 10 02 000 14 20590 Cleaning scraper ТМ 1672 03 00 000 15 13669 2 L cup 16 1215 Lockable swivel caster 125 mm 3300 PUR 125 F18 17 77963 Cart ТR1 17 1 1203 Lockable swivel caster 75 mm 18 1838 LDPE bags 50 pcs 19 21480 Chamber door assembled TM 2677 08 00 000 19 1 Chamber door sticker ...

Page 38: ...duc 32А 3 5 32VDC SAL963460 36 7 13450 Contactor 9A LC1D09M7 36 8 13449 Contactor 32A LC1D32M7 36 9 77 Circuit breaker S203 C32 36 10 3895 EMI filter DL 25EB3 37 22044 Lower rear panel ТМ 1672 01 00 005 38 22045 Wire channel cover ТМ 1672 01 00 013 39 20569 Corn dispensing tube ТМ 1672 01 36 000 40 21495 Heater ТМ 1672 01 23 000 40 1 3744 Finned heating element 2500 W 230 V 1GIK8BL33001 40 2 21496...

Page 39: ...35B 50 21507 Backlight glass unit assembled TM 2677 16 00 000 51 21508 Backlight assembled TM 2677 17 00 000 51 1 2281 Lamp socket R7s 206 51 2 13454 Halogen lamp 64684 ECO 48W 78mm 230V R7s 51 3 21509 Lamp wire set 52 2666 Profiled gasket silicone white 14 12 53 13860 Rockwool 38 mm 1 roll 1260 1300 128 54 22407 Thermocouple ДТПК 124 00 32 2 5 55 2741 Socket female C016 30G006 100 12 56 20579 Oil...