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RoboLabs Robopop 75, User Manual

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7

Troubleshooting

7.1

Too much scrap

Possible reasons

Solution

Low quality corn

Use high quality corn

Too high turbine speed

Decrease turbine speed

7.2

Popcorn is not crispy

Possible reasons

Solution

Low quality corn

Use high quality corn

Extreme ambient conditions

Provide proper ambient conditions

No exhausting hood

Provide exhausting hood

Popcorn is still hot

Let popcorn to cool down

7.3

Err 1 message

Turbine speed is below 20 Hz. A qualified technician must be called.

7.4

Err 2 message

Possible reasons

Solution

Low quality corn

Use high quality corn

Corn storage conditions are bad

Provide proper storage conditions

Wrong settings

Adjust the settings

7.5

Err 3 message

Temperature sensor fault. A qualified technician must be called.

7.6

Err 4 message

PLC to temperature module connection fault. A qualified technician must

be called.

18

Summary of Contents for Robopop 75

Page 1: ...Vortex popcorn machine Robopop 75 VPM RM4LT VPM RM4LTUS User manual Read this manual carefully before use and keep for future reference PDF version of this manual is available on www robolabs pro ...

Page 2: ...he machine while it is con nected to the mains Some parts might be hot while in operation DO NOT process other kernels than corn Only instructed personnel is allowed to operate the equipment DO NOT not leave running machine unattended Read and understand all instructions before use 2 ...

Page 3: ... 3 3 Sifter and scrap tray 8 3 4 Hopper 9 3 5 Control panel 9 3 6 Popcorn cart 9 4 Intended use 10 4 1 Modes of operation 10 4 2 Operating parameters 11 4 3 Quick start instructions 12 4 4 Display notifications 13 4 5 Forced purge feature 13 5 Popcorn quality 14 5 1 Raw corn 14 5 2 Moisture content 14 5 3 Production capacity 14 6 Maintenance and cleaning 15 6 1 Outer surface cleaning 15 6 2 Chambe...

Page 4: ...message 18 7 5 Err 3 message 18 7 6 Err 4 message 18 8 Technical manual 19 8 1 Sifter and feeder testing 19 8 2 Setup mode 19 8 3 Light bulb replacement 22 8 4 VFD unit 23 8 5 Temperature limiter setup 25 8 6 Optical amplifier setup 26 8 7 Electric box layout 27 9 Transportation and storage 29 10 Quality control check 29 11 Warranty obligations 30 12 Manufacturer details 30 4 ...

Page 5: ...ately removed from the hot area thus its nutritional value and taste are kept as much as possible The machine is intended for professional use only 1 2 Technical specifications Model VPM RM4LT VPM RM4LTUS Throughput up to 34 kg h up to 34 kg h Rated voltage 3N 230 400 V 3P 208 240 V Rated frequency 50 Hz 60 Hz Rated power 11 3 kW 11 3 kW Dimensions LxWxH 1370x600x1690 mm 1370x600x1690 mm Weight 20...

Page 6: ...r service agent or qualified persons in order to avoid hazard Connections must be done by qualified electrician ONLY For 400 V 50 Hz service use IEC 60309 3P N PE 32 A plug For 208 240 V 60 Hz service use NEMA 15 60P plug Equipotential bonding wire up to 10 sq mm shall be connected to screw terminal marked with IEC 5021 sign 2 2 Ambient conditions and vent requirements The equipment must be operat...

Page 7: ...lation hood measuring at least 800x800mm must be provided above the machine with a min imum capacity of 750 m3 h 3 Design and operating principle Main components of the machine are 1 Turbine 2 Chamber 3 Hopper with feeder 4 Sifter perforated drum 5 Popcorn cart with plastic bag 6 Scrap tray 7 Control panel see Figure 1 Figure 1 Robopop 75 main components 7 ...

Page 8: ...ing heated up and finally immediately blown away from the chamber once popped Chamber can be easily accessed through the door provided Halogen lamp illuminates chamber inside helping operator to control the process inside Chamber is equipped with optical sensor 1 and temper ature sensor 2 Optical sensor is to monitor processes in the chamber Popper uses sig nal from this sensor in order to maintai...

Page 9: ...adjusting buttons marked with up and down arrows 4 START PAUSE push button with light indicator This button is used for start ing machine pause mode activation and other operating purposes 5 COOLING TURN OFF push button This button is used to turn machine into cooling mode and other operating pur poses 3 6 Popcorn cart Popper delivery set includes wheeled cart and 200 liter bags set Cart is equipp...

Page 10: ...corn kernels are being heated up in the chamber even tually being blown out from the chamber once popped 3 Purging turbine is accelerated to higher speed in order to blow everything that are left in the chamber i e un popped kernels dust and other scrap Pause mode Machine doesn t process corn in this mode but maintains temperature in the chamber popping process can be resumed at any time The sifte...

Page 11: ...perature causes smaller popcorn Too low temperature reduces capacity causes improperly popped kernels Common popping temperature for Butterfly is between 200 215 C for Mushroom it is be tween 210 225 C Temperature set point can be adjusted during heating or popping modes Press and hold one of the adjustment buttons The changing value appears on the display Once desired value is reached release the...

Page 12: ...ed in popping mode automatically 6 To suspend the process for short time press the START PAUSE push button The machine will stop making popcorn but will main tain temperature in the chamber at the set value To resume pop ping press the START PAUSE push button again 7 To end the operation press the COOLING TURN OFF push but ton The machine stops supply corn to the chamber and is switched to cooling...

Page 13: ...r Add corn Err1 Turbine fault See Troubleshooting Err2 Chamber clogged See Troubleshooting Err3 Temperature sensor fault See Troubleshooting Err4 Interconnection fault See Troubleshooting 4 5 Forced purge feature The machine automatically actuates purge procedure during machine op eration However it is possible to actuate the purge procedure at any time If you see that chamber is going to be clogg...

Page 14: ... time to cool down before the next stage of processing e g coating At the same time don t expose popcorn for too long in open containers because popcorn starts to take moisture back from the ambient air Use air tight containers if needed to keep popcorn moisture content at the proper level 5 3 Production capacity Due to the nature of popping process there the weight of raw corn pro cessed is not t...

Page 15: ...y Sifter cleaning once a week Sifter rollers cleaning every two weeks Feeder cleaning every month 6 1 Outer surface cleaning Clean outer surfaces of the machine with a soft and clean cloth slightly damped with soap solution Wipe dry immediately 6 2 Chamber cleaning It is necessary to clean the chamber of husk and dust once a day To clean the chamber unfasten the latches which hold the door and pul...

Page 16: ...n The new batch won t be started until the previous batch is evacuated from the chamber thus the possibility of clogged chamber is minimal However in case of lack of voltage in the mains or using Emergency stop button during the operation or other reasons the chamber may get clogged with popcorn In such case do the following 1 DO NOT PANIC 2 Unplug the machine from the mains 3 DO NOT open the cham...

Page 17: ...the sifter rollers might accumulate corn dust and oil be coming greasy and slippery affecting normal sifter operation Thoroughly clean the sifter rollers surface to provide good friction 6 6 Feeder cleaning Use a soft dry clean cloth to clean the feeder inner surfaces It is allowed to use a vacuum cleaner to remove dust from inside the feeder 6 7 Conservation If machine is not used for long time d...

Page 18: ...Provide exhausting hood Popcorn is still hot Let popcorn to cool down 7 3 Err 1 message Turbine speed is below 20 Hz A qualified technician must be called 7 4 Err 2 message Possible reasons Solution Low quality corn Use high quality corn Corn storage conditions are bad Provide proper storage conditions Wrong settings Adjust the settings 7 5 Err 3 message Temperature sensor fault A qualified techni...

Page 19: ... are two ways to enter the setup mode and change the parameters 1 If machine is turned off press and hold COOLING button and press START PAUSE button once release COOLING button as you see St S on the display 2 If machine is running heating popping or cooling mode press and hold two temperature adjustment push buttons the display shows test and when you see next reading release the buttons The rea...

Page 20: ...ged chamber FP Freq_Popping Turbine speed increment in Hz for popping stage Fb Freq_Boost Turbine speed increment in Hz for purge stage Cn Cnt_Pop Count threshold for optical sensor in the chamber Pt Temp_P Proportional band PID regulation parameter It Temp_I Integral time PID regulation parameter dt Temp_d Derivative time PID regulation parameter tE Temp_Preheat During heating stage heaters opera...

Page 21: ...topped the machine is in either heat ing or popping or cooling stages then press and hold two temperature adjustment push buttons for 5 seconds to exit Param Description Default Min Max Inc tP Time_Popping 180 150 300 30 Fr Feeder_RPM 160 100 350 10 tF Time_Feeder 10 10 30 5 tb Time_Boost 10 10 30 5 tH Time_Heating 40 10 60 5 Sr Sifter_RPM 95 10 95 5 FP Freq_Popping 10 10 15 1 Fb Freq_Boost 20 15 ...

Page 22: ... frame of the screen and turn it gently to detach the screen 5 The lightbulb 3 is being hold by spring loaded socket 2 Shift the bulb upwards or downwards to release its opposite end and then take the bulb out 6 DO NOT touch the new bulb with bare fingers skin fat can cause bulb destruction during further operation If the bulb is greasy it is required to wipe it thoroughly with soft clean and dry ...

Page 23: ...ine on 3 Use up and down arrow keys on VFD control panel to set the desired value New figure will be shown on the display in real time in format FXX X 4 Close the electric box F must be set in the range between 20 and 40 Hz Values beyond this range may cause clogged cham ber or machine failure 23 ...

Page 24: ...on or to the main mode Parameter Value Description 00 02 9 Settings initialization 00 03 0 Start up display selection 01 00 70 00 Maximum output frequency 01 16 4 Auto accel decel 02 00 3 Source of first master frequency command RS 485 02 01 4 Source of first operation command RS 485 02 04 0 Motor direction control 02 07 1 Up Down mode 02 09 0 Source of second frequency command 02 10 1 1st and 2nd...

Page 25: ... the display release the MODE button To access the first group of parameters press and hold the MODE button 2 seconds until you see PAr1 on the display Use MODE button to list parameters Actual value of the parameter is shown in the lower line of the display Use up or down arrow keys to change the value Once the new value is set press MODE button to proceed to the next parameter Group Param Value ...

Page 26: ...position To adjust the optical amplifier put a folded sheet of white paper in the chamber as shown on the picture below so the sight line of the sensor is interrupted with this paper screen If the operation indicator 1 is lit up then rotate the knob 3 counter clockwise until the indicator turns off After that slowly rotate the knob 3 until indicator 1 is lit up 26 ...

Page 27: ...mperature controller 5 DC1 main controller 6 TV power supply unit 7 DD1 step driver 8 DD2 step driver 9 UZ VFD unit 10 FV voltage control relay 11 KM1 contactor 12 KM2 contactor 13 VS1 VS2 solid state relays 14 QF circuit breaker 15 EMI filter 16 DC3 display 17 SA1 switch 18 SA2 push buttons 19 SB1 push button 20 SB2 push button 27 ...

Page 28: ...perature controller 5 DC1 main controller 6 TV power supply unit 7 DD1 step driver 8 DD2 step driver 9 UZ VFD unit 10 QF2 circuit breaker 11 KM1 contactor 12 KM2 contactor 13 VS1 VS2 solid state relays 14 QF1 circuit breaker 16 DC3 display 17 SA1 switch 18 SA2 push buttons 19 SB1 push button 20 SB2 push button 28 ...

Page 29: ...Ambient temperature during the transportation and storage must be between mi nus 25 C and 55 C minus 13 F and 131 F 10 Quality control check Product name Serial no The equipment is made with accordance to mandatory requirements of the state standards actual technical documentation and approved for use QC Engineer STAMP HERE Signature Full name DD MM YYYY 29 ...

Page 30: ...y 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 nevertheless th...

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