RoboLabs ROBOSUGAR CPA-10 User manual

OPERATION MANUAL
ROBOSUGAR CPA-10, CPA-10A
2018

ROBOSUGAR CPA-10(A) Sep-18
2
SAFETY REQUIREMENTS
DO NOT DISASSEMBLE CARAMELIZER OR REMOVE SEPARATE
COMPONENTS WHILE EQUIPMENT IS CONNECTED TO THE MAINS!
READ CAREFULLY THE MANUAL BEFORE START!
ONLY INSTRUCTED PERSONNEL ARE ALLOWED TO OPERATE THE
MACHINE!
IT IS PROHIBITED TO RUN THE MACHINE WITH EMPTY KETTLE! IT
WILL LEAD TO MACHINE OVERHEATING AND FAILURE!
DO NOT USE THE MACHINE FOR MIXING HEAVY OR ABRASIVE
PRODUCTS!
MANY PARTS ARE HOT WHILE IN OPERATION!
BURN HAZARD!
BEWARE OF MOVING PARTS OF THE MACHINE WHILE IN OPERATION!

ROBOSUGAR CPA-10(A) Sep-18
3
1. OVERVIEW
1.1 DESIGNATION
RoboSugar CPA-10A and RoboSugar CPA-10 caramelizers are
intended for making caramel coated popcorn.
1.2 TECHNICAL SPECIFICATIONS
Productivity1
up to 14
kg/h
Operating volume
37,5
L
Rated voltage
Single phase 208… 240
Vac
Rated frequency
50/60
Hz
Rated power
5.5
kW
Dimensions2(LxWxH)
(CPA-10) 1650х810х1500
(CPA-10A) 1800х810х1650
mm
Weight
(CPA-10) 160
(CPA-10A) 170
kg
Ingress protection
IP22
CE certificate №161299117 dated 20.06.2016
1.3 DELIVERY SET
Delivery set includes:
RoboSugar CPA-10(A) machine
1
pc
Popcorn container
1
pc
Discharge container
1
pc
Kettle lid
1
pc
Protection paddle
1
pc
Documentation set
1
set
1
Depending on recipe and ingredients used
2
See Appendix B for more details

ROBOSUGAR CPA-10(A) Sep-18
4
1.4. OVERVIEW
General view of RoboSugar CPA-10A machine is shown on the Fig.1
below. RoboSugar CPA-10 (semi-automatic) doesn’t have pulling
mechanism for popcorn container. Apart from that, machines have the
same design.
Рис.1 RoboSugar CPA-10A general appearance
(1) –kettle; (2) –popcorn container; (3) –cooling belt; (4) –controls; (5) –ready-to-eat
container; (6) –scrap tray
2. INTENDED USE
2.1 PROTECTORS AND LOCKUPS
The machine can be turned off in any time with the main switch on the
front panel.
There is an emergency temperature regulator located in heating
elements area. In case of excessive or uncontrolled heating it will cut off
power supply to the heaters.
2.2 AMBIENT CONDITIONS
The equipment must be operated at the ambient temperature from +5°
to +40°C and relative humidity not more than 45% at 40°C. The

ROBOSUGAR CPA-10(A) Sep-18
5
temperature decreasing related to RH increasing, for example, 90% of
RH at 20°C. Altitude above sea level should not exceed 1000 m. Ingress
protection rating IP22 (IEC 60529).
While in operation, kettle of RoboSugar CPA-10(A) emits a lot of steam
and heat. It is essential to provide exhausting hood (800x800 mm, 500
m3/h or more) installed over the kettle. See ANNEX B for more details.
Ambient conditions have strong impact on the end product quality. See
section 2.7 for more details.
2.3. GETTING STARTED
Unpack machine carefully, check delivery set, and remove protective
film from all surfaces. Put the machine on even floor. Once machine is
placed, lock all four swivel casters to avoid unexpected machine
roaming.
Dumping mechanism for popcorn container must be set up for
RoboSugar CPA-10A machine (see ANNEX A).
Insert steel paddle under the belt from the kettle’s side. During
operation, small particles of caramel and popcorn will be accumulated
on the paddle, this will make cleaning easier.
Install stand for discharge box.
In the upper part of conveyor belt drive shaft is located. Unscrew four
wing nuts and remove protective shroud. There is a silicone scraper
under the shroud. Check the gap between scraper and conveyor belt, it
should be minimal; but without touching each other, see Fig.2:
Fig.2 Checking the gap

ROBOSUGAR CPA-10(A) Sep-18
6
2.4 POWER REQUIREMENTS
EQUIPMENT MUST BE GROUNDED!
MAINS CONNECTIONS MUST BE DONE
BY QUALIFIED ELECTRICIAN ONLY!
IT IS PROHIBITED TO USE POWER SUPPLY WITH
CHARACTERISTICS OTHER THAN SPECIFIED!
Machine uses power supply with voltage range from 208 to 240 volts, 50
or 60Hz.
There is a voltage relay installed in the circuit, which won’t let the
machine to be energized if voltage exceeds allowed limits.
It is recommended to use 32A 2+E plug
(pin and sleeve type IEC60309) for
power supply connecting. Follow the
wiring diagram sticker attached to the
cord, as shown on Fig.3:
UNSTABLE POWER SUPPLY MAY AFFECT MACHINE OPERATION!
Fig.3 Connection diagram

ROBOSUGAR CPA-10(A) Sep-18
7
2.5 CARAMEL RECIPES
3
Below are few caramel recipes to start with. Depending on customer’s
needs, those recipes may be modified or substituted with your own
recipes. Feel free to experiment with different recipes to get the best
results.
Caramel recipe # 1:
Super Caramel Premix or similar –1300 g
sugar (beet or cane) –1200 g
coconut oil or butter –200 g
water
4
–500 g
lecithin Free-N-Easy
5
Caramel recipe # 2:
Super Caramel Premix or similar –1050 g
sugar (beet or cane) –750 g
coconut oil or butter –150 g
water –375 g
Caramel recipe # 3:
Super Caramel Premix or similar –1100 g
сsugar (beet or cane) –1000 g
coconut oil or butter –200 g
water –300 g
3
Feel free to experiment with different ratios of ingredients, or even with different
ingredients. This way you will be able to get the result that suits your needs in the best
way!
4
The main purpose of adding water is to provide proper blending of all ingredients; almost
all water will be boiled down during caramel cooking stage. Mind this while calculating
the output!
5
Free’N’Easy lecithin helps popcorn not to stick to each other. Lecithin should be applied
onto popcorn in the middle of mixing stage.

ROBOSUGAR CPA-10(A) Sep-18
8
2.6 MACHINE OPERATION
RoboSugar CPA-10 (A) has following controls
(Fig.4):
- temperature regulator
- main switch (ON-OFF)
- HEATING push button with backlight
- MIXING push button with backlight
- COOLING push button with backlight
Each button actuates one of the named
stages. Corresponding backlights indicates
current stage of operation. While in operation,
the machine switches the stages
automatically, however, any stage may be
actuated manually by pressing the button.
The operation process consists of the
following stages.
HEATING STAGE
The mixture in the kettle is being heated till
caramel is ready. Kettle mixer operates
occasionally at this stage, providing proper
blending of all ingredients. Almost all water
will be evaporated at this stage. Once
caramel is ready, popcorn will be automatically dumped into the kettle.
Upon completion of heating stage machine will give an audible audio
alarm.
MIXING STAGE
Once popcorn is dumped into the kettle, the mixer operates
Fig.4 Controls

ROBOSUGAR CPA-10(A) Sep-18
9
continuously for 1.5 minutes, providing smooth coating. Once time is
expired, coated popcorn will be dumped to the cooling belt
automatically. Upon completion of mixing stage machine will give an
audible audio alarm.
IMPORTANT! See STARTING NEXT BATCH section below!
COOLING STAGE
Caramel coated popcorn needs to be cooled down and separated.
Cooling conveyor belt operates continuously, providing popcorn cooling
down and separation.
Once cooling is completed, ready-to-eat product will be discharged
automatically into dedicated container. Upon completion of cooling
stage machine will give an audible audio alarm.
It is possible to finish cooling before time. To do this, press and hold
COOLING button for 5 seconds, then the belt will stop and the product
will be dumped to the container.
STARTING NEXT BATCH
IT IS REQUIRED TO GET THE INGREDIENTS
PREPARED IN ADVANCE!
Once the first batch of caramel coated popcorn went to the cooling
conveyor belt, and the kettle got back to initial position, the machine is
ready for the next batch. HEATING button will be blinking.
Since the kettle is quite hot, it is strictly required to put all ingredients at
the same time; put oil first, then dry ingredients and then water. Once
you put all ingredients, press blinking HEATING button immediately, to
actuate the mixer, thus avoiding burning of ingredients or early
evaporation of water.
Starting next batch before finishing previous one will maximize overall
productivity.

ROBOSUGAR CPA-10(A) Sep-18
10
CPA-10/CPA-10A OPERATION ORDER
RoboSugar CPA-10 (semi-automatic)
To make caramel coated popcorn, do the following:
1. Put caramel ingredients into the kettle. Put popped popcorn into
popcorn container.
2. Turn the main switch to ON position, set temperature if needed, and
press HEATING button.
3. Audible alarm means that caramel cooking is completed. Dump
popcorn container into the kettle and press MIXING button.
4. Audible alarm means that mixing is completed. Press COOLING
button, the conveyor will be activated. Tilt the kettle and dump popcorn
onto the belt. Once cooling stage is done, popcorn will be discharged
into container automatically.
RoboSugar CPA-10A (automatic)
1. Remove safety clamp that interlocks kettle and popcorn container
handles (Fig.5):
2. Put caramel ingredients into the
kettle, put popped popcorn into
popcorn container.
3. Turn the machine on with the main
switch. Set the temperature if needed.
After this, machine will do the rest
automatically.
4. Upon completing, put safety clamp back.
Fig.5 Safety clamp

ROBOSUGAR CPA-10(A) Sep-18
11
2.7 END PRODUCT QUALITY
TEMPERATURE ADJUSTMENT
Due to constructive features, temperature value set on the
thermoregulator may be different, depending on recipes used. The goal
is to get good taste rather than reach some temperature value.
The following recommendations will help you to find out the right
temperature that should be set on the thermoregulator.
Make a batch of caramelized popcorn with default temperature setting
(165°С) and give it a try.
If caramel is sticky to the tooth, it means that caramel is undercooked;
therefore, the temperature value must be increased.
If caramel has bitter taste with hint of burnt, it means that caramel is
overcooked; therefore, the temperature value must be reduced.
Caramel that cooked with normal temperature and properly cooled is
crunchy and doesn’t stick to the tooth.
POPCORN CRUNCHINESS
Crunchiness of caramel coated popcorn comes mostly from caramel
layer. To be crispy, caramel should be properly cooked, which means
that there is virtually no water left in the mix.
However, even if caramel is cooked properly, the result may be not so
good. Popcorn is highly hygroscopic product. It is very important to
make sure that popcorn you put into the machine has not more than
1.0—1.5% of moisture. Otherwise, excessive moisture will ingress into
caramel layer after coating and make it sticky.
Except providing proper ambient conditions (see section 2.2), some
additional equipment may be required in order to keep popcorn in good
condition at intermittent stages as well as finished product.

ROBOSUGAR CPA-10(A) Sep-18
12
2.8 MACHINE SETTINGS
6
Some aspects of machine operation may be adjusted. To adjust settings
do the following:
Turn the machine off, then press and hold HEATING and COOLING
pushbuttons together and turn the main switch in ON position. You will
see flashing buttons and hear buzzer signals.
Default values are the following:
1 –mixing frequency during heating stage –5 s;
2 –mixing stage duration –90 s;
3 –cooling stage duration –300 s.
Buttons are flashing in cyclic way. Count of flashes per single cycle
points current value:
Frequency of mixing
in heating stage
Duration of mixing
in mixing stage
Duration of cooling process
Thus, with default settings, HEATING, MIXING, COOLING backlights
are flashing 2, 3 and 5 times per cycle, respectively.
To adjust any value, corresponding button must be pressed. Each
stroke increases the value by one point. Once maximum value is
reached, further stroke will set minimum value.
For example, let’s suppose that cooling time should be changed from
300s to 240s. Pressing COOLING button four times we’ll make changes
like this: 360s –120s –180s –240s.
To exit adjustment mode and save the changes, turn the machine off.
6
Applicable for machines with s/n starting with 1338.215.04.164.

ROBOSUGAR CPA-10(A) Sep-18
13
3. TECHNICAL MAINTENANCE
3.1 GENERAL INSTRUCTIONS
The maintenance purpose is to keep the machine operable during the
entire service life. The recommended
7
maintenance schedule with types
of actions is presented below:
PROCEDURE
PERIOD
Kettle cleaning
once a day
Scrap tray cleaning
once a day
Outer surface cleaning
once a day
Conveyor drive shaft cleaning
once a week
Conveyor belt cleaning
once a week
DISCONNECT THE MACHINE FROM THE MAINS BEFORE
TECHNICAL MAINTENANCE!
DO NOT USE SHARP TOOLS OR OBJECTS WHILE PROVIDING
TECHNICAL MAINTENANCE!
DO NOT USE ABRASIVE SOLUTIONS!
DO NOT LET ALL WATER TO BOIL DOWN!
DO NOT POUR MORE THAN 4 L OF WATER INTO THE KETTLE!
DO NOT REMOVE THE LIDWHILE KETTLE IS HOT!
HOT STEAM INSIDE! BURN HAZARD!
7
Period may be different. Maintenance procedures must be done as necessary.

ROBOSUGAR CPA-10(A) Sep-18
14
3.2 MAINTENANCE ORDER
KETTLE CLEANING
8
Pour not more than 4 liters of water in the kettle, close the kettle with lid
provided in the delivery set, and turn the main switch in ON position.
Wait until water is started to boil; let it boil for a few minutes, so hot
water steam will be able to fill the kettle properly. Turn off the machine
and let the kettle to cool down.
In case of severe carbon build ups, use special cleaning product (Heat
N Kleen or similar).
SCRAP TRAY CLEANING
Take out scrap tray, remove scrap, then wash the tray with warm water.
PADDLE CLEANING
From the kettle’s side, there is a protective paddle laid under the
conveyor belt. During machine operation, a lot of small particles of
caramel and popcorn are accumulated onto this part. Take it out and
wash with warm water.
CONVEYOR DRIVE SHAFT CLEANING
It is important to clean conveyor drive shaft area once in a week or more
often. To get access to the area, remove four wing nuts and take
protective shroud out. It is convenient to clean shaft’s gears with stiff
bristle brush. Once the area is cleaned, put silicone scraper, mind its
position (refer to section 2.3).
8
The machine must be plugged in for kettle cleaning procedure.

ROBOSUGAR CPA-10(A) Sep-18
15
CONVEYOR BELT CLEANING
During normal operation belt contamination is minimal. Use warm water
with cloth for cleaning. It is convenient to use a steam generator as well.
DURING MACHINE OPERATION SOME AMOUNT OF DARK-
COLOURED CONDENSATE MAY BE FOUND BELOW THE KETTLE,
ON MIXER MOTOR HOUSING AND AROUND. IT SHOULD BE
REMOVED AS NECESSARY!
4. TRANSPORTATION AND STORAGE
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 to +55°C.

ROBOSUGAR CPA-10(A) Sep-18
16
5. ACCEPTANCE CERTIFICATE
Equipment is met mandatory requirements of the state standards, actual
technical documentation, and approved for use.
TEST CERTIFICATE
CPA-10
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
_________________
DD.MM.YYYY
_________________
Full Name

ROBOSUGAR CPA-10(A) Sep-18
17
6. WARRANTY OBLIGATIONS
The manufacturer guarantees trouble-free operation of the equipment
during 12 months from the date of receiving the equipment by dealer (in
accordance with transport documentation); or, in case of purchase
directly through Trapeza LLC, from the purchase date, given that terms
of using, transportation, and storage are met.
The warranty repair is performed upon presentation of this manual and
filled warranty card with the seller’s seal and the date of sale.
Technical specifications of the equipment can be changed 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; nevertheless, the manufacturer is not
responsible for any typographical errors or misprints.
Due to constant improvement of the equipment, technical
specifications are subject to change without prior notice!
7. MANUFACTURER DETAILS
NPO Tvertorgmash LLC
11 Industrial Street, Tver, 170000 Russia
Technical support:
Email: [e-mail]
Phone: [phone]

ROBOSUGAR CPA-10(A) Sep-18
18
ANNEX A.
DUMPING MECHANISM SETTING UP
1. Remove three fasteners; take screws out:
2. Mount the pillar, fix it with the fasteners.
3. Connect electric magnet. Wire colour codes are not important.
Insulate joints if needed.
5. Stuff wires inside the pillar, then put end-piece with the wire into the
end of pillar and tighten the fixing screw:

ROBOSUGAR CPA-10(A) Sep-18
19
6. Install gas spring assembly. It is convenient to do with kettle turned
down. Adjust assembly position it the way that steel bar doesn’t touch
anything during kettle movement. Fix the assembly’s position with two
screws:
7. Put the popcorn container into the cradle and fix it with two plastic
ties.
MAKE SURE THAT KETTLE AND POPCORN CONTAINER DON’T
TOUCH EACH OTHER WHILE CONTAINER IS MOVING!
8. If kettle is touching container during turning down, then pillar position
must be adjusted; to do this, loosen three fixing bolts, adjust pillar
position, and finally tighten all three bolts.

ROBOSUGAR CPA-10(A) Sep-18
20
ANNEX B.
DIMENSION REQUIREMENTS
All dimensions in mm.