RoboLabs ROBOPOP 60 User manual

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

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Table of contents
Safety requirements...........................................................................................3
1. Overview........................................................................................................4
1.1. Purpose...................................................................................................4
1.2. Technical Specifications..........................................................................4
1.3. Delivery Set.............................................................................................4
1.4. Power Requirements...............................................................................5
1.5. Ambient Conditions.................................................................................5
1.6. Safety Components.................................................................................5
1.7. Main Components...................................................................................7
1.8. Getting Started........................................................................................9
2. Intended Use...............................................................................................10
2.1. Operation Modes...................................................................................10
2.2. Quick Operation Guide..........................................................................10
2.3. Program settings...................................................................................14
2.4. System 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 settings...............................................29
Annex C. VFD settings ....................................................................................30
Annex D. Testing mode ...................................................................................31
Annex E1. Chamber optical sensor setup........................................................32
Annex E2. Corn hopper sensor setup..............................................................33
Annex F. Parts list............................................................................................34

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Safety requirements
DO NOT WASH MACHINE WITH WATER!
ONLY INSTRUCTED 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!

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1. Overview
1.1. Purpose
Vortex Popcorn machine VPM-RM4 (Robopop® 60) (hereinafter “popper” or
“machine”) is a hot-air popper for making popcorn. Both Butterfly and
Mushroom varieties can be processed. Built-in automatic salt/oil application
system allows making salted movie-style popcorn. Popper built on patented
Vortex technology that has following benefits:
- No oil is used at all. Hot-air popped popcorn has no carcinogens and
trans-fats; moreover, production cost is lower.
- Maximum taste and nutritional value are preserved, 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 scraper
1 pc
Cleaning brush
1 pc
Popcorn cart
2 pc
LDPE bags
50 pcs
Spare halogen light bulb
1 pc
2 L cup
1 pc
Documentation
1 set
1
Weight of raw corn processed. Actual production capacity of ready-to-eat product depends
on corn quality and settings. Weight loss caused by natural reasons during the process may
be up to 20%.

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1.4. Power Requirements
CONNECTIONS MUST BE DONE ONLY BY QUALIFIED ELECTRICIAN!
ELECTRIC SOCKET MUST HAVE GROUNDING TERMINAL!
IF SUPPLY CORD DAMAGED, IT MUST BE REPLACED BY MANUFACTURER, SERVICE AGENT, OR
QUALIFIED PERSONS IN ORDER TO AVOID HAZARD!
It is necessary to periodically check electric connections, including grounding
connection. Whenever any fault conditions are found, do not turn the equipment
and call for qualified electrician!
Equipotential bonding wire (up to 10 sq.mm) shall be connected to screw
terminal marked with IEC 5021 sign.
Cable plug is not included in the delivery set. Use a 32 A plug. Refer to the
wiring diagram on the power cord label.
It is necessary to check electric wires 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.
While in operation, a lot of moisture and heat is coming out of the popper. It is
essential to provide exhausting hood (800x800 mm, 750 cu.m/hr or more)
installed above popper’s output port.
Ambient conditions have strong effect on the end product quality! See
section 2.7 for more details!
1.6. Safety Components
EMERGENCY STOP button located on the back side of the machine should be
used in case of emergency, pressing the button turns machine off immediately.
USING EMERGENCY STOP BUTTON MAY LEAD TO CHAMBER CLOGGING!

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32 A circuit breaker protects the machine from short circuit.
Voltage control relay analyzes voltage at the machine’s input. Tolerance gap is
preset on the unit. If the voltage value is beyond the gap, popper won’t be
energized.
Safety temperature sensor is located 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 screen.
Popper has four swivel lockable casters, which avoid spontaneous movements.

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1.7. Main Components
Main components are: 1 –Turbine (not shown); 2 –Chamber; 3 –Corn
Hoppers; 4 –Controls; 5 –Salt Hopper; 6 –Sifter; 7 –Scrap Tray; 8 –Oil
Pump; 9 –Oil cabinet; 10 –Popcorn Cart, see Fig.1:
Fig. 1 Main components
Turbine (Blower)
The turbine provides constantly circulating airflow inside the popper. This is a
direct type drive; the blower sits on motor’s 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 the chamber
once popped.
Chamber can be easily accessed through the door provided. Halogen lamp
illuminates chamber inside, helping operator to control the operation.

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Chamber is equipped with temperature sensor and optical sensor.
Chamber optical sensor
The chamber optical sensor monitors processes happening in the chamber.
Popper uses signal from this sensor in order to maintain smooth and effective
operation process.
Chamber temperature sensor
Chamber temperature sensor helps to maintain the temperature in the chamber.
Corn sensor
Each corn hopper has corn sensor that controls amount of corn left in the
hopper. Sensor trips whenever few kg of corn are left in hopper; 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. Turns oil warmer on.
HMI panel. Two-way communication between machine and operator.
Salt feeder
Salt applicator includes following parts: salt hopper with cover, feeding auger,
blowing fan, and removable salt application tube.
Oil compartment and oil pump
Oil compartment has enough room to accommodate two oil canisters, 22 kg

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each. Draw-out tray makes canister replacing easier. Heating elements below
compartment are provided.
Popcorn cart
Two movable carts and 200 liter bags (LDPE) are included in the delivery set.
Using two carts makes easier changing full bag for an empty one. The machine
is equipped with cart sensor tripping whenever cart is full and needed to be
replaced.
Cart sensor
The sensor trips when plastic bag in cart is full with popcorn. Once sensor is
triggered, warning message appears on the screen and audible alarm 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. Turn the machine on by pressing START button.
Check sifter operation. Press SIFTER RUN&STOP button and hold it for a
while. Sifter should rotate then. If it does not rotate evenly and extraneous
sound is heard, it means that sifter isn’t aligned on the rollers. To align the sifter,
lift it with hands and place on the rollers.

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2. Intended Use
2.1. Operation Modes
The popper has following operation modes:
- Heating mode. Once desired program button is pressed, popper
automatically starts to heat up. Upon reaching certain temperature popper
switches automatically to popping mode.
- Popping mode. This is the main operation mode.
- Pause mode. Popper doesn’t process corn in this mode, but maintains
temperature in the chamber; thus, popping process can be resumed in no
time.
- Cooling mode. Before turning 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!
Make sure that scrap tray is empty and chamber is clean and not clogged.
Put empty plastic bag into popcorn cart and put the cart under the sifter.
Put raw corn in corn hoppers, salt in salt hopper, and liquid oil in oil
compartment. Turn the machine on. Start screen will appear:

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Fig. 2 Start screen
Press Butterfly or Mushroom program button. Program settings screen will
appear:
Fig. 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

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Cart/Bag replacing
There are two carts for plastic bags included in the delivery set. Make sure that
you put plastic bag into each cart prior to use. Each cart is equipped with swivel
casters; it is convenient to keep empty cart close to full cart and once first cart is
full, then swiftly shift them.
Also, it is possible to give a short break to the sifter in order to replace cart or
bag. Press and hold SIFTER RUN&STOP button for 1 sec. Sifter will stop in
smooth manner. After 10 seconds its operation will be resumed automatically.
DO NOT USE PAUSE BUTTON FOR CHANGING THE CART!
Program settings adjustment
Program settings can be adjusted either before warming up stage or during
popping stage. During popping stage, press and hold sprocket icon button in the
upper right corner of 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, ‘Load corn in left (right)
hopper’ message will appear on the screen. If more popcorn needs to be
processed, top up the hopper. Otherwise, ignore the message, and machine will
process the corn amount left. See “Corn Sensor Delay” setting in section 2.3.
There are no sensors for oil and salt. Refill oil and salt as necessary.
Pause mode
The purpose of pause mode is to stop popcorn production for a while, or to
switch between Butterfly and Mushroom programs. During the pause mode
oil/salt operation is suspended; the temperature in chamber is kept on the set
value.
DO NOT USE PAUSE BUTTON FOR CHANGING THE CART!

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Program change
To switch the program, press PAUSE button. Corn supply will stop immediately.
It will take 3 minutes to finish processing of corn kernels in the chamber. After
this, two program buttons, Butterfly and Mushroom, will appear on the screen.
Cooling down
To stop the operation, TURN OFF button should be pressed. Corn feeding will
be stopped immediately. Corn in the chamber will be processed. If Butterfly
program was chosen, oil and salt application will be active for some time.
Cooling takes some time, after a while the main screen appears.
Turning off
To turn the machine off, press and hold TURN OFF button. Also, machine will
be turned off automatically after 10 minutes if nothing pressed.
Chamber clogging
If 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 completely.
5. Take out the door and clean up the chamber. Pay attention to chamber inner
hollows as well as to corn delivery tube, which may be clogged with popped and
unpopped popcorn. Use a suitable tool (piece of cable, or probe or hose), which
is flexible and strong enough for shattering the clog inside the tube.
6. Once chamber is clean close the door and turn the machine on. Release
OVER.LOCK indicator. See section 2.4.
CHAMBER CLOGGING CAUSED BY ACTIONS OF UNEXPERIENCED USERS OR IMPROPERLY
CHOSEN PARAMETERS IS NOT A WARRANTY CASE!

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2.3. Program settings
Machine settings directly affect popcorn quality as well as machine operation. It
is important to understand the way each parameter or setting affects end
product and machine operation; and also the way how settings interact to each
other.
There are two settings groups: program settings and system settings.
Popping temperature
Popping temperature is to be chosen by user. During operation, the machine
maintains the chamber temperature at this value. Due to different features of
used corn and chosen settings, and also nature of complex processes
happening in the chamber, slight temperature fluctuation is allowed (±5°C).
Popping temperature 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. Current chamber temperature can be found in
the upper left corner of the popping screen.
Oil and salt feed rate
Oil and salt are only available in Butterfly program only. Oil and salt feed rate
values directly affect amount of oil/salt to be supplied to the product for the
same time.
2.4. System settings
System settings can be accessed from the start screen or from popping screen.
Press SETTINGS, enter password ‘6666’, and confirm with ENTER. System
settings screen will appear:

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Fig. 5 System settings screen
All values in blue are available for adjustment. Press any of them, type new
value and confirm with ENTER. Values in black are for reference only and
cannot be changed.
Turbine speed
Turbine speed defines airflow intensity in the chamber. Due to popcorn shape,
turbine speed for Mushroom is normally higher than the same for Butterfly.
As like the popping temperature, extreme values of turbine speed may cause a
bunch of issues. Too low values lead to popcorn accumulation in the chamber,
and finally clogging. Too high values increase scrap rate.
Airflow 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. If high quality corn is used, then auger
rate may be increased. Keep this setting at low value to make machine’s
behavior more stable and tolerant to low quality corn, improperly chosen
parameters and unexperienced operators.
Oil turn on delay
Defines how soon oil and salt applicators will be turned on after the machine
turned in popping mode (corn started to be supplied into the chamber).

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Oil turn off delay
Time delay oil and salt applicators operates once machine is turned in pausing
or cooling mode.
Sifter speed
Sifter speed setting defines how fast sifter rotates. Too slow sifter may cause
chamber clogging; too fast 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 parameters to be changed by unauthorized personnel.

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2.5. Operation indicators
In the lower part of the settings screen there are some indicators presented
2
:
OVERLOAD (OVER.LOCK)—chamber sensor operation indicator. Becomes
red once tripped.
MUST be released in order to continue operation! Press and
hold until it turns black!
EM.STOP (EM.LOCK) —becomes red once machine has been turned off with
emergency stop button
3
.
MUST be released in order to continue operation! Press and
hold until it turns black!
PURGE ON/OFF (PURGE ON) —automatic chamber purge option. While
activated, machine periodically increases turbine speed on a time basis defined
by “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 language.
While machine in popping mode most system settings can be adjusted, except
(no access to operation indicators though). Press and hold sprocket icon button
in the upper right corner of the popping screen (see Fig.5). Parameters screen
will appear. Press MODIFY button, enter password ‘6666’, and press ENTER.
2
Some settings are not available during operation mode.
3
Upon certain temperature conditions.

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2.6. Display notifications
During normal machine operation different notifications may be displayed on the
screen. Below is the list and operator’s actions suggested to be taken.
Heating / Popping / Pause / Cooling
Indicates current operation mode.
Load corn in left (right) hopper
Corn sensor has been tripped. Refill the hopper or let the machine to process
kernels left. See also “Corn Sensor Delay” setting.
Change bag with popcorn
Bag sensor is tripped. Replace the full cart. Failing to do so will lead to sound
alarm activation and machine will automatically go in pause mode shortly.
Oil and salt will start automatically
While Butterfly program in operation, this message will appear once corn
kernels started to be supplied 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 chamber. If it is not sufficient, then sensor trips and machine switches
into cooling mode, and said message can be seen on the screen.
Chamber clogging sensor trips not only in case of actual clogging, but also in
case if too small amount of corn was put in the hopper or corn sensors have
been blinded (for purpose or incidentally). To continue operation, related
indicator should be released. See “Overload” indicator in section 2.4.
Automatic machine disconnection
Machine has been forcedly switched into cooling mode. Use an observation port

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on the chamber’s door to make sure that the chamber is really clogged. Wait
patiently while machine is cooled down. Do not open the chamber, do not use
fire extinguisher! Once the machine is cooled down, 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 more than
350°C.

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2.7. Popcorn quality
Popcorn is a very sensitive product that requires ultimate attention towards
many aspects. Understanding popcorn processing technology is the key to
good quality production.
Raw corn
It is impossible to get good stable result using low quality supplies, first of all,
raw corn kernels. Choose reputable and reliable corn suppliers. Make sure that
raw corn is stored and handled properly at your production site. Ask your corn
suppliers for recommendations on storage and handling recommendations.
Popcorn crunchiness
Popcorn is crunchy when its moisture content doesn’t exceed 1-1.5%. 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 product flow is
established. To provide smooth temperature regulation, corn auger rotates
slower in the beginning of popping stage and gradually increases its speed until
set value is reached.
For this reason, it is strictly necessary to have long operation sessions rather
than short ones. This is essential for high quality of the end product and high
production capacity as well as for stable machine operation.