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: