RoboLabs SUGARLIPS 20 User manual

OPERATING MANUAL
SUGARLIPS 20 (CP-20)
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. Safety components..................................................................................5
1.6. Ambient conditions..................................................................................5
1.7. Main components....................................................................................6
1.8. Getting started.........................................................................................6
2. Intended use..................................................................................................7
2.1. Caramel recipes......................................................................................7
2.2. Machine operation...................................................................................7
2.3. Product quality ........................................................................................8
3. Technical maintenance................................................................................10
4. Troubleshooting...........................................................................................11
5. Transportation and storage..........................................................................11
6. Acceptance certificate..................................................................................12
7. Warranty obligations....................................................................................13
8. Manufacturer details....................................................................................13
Annex A. Electric component list......................................................................14
Annex B1. Temperature regulator settings.......................................................15
Annex B2. Timers settings...............................................................................16
Annex C. Replacing sealing rings....................................................................16

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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!

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1. Overview
1.1. Purpose
SugarLips CP-20 machine intended for cooking caramel and coating popped
popcorn with it (hereinafter –“caramelizer” or “machine”).
1.2. Technical specifications
Productivity
up to 35 kg/hr (75 lbs/hr)
Kettle size
75 liters (20 gallons)
Rated voltage
3/N/PE AC 230/400 V, 50/60 Hz
Rated power
12.2 kW
Overall dimensions
720x900x1150 mm
Weight
100 kg
Ingress protection
IP22
1.3. Delivery set
Caramelizer
1 pc
Popcorn container 75 liters (20 gallons)
1 pc
Container for finished product
1 pc
Documentation set
1 pc
Mixer
1 pc
Deflector
2 pcs
Teflon ring
2 pcs
Silicone ring
2 pcs
Spare PTFE scraper
1 pc
Steel washer
1 pc
M6 screw-bolt
5 pcs
М6 screw-nut
5 pcs
M6 washer
5 pcs
M6 spring washer
5 pcs

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1.4. Power requirements
ELECTRIC SOCKET MUST HAVE GROUNDING CONTACT!
CONNECTIONS MUST BE DONE ONLY BY QUALIFIED ELECTRICIAN!
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
on, 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. Safety components
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.
1.6. 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 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).
During the operation, machine emits a lot of steam and heat. It is essential to
provide exhausting hood (800x800 mm, 1000 cu.m/hr or more) installed over
the kettle.
Ambient conditions have strong impact on the end product quality. See section

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2.3 for more details.
1.7. Main components
Caramelizer has following components: 1 –Kettle with heaters; 2 –Control unit;
3 –Mounting base, 4 –Deflectors; 5 –Mixer, see Fig.1:
Fig. 2 Main components
1.8. Getting started
Unpack machine carefully, check delivery set, and remove protective film from
all surfaces. Put the machine on special table (not included in the delivery set).
Install the mixer inside the kettle, using rubber and PTFE sealing rings, as
shown in Annex C.
Mount two metal deflectors inside the kettle using fasteners from the delivery
set.

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2. Intended use
2.1. Caramel recipes
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.
Recommended
1
Recipe
By default, it is recommended to use the following recipe for caramel mixture
(per 70 liters of popped ‘Mushroom’ popcorn):
- Caramel premix or similar —2800 g
- Sugar (beet or cane) —2000 g
- Coconut oil or butter —240 g
- Water —1000 g
To avoid excessive stickiness it is recommended to use Free-N-Easy liquid
lecithin from Gold Medal Co. Lecithin should be sprayed on popcorn already
coated with caramel, in the ending of mixing stage, before cooling.
2.2. Machine operation
Machine controls has following items on control panel:
- Temperature regulator
- Main switch 3-pos.
The main switch has three positions: HEATING, OFF, MIXING.
Heating Stage
The switch is in HEATING position. The mixture in the kettle is being heated
and periodically stirred with the mixer, to provide proper mixing of all
ingredients. Once temperature set point is reached, operator will hear the sound
alarm.
1
You are welcome 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!

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Mixing Stage
The switch is in MIXING position. Heaters are not energized, mixer operates
continuously.
Operation Order
To make caramel coated popcorn, do the following:
1. Apply liquid lecithin on the kettle sidewall, to minimize caramel stuck.
2. Put caramel ingredients into the kettle. Put popped popcorn into popcorn
container.
3. Turn the main switch to HEATING position; adjust the temperature set point if
necessary.
4. Wait for sound signal.
5. Once temperature is reached, set the switch in MIXING position and dump
prepared popcorn in the kettle.
6. Apply liquid lecithin during mixing, to help popcorn being separated.
7. Once popcorn is properly coated with caramel, tip the kettle with handle,
discharging popcorn onto a cooling table
2
.
8. Once kettle is empty, get the kettle back to straight position and set the
switch to OFF position.
2.3. 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 (180°С)
and give it a try.
2
Cooling table is not included in the delivery set and must be purchased separately.

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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 1.5), some additional
equipment may be required in order to keep popcorn in good condition at
intermittent stages as well as finished product.

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3. Technical maintenance
The maintenance purpose is to keep the machine operable during the entire
service life. The recommended
3
maintenance schedule with types of actions is
presented below:
PROCEDURE
PERIOD
Kettle cleaning
once a day
Outer surface cleaning
once a day
DISCONNECT THE MACHINE FROM THE MAINS BEFORE TECHNICAL MAINTENANCE!
DO NOT USE SHARP TOOLS OR ABRASIVES!
DO NOT LET ALL WATER TO BOIL OUT!
DO NOT PUT MORE THAN 2 LITERS OF WATER INTO THE KETTLE!
DO NOT REMOVE THE LID WHILE KETTLE IS HOT!
HOT STEAM INSIDE! BURN HAZARD!
Kettle cleaning
4
Pour not more than 2 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 (Heet-N-Kleen
or similar).
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!
3
Period may be different. Maintenance procedures must be done as necessary.
4
The machine must be turned on for kettle cleaning procedure.

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4. Troubleshooting
Problem
Possible cause
Possible remedy
Caramel coated popcorn is not
crunchy
Popcorn is still too hot
Too low temperature set
value
Improper recipe
Popcorn had excessive
moisture before coating.
Extreme ambient
conditions.
Make sure that popcorn is properly cooled
down
Increase the temperature set value
Use proper recipe
Make sure that moisture content of popped
popcorn being put in the machine does not
exceed 1.5%
Provide proper ambient conditions and purge
ventilation.
Caramel coated popcorn is too
dark and/or has bitter taste.
Too high temperature set
value
Improper recipe
Decrease the temperature set value
Use proper recipe
Dark thick liquid appears under
the kettle (next to the motor and
the shaft)
Irregular outer surface
cleaning
Mixer sealing rings are
worn out.
Mixer sealing rings are not
in proper order.
Perform cleaning as necessary, on regular
basis
Replace the sealing rings, see Annex related.
Make sure that sealing rings are put in proper
order, see Annex related.
5. 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 and +55°C.

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6. Acceptance certificate
ACCEPTANCE CERTIFICATE
_____________
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

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7. 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!
8. Manufacturer details
NPO Tvertorgmash LLC
11 Industrial Street, Tver, 170000 Russia
Technical support:
Email: [e-mail]
Phone: [phone]

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Annex A. Electric component list
SIGN
DESIGNATION
MODEL
SPECS
AT
Safety limiter
NT-353LF, Tecasa
360°C
BT
Temperature sensor
ДТПК124-00.32/4 Owen
Type K
BZ
Buzzer
SC235B, Sonitron
24 Vdc
C
Capacitor
CBB61
450 Vac, 8 uF
DC1
Temperature regulator
TCN4S-24R, Autonics
230 Vac
DC2, DC3
Timer
AT8N, Autonics
230 Vac
DC2, DC3 sockets
PS-08, Autonics
—
EK1, EK2, EK3
Heater
1GIK3ED30001, IRCA
4 kW, 230 Vac
FV
Voltage control relay
RM17UBE15, Schneider Electric
5 A, 250 Vac
K
Electromechanical relay
G2RV-SR700, Omron
Contact: 6 A, 250 Vac
Input 24 Vdc
KM
Contactor
LC1D32M7, Schneider Electric
32 A, 690 Vac
M
AC motor with gearbox
Y100-140F 104JB30G1542, Linix
140 W, 230 Vac
PSU
Power supply unit
DVP-PS02, Delta
Output: 2 A, 24 Vdc
QF1
Main circuit breaker
S203-C32, ABB
32 A, 400 Vac
QF2
Motor circuit breaker
S201-C2, ABB
2 A, 400 Vac
SA
Switch
В101S30, Emas
4 A, 250 Vac
Contact block
B1, Emas
4 A, 250 Vac
VS
Solid state relay
SA842070, Celduc
25 А, 600 Vac, input 24 Vdc

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Annex B1. Temperature regulator settings
Parameter
Value
Description
Temperature sensor —K type thermocouple
90
SV low-limit value
220
SV high-limit value
Control type
Control output
20.0
Control cycle
AL1 alarm operation mode
5
Alarm output hysteresis
-5
AL1 alarm temperature
100
Proportional band
0
Integral time setting
0
Derivative time setting
Lock setting
Default temperature set value (SV) is 170°С.

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Annex B2. Timers settings
DC2: mode B, 3 sec.
DC3: mode B, 30 sec.
Annex C. Replacing sealing rings
Fig. 1 Mixer sealing rings: 1 –PTFE ring; 2 –Rubber sealing ring; 3 –Fixing screw bolt
To replace the rings, loose the fixing bolt, take off the mixer from the shaft,
replace old rings with new ones, note the correct disposition order –rubber
sealing ring must be under PTFE ring.