RoboLabs Vortex Popcorn Robopop 60 Instruction Manual

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Popcorn machine

VPM-RM4

Instruction manual

Original instructions. Read this document before use and keep it for future

reference. PDF version is available on www.robolabs.pro

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Page 1 Popcorn machine VPM-RM4 Instruction manual Original instructions. Read this document before use and keep it for future reference. PDF version is available on www.robolabs.pro...
Page 2 Contents 1 Safety requirements.......................... .3 2 General information...........................4 2.1 Designation..........................4 2.2 Technical specifications......................4 2.3 Delivery set..........................4 2.4 Packing............................4 2.5 Transporting and storage......................4 2.6 Design and principle of operation....................5 2.7 Stages of operation........................7 2.7.1 Standby mode........................7 2.7.2 Heating stage........................7 2.7.3 Popping stage........................
Page 3 This document (hereinafter — the manual) contains essential information on installation, intended use, and technical maintenance of popcorn machine VPM-RM4 (hereinafter — the machine). The manual is intended for operators who work with the machine, and for technical personnel who conduct installation, commissioning, and technical service. The manual must be kept during all life time of the machine in place readily available for operators, and technical personnel.
Page 4 Safety requirements This is the safety alert symbol. It is used to alert you to potential physical injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. • Not grounded machine can cause electric shock. Power outlet MUST HAVE proper grounding to avoid electric shock.
Page 5 General information Designation Popcorn machine VPM-RM4 (hereinafter — the machine) is intended to make popcorn. Commercial use only. Technical specifications Throughput up to 28 kg/h Rated voltage 400 VAC Rated current 27 A Rated frequency 50 Hz Net dimensions (LxWxH) 1470x610x1700 mm Net weight 250 kg Design life...
Page 6 Design and principle of operation Main components of the machine are shown on Fig. 1. Motor (13) with turbine (25) causes air circulation inside the machine. Air goes from the turbine to the working chamber (20), then to the heating elements area (24), where it is heated, and finally goes back to the turbine. In the low part of the working chamber there is perforated bowl (23), that has many holes of special shape, which cause air vortex inside the chamber as airflow goes through the bowl.
Page 7 Working chamber inside is shown on Fig. 2. The perforated bowl (7) has many holes of special shape. Air flow from turbine goes from below and, due to that holes, creates air vortex inside the chamber (shown by an arrow). Corn kernels come into the chamber from the supply tube (3).
Page 8 Oil pump cabinet is shown on Fig. 4. The oil pump has motor (7) that drives gear-type pump unit (2) that is immersed in oil canister. Cover (4) can be adjusted by height with a fixing screw (3) to fit oil canisters of different height. Oil goes through the pipe that is connected via quick-release connector (5), and then goes to the oil nozzle in the sifter cabinet.
Page 9 2.7.3 Popping stage Machine processes corn kernels by continious flow. 2.7.4 Pause stage Whenever the operator initiates pause, the machine processes current batch of corn, and then stop feeding next batches of corn. The temperature in the chamber is maintained at the set value.
Page 10 Commissioning Not grounded machine can cause electric shock. Power outlet MUST HAVE proper grounding • to avoid electric shock. • Wall receptacle MUST be installed by a qualified electrician. If supply cord damaged, it MUST be replaced by manufacturer, service agent, or a skilled •...
Page 11 Electric requirements The machine requires 3 phase 400 V 50 Hz five-wire system (L1-L2-L3-N-GND). Use 3P+N+PE 32 A 400 V pin and sleeve connector (IEC 60309). Connecting to the mains must be arranged in conformity with all requirements applicable in the country of use at the moment of commissioning.
Page 12 Intended use DO NOT use machine if supply cord, cable plug, or wall receptacle are damaged. • • DO NOT allow supply cord to be twisted, bent, pulled, contacted with sharp edges, or to be mechanically impacted in any other way. DO NOT let supply cord to be in contact with hot surfaces.
Page 13 4. Press START push button on the control panel. Wait until start screen appears: 5. Press BUTTERFLY or MUSHROOM button on the screen, program setting screen appears: 6. ATTENTION! If no button pressed, the machine will proceed to heating stage automatically in 15 seconds.
Page 14 12. To replace full bag of popcorn DO NOT use PAUSE button on the screen. Press SIFTER push button under the screen. The sifter stops for 20 seconds, and then resumes rotation. In this time replace full cart with an empty one. 13.
Page 15 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. Call for a technician. Temperature sensor failure — The temperature reading from the temperature sensor is more than 350°C.
Page 16 Notes on using oil and salt Most kinds of liquid oil without any added powder may be used. Oil pumping rate depends on oil thickness; it is essential to avoid oil temperature fluctuations to keep pumping rate the same. To be sure that oil is kept at the same temperature following conditions must be met: 1.
Page 17 HMI interface The HMI interface consists a range of screens, that provide ability of controlling and monitoring of machine operation, changing parameters of operation and settings of the machine, and also testing of the machine. Start screen Once machine turned on, start screen appears: There are two program buttons, BUTTERFLY and MUSHROOM, which allow to run the machine for processing corn from either of two corn bins.
Page 18 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. It is recommended to choose popping temperature set value for Butterfly from 200…215 °C range;...
Page 19 Left upper corner reads the current temperature in the chamber. Middle white line represents the set value. Two other white lines, above and below, represent the value 10 degrees more and less, respectively. The screen fit 30 minutes of temperature log. In the lower part of the screen are PID parameters.
Page 20 Popping delay — the time machine waits before starting popping mode, in order to make sure that the chamber is heated evenly. Password change — to change the password that is required for program settings. Operation time — total time of machine operation, in hours. Number of starts —...
Page 21 Testing screen To enter general settings screen press SETTINGS on the start screen, type 3333 on the screen keypad, and then press ENTER, the settings screen appears: In this screen one can check operation of different parts of the machine, and also see the status of its sensors and so on.
Page 22 OIL — Adjusts oil pumping rate. Effective only while in this screen, it does not affect the oil pump speed set in Butterfly program settings screen. SALT — Adjusts salt supply rate. Effective only while in this screen, it does not affect the salt supply rate set in Butterfly program settings screen.
Page 23 Cleaning ALWAYS unplug before cleaning. • • DO NOT use excessive water or water jet for machine cleaning. DO NOT spill water on electric panels or parts. Using excessive water during cleaning can cause short circuit and electric shock. • DO NOT immerse machine and/or supply cord into water. •...
Page 24 Weekly cleaning 1. Empty the corn bins and salt bin. 2. Remove wing-screws that fix the corn bins; remove the bins by pulling them out. 3. Wipe internal surfaces of corn bins with a soft clean cloth dampened with mild soap; then remove soap residues with a cloth dampened with water.
Page 25 Technical service ALWAYS unplug while servicing. • • Technical maintenance and repair MUST be conducted by a qualified technician only. • A warning tag (DO NOT TURN ON! WORK IN PROGRESS!) must be placed at the switchboard during servicing. ALWAYS use safety googles while servicing. •...
Page 26 5. Check the cable gland for supply cord. Cord must be tightly secured by the gland. Tighten loosen gland. 6. Check the resistance between the grounding pin in the plug and accessible conductive parts. The result must not exceed 0,2 Ohm. 7.
Page 27 7. Check the heaters EK1-EK4. There should be no open or close circuit, nor ground fault. While at room temperature, resistance of each element should be around 21 Ohm. If heating element terminals, busbars or wires corroded or burnt, replace them. While replacing, use electro-conductive anti-seize paste.
Page 28 Electric panels layout Electric panels component layout is shown on Fig. 7. The component designations corresponds to the same on the wiring diagram. Figure 7...
Page 29 VFD unit High voltage remains in capacitors in the output circuit of the VFD unit. • WAIT AT LEAST 10 MINUTES after VFD unit is de-energized, and then confirm that the • capacitors have fully discharged by measuring the voltage between braking module terminals ;...
Page 30 Table 1: VFD unit UZ settings Parameter Value Description 00.02 9 Parameter reset 01.00 70.00 Maximum output frequency 01.16 4 Auto acceleration/deceleration 02.00 3 Source of first master frequency command 02.01 4 Source of first operation command 02.07 1 Up/Down Mode 02.11 40.0 Keypad frequency command 09.00...
Page 31 Fiber amplifier The purpose of fiber amplifier is to watch the processes happening in the chamber. The amplifier uses heat-resistant fiber that conduct light from the amplifier to the chamber. Head of the fiber is located adjacent to the temperature sensor inside the chamber. Principle of operation is the following: light is emitted from the fiber head, whenever there is an obstacle (a kernel of corn) crosses the light beam closer than certain distance (sensing distance), the amplifier changes its output (sending it to the main PLC).
Page 32 Thermal cut-out Thermal cut-out DC4 (hereinafter — unit) connected to the sensor BT1 located in the heating elements area. Output of the limiter drives the contactor KM1 that feeds the heaters. If the temperature in the heaters area reaches 350 °C (SV+AL1), the PLC is shutting down the heating. If temperature keeps rising, then upon reaching 370 °C, the relay output of the unit opens the contactor, thus de-energizing the heaters.
Page 33 Stepper driver • Changing driver’s settings while it is energized might damage the driver. ALWAYS turn off the machine before changing the driver settings. Stepper drivers drive step motors that control corn and salt augers, sifter, and oil pump, see Table 4. Driver appearance and its terminals layout are shown on Fig.
Page 34 Photoelectric sensor Photoelectric sensors BL1 (Butterfly corn bin), BL2 (Mushroom corn bin), BL3 (popcorn bag) are sensors of diffuse-reflective type. The sensor trips whenever distance (1) to corn seeds in corn bins, or popped corn in popcorn bag exceeds certain threshold, see Fig. 11. The threshold can be adjusted with adjustment screw (3).
Page 35 7.10 Troubleshooting Trouble Possible reason Remedy The machine does not turn on after Machine is not plugged in. Plug in the machine to mains. pressing START push button. Supply cord fault. Check supply cord for continuity. Replace fault cord. No power in the wall receptacle. Check the voltage in the receptacle.
Page 36 Trouble Possible reason Remedy Open circuit. Check continuity between: Circuit breaker QF; • • Filter EMI; Contactor KM2; • Switch SA1; • • Push button SB1; Power supply unit PSU; • PLC DC1. • Restore connection, face up pitted contacts, tighten loosen contacts. Machine doesn’t turn off.
Page 37 Trouble Possible reason Remedy Solid-state relay VS1, VS2 fault. Check relay operation. Load terminals should be closed while control voltage is applied, and should be opened otherwise. Replace fault relay. While replacing, use thermal-conductive paste applied between the relay and the heat sink.
Page 38 Trouble Possible reason Remedy Phase loss. Check if all phases present at the machine’s input and the voltage is in allowed range, 230 V ±10% between the neutral (N) and each phase wire (L1, L2). Door chamber do not close the Adjust door chamber latches to chamber tightly.
Page 39 Trouble Possible reason Remedy Turbine doesn’t work. Motor M1 fault. Check the motor. Its rotor should spin freely. Make sure that there is no open or short circuit, nor ground fault in its windings. Resistance of each winding must be about the same.
Page 40 Trouble Possible reason Remedy Sifter doesn’t stop upon SIFTER Push button SB2 fault. Check the push button operation. push button is pressed. While it is pressed, contacts should open or close (depending on contact block type). Replace fault push button. Open circuit.
Page 41 Trouble Possible reason Remedy Stepper driver DD5 fault. Check to see if there are pulse voltage on (A+), (A-), (B+), (B-) terminals of the driver during its operation. Also it can be checked by swapping with other driver. Replace fault driver. Open circuit.
Page 42 Trouble Possible reason Remedy Switch SA2 fault. Check switch operation. Switch contacts should open and close as switch is operated, in accordance with the wiring diagram. Replace fault switch. Open circuit. Check continuity between: • Heating elements EK5, EK6; Switch SA2; •...

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Vpm-rm4