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Summary of Contents for RoboLabs CP-20EU
- Page 1 Caramel and savory coater CP-20EU 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 2: Table Of Contents
Contents 1 Safety requirements.......................... .4 2 General information...........................5 2.1 Designation..........................5 2.2 Technical specifications......................5 2.3 Delivery set..........................5 2.4 Packing............................5 2.5 Transportation and storage......................6 2.6 Design and principle of operation....................6 3 Commissioning..........................9 3.1 Ambient requirements........................9 3.2 Unpacking and installation......................9 3.3 Electric requirements...................... - Page 3 This document (hereinafter — the manual) contains essential information on installation, intended use, and technical maintenance of CPA-20EU caramel and savory coater (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.
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Page 4: Safety Requirements
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 •... -
Page 5: General Information
General information Designation Caramel and savory coater CPA-20EU (hereinafter — the machine) is intended for making caramel and savory coated popcorn. Commercial use only. Technical specifications Kettle volume 75 L Rated voltage 400 V Rated frequency 50 Hz Rated current 15 A Dimensions (LхWхH), not more 211×99×173 cm Weight, not more... -
Page 6: Transportation And Storage
Transportation and storage The machine 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 plus 55 °C. Design and principle of operation Main components of the machine are shown on Fig. - Page 7 Inside the kettle (see Fig. 2) following elements are located: Mixer (1) that stirs slurry and popcorn. Fixing Nut (3) secures the mixer on its Shaft (4); it can be released so the mixer can be removed for cleaning purposes. Deflectors (2) speed up mixing process.
- Page 8 Operation of the machine consists of three stages: 1. Caramel or savory slurry is prepared in the kettle. Heating elements provide needed temperature. Mixer operates intermittently, providing even texture of the slurry. 2. Once slurry is done, dumping mechanism automatically dumps popped popcorn into the kettle.
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Page 9: Commissioning
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 person in order to avoid hazard. - Page 10 8. Release retaining roller in the dumping mechanism, see Fig. 4. Figure 4 9. Turn over the flipping handle with bucket cradle, and then secure the retaining roller, see Fig. 5. During flipping the cradle, make sure the steel wire fits the pulley of dumping mechanism.
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Page 11: Electric Requirements
15. Connect machine to the power service. 16. Perform operation check (see corresponding section). 17. Fill in ‘Commissioning report’ in Factory Certificate. 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
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. •... -
Page 13: Caramel Popcorn Making
Caramel popcorn making 1. Prepare popped popcorn, and caramel ingredients. 2. Set the main switch to (I) position. Blinking H indicator means that the machine is ready for operation. 3. Pull the handle of dumping mechanism down until the electric magnet snaps and holds the plastic bucket in low position. -
Page 14: Temperature Set Up
Temperature set up Caramel quality depends on set temperature. It is necessary to find optimal set value for each recipe and machine. In the beginning, it is recommended to do few trial batches to find optimal temperature set value. On thermostat panel (see Fig. 7) there are two display lines. The upper line (1) reads the current temperature in the kettle. -
Page 15: Thermal Cut-Out
Thermal cut-out A thermal cut-out of capillary type is installed in the kettle. Its sensing element is mounted in the heating elements area. In case of heating elements overheating, the thermal cut-out opens the power circuit for the heating elements, so to avoid kettle overheating. -
Page 16: Cleaning
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 17 10. Press M push button; the kettle starts to tilt down. Place the container under the kettle, wait for water to come out; the kettle moving might be stopped at any moment by pressing H push button. 11. After all water is gone from the kettle, press C push button; kettle will start to be back in the upright position.
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Page 18: Technical Service
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. • Make sure the kettle is cooled down before servicing. -
Page 19: Technical Maintenance Stage 1 Schedule
6.1.1 Technical maintenance Stage 1 schedule 1. Ask the operators who work with the machine for any issues related to the machine and its operation. 2. Ensure that the machine is installed in accordance with the installation instructions (see section 3). 3. -
Page 20: Technical Maintenance Stage 2 Schedule
6.1.2 Technical maintenance Stage 2 schedule 1. Release fixing nut (2) (see Fig. 9), take off the mixer (1), check sealing collar (3) and PTFE collar (4) if they are worn out. Replace worn out collars. Figure 9 2. Tilt the kettle, acting as described in cleaning section, then unplug the machine. 3. - Page 21 the motor windings. There must be no short nor open circuit, as well as no ground fault. 10. Take off the mixer motor from the mixer shaft, and then remove covering plate so to get access to the heating elements EK1-EK3. Inspect heating elements terminals, as well as respective wiring.
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Page 22: Supply Cord Replacing
Supply cord replacing 1. Unplug the machine. 2. Open electric panel. 3. Disconnect supply cord wires from terminals. 4. Release cable gland, remove old cord. 5. Insert new cord in the cable gland; connect to the terminals. 6. Tighten cable gland; make sure the cord is secured firmly and cannot move back and forth through the gland. -
Page 23: Kettle Position Sensors
Kettle position sensors Proximity sensors BL1 and BL2 are used to control position of the kettle, see Fig. 12 (kettle is not shown for clarity). The sensors react to steel pin that is installed on the kettle. When the kettle is in upright position, the pin is placed in front of BL1 sensor. -
Page 24: Thermostat
Thermostat Thermostat DC3 (hereinafter — unit) connected to a sensor BT located in the kettle. While in operation, the upper display line reads current temperature in the kettle (PV), lower display line reads set value (SV). The unit is in operation mode. There are two setting groups, Group 1 and Group 2. -
Page 25: Vfd Units
VFD units 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 26 Table 2: Module UZ1 (kettle tilt) settings Parameter Value Description 00.02 Parameter reset 00.03 Start-up display selection 01.00 50.00 Maximum output frequency 01.09 Accel time 1 01.10 Decel time 1 01.16 Auto acceleration/deceleration 02.00 Source of first master frequency command 02.01 Source of first operation command 02.04...
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Page 27: Electric Panel Layout
Electric panel layout Electric components designations is shown on Fig. 14. For component designations see wiring diagram. Figure 14... -
Page 28: Troubleshooting
Troubleshooting 6.8.1 Machine does not turn on 1. Machine is not plugged to the mains. Plug in the machine to mains. 2. Emergency stop switch SA2 is actuated. Turn the switch actuator clockwise to release. 3. Emergency stop switch SA2 fault. Check the switch operation. While not actuated, its contacts should be closed. -
Page 29: Mixer Does Not Spin
While replacing, use thermal-conductive paste applied between the relay and the heat sink. Tighten all loosen mounting joints. 3. Contactor KM1 fault. Check the contactor operation. Its core should move back and forth easily, no short or open circuit in its coil. While the core pushed inside, contacts (1), (3), (5), (13) should be closed to (2), (4), (6), (14), respectively;... -
Page 30: Plastic Bucket Does Not Tip
6.8.5 Plastic bucket does not tip 1. Steel cable torn down or its fixing is loosen. Check the steel cable and its fixing. Replace torn steel cable. 2. Gas spring fault. Check gas springs. Replace fault gas springs. 3. Relay K3 fault. Check relay operation. When control voltage is applied to terminals (A1+) and (A2-), contacts (11) and (14) must be closed;... -
Page 31: Kettle Tilt Motor Gets Too Hot
6.8.8 Kettle tilt motor gets too hot 1. Proximity sensor BL1, BL2 fault. Check proximity sensor operation and make sure they are properly positioned and fixed. Replace fault proximity sensor. 2. Open circuit. Check continuity between: BL1, BL2, DC1, PSU. Restore connection, face up pitted contacts, tighten loosen contacts. -
Page 32: Circuit Breaker Trips
3. Extension module DC2 fault. Check the module operation. When output LED are lit up, respective output terminals (Y0-Y7) and C0 terminal must be closed. Replace fault module. 4. Open circuit. Check continuity between: HL1-HL3, DC2, PSU. Restore connection, face up pitted contacts, tighten loosen contacts.
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