- Robopop
Contents
1. DF A model Robopop Mark 3 has not function change corn feeder Popcorn machine Robopop Mark 3 DF is equipped with double corn feeder which allows to quickly switch between salted popcorn butterfly and popcorn mushroom for further caramelization Every recipe is linked to it s feeder fig 2 So the recipe lt lt BUTTERFLY gt gt will enable the left feeder with index X and the recipe lt lt MUSHROOM gt gt will activate the right feeder with index O It means that if you select lt lt MUSHROOM gt gt recipe corn will be supplied from the right feeder To switch from one feeder to the other during popping process it s necessary to press the button lt lt CHANGE FEEDER gt gt fig 9 Butterfly POPPING Temp 207 5 Corn ON Salt ON Oil ON Fig 9 Operation mode for the machine Mark 3 DF In this case the machine will go to popcorn change mode fig 10 The active corn feeder will be disabled immediately salt and oil supply will be stopped in 1 5 min and sifter will be disabled in another 1 5 min Fig 10 Change of corn feeder The machine will go to feeder selection mode fig 11 As soon as the sifter stops it will be necessary to clean it by removing oil and salt residues and afterwards select another feeder by pressing the button lt lt MUSHROOM gt gt for example fig 11 CHOOSE FEEDER CHANGE BAG AND CLEAN SIFTER Fig 11 Feeder selection after popcorn change The2. on the screen fig 12 2 Popcorn machine model Mark 3 or Mark 3 DF Software version Total operation time of the machine Tons of corn popped by the machine Number of chamber overloads Number of emergency shutdowns of the machine Main recommended temperature ranges for various types of corn Information Model Firmware ROBOPOP MARK 3 LCD 3MDF V3 K306 M3DF V3 NO DATA Key operation parameters Operation time 0 0 hours Corn total 1 0 00 tons Corn total 2 0 00 tons Overload IRI 0 Emergency stop 0 Popcorn butterfly Preferred and Weaver temp 210 C Popcorn mushroom Preferred Jumbo temp 215 C Chamber Cleaning Popcorn mushroom Weaver and Vogel temp 230 C Robopop and Vortex Popcorn are registred trade marks All rights reserved Fig 12 2 Information screen The data on this screen are only for reading and cannot be modified To go back to the main screen press the button lt lt BACK gt gt Popcorn machine Robopop Mark 3 and Mark 3 DF User guide to set up popcorn machine Firmware V3 Maintenance manual 1 st access level 2 1 Modification of recipe settings In order to be able to modify the recipe settings it is necessary to get access to settings Press the button lt lt SECURITY LEVEL gt gt on the main screen fig 2 and then enter the code lt lt 666666 gt gt fig 13 aoro RIAAN DUT DATA MIN 0 MAX 999999 1 2 3 D ee Fig 13 Entering the access co
3. signal OIL PUMP activation of oil supply pump Testing WARNING IGNORANCE IN OPERATION LEADS TO RUINING MACHINE MOTOR ON HEATER OFF TEMP 190 3 C 2700 RPM HEATER CTRL OFF CORN F1 OFF SIFTER OFF SALT FAN OFF SALT FEED OFF SEPARATOR OFF ALARM OFF OIL PUMP OFF Fig 21 Test mode The data from the following sensors are displayed in test mode TEMP 180 C current temperature from temperature sensor Sensor Corn 1 optical sensor to check the availability of corns in corn feeder for model Mark 3 DF sensor for feeder with index X Sensor Corn 2 only for models Mark 3 DF optical sensor to check the availability of corns in corn feeder with index O Sensor Bag optical sensor to check the availability of popcorn in the bag Sensor Overload optical sensor to define the chamber overload with corns To exit the test mode press the button lt lt BACK gt gt In this case all activated machine units will be stopped and the access level will be reset to zero 3 2 Emergency stop meter reset To reset the emergency stop meter it is necessary to get access to test mode see 3 1 Press the button lt lt INFORMATION gt gt on the main screen Press the button R fig 12 2 near the emergency stop meter on the main screen 3 3 Error codes on display While the machine is heated the working capacity of the main machine units is checked Mushroom ATTENTION CHECK CHAMBER L
4. 5 Salt input rate 5 Oil input rate ON Fig 3 Recipe screen The machine will activate the warm up mode fig 3 In this case you will hear the specific noise from turbine running and the light will go on in the chamber Pressing the button lt lt TURN ON gt gt will interrupt the warm up process and the machine will go to cooling mode The details of the cooling mode see in chapter 1 6 Machine turn off Butterfly HEATING Fig 4 Chamber warm up A wide white strip in the middle of the screen is the temperature scale showing the temperature increase in the chamber As soon as this strip covers the whole width of the screen the machine will switch to popping mode fig 5 The sifter will automatically start rotating during chamber warm up the temperature scale will cover around 80 of the screen width Butterfly POPPING Temp 209 3 Comm ON Salt ON Oil ON Fig 5 Popping mode As soon as popping process starts the corn feeder will be activated and the corn will be fed into chamber If the recipe requires the use of salt and oil they will be automatically supplied only after popcorn comes into sifter This will start within around 3 minutes in case of standard settings 1 3 Interrupt the machine operation In case of any need to interrupt the popping process press the button lt lt PAUSE gt gt The machine will go to standby mode see fig 6 Butterfly TEMPORARY STOP Temp 213 1
5. Corn OFF Salt ON Oil ON BACK TO POPPING Fig 6 Standby mode The activation of standby mode will immediately stop the corn feeding process but salt and oil feeding will be stopped with some delay automatically In case of standard settings oil and salt feeding will be stopped only in 1 5 minutes this time is required for popcorn to leave the sifter completely To continue the process press button lt lt BACK TO POPPING gt gt fig 6 1 4 In process messages If during the popping process there will be no more corn in feeder the machine will inform you by giving the alarm signal and displaying the corresponding alert message on the screen fig 7 Butterfly FEED BUTTERFLY ATTENTION Temp 20914 Corn ON Salt ON Oil ON Fig No more corn If the hopper is not filled up with corn within 30 sec the machine will automatically go to standby mode fig 6 If during the popping process the bag with popped popcorn becomes full to the top the machine will inform you by giving the alarm signal and displaying the corresponding alert message on the screen fig 8 Butterfly ATTENTION BAG OVERLOAD Temp 211 1 C Salt ON Oil ON Fig 8 Popcorn bag is full to the top If you do not replace the bag within 30 sec the machine will automatically go to standby mode fig 6 1 5 Replacement of corn feeder only for Mark 3 DF IMPORTANT This information applies only to model Robopop Mark 3
6. IGHT Fig 22 Displaying the error messages during machine heating In case of any failures the corresponding information will be displayed on the screen fig 22 The machine will go to automatic OFF mode without participation of the operator fig 23 COOLING CHECK CHAMBER LIGHT AUTOMATIC TURN OFF Fig 23 Machine automatic OFF Error codes their causes and elimination methods are described below ERR01 Check temperature sensor The machine will analyze the temperature sensor data The temperature parameters from 10 C to 270 C are considered as correct If the temperature inside the chamber is different from mentioned above the error will be detected Elimination method for this problem is the replacement of temperature sensor In some cases such error can occur if the machine was kept under low temperatures for a long time and was not able to get heated enough In this case it is recommended to wait until the machine gets heated ERRO2 Check chamber light One of the main causes of such error is the failure of either the lighting lamp in chamber or the lamp power unit To eliminate this problem replace the failed unit If during diagnostics it is detected that the lamp and the power unit are in order then such error is caused by the failure of chamber overload sensor the sensor is constantly darkened or by foreign objects eg corn peels falling onto the sensitive element ERRO3 Check overload sensor This e
7. Popcorn machine Robopop Mark 3 and Mark 3 DF User guide to set up popcorn machine Firmware V3 User manual 1 1 Circulate oil Prior to start making popcorn it is required to perform some preparatory actions First fill up the feeder with corn second check up the salt availability in the salt feederand the oil level in oil canister In case of using the oil with melting temperature exceeding the room temperature coconut oil palm oil warm up the oil and check the oil feeding system prior to start the machine If you fail to do this the solidified oil can result in machine damage Robopop machine is equipped with the heated oil chamber However this chamber is intended only to keep the oil in melted condition and should not be used for melting the solidified oil It is also recommended to use this chamber for the storage of oil nozzle and oil hose when the machine is not in use This will help to avoid oil solidification inside the feeding system To switch on the chamber it is necessary to set toggle switch lt lt OIL WARMER gt gt to lt lt ON gt gt position see fig 1 ortex popcorn machine Robopop am ON an ON 9 N AS fi AW POWER RUSSIA USA EU PATENT AND PATENT PENDING Fig 1 Control panel of Robopop machine After the oil is melted it is necessary to bleed the oil nozzle to make sure that oil enters the sifter To do this dip the oil suction unit into the oil cani
8. corn feeder is activated For example if during popping process the temperature goes below 190 C having the parameters shown in fig 16 the corn feeding will be stopped automatically and the machine will go to warming mode In addition the feeder will be stopped when the temperature in chamber goes up above 230 C which prevents the corn burning lt lt HEATER gt gt indicator shows if heating elements are enabled at the moment Modification is possible only for proportionality coefficient as well as integration and differentiation time The black line in temperature diagram shows the current temperature in chamber the red line shows the temperature setting in chamber 2 4 Modification of parameters during machine operation To get access to parameters modification during the machine operation it is necessary first to get access to settings see par 2 1 and then start the machine in normal manner Additional functions will be available in popping mode Modification of PID regulator parameters and viewing of chamber temperature diagram Modification of current recipe parameters Modification of machine units operating parameters In order to go to PID regulator screen press the button Temp 210 C fig 17 during the popping process Butterfly POPPING Temp 21411 Corn ON Salt ON Oil ON Fig 17 Popping mode To modify the popping parameters it is necessary to pause the machine by pressing th
9. de NA CMe Hb A3biKa H KMHTE SECURITY LEVEL Be eanre 6666 For changing language press SECURITY LEVEL enter 666666 aE E Then the message will appear on the main display access to all settings After selecting one of the recipes lt lt BUTTERFLY gt gt or lt lt MUSHROOM gt gt you will get the recipe screen but now you will have the access to modifying the settings fig 14 To make the settings higher press the button gt gt to make the settings lower press the button lt lt These buttons are available opposite each parameter The modified parameters will be stored automatically The temperature mode in the chamber can be modified from 200 C to 235 C with 5 C interval Corn feeding level can have the following values MIN 2 3 4 5 6 MAX The minimum value corresponds to the productivity 10 kg of corn per hour maximum value 34 kg per hr Salt feeding level has the following values OFF MIN 2 3 4 5 6 7 8 9 MAX Maximum salt feeding level corresponds to 1 5 kg of salt per hr this value is actual for salted mixture Flavacol Oil feeding has only two values OFF oil feeding is off and ON oil feeding is on Mushroom Temperature lt lt 215 0 C gt gt Feed rate lt lt 5 gt gt Salt input rate OFF gt gt Oil input rate OFF gt gt Chamber Cleaning ON Fig 14 Modification of recipe settings lt lt MUSHROOM gt gt recipe has one
10. e button lt lt PAUSE gt gt After this press the button TEMPORARY STOP fig 18 You will get to the screen for modification of popping parameters fig 19 In this case the machine will go to standby mode Butterfly TEMPORARY STOP press here to change popping options Temp 208 1 Corn OFF Salt ON Oil ON Fig 18 Standby mode This screen is similar to the screen shown in fig 14 The popping parameters are modified by pressing the buttons lt lt or gt gt To go back press the button lt lt BACK gt gt To resume the operation press the button lt lt BACK TO POPPING gt gt fig 18 Butterfly Temperature lt lt 210 0 5 gt Feed rate lt lt 5 gt gt Salt input rate lt lt 5 gt gt Oil input rate lt lt ON Temp 208 17 C Corn OFF Salt ON Oil ON Fig 19 Modification of popping parameters To get access to the machine units performance settings press the button lt lt SETTINGS gt gt Fig 19 To reset the access level to zero press lt lt SECURITY LEVEL gt gt on the main screen fig 2 and then press lt lt ENTER2 gt fig 13 without entering any password Popcorn machine Robopop Mark 3 and Mark 3 DF User guide to set up popcorn machine Firmware V3 Service manual 2 nd access level 3 1 Testing of individual machine units In order to be able to start individual machine units it is necessary to get access to test mode To do this press the button lt l
11. hine will be automatically switched to pause mode During this time the alarm signal will also go on if the bag is filled to the top with popcorn if the corn feeder is empty and the chamber is overloaded MIN sifter speed rpm minimum sifter speed corresponding to minimum supply of corn MAX sifter speed rpm maximum sifter speed corresponding to maximum supply of corn Sifter rotation speed depends on corn feeding speed This is done to ensure the equal sifter filling with corn MAX salt rate speed rpm maximum speed of salt feeder screw rotation corresponding to maximum recipe value Settings Chamber cleaning in 54 min After alarm pause 30 0 s MIN sifter speed 40 rpm Current sifter speed 0 rpm MAX sifter speed 90 rpm Current feed rate speed 0 rpm MAX salt rate speed 40 rpm Current impeller speed O rpm Flavoring feed rate delay 120 0s Flavoring stop delay 90 0 s MIN feed rate speed 10 rpm Speed step 4 rpm MAX feed rate speed 34 rpm Feed rate increase in JA Motor turn off temperature 180 0 C DEFAULT EN Fig 15 Screen of settings Flavoring feed rate delay s delay in activating the feeding of oil and salt after corn feeding is enabled This delay is necessary in order salt and oil are not supplied directly on popcorn Flavoring stop delay s delay in stopping the feeding of oil and salt after corn feeding is off Time for popcorn to leave the chamber is 60 sec i e popcorn will
12. more setting lt lt Chamber cleaning gt gt This setting has to be activated if you are working with corn Preferred Popcorn Jumbo and the burnt corn is collected in chamber If this setting is activated when the machine has been continuously running for 52 minutes this value can be modified in settings the machine will automatically pause the operation clean the chamber by reducing the temperature and go back to normal operation In this case the collection of the burnt corn in chamber will be minimized Automatic chamber cleaning will normally take 8 10 minutes 2 2 Modification of machine units operating parameters To modify the machine units operating parameters it is also necessary to get the access to settings see par 2 1 Then press the button lt lt SETINGS gt gt on the main menu and you will get to the screen of settings fig 15 Digital parameters highlighted with blue color can be changed by pressing Digital parameters highlighted with black color are only for reading The button DEFAULT will bring all parameters to default settings incl the recipe parameters the button EN will change the language of machine interface It is possible to modify the following parameters on the screen of settings Chamber cleaning min the time of continuous operation of the machine after which the chamber will be automatically switched to cleaning mode After alarm pause s the time within which the mac
13. ng temperature is also a critical parameter for the mode lt lt Chamber cleaning gt gt The chamber will be cooled down from the temperature which 10 C higher than the preset value It means that decreasing the cooling temperature to 160 C for example will increase the chamber cleaning time but improve the cleaning effectiveness as the air viscosity will go down with lower temperature and the carry out force will be higher 2 3 PiD regulator setting To regulate the chamber temperature the machine Robopop uses PID regulator which ensures the more precise maintenance of the preset temperature To get access to PID regulator parameters first go to settings see par 2 2 then press the button lt lt NEXT gt gt fig 15 There are numeric parameters and indicators on the top of PID regulator screen fig 16 and chamber temperature diagram in the range of 180 C 250 C on the bottom of the screen PID controller Chamber temperature 212 4 C Proportionality constant 10 00 MIN temperature 190 0 C Integration time 1 00 s MAX temperature 230 0 C Differentation time 1 00 s 250 C Fig 16 PlD regulator screen Most of parameters are only for reading Therefore PlD regulator screen will display the current temperature in the chamber max and min temperature this temperature will be calculated automatically dependent on the temperature set for chamber Min and max temperature is the range within which the
14. rror means the failure of the chamber overload sensor sensor is constantly lightened Replace it ERR04 Check impeller assembly During operation the machine constantly controls the turbine rotation speed If the speed falls below 2500 revolutions per minute this error will be displayed There can be several causes of failures breakdown of V belt electrical motor failure seizure of the turbine bearing unit failure of speed sensor It s necessary to define the exact cause of the failure and replace the failed element
15. sifter will start immediately and go to popping mode fig 9 The feeder change normally takes about 3 5 minutes 1 6 Machine turn off The machine can be stopped both during the chamber warming up fig 4 and during popping fig 5 by pressing the button lt lt TURN ON gt gt The machine will automatically go to cooling mode fig 12 COOLING Fig 12 Cooling mode The activation of the cooling mode will immediately stop the corn feeding process salt and oil feeding if used for the recipe selected will be stopped with some delay heating elements will be disabled The sifter will be disabled with 3 min delay This time is enough for all popcorn to leave the chamber Wide white strip in the middle of the screen is the temperature scale showing the temperature decrease in chamber As soon as the strip disappears from the screen the turbine will be automatically stopped The chamber cooling process usually takes 10 12 minutes IMPORTANT To stop popcorn machine Robopop Mark 3 DF during popping process first press the button lt lt PAUSE gt gt fig 9 and then lt lt TURN ON gt gt fig 6 By pressing the button lt lt RESUME POPPING gt gt fig 12 you will activate the machine warming up and the popping process will be resumed 1 7 Statistical data review To review the data on machine operation press the button lt lt INFORMATION gt gt on the main screen fig 2 The following data are available
16. stay in sifter for minimum 1 5 min after the corn feeding is off MIN feed rate speed rpm minimum speed of corn feeder screw rotation corresponding to minimum recipe value In addition the screw rotation speed is in strict compliance with the productivity i e if the screw rotation speed is 34rpm rev min the productivity will be 34 kg of corn per hour Speed step rpm number of revolutions by which the corn feeding speed is increased in case of higher level of corn feeding Feed rate increase s delay after which the machine will go to the next level of feeding Corn feeder always starts operation from minimum speed The corn is supplied step by step with some delay from minimum level to the second level from the second level to the third level etc until it reaches the level set in the recipe This is done to avoid the significant temperature decrease in the chamber and to adjust P D regulator to the availability of corns in the chamber Example Having the parameters shown in fig 15 and corn feeding level 5 the corn feeding will be increased from 10 to 26 kg per hour level correspondence to revolutions productivity 10 14 18 22 26 30 34 rpm within 4 minutes Motor turn off temperature C the temperature which will start the sifter during the warming phase and which will stop the motor in case the temperature goes below the set value during the chamber cooling phase The cooli
17. ster IMPORTANT Oil shall be homogeneous and liquid without any solid particles of non melted oil Such solid particles can lead to clogging of oil system Switch on the machine by turning the toggle switch lt lt POWER gt gt to lt lt ON gt gt position Wait for LCD display booting Press button lt lt PUMPING ON gt gt on the main screen fig 1 Wait until the oil starts dripping from the oil nozzle After this switch off the oil circulation by pressing the button lt lt PUMPING OFF gt gt If oil doesn t come out of the nozzle within 30 seconds it s necessary to circulate oil manually the details see in the complete version of operating manual After oil circulation the machine is ready for operation 1 2 Machine startup Select one of the preset recipes on the main screen fig 2 by pressing the button lt lt BUTTERLY gt gt or lt lt MUSHROOM gt gt Choosing variety ZNA CMeHbI S3biKa HAMKMUTe SECURITY LEVEL apeanre 666666 3atem SETTINGS H BbiGepure Aabik Haas EN For changing tanguage press SECURITY LEVEL enter 666666 enter SETTINGS choose language pressing EN Fig 2 Main screen After pressing the corresponding button you will see the recipe screen fig 3 where you can get familiar with pre settings To go back to the main screen please press the button lt lt BACK TO MENU gt gt To start popping press the button lt lt START gt gt Butterfly Temperature Z1O O C Feed rate
18. t SECURITY LEVEL gt gt on the main screen fig 2 and then enter the code lt lt 333333 gt gt fig 13 After this the message will appear on the main screen access to testing Press lt lt TESTING gt gt fig 20 on the main screen and you will get to test mode Choosing variety access to testing AAS CMe HbI A3bi Ka HaKMHTe SECURITY LEVEL ape are 666666 sate SETTINGS Y BbiGepure asbik Haxxas EN For changing language press SECURITY LEVEL enter 666 enter SETTINGS choose language pressing EN Fig 20 Test mode access It s possible to start individually the following machine units in test mode fig 21 MOTOR startup of the main motor and chamber lighting motor startup delay is 10 sec 2700 RPM turbine rotation speed in real time it is updated every 6 sec speed is shown in revolutions per minute HEATER activation of heating elements Encouraged to include heating elements only after the launch of the main motor CORN F1 starting the corn feeder screw drive for model Mark 3 DF starting the corn feeder with index X CORN F2 only for models Mark 3 DF starting the O corn feeder screw drive SIFTER sifter starting SALT FAN salt feeder fan starting SALT FEED salt feeder screw drive starting SEPARATOR separator fan starting as well as blocking of lt lt POWER gt gt switch on control panel fig 1 ALARM activation of sound and light
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