Corn auger time - 35

Sifter speed - 50

Popping time - 135

Add pooping frequency - 6

Purge chamber every - 10

Add purge chamber frequency - 20

Cjrn auger speed - 330

Clogging of the working chamber (the chamber is clogged with popcorn)

The reasons:

1. Optical sensor not calibrated

2. Poor grain quality

3. Too high grain feed rate

4. Sifter rotating slowly (or not rotating)

Important! Stop the machine using the Emergency Stop button. DO NOT OPEN the chamber cover - air entry may cause a fire. Let the device cool down. Then clean the chamber from the inside, clean the metal channel with a brush (grain is fed through it), and vacuum the chamber.

The chamber clogging sensor is triggered, although the chamber is not clogged

1. Optical sensor is not properly calibrated

Machine warms up slowly

1. One or more heating elements burned out (order new heating elements and install them, see example video1 https://youtu.be/EEywpZc6ZUY and video2 https://youtu.be/P1f_gPg4IiU  )

2. Insufficient voltage in the network

I connected my Grand Robopop220 to the RoboFactory line, but I can't change the settings via the touchscreen on the control box

1. Most likely you have an old Grand Robopop220 with the old firmware. It is necessary to update the firmware of the DVP-12SA2 unit to the v42 level or replace the unit with the same unit with the new firmware (contact the supplier). This is what the desired block looks like inside the Grand Robopop220 electrical components box

Sifter does not rotate

1. The sifter is installed incorrectly (the guides are not on the rollers)

2. Husk on rollers

Camera light not on

1. Bulb burnt out

To replace lightbulb do the following. 

1. Turn off the machine and disconnect it from the mains. Wait until the machine cools down.

2. Take the chamber door off to open the chamber. 

3. Backlight is located on the right sidewall of the chamber. 

4. Remove four screws that hold the lamp screen and take the screen off. If it is stuck, carefully insert a flat screwdriver under the metal frame of the screen and turn it gently to detach the screen. 

5. The lightbulb is being held by the spring-loaded socket. Shift the bulb upwards or downwards to release its opposite end, and then take the bulb out. 

THE BULB MAY BE EXTREMELY HOT! BURN HAZARD! 

6. One must not touch the new lightbulb with bare fingers; skin fat can cause bulb destruction during further operation. If the bulb is greasy, it is required to wipe it thoroughly with a soft, clean, and dry cloth before putting it in. 

7. Once bulb replacing is done, put the protective screen back and fix it with four screws. Close the chamber. 

The sifter rotates in the opposite direction

1. Swap wires L1 and L2

Grain pouring from the conveyor

1. Mount the sifter over the conveyor (the edge of the sifter hangs over the conveyor)

1. The edge of the sifter must be at least one section away from the edge of the conveyor, as shown in the figure below.

Conveyor rotates in the opposite direction

1. Change any two phases, and the direction of the conveyor will change. This must be done in the control cabinet (central control box)

Conveyor belt sags or regularly slips off one/several guide rollers

1. Pull the roller (Idle Roller). This roller requires periodic advance - every 250 hours of operation (but the first 1000 hours - every 50 hours)

To do this, first, loosen 4 nuts (wrench 17). And then with a 23 wrench, turn the nut on the guide pin in the direction of the red arrow. After that, tighten the 4 nuts again with a 17-wrench. Make sure that the distances on the stud are the same on both sides of the conveyor, otherwise, the roller will warp and it may stall during rotation.

A conveyor belt moves too slowly, Grand Robopop220 popcorn spills out

1. Increase the speed of the tape in the settings on the touchscreen. Find a conveyor, there will be a rectangle with numbers next to it. Hold it with your finger, a data entry window will appear. Enter the desired value and press Enter.

Popcorn accumulates under the conveyor belt

1. This is part of the operation of the conveyor - a small part of the popcorn sticks to the conveyor and falls already under the conveyor. Remove fallen popcorn promptly.

The motor began to make creaking sounds

1. Check drive roller bearing lubrication. It needs to be lubricated on both sides once a month. Recommended lubricant - Shell Alvania 2, 3 or Castrol LM, LMX

The conveyor belt is not moving. Electricity is ok.

1. Check the connection of the conveyor to the control cabinet, the contact may have come off.

2. Check the efficiency of the conveyor motor - open the box with wires, and measure the resistance between windings 1-2, 2-3, 3-1. It should be about the same. If somewhere it is very different or OL (open circuit) - the motor must be replaced

The motor moves/vibrates slightly while the conveyor is moving.

1. This is normal, as intended by the supplier.

https://drive.google.com/file/d/1XgEZvYvfMwpNA9ITNmMGCmTdKRVHeEU3/view?usp=sharing

The touchscreen displays “Low level” when the tank has popcorn.

1. Check the condition of the Low-level sensor. Is it calibrated? Has his head been cleaned? Does it have power (is the indicator light on)? Check the indication - if there is no product at the sensor, one green light is on. When there is a product, the orange and green lights should be on simultaneously. The test can be performed by sliding a piece of white paper under the sensor. Disconnect the wires from the sensor and reconnect.

1. Check where the sensor “shoots” - it may have shifted and “looks” into the hopper body (the laser beam hits the metal body of the hopper, not the product)

Why do we need two level sensors and how do they work?

1. The top sensor is set to a longer distance than the bottom sensor - it needs to catch the heap cone to prevent overflow.

The sensors must come immediately with cables labeled accordingly. If something was disconnected/reconnected, the sensors may have been mixed up in places. This is also indicated by the video https://photos.app.goo.gl/jTvf95tJLAs8KsQQ7  - at the beginning, when the lower sensor is not blocked, the panel shows the EMPTY state, which means that the upper sensor worked at that moment. After the lower sensor is covered, the panel displays two states at the same time, which of course cannot be, but the program simply processes the sensor signals.

1. The mounted sensor is located outside the bunker and "shoots" into the gap in the bunker wall. When installing the sensor bracket, make sure that the beam hits the hole directly and is not obstructed by the bin wall. This may be the reason why the upper sensor has tripped when the hopper is empty.

2. If, for some reason, the settings for the sensing distance have gone astray, then the upper sensor may react to the opposite wall of the hopper, reflecting from it, which again leads to an incorrect signal.

I recommend checking the response distances of both sensors, taking into account the above. Correctly shield the sensor beam with white paper inside the hopper. Calibrate with a screwdriver - turn the screw until the sensor triggers (orange and green signals are on simultaneously)

Vibratory feeder and hopper are enabled on the Touch screen, but they do not work

1. Check the position of the “On/Off” side lever switch on the hopper body. If it is disabled, then neither the hopper nor the vibratory feeder will work..

1. You can also start both elements in manual mode by turning on the side lever and pressing the “Start” button (the green light will turn on).

Vibratory feeder on but popcorn not moving

1. Too little vibration. Increase it in manual mode on the adjustment module with the Up arrow

1. The vibratory feeder tray is dirty (for example, with oil - it is sticky). The popcorn is stuck to it and cannot move and slide freely. Stop the hopper and vibratory feeder. Wipe the tray clean, and turn it on again. Check if the oil supply pipe is installed incorrectly.

I see some washers, but I don’t understand why they are?

Those semi-round segments are intended to be put inside the vibrating motor, see the picture attached. More segments put in the motor cause more intensive vibration of the hopper. If you see that popcorn inside the hopper tends to "stick" to the walls, then it makes sense to add a few segments, increased vibration might help popcorn to leave the hopper.

1. Unplug the machine.

2. Open two covers on the sides of the motor (see another picture attached).

3. Add segments on each side. The number of segments added on each side must be equal!

4. Close the covers.

5. Attach the motor back to the hopper.

6. Run the machine.

The sensor shows that the hopper is full, but nothing is spilling over the edge.

1. The sensing distance of the upper sensor is longer than that of the lower one. He has to catch the “slide” near the mountain of popcorn in a hopper. That is, as soon as the top/slope of the mountain reaches the laser beam, the sensor is triggered (distance is about 1.5 feet). This is done because there is already a lot of popcorn in the hopper. It doesn't need to be done anymore. You need to work out the popcorn that is. Put the Grand Robopop220 into pause mode and wait for the High-level sensor to stop working

There is a lot of popcorn in the hopper, but the top sensor did not work!

1. Check visually where exactly in the hopper the “top” of the mountain is formed. It should form in the center. If the conveyor and hopper are offset from each other, the top of the mountain may form in the corner farthest from the sensor. In this case, it will take a long time before he picks up a signal from the “mountainside”. Center the position of the hopper on the conveyor so that the hill forms in the center.

On the touchscreen, I see Feeder and Conv icons. No. 1, but only Feeder works

1. This is one of the firmware versions. In your case Feeder (hopper vibration) and Conv. No. 1 (tray-vibrating feeder) is connected in parallel and both are turned on with the Feeder button. However, you can still turn off the vibratory feeder manually using the start/stop button on the hopper side controller.

Mixers spin in the opposite direction https://photos.app.goo.gl/AxKqiUafzkEaz8yT8

1. Change any two phases inside the oil station control cabinet (see pic), the rotation direction of the mixers will change

One or both mixers are spinning heavily, the motor is hot

1. Something is preventing the mixer from turning. Check the tightness of the wing caps on the lid of each tank, they may be too tight. Loosen the tightening, and check if the mixer has become freer to rotate

2. The product is stuck to the bottom and does not allow the mixer to rotate. Take a bucket, turn on the pump and drain the tank (or put the oil hose nozzle into the second tank and drive the remaining oil there). Examine the bottom - if the product is stuck there, unscrew the lambs, and pull out the lid with the mixer and the motor. Clean the bottom with a plastic scraper. Make sure that there are no lumps of product in the tubes and that there is no blockage. If necessary, pour hot water and turn on the pump again, drain the water and lumps of the product into a separate bucket.

Sometimes the cheese mixture will harden at the bottom because the protein has curdled. This is due to overheating (the milk protein in the cheese mixture overheats at temperatures over 55°C /130°F). Do not overheat the mixture!

One or both mixers seem to vibrate when rotating, the cover of the oil tanks moves and vibrates

1. Open the oil tank lid, and make sure the mixer shaft is on the spindle, centered exactly on the bottom of the tank. Perhaps you missed the installation and the mixer axis makes circular movements around the spindle. Unscrew the winglets, lift the lid with the motor, and put the mixer axle on the spindle in the center. Twist the lambs, check the rotation of the mixer.

I see a blue glow near the oil tank, what does this mean?

1. If you remove the protective cover, you will see a volume sensor. If the tank is empty, it does not glow. If there is oil in the tank, you will see a blue glow. Sometimes the sensor glows even if the tank is empty - this indicates that the sensor is dirty (see below).

The sensor on the touchscreen indicates that there is oil in the tank, although the tank is empty.

1. Contamination around the sensor in the product contact area (hardened oil mixture, for example). Must be checked and cleaned if necessary.

1. Sensor head damage. It is necessary to check the integrity visually and by touch.

2. Changing the position of the sensor (if one of the employees unscrewed the sensor

My Volume sensor is out of order, can I buy an analog and install it myself?

1. 25486 is the LBFS-01111.0 Baumer sensor. However, the problem is that the sensor is configured at the factory using a special programmer and software.

2. A sensor with default settings will probably not work correctly.

What to do so that the oil in the pipes does not freeze

1. Always turn on reverse when you pause. This will collect most of the oil from the oil tube back into the tank.

1. When cleaning, use hot water to flush the tanks - this will also flush the hoses of oil residue on the walls.

2. Do not use very hot water (above 70°СF/ 158°F) - oil system hoses are not heat resistant, and high temperatures are detrimental to their durability.

Can oil be left in tanks overnight?

1. As for the question about the constant heating of the tanks, the instructions have a clear indication of the need for daily cleaning.

2. Thus, the situation "keep the heater on so that the oil does not freeze" should not arise at all. The line is either running and the oil is in the tank at operating temperature, or the line is not running and the tank is clean. Storage of oil or oil mixture in the tanks of the product is not provided.

There is some black short piece of hose in the kit, what is it? Can it be thrown away?

1. This is a spare hose for the peristaltic pump. Don't throw it away, save it for future use

I have a clogged oil pipe, can I set the pump to maximum power and clean it this way?

1. You can really try it, but it's far from certain that it will help. The peristaltic pump is specially made "soft" - it does not create a lot of pressure. First of all, this is necessary so that the oil does not splatter (it is very difficult to wipe off). Secondly, it makes the oil supply more uniform (evenly applied to the product).

2. You can also try to turn on the reverse, drive off the oil, and then turn on the feed again.

3. In extreme cases, you need to disassemble the oil pipe system - unscrew the clamps, move the hoses by rotating clockwise and counterclockwise and pull them out. Flush both short hoses, and flush the long hose. Check the condition of the T and L-shaped taps (here it is useful to have a flexible plumbing brush) Blockage can also occur in the peristaltic pump. Here is a video on how to get the hose out of it:https://youtu.be/wm5p67aqBr0

I have a clogged spout at the end of the oil system. It is inside and nothing flows out of it.

1. Several holes with a diameter of 5 mm are made in the spout. If you have clumps of product in your oil mixture, they can clog one or more holes. This is critical - the more holes are clogged, the more difficult it is for the oil mixture to come out. The pressure builds up and the spout can simply knock out from the end of the oil tube (it is not fixed with a thread, only with a rubber seal - this is a safety measure)

Is it possible to work without a spout at all

1. Theoretically, it is possible, but the oil mixture will be supplied with a thicker jet, which adversely affects the quality of the coating. This is especially important at high oil pump speeds.

How to properly install the spout?

That's right:

That's so wrong and right

First, the metal end of the oil hose is inserted into the bracket, and then the spout is inserted into it (it must be inserted with force, it is fixed with an internal rubber o-ring). The oil from the spout must NOT come into contact with the vibratory feeder tray.

I turned on the oil station, added oil, and the temperature on the Autonics sensors went down. Why?

1. Check the wire connection at terminals BT1 and BT2. These are thermocouple terminals. If the polarity is reversed (+/-), then the sensor will show a drop in temperature, although it is actually growing. Disconnect the VT1 wires (black and white), swap them, and fix them. Check the readings of the Autonics temperature sensor. If everything is in order now, do the same for the black and white wires of VT2

Is it possible to increase the rotation speed of mixers inside oil tanks

1. This can be done, not with a touchscreen, but with a Delta VFD inverter inside the oil station control cabinet. Study the Appendix to the operation manual of the Oil Station, there are inverter settings

What ingredients can be used in an oil station?

1. Fine dispersion is important - the finer the grinding, the better. For example, coarse granular salt will work as an abrasive inside a tank. Therefore, it is necessary to use a special finely dispersed salt.

Why do oil system components get clogged?

1. You need to research the recipe - exactly what ingredients you use. Some, such as cheese powder, are temperature sensitive. Above 55°C/130°F, the milk protein in the cheese powder begins to coagulate, the powder lumps, cakes, and begins to clog the system. Other ingredients do not dissolve in oil, are heavier than it (by density), and can accumulate at the bottom (paprika). Some ingredients (grass, dill) tend to stick together, which also leads to clogging. The supplier company can guarantee the operation of the equipment - technology. But it does not guarantee technology - that any of your recipes will work stably on the RoboFactory line.

Below is a photo of the cured cheese mixture - avoid overheating the mixture/clogging the tubes

Can oil tanks be loaded with solid oil?

1. In no case. Although oil tanks are heated, they are designed to heat liquid oil, not to melt solid oil. If the oil in the bucket has hardened, heat it up (Excalibur, ordinary spiral tiles, RP60 heating compartment overnight) and load it into oil tanks only when it is liquid

2. However, you do not need to heat the oil to the correct temperature before you fill it into the tanks. Just enough to be liquid.

Give the recipe for the butter-cheese mixture for the RoboFactory line:

1. We use the following recipe. For example, for our cheese mixture, we use the following weight ratio: 1/0.45/0.05 (butter, cheese, salt, respectively).

2. You can use your recipe.

Why is it so important to use finely divided salt for cheese mixture?

1. As for powder cheese, it is not pure, there is always a base on which it is applied, most likely dextrin, you need to look at the product passport. Often cheese is generally butter, and the base (starch), a little cheese, flavoring, and coloring. So it sticks and hardens along with all the other ingredients.

I want to buy RoboFactory equipment, but I'm not sure if my recipe will work?

1. In general, you need to keep in mind that there is a technique, and there is a technology for preparing a product, and these are different things (although related). From this, it follows, for example, that it is pointless to indicate any recipes in the instructions for such equipment because enterprises usually have a technologist who knows his recipes. And the physical launch of the line (so that everything spins and moves) is only a small part of the launch process.

2. The main part is adjusting the production process to the finished product, and this part cannot be described in any instructions, it must be done on-site. You must have a food engineer, or you must have a good understanding of your product and recipe. If you have any doubts - contact a Robolabs representative for information - our team has engineers, technologists, and service specialists who will help you find the answer.

3. You can email your recipe to our head of R&D department at advice@robolabs.pro