Belshaw MARK V Operator’s Manual

The #1 Source for Donut and Bakery Equipment www.belshaw.com

OP

ERATOR’S MANUAL

TECHNICAL SUPPLEMENT

Donut Robot

Mark II, Mark II GP,

Mark V, Mark V GP

A

utomated Donut Fryer

USA/Canada 1-800-578-2547

SUPPORT

International ([phone]

®

Email [e-mail]
Web www.belshaw.com

Donut Robot



Mark II, Mark II GP

Mark V & Mark V GP

Operator’s Manual

Belshaw Adamatic Bakery Group

814 44th Street Northwest, Suite 103

Auburn, WA 98001 USA

Phone: [phone] • E-mail: [e-mail]

www.belshaw-adamatic.com

EQUIPMENT RECORD

Please provide the information below when you correspond with Belshaw about your machine.

Purchased by _____________________________________________________________________

Installed by ______________________________________________________________________

Date of Installation ________________________________________________________________

Model number ____________________________________________________________________

Serial number

IN CASE OF DAMAGE TO EQUIPMENT

In case of damage to the equipment upon delivery, follow these steps immediately.

1. Inform the freight carrier. The phone number will be on the shipping receipt or label.

2. Take photographs of the equipment, both inside and outside the box or crate.

3. Do not throw away any packaging.

4. Report the damage to the distributor (or other party) from whom you bought the equipment.

5. Email your photos to the distributor (or other party) AND to Belshaw Customer Service at

[e-mail]. Include a Belshaw Order Number in your communications. Your Order

Number will begin with “CO…, followed by 6 digits) and should be marked on the box or crate.

IN CASE OF MISSING ITEMS

1. If possible, note the missing items on the delivery receipt of the freight carrier.

2. Take photographs of the entire shipment.

3. Follow steps 2 – 5 above.

012916

MN-1012EN

Belshaw Adamatic Bakery Group

814 44th Street Northwest, Suite 103

Auburn, WA 98001 USA

Phone: [phone] • Fax: [phone]

E-mail: [e-mail] • http://www.belshaw-adamatic.com

Belshaw Adamatic Bakery Group • www.belshaw-adamatic.com • 206-322-5474 •[e-mail]

2 MN-1012EN Donut Robot Mark II / Mark V OM

Contents

1 Introduction 4

Major components of the Donut Robot® Mark II and Mark V 5

2 Operation 6

Operating Controls 6
Inserting Shortening 7
Heating Shortening 7
Making Cake Donuts 8
Making Yeast-Raised Donuts 9

3 Cleaning 10

Cleaning the Hopper and the Plunger 10
Cleaning the Conveyor and the Kettle 11

4 Maintenance 14

Taking Care of the Plunger, Hopper, and Cylinder 14
Lubrication 14

5 Accessories 15

FT-42 Feed Table 15
Roto Cooler 17
Filter Flo Siphon 18
Shortening Reserve Tank 20

5 Donut-Making Helps 21

Tips on Making Quality Cake Donuts 21
Calculating Correct Water Temperature 22
Ratios of Plunger Sizes to Donut Weights 22
Temperature Conversion 22

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Donut Robot Mark II / Mark V OM MN-1012EN 3

1 Introduction

The Donut Robot® Mark II and Mark V are
designed to automatically deposit and fry cake
donut products, and to fry yeast-raised donut
products. It is not designed to deposit or fry any
other products.
The Donut Robot is designed to be used on a flat,
stationary table or countertop, with the operator
standing opposite the heater head of the machine.
The operator must work safely at all times and
read this manual and follow its instructions and
warnings.
The Donut Robot® produces only 71.5 dB(A) of
equivalent A-weighted sound pressure at
workstations. This has been determined during a
dry run of the machine, using a Bruel & Kjaer
sound level meter, type 2236.
Study the instructions and warnings in this
manual carefully. A thorough understanding of
how to install, maintain, and safely operate the
Donut Robot® will prevent production delays and
injuries.
To use the Donut Robot® safely, heed the
following warnings and all other warnings that
appear in this manual:

• Make sure the machine is secured to the

work surface. Doing so will prevent the
machine from moving or falling, which
could cause serious injury.

• Never let water and hot shortening come

in contact with each other. Moisture
causes hot shortening to spatter, which
may cause serious burns.

• Do not overfill the kettle with

shortening. If shortening overflows the

kettle, it could cause serious burns or
could cause someone to slip on the floor
and be seriously injured.

• Hot shortening can cause serious burns.

Make sure that the system and the
shortening are cool before attempting
any adjustment, repair, disassembly, or
cleaning.

• To avoid electrocution or other injury,

unplug the machine before attempting
any adjustment, repair, disassembly, or
cleaning.

• To avoid damaging the machine, never

use force to assemble, disassemble,
operate, clean, or maintain it.

• Be careful never to get shortening, water,

or other materials on the floor. If
anything does get spilled on the floor,
clean the area immediately. Materials on
the floor can cause people to slip or fall,
resulting in serious injury or loss of life.

• To prevent unintentional startup and

possible fire, unplug the machine if there
is a local power outage. When the
power is restored, it is safe to plug the
machine in again.

• To avoid electrocution, make sure that

all electrical cords are not frayed or
cracked and that they do not pass
through any water or shortening.

• Make sure that all electrical cords are

routed so that no one will trip over them.

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4 MN-1012EN Donut Robot Mark II / Mark V OM

Major components of the Donut Robot® Mark II and Mark V

The photos below show the major visible components in a Donut Robot Mark II. The Donut Robot
Mark V is 50% longer. All components apply to Mark II and Mark V, both standard and GP models.

Figure 1.1. Donut Robot Mark II. (components apply also to Donut Robot Mark V)

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Donut Robot Mark II / Mark V OM MN-1012EN 5

1 2 2

3

2 Operation

Figure 1.2, Temperature controller

IMPORTANT

To unpack and install your Donut Robot®, follow the installation instructions in the Technical

Supplement to this manual.

CAUTION

Read this section completely before operating the machine!

Operating Controls

1. Ensure that the Donut Robot has been

connected to correct power source.

2. Ensure the fryer is filled with shortening.

If there is no shortening in the fryer, see
the section below, “Inserting Shortening”.

3. Turn on the main circuit breaker on the

back of the heater head ( POWER
LIGHT will turn on).

4. Turn on the FRYER HEAT switch

(the temperature controller will turn on).

5. Set the TEMPERATURE

CONTROL to the target frying
temperature (See Figure 1.2)
(TEMPERATURE CONTROL light
will turn on when fryer is heating).

6. Set FRYER CONVEYOR switch to

AUTO (the conveyor will start
automatically when the target
temperature is reached).

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6 MN-1012EN Donut Robot Mark II / Mark V OM

3

4 5 6

2

NOTE

The FRYER CONVEYOR switch can

also be turned to ON (The conveyor will

run immediately, make sure the shortening

is completely melted before using ON

position).

7. Turn the FRY TIME dial to adjust

the fry time to the desired speed. As the
fry time goes down the speed of the
conveyor increases.

8. Set the Feed table/Cake Donut

depositor switch to FEED TABLE for
yeast-raised donuts or CAKE DONUT
DEPOSITOR for cake donuts or mini
donuts.

9. Connect the Cake Donut Depositor or

Feed Table to the electrical connector
socket located at the left end of the
control panel.

Inserting Shortening

WARNING

Hot shortening is much hotter than boiling

water! It will cause severe burns if it

touches your skin. Never touch hot

shortening. Always exercise extreme

caution with hot shortening. Use oven

gloves when working near hot shortening.

1. When the shortening reaches the correct

frying temperature, it should reach the top of
the flight bars or chains.

2. If your fryer has a drain, close the drain

valve.

3. Put shortening in the kettle using one of

these methods:
a. Pre-melt shortening in a pan on the stove

and carefully pour it into the kettle.

b. Use the optional EZ Melt to melt

shortening and transfer it to the kettle.
See your EZ Melt manual.

c. Put solid shortening into the kettle,

packing it tightly around the elements
and bulbs without air spaces.

WARNING

Air spaces can cause the shortening to

overheat and catch on fire. Pack the

shortening tightly without air spaces.

WARNING

Shortening expands as it increases in

temperature. Do not fill shortening all the

way up to the flight bars or chains, if it is

cold. The shortening level will rise by up to

1 inch (25 mm) when it is fully heated.

Heating Shortening

1. Turn on the FRYER HEAT switch (the

temperature controller will turn on).
a. If you are heating solid shortening using

method 2c above, turn the heat switch on
and off every 10 seconds, until the solid
shortening has melted and no air pockets
remain.

IMPORTANT

If you are heating solid shortening, turn

the heat switch on and off every 10 seconds,

until shortening has melted around the

elements and no air pockets remain.

2. Wait for the shortening to reach the desired

temperature. When it does, the Temperature
Control light on the front of the heater head
will turn off and the conveyor will start. DO
NOT run the conveyor until all the
shortening has melted.

3. If you are using the optional Shortening

Reserve Tank, fill it with shortening. Then
position it on the conveyor side panels either
ahead of or behind the turner, but not above
it. The heat of the fryer will melt the
shortening in the tank.

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Donut Robot Mark II / Mark V OM MN-1012EN 7

4 5 3

NOTE

If the Power light is on but the

Temperature Controller fails to turn on,

the high temperature limit control could be

tripped. Push the red reset button on the

back bottom of the heater head.

Making Cake Donuts

1. If not already in place, install the swing

column, install the depositor’s cutter head,
and install the hopper and the plunger.

2. Swing the hopper away from the fryer so it

is not directly above the fryer.
a. It may be necessary to disengage the

swing connecting rod from the swing
column throw arm.

3. Adjust the size selector dial on the

depositor’s crankshaft assembly. This dial
regulates the donut weight. The higher the
setting, the larger the donuts will be. Adjust
the dial setting as follows:

a. Unscrew the dial lock nut 1/2 turn.
b. Turn the dial to the desired position, as

indicated by the marks on the crank
plate.

c. Tighten the dial in place with the lock

nut. Tighten it using your fingers
only.

4. Put batter into the hopper. ‘PRIME’ the

hopper to expel any air that may be trapped
in the bottom of hopper. To prime the
hopper:

a. Hold a mixing bowl or other

receptacle under the depositor hopper.

b. Hold DOWN the switch on the

depositor until it has dropped two or
three donuts into the bowl.

NOTE

Holding down the prime switch causes the

depositor to run continuously without the

normal delay between cuts.

c. Put the batter in the bowl back into

the hopper.

5. Return the hopper into position over the

fryer and reconnect the swing connecting
rod to the swing column throw arm.

6. Turn the FRY TIME dial to adjust the

fry time to the desired speed.

7. For 2 donuts (or 4 mini donuts) per row, set

the Feed table/Cake Donut depositor
switch to CAKE DONUT DEPOSITOR.
For 1 donut (or 2 mini donuts) per row, set
the switch to FEED TABLE.

8. Turn on the cake donut depositor by pushing

UP the switch on the depositor.

9. Set FRYER CONVEYOR switch to

AUTO.

NOTE

If the conveyor becomes jammed, a

warning buzzer will sound about a minute

later and stop when the conveyor is turned

off. The conveyor drive motor is impedance-

protected so it will not burn out due to

jamming.

WARNING

If the conveyor becomes jammed:

1. Turn off the conveyor drive and the heater.

2. Allow the system to cool down.
HOT SHORTENING IS DANGEROUS.

3. Determine the cause of the jamming.

4. Clear it.

5. Restart the system.

1. Continue adding shortening to the kettle to

maintain the proper shortening level (level
chain).

2. Continue adding batter to the hopper as

needed.

a. You can add batter to the hopper

without priming it again as long as it
does not become empty.

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8 MN-1012EN Donut Robot Mark II / Mark V OM

4

3

b. If the hopper does become empty, you

must prime it again.

c. When you fill the hopper for the last

time, you will want to use all of the
batter in the hopper. To do so, push the
dough to the bottom of the hopper using
a rubber scraper or spatula.

WARNING

To avoid injury, never put your hand in or
under the hopper while the machine is on.

If the conveyor becomes jammed:

1. Turn off the conveyor drive and the heater.

2. Allow the system to cool down. HOT

SHORTENING IS DANGEROUS.

3. Determine the cause of the jamming.

4. Clear it.

5. Restart the system.

10. Turn on the Feed Table switch to activate

the Feed Table.

11. Load proof cloths with donuts onto the

Feed Table as needed.

Making Yeast-Raised Donuts

To make yeast-raised donuts, remove both the
depositor, and the swing column that supports it.
They will not be used for yeast raised donuts.

1. Unplug the depositor power cord of your

Donut Robot.

2. Release the plunger from the depositor.

3. Unscrew and lift off the hopper.

4. Lift off the depositor and swing column.

5. Install your Feed Table and plug into the

fryer.

6. Refer to Section 5 of this manual for

instructions how to use the Feed Table.

7. Ensure there is sufficient shortening in

the fryer. The shortening should come up
to the level of the chains.

8. Turn the FRY TIME dial to adjust

the fry time to the desired speed.

9. Set FRYER CONVEYOR switch to

AUTO.

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Donut Robot Mark II / Mark V OM MN-1012EN 9

3 Cleaning

WARNING

Thoroughly clean and dry the floor if

shortening, water, or other materials are

spilled. Materials spilled on the floor can

cause serious injury or loss of life.

WARNING

To avoid electric shock or damage to the

machine, never allow water, steam,

shortening, cleaning solution, or any other

liquid to enter the heater head or the

depositor.

Cleaning the Hopper and the Plunger

You must clean the hopper and the plunger daily,
or after each use. Follow these general
guidelines:

• Use household dishwashing detergent.

Do not use strong alkali cleaners such as
lye, soda ash, or trisodium phosphate, as
these discolor and corrode aluminum.

• Wash, dry, and lubricate parts

thoroughly to prevent rusting.

• When washing parts by hand, wash each

part separately; do not put any other
utensil or dish in the sink with the part
being washed.

Cleaning method

1. Unplug the depositor power cord.

2. Remove the plunger and the hopper.
a. Pull the plunger connecting rod up and

away from the plunger to release the top
of the plunger.

b. Lift out the plunger and set aside
c. Loosen the two mounting studs holding

the top of the hopper

d. Remove the hopper

3. Wash the hopper and the plunger thoroughly
in hot water and mild detergent.

4. Rinse the hopper and the plunger separately
in clear, hot water.

5. Dry each part completely.

6. Dip the plunger and the hopper cylinder in
vegetable oil or shortening to prevent rust
and sticking.

7. Wipe the depositor assembly with a soft
cloth dampened with hot water and an
appropriate cleaner. Wipe it with another
damp cloth to remove the cleaner. Wipe it
dry.

CAUTION

Never immerse the depositor’s cutter head

in water. This may cause an electric shock

and/or damage to the machine.

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10 MN-1012EN Donut Robot Mark II / Mark V OM

Cleaning the Conveyor and the Kettle

The conveyor and fryer kettle should be well
cleaned once per week for normal usage.
After cleaning, dry the conveyor, then return the
conveyor to the fryer and cover with shortening.
If left open to the air overnight, water trapped in
the chain may cause staining.

Step 1: Drain the shortening

WARNING

To avoid being burned or electrocuted,

disconnect the machine from the power

source before cleaning the fryer.

1. Disconnect the machine from the power

source.

2. Unplug the depositor power cord.

3. Let the shortening cool to 100°F/38°C.

4. Lift the depositor off the swing column, and

set to one side.

5. Lift off the swing connecting rod that

extends to the base of the column supporting
the depositor.

6. Drain the shortening, using the drain valve

under the fryer (if installed) or Filter-Flo
Siphon.

a. If the fryer has a drain valve and an

EZMelt filtration system, open the drain
valve and empty the fryer kettle.

b. If you have a Filter Flo Siphon,use this to

transfer the shortening into a large metal
bucket. (See the instructions in Appendix
A)

conveyor and keep running for 15-20
minutes.

3. Scrub the soiled parts of the kettle and

conveyor while the solution is under heat.
Use oven gloves for protection.

4. Turn off the heater and disconnect the

machine from the power source.

5. Clean the control panel with a damp cloth

only. DO NOT clean the control panel while
power is connected.DO NOT allow cleaning
solution or water onto the control panel.

Step 3: Drain the cleaning solution

1. Allow the cleaning solution to cool to

100°F/38°C.

2. Drain the cleaning solution from the kettle

using one of these methods. (These are the
same methods already used to drain
shortening.)
a. If the fryer has a drain valve, drain the

water into a large bucket. DO NOT
drain the cleaning solution into the
EZMelt.

b. If you have a Filter Flo Siphon, remove

its filter assembly. Then use the Filter
Flo to siphon the cleaning solution into
one or more large buckets. (For Filter
Flo instructions, see Appendix A.)

3. Pour out the solution down a drain.

WARNING

Clean and dry and floor spills immediately.
Liquid on the floor can cause serious injury

or loss of life.

Step 2: Wash the kettle and conveyor

1. Pour hot water into the kettle, up to the level

of the chains. Add about 2 oz/59 ml of
trisodium phosphate (TSP) or other
appropriate cleaner.

2. Connect the machine to the power source.

Using the temperature controller, heat the
solution to 200°F/93°C. Turn on the

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Donut Robot Mark II / Mark V OM MN-1012EN 11

Step 4: Rinse with water

1. Pour clean water into the kettle, up to the

normal level of the shortening.

2. Connect the machine to the power source.

Heat the water to 200°F/93°C.

3. Run the conveyor for 5-10 minutes.

4. Turn off the heater and disconnect the

machine from the power source. Allow the
water to cool to 100°F/38°C.

5. Drain the rinse water from the kettle using

the same method as Step 4

Step 5: Remove the conveyor

1. Ensure that the conveyor is cool to the

touch. If possible, ask another person to help
you lift it. Use oven gloves.

2. Obtain two clean pieces of wood, at least 1”

x 1” x 15” (2.5 cm x 2.5 cm x 38 cm).

3. Remove the conveyor from the fryer as

explained below:

a. Lift the infeed side of the conveyor UP

by 2” (5 cm), to rise above the locator
pins on the infeed side.

b. Lift the front of the conveyor (the side

closest to you) UP by 4” (10 cm)

c. Pull the entire conveyor toward you,

and away from the control panel .

d. The conveyor should now be free from

the rest of the fryer

4. Place the conveyor on a clean surface, using

the two wood pieces to lift the bottom clear
of the surface.

5. OR, rest the conveyor on top of the fryer

kettle, using the two pieces of wood as
shown in Figure 2 below.

Thoroughly dry all parts, including the conveyor,
the heating element(s), the inside of the kettle,
and the drain.

1. There should be no water drops anywhere

on the Donut Robot.

2. If your kettle has the optional drain
assembly, make sure no water is in the drain
or drain tube.

3. After cleaning, return the conveyor to the
fryer and cover with shortening. Water
trapped in the chain may cause staining.

Step 7: Cleaning the turner, heating element, and kettle

1. If the turner requires extra cleaning, remove
and clean it as follows.

2. Set the conveyor on a clean surface.
a. Use the same pieces of wood as in Step

6 to raise the conveyor 1” (25 mm) from
the surface. This will enable the turner to
turn freely.

3. Move the flight bars of the conveyor until
the turner is in the middle of a flight pocket.
Do this by turning the round motor coupling
on the outfeed end of the conveyor.

4. Swing the turner cam weight up out of
position. (See Figure 3).

5. Holding the turner in one hand, lift up and
pull out the turner cam with the other hand.

Figure 2: Rest the conveyor on the fryer.

Step 6: Dry all parts

WARNING

All parts must be dried thoroughly.

Failure to dry the kettle, conveyor, and all

parts of the Donut Robot completely will

cause Shortening to spatter or overflow the

fryer and may result in fire, injury, or

death.

Figure 3 Removing the Turner Cam

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12 MN-1012EN Donut Robot Mark II / Mark V OM

6. Lift out the turner. See Figure 4.

Figure 4 Removing the Turner

7. Wash the turner cam and turner using mild

detergent and warm water.

12. Rinse the turner cam and turner in clear

water.

13. Dry thoroughly.

WARNING

All parts must be dried thoroughly.

Moisture causes hot shortening to

spatter, which may cause serious injury.

14. To clean the drop plate, remove it by lifting

its forward end and sliding it toward the rear
of the conveyor. (See Figure 5) Wipe the
drop plate with a damp cloth.

CAUTION

If the drop plate is scratched, donuts will

stick to it. To prevent this from happening,

always wipe the drop plate in the direction

of the grain in the metal, which runs

parallel to the length of the conveyor, and

never use abrasive cleaners.

Figure 5 Removing the Drop Plate

15. Brush off any carbon that has accumulated

on the Donut Robot’s heating element.
Accumulated carbon can cause corrosion
and ineffective heating.

16. Tilt the heater head assembly back, raising

the heating element out of the kettle.

17. Lift the kettle out of the fryer case.

18. Clean all parts of the kettle if needed, inside

and out.

19. Ensure all parts are dry

20. Replace the kettle and lower the heater head.

21. Put the drop plate, turner cam, and turner

back on the conveyor.

22. Replace the conveyor
a. When you replace the conveyor, line up

the notch in the drive coupling with the
large bolt in the motor drive (at the right
end of the heater head).

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Donut Robot Mark II / Mark V OM MN-1012EN 13

4 Maintenance

WARNING

To avoid being burned, electrocuted, or

otherwise injured, always unplug the

machine and allow it to cool down before

making adjustments, clearing obstructions,

lubricating, cleaning, or disassembling.

Taking Care of the Plunger, Hopper, and Cylinder

The plunger, hopper, and cylinder of your Donut
Robot are precision instruments. With proper
care, they will perform well for years. Follow
these guidelines:

* Clean these parts only in the manner

explained in this manual.

* Handle these parts with care. Avoid

dropping them on hard surfaces.

* Do not force the machine if it becomes

jammed. To avoid damaging the
plunger, disassemble the machine and
remove any obstructions.

Lubrication

Daily

Before using the machine each day, apply Food
Grade mineral oil to the plunger connecting rod.
The oil should penetrate the ball lock and the
spring socket. See Figure 6.

Figure 6 Lubricating the Connecting Rod.

Weekly

Apply a few drops of Food Grade mineral oil to
the swing column where it contacts the swing
column bracket.

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14 MN-1012EN Donut Robot Mark II / Mark V OM

5 Accessories

This section contains information about accessories which can be used with your Donut Robot:

• Feed Table

• Roto Cooler

• Filter Flo Siphon

• Shortening Reserve Tank

FT-42 Feed Table

Figure 7 FT-42 Feed Table with Feed Table cloth.

The FT-42 Feed Table is designed to supply
proofed yeast-raised donuts to the Donut Robot.
It produces less than 70 dB(A) of equivalent A­weighted sound pressure at work stations. This
has been determined while running the machine,
using a Bruel & Kjaer sound level meter, type

2236. The Feed Table is meant to be used on a
flat, stationary table or countertop, positioned
end-to-end with the Donut Robot. The operator
is expected to read and follow these instructions.

Installation

1. Unplug the depositor power cord of your
Donut Robot.

2. Release the plunger from the depositor.

3. Unscrew and lift off the hopper assembly.

4. Lift off the depositor and swing column.

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Donut Robot Mark II / Mark V OM MN-1012EN 15

5. Lift the outfeed end of the Feed Table and
set the brace under the trip shelf over the
edge of the kettle.

WARNING

To avoid injury, make sure that the Feed

Table is turned off before proceeding.

6. Plug the Feed Table power cord into the
outlet on the end of the heater head.

7. Set the switch on the control panel to “Feed
Table”.