Belshaw Adamatic Donut Robot Mark 2 User Manual

Donut Robot®

Mark II

Operator’s Manual

and

Technical Supplement

Belshaw Bros., Inc.

814 44th Street NW, Suite 103 Auburn, WA 98001 USA

Tel: [phone]

Fax: [phone]

Toll Free (US): 1-800-578-2547 E-mail: [e-mail] www.belshaw.com

Donut Robot®

Mark II & Mark II GP

Operator’s Manual

Belshaw Bros., Inc.

814 44th Street Northwest, Suite 103

Auburn, WA 98001 USA

Phone: [phone] • Fax: [phone] E-mail: [e-mail] • http://www.belshaw.com

If you accept the machine from the shipping company, you are, in effect, saying that the machine is in good condition, and you must pay for the machine. The freight company has accepted the responsibility for the safe delivery of our machines. For your protection, inspect the machine to see that no parts are bent, scratched, or otherwise damaged. If any damage has occurred in shipping, file a freight claim with the shipping company immediately.

EQUIPMENT RECORD

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

Purchased by _____________________________________________________________________

Installed by ______________________________________________________________________

Date of Installation ________________________________________________________________

Model number ___________________________________________________________________

Serial number

011108 MN-1012EN

Belshaw Bros., Inc.

814 44th Street Northwest, Suite 103

Auburn, WA 98001 USA

Phone: [phone] • Fax: [phone]

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

Contents

1	Operation	1
Making Cake Donuts		1
Making Yeast-Raised Donuts		3
2	Cleaning	5
Cleaning the Hopper and the Plunger		5
Cleaning the Conveyor and the Kettle		6
3	Maintenance	11
Taking Care of the Plunger, Hopper, and Cylinder		11
Lubricating		11
4	Related Products	12
FT-42 Feed Table		12
Roto Cooler		15
Icing Finishing Tree and Roto Cooler		16
Sugaring Tray and Roto Cooler		17
Filter Flo Siphon		18
Shortening Reserve Tank		21
5	Donut-Making Helps	22
Tips on Making Quality Cake Donuts		22
Calculating Correct Water Temperature		23
Ratios of Plunger Sizes to Donut Weights		23
Temperature Conversion		23

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Preface

The Donut Robot Mark II is designed to automatically cut and fry cake donut products, and to fry yeast-raised donut products. It is not designed to cut or fry any other products.

The Mark II 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 Mark II 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 Mark II will prevent production delays and injuries.

To use the Mark II 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. 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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1	Operation

Read each step completely before doing what it tells you to do.

Making Cake Donuts

1.If necessary, install the swing column, connect the swing connecting rod, install the cutter head, and install the hopper and the plunger.

2.When the shortening reaches the correct frying temperature, it should reach the middle of the flight bars.

Shortening expands as it increases in temperature. This means that unless the shortening is at frying temperature when you put it in the kettle, you should put it in gradually. Let the shortening in the kettle heat up before you add more.

Put shortening in the kettle using one of these methods:

•Pre-melt shortening in a pan on the stove and carefully pour it into the kettle.

•Use the optional EZ Melt to melt shortening and transfer it to the kettle. See your EZ Melt manual.

WARNING

Hot shortening causes severe burns.

•Put solid shortening into the kettle, packing it tightly around the elements and bulbs.

WARNING

Air spaces can cause the shortening to overheat and catch on fire.

3.Turn the heating element on by turning the thermostat knob above 200°F/93°C. Two pilot lights will come on. The one on top of the heater head indicates that the heating element has been turned on (that the thermostat is set above 200°F/93°C). The one on the front of the heater head indicates that the shortening has not yet reached the desired temperature. This light will go out if the high temperature limit control breaks the circuit.

Note: If the high temperature limit control does break the circuit, push the red reset button on the back of the heater head.

4.Wait for the shortening to reach the desired temperature. When it does, the pilot light on the front of the heater head will go out. DO NOT run the conveyor until all the shortening has melted.

5.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.

6.Disengage the swing connecting rod from the swing column throw arm and swing the hopper away from over the fryer.

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7.Adjust the size selector dial on the cutter head’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.

8.Put dough into the hopper. Prime the hopper to expel any air that may be trapped in the bottom of it. To prime the hopper:

a.Hold a mixing bowl under the cutter.

b.Hold down the prime switch on the cutter head and run the cutter until it has dropped two or three donuts into the bowl.

Note: Holding down the prime switch causes the cutter to run continuously without the normal delay between cuts.

c.Put the dough in the bowl back in the hopper.

9.Return the hopper into position over the fryer and reconnect the swing connecting rod to the swing column throw arm.

10.Choose the appropriate fry time for your product using the fry time control knob on the heater head.

11.Using the switch on the heater head, select the number of donuts−one or two−you want to cut during each swing cycle of the hopper.

12.Turn on the cutter using the power switch on the cutter head.

13.Turn on the conveyor drive using the power switch on the heater head.

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 is impedanceprotected 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.

14.Continue adding shortening to the kettle to maintain the proper shortening level (see step 1). There are three ways to do this:

•Melt some shortening in a pan on the stove and carefully pour it into the kettle.

•If you are using the optional EZ Melt, transfer more shortening from it. See your EZ Melt manual.

•If you are using the optional Shortening Reserve Tank, push open the supply valve.

15.Continue adding dough to the hopper as needed. You can add dough to the hopper without priming it again as long as it does not become empty. If the hopper does become empty, you must prime it again.

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16.When you fill the hopper for the last time, you will want to use all of the dough in the hopper. To do so, push the dough to the bottom of the hopper using a rubber scraper or spatula. Be careful not to jam the scraper in the donut cutter.

WARNING

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

Making Yeast-Raised

Donuts

1.Remove the hopper and plunger, the cutter head, and the swing column, if they are installed.

2.When the shortening reaches the correct frying temperature, it should reach the middle of the flight bars.

Shortening expands as it increases in temperature. This means that unless the shortening is at frying temperature when you put it in the kettle, you should put it in gradually. Let the shortening in the kettle heat up before you add more.

Put shortening in the kettle using one of these methods:

•Pre-melt shortening in a pan on the stove and carefully pour it into the kettle.

•Use the optional EZ Melt to melt shortening and transfer it to the kettle. See your EZ Melt manual.

WARNING

Hot shortening causes severe burns.

•Put solid shortening into the kettle, packing it tightly around the elements and bulbs.

WARNING

Air spaces can cause the shortening to overheat and catch on fire.

3.Turn the heating element on by turning the thermostat knob above 200°F/93°C. Two pilot lights will come on. The one on top of the heater head indicates that the heating element has been turned on (that the thermostat is set above 200°F/93°C). The one on the front of the heater head indicates that the shortening has not yet reached the desired temperature. This light will go out if the high temperature limit control breaks the circuit.

Note: If the high temperature limit control does break the circuit, push the red reset button on the back of the heater head.

4.Wait for the shortening to reach the desired temperature. When it does, the pilot light on the front of the heater head will go out. DO NOT run the conveyor until all the shortening has melted.

5.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.

6.Install your Feed Table and load proof cloths on it. Refer to Appendix A, “Related Products,” for complete installation and operation instructions for the Feed Table.

7.Choose the appropriate fry time for your product using the fry time control knob on the heater head.

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8.Turn on the conveyor drive using the power switch on the heater head.

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 is impedanceprotected 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.

9.Continue adding shortening to the kettle to maintain the proper shortening level (see step 1). There are three ways to do this:

•Melt some shortening in a pan on the stove and carefully pour it into the kettle.

•If you are using the optional EZ Melt, transfer more shortening from it. See your EZ Melt manual.

•If you are using the optional Shortening Reserve Tank, push open the supply valve.

10.Continue loading proof cloths onto the Feed Table as needed.

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2	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 electrocuting yourself or damaging the machine, never allow water, steam, shortening, cleaning solution, or any other liquid to enter the heater head or the cutter head assembly.

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.

To clean the hopper and the plunger:

1.Unplug the cutter head power cord.

2.Remove the plunger and the hopper. To do so, reverse the procedures found in Steps 2 and 3 of “Assembling the Cutter” in Section 1.

3.Pre-soak the parts, if necessary, to loosen stubborn or dried-on deposits.

4.Wash the hopper and the plunger separately in hot water and a detergent recommended for aluminum. Use a non-scratching plastic scouring cloth to remove soil and restore luster.

5.Rinse the hopper and the plunger separately in clear, hot water (170°-190°F/77°-88°C).

6.Dry each part completely.

7.Dip the plunger and the hopper cylinder in mineral oil or liquid shortening to prevent rust and sticking.

8.Wipe the cutter head 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

To avoid electrocuting yourself or damaging the machine, never immerse the cutter head assembly.

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Cleaning the Conveyor and the Kettle

There are four basic steps to cleaning the conveyor and the fryer kettle: removing the shortening, washing, rinsing, and drying. You must perform all four steps and perform them in the order listed.

Figure 3-1. Draining the Shortening off of the Conveyor.

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

3.Unplug the cutter head power cord.

4.Lift the cutter head off the swing column.

5.Remove the conveyor assembly as follows:

a.Obtain two pieces of wood, at least 1” x 1” x 15” (2.5 cm x 2.5 cm x 38 cm).

b.Lift off the swing connecting rod.

c.Lift the conveyor assembly from the conveyor locating pin and pull it away from the heater head to disengage the main drive shaft coupling from the conveyor drive coupling.

d.Lift the outfeed end of the conveyor. Slide one piece of wood under the conveyor and lay it across the top of the kettle. Lift the other end of the conveyor and do the same with the other piece of wood. The conveyor will now be resting on the two pieces of wood. Let the shortening drain off of the conveyor and into the kettle. See Figure 3-1.

6.If you want to clean the turner assembly, remove and clean it as follows:

a.Move the flight bars of the conveyor until the turner is in the middle of a flight pocket.

b.Swing the turner cam weight up out of position.

c.Lift up and pull out on the turner cam assembly. See Figure 3-2.

Figure 3-2. Removing the Turner Cam

Assembly.

d.Lift out the turner assembly. See Figure 3-3.

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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 3-3. Removing the Turner Assembly.

e.Wash the turner cam assembly and turner assembly using mild detergent and warm water.

f.Rinse the turner cam assembly and turner assembly in clear water.

g.Dry these parts thoroughly.

WARNING

All parts must be dried thoroughly. Moisture causes hot shortening to spatter, which may cause serious injury.

7.If you want to clean the drop plate, remove it by lifting its forward end and sliding it toward the rear of the conveyor. (See Figure 3-4.) Wipe the drop plate with a damp cloth.

Figure 3-4. Removing the Drop Plate.

8.After the shortening has drained off of the conveyor assembly, set the conveyor assembly aside.

9.Check again to see that the shortening in the kettle has cooled to 100°F/38°C.

10.Remove the shortening from the kettle using one of these methods:

•Use an optional Filter Flo Siphon to siphon the shortening into one or more large metal buckets. (See the instructions in Appendix A.) Be careful not to disturb the sediment that has accumulated in the bottom of the kettle.

•Tilt the heater head assembly back, raising the heating element out of the

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kettle. Lift the kettle out of the fryer case and carefully pour the shortening into one or more large metal buckets. Be careful not to disturb the sediment that has accumulated in the bottom of the kettle.

•Using a small saucepan or a metal pitcher, scoop as much of the shortening as you can into one or more large metal buckets. Then lift the kettle out of the fryer case and carefully pour the rest of the shortening into a metal bucket. Be careful not to disturb the sediment that has accumulated in the bottom of the kettle.

WARNING

Do not use plastic buckets. If the shortening is not cool enough, the buckets will melt; possibly causing you to be burned, and causing shortening to get on the floor.

WARNING

Do not allow the shortening to overflow the buckets. Shortening will get on the floor, and if the shortening is not cool enough, you may be burned.

WARNING

Thoroughly clean and dry the floor if shortening is spilled. Shortening on the floor can cause serious injury or loss of life.

11.Return the kettle to the fryer case, if you have removed it.

12.Tilt the heater assembly down.

13.Brush off any carbon that has accumulated on the heating element. Accumulated carbon can cause corrosion and ineffective heating.

14.Tilt the heater head assembly back, raising the heating element out of the kettle.

15.Lift the kettle out of the fryer case. Remove and dispose of the remaining shortening and the accumulated sediment. Dry the outside of the kettle.

16.Put the kettle back in the fryer case.

17.Tilt the heater head assembly down.

18.Put the drop plate, turner cam assembly, and turner assembly back on the conveyor assembly.

19.Install the conveyor assembly.

Washing

1.Pour hot water into the kettle, up to the normal level of the shortening. Add about 2 oz/59 ml of trisodium phosphate or other appropriate cleaner.

2.Connect the machine to the power source. Heat the solution to 200°F/93°C. Turn on the conveyor. Keep the solution at this temperature for 15-20 minutes.

3.Turn off the conveyor and scrub the soiled parts while the solution is under heat. Do not use any abrasive cleaners or scrapers.

4.Turn off the heater and disconnect the machine from the power source. Allow the cleaning solution to cool to 100°F/38°C.

5.Remove the conveyor and tilt the heater head back as you did before.

6.Remove the cleaning solution from the kettle using one of these methods:

•If you have an optional Filter Flo Siphon, remove its filter assembly. Then use the Filter Flo to siphon the cleaning solution into one or more large metal buckets. (See the instructions in

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Appendix A.) When the cleaning solution has stopped draining, carefully carry the buckets to the sink and slowly pour the solution into the sink.

•Lift the kettle out of the fryer case, carefully carry it to the sink, and slowly pour the cleaning solution into the sink.

•Using a small saucepan or a metal pitcher, scoop as much of the cleaning solution as you can into one or more large metal buckets. Then lift the kettle out of the fryer case and carefully pour the rest of the cleaning solution into a metal bucket. Carefully carry the buckets to the sink and slowly pour the solution into the sink.

WARNING

Do not use plastic buckets. If the cleaning solution is not cool enough, the buckets will melt; possibly causing you to be burned, and causing cleaning solution to get on the floor.

WARNING

Do not allow the cleaning solution to overflow the buckets. Cleaning solution will get on the floor, and if the solution is not cool enough, you may be burned.

WARNING

Thoroughly clean and dry the floor if cleaning solution is spilled. Liquid on the floor can cause serious injury or loss of life.

7.Lift the kettle out of the fryer case, if you have not done so already.

8.Rinse the kettle thoroughly and dry it on the outside.

9.Install the kettle, tilt the heater head assembly down, and install the conveyor assembly as before.

Rinsing

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.Lift the conveyor assembly out of the fryer case. Tilt the heater head assembly back.

6.Remove the water from the kettle using one of these methods:

•If you have an optional Filter Flo Siphon, remove its filter assembly. Then use the Filter Flo to siphon the cleaning solution into one or more large metal buckets. (See the instructions in Appendix A.) When the cleaning solution has stopped draining, carefully carry the buckets to the sink and slowly pour the solution into the sink.

•Lift the kettle out of the fryer case, carefully carry it to the sink, and slowly pour the cleaning solution into the sink.

•Using a small saucepan or a metal pitcher, scoop as much of the cleaning solution as you can into one or more large metal buckets. Then lift the kettle out of the fryer case and carefully pour the rest of the cleaning solution into a metal bucket. Carefully carry the buckets to the sink and slowly pour the solution into the sink.

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WARNING

Do not use plastic buckets. If the water is not cool enough, the buckets will melt; possibly causing you to be burned, and causing water to get on the floor.

WARNING

Do not allow the water to overflow the buckets. Water will get on the floor, and if the water is not cool enough, you may be burned.

WARNING

Thoroughly clean and dry the floor if water is spilled. Water on the floor can cause serious injury or loss of life.

Drying

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

WARNING

All parts must be dried thoroughly. Moisture causes hot shortening to spatter, which may cause serious injury.

2.Assemble the Donut Robot as before.

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3	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.

Lubricating

Daily

Before using the machine each day, apply ediblegrade mineral oil to the plunger connecting rod. The oil should penetrate the ball lock and the spring socket. See Figure 4-1.

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.

Figure 4-1. Lubricating the Connecting Rod.

Weekly

Apply a few drops of SAE 30 machine oil to the swing column where it contacts the swing column bracket.

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4	Related Products

This appendix contains information about the following products which you might use with your Donut Robot®:

•Feed Table

•Roto Cooler

•Icing Finishing Tree and Roto Cooler

•Sugaring Tray and Roto Cooler

•Filter Flo Siphon

•Shortening Reserve Tank

FT-42 Feed Table

SPECIFICATIONS

Dimensions	Shipping	Electrical Data	Construction	Standard
	Weight			Equipment
L = 52”/132 cm	73 lb/33.1 kg	115 V	Stainless steel,	Complete conveyor
W = 19”/48 cm		1 Phase	nickel-plated mild	assembly, including
			steel, and aluminum	drive system and
H = 11 3/4”/		50 Hz	alloys.	controls. Does not
				include proofing
30 cm
				cloths or proofing
				boards.

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Figure 4-1. FT-42 Feed Table.

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 A- weighted 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 cutter head power cord of your Donut Robot.

2.Release the plunger from the cutter head.

3.Unscrew and lift off the hopper assembly.

4.Lift off the cutter head and swing column.

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 Donut Robot to cut one cut per pocket.

Operation

1.Test to make sure that the automatic timing for the Feed Table is working. To do this:

a.Turn on the Donut Robot’s conveyor drive.

b.Turn on the Feed Table’s conveyor drive.

The Feed Table should receive a signal from the Donut Robot, move forward the distance needed to supply one pocket of donuts, and then stop until it receives the next signal.

2.Proof your donuts on the proofing cloths from the Feed Table.

3.Put a proofing board, with a proofing cloth on it, on the Feed Table.

4.Press the prime switch on the power head assembly. The hooks on the Feed Table will grab the proofing cloth off of the proofing board. Allow the cloth to advance to the front of the Feed Table.

5.Release the prime switch and turn on the main power. Remove the proofing board.

When the Feed Table is on, the Feed Table automatically advances donuts when the Donut Robot is ready to accept them. After the donuts go into the fryer, the proofing cloths are carried underneath the Feed Table and fall onto the work surface.

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