Belshaw Adamatic Donut Robot Mark 5 User Manual

®
Donut Robot
Mark V
and
Technical Supplement
Belshaw Bros., Inc. 814 44th Street NW, Suite 103 Auburn, WA 98001 USA Tel: (206) 322-5474 Fax: (206) 322-5425 Toll Free (US): 1-800-578-2547 E-mail: service@belshaw.com www.belshaw.com
Donut Robot
Mark V
Operator’s Manual
Belshaw Bros., Inc.
814 44
Phone: (206) 322-5474  Fax: (206) 322-5425
E-mail: service@belshaw.com http://www.belshaw.com
th
Street NW, Suite 103
Auburn, WA 98001 USA
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. Belshaw cannot pay for
shipping damage, because the freight company has accepted the machine from Belshaw in good condition, and is responsible for its safe delivery. 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.
IMPORTANT
Keep this manual for reference purposes.
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
011708
MN-1022EN
Belshaw Bros., Inc.
814 44
th
Street NW, Suite 103
Auburn, WA 98001 USA
Phone: (206) 322-5474  Fax: (206) 322-5425
E-mail: service@belshaw.com http://www.belshaw.com
Contents
1 Operation 1
Making Cake Donuts 1 Making Yeast-Raised Donuts 2
2 Cleaning 5
Cleaning the Hopper and the Plunger 5 Cleaning the Conveyor and the Kettle 6
3 Maintenance 11
Lubricating 11 Taking Care of the Plunger, Hopper, and Cylinder 12
4 Related Products 13
FT-42 Feed Table 13 Roto Cooler 16 Icing Finishing Tree and Roto Cooler 17 Sugaring Tray and Roto Cooler 18 Filter Flo Siphon 19 Shortening Reserve Tank 22
5 Donut-Making Helps 23
Tips on Making Quality Cake Donuts 23 Calculating Correct Water Temperature 24 Ratios of Plunger Sizes to Donut Weights 24 Temperature Conversion 24
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Donut Robot Mark V OM MN-1022EN iii
Preface
The Donut Robot Mark V 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 V uses electrical elements to heat shortening in its kettle.
The Mark V 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.
Study the instructions and warnings in this manual carefully. A thorough understanding of how to install, maintain, and safely operate the Donut Robot Mark V will prevent production delays and injuries.
To use the Mark V 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, mop it up 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
For general information on donut production, refer to Section 5, “Donut-Making Helps.”
WARNING
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.
Air spaces can cause the shortening to
overheat and catch on fire.
3. Turn the heating element to the desired temperature. 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/ 93C). 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.
Put solid shortening into the kettle,
packing it tightly around the elements and bulbs.
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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 donutsone or twoyou want to cut during each swing cycle of the hopper.
12. Turn on the cutter using the power switch on the cutter head.
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 2). 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.
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.
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.
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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.
WARNING
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
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.
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.
Air spaces can cause the shortening to
overheat and catch on fire.
3. Turn the heating element to the desired temperature. 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/ 93C). 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.
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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 2). There are three ways to do this:
Melt some shortening in a pan on the
stove and carefully pour it into the kettle.
WARNING
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
cutter head assemblies.
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 of the Technical Supplement.
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.
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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.
Removing the Shortening
WARNING
Figure 2-1. Draining the Shortening off of
the Conveyor.
6. If you want to clean the turner assembly, remove and clean it as follows:
To avoid being burned, electrocuted, or
otherwise injured, unplug the machine
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.
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 2-2.
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 thing 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
2-1.
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Figure 2-2. Removing the Turner Cam
Assembly.
d. Lift out the turner assembly. See Figure
2-3.
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 2-3. Removing the Turner Assembly.
e. Wash the turner cam assembly and the
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 2-4.) Wipe the drop plate with a damp cloth.
Figure 2-4. 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. You may drain it out (if your kettle has the optional drain), siphon it out, or pour it out.
You may transfer the shortening to a
Belshaw EZ Melt or to one or more large metal buckets. If you use buckets, and you want to re-use the shortening, either place a filter over each bucket, or be careful not to
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Donut Robot Mark V OM MN-1022EN 7
disturb the sediment that has accumulated on 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.
raising the heating element out of the kettle. Use a small saucepan or a metal to pitcher to scoop as much shortening as you can into an EZ Melt or one or more metal buckets. Then lift the kettle out of the fryer case and carefully pour the remaining shortening into an EZ Melt or a large metal bucket.
11. Return the kettle to the fryer case, if you have removed it, and tilt the heater head assembly down.
12. Brush off any carbon that has accumulated on the heating element. Accumulated carbon can cause corrosion and ineffective heating.
13. Tilt the heater head assembly back, raising the heating element out of the kettle.
14. Dispose of the carbon and other sediment using one of these methods:
If your kettle has the optional drain, put a
bucket under the drain, and scrape the carbon and other sediment through the drain, using a non-abrasive, non-metallic spatula.
If your kettle does not have the optional
drain, do the following:
Draining
Put an EZ Melt or a metal bucket under the drain. Slowly open the drain valve. If you are using a bucket and the bucket becomes full, close the drain valve, put another bucket under the drain, and resume draining.
Siphoning
Put an EZ Melt or a metal bucket under a Belshaw Filter Flo Siphon. (Refer to the Filter Flo Siphon instructions in Appendix A.) If you are using a bucket and the bucket becomes full, stop the siphon, put another bucket under the siphon, and resume siphoning.
Pouring
Tilt the heater head assembly back,
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8 MN-1022EN Donut Robot Mark V OM
a. Lift the kettle out of the fryer case. b. Use a non-abrasive, non-metallic spatula
to scrape the carbon and other sediment
out of the kettle. c. Dry the outside of the kettle. d. Put the kettle back in the fryer case.
15. Tilt the heater head assembly down.
16. Put the drop plate, turner cam assembly, and turner assembly back on the conveyor assembly.
17. Install the conveyor assembly.
18. If your kettle has the optional drain, close the drain valve.
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, transfering it to one or more large metal buckets. You may drain it out (if your kettle has the optional drain), siphon it out, or pour it out.
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
Thoroughly clean and dry the floor if
cleaning solution is spilled. Liquid on the
floor can cause serious injury or loss of life.
Draining
Put a large metal bucket under the drain. Slowly open the drain valve. If the bucket becomes full, close the drain valve, put another bucket under the drain, and resume draining.
Siphoning
Put a large metal bucket under a Belshaw Filter Flo Siphon. Remove the filter from the siphon. (Refer to the Filter Flo Siphon instructions in Appendix A.) If the bucket becomes full, stop the siphon, put another bucket under the siphon, and resume siphoning.
Pouring
Tilt the heater head assembly back, raising the heating element out of the kettle. Use a small saucepan or a metal to pitcher to scoop as much cleaning solution as you can into one or more metal buckets. Then lift the kettle out of the fryer case and carefully pour the remaining solution into a large metal bucket.
Carefully carry the buckets to the sink and
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.
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Donut Robot Mark V OM MN-1022EN 9
slowly pour the solution into the sink.
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.
10. If your kettle has the optional drain, close the drain valve.
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, transfering it to one or more large metal buckets. You may drain it out (if your kettle has the optional drain), siphon it out, or pour it out.
WARNING
Slowly open the drain valve. If the bucket becomes full, close the drain valve, put another bucket under the drain, and resume draining.
Siphoning
Put a large metal bucket under a Belshaw Filter Flo Siphon. Remove the filter from the siphon. (Refer to the Filter Flo Siphon instructions in Appendix A.) If the bucket becomes full, stop the siphon, put another bucket under the siphon, and resume siphoning.
Pouring
Tilt the heater head assembly back, raising the heating element out of the kettle. Use a small saucepan or a metal to pitcher to scoop as much water as you can into one or more metal buckets. Then lift the kettle out of the fryer case and carefully pour the remaining water into a large metal bucket.
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. Liquid on the floor can cause
serious injury or loss of life.
Carefully carry the buckets to the sink and slowly pour the water into the sink.
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.
3. If your kettle has the optional drain, close the drain valve.
Draining
Put a large metal bucket under the drain.
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10 MN-1022EN Donut Robot Mark V OM
3 Maintenance
WARNING
To avoid being burned, electrocuted, or
otherwise injured, always unplug the
machine and allow it to cool before
performing any maintenance.
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 3-1.
Weekly
Apply a few drops of SAE 30 machine
oil to the swing column where it contacts the swing column bracket.
Remove the heater head cover and
lightly coat the gear teeth with multipurpose grease. Replace the cover. See Figure 3-2.
Figure 3-2. Lubricating the Drive Gears.
Figure 3-1. Lubricating the Connecting Rod
Assembly.
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Yearly
Lubricate the conveyor drive motor as explained below. To help you better understand where to lubricate, refer to Figure D-3 in Appendix D, “Parts Lists.”
1. Disconnect the machine from the power source.
2. Remove the back cover of the heater head.
3. Unscrew the two bolts that connect the conveyor drive assembly to the bottom of the heater head.
CAUTION
Be gentle with all parts of the conveyor
drive assembly, especially when pulling the
assembly out of the heater head and
putting it back in the heater head..
Damaging the parts could stop production.
5. Apply 4 to 6 drops of SAE 30 machine oil through the lubricating hole in the bearing cap until the felt pad is saturated. See Figure 3-4.
Figure 3-4. Lubricating the Conveyor Drive
Motor.
6. Carefully put the motor back in the heater head, bolt the motor to the bottom of the heater head, and replace the back cover of the heater head.
4. Carefully pull the motor out of the heater head. See Figure 3-3.
Figure 3-3. Removing the Conveyor Drive
Motor.
Taking Care of the Plunger, Hopper, and Cylinder
The plunger, hopper, and cylinder of your Donut Robot are precision instruments. If you take good care of them, 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.
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12 MN-1022EN Donut Robot Mark V OM
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