Cleveland Range KGT-25, KGL-25-T, KCL-25-T, KGL-25, KGT-25-T User Manual

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MODELS:

KGL-25

KGL-25-T

KGT-25

KGT-25-T

Enodis

Operators Manual

Installation, Operation & Service

Gas 25 Gallon Kettle

1333 East 179th St., Cleveland, Ohio, U.S.A. 44110

Phone: (216) 481-4900Fax: (216)481-3782

Visit our web site at www.clevelandrange.com

SE95052

FOR THE USER

IMPORTANT!

ENSURE KETTLE IS AT ROOM TEMPERATURE AND PRESSURE GAUGE IS SHOWING ZERO OR LESS PRESSURE PRIOR TO REMOVING ANY FITTINGS.

 

 

 

 

 

 

 

 

FOR YOUR SAFETY

 

 

 

WARNING: Improper installation,

 

 

 

 

 

 

adjustment, alteration, service or

 

 

DO NOT STORE OR USE

 

 

 

maintenance can cause property

 

 

GASOLINE OR ANY OTHER

 

 

 

damage, injury or death. Read the

 

 

FLAMMABLE LIQUIDS AND

 

 

 

installation operating and

 

 

VAPOURS IN THE VICINITY

 

 

 

maintenance instructions

 

 

OF THIS OR ANY OTHER

 

 

 

thoroughly before installing or

 

 

APPLIANCE.

 

 

 

servicing this equipment.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

IMPORTANT

POST IN A PROMINENT LOCATION, INSTRUCTIONS TO BE FOLLOWED IN THE EVENT THE USER SMELLS GAS. THIS INFORMATION SHALL BE OBTAINED BY CONSULTING

YOUR LOCAL GAS SUPPLIER.

KEEP APPLIANCE AREA FREE AND CLEAR FROM COMBUSTIBLES.

DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATION AIR.

ALL SERVICE MUST BE PERFORMED BY A QUALIFIED CLEVELAND RANGE

TECHNICIAN.

RETAIN THIS MANUAL FOR YOUR REFERENCE.

TABLE OF CONTENTS

Installation

Operating Instructions

Cleaning Instructions

Service Parts

Maintenance

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Shipping Damage Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Specification Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

General Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Operating the Kettle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Approximate Boiling Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Care & Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Recommended Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Faucet Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Component Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Burner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2" Tangent Draw-OffValve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

General Assembly - Tilting Models . . . . . . . . . . . . . . . . . . . . . 12-14

- Stationary Models. . . . . . . . . . . . . . . . . . . 15-16

Console Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Hinge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Inspection & Maintenance Check List . . . . . . . . . . . . . . . . . . . . . 19

Safety Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21

- Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

- Safety Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

- Low Water Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

- Operating Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Hinge Adjustment Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Calibrating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Pressure Relief Valve Periodic Testing Procedure. . . . . . . . . . . . . 23

Reservoir Fill Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Kettle Jacket Filling & Draining Procedures . . . . . . . . . . . . . . . . 25

Kettle Venting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Vacuum Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Repairing Leaks in Steam Jacketed Kettle Fittings . . . . . . . . . . . . 27

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Sequences of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-31

Symbol Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-33

INSTALLATION

INSPECTION

Before unpacking visually inspect the unit for evidence of damage during shipping.

If damage is noticed, do not unpack the unit, follow shipping damage instructions.

SHIPPING DAMAGE

INSTRUCTIONS

If shipping damage to the unit is discovered or suspected, observe the following guidelines in preparing a shipping damage claim.

1.Write down a description of the damage or the reason for suspecting damage as soon as it is discovered. This will help in filling out the claim forms later.

2.As soon as damage is discovered or suspected, notify the carrier that delivered the shipment.

3.Arrange for the carrier's representative to examine the damage.

4.Fill out all carrier claims forms and have the examining carrier sign and date each form.

GENERAL

Installation of the kettle must be accomplished by qualified installation personnel working to all applicable local and national codes. Improper installation of product could cause injury or damage.

This equipment is built to comply with applicable standards for manufacturers. Included among those approval agencies are: UL, A.G.A., NSF, ASME/N.Bd., CSA, CGA, ETL, and others. Many local codes exist, and it is the responsibility of the owner/installer to comply with these codes.

Observe all clearance requirements to provide proper make-upair flow. Do not obstruct the flow of combustion and ventilation air. Check rating plate to ensure that kettle has been equipped to operate with the type of gas available at the installation.

Dimensions and clearance specifications are shown on the SPECIFICATION DRAWING (see page #3-4).

CLEARANCE REQUIREMENTS

FOR CLEARANCE REQUIREMENTS (TO COMBUSTIBLE AND NONCOMBUSTIBLE WALLS) AND ASSEMBLY DETAILS REFER TO SPECIFICATION DRAWING ON PAGE #3.

Note:

 

 

 

 

 

 

suggested

drain

 

 

 

 

 

 

refer to

 

 

 

 

#3.

1.

 

 

 

 

 

 

 

location, and

 

level

 

 

 

adjustable feet.

2.

Once

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

and

 

 

 

 

 

 

4 7/8" (124mm)

 

 

 

 

 

 

120

 

 

120

 

 

 

 

 

 

 

7/16"Ø, 3 HOLES

 

 

 

 

 

 

 

ON 3 1/8" (80mm) B.C.D.

 

the

FLANGED FOOT DETAIL

 

5/16"

 

 

 

 

(REAR LEGS ONLY)

 

and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

bolts are

 

 

 

 

 

 

 

flanged feet.

3.

Seal

 

 

 

 

 

 

silicone

GAS

ENSURE

THE

KETTLE'S

ON THE

RATING

 

It is

(drip leg) be

installed

gas pressure

exceeds

regulator must

be

14” water column

gas

 

Connect

located at the

rear of

 

Installation

local codes

and/or

Z223.1 Latest

Edition

Codes for Gas

Burning

CAN/ CGA B149.1

and CAN/

a gas pipe joint

compound

. Test all pipe

joints for

solution. Ensure that

the gas

manifold

pressure

plate.

The

valve must be

disconnected

system during

any

test pressures in

excess

must be

isolated

system by closing

its

any pressure

testing

at test

pressures

(3.45 kPa).

1

ELECTRICAL

ENSURE THE ELECTRICAL SUPPLY MATCHES THE KETTLE'S REQUIREMENTS AS STATED ON THE RATING LABEL.

A cord and plug are supplied with the unit. Simply plug the unit into any grounded outlet rated for a minimum of 10 amps. See GENERAL ASSEMBLY (pages #12-16)drawings for location of wiring diagram.

WARNING: Electrical Grounding Instructions.

This unit is equipped with a three-prong(grounding) plug for your protection against shock hazard and should be plugged directly into a properly groundedthree-prongreceptacle. Do not cut or remove the grounding prong from this plug. Standard supply voltage is 115 volts A.C., however, optional A.C. voltages can be supplied on special order. A separate fused disconnect switch must be supplied and installed in the high voltage electrical supply line. The kettle when installed, must be electrically installed and grounded in accordance with local codes, or in the absence of local codes, with National Electrical Code, ANSI/NFPA70-1990(USA) or the Canadian Electrical Code, CSA C22.2, Part 1 (Canada).

VENTILATION

Gas fired kettles are only to be installed under a ventilation hood in a room which has provisions for adequate make up air. Further information can be obtained by referring to the U.S.A. National Fire Protection Associations NFPA96 regulations. These standards have also been adopted by the National Building Code in Canada.

WATER

The sealed jacket of the gas-firedkettle is precharged with the correct amount of awater-basedformula, and therefore, no water connection is required to the kettle jacket. The kettle can be equipped with optional hot and cold water taps, the taps require 1/2" copper tubing as supply lines.

INSTALLATION CHECKS

Although the kettle has been thoroughly tested before leaving the factory, the installer is responsible for ensuring the proper operation of kettle once installed.

DO NOT ATTEMPT TO OPERATE THIS APPLIANCE DURING A POWER FAILURE.

KEEP APPLIANCE AND AREA FREE AND CLEAR OF COMBUSTIBLES.

1.Before turning the kettle on, read the vacuum/pressure gauge. The gauge's needle should be in the green zone. If the needle is in the "VENT AIR" zone, follow air venting procedure.

2.Supply power to the kettle by placing the fused disconnect switch to the "ON" position.

3.Turn on main gas supply to unit. Open the kettle's shut-offvalve (located at back of console).

4.Turn the temperature control knob to "1" (Min.). The green LED light should remain lit, indicating the burner is lit, until the set temperature is reached. Then the green light will cycle on and off, indicating the burner is cycling on and off to maintain temperature.

5.Tilt the kettle forward. The red "LOW WATER" light should be lit when the kettle is in a tilted position. This light indicates that the burner has automatically been shut off by the kettle's safety circuit. This is a normal condition when the kettle is in a tilted position.

6.Raise the kettle to the upright position. The red "LOW WATER" light should go out when the kettle is upright. If the red light remains lit in the upright position, it indicates a low water condition, and water must be added to the reservoir before the kettle can be operated. Refer to the "RESERVOIR FILL PROCEDURES", on page #19.

7.Turn the temperature control knob to "10" (Max.) and allow the kettle to preheat. The green light should remain on until the set temperature is reached. Then the green light will cycle ON and OFF, indicating the burner is cycling ON and OFF to maintain

kettle must be thoroughly cleaned cooking. See CLEANING

#7) for detailed information and

2

SPECIFICATION DRAWING - TILTING MODELS

FOOT LOCATION &

FLOOR DRAIN DETAIL

FLANGED

FOOT DETAIL

NOTES

OVERALL DEPTH

SPECIFICATIONS

3

SPECIFICATION DRAWING - STATIONARY MODELS

7/16" (11 mm) Ø

4 7/8"

3 HOLES ON

124 Ø mm

3 1/8" (80 mm) Ø

 

B.C.D.

 

 

120º

 

TYP

1 5/8" (42 mm) Ø

 

 

FOOT LOCATION &

 

FLOOR DRAIN DETAIL

1" (25 mm)

9/16"

MAX. ADJUSTMENT 14 mm

FLANGED

FOOT DETAIL

SPECIFICATIONS

NOTES

4

OPERATING INSTRUCTIONS

2

3

1

7

4

5

6

8

General Parts Drawing

ITEM #

DESCRIPTION

FUNCTION

1.

Tilt Wheel (tilting models only)

Used for tilting the kettle.

2.

Vacuum/Pressure Gauge

Indicate steam pressure in PSI inside steam jacket as well as

 

 

vacuum in inches of mercury.

3.

Pressure Relief Valve

This valve is used to vent the kettle and in the unlikely event there is

 

 

an excess steam build-upin the jacket, this valve opens

 

 

automatically to relieve this pressure.

4.

Low Water Indicator Light (Red)

When lit, indicates that the kettle is low on water and will not operate

 

 

in this condition (see RESERVOIR FILL PROCEDURES on page #24).

5.

On-OffSwitch/

Turns kettle ON/OFF and allows the operator to adjust the kettle

 

Solid State Temperature

temperature in increments from 1 (Min.) to 10 (Max.).

 

Control

(see TEMPERATURE RANGE CHART on page #6).

6.

Heat Indicator Light (Green)

When lit, indicates that the kettle's burner is on.

 

 

Cycles ON-OFFwith burner.

7.

Water Level Sight Glass

Displays water level in steam jacket.

8.

Ignition Failure Indicator Light

Indicates failure of heating system to ignite.

 

(Amber)

 

9.

Tangent Draw-OffValve

Used for draining product or wash water from kettle. It is supplied as

 

 

standard equipment on stationary kettles and is optional on tilting kettles.

5

OPERATING THE KETTLE

DO NOT ATTEMPT TO OPERATE THIS APPLIANCE DURING A POWER FAILURE.

KEEP APPLIANCE AND AREA FREE AND CLEAR OF COMBUSTIBLES.

DO NOT LEAN ON OR PLACE OBJECTS ON KETTLE LIP. SERIOUS INJURY COULD RESULT IF KETTLE TIPPED OVER, SPILLING HOT CONTENTS.

1.Before turning kettle on, read the Vacuum/Pressure Gauge (2). The gauges needle should be in the green zone. If the needle is in the "VENT AIR" zone, refer to the Kettle Venting Instructions (page #21). Any air that may be present will increase cooking times. Once heated, the kettle's normal maximum operating pressure is approximately 1012 psi while cooking a water base product.

2.Ensure that the electrical service to the kettle is turned on at the fused disconnect switch.

Temperature

Approximate

Control

Product Temperature

Setting

° F

° C

 

 

 

MIN.

120

49

1.

130

54

2.

145

63

3.

160

71

4.

170

77

5.

185

85

6.

195

91

7.

210

99

8.

230

110

9.

245

118

MAX.

265

130

NOTE: Certain combinations of ingredients will result in temperature variations

Temperature Range Chart

3.Preheat the kettle by turning the ON/OFF Switch/Solid State Temperature Control (5) to the desired temperature setting (see above, TEMPERATURE RANGE CHART). The Heat Indicator Light (Green) (6) will remain lit, indicating the burner is on, until the temperature setting is reached. When the green light goes off, the burners are off, and preheating is complete.

NOTE: When cooking egg and milk products, the kettle should not be preheated, as products of this nature adhere to hot cooking surfaces. These types of food should be placed in the kettle before heating is begun.

4.Place food product into the kettle. The Heat Indicator Light (Green) (6) will cycle on and off indicating the burners are cycling on and off to maintain the set temperature.

NOTE: Do not fill kettle above recommended level marked on outside of kettle.

NOTE: The Low Water Indicator Light (Red) (4) should not be lit during kettle operation. This light indicates that the burners have been automatically shut off by the kettle's safety circuit. It is normal for the red light to come on when the kettle is in a tilted position. However, the kettle cannot be operated when the red light remains lit while the kettle is in the upright position. This indicates a low water condition, and water must be added to the reservoir. Refer to Reservoir Fill Procedures on page #19 of this manual for details.

5.When cooking is completed turn ON/OFF Switch/Solid State Temperature Control (5) to the "OFF' position.

NOTE: A five minute completeshut-ofperiod is required before relighting.

6.Pour the contents of the kettle into an appropriate container by tilting the kettle forward. Care should be taken to pour slowly enough to avoid splashing off the product.

NOTE: As with cleaning food soil from any cookware, an important part of kettle cleaning is to prevent food from drying on. For this reason, cleaning should be completed immediately after cooked foods are removed. Refer to the Cleaning Instructions (page #6) for detailed kettle washing procedures.

APPROXIMATE BOILING TIMES

The accompanying chart shows approximate times required for electric kettles of various capacities to boil water. The ON/OFF Switch/Solid State Temperature Control (5) must be set at “10” (Max.) throughout theheat-upperiod. Water will boil about 1/3 faster if the kettle is filled only to the outer steam jacket’s welded seam resulting in a kettle filled to 2/3 capacity.

 

Kettle Capacity

Minutes

 

25 gallon

37

 

 

Approximate Boiling Times

 

6

CLEANING INSTRUCTIONS

CARE AND CLEANING

Your kettle must be cleaned regularly to maintain its fast, efficient cooking performance, and to ensure its continued safe, reliable operation.

 

WARNING: Do not use chloride

 

base detergents. There is a growing

 

number of non-chloridecleaners

 

available. If unsure of the cleaners

 

chlorine content consult the supplier.

 

Also avoid cleaners containing

 

quaternary salt as they can cause

Chloride Cleaners

the stainless steel to pit and rust.

 

WARNING: If any gaskets or seals are found defective, replace or repair immediately. (See Service Parts Drawings for part identification.)

1.Place the kettle's On-OffSwitch/Solid State Temperature Control (5) to the "OFF" position.

2.Prepare a warm water and mild detergent solution in the kettle.

3.Remove food soil inside the kettle using a nylon brush.

WARNING: Do not use a metal bristle brush or scraper, as this may permanently damage the kettle's stainless steel surface.

Wire Brush & Scrapers

4.Loosen food which is stuck to the kettle by allowing it to soak at a low temperature setting.

5.If the kettle is equipped with a draw-offvalve, it should be cleaned as follows:

a)Remove drain screen from bottom of kettle. Thoroughly wash and rinse the screen either in a sink or a dishwasher, then replace it into the kettle.

b)Disassemble the draw-offvalve first by turning the valve knobcounter-clockwise,then turning the large hex nutcounter-clockwiseuntil the valve stem is free of the valve body.

c)In a sink, wash and rinse the inside of the valve body using a nylon brush.

d)Reassemble the draw-offvalve by reversing the procedure for disassembly. The valve's hex nut should be hand tight only.

6.Rinse kettle interior thoroughly, then drain the rinse water. Do not leave water sitting in unit when not in use.

7.Using mild soapy water and a damp sponge, wash the exterior of the kettle, rinse, and dry.

NOTE: For more difficult cleaning applications one of the following can be used: alcohol, baking soda, vinegar, or a solution of ammonia in water.

Avoid the use of chloride cleansers, which may damage the kettle's stainless steel surface.

 

WARNING: Steel wool should

 

never be used for cleaning the

 

cooking chamber of the kettle.

 

Particles of steel wool become

 

embedded in the cooking surface

 

and rust, which may corrode the

Steel Pads

stainless steel.

 

NOTE: Unit should not be cleaned with a water jet.

8. Leave the cover off when the kettle is not in use.

RECOMMENDED CLEANERS FOR SPECIFIC SITUATIONS

Job

Cleaning Agent

Comments

Routine Cleaning

Soap, Ammonia

Apply with cloth or

 

Detergent, Medallion

sponge

Fingerprints

Arcal 20, Lac-O-Nu

Provides barrier film

& Smears

Ecoshine

 

Stubborn Stains

Cameo, Talc, Zud

Rub in direction

& Discolouration

First Impression

of polish lines

Grease & Fatty Acids,

Easy-Off,De-GreaseIt

Excellent removal

Blood, Burnt-OnFoods

Oven Aid

on all finishes

Grease & Oil

Any good commercial

Apply with sponge

 

detergent

or cloth

Restoration/

Benefit, Super Sheen

 

Passivation

 

 

 

 

 

7

SERVICE PARTS

WARRANTY

Our Company supports a worldwide network of Maintenance and Repair Centers. Contact your nearest Maintenance and Repair Centre for replacement parts, service, or information regarding the proper maintenance and repair of your cooking equipment

In order to preserve the various agency safety certification (UL, NSF, ASME/Ntl. Bd., etc.), only factorysupplied replacement parts should be used. The use of other than factory supplied replacement parts will void warranty.

FAUCET ASSEMBLY (optional)

ITEM

PART

DESCRIPTION

QTY.

NO.

NO.

 

 

1.

 

3/4" SPOUT

 

 

KE50825-7

FOR STATIONARY KETTLES . . . . . .

. . . . .1

 

KE50825-2

FOR TILTING KETTLES . . . . . . . . . . .

. . . .1

2.

FA95022

RETAINING RING . . . . . . . . . . . . . . . .

. . . .1

3.

FA05002-19

"O" RING . . . . . . . . . . . . . . . . . . . . . . .

. . . .1

4.

KE51736

LONG FAUCET NUT . . . . . . . . . . . . .

. . . .1

5.

SE50020

HOT WATER STEM ASSEMBLY . . . . .

. . . .1

 

 

(DOUBLE PANTRY ONLY)

 

6.

SE50021

COLD WATER STEM ASSEMBLY . . . .

. . . .1

7.

KE51401

SINGLE PANTRY BODY . . . . . . . . . . .

. . . .1

 

 

(C/W ITEM NO. 6)

 

8.

KE50335

ADAPTER WASHER . . . . . . . . . . . . . .

. . . .1

 

 

(SINGLE PANTRY ONLY)

 

9.

KE51403

DOUBLE PANTRY BODY . . . . . . . . . .

. . . .1

 

 

(C/W ITEM NO. 5&6)

 

10.

SK00395-1

FAUCET MOUNTING BRACKET . . . .

. . . .1

11.

FA11258

HEX CAP SCREW . . . . . . . . . . . . . . .

. . . .2

12.

FA30505-1

WASHER . . . . . . . . . . . . . . . . . . . . . .

. . . .2

13.

FA21008

HEX NUT . . . . . . . . . . . . . . . . . . . . . .

. . . .2

14.

SE50447

WASHER HORSESHOE . . . . . . . . . . .

. . . .1

1

2

1

3

4

2

5 3

6

4

6

10

7

9 11

8

12 13

10

11

12

14

13

8

COMPONENT MOUNTING PLATES

STATIONARY MODELS

TILTING MODELS

3

4

5

10

2

5

9

10 11 12 13

8

7

4

1

7

3 5 10

8

1

2

6

9

ITEM NO.

PART NO.

DESCRIPTION

QTY.

1.

KE01927-1

COMPONENT MOUNTING PLATE (STATIONARY MODELS) . . . . . . . . . . . . .

. .1

 

KE01927

COMPONENT MOUNTING PLATE (TILTING MODELS) . . . . . . . . . . . . . . . . .

. .1

2.

KE50753-7

RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

3.

KE00458

SSK CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

4.

KE50303

ELECTRONIC BOX HOLDER (STATIONARY MODELS) . . . . . . . . . . . . . . . . .

. .1

 

KE52548

ELECTRONIC BOX HOLDER (TILTING MODELS) . . . . . . . . . . . . . . . . . . . . .

. .1

5.

FA11089

SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

6.

FA11052

SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

9.

FA32004

TOOTH LOCKWASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

10.

FA32005

TOOTH LOCKWASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .6

11.*

KE53469-2

IGNITION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

12.*

FA10245

SCREW (8-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .4

13.*

FA20004

HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .4

 

 

FOR 120V OPTION

 

7.

KE53838-20

TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

8.

KE53838-27

TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

 

FOR 240V OPTION

 

7.

KE53838-18

TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

8.

KE53838-21

TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

* LOCATED IN GEARBOX ON GAS MODELS

9

BURNER ASSEMBLY

17 16 15

2

3

12

14

13

11

7

8

10

1

4

5

6

9

ITEM NO.

PART NO.

DESCRIPTION

QTY.

1.

KE54897-1

MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

2.

KE54890-1

IGNITION GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

3.

FA11144

SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

4.

KE54881-1

BOTTOM COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

5.

KE54894-1

HOLDER, BOTTOM COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

6.

KE54895-3

INSULATION ON TOP OF COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

7.

KE01500-2

BURNER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

8.

KE01500-4

BURNER WITHOUT IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

9.

KE02195-1

BURNER PAN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

10.

KE54895-2

INSULATION BETWEEN BOTTOM COVER & BURNER ASSEMBLY . . . . . . .

. .2

11.

KE54895-4

INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

12.

KE53406-21

GAS ORIFICE, NATURAL GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

 

KE53406-18

GAS ORIFICE, LP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

13.

FI05134-1

COMPRESSION FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

14.

FI00565-6

NIPPLE 3/8 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

15.

KE53437-1

IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

16.

FA11145

SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

17.

KE54775

IGNITOR POSITION HOLDING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

10

2" TANGENT DRAW-OFFVALVE

7

6

5

4

3

2

1

ITEM NO.

PART NO.

DESCRIPTION

QTY.

1. - 7.

KE50972-B

DRAW-OFFASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

1.

FA95049

WING NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

2.

KE527551

KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

3.

KE52754

HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

4.

KE52753

RETAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

5.

KE52752

PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

6.

FA00111

"O" RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

7.

KE52751

VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

11

GENERAL ASSEMBLY - TILTING MODELS (pg. 1 of 3)

62

3

2

4

60

VIEW "G"

MANIFOLD & BURNER TUBE PIPING DETAIL

55

56

57

8

10

13 12 11 12 14

5

L2

L3

60 L5

 

 

6

 

 

9

L4

7

G

L1

61

1

ITEM NO.

PART NO.

DESCRIPTION

QTY.

1.

KE00099

ADJUSTABLE FOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

2.

KE51723-1

SAFETY VALVE (50 PSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

3.

KE50429-3

PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

4.

KE54852-1

BRACKET FOR SAFETY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

5.

KE529773

LID FOR GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

6.

KE00508

HANDWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

7.

KE54821-8

SUPPLY CORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

8.

CHS-KGL-25-T

SPRING HINGE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

9.

KE00351

TRUNNION BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

10.

FI05321-1

NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

11.

KE54667-3

BURNER TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

12.

FI05134-1

COMPRESSION FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

12

GENERAL ASSEMBLY - TILTING MODELS (pg. 2 of 3)

25 26

 

 

 

 

 

27 28

 

 

 

 

 

29 30

 

 

 

 

 

 

 

 

 

 

23

B

 

 

 

B

24

C

 

 

 

 

C

21 22

15 16

17

18

19

20

37 38 39

40

41

36

42

43

45

43

42

46

47 48 49 50

58

53

59

44

31

 

32

 

33

 

34

 

35

60

51 52 53 54

13.

FI05198-5

COMPRESSION ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

14.

FI00565-6

NIPPLE 3/8 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

15.

FI05222

SWIVEL ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

16.

FI05231

FLUSH BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

17.

FI05223

SPECIAL NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

18.

KE02053

GAS VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

19.

FI00607

CLOSE NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

20.

F01518-1

GAS SHUT OFF VALVE

 

 

GAS OPTIONS:

 

 

 

KE54618-1

PRESSURE REGULATOR (PROPANE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

KE54618-2

PRESSURE REGULATOR (NATURAL GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

21.

F105226-12

NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

22.

FI00040

ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

13

GENERAL ASSEMBLY - TILTING MODELS (pg. 3 of 3)

23.

FA19177

HEX SOCKET SET SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

24.

FA20047

JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

25.

KE50294-1

MERCURY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

26.

KE54456-1

MERCURY SWITCH BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

27.

KE50295-1

CLIP FOR MERCURY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

28.

FA11396

HEX HEAD BOLT (3/8-24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

29.

FA31031

SPLIT LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

30.

FA15018-7

SCREW 6-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

31.

KE52833

WORM GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

32.

FA10772

SOCKET HEAD CAP SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

33.

FA20030

JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

34.

FA95007-4

RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

35.

FA95055-1

SQUARE KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

36.

KE50315

WORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

37.

KE51730

TILT SHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

38.

FA31010

SPLIT LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

39.

FA20030

HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

40.

KE503752

TILT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

41.

FA95005

TENSION PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

42.

KE52193

THRUST BEARING SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

43.

KE52191

ROLLER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

44.

KE52192

THRUST WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

45.

FA30088

WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

46.

FA95008

JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

47.

KE53469-2

IGNITION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

48.

FA10245

SCREW (8-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

49.

FA20004

HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

50.

FA32005

TOOTH LOCKWASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

51.

KE53390

GAS VALVE MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

52.

FA10367

BINDING HEAD SCREW (10-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

53.

FA32006

TOOTH LOCKWASHER (J10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

54.

FA20007

MACHINE SCREW NUT (10-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

55.

KE53316

SAFETY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

56.

KE00515

THERMISTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

57.

KE50556-1

LOW WATER PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

58.

KE01928-1

COMPONENT MOUNTING PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

 

(see COMPONENT MOUNTING PLATES on page #9)

 

59.

FA20006

MACHINE SCREW NUT (10-24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

60.

FA11145

SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

61.

KE54833-2

SNAP-INBUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

62.

KE54468

WATER LEVEL SIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

LABELS

 

 

 

L1.

KE95555-5

OPERATING INSTRUCTION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

L2.

KE95552

RATING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

L3.

KE95551

GAS KETTLE LABEL GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

L4.

KE95040

DIRECTION OF TILT LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

L5.

KE90424

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

14

GENERAL ASSEMBLY - STATIONARY MODELS (pg. 1 of 2)

34

31

5

7

8 10

L3

 

 

VIEW "B"

 

 

 

 

 

 

 

MANIFOLD & BURNER

 

 

 

 

21

 

 

 

TUBE PIPING DETAIL

 

 

 

 

 

 

 

 

 

 

A

 

 

 

 

 

 

 

 

 

 

 

 

 

25

 

 

 

 

 

6

7

9

10 L1

27

 

 

 

 

 

14 15 16

 

26

28

29

28

30

VIEW "A"

COMPONENT MOUNTING BOX

WITH LID REMOVED

11

2

3

4

32

13

19 20

12

23

33

24

25

17 18

L4

L2

B

22

1

15

GENERAL ASSEMBLY - TILTING MODELS (pg. 2 of 2)

ITEM NO.

PART NO.

DESCRIPTION

QTY.

1.

KE00099

ADJUSTABLE FOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .3

2.

KE01928-2

COMPONENT MOUNTING PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

 

(see COMPONENT MOUNTING PLATES on page #9)

 

3.

FA20006

MACHINE SCREW NUT (10-24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

4.

FA32006

TOOTH LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

5.

KE54991-1

LID (COMPONENT BOX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

6.

KE54991-2

LID (SIDE BOX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

7.

FA95074

ANCHOR NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .8

8.

KE54846-4

GASKET (COMPONENT BOX LID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

9.

KE54846-5

GASKET (SIDEBOX LID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

10.

FA95031

PAN HEAD PHILLIPS DRIVE SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .8

11.

KE50429-3

PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

12.

KE54852-1

BRACKET FOR SAFETY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

13.

KE54941-6

SAFETY VALVE (50 PSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

14.

KE53316

SAFETY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

15.

KE00515

THERMISTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

16.

KE50556-1

LOW WATER PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

17.

KE02053

GAS VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

18.

FA10360

SCREW PAN HEAD PHILLIPS (10-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.2

19.

F01518-1

GAS SHUT OFF VALVE (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

 

 

GAS OPTIONS:

 

 

KE54618-1

PRESSURE REGULATOR (PROPANE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

 

KE54618-2

PRESSURE REGULATOR (NATURAL GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

20.

FI00607

CLOSE NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

21.

KE54821-8

SUPPLY CORD (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

22.

KE54833-2

SNAP IN BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

23.

FA00152

STREET ELBOW (3/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

24.

FI00355

BUSHING (3/4 X 3/8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

25.

FI00565-3

NIPPLE (3/8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

26.

FI05198-5

COMPRESSION ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

27.

FI00265

COUPLING (3/8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

28.

FI05134-1

COMPRESSION FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.2

29.

KE54667-4

BURNER TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

30.

FI00565-6

NIPPLE (3/8 NPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

31.

KE51238

CORD CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

32.

CHS-25

SPRING HINGE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

33.

FA11145

SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.2

34.

KE54468

WATER LEVEL SIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

LABELS

 

 

 

L1.

KE90424

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

L2.

KE95555-5

OPERATING INSTRUCTION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

L3.

KE95552

RATING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

L4.

KE95551

LABEL SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.1

16

4 7

8

1

5 7

3

2

6 7

ITEM NO.

PART NO.

DESCRIPTION

QTY.

1.

SE00114

POTENTIOMETER WITH ON/OFF SWITCH, C/W ITEM #2 . . . . . . . . . . . . . . .

. .1

2.

KE51005

RUBBER BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

3.

KE50569-1

KNOB, POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

4.

KE50567-1

L.E.D., RED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

5.

KE50568-1

L.E.D., GREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

6.

KE50567-2

L.E.D., AMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

7.

FA05002-18

"O" RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .3

17

HINGE ASSEMBLY

9

4

7

11

8

6

10

1

9

5

12 13 2 3

ITEM NO.

PART NO.

DESCRIPTION

QTY.

1. - 11

SE00120-1

Hinge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

1.

KE50882

Hinge Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

2.

KE51217

Hinge Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

3.

KE50121-2

Hinge Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

4.

KE50823-1

Hinge Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

5.

KE50824

Hinge Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

6.

KE50819-1

Hinge End Piece, LHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

7.

KE50820

Hinge Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

8.

KE50819

Hinge End Piece, RHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

9.

FA11284

Screw, Socket Head, 1/4-20x 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .4

10.

FA11507

Cutting Screw, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

11.

KE54907-10

Plug Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

12.

KE50151-12

Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

13.

 

Cover Handle (specify model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

18

MAINTENANCE

ALL SERVICE MUST BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN.

IMPORTANT!

ENSURE KETTLE IS AT ROOM TEMPERATURE AND PRESSURE GAUGE IS SHOWING ZERO OR LESS PRESSURE PRIOR TO REMOVING ANY FITTINGS.

Cleveland Range equipment requires little preventative maintenance. We do however provide the following chart as a guideline for inspection and maintenance to keep your unit functioning at 100%.

INSPECTION AND MAINTENANCE CHECKLIST

The following check should be completed every six months or more frequently if unit is in a high volume facility.

WARNING: It is imperative that damaged seals be repaired immediately to prevent equipment failure and/or damage.

ITEM

CHECK

HAND WHEEL (tilting models only)

Check hand wheel for tightness. If loose tighten allen screw.

LUBRICATION (tilting models only)

Check that kettle tilts smoothly. Grease trunnion housings and

 

gear/worm assembly every three months as

 

recommended in LUBRICATION PROCEDURE on page #22.

GEAR/WORM

Inspect for play. Tighten Allen screws if required.

PRESSURE GAUGE

Check that the gauge does not have moisture on its inside face.

 

Replace if moisture is present.

 

Check that the gauge shows a vacuum (needle is well into the Green

 

zone) when cold and shows between 25-40psi when unit is hot. If not

 

follow VACUUM LEAK TEST on page #26.

PRESSURE RELIEF VALVE

Check pressure relief valve as described in PRESSURE RELIEF VALVE

 

TESTING PROCEDURE on page #22.

TEMPERATURE CHECK

Following the CALIBRATING PROCEDURE on page #23, check the

 

inner kettle surface temperature with a digital surface thermometer and

 

adjust if required.

ON/OFF SWITCH/

Check for damage. Replace if necessary.

TEMPERATURE CONTROL

 

SPRING ASSIST COVER

Check cover is tightly secured to handle and insure spring is holding

 

cover up - adjust if required. Refer to HINGE ADJUSTMENT

 

INSTRUCTIONS on page #22.

19

SAFETY INSPECTION CHECKLIST-

TILTING MODELS (pg. 1 of 2)

Regular inspection and maintenance of units is essential to obtain trouble free and safe operation of equipment. Inspections must include testing of the pressure relief valve and checks of the operating system to insure that it has not been altered.

No safety features designed into the equipment should ever be tampered with. Tampering with or bypassing controls is a very dangerous practice and unfortunately we have seen several cases of this. Following is a short list of the most common and the most dangerous alterations performed on kettles.

SAFETY VALVE:

This illustrations show the correct configuration of a factory installed Safety Valves.

Any modifications are unacceptable.

Incorrect Installations

1 Safety valve has plug threaded into the discharge opening preventing any steam from escaping.

2 Safety valve’s tube diameter has been reduced.

3 Safety valve is sticking, frozen shut or plugged. To test, refer to page 23, PRESSURE RELIEF VALVE PERIODIC TESTING PROCEDURE.

4 Safety valve is plumbed to a drain or water line creating back pressure and reducing flow.

1

Plug

2 Tube diameter reduced

Frozen, 3 stuck, or

plugged

Plumbed to drain or

water line

4

This illustrations show the correct configuration of a factory installed Safety Valves.

Any modifications are unacceptable.

20

SAFETY INSPECTION CHECKLIST-

TILTING MODELS (pg. 2 of 2)

SAFETY THERMOSTAT:

 

 

Incorrect

 

 

Installations

 

1

2

3

 

Safety thermostat

 

 

 

1 probe is not

 

 

 

 

completely

 

 

 

 

inserted into

Probe

 

 

 

tubing.

 

 

 

Safety thermostat

fully

 

 

 

 

 

 

2 probe is removed

inserted

 

 

 

in tube

 

 

 

from tubing.

 

Safety thermostat

Wiring is properly

Probe

Probe

Thermostat

3 electrical

connected

removed

removed

electrically

connection is

 

partially

completely

bypassed

bypassed.

Low Water Level Probe:

Probe properly attached

(A)

(B)

 

Probe bypassed by

 

 

Probe bypassed by

running (A) an

 

(B) grounding the

 

additional wire

 

 

connecting wire

 

 

 

 

 

 

 

 

Operating

Thermostat:

265º

260º - 270º

MAXIMUM

 

 

KETTLE

 

TEMPERATURE

If maximum temperature is not in this range (on empty kettle), refer to the CALIBRATING PROCEDURE on page #23.

21

LUBRICATION PROCEDURE

Lubricate the following parts every three months to insure smooth operation and reduce wear.

 

TRUNNION

Adjusting

HOUSING ,

Screw

 

WORM SCREW

Worm

AND TILT GEAR

Screw and

These parts are

Tilt

accessed through the

Gear

Cross

top cover of the

Bar

console.

 

Apply grease to gear

 

teeth. Check for

excessive play and adjust with adjusting screw located on top of cross bar.

Trunnion Housing

Grease Nipple

KETTLE

TRUNNIONS

On the left hand side of the kettle there are two grease nipples on the top back portion of the trunnion housing. On the right hand side of the kettle you must remove the console cover to access the grease nipple.

HINGE ADJUSTMENT

INSTRUCTIONS 3/8" Allen wrench

1.Insert 3/8" Allen wrench.

2.Turn clockwise to relieve tension on spring.

3.While tension is released remove one of the two slotted screws.

4.To prevent Allen wrench from springing back abruptly while the second slotted screw is removed, insert a pin (approximately 1/8") in the hole where the first slotted screw was removed from.

5.Remove second slotted screw.

6.While holding Allen wrench remove pin.

7.Turn Allen wrench clockwise to tighten or counter-clockwiseto loosen tension to produce desired effect.

8.Re-insertpin in one of the two holes.

9.Tighten one slotted screw in the other hole (it may be necessary to turn Allen wrench slightly to align holes).

10.Remove pin and repeat step number 9. for other slotted screw.

22

CALIBRATING PROCEDURE

1.Insure the unit has a vacuum before you begin calibrating procedures. If unit requires venting refer to Kettle VENTING INSTRUCTIONS on page #26.

2.Set On-OffSwitch/Temperature Control to "10" (Max.).

3.Allow the unit to cycle twice.

4.Check temperature of the inner kettle surface with a digital surface thermometer.

5.Temperature should be between 260° F and 265° F.

6.Using a screw driver adjust temperature by turning the potentiometer on the black box. Turn very little. Turn clockwise to INCREASES and counterclockwise to DECREASE temperature.

7.Allow the unit to cycle twice.

8.Check temperature of the inner kettle surface with a digital surface thermometer.

9.Repeat steps 4. through8. until unit is calibrated.

Pressure Relief Valve/Gauge Assembly Drawing

Pressure Gauge

Pressure Relief Valve

Guard Bracket

DANGER: PRESSURE RELIEF VALVE WILL EXHAUST HIGH TEMPERATURE STEAM. CONTACT WITH SKIN COULD RESULT IN SERIOUS BURNS. KEEP FACE,

HANDS AND BODY CLEAR OF DISCHARGE.

DANGER: WORKING ON MACHINES

WITH POWER COULD RESULT IN

SEVERE ELECTRICAL SHOCK.

1.Remove guard bracket from pressure relief valve/gauge assembly.

2.With the kettle empty, set On-OffSwitch/Temperature Control to "10" (Max.). Allow the kettle to heat until the unit cycles off.

3.Switch On-OffSwitch/Temperature Control to "0" (Off) and disconnect main power at fused disconnect switch.

PRESSURE RELIEF VALVE PERIODIC TESTING PROCEDURE

WARNING: IMPROPER REFILLING OF KETTLE JACKET WILL RESULT IN IRREVERSIBLE DAMAGE TO UNIT.

Most insurance agencies require periodic testing of pressure relief valves used on pressure vessels. This procedure will allow you to safely and quickly test your kettle's pressure relief valve. We recommend this test be performed twice a year.

NOTE: The following instruction is intended for use by qualified service personnel.

WARNING: Kettle surface will be hot and steam will be released during testing. Take necessary precautions including the use of gloves and eye protection to prevent personal injury.

4.Stand to the side of the pressure relief valve discharge tube and pull valve open for a maximum of one second. Repeat test three to four times. Each time the mechanism should move freely and be accompanied by a rapid escape of steam.

5.Replace guard bracket from pressure relief valve/gauge assembly.

If valve appears to be sticking replace pressure relief valve.

If foreign material is discharged then drain kettle (see KETTLE JACKET FILLING & DRAINING PROCEDURES on page #25) and replace pressure relief valve.

See RESERVOIR FILL PROCEDURE (page #24) for full instructions on the correct method for refilling kettle jacket.

WARNING: Improper refilling of kettle jacket will result in irreversible damage to unit.

NOTE: Rust inhibitor is purchased locally. Read directions and do not exceed manufacturer's recommendation (excessive rust inhibitor can also cause solidification).

23

RESERVOIR FILL

PROCEDURES

WARNING: IMPROPER REFILLING OF KETTLE JACKET WILL RESULT IN IRREVERSIBLE DAMAGE TO UNIT.

The kettle's water level must be maintained at the proper level. Under normal operating conditions, the sealed water reservoir should never require the addition of water.

If the red "low water" light comes on during use (while the kettle is in an upright position), the water level has reached a critically low level. The low water protection control has automatically shut off the gas burner. The following procedure must be completed before further use:

DANGER: PRESSURE RELIEF VALVE WILL EXHAUST HIGH TEMPERATURE STEAM. CONTACT WITH SKIN COULD RESULT IN SERIOUS BURNS. KEEP FACE,

HANDS AND BODY CLEAR OF DISCHARGE.

DANGER: WORKING ON MACHINES

WITH POWER COULD RESULT IN

SEVERE ELECTRICAL SHOCK.

NOTE: Have a qualified service technician repair the leakage problem and add water to the unit. Ensure that the red "low water" light is on when the kettle is upright. On tilting kettles, it is normal for the red light to come on when the kettle is in a tilted position.

CAUTION: Only distilled water should be used when adding water to a partially filled water reservoir (If unit is completely empty see KETTLE JACKET FILLING & DRAINING PROCEDURES on page #25). Local tap water conditions may cause kettle damage which is not covered under warranty. Rust inhibitor is purchased locally. Read directions and do not exceed manufacturer's recommendation (excessive rust inhibitor can also cause solidification).

DISTILLED WATER REQUIREMENTS

 

When red “Low

When the reservoir is

Kettle

Water Light” comes

completely empty,

Capacity

on, add distilled water

add distilled water

 

 

 

25 gallon

Approximately 1 gal.

4.4 gallon

 

 

 

D. Fill unit via Street Elbow

C.

Attach Street

Elbow

B.*

Remove

Pressure

Relief

Valve

A. Remove

Guard

Bracket

*Important- Pull ring on Pressure Relief Valve prior to removal to insure vessel is not pressurized.

Pressure Relief Valve/Gauge Assembly Drawing

 

 

150

200

 

 

 

100

 

250

 

 

 

20

 

 

50

30

 

 

10

 

40

300

 

 

 

 

 

 

 

0

0

 

 

50

 

 

I

 

 

 

 

R

 

 

 

350

 

A

 

 

 

 

T

 

 

 

 

 

N

 

60

 

 

E

 

 

 

 

 

V

 

psi

 

400

 

 

 

 

 

 

 

 

kPa

1.Ensure kettle is at room temperature and pressure gauge showing zero or less pressure.

2.Shut off power to the kettle at the fused disconnect switch.

3.Remove Guard Bracket (A).

4.Pull Pressure Relief Valve (B) open to insure vessel is not pressurized.

5.Remove Pressure Relief Valve (B).

6.Replace Pressure Relief Valve (B) with Street Elbow (C).

7.Add distilled water (D) through the Street Elbow (C), using a funnel if necessary. Fill the unit to the high

level mark on the Sight Glass.

Sight

Glass

8.Apply a thread sealant (i.e. Teflon tape) to the Pressure Relief Valve's (B) thread and replace.

9.Replace Guard Bracket (A).

10.Restore power to unit at the fused disconnect switch.

11.The kettle must now be vented. (Refer to the KETTLE VENTING INSTRUCTIONS on page #26).

24

KETTLE JACKET FILLING & DRAINING PROCEDURES

Under normal circumstances the kettle does not require the draining of all fluid. If the red “low water” light is on, follow the Reservoir Fill Procedures (page #9) in this manual.

If unit must be drained follow the procedures described on the following pages.

WARNING: IMPROPER REFILLING OF KETTLE JACKET WILL RESULT IN IRREVERSIBLE DAMAGE TO UNIT.

Use only a mixture of water and rust inhibitor to refill kettle jacket (see instructions below).

Contact your local water treatment company and purchase rust inhibitor with the specifications described below.

Recommended Corrosion Inhibitors for Closed Systems.

DESCRIPTION

Recommended for our units is a blend of SODIUM NITRITE and BORAX for corrosion inhibition of ferrous metals and axoles for copper and copper alloy corrosion protection. Product should be formulated for hot or cold closed recalculating water systems.

Source the chemicals stated above from your local water treatment company. Mix only with water and follow manufactures recommended mixing rate.

DISPOSAL OF INHIBITOR

Do not dispose of chemicals in any system which may discharge into water supplies used for drinking or washing or that could accidentally discharge into such systems, or into stream accessible to animals.

Follow all Federal, State and local codes when disposing of product.

Refill Quantities (water and corrosion inhibitor mixture)

Kettle Size

U.S. Gallons

Liters

25 gallon

4.4

16.6

Draining Procedure

DANGER: WORKING ON MACHINES

WITH POWER COULD RESULT IN

SEVERE ELECTRICAL SHOCK.

DANGER: PRESSURE RELIEF VALVE WILL EXHAUST HIGH TEMPERATURE STEAM. CONTACT WITH SKIN COULD RESULT IN SERIOUS BURNS. KEEP FACE,

HANDS AND BODY CLEAR OF DISCHARGE.

DANGER: EXTREMELY

HOT SURFACES.

WORK ONLY ON COLD KETTLE.

1.Shut off gas supply.

2.Disconnect gas line and electrical connection.

3.Remove bolts holding kettle to table.

4.Pull ring on pressure relief valve to insure there is no pressure within the kettle jacket.

5.Remove sight glass.

Sight

Glass

6.Tilt kettle on its side (sight glass down) and allow to drain (pull ring on pressure relief valve to speed up draining).

7.Tilt kettle upright and refill with water. Tilt kettle again on its side and allow to drain. Repeat until water drains clear.

8.Apply a thread sealant (i.e. Teflon tape) to the sight glass threads and replace.

Refilling Unit (see RESERVOIR FILL

PROCEDURES on page #24 for details).

25

KETTLE VENTING

INSTRUCTIONS

 

150

200

 

 

Pressure

100

 

250

 

 

20

 

 

Gauge

50

30

 

 

10

 

40

300

 

 

 

 

 

 

 

 

0 0

 

 

50

 

Pressure

I

 

 

 

Relief

R

 

 

 

350

A

 

 

 

T

 

60

 

V

 

 

Valve

N

 

 

 

 

 

E

 

 

 

 

 

 

 

psi

 

400

 

 

 

 

kPa

 

Guard

Bracket

The following venting procedure should be followed when the Vacuum/Pressure Gauge needle is in the "VENT AIR" zone:

NOTE: Check for and eliminate leaks prior to venting (See REPAIRING LEAKS IN STEAM JACKETED KETTLE FITTINGS on page #27).

DANGER: PRESSURE RELIEF VALVE WILL EXHAUST HIGH TEMPERATURE STEAM. CONTACT WITH SKIN COULD RESULT IN SERIOUS BURNS. KEEP FACE,

HANDS AND BODY CLEAR OF DISCHARGE.

DANGER: WORKING ON MACHINES

WITH POWER COULD RESULT IN

SEVERE ELECTRICAL SHOCK.

5 6

7

4

8

3

 

 

9

1

10

 

OFF

 

1.Remove guard bracket from pressure relief valve/gauge assembly.

2.Set On-OffSwitch/Temperature Control to to "10" (Max.), heat the empty kettle until unit cycles off.

3.Vent kettle by pulling safety valve ring 8-10times in short2-3second blasts with a 5 second interval between pulls.

 

 

150

200

 

 

 

100

 

250

 

 

 

20

 

 

50

30

 

 

10

 

40

300

 

 

 

 

 

 

 

0

0

 

 

50

 

 

I

 

 

 

 

R

 

 

 

350

 

A

 

 

 

 

T

 

 

 

 

 

N

 

60

 

 

E

 

 

 

 

 

V

 

psi

 

400

 

 

 

 

 

 

 

 

kPa

NOTE: If unit cycles ON, stop venting and wait for kettle to cycle OFF before continuing.

4.Set On-OffSwitch/Temperature Control to to "0" (Max.). Add cold water to kettle until its surface temperature is below 100°F. The pressure gauge needle should be in the green zone, indicating a vacuum in the kettle’s jacket.

5.Replace guard bracket from pressure relief valve/gauge assembly.

VACUUM LEAK TEST

PROCEDURE

Pressure

Gauge

Pressure

Relief Valve

Water Level

Probe

If the kettle will not hold vacuum, test for leaks at:

A.Water Level Probe.

B.Pressure Relief Valve.

C.Pressure Gauge.

LEAK TEST PROCEDURE:

1.Heat kettle until unit cycles off.

2.Shut off power to the kettle at the fused disconnect switch.

3.Spread Bubble Type Leak Detector over suspected areas and watch closely for bubbles.

4.Repair areas as required.

REPAIRING LEAKS IN STEAM JACKETED KETTLE FITTINGS

If unit will not hold a vacuum the most likely cause is a leak at one of the fittings.

Often, the easiest way to eliminate a leak is reseal the suspect areas.

1. Water Level Probe

Remove,clean threads, apply teflon thread sealant

and reinstall.

2. Pressure Relief Valve

A/ Inspect for signs of leaks. Replace if required.

B/ Remove, clean threads, apply teflon thread

sealant and reinstall.

3. Pressure Gauge

A/ Inspect face of gauge. If it contains moisture

on the inside of face replace.

26

WIRING DIAGRAM

TABLE-TOPGAS KETTLE,120-240VOLTS

KE90424-F

27

SEQUENCE OF OPERATIONS

1.To turn the unit on, turn the switch to the on position.

Power is sent to primary side of the 120vac/16vac transformer.

Power is sent to the normally closed high limit.

From the high limit power is sent to the normally open contacts of the 12VDC relay.

2.From the secondary of the transformer 16VAC is sent to the controller.

Power is sent to the red LED (low water indicator light) from terminal 4 of the controller.

If the water probe is grounded through water the LED will go off.

If the water probe is not grounded the LED will remain on and the unit will not heat.

If the resistance of the thermistor is higher than the setting of the potentiometer( the unit is calling for heat) then 16VDC is sent to the coil of the relay and the green LED (heat indicator light)

The 12VDC relay will close until the unit reaches temperature

3.With the contacts of the relay closed, power is sent to the 24 VAC transformer.

The transformer sends 24 VAC to the ignition module.

Ignition module sends 24 VAC to the Amber LED

The ignition module will send spark to the igniter and 24 VAC to the gas valve.

With 24VAC to the gas valve the valve opens and gas is sent to the burner.

Spark and gas together cause ignition.

When this happens and the module reads at least 0.7 micro amps DC within 4 seconds, the Amber light will go out and the 24 VAC will remain on the gas valve.

The unit will heat causing the water to boil and steam to be generated.

If the module does not see the 0.7 micro-ampsin 4 seconds, the module will try again in 15 seconds. It will try 3 times then lock out.

4.The kettle will heat (build pressure) until the controller is satisfied by the thermistor at the setting of the potentiometer.

The controller will then turn off the heat circuit until the temperature of the kettle is below the setting.

When the temperature drops below the setting the controller will send 12 VDC to the relay and the heat circuit will be energized again.

5.To turn the unit off, place the switch in the off position.

Power will be removed from the controller and the heat circuit will de-energize.

28

PROBLEM:

KGL-25

Kettle Won't

Heat

Replace the on/off

Is 16 VAC at the

switch (toggle

Yes secondary side of No

or rotary).

the transformer?

 

 

 

 

No

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is there 115 VAC

Replace the

Yes

 

to the primary of

 

transformer.

 

 

the transformer?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

Supply115

 

 

 

VAC to the

 

 

 

kettle.

Does red light come on when unit is first turned on?

No

Is 16 VAC measured across Pins 9 and 10 on the controller?

Does red light go Yesoff shortly after unit is turned on?

Yes

With the potentiometer set

Yesat 10, is 12 VDC atthe coil of the

relay?

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace the

 

 

 

Does the relay pull

No

 

 

relay.

 

 

 

in?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace the

 

 

 

Is there 115 VAC

 

 

 

to the primary of

No

 

high limit.

 

 

the ignition

 

 

 

 

 

 

 

 

 

 

 

 

 

 

transformer?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

Replace the

 

 

 

Is there 24 VAC to

ignition

No

 

 

the ignition

 

transformer

 

 

 

Module?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace the

No

Add water to

 

 

 

 

 

 

wire harness in

jacket of Kettle.

 

 

 

 

 

 

the trunion

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

With the jumper

 

 

 

 

 

 

 

 

 

 

 

 

 

 

With a jumper

 

 

 

 

 

 

removed and the

 

across pins 5 and

 

 

 

 

 

 

probe wire

 

7 on the controller,

 

 

 

 

 

 

grounded at the

No

 

No

 

 

is there 12 VDC

 

 

 

probe, is 12 VDC

 

 

 

 

 

 

 

 

across the coil of

 

 

 

 

 

 

measured across

 

the DC relay?

 

 

 

 

 

 

the coil of the DC

 

 

 

 

 

 

 

 

 

 

 

 

 

relay?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Does the

 

 

 

 

 

 

Add water

 

potentiomer have

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

a resistance of

 

 

 

 

 

 

 

 

 

 

 

 

 

50,000 ohms on

 

 

 

 

 

 

 

 

 

 

 

 

 

low and 0 ohms at

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

high?

 

 

 

 

 

 

Replace the

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

potentiometer

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Does the probe

 

 

 

 

 

 

 

 

 

 

 

 

 

have a resistance

 

 

 

 

 

 

 

 

 

 

 

 

 

of 100,000 ohms +

 

Replace the

 

Yes

 

 

10% at room

 

 

 

 

 

 

controller

 

 

 

 

 

 

 

 

temperature?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace Probe

 

 

 

 

 

 

 

 

 

 

 

 

No

Replace

the Ignition

module.

Is there 24 VAC to the Gas valve for 4 Seconds?

Yes

Is there Gas to the

 

 

 

Replace the

 

No

 

burner?

 

 

gas valve

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

Is there Spark to No the ignitor for 4

seconds.

Yes

If there

is spark and gas to the burner assmbly there should be flame. Check alighnment.

29

PROBLEM:

KGL-25

Kettle Not

Hot Enough

Does the kettle

 

 

 

 

 

See Problem:

 

 

 

 

 

No

 

 

 

 

 

heat at all?

 

 

 

 

kettle won't heat.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

With kettle pot

 

 

 

 

 

 

 

 

 

empty and

 

 

 

 

 

 

 

 

 

temperature knob

 

 

 

 

 

Unit is

 

 

 

set at 10, is the

 

Yes

 

operating

 

 

 

 

 

 

 

 

temperature of the

 

 

 

 

 

properly

 

Yes

surface of the pot

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

260 degrees?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Vent

the kettle per instructions in No the manual.

Replace

Yes

controller.

No

When unit is cold (room temp) is the pressure gauge in the green?

Yes

When the unit is calling for heat (the green light is on), is there flame at the burner?

Yes

Is the resistance of the thermister 100,000 ohms +10% at room temperature?

Yes

Is the potentiometer resistance 50,000 ohms at low and 0 ohms at high?

Replace the igniton transformer

No

Is there 24 VAC to the ignition module?

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Is there 115 VAC

 

 

 

 

 

 

 

to the primary of

 

 

 

Replace the

No

 

 

 

No

 

 

the ignition

 

 

high limit

 

 

 

 

 

 

 

 

 

 

 

 

 

 

module?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

No

Replace the

thermister.

No

Replace the potentiometer.

30

PROBLEM:

KGL-25

Kettle Gets

Too Hot

The

kettle is working Yes properly.

Replace the

No

gas valve.

Replace the

No

Relay

With the kettle empty and the temperature set at 10, is the surface temp 260-265degrees?

No

Does the kettle continue to call for heat (green light stays on) when the kettle reaches 260-265degrees?

No

Is there 115 vac to the primary of the ignition transformer?

Yes

Is there DC voltage to the coil of the relay?

Yes

Replace the

controller

Is the resistance of ;the thermister

Yes 100,000 ohms + No

Replace the

10% at room temperature?

thermister.

Yes

Is the resistance of the potentiometer

50,000 ohms at No

Replace the

the low setting and 0 ohms at high?

potentiometer

Yes

Replace the

controller

PROBLEM: Red Add Water LED Stays On

Add the proper

 

 

 

Does Red LED stay on

 

 

 

 

 

 

after adding the proper

 

 

 

amount of distilled

 

No

 

 

 

 

 

 

 

amount of distilled

 

 

 

water and rust

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

water and rust inhibitor?

 

 

 

inhibitor.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Clean or

 

 

 

 

Is the red LED on

 

 

 

 

replace water

 

 

No

 

 

with probe

 

 

 

 

 

 

 

 

 

 

 

 

probe.

 

 

 

 

grounded?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Yes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Does the red LED

 

 

 

 

Replace the

 

 

 

 

stay on with a

 

 

 

Replace the

wire harness in

 

 

No

 

 

jumper between

 

Yes

 

 

 

 

 

 

 

controller.

the trunion.

 

 

 

 

pins 5 and 7 on

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

the controller?

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

31

Symbol Legend (page 1 of 2)

English French Spanish Italian German Chinese-SimplifiedChinese-Traditional

RISK OF ELECTRICAL SHOCK

DANGER DE SECOUSSE ÉLECTRIQUE

PELIGRO DE ELECTROCHOQUE

PERICOLO DI SCOSSA

STROMSCHLAG-GEFAHR

SPLASHPROOF

ANTIÉCLABOUSSURES

A PRUEBA DE SALPICADURAS

PROTETTO CONTRO GLI SPRUZZI

SPRITZWASSERDICHT

DISCONNECT ELECTRICAL SUPPLY BEFORE WORKING ON KETTLE

COUPER LE COURANT AVANT D'INTERVENIR SUR L'ÉQUIPEMENT

DESCONECTAR LA ALIMENTACION ELECTRICA ANTES DE REALIZAR TRABAJOS EN EL EQUIPO DISINSERIRE LA CORRENTE PRIMA DI LAVORARE SULLA MACCHINA

STROMVERSORGUNG AUSSCHALTEN, BEVOR AM GERÄT GEARBEITET WIRD

MAIN POWER ALIMENTATION ÉLECTRIQUE ALIMENTACION PRINCIPAL ALIMENTAZIONE HAUPTSTROM

OFF

ARRÊT

APAGADO

SPENTO

AUS

CONTINUE

CONTINUER

CONTINUAR

CONTINUA

WEITER

START OF ACTION DÉBUT DE L'ACTION

INICIAR FUNCIONAMIENTO INIZIO OPERAZIONE FUNKTION STARTEN

FAST START DÉMARRAGE RAPIDE INICIO RAPIDO AVVIAMENTO RAPIDO SCHNELLER START

ON

MARCHE

ENCENDIDO

ACCESO

AN

PAUSE, INTERRUPTION PAUSE, INTERRUPTION PAUSA, INTERRUPCION PAUSA, INTERRUZIONE PAUSE, UNTERBRECHUNG

RESET

RÉENCLENCHER

RECONECTAR

RESET

NULLSTELLEN

STOP OF ACTION ARRÊT DE L'ACTION

PARAR FUNCIONAMIENTO ARRESTO OPERAZIONE FUNKTION STOPPEN

FAST STOP, EMERGENCY ARRÊT RAPIDE D'URGENCE PARADA RAPIDA, EMERGENCIA ARRESTO RAPIDO, EMERGENZA SCHNELLER STOPP, NOTFALL

32

Symbol Legend (page 2 of 2)

English French Spanish Italian German Chinese-SimplifiedChinese-Traditional

AUTOMATIC TEMPERATURE CONTROL COMMANDE AUTOMATIQUE DE LA TEMPÉRATURE AJUSTE AUTOMATICO DE TEMPERATURA CONTROLLO AUTOMATICO TEMPERATURA AUTOMATISCHE TEMPERATURREGELUNG

BURNER AND/OR ELEMENT ENERGIZED BRÛLEUR ET/OU ÉLÉMENT ALLUMÉ QUEMADOR O ELEMENTO ENCENDIDO FIAMMA E/O ELEMENTO ATTIVATI

BRENNER ODER ELEMENT EINGESCHALTET

HEATING ÉBULLITION CALEFACCION RISCALDAMENTO HEIZUNG

HEAT ADJUSTMENT

RÉGLAGE DE LA CHALEUR

REGULACION DE CALOR

REGOLAZIONE RISCALDAMENTO

WÄRMEREGULIERUNG

LOW WATER

NIVEAU BAS DE L'EAU NIVEL DE AGUA BAJO LIVELLO BASSO WASSERSTAND NIEDRIG

IGNITION FAILURE PANNE D'ALLUMAGE FALLO DE ENCENDIDO MANCATA ACCENSIONE ZÜNDUNGSFEHLER

COOLING

REFROIDISSEMENT

REFRIGERACION

RAFFREDDAMENTO

KÜHLUNG

MIXER BRIDGE

PONT DU MÉLANGEUR PUENTE DE MEZCLADORA MENSOLA MESCOLATORE MISCHER-BRÜCKE

 

LEFT KETTLE BOUILLOIRE GAUCHE HERVIDOR IZQUIERDO BOLLITORE SINISTRO LINKER KOCHKESSEL

 

RIGHT KETTLE BOUILLOIRE DROITE HERVIDOR DERECHO BOLLITORE DESTRO RECHTER KOCHKESSEL

MIX MÉLANGER MEZCLAR MESCOLATURA MISCHEN

UP

HAUT

ARRIBA

SU

RAUF

HOT WATER

EAU CHAUDE AGUA CALIENTE ACQUA CALDA HEISSES WASSER

LIFT

LEVER

LEVANTAR

SOLLEVARE

HEBEN

DOWN

BAS

ABAJO

GIÙ

RUNTER

COLD WATER

EAU FROIDE

AGUA FRIA ACQUA FREDDA KALTES WASSER

33