Cleveland Range KEL-100-T User Manual

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Operators Manual

Installation, Operation & Service

Electric Floor Model Kettles

For units built after August 1999

MODELS:

KEL-25,KEL-30,KEL-40,KEL-40-SH,KEL-60,KEL-80,KEL-100

KEL-25-T,KEL-40-T,KEL-60-T,KEL-80-T,KEL-100-T

KEL-40-SH,KEL-40-TSH,KEL-60-SH,KEL-60-TSH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Cleveland

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Enodis

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Visit our web site at www.clevelandrange.com

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SE95036 Rev. 6

 

 

 

 

 

 

 

 

For your safety

DANGER

Keep clear of pressure

Keep hands away from

relief discharge.

moving parts and pinch points.

IMPORTANT

Inspect unit daily for

Do not fill kettle above

recommended level

proper operation.

marked on outside of kettle.

 

CAUTION

Surfaces may be extremely hot! Use

Wear protective equipment

protective equipment.

when discharging hot product.

Do not lean on or place objects on kettle lip.

Stand clear of product discharge path when discharging hot product.

SERVICING

Shut off power at main

 

Ensure kettle is at room

fuse disconnect prior

0

temperature and pressure

to servicing.

gauge is showing zero or less

 

prior to removing any fittings.

GAS APPLIANCES

Do not attempt to operate this appliance during a power failure.

Keep appliance and area free and clear of combustibles.

INSTALLATION

GENERAL

Installation of the kettle must be accomplished by qualified electrical 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, NSF, ASME/Ntl. Bd., CSA, CGA, ETL, and others. Many local codes exist, and it is the responsibility of the owner/installer to comply with these codes.

Note: Maximum voltage for LVD (low volt directive for Europe) to be 440 volts for CE marked appliances.

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 shown below.

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.

INSTALLATION

The first installation step is to refer to the Specification Sheets or Specification Drawings for detailed clearance and drain requirements in order to determine the location of the kettle. Next, carefully cut open the shipping carton for easy removal of the kettle.

CLEARANCE REQUIREMENTS & RECOMMENDED FLOOR DRAIN LOCATIONS

Clearance Requirements

 

 

Back

Left Side

Right Side *

 

 

0

 

0

 

12'

 

 

* Minimum recommended

 

 

 

clearance for service

 

 

 

 

2" Tangent

 

 

 

2" Tangent

 

 

Draw-Off

 

 

 

Draw-Off

 

 

Valve

 

 

 

Valve

 

 

 

 

RECOMMENDED

 

RECOMMENDED

 

 

FLOOR DRAIN

 

FLOOR DRAIN

 

A

 

 

 

A

 

 

 

 

 

 

 

 

B

 

 

 

B

 

 

 

 

 

 

 

 

 

 

RECOMMENDED

 

RECOMMENDED

 

 

 

 

FLOOR DRAIN

 

FLOOR DRAIN

 

 

 

 

 

 

12" x 12"

 

 

C

 

 

 

 

C

 

 

 

D

 

 

D

 

 

 

Tilting

 

Stationary

 

 

Models

 

Models

 

Recommended Floor Drain Locations **

Model #

 

A

 

B

C

D

KEL-25

 

22 3/8”

34”

5 1/4”

11 1/4”

KEL-30

 

25 3/8”

37”

6 3/4”

12 3/4”

KEL-40

 

28 5/8”

40”

7 3/4”

13 3/4”

KEL-40-SH

32 1/2”

44”

9 1/2”

15 1/2”

KEL-60

 

32 1/2”

44”

9 1/2”

15 1/2”

KEL-80

 

35 7/8”

47”

11 1/4”

17 1/4”

KEL-100

 

38 3/8”

50”

12 1/2”

18 1/2”

KEL-25-T

 

22 1/4”

51 3/4”

4

24”

KEL-40-T

 

26

 

56

5 1/2”

28 1/2”

KEL-60-T

 

29 3/4”

62 1/2”

5 1/2”

31”

KEL-80-T

 

30 1/2”

65 3/8”

5 1/2”

35 1/2”

KEL-100-T

34 1/8”

69 1/4”

4”

40 1/2”

**Above dimensions apply to standard 2" Tangent Draw-OffValve only. For other valves consult factory.

RECOMMENDED FLOOR DRAIN DETAIL

RECOMMENDED

FLOOR

FLOOR SLOPE

DRAIN

 

1" IN 4'

4" MINIMUM,

PIPE DRAIN

6" RECOMMENDED

RECOMMENDED

 

MINIMUM VALVE

 

SIZE PLUS 1"

ASSEMBLY

 

FLANGED

FOOT (5" DIA)

(3) 7/16" DIA. 3 1/8" HOLES

Flanged Foot Detail

Position the kettle in it's permanent location, and level the kettle by turning the adjustable flanged feet. Once positioned and leveled, permanently secure the kettle's flanged feet to the floor using 5/16" lag bolts and floor anchors (supplied by the installer). There are three bolts required to secure each of the flanged feet.

WIRE CONNECTION

Install in accordance with local codes and/or the National Electric Code ANSI/NFPA No. 70-1990(USA) or the Canadian Electric Code CSA Standard C22.1 (Canada). A separate fused disconnect switch must be supplied and installed. The kettle must be electrically grounded by the installer.

The electrical supply must match the power requirements specified on the kettle's rating plate. The copper wiring must be adequate to carry the required current at the rated voltage.

Note: Maximum voltage for LVD (low voltage directive for Europe) to be 440 volts for CE marked appliances.

THREE

BLACK

BLUE

RED

 

SINGLE

BLACK

BLUE

RED

 

 

 

 

 

 

 

 

PHASE

 

 

 

 

 

PHASE

 

 

 

RED

 

 

 

 

 

RED

 

 

 

YELLOW

 

 

 

 

 

YELLOW

 

 

 

BLACK

 

 

 

 

 

BLACK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

L1

L2

L3

L1

L2

The kettle is wired for 3-phaseoperation at the factory. For single phase operation, rewire the terminal block to that shown in the above diagram.

Note: Ensure main power is turned off before connecting wires.

Stationary Models

Remove the screws securing the dome-shapedservice cover underneath the kettle and remove the cover. A wiring diagram is affixed to the inside of cover. Fasten permanent copper wiring to thethree-connectionterminal block, Be sure to connect ground wire to the separate ground terminal connector (ground lug). Slide the cover's slot over the wiring and secure the cover to kettle with the screws.

Tilting Models

First remove the handwheel by loosening the allen screw. Then remove the two screws at the front and rear of the console cover and remove the cover. A wiring diagram is affixed to the underside of the console cover. Feed permanent copper wiring through the cut-outin the bottom of the console, and fasten to thethree-connectionterminal block. Be sure to connect the ground terminal connector (ground lug). Replace the console cover and handwheel.

WATER

The sealed jacket of the electric kettle is precharged with the correct amount of a waterbased formula, 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.

Visual Checks

1.Check Tilting (tilting kettles):

A/ Gearbox tilts kettle smoothly and freely.

2.Insure there are:

A/ Three lag bolts securely holding each foot

B/ The bottom cover (stationary kettles) is in place and held with a nut.

C/ The console cover (tilting kettles) is in place and held with a screw.

Performance Checks

1. Supply power to the kettle by placing the

 

 

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

fused disconnect switch to the "ON" position.

2.Before turning the kettle on, read the Vacuum/Pressure Gauge (4). The gauge's needle should be in the green zone. If the needle is in the "VENT AIR" zone, follow Kettle Venting Procedure in the Service Manual.

3.Turn the kettle's ON/OFF Switch/Solid State Temperature Control (1) to "1" (Min.). The Heat Indicator Light (Green) (2) should remain lit, indicating the element is on, until the set temperature is reached (130°F/54°C). Then the green light will cycle on and off, indicating the element is cycling on and off to maintain temperature.

4.Tilt the kettle forward (tilting models only). After a few moments the Low Water Indicator Light (Red) (3) should be lit when the kettle is in a tilted position. This light indicates that the element has automatically been shut off by the kettle's safety circuit. This is a normal condition

when the kettle is in a tilted position.

5.Raise the kettle to the upright position. The Low Water Indicator Light (Red) (3) should go out when the kettle is upright.

6.Turn the ON/OFF Switch/Solid State Temperature Control (1) to "10" (Max.) and allow the kettle to preheat. The green light should remain on until the set temperature (260°F/127°C) is reached. Then the green light will cycle ON and OFF, indicating the element is cycling ON and OFF to maintain temperature. Fill the kettle with cold water to the steam jacket’s welded seam. Refer to the Temperature Range Chart for the time required to bring the water to a boil.

7.When all testing is complete, empty the kettle and turn the ON/OFF Switch/Solid State Temperature Control (1) to the “OFF” position.

CLEANING

After installation the kettle must be thoroughly cleaned and sanitized prior to cooking.

OPERATING INSTRUCTIONS

CONTROL PANEL

5

6

 

7

4

 

 

8

3

 

3.

 

9

 

2

10

 

 

 

1

 

 

 

 

OFF

 

 

 

 

 

 

 

 

 

 

1.

4.

 

 

 

5.

 

 

 

 

 

 

 

KE95555-2-A

2. 4.

5.

6.

8.

 

8.

 

 

 

 

 

 

 

 

 

 

 

 

CONTROL PANEL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TILTING KETTLE

STATIONARY KETTLE

 

 

 

 

 

 

 

 

 

 

 

General Parts Drawing

 

 

 

 

ITEM #

DESCRIPTION

FUNCTION

1.

 

 

 

On-OffSwitch/Solid State

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

 

 

 

 

Temperature Control

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

 

 

 

 

 

 

 

(see Temperature Range Chart in the Operating Instructions

 

 

 

 

 

 

 

section).

2.

 

 

 

Heat Indicator Light (Green)

When lit, indicates that the kettle element is on.

 

 

 

 

 

 

 

Cycles ON-OFFwith element.

3.

 

 

 

Low Water Indicator Light (Red)

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

 

 

 

 

 

 

 

in this condition. This will also light when the kettle is tilted.

4.

 

 

 

Vacuum/Pressure Gauge

Indicate steam pressure in PSI inside steam jacket as well as

 

 

 

 

 

 

 

vacuum in inches of mercury.

5.

 

 

 

Pressure Relief Valve

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

 

 

 

 

(not shown)

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

 

 

 

 

 

 

 

automatically to relieve this pressure.

6.

 

 

 

Tilt Wheel

Used for tilting the kettle up or down. Some units have an optional

 

 

 

 

 

 

 

Power Tilt Control Switch located in the same position.

7.

 

 

 

Power Tilt Control Switch

Used for tilting the kettle up or down.

 

 

 

 

(not shown)

 

 

 

 

8.

 

 

 

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.

OPERATING THE KETTLE

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 (4). The gauges needle should be in the green zone. Once heated, the kettle's normal maximum operating pressure is approximately10-12psi, 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

 

 

 

1. (Min.)

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

10. (Max.)

260

127

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 (1) to the desired temperature setting (see above "Temperature Range Chart"). The Heat Indicator Light (Green) (2) will remain lit, indicating the burner is lit, until the temperature setting is reached. When the green light goes off, the heaters 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) (2) will cycle on and off indicating the elements 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) (3) should not be lit when kettle is in upright position during operation. This light indicates that the elements have been automatically shut off by the kettle's safety circuit. It is, however, normal for the red light to come on when the kettle is in a tilted position.

5.When cooking is completed place ON/OFF Switch/Solid State Temperature Control (1) to the "OFF' position.

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.

APPROXIMATE BOILING TIMES

 

 

 

 

 

Times in Minutes

 

 

Gals.

Ltrs.

 

Standard Wattage

High Wattage*

 

 

 

 

 

 

 

 

 

 

 

208V

240V

480V

208V

240V

480V

25

95

60

45

60

40

30

30

40

150

60

50

75

40

30

30

60

225

100

75

75

50

40

40

80

300

130

100

100

65

50

50

100

375

160

120

120

80

60

60

*High Wattage is only available with 3 phase units.

The accompanying chart shows approximate times required for electric kettles of various capacities to boil water. The ON/OFF Switch/Solid State Temperature Control (1) must be set at "10" (Max.) throughout the heatup period. 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.

CLEANING INSTRUCTIONS

CAUTION

SURFACES MAY

BE EXTREMELY HOT!

CARE AND CLEANING

Cooking equipment must be cleaned regularly to maintain its fast, efficient cooking performance and to ensure its continued safe, reliable operation. The best time to clean is shortly after each use (allow unit to cool to a safe temperature).

WARNINGS

 

Do not use detergents or

 

cleansers that are chloride

 

based or contain quaternary

 

salt.

 

Chloride Cleaners

 

Do not use a metal bristle

 

brush or scraper.

 

Wire Brush &

 

Steel wool should never be

 

used for cleaning the stainless

 

steel.

 

Steel Pads

 

Unit should never be cleaned

 

with a high pressure spray

 

hose.

 

High Pressure

 

Spray Hose

 

Do not leave water sitting in unit

 

when not in use.

Stagnant

Water

CLEANING INSTRUCTIONS

1.Turn unit off.

2.Remove drain screen (if applicable). Thoroughly wash and rinse the screen either in a sink or a dishwasher.

3.Prepare a warm water and mild detergent solution in the unit.

4.Remove food soil using a nylon brush.

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

6.Drain unit.

7.Rinse interior thoroughly.

8.If the unit is equipped with a Tangent Draw-OffValve, clean as follows:

a)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.

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

c)Use a nylon brush to clean tangent draw-offtube.

d)Rinse with fresh water.

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

9.If the unit is equipped with a Butterfly Valve, clean as follows:

a)Place valve in open position.

b)Wash using a warm water and mild detergent solution.

c)Remove food deposits using a nylon brush.

d)Rinse with fresh water.

e)Leave valve open when unit is not in use.

10.Using mild soapy water and a damp sponge, wash the exterior, rinse, and dry.

NOTES

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

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

For more detailed instructions refer to the Nafem Stainless Steel Equipment Care and Cleaning manual (supplied with unit).

STAINLESS STEEL EQUIPMENT CARE AND CLEANING

(Suppied courtesy of Nafem. For more information visit their web site at www.nafem.org)

Contrary to popular belief, stainless steels ARE susceptible to rusting.

4.

Treat your water.

 

 

 

 

 

 

Corrosion on metals is everywhere. It is recognized quickly on iron and

 

Though this is not always practical, softening hard water can do much

steel as unsightly yellow/orange rust. Such metals are called “active”

 

to reduce deposits. There are certain filters that can be installed to

because they actively corrode in a natural environment when their atoms

 

remove distasteful and corrosive elements. To insure proper water

combine with oxygen to form rust.

 

treatment, call a treatment specialist.

 

Stainless steels are passive metals because they contain other metals, like

5.

Keep your food equipment clean.

 

chromium, nickel and manganese that stabilize the atoms. 400 series

 

Use alkaline, alkaline chlorinated or non-chloridecleaners at

stainless steels are called ferritic, contain chromium, and are magnetic;

 

 

recommended strength. Clean frequently to avoid build-upof hard,

300 series stainless steels are called austenitic, contain chromium and

 

 

stubborn stains. If you boil water in stainless steel equipment,

nickel; and 200 series stainless, also austenitic, contains manganese,

 

 

remember the single most likely cause of damage is chlorides in the

nitrogen and carbon. Austenitic types of stainless are not magnetic, and

 

 

water. Heating cleaners that contain chlorides have a similar effect.

generally provide greater resistance to corrosion than ferritic types.

 

6.

Rinse, rinse, rinse.

 

 

With 12-30percent chromium, an invisible passive film covers the steel’s

 

 

 

If chlorinated cleaners are used, rinse and wipe equipment and

surface acting as a shield against corrosion. As long as the film is intact

 

and not broken or contaminated, the metal is passive and stain-less.If the

 

supplies dry immediately. The sooner you wipe off standing water,

passive film of stainless steel has been broken, equipment starts to

 

especially when it contains cleaning agents, the better. After wiping

corrode. At its end, it rusts.

 

equipment down, allow it to air dry; oxygen helps maintain the

Enemies of Stainless Steel

 

stainless steel’s passivity film.

 

7.

Never use hydrochloric acid (muriatic acid) on stainless steel.

There are three basic things which can break down stainless steel’s

8.

Regularly restore/passivate stainless steel.

passivity layer and allow corrosion to occur.

1.

Mechanical abrasion

 

 

 

 

 

2.

Deposits and water

Recommended cleaners for specific situations

3.

Chlorides

Job

 

 

Cleaning Agent

Comments

Mechanical abrasion means those things that will scratch a steel surface.

Routine cleaning

Soap, ammonia,

Apply with cloth or sponge

 

 

 

detergent, Medallion

 

Steel pads, wire brushes and scrapers are prime examples.

 

 

 

 

 

 

 

 

 

Fingerprints & smears

Arcal 20, Lac-O-Nu

Provides barrier film

Water comes out of the faucet in varying degrees of hardness. Depending

 

 

 

Ecoshine

 

on what part of the country you live in, you may have hard or soft water.

 

 

 

 

 

Stubborn stains &

Cameo, Talc, Zud,

Rub in direction of polish lines

Hard water may leave spots, and when heated leave deposits behind that

discoloration

First Impression

 

if left to sit, will break down the passive layer and rust stainless steel. Other

 

 

 

 

 

Grease & fatty acids,

Easy-off,De-Grease

Excellent removal on all finishes

deposits from food preparation and service must be properly removed.

blood, burnt-on-foods

It Oven Aid

 

Chlorides are found nearly everywhere. They are in water, food and table

 

 

 

Grease & oil

Any good

Apply with sponge or cloth

salt. One of the worst chloride perpetrators can come from household and

 

 

 

commercial detergent

 

industrial cleaners.

Restoration/Passivation

Benefit, Super Sheen

 

So what does all this mean? Don’t Despair!

 

 

 

 

 

Review

 

 

Here are a few steps that can help prevent stainless steel rust.

 

 

1.

Stainless steels rust when passivity (film-shield)breaks down as a

1. Use the proper tools.

 

result of scrapes, scratches, deposits and chlorides.

 

 

 

 

When cleaning stainless steel products, use non-abrasivetools. Soft

2.

Stainless steel rust starts with pits and cracks.

 

cloths and plastic scouring pads will not harm steel’s passive layer.

 

3.

Use the proper tools. Do not use steel pads, wire brushes or scrapers

 

Stainless steel pads also can be used but the scrubbing motion must

 

be in the direction of the manufacturers’ polishing marks.

 

to clean stainless steel.

 

2.

Clean with the polish lines.

4.

Use non-chlorinatedcleaners at recommended concentrations. Use

 

Some stainless steel comes with visible polishing lines or “grain.”

 

only chloridefree cleaners.

 

 

5.

Soften your water. Use filters and softeners whenever possible.

 

When visible lines are present, always scrub in a motion parallel to the

 

lines. When the grain cannot be seen, play it safe and use a soft cloth

6.

Wipe off cleaning agent(s) and standing water as soon as possible.

 

or plastic scouring pad.

 

Prolonged contact causes eventual problems.

3. Use alkaline, alkaline chlorinated or non-chloride containing cleaners.

While many traditional cleaners are loaded with chlorides, the industry is providing an ever-increasingchoice ofnon-chloridecleaners. If you are not sure of chloride content in the cleaner used, contact your cleaner supplier. If your present cleaner contains chlorides, ask your supplier if they have an alternative. Avoid cleaners containing quaternary salts; it also can attack stainless steel and cause pitting and rusting.

To learn more about chloride-stresscorrosion and how to prevent it, contact the equipment manufacturer or cleaning materials supplier.

Developed by Packer Engineering, Naperville, Ill., an independent testing laboratory.

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

ITEM

PART

DESCRIPTION

QTY.

NO.

NO.

 

 

1.

KE50825-5

3/4" Spout . . . . . . . . . . . . . . . . . .

. . . .1

 

 

(KEL-25/30/40/60/80/100&40-SH)

 

KE50825-3

3/4" Spout (KEL-25-T) . . . . . . . . .

. . . .1

 

KE50825-2

3/4" Spout (KEL-40/60/80/100-T)

. . . .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)

 

1

2

1

3

4

2

5 3

6

4

6

10

7

9 11

8

12 13

10

11

12

14

13

8.

KE50335

Adapter Washer . . . . . . . . . . . . . . . . .

1

 

 

(Single Pantry only)

 

9.

KE51403

Double Pantry Body . . . . . . . . . . . . . .

1

 

 

(c/w Item No. 5&6)

 

10.

KE54159

Faucet Mounting Bracket . . . . . . . . . .

1

11.

FA11258

Hex Cap Screw . . . . . . . . . . . . . . . . . .

2

12.

FA30505

Washer . . . . . . . . . . . . . . . . . . . . . . . .

2

13.

FA21008

Hex Nut . . . . . . . . . . . . . . . . . . . . . . . .

2

14.

SE50447

Washer Horseshoe . . . . . . . . . . . . . . .

1

HINGE ASSEMBLY

9

4

7

11

8

6

10

1

9

5

12 13 2 3

ITEM NO.

PART NO.

DESCRIPTION

QTY.

 

 

Hinge Assembly

 

1. - 11

KE50597-1

25 - 40 Gallon, 20 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .1

 

KE50597-2

60 - 80 Gallon, 30 - 40 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . .

. . .1

 

KE50597-3

100 - 150 Gallon, 60 - 100 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . .

. .1

 

KE50597-4

KDM-60,KDM-60-T,Cook Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

KE50597-5

KDL-200,KDL-250,KDL-150-F,KDL-250-F . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

1.

KE50822

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

. .1

2.

KE51217

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

. .1

3.

KE50121-2

Hinge Spring Light - forKE50597-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

KE50121-1

Hinge Spring Heavy - forKE50597-1,KE50597-3,KE50597-4,KE50597-5, . .1

4.

KE50823-1

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

. .1

5.

KE50824

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

. .1

6.

KE50819-1

Hinge End Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

7.

KE50820

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

. .1

8.

KE50819

Hinge End Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

9.

FA11284

Screw, Socket Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .4

10.

FA11507

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

11.

SK50418

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

. .1

12.

KE50151-2

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

. .1

13.

 

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

. .1

KETTLE BOTTOM & SIDE

11

 

 

2

 

 

 

 

1

 

 

 

 

 

3

 

 

 

 

 

 

29

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

28

 

 

 

 

5

6

 

 

 

 

 

 

 

 

10

 

 

31

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Element

 

 

 

 

 

 

 

 

Terminals

 

30

 

 

 

 

 

20

 

 

 

 

 

 

 

 

 

 

 

 

18

27

 

21

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

22

 

 

 

 

 

25

9

 

 

 

 

 

 

 

8

 

7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

26

24

 

23

7

 

 

 

 

 

 

 

 

 

 

 

 

 

19

 

 

 

12

14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

16

 

 

 

 

 

 

 

 

15

 

 

 

 

 

 

 

 

 

17

 

 

 

 

 

 

ITEM NO.

PART NO.

DESCRIPTION

 

 

QTY.

1.

 

KE50556-1

Probe, Water Level . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . .1

2.

 

KE54941-5

Safety Valve, 50 PSI, 1/2" (North America) . .

. . . . . . . . . . . . . . . . . . . .

. . . . . . .1

 

 

KE54941-31

Safety Valve, 50 PSI, 1/2", (Europe) . . . . . . .

. . . . . . . . . . . . . . . . . . . .

. . . . . . .1

3.

 

KE51226

Wire Connector Terminal

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

. . . . . . .10

4.

 

KE51225

Edge Connector . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

. . . . . . .1

5.

 

KE00458

Solid State Control Box .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . .1

6.

 

KE50753-7

Relay, 12 VDC . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . .1

7.

 

KE54761

Bracket, Terminal Block

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . .1

8.

 

KE50377

Terminal Block Section .

. . . . . . . . . . . . . . .

(Large, White) . . . . . . . . .

. . . . . .3

 

 

SK50055-1

Terminal Block Section .

. . . . . . . . . . . . . . .

(Small) . . . . . . . . . . . . . . .

. . . . . .3

9.

 

KE50376

Terminal Block End Section . . . . . . . . . . . .

(Large, White) . . . . . . . . .

. . . . . .1

 

 

SK50054-1

Terminal Block End Section . . . . . . . . . . . . .

(Small) . . . . . . . . . . . . . . .

. . . . . .1

 

 

SK50054-2

Terminal Block End Barrier . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . .1

10.

 

KE53838-11

Transformer, 380-415to120-220V . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . .1

 

 

KE53838-12

Transformer, 440-480to 240V . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . .1

 

 

KE53838-13

Transformer, 600 to 240V

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . .1

11.

KE000714-4

Pressure Gauge, for units built prior to February 2005 . . . . . . . . . . . . . . . . . .

.1

 

KE50429-5

Pressure Gauge, for units built after January 2005 . . . . . . . . . . . . . . . . . . . . . .

1

12.

SE003013-1

L.E.D., Red, Replacement Kit., (includes LED & "O" Ring) . . . . . . . . . . . . . . . .

1

 

SE003013-2

L.E.D., Green, Replacement Kit., (includes LED & "O" Ring) . . . . . . . . . . . . . . .

1

 

SE003013-3

L.E.D., Amber, Replacement Kit., (includes LED & "O" Ring) . . . . . . . . . . . . . .

1

14.

SE00115

Potentiometer with ON/OFF Switch, c/w Item #15 . . . . . . . . . . . . . . . . . . . . . . .

1

15.

KE51005

Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

16.

KE50569-1

Knob, Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

17.

KE55069-5

Safety Thermostat (140° C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

18.

KE50515

Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

19.

KE50750-3

Contactor, 208/240V, 40 Amp. (standard kettles) . . . . . . . . . . . . . . . . . . . . . . . .

2

 

KE50750-4

Contactor, 208/240V, 50 Amp. (special high wattage kettles - 6 elements) . . . .

2

 

KE50750-5

Contactor, 208/240V, 60 Amp. (special high wattage kettles - 6 elements) . . . .

2

20.

KE51139-1

Fuse Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

21.

KE52936-1

Fuse, 1/2 amp (used on 380 to 600V units) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

22.

KE54833-3

Snap-InBushing, .875" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

23.

KE54833-4

Snap-InBushing 1.093" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

24.

KE50473

Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

25.

KE53838-21

Transformer, 240 to 16V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

26.

KE00688

Transformer Enclosure (stationary kettles only) . . . . . . . . . . . . . . . . . . . . . . . . .

1

27.

KE50392

Bracket, Electrical Entry, 1 3/4" hole (stationary kettles only) . . . . . . . . . . . . . . .

1

 

 

Bottom Cover - Stationary

 

28.

KE601174-1

KEL-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

KE601174-2

KEL-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

KE601174-3

KEL-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

KE601174-4

KEL-60 /40-SH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

KE601174-5

KEL-80 /60-SH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

KE601174-6

KEL-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

 

Bottom Cover - Tilting

 

 

KE50999-1

KEL-25-T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

KE65099-2

KEL-40-T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

KE50999-3

KEL-60-T /40-TSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

KE50999-4

KEL-80-T /60-TSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

KE50999-5

KEL-100-T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

 

Bottom Cover Gasket - Stationary & Tilting

 

29.

KE55425-5

25 Gallon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

KE55425-6

30 Gallon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

KE55425-7

40 Gallon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

KE55425-8

60 Gallon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

KE55425-9

80 Gallon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

KE55425-10

100 Gallon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

 

Component Enclosure - Stationary

 

30.

KE50389

all stationary models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

 

Component Enclosure - Tilting

 

 

KE50471

all tiling models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

 

Component Enclosure Gasket - Stationary

 

31.

KE55425-16

all stationary models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

 

Component Enclosure Gasket - Tilting

 

 

KE55425-11

all tiling models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

CONTROL CONSOLE COMPONENTS - HAND TILT

45

44

43

CONTROL CONSOLE COMPONENTS - HAND TILT

ITEM NO.

PART NO.

DESCRIPTION

 

QTY.

1.

FA11134

Screw, 10-24x 3/8" SS . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . .2

2.

KE50325

Gear Box Lid . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

3.

FA95008

Locknut, 3/4-16 . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

4.

FA30088

Washer, 1 1/2" 0.D. x 13/16" I.D. x .125 "W.

. . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5.

SE00036

Thrust Bearing Assembly and Spacer . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

6.

KE53838-21

Transformer, 240/16V . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

7.

KE50315

Worm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

8.

FA95005

Tension Pin . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

9.

KE50375

Tilt Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

10.

FA19505

Set Screw, hand wheel . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

11.

KE00508

Hand Wheel . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

12.

FA95007

Retaining Ring (25-40gallon) . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .2

 

FA95050

Retaining Ring (60 gallon & up) . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .2

13.

KE00151

Segment Gear (25-40gallon) . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

KE52833

Segment Gear (60 gallon & up) . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

14.

FA95048

Woodruff Key (25-40gallon) . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

FA95051

Woodruff Key (60 gallon & up) . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

15.

KE51711

Roller Bearing, trunnion (25-40gallon) . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .2

 

KE517111

Roller Bearing, trunnion (60 gallon & up) . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .2

16.

KE50377

Terminal Block Section (large, white) . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .3

 

SK50055

Terminal Block Section (small, black) . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .3

17.

KE50376

Terminal Block End Section (large, white) . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

SK50054

Terminal Block End Section (small, black) . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

18.

T40226

Bearing Assembly . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

19.

FA10623

Bolt, 5/16-24x 1 1/2" . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

20.

FA20029

Hex Nut, 5/16-24 . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

21.

KE51891

Washer, 1 1/2" 0.D. x 13/16” I.D. x .037" W.

. . . . . . . . . . . . . . . . . . . . . . . . . . . .2

25.

KE51730

Bearing, tilt shaft . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

43.

SK24744500

Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

44.

KE602748

Bracket, 380 & 415 Volt (60 gallon and up)

. . . . . . . . . . . . . . . . . . . . . . . . .

. .1

45.

KE602754

Bracket, 380 & 415 Volt (25-40gallon and up) . . . . . . . . . . . . . . . . . . . . . . .

. .1

CONTROL CONSOLE COMPONENTS - POWER TILT

 

45

40

44

 

 

 

43

 

42

 

41

 

 

CONTROL CONSOLE COMPONENTS - POWER TILT

ITEM NO.

PART NO.

DESCRIPTION

QTY.

1.

KE503252

Gear Box Lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .1

2.

FA11134

Screw, 10-24x 3/8" S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.

KE52832-1

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .1

4.

KE53838-8

Transformer, 208/120V (HG3J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

KE53838-9

Transformer, 220, 240/120V (HG5J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

5.

KE50583

Buna-NInsert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

6.

KE50582

Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

7.

KE50377

Terminal Block Section (large, white) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .3

 

SK50055

Terminal Block Section (small, black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .3

8.

KE50376

Terminal Block End Section (large, white) . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

SK50054

Terminal Block End Section (small, black) . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

9.

FA95008

Locknut, 3/4-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

10.

FA30088

Washer,1 1/2" 0.D. x 13/16" I.D. x .125" W. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

11.

SE00036

Thrust Bearing Assembly and Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

12.

FA95005

Tension Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

14.

KE003209-11

Complete Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

KE603208-4

Momentary Switch Activator*** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

KE603208-7

Contact Section Holder, Latch*** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

KE603208-9

Contact Block*** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 4

 

***NOTE: for units built prior to Dec. 2006 order Complete SwitchKE003209-11

 

17.

KE50752

Transformer, 240/16V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

18.

FA95007

Retaining Ring (25-40gallon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

FA95050

Retaining Ring (60 gallon & up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

19.

FA95048

Woodruff Key (25-40gallon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

FA95051

Woodruff Key (60 gallon & up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

20.

KE50580

Water Resistant Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

22.

KE51007

Micro Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

23.

FA00012

"O" Ring, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

24.

KE00151

Segment Gear (25-40gallon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

KE52833

Segment Gear (60 gallon & up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

25.

KE50315

Worm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

26.

KE50441

Tilt Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

27.

FA11092

Screw, 8-32x 1/2", SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .4

28.

KE51711

Roller Bearing, trunnion (25-40gallon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

 

KE517111

Roller Bearing, trunnion (60 gallon & up) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

29.

KE51731

Bearing, tilt shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

30.

FA10623

Bolt, 5/16-24x 1 1/2" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

31.

FA20028

Hex Nut, 5/16-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

32.

T40226

Bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

33.

KE51891

Washer, 1 1/2" 0.D. x 13/16" I.D. x .037" W. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

37.

FA95037

Key, 3/16" x 3/16" x 3/4" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

39.

KE50579-1

Circuit breaker, 1.5 amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

40.

KE50581

Bridge Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

41.

KE54535

Edge Connector (11 pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

42.

KE50753-10

Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .2

43.

SK24744500

Switch (CE option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

44.

KE602748

Bracket, 380 & 415V (60 gallon and up) (CE option) . . . . . . . . . . . . . . . . . . .

. .1

45.

KE602754

Bracket, 380 & 415V (25-40gallon and up) (CE option) . . . . . . . . . . . . . . . .

. .1

TRUNNION ASSEMBLY

ITEM

PART

DESCRIPTION

QTY.

NO.

NO.

 

 

1.

KE00354

TRUNNION BEARING ASSEMBLY .

. . . . .1

 

 

(INCLUDES PART # 3 & 6)

 

2.

KE00351

TRUNNION BEARING ASSEMBLY . .

. . . .1

 

 

(INCLUDES PART # 3 & 6)

 

3.

KE51711

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

. . . 2

4.

KE51571-1

SPHERICAL WASHER . . . . . . . . . . . .

. . . .1

5.

FA95081-3

BOLT, 5/16-18X 1/2" . . . . . . . . . . . . .

. . . .1

6.

KE51886

GREASE NIPPLE . . . . . . . . . . . . . . . .

. . . .2

7.

FA95027

MODIFIED BOLT, 5/16-18X 1 1/2" . .

. . .4/2

TANGENT DRAW-OFFVALVE

3

2

1

For tilting units with covers

1

For tilting units

without covers

6

3

4

2

 

5

7

7

6

5

4

ITEM NO.

PART NO.

DESCRIPTION

QTY.

1. - 7.

KE50973

2” DRAW-OFFASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .1

 

KE50972-B

3” DRAW-OFFASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

1.

FA95049

WING NUT, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

FA21050

ACCORN NUT, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

FA21501-1

ACCORN NUT, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

2.

KE52755

KNOB, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

SE50018

KNOB, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

3.

FI05180-1

HEX NUT, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

FI05180-2

HEX NUT, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

4.

KE52753

RETAINER, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

SE50013

RETAINER, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

5.

KE52752

PISTON, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

SE50010

PISTON, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

6.

FA05002-24

"O" RING, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

FA05002-38

"O" RING, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

7.

KE50972-B

VALVE BODY, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

 

KE50973

VALVE BODY, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .1

SPARE PARTS LIST

ITEM ON.

DESCRIPTION

QTY.

QTY.

 

 

DOMESTIC

OVERSEAS

Refer to Kettle Bottom & Side for parts drawing

 

 

 

 

 

 

KE00458

Solid State Control Box

1

1

 

 

 

 

KE50753-7

Relay, 12 VDC

 

1

 

 

 

 

KE50750-5

Contactor, 208/240V, 60 Amp.

1

2

 

(special high wattage kettles - 6 elements)

 

 

 

 

 

 

KE53838-11

Transformer, 380-415to120-220V

 

1

 

 

 

 

SE00115

Potentiometer with ON/OFF Switch, c/w Rubber Boot

1

1

 

 

 

 

KE51005

Rubber Boot

1

1

 

 

 

 

KE50569-1

Knob, Potentiometer

1

1

 

 

 

 

KE50515

Thermistor

 

1

 

 

 

 

KE51005

Rotary Seal

 

1

 

 

 

 

KE52936-1

Fuse, 1/2 amp (used on 380 to 600V units)

 

1

 

 

 

 

KE53838-19

Transformer, 120 to 16V

1

1

 

 

 

 

KE53838-21

Transformer, 240 to 16V

1

1

Refer to Faucet Assembly for drawing

 

 

 

 

 

 

FA05002-19

"O" Ring for Faucet Spout

1

1

 

 

 

 

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 CHECK LIST

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

 

 

BOTTOM COVER GASKETS

Check to see both

 

gaskets are in place

 

and are not cracked

 

or split.

Kettle Bottom

Gaskets

CONSOLE COVER

Insure there are two screws firmly holding down the cover. If not replace

 

screws.

HAND WHEEL (hand tilt models only)

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

TILTING (tilting models only)

Check that kettle tilts smoothly. Grease as described in LUBRICATION

 

PROCEDURE.

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 PROCEDURE.

PRESSURE RELIEF VALVE

Check pressure relief valve as described in PRESSURE RELIEF VALVE

 

TESTING PROCEDURE.

TEMPERATURE CHECK

Following CALIBRATING PROCEDURE check the inner kettle surface

 

temperature with a digital surface thermometer and adjust if required.

CALIBRATING PROCEDURE

1.Insure the unit has a vacuum before you begin calibrating procedures. If unit requires venting refer to Kettle Venting Instructions.

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

Gauge

Pressure

Relief

Valve

Pressure Relief

Valve/Gauge Assembly Drawing

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.

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

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

3.

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.

If valve appears to be sticking replace pressure relief valve.

If foreign material is discharged then drain kettle and replace pressure relief valve.

See KETTLE JACKET CLEANOUT AND PASSIVATION PROCEDURES 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).

RESERVOIR FILL

PROCEDURES

The kettle's water level must be maintained at the proper level to submerge the heater elements. 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 heater elements. The following procedure must be completed before further use:

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, as the elements are not submerged in water at this point.

DISTILLED WATER REQUIREMENTS

 

When Red “Low Water

Kettle

Light” comes

Capacity

on, add Distilled Water

 

25 gallon

1.0 U.S Gallons

30 gallon

1.5 U.S Gallons

40 gallon

2.0 U.S Gallons

60 gallon

2.1 U.S Gallons

80 gallon

2.6 U.S Gallons

100 gallon

2.8 U.S Gallons

 

 

 

 

 

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.

C. Fill unit via Street Elbow

B.

Attach Street

Elbow

A.*

Remove

Pressure

Relief

Valve

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

3.Pull Pressure Relief Valve (A) open to insure vessel is not pressurized.

4.Remove Pressure Relief Valve (A).

5.Replace Pressure Relief Valve (A) with Street Elbow (B).

6.Add distilled water (C) through the Street Elbow (B), using a funnel if necessary. Refer to Distilled Water Requirements chart for the proper amount required.

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

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

9.The kettle must now be vented. (Refer to the KETTLE VENTING INSTRUCTIONS).

KETTLE VENTING INSTRUCTIONS

 

 

150

200

 

Pressure

 

100

250

 

 

 

20

 

Gauge

50

30

 

10

40

300

 

 

 

 

 

 

 

Pressure

0

I

 

50

 

0

 

 

 

 

 

R

 

 

350

Relief

 

A

 

 

 

E

 

 

 

 

T

 

 

 

 

 

N

 

60

 

Valve

 

V

 

400

 

 

psi

kPa

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).

5 6

7

4

8

3

 

 

9

1

10

 

OFF

 

 

 

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.Turn kettle ON and set Temperature Control to 10 (Max.), heat the empty kettle until unit cycles off.

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

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

3.Turn kettle OFF. 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.

Pressure Relief Valve/Gauge Assembly Drawing

VACUUM LEAK TEST PROCEDURE

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

A.Water Level Probe (Remove bottom cover).

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 are and watch closely for bubbles.

4.Repair areas as required.

WATER LEVEL

PROBE

PRESSURE

GAUGE

PRESSURE

RELIEF

VALVE

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.

 

 

B/

Remove, clean threads, apply teflon thread sealant and reinstall.

LUBRICATION PROCEDURE

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

Adjusting

TRUNNION

HOUSING,

Screw

 

WORM SCREW

Worm

AND TILT GEAR

Screw and

These parts are

Tilt

Gear

accessed through the

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 two grease nipples.

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.

400
150 200

KETTLE JACKET CLEANOUT AND PASSIVATION PROCEDURES

The following procedure should be preformed at least once every three years to prevent possible corrosion and ensure the optimum life of the kettle.

WARNING:

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

DANGER:

WORKING ON MACHINES WITH POWER COULD RESULT IN SEVERE ELECTRICAL SHOCK.

DANGER:

MOLYFILM 315 IS CORROSIVE, AVOID CONTACT WITH SKIN AND EYES.

DANGER:

EXTREMELY HOT SURFACES. WORK ONLY ON COLD KETTLE.

DANGER:

AVOID INHALATION - VAPORS FROM MOLYFILM 315 MAY BE HARMFUL OR FATAL.

DESCRIPTION - Molyfilm 315 inhibits corrosion in stainless steel and copper. A pH buffer is present to assist in maintaining the appropriate pH to assist in corrosion inhibition.

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

SHELF LIFE - Molyfilm 315’s effectiveness will diminish after three years.

REFILL QUANTITIES (ORDERING INFO: 1 Liter Molyfilm 315 Rust Inhibitor - Part#KE600340-1)

IMPORTANT: To ensure satisfactory mixing follow the MIXING / FILLING PROCEDURE described below.

Kettle Size

Volume of Water

Volume of Molyfilm 315

 

U.S. Gal.

Liters

oz.

cc (ml.)

25 U.S. Gal.

3.8

14.2

5.1

150

30 U.S. Gal.

4.3

16.3

5.9

172

40 U.S. Gal.

4.8

18

6.5

190

60 U.S. Gal.

5.8

21.8

7.8

230

80 U.S. Gal.

6.5

24.6

8.9

260

100 U.S. Gal.

7.3

27.5

9.9

290

MIXING / FILLING PROCEDURE

1.Refer to chart to determine the required volumes of water and Molyfilm 315.

2.In a separate container mix 1/2 gallon of the required volume of water with the total required volume of Molyfilm 315.

3.Pour mixture into kettle.

4.Pour the remaining required volume of water into kettle.

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.

FLUSHING PROCEDURE

WARNING: The fused disconnect switch must be off before removing the kettles bottom cover.

1. Ensure kettle is at room temperature

 

100

250

 

and pressure gauge showing zero

50

20

30

 

10

40

300

or less pressure.

 

 

 

 

 

 

 

 

 

 

0

0

 

50

 

2. Shut off power to the kettle at the

 

R

 

350

 

I

 

 

A

 

 

 

T

 

 

 

 

N

 

 

 

 

E

 

60

 

fused disconnect switch.

 

V

 

 

 

 

 

psi kPa

 

3.Pull pressure relief valve ring open to insure vessel is not pressurized.

4.Pull pressure relief valve ring open to insure vessel is not pressurized.

5.Remove pressure relief valve.

6.Replace pressure relief valve with street elbow.

7.Remove bottom cover from kettle.

8.Remove low water level probe and allow water to drain.

9.Add water through the street elbow and flush out as much debris as possible with water.

10.Apply a thread sealant (i.e. Teflon tape) to the low water level probe threads and replace.

11.Fill kettle jacket with a mixture of water and Molyfilm 315 (see REFILL QUANTITIES chart).

12.Remove street elbow.

13.Apply a thread sealant (i.e. Teflon tape) to the pressure relief valve's thread and replace.

14.Turn kettle on, vent and heat on high for 1/2 hour.

15.Cool and drain kettle as per above procedure.

Remove

Attach

Fill unit via

Pressure

Street

Street Elbow

Relief

Elbow

 

Valve

 

 

Important- Pull pressure

relief valve ring open to insure vessel is not pressurized.

Low Water

Level Probe

REFILLING UNIT

1.Apply a thread sealant (i.e. Teflon tape) to the low water level probe threads and replace.

2.Fill kettle jacket with a mixture of water and Molyfilm 315 (see REFILL QUANTITIES chart).

3.Remove street elbow.

4.Apply a thread sealant (i.e. Teflon tape) to the pressure relief valve's thread and replace.

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

6.Vent kettle. See Kettle Venting Instructions for proper procedure.

DIAGNOSTIC GUIDE

This section contains servicing information intended for use by Authorized Service Personnel.

NOTE 1: If Fault Isolation Procedure is required, be sure to start at step #1.

NOTE 2: On table type kettles the entire control mounting panel may be removed from kettle control housing for easier troubleshooting and parts replacement.

A/ Problem: Kettle is not heating at all. (Kettle must be on and temperature control set.)

Possible Causes

 

 

 

 

1.

No incoming power.

6.

Defective safety thermostat.

10.

Defective thermistor.

2.

Kettle is tilted.

7.

Defective contactor/s.

11.

Defective 240/16 VAC

3.

Low water condition.

8.

Defective potentiometer

 

transformer.

4.

Defective ON/OFF switch.

 

(temperature control).

12.

Defective control box.

9.

Defective low water level

13.

Defective elements.

5.

Defective 12 VDC relay.

 

probe.

 

 

 

 

 

 

 

Fault Isolation Procedure

Step Test

1.Is there proper incoming voltage at terminal block?

2.Is the red LED illuminated?

3.Is the green LED illuminated?

4.Do both contactors energize?

5.Measure continuity across safety thermostat. Is it an open circuit?

6.Is there 120 VAC present across the coils of the contactors?

7.Remove wire from low water level probe and ground it to the body of the kettle. Do the contactors now energize?

8.Is there 16 VAC present at output of 16 VAC transformer?

Result

Remedy

Yes

Go to step #2.

No

Correct external power supply problem.

Yes

Follow Reservoir Fill Procedure. If this

 

does not correct the problem, go to

 

Problem D.

No

Go to step #3.

Yes

Go to step #4.

No

Go to step #7.

Yes

Check contactor contacts for pitting. Voltage

 

across contactor terminals while in a closed

 

position indicates a poor contact. Replace

 

contactor/s as necessary. Check elements

 

for short at ground or an open circuit. If

 

element/s are defective contact the factory.

 

Elements are not field replaceable.

No

Go to step #5.

Yes

Replace defective safety thermostat.

No

Go to step #6.

Yes

Replace defective contactor/s.

No

Go to step #6.

Yes

Clean or replace defective low water

 

level probe. Replace defective red LED.

No

Go to step #8.

Yes

Go to step #9.

No

Replace defective 240/16 VAC transformer.

9.Measure continuity of ON/OFF switch/ temperature control. Is it operating properly?

10.Unplug control box and measure the resistance across potentiometer. Is it approximately 0 ohms at maximum setting and 50,000 ohms at minimum?

11.Remove edge connector from control box. While kettle is cold or thermistor is removed and allowed to cool, measure the resistance between edge connector’s pins #2 and #7. Is it approximately 100,00 ohms?

Yes

Go to step #10.

No

Replace defective ON/OFF switch/

 

temperature control.

Yes

Go to step #11.

No

Replace defective potentiometer

 

(ON/OFF switch/temperature control)

Yes

Spray contact cleaner on control box

 

terminals and edge connector. Try box

 

again, if the problem still exists, replace

 

defective control box.

No

Replace defective thermistor.

B/ Problem: Kettle heats too slowly or not hot enough. (Note: normal max. operating pressure with an empty kettle is30-35psi.)

Possible Causes

 

 

 

 

1.

Air in jacket requires

3.

Defective potentiometer

5.

Defective contactor/s.

 

venting.

 

(temperature control).

6.

Defective control box.

2.

Defective safety thermostat.

4.

Defective thermistor.

7.

Defective elements/s.

Fault Isolation Procedure

Step Test

1.In a cold state, does the pressure gauge read in the green zone?

2.Do the contactors shut off too early? (before reaching normal maximum operating pressure.)

3.Does the green LED remain illuminated after the contactors shut off?

4.Unplug control box and measure the resistance across potentiometer (temperature control). Is it approximately 0 ohms at maximum and 50,000 ohms at minimum setting?

Result

Remedy

Yes

Go to step #2.

No

There is air present in the jacket of the

 

kettle. Follow Kettle Venting Procedure.

 

If constant venting is required, there is a

 

leak that should be corrected.

Yes

Go to step #3.

No

Check contactor contacts for pitting.

 

Voltage across terminal of contactor

 

while energized signifies a poor

 

contact. Replace contactor/s as

 

necessary. Check elements for short to

 

ground or open circuit. If elements are

 

defective, contact the factory. Elements

 

are not field replaceable.

Yes

Replace defective safety thermostat.

No

Go to step #4.

Yes

Go to step #5.

No

Replace defective thermistor.

Yes

Go to step #6.

5. Remove kettle thermistor and allow to No Replace defective thermistor cool. Remove edge connector from

control box. Test resistance across edge connector's pins #2 and #7. Is it approximately 100,000 ohms?

6.Turn the potentiometer on the control box clockwise to increase the maximum operating temperature. Does the kettle now achieve maximum operating pressure of 30-35psi in an empty kettle?

Yes

Kettle is operating correctly.

No

Spray contact cleaner on control

 

terminals and edge connector. Try box

 

again. If problem still exists, replace

 

defective control box.

C/ Problem: Kettle is overheating.

Possible Causes

 

 

 

 

1.

Defective thermistor

2.

Defective potentiometer

3.

Defective 12 VDC relay.

.

 

 

(temperature control).

4.

Defective control box.

Fault Isolation Procedure

Step Test

1.Does the green LED turn off even though the contactors remain energized?

2.Unplug the control box and measure the resistance across the potentiometer (temperature control), Is the resistance approximately 0 ohms at maximum and 50,000 ohms at minimum setting?

Result

Remedy

Yes

Replace defective 12 VDC relay.

No

Go to step #2.

Yes

Go to step #3.

No

Replace defective thermistor.

3.Remove kettle thermistor and allow to cool Remove edge connector from control box. Test resistance across edge connector’s pins #2 and #7. Is it approximately 100,000 ohms?

Yes

Go to step #4.

No

Replace defective thermistor.

4.Turn the potentiometer (temperature control) on the control box counterclockwise to decrease the maximum operating temperature. does the kettle continue to overheat?

Yes

Spray contact cleaner on control box terminal

 

and edge connector. Try box again. If problem

 

still exists, replace defective control box.

No

Kettle is operating correctly.

D/ Problem: Red LED remains illuminated even though water has been added.

Possible Causes

1.Defective low water level probe

Fault Isolation Procedure

Step Test

1.Remove wire from low water level probe and ground the wire to the body of the kettle. Does the red LED turn off?

2.Defective control box.

Result

Remedy

Yes

Replace or clean defective low water

 

level probe.

No

Spray contact cleaner on control box

 

terminals and edge connector. Try box

 

again. If problem still exist, replace

 

defective control box.

WIRING DIAGRAM

200-240v

OUTSIDE

LIMIT OF NORTH

AMERICA

WIRING DIAGRAM

380-600v

LIMIT

OUTSIDE

OF NORTH

AMERICA