Cleveland SSE-25-T, KEL-40-T, SSE-40-L, SSE-40-T, KEL-60 Installation, Operation And Repair Manual

CLEVELAND

INSTALLATION, OPERATION AND REPAIR MANUAL

CLEVELAND RANGE INC.

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

(216)481-4900

9209 REV:1 213-01CC

KET-06

CLEVELAND

INSTALLATION, OPERATION AND MAINTENANCE

INSTRUCTIONS FOR

ELECTRIC SELF-CONTAINED KETTLES

FLOOR MODELS

KEL-25 KEL-40 KEL-60 KEL-80 KEL-100

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

SSE -25-L SSE -40-L SSE -60-L SSE -80-L SSE -100-L

SSE -25-T SSE -40-T SSE -60-T SSE -80-T SSE -100-T

RETAIN THIS MANUAL FOR YOUR REFERENCE

INSTALLATION INSTRUCTIONS

WARNING:

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

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

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.

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 sheet for the clearance requirements, in order to determine the location of the kettle. Next, carefully cut open the shipping carton for easy removal of the kettle.

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 for ms 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.

ASSEMBLY Position the kettle in its' 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 inch lag bolts and floor anchors (supplied by the installer). There are three bolts required to secure each of the flanged feet.

1

ELECTRIC SERVICE CONNECTION

TILTING MODELS

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 electric 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. Refer to specifi cation sheet for all electrical specifications.

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

Remove the screw at the 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 cutout in the bottom of the console, and fasten to the three-connection terminal block. Be sure to connect the ground wire to the separate ground terminal connector (ground lug). Replace the console cover and secure it with the screw.

INSTALLATION CHECK

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

1. Supply power to the kettle by placing the fused disconnect switch to the "on" position.

2. Read the vacuum/pressure gauge to ensure that the needle rests in the green zone(at room temperature). If the needle is in the "vent air" zone, refer to the "Kettle Venting Instructions".

3. Place the kettle's power on/off switch to the "on" position.

ELECTRICAL CONNECTION STATIONARY MODELS

Remove the screws securing the dome -shaped service cover underneath the kettle and remove the cover. A wiring diagram is affixed to the inside of cover. Fasten permanent copper wiring to the three-connection terminal 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.

4. Turn the temperature control knob to "min". The green LED light should remain lit, indicating the heater elements are energized, until the set temperature (124°F/50°C) is reached. Then the green light will cycle on and off with the thermistor (solid state control).

2

5. If the kettle is a tilting model, 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 heater elements are not submerged in water, and they have automatically been shut off by the kettle's safety circuit. This is a normal conditon when kettle is in a tilted position.

6 Lower 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 reservoir before the kettle can be operated. Refer to the "Reservoir Fill Procedures", on the kettle's label, for details.

7. Turn the temperature control knob to "max." and allow the kettle to preheat. The green light should remain on until the set temperature is reached (260°F/127° C), then cycle on and off with the thermistor. Fill the kettle with cold water to the steam jacket's welded seam. Refer to the chart below for the time required to bring the water to a boil.

8. When all testing is complete, empty the kettle and place the power on/off switch in the "off" position.

The accompanying chart shows approximate times required for electric kettles of various capacities to boil water. Temperature control knob must be set at "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.

KETTLE VE NTING INSTRUCTIONS

If the vacuum/pressure gauge reading is in the "vent air" zone, it means that the air has entered the steam/water jacket, resulting in little or no vacuum. Air inside the jacket will act as an insulator therefore reducing kettle efficiency. To remedy this situation, the following venting procedures should be followed:

1. With the temperature control knob set at number 6 or 7, heat the empty kettle until the vacuum/pressure gauge indicates 5-10 psi.

2. Release steam and air from the steam/water jacket by loosening, one -half turn, the 7/16 inch chrome-plated brass venting valve nut (located at the rear of the kettle) for 10-15 seconds.

3. Tighten the vent valve nut, being careful not to overtighten.

The kettle's steam/water jacket should now be free of air. At room temperature, the pressure gauge needle should rest in the green zone, indicating a vacuum in the kettle's jacket.

3

To check the gauge for proper vacuum after venting, the temperature can be quickly reduced by filling the kettle with cold water.

If the kettle will not hold a vacuum, have a qualified service technician test for leaks at the vent valve, the safety valve, the probe, and the vacuum/pressure gauge fittings. We suggest mixing a 50/50 solution of liquid detergent and water while heating the kettle to at least 5 psi pressure. Then, shut off power to the kettle at the fused disconnect switch.

The soapy solution should be applied to the suspected area while the gauge shows at least 5 psi pressure. Any bubbles which appear will indicate a leak.

WARNING: The fused disconnect switch must be off before removing the kettle's bottom cover, which exposes dangerous high voltage.

RESERVOIR FILL PROCEDURES The reservoir'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 locate and repair the leakage problem before adding 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.

1. Ensure kettle is at room temperature.

2. Shut off power to the kettle at the fused

disconnect switch.

3- Remove the bottom cover (tilting kettles

can be tilted forward for easier access to the cover). Tilt the kettle back to the upright position once the cover has been removed.

4. Unscrew and remove the chrome -plated brass venting valve nut located on the back of the ke ttle.

5. Hold the safety valve open while adding distilled water through the vent hole, using a funnel. Refer to chart below for the proper amount required.

6. Place the chrome -plated brass venting valve nut into the water fill bole and carefully tighten. Do not overtighten. Replace bottom cover.

7. Restore power to the kettle at the fused disconnect switch.

8. The kettle must now be vented. Refer to the "Kettle Venting Instructions".

CAUTION: Only distilled water

should be used when adding water to a partially filled water reservoir. Local tap water conditions may cause kettle damage which is not covered under warranty.

4

DISTILLED WATER REQUIREMENTS

When Red

When the

Reservoir is

Completely Empty,

"Low Water Light''

Kettle

Capacity

30gaL 1.80 gal 4.25 gal

40 gal

60 gal 2.10 gal 5.50 gal 80 gal 2.60 gal 6.25 gal 100 gal 2.80 gal 7.00 gal

Comes on, Add

Distilled Water

2.00 gal.

Add Distilled Water

4.50 gal

OPERATING INSTRUCTIONS

1. Before turning the kettle on, read the vacuum/pressure gauge. The gauges needle should be in the green zone. If the needle is in the "vent air" zone, refer to the "Kettle

Venting Instructions". Any air that may be

present will increase cooking times. Once heated, the kettle's normal maximum operating pressure is approximately 10-12 psi, while cooking a water base product

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

3. Place the kettle's power on/off switch to the "on" position.

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.

5. Place the food product into the kettle.

6. Turn the temperature control knob to the required temperature setting between "Min." (120° F/49° C) and "Max." (260° F/127° C). The green light will cycle on and off with the solid state control, indicating the heaters are cycling on and off to maintain the set temperature.

7. The red "low water" light should not be lit during kettle operation. This light indicates that the heater elements are not submerged in water, and they have been automatically shut off by the kettle's safely circuit. On tilting kettles, 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 the "Reservoir

Fill Procedures " for details.

4. Preheat the kettle by turning the temperature control knob to the desired temperature setting (see temperature range chart). The green light will remain lit, indicating the heater elements are energized, until the temperature setting is reached. When the green light goes off, the heaters are off, and preheating is complete.

8. When cooking is completed, place the power on/off switch to the “off” position.

5

9. Pour the contents of the kettle into an appropriate container by opening the draw-off valve or 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 pan 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 "Care and Cleaning Instructions" for detailed kettle washing procedures.

WARNING: Do not use chloride base detergents.

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

2. Remove food soil inside the kettle using a nylon brush. Do not use a metal bristle brush, as this may permanently damage the kettle's stainless steel surface.

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

4. If the kettle is equipped with a draw-off valve, it should be cleaned as follows:

TEMPERATURE RANGE CHART

Temperature

Control

Setting

Minimum 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 Maximum 260 127

* Approx. Product

Temperature

°F °C

* Certain combinations of ingredients will result in temperature variations.

a. Remove the drain screen from the

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

b. Disassemble the draw-off valve

first by turning the valve knob counter-clockwise, then turning the large hex nut counterclockwise until the valv e stem is free of the valve body.

c. In a sink, wash and rinse the

valve stem, hex nut and knob. Wash and rinse the inside of the valve body using a nylon brush.

d. Reassemble the draw-off valve by

reversing the procedure for disassemble. The valve 's hex nut should be hand tight only.

CARE AND CLEANING Your kettle must be cleaned regularly to

maintain its fast, efficient cooking performance, and to ensure its continued safe, reliable operation.

6

5. Rinse kettle interior thoroughly, then dram the rinse water.

ELECTRIC KETTLE CALIBRATING PROCEDURE

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

7. Using mild soapy water and a damp sponge, wash the exterior of the kettle, rinse, and dry. Avoid soaking the electric control panel. Always turn off equipment power before using water to wash equipment.

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 kettle. Particles of steel wool become embedded in the cooking surface and rust, which may corrode the stainless steel.

WARNING: Never hose down the kettle. Water seeps into the underside of the kettle, shorting and burning out the elements.

1. Insure the unit has a vacuum before you begin calibrating procedures. If unit requires venting refer to "KETTLE VENTING INSTRUCTIONS'' in this manual.

2. Turn kettle on and set temperature dial to maximum (10).

3. Allow the unit to cycle twice.

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

5. Temperature should be 265°F.

6. Using a screw driver adjust temperature by turning the potentiometer on the black box. Turn very little. Turn clockwise to INCREASE, and counter-clockwise to DECREASE temperature.

7. Allow the unit to cycle twice.

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

9. Repeat steps 4 through 8 until unit is calibrated.

MAINTENANCE This equipment requires very little preventive

maintenance other than daily cleaning. Some kettles are equipped with handwheel tilting mechanisms which require periodic preventive maintenance to assure continued trouble-free operation. Inspect the worm screw, tilting gears and bearings occasionally (at least once a year). Lubricate as required using a high temperature grease. Remove bottom cover, heat kettle and test pressure relief valve twice a year.

7

OPERATING CONTROLS AND INDICATORS

ITEM NO. DESCRIPTION FUNCTION

16 On-Off Toggle Switch

( Pg. 213-09DR )

20 Solid State Temperature Control Knob

( Pg. 213-09DR )

17 Heat Indicator Light (Green)

( Pg. 213-09DR )

21 Low Water Indicator Light (Red)

( Pg. 213-09DR )

15 Vacuum/Pressure Gauge

( Pg. 213-09DR )

5 Pressure Relief Valve

( Pg. 213-09DR )

Controls electrical power to kettle.

This control knob allows the operator to select kettle heat increments from Min. to Max.(see temperature setting chart in the operating instructions section of this manual).

When lit, indicates that the kettle heating elements are on. Cycles On-Off with solid state contols.

When lit, indicates that the kettle heating elements have cut out and the unit requires more water. (See Reservoir Fill Procedure).

Indicates steam pressure in PSI inside the steam jacket as well as vacuum in inches of mercury.

In the unlikely event that there is an excess steam build-up in the jacket, this valve opens automatically to relieve this pressure.

1 Chrome Plated Brass Vent

( Pg. 213-09DR )

NS Service Cover

( Not Shown )

1-7 Daw-Off Valve

( Pg. 600-04TD )

11 Hand Wheel

( Pg. 213-10DR )

16 Power Tilt Control Switch

( Pg. 213-12DR )

This valve is used to vent the kettle if there is insufficient vacuum as well as for refilling the kettle with water. (See Venting Instructions and Reservoir Fill Procedures).

Located underneath the kettle. Remove this cover for easy access to contactor, kettle control box, etc.

This valve is used to empty the kettle of either food products or wash water. It is supplied as standard equipment on stationary models and is optional on tilting kettles.

Turn to tilt kettle for pouring.

This switch allows the operator to tilt the kettle up or down.

8

PARTS LIST - KETTLE BOTTOM

ITEM NO. PART NO. DESCRIPTION QTY.

1. F105025 Bleed vent elbow 1

2. KE50570 Bleed vent nut 1

3. F105022 Connector 1

4. KE50556 Probe, low water 1

5. KE51723 Safety valve, 50 PSI, 1/2" 1

6. KE50997

7. KE51226 Wire connector terminal 10

8. KF51225 Edge connector 1

9. KE00458 Solid state control box 1

10. KE50753 Relay, 12 VDC 1

11. KE51322 Contactor, 208/240V, 40 Amp. 2

KE50750 Contactor, 208/240V, 50 Amp. 2

KE50751 Contactor, 208/240V, 60 Amp. 2

12. KE50377 Terminal block section 3

SK50055 Terminal block section 3

13. KE50376 Terminal block end section 1

SK50054 Terminal block end section 1

14. KE50752 Transformer 1

15. KE50429 Pressure gauge 1

16. KE50504 Switch, toggle, SPST 1

17. KE50568

18. SK50062 Rubber boot 1

19. KE50988 Potentiometer 1

20. KE50569 Knob, potentiometer 1

21. KE50567 L.E.D. red 1 22 KE50558 Safety Thermostat (140° C) 1

23. KE00515 Thermistor 1

24. KE51005 Rotary seal 1

Blow down tube

(Standard kettles)

(Special high wattage kettles-6 elements)

(Large, white)

(Small, black)

(Large, white)

(Small, black)

L. E. D green

1

9

KETTLE BOTTOM

10

PARTS LIST - CONTROL HOUSING

ITEM NO. PART NO. DESCRIPTION QTY.

1. FA11134 Screw, 10-24 x 3/8"SS 2

2. KE50325 Console cover 1

5. FA95008 Locknut, 3/4 -16 2

4. FA30088 Washer, 1 1/2 -OD x 13/16"ID x .125"W 1

5. See note 2

6. KE50752 Transformer, 240/16V 1

7. KE50315 Worm 1

8. FA95005 Tension pin 1

9. KE50375 Tilt shaft 1

10. FA19186 Set screw, hand wheel 1

11. KE00508 Hand wheel 1

12. FA95007 Retaining ring 2

13. KE00151 Worm gear 1

14. FA95006 Woodruff key 1

15. KE51711 Bearing, roller, trunnion 2

16. KE50377 Terminal block section 3

(Large, white) SK50055 Terminal block section 3 (Small, black)

17. KE50376 Terminal block end section 1

(Large, white) SK50054 Terminal block end section 1 (Small, black)

18. SE00034 Bearing assy. 1

19. FA10623 Boll, 5/16-24 x 1 1/2" 1

20. FA20029 Nut, hex, 5/16-24 1

21. KE51891 Washer, 1 1/2"OD x 13/16"ID x .037"W 2

22.-24. SE00036 Thrust bearing assy. 2 22 KE52192 Washer, thrust bearing 4

23. KE52191 Bearing, thrust 2

24. KE52193 Spacer, thrust bearing 2

25. KE51730 Bearing, tilt shaft 1

Note: Please order Item no. 22.-24. - Part no. SE00036

11

CONTROL HOUSING

12

PARTS LIST- POWER TILT OPTION

1.

1 2.

1 3.

1 4.

1

1 5,

1 6.

2 7.

3

1

2

1

2

1

6

1

2

1

4

2

1

2

4

2

1

ITEM NO.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30. 31-

32.

33.

34.-36.

34.

35.

36.

37.

38.

39.

PART NO.

KE51012 FA11134 KE50577 KE51224 KE52386 KE50583 KE50582 KE50377

SK50055

KE50376

SK50054

FA95008 FA30088

FA95005 KE50581 KE51011 KE51009 KE51010 KE50752 FA95007 FA95006 KE50580 KE51223 KE51007 FA00012 KE00150 KE50315 KE50441 FA11081 KE51711 KE51731 FA10623 FA20229 SE00034 KE51891 SE00036 KE52192 KE52191 KE52193 FA95037 FA95014 KE50579

DESCRIPTION

Gear box lid Screw, 10-24 x 3/8" SS Motor Transformer, 208/120V(HG3J) Transformer, 220, 240/120V(HG5J) Buna-N insert Coupling Terminal block section (Large, white) Terminal block section (Small, black) Terminal block end section (Large, white) Terminal block end section (Small, black) Locknut, 3/4 -16 Washer, 1 1/2"OD x 13/16"ID x .125"W See note Tension pin Bridge rectifier Contact section Square spacer plate Square actuator Transformer, 240/16V Retaining ring Woodruff key Water resistant boot Bottom cover Micro switch "0" Ring, circuit breaker Worm gear Worm Tilt shaft Screw, 8-32 x 1/2", SS Bearing, roller, trunnion Bearing, tilt shaft Bolt, 5/16-24 x 1 1/2" Nut, hex, 5/16-24 Bearing assembly Washer, 1 1/2"OD x 13/16"ID x .037"W Thrust bearing assembly Washer, thrust bearing Bearing, thrust Spacer, thrust bearing Key, 3/16" x 3/16" x 3/4" Key, 3/16" x 3/16" x 1" Circuit breaker, 1 amp

QTY.

Note: Please order item no. 34.-36. - Part no. SE00036

13

POWER TILT OPTION

14

PARTS LIST - TRUNNION ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY.

1 KE00354-D Trunnion bearing casting 1 2 KE00351-D Trunnion bearing casting 1 3 KE00349 Bolt, 5/16-18 x 1/2" 1 4 KE50666 Spherical washer 1

15

PARTS LIST - 2" TANGENT DRAW-OFF VALVE

ITEM NO. PART NO. DESCRIPTION QTY.

1. to 7. KE50972-B Draw-off assembly 1

1. FA21008 Hex nut 1

2.

3. KE52754 Hex nut 1

4. KE52753 Retainer 1

5. KE52752 Piston 1

6. FA00111 "O" Ring 1

7. KE52751 Valve body 1

FA95049 Wing nut KE527551 Knob 1

16

PARTS LIST - FAUCET

ITEM NO. PART NO. DESCRIPTION QTY.

1

2 KE51404 Spout nut, short(used on spout KE50833) 1

KE50833 for KS-E-LA KE50828 for KT-20-EA KE50829 for KT-30-EA, KT-4O-EA, KT-60-EA

KE51736 Spout nut, tall (used on spouts 1

3 FA95022 Retaining ring 1 4 FA00016 "O"ring 1 5 SE50021 Cold water stem assemby 1 6 SE50020 Hot water stem assembly 1 7 KE51403 Double pantry control valve

8 SE50022 Yoke connection kit 1

3/4" Spout 1

KE50828, KE50829 and KE50830)

(c/w item no. 5,6,8) 1

17

PARTS LIST - HINGE ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY.

1.-9. SE00057 Hinge assembly (40 gal. and under) 1

1. KE51218 Body, spring assist hinge 1

2. KE50824 Hinge bearing 1

3. KE50823 Pin (hinge) 1

4. KE50820 Insert, brass adjustment 1

5. KE50819 End piece 1

6. FA11507 Screws, adjustment 2

7. FA11284 Bolts, end block 2

8. KE50122 Spring (40 gal. and under) 1

9. KE50821 Cylinder 1

10. KE50151 Knob, ball type 1

11.

12. KE00095 Lid holder 1

13. FA30500 Washer, lid holder 1

14. FA11223 Bolt, lid holder 1

SE00058 Hinge assembly (60 gal. and over) 1

KE50121 Spring (60 gal. and over) 1

Cover handle (specify model) 1

18

ALL KETTLES AND SKILLETS HINGE ADJUSTMENT INSTRUCTIONS

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-clockwise to loosen tension to produce desired effect.

8. Re-insert pin 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.

19

ALL ELECTRIC KETTLES SERVICING 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 top kettles the entire control mounting panel may be removed from kettle control

housing for easier troubleshooting and pans replacement.

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

Possible Causes

1. No incoming power. 8. Defective potentiometer.

2. Kettle is tilted. 9. Defective low water level probe.

3. Low water condition. 10. Defective thermistor.

4. Defective on/off switch. 11. Defective 240/16 VAC transformer.

5. Defective 12 VDC relay. 12. Defective control box.

6. Defective safety thermostat. 13. Defective elements.

7. Defective contactor/s.

Fault Isolation Procedure Step Test Result Remedy

1. Is there proper incoming voltage at terminal

block?

2. Is the red LED illuminated? Yes Follow Kettle Filling Procedure. If this does

3. Is the green LED illuminated? Yes Go to step #4.

4. Do both contactors energize? Yes Check contactor contacts for pitting. Voltage

Yes Go to step #2.

No Correct external power supply problem.

not correct the problem, go to PROBLEM D.

No Go to step #3 .

No Go to step #7

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.

20

5. Measure continuity across safety thermostat.

Is it an open circuit?

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

Yes Replace defective safety thermostat. No Go to step #6.

Yes Replace defective contactor/s.

No Replace defective 12 VDC relay.

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?

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

10. Unplug control box and measure the resistance across potentiometer. Is it approx. 0 ohms at max. and 50,000 ohms at min. settings?

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.

Yes Go to step #10.

No Replace defective ON/OFF switch. Yes Go to step #11.

11. Remove edge connector from control box. While kettle is cold or thermistor is removed and allowed to cook, measure the resistance between edge connectors pins #2 and #7. Is it approx. 100,000 ohms?

No Replace defective potentiometer. 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.

21

B/ Problem: Kettle heats too slowly or not hot enough.

signifies a poor contact. Replace contactor/s as

.

(Note: normal max. operating pressure with an empty kettle is 25-30 psi.)

Possible Causes

1. Air in kettle jacket-requires venting. 5. Defective contactors.

2. Defective safety thermostat. 6. Defective control box.

3. Defective potentiometer. 7. Defective element/s.

4. Defective thermistor.

Fault Isolation Procedure Step Test Result Remedy

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

2. Yes Go to step #3.

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

3. Yes Replace defective safety thermostat.

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

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.

No Check contactor contacts for pitting. Voltage

across terminal of contactor while energized

necessary. Check elements for short to ground or open circuit If elements are defective, contact the factory. Elements are not field replaceable.

4. Yes Go to step #5 .

Unplug control box and measure the resistance across potentiometer. Is it approx. 0 ohms at max. and 50,000 ohms at min. setting? No Replace defective potentiometer.

5. Yes Go to step #6 .

Remove kettle thermistor and allow to cool. Remove edge connector from control box. Test resistance across edge connectors pins #2 and #1 Is it approx. 100,000 ohms?

No Go to step #4.

No Replace defective thermistor.

22

6. Yes Kettle is operating properly.

control box.

Does the green LED turn off even though the

Turn the potentiometer on the control box clockwise to increase the max. operating temperature. Does the kettle now achieve max. operating pressure of 25-30 psi in an empty kettle?

No Spray contact cleaner on control terminals

and edge connector. Try box again. If problem still exists, replace defective

C/Problem: Kettle is overheating. Possible Causes

1. Defective thermistor.

2. Defective potentiometer.

3. Defective 12 VDC relay.

4. Defective control box.

Fault Isolation Procedure Step Test Result Remedy

1. Yes Replace defective 12 VDC relay. contractors remain energized?

2. Yes Go to step #3.

Unplug the control box and measure the

No Go to step #2.

resistance across the potentiometer, Is the resistance approx. 0 ohms at max. and 50,000 ohms at min. settings?

3. Yes Go to step #4.

Remove kettle thermistor an allow to cool.

No Replace defective thermistor.

Remove edge connector from control box. Test resistance across edge connectors pins #2 and #7. Is it approx. 100,000 ohms?.

4. Yes Spray contact cleaner on control box

Turn the potentiometer on the control box counter-clockwise to decrease the max. operating temperature. Does the kettle continue to overheat?

No Replace defective thermistor.

terminal and edge connector. Try box again. If problem still exists, replace defective control box.

No Kettle is operating properly.

23

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

VOLTS

Possible Causes

1. Defective low water level probe.

2. Defective control box.

Fault Isolation Procedure Step Test Result Remedy

1. Yes Replace or clean defective low water

Remove wire from low water level probe and ground the wire to the body of the

level probe.

kettle. Does the red LED turn off?

No Spray contact cleaner on control box

terminals and edge connector. Try box again. If problem still exist, replace defective control box.

MODEL ELECTRICAL RATINGS

KS20/KT20

KS30/KT30 12.3 59 12.3 34 16.4 68 16.4 39 — — 13.6 21 KS40/KT40 14.8 71 14.8 41 19.6 82 19.6 47 — — 16.4 25

208 1 Phase

KW AMP

9.8 47

3 Phase KW AMP KW AMP KW AMP KW AMP KW AMP

9.8 27 13 55 13 32 — — 11 25

240 VOLTS 1 Phase

3 Phase

220/380 VOLTS 1 Phase 3 Phase

KS60/KT60 14.8 71 14.8 41 19.6 82 19.6 47 — — 16.4 25

240/416 VOLTS

1 Phase 3 Phase KS20/KT20

KS30/KT30 — — 16.4 23 9.8 21 9.8 12 18 31 18 18 KS40/KT40 — — 19.6 27 B.I 27 13.1 16 18 31 18 18 KS60/KT60 — — 19.6 27 19.6 41 19.6 24 24 42 24 24

KW AMP

— —

KW AMP KW AMP KW AMP KW AMP KW AMP 13 18 9.8 21 9.8 12 18 31 18 18

1 Phase

480 VOLTS

3 Phase

1 Phase

575

3 Phase

For electrical supply other than shown above, refer to the wiring diagram affixed to the underside of the console cover.

NOTE: Amperage (amps/ph) column above is the actual current draw of the unit. Please reference electrical codes in your area for the correct wire and circuit breaker sizing.

24

STANDARD NORTH AMERICAN WIRING DIAGRAM

For electrical supply other than shown above, refer to the wiring diagram affixed to the underside of the console cover. NOTE: Please reference electrical codes in your area for the correct wire and circuit breaker sizing.

25

STANDARD EUROPEAN WIRING DIAGRAM

For electrical supply other than shown above, refer to the wiring diagram affixed to the underside of the console cover. NOTE: Please reference electrical codes in your area for the correct wire and circuit breaker sizin g.

26

HARRISONS & CROSFIELD (CANADA) LTD.

PRODUCT: ETHYLENE GLYCOL DATE:

24

October

1986

alaise, lumbar pain, oliguria, uraemia,

related teratogenic effects in rats and

suggest that it has caused birth defects in humans. Two chronic feeding studies, using rats and mice have not

related increases in tumour incidence, or a different

glycol has been supported by numerous in vitro genotoxicity studies showing it does not produce mutagenic or

MATERIAL SAFETY DATA SHEET

SUPPLIER: Harrisons & Crosfield (Canada) Ltd. 777 Supertest Road, Downsview, Ontario, M3J 2M5 Phone (416) 736 9299, Telex 06-524509 Emergency Phone (416) 667 8074

I. IDENTIFICATION

SYNONYMS: Glycol; EG; MEG; 1, 2 ethanediol CHEMICAL NAME: Ethylene glycol CHEMICAL FAMILY: Glycols CHEMICAL FORMULA: HOC2H4CH C.A.S. NUMBER: 107-21-1 SHIPPING NAME: CLASSIFICATION: Not regulated P.I.N.: PACKING GROUP:

II. HAZARDOUS INGREDIENTS

Ingredient Range % TLV (ppm) Ethylene glycol 100 Vapor-50 ppm

III. HEALTH HAZARDS

THRESHOLD LIMIT VALUE: Vapour - 50 ppm. Paniculat e - 10 mg/m3 EFFECTS OF OVEREXPOSURE:

EYES: Liquid, vapours, and particularly mists, may cause discomfort in the eye with transient conjunctivitis. Serious corneal injury is not anticipated.

SKIN: slightly irritating. INHALATION: May cause irritation of the throat and headache. High vapour concentrations caused, for

example, by heating the material in an enclosed and poorly ventilated workspace may produce nausea, headache, and dizziness.

INGESTION: May cause abdominal discomfort and pain (dizziness, m and central nervous system depression. Severe kidney damage follows the swallowing of large volumes of ethylene glycol. May be fatal.

CHRONIC HEALTH HAZARDS: Inhalation of mists may produce signs of effects on the central nervous system, particularly dizziness and nystagmus.

OTHER HEALTH HAZARDS: Ethylene glycol has been shown to produce dose -

mice when given by gavage or drinking water at high concentrations. There is no available information to

produced any evidence that ethylene glycols causes dose pattern of tumours compared with untreated controls. The absence of a carcinogenic potential for ethylene

clastogenic effects.

PRODUCT: ETEYLENE GLYCOL DATE:

24

October

1986

FIRST AID:

FLAMMABLE LIMITS

(%

in air): LOWER:

3.2

UPPER:

15.3

(est)

BOILING POINT (C)

: 197

SPECIFIC GRAVITY (20C)

: 1.12

VAPOUR PRESSURE:

0.08

VAPOUR DENSITY (air=l)

: 2.1

WATER

SOLUBILITY: Complete VOLATILITY

(%):

Nil EVAPORATION RATE:(Butyl acetate=1):

< 0.01

CONDITIONS TO AVOID: None currently known.

HAZARDOUS DECOMPOSITION PRODUCTS: Carbon dioxide and/or carbon

monoxide produced on burning

.

HAZARDOUS POLYMERIZATION: No.

EYES: Flush with water for at least 15 minutes. SKIN: Remove contaminated clothing and flush skin with water. INHALATION: Remove to fresh air. Call a physician if discomfort persists. INGESTION: If conscious, give two glasses of water and induce vomiting. Call a physician.

NOTES TO PHYSICIAN: The principle toxic effect of the material, when swallowed, will be due to the

ethylene glycol content, which caused kidney damage. Early administration of ethanol may block the formation of nephrotic metabolites in the liver. Ethanol should be given intravenously, as a 5% solution in sodium bicarbonate, at a rate of about 10 ml. of ethanol per hour. A desir ed therapeutic level of ethanol in blood is 100 mg/dL. Hemodialysis may be required. See also Section IX.

FLASH POINT & method (C): 116 (TCC)

EXTINGUISHING MEDIA: Use water spray, carbon dioxide, dry chemical, alcohol-type or universal-

type foams applied by the manufacturers' recommended technique.

SPECIAL FIRE FIGHTING PROCEDURES: Do not spray pool fires directly. A solid stream of water

directed into hot, burning liquid can cause frothing. Use self -contained breathing apparatus and protective clothing.

UNUSUAL FIRE & EXPLOSION HAZARDS: None currently known

The following physical data are approximate only and do not represent specification value s. They should only be used in the context of this Material Safety Data Sheet.

APPEARANCE & ODOUR: Colourless liquid, mild odour.

STABILITY: Stable.

INCOMPATIBILITY: Strong oxidizing agents.

CONDITIONS TO AVOID: None currently known.

PRODUCT: ETEYLENE GLYCOL DATE:

24

October

1986

STEPS TO BE TAKEN IF MATERIAL IS RELEASED OR SPILLED: Wear suitable protective

PROTECTIVE

GLOVES: Rubber or plastic.

en described in a number of patients

equipment. Small spills - flush with large quantities of water. Large spills - collect for disposal.

WASTE DISPOSAL METHODS: Incinerate in a furnace where permitted by Federal, Provincial, and

local laws and regulations.

RESPIRATORY PROTECTION: NIOSH or MSHA approved air supplied mask in high concentrations.

VENTILATION: General mechanical room ventilation is expected to be adequate if handled in covered

equipment. Local exhaust ventilation is needed at points where vapour is expected to be vented to the air.

EYE PROTECTION: Monogoggles or face shield. ADDITIONAL PROTECTIVE EQUIPMENT: Eye bath and safety shower.

HANDLING & STORAGE: May be fatal if swallowed. Do not breathe mist. Avoid prolonged or repeated

breathing of vapour. Avoid contact with eyes. Wash thoroughly after handling. Where heavy concentrations of fine mist are present, a respirator should be used to prevent inhaling mist particles.

OTHER INFORMATION: Pulmonary oedema with hypoxemia has be

following poisoning with ethylene glycol. The mechanism of production has not been elucidated, but it appears to be noncardiogenic in origin in several cases. Respiratory support with mechanical ventilation and positive end-expiratory pressure may be required.

PREPARED BY: Regulatory Services DATE ISSUED: 28 July 1986 Harrisons & Crosfield (Canada) Ltd. DATE REVISED:24 Oct. 1986

The information provided in this Material Safety Data Sheet has been obtained from sources believed to be reliable. Harrisons & Crosfield (Canada) Ltd. provides no warrants express or implied and assumes no responsibility for the accuracy or the completeness of the da ta contained herein.

DEN

SITY (Air=1)

Lower

EMERGENCY Tel. No.

FINNAN ENGINEERED

PRODUCTS LIMITED

MATERIAL SAFETY DATA SHEET

POISON CONTROL CENTER

(416) 438-6070

(416) 294-5237 (416) 497-5512

NAME OF PRODUCT FINNAN 1524L and 1529L

PURPOSE OF PRODUCT Closed System Corrosion Inhibitor

CHEMICAL NAME Mixture FORMULA

COMPONENTS WT/ WT

Sodium Nitrite 20-24 120mg/Kg Assists combustion 7632-00-0 Tolytriazole 0.2-0.3 675mg/Kg Toxic 29385-43-1

Sodium Hydroxide 0.8 N/Av. Corrosive 1310-73-2 Sodium Tetraborate 3.3 2660mg/Kg LDL0, man, 709 mg/Kg 1330-43-4

SECTION I PRODUCT INFORMATION

Toronto: l-800-268-9017

Quebec

City : 418-656-8090

SECTION II HAZARDOUS INGREDIENTS

Oral-rat

%

SECTION III PHYSICAL STATE

LD50

April 28/89

HAZARD CAS NO.

APPEARANCE AND PHYSICAL STATE

Straw color liquid

1. BOILING POINT ° C (°F) >100°C 5. pH OF PRODUCT OR ACID/BASE

PRESSURE N/Ave. 2. VAPOUR

3. SOLUBILITY IN WATER Miscible 7. FREEZING POINT N/Av.

4. PERCENT VOLATILE 71% as water 8. AUTODECOMPOSITION TEMP. 490°C

SECTION IV FIRE AND EXPLOSION HAZARD DATA

FLASH POINT N/Ap. FLAMMABLE LIMITS : Upper

EXTINGUISHING MEDIA As appropriate for combustibles in area.

SPECIAL FIRE FIGHTING PROCEDURES Self -contained breathing apparatus and protective clothing must be worn

in fighting all fires involving chemicals.

ODOUR

Mild

11.5-12.0

CONTENT

6. SPECIFIC GRAVITY (Water=1) 1.20-1. 22

materials and dispose of.

Follow your local, provincial and federal chemical disposal regulations.

SECTION V HEALTH HAZARD DATA

A - EFFECTS OF ACUTE OVEREXPOSURE

(A) SKIN Corrosive to skin, may cause dermatitis.

(B) INHALATION For nitrite , 4 hr. LC50 in rats: 1.45 mg/litre of air.

(C) INGESTION Harmful or fatal if swallowed.

(D) EYES Corrosive to eyes.

B - EFFECTS OF CHRONIC OVEREXPOSURE

- Nitrite not listed as a carcinogen by ACGIH, IARC or OSH.

- Nitrite tests on animals demonstrate no embryotoxic or reproductive toxicity.

- See Appendix.

SECTION VI EMERGENCY AND FIRST AID

(A) SKIN Wash with soap and water at once while removing contaminated clothing (B) INHALATION No exposure is expected at room temperature.

(C) INGESTION If victim is conscious, induce vomiting by giving two glasses of water or salt water and inserting

finger down throat. Call Poison Control or a physician immediately.

(D) EYES Immediately flush eyes with copious amounts of water for 20 mins. Consult a physician if

redness or irritation persists.

SECTION VII TOXICOLOGICAL DATA

EXPOSURE LIMITS: Not established.

ROUTE OF ENTRY: Skin or eye contact, ingestion.

SECTION VIII SPILL OR LEAK PROCEDURES

STEPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED Collect and reuse as much as possible, absorb the residues with sand or other mineral absorbent

DISPOSAL PROCEDURES

SECTION IX PROTECTION INFORMATION

EXHAUST

GLASSES

SHIELD

AVOID

RESPIRATORY PROTECTION: LOCAL

MECHANICAL

GLOVES APRONS SAFETY

CHEMICAL GOGGLES

OTHER PROTECTIVE EQUIPMENT: Eyewash station.

SECTION X REACTIVITY DATA

STABILITY STABLE UNSTABLE HAZARDOUS DECOMPOSITION OR COMBUSTION PRODUCTS

Toxic brown nitrogen dioxide gas is formed. CONDITIONS TO

SECTION XI HANDLING AND STORAGE PRECAUTIONS

Handle as an alkaline liquid. Store away from acids and oxidizing chemicals. Keep the lid closed at all times.

SECTION XII FURTHER INFORMATION

FACE

Under certain circumstances, when dry nitrite comes in contact with combustible material, it may act as a source of oxygen, thus assisting combustion.

Do not add amines to water systems containing Finnan 1524L or Finnan 1529L to avoid formation of carcinogenic nitrosamines.