Cleveland KGL-60 Service Manual

Cleveland

™

Maintenance Procedures

& Parts Lists

Gas Floor Model Kettles

For units built after April 2010

KGL-40, KGL-60, KGL-80, KGL-100 KGL-40-T, KGL-60-T, KGL-80-T KGL-40-SH, KGL-60-SH, KGL-40-TSH

KGL-40-T

For your future reference.

Model # ______________________________________

Serial # _______________________________________

KGL-40

KGL-40SH

1333 East 179th St., Cleveland, Ohio, U.S.A. 44110 Ph: 216.481.4900 Fx: 216.481.3782 www.clevelandrange.com

This manual is to be used in conjunction with the “Operators Manual”. See “Operators Manual” for safety warnings, correct operation, installation and preventative maintenance.

SE95003-1 PRTS Rev. 8

February 2012

STATEMENT OF RESPONSIBILITIES /

DÉCLARATION DES RESPONSABILITÉS /

DECLARACIÓN DE RESPONSABILIDADES

This document is for use by experienced and trained Qualified Cleveland Range, LLC Authorized Service Representatives who are familiar with both the safety procedures, and equipment they service. Cleveland Range, LLC assumes no liability for any death, injury, equipment damage, or property damage resulting from use of, improper use of, or failure to use the information contained in this document. Cleveland Range, LLC has made every effort to provide accurate information in this document, but cannot guarantee that this document does not contain unintentional errors and omissions.

The information in this document may be subject to technical and technological changes, revisions, or updates. Cleveland Range, LLC assumes no liability or responsibility regarding errata, changes, revisions, or updates.

Qualified Cleveland Range, LLC Authorized Service Representatives are obligated to follow industry standard safety procedures, including, but not limited to, OSHA regulations, and disconnect / lock out / tag out procedures for all utilities including steam, and disconnect / lock out / tag out procedures for gas, electric, and steam powered equipment and / or appliances.

All utilities (gas, electric, water and steam) should be turned OFF to the equipment and locked out of operation according to OSHA approved practices during any servicing of Cleveland Range equipment

Qualified Cleveland Range, LLC Authorized Service Representatives are obligated to maintain up-to-date knowledge, skills, materials and equipment.

Ce document est destiné à l’usage des Représentants de Service qualifiés et autorisés de Cleveland Range, LLC qui possèdent l’expérience et la formation ainsi que la bonne connaissance des mesures de sécurité et du matériel qu’ils entretiennent.

Cleveland Range, LLC décline toute responsabilité pour tout cas de décès, blessure, dommage matériel ou dommage aux biens résultant de l'utilisation, de la mauvaise utilisation ou du manquement d’utilisation des renseignements contenus dans ce document.

Cleveland Range, LLC s’est efforcé à fournir des renseignements précis dans ce document mais ne peut garantir que ce document soit exempt d’erreurs et d’omissions non intentionnelles.

Les renseignements contenus dans ce document peuvent être assujettis à des changements techniques et technologiques, des révisions ou des mises à jour.

Cleveland Range, LLC décline toute obligation ou responsabilité concernant les errata, modifications, révisions ou mises à jour.

Les Représentants de Service qualifiés et autorisés de Cleveland Range, LLC sont tenus de se conformer aux mesures de sécurité normalisées de l’industrie, y compris, mais sans s'y limiter, les réglementations de l'OSHA, les procédures de débranchement / verrouillage / étiquetage relatives à tous les services publics, dont l’approvisionnement en vapeur, et les procédures de débranchement / verrouillage / étiquetage relatives aux équipements et/ou appareils fonctionnant au gaz, à l’électricité et à la vapeur.

Au cours de tout entretien d’un appareil Cleveland Range, tous les services publics (gaz, électricité, eau et vapeur) doivent être FERMÉS au niveau de l’appareil et le dispositif de fonctionnement doit être verrouillé suivant les pratiques approuvées de l’OSHA.

Les Représentants de Service qualifiés et autorisés de Cleveland Range, LLC sont tenus d’actualiser en permanence leurs connaissances, compétences, matériel et équipement.

Este documento está destinado para el uso de los Representantes de Servicio calificados y autorizados de Cleveland Range, LLC quienes cuentan con la experiencia y la capacitación así como el buen conocimiento de las medidas de seguridad y de los equipos que mantienen.

Cleveland Range, LLC, declina toda responsabilidad en caso de cualquier fallecimiento, lesiones, daños al equipo o daños a la propiedad resultantes de la utilización, del uso indebido o de la falta de utilización de la información provista en este documento.

Cleveland Range, LLC se ha esforzado en suministrar información precisa en este documento, pero no puede garantizar que este documento esté exento de errores y de omisiones no intencionales.

La información contenida en este documento podría estar sujeta a cambios técnicos o tecnológicos, revisiones o actualizaciones. Cleveland Range, LLC declina toda obligación o responsabilidad con respecto a erratas, modificaciones, revisiones o actualizaciones.

Los Representantes de Servicio calificados y autorizados de Cleveland Range, LLC tienen la obligación de seguir los procedimientos estándar de seguridad de la industria; los cuales incluyen pero no se limitan a los reglamentos de la OSHA (La Administración de la Seguridad y Salud Ocupacionales), los procedimientos de desconexión, cierre y etiquetado relativos a todos los servicios públicos incluyendo el suministro de vapor y los procedimientos de desconexión, cierre y etiquetado para los equipos y/o aparatos que funcionan a base de gas, electricidad o vapor.

Cuando se esté dando servicio o mantenimiento a un aparato de Cleveland Range, todos los servicios públicos (gas, electricidad, agua y vapor) deben estar APAGADOS para el equipo en cuestión y se debe seguir el procedimiento de cierre de operaciones de acuerdo con las prácticas aprobadas por la OSHA.

Los Representantes de Servicio calificados y autorizados de Cleveland Range, LLC tienen la obligación de actualizar constantemente sus conocimientos, destrezas, materiales y equipamiento.

TROUBLESHOOTING AND

MAINTENANCE PROCEDURES

The following trouble shooting guide and maintenance procedures

are meant to be used by Qualified Service Technician

ANY REPAIRS TO THE PRESSURE VESSEL MUST BE DONE BY A CERTIFIED PRESSURE

VESSEL REPAIR SHOP AND ALL REPAIR METHODS AND MATERIALS MUST BE

APPROVED BY THE MANUFACTURER.

For periodic maintenance recommendations see “Operators Manual”.

TROUBLESHOOTING GUIDES

GENERAL

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

position.

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

■ Power is sent to the normally closed high limit.

■ From the high limit power is sent to the normally

open contacts of the 12VDC relay and the L1 and L2 terminals of the ignition module.

2. From the secondary of the transformer 16VAC is

sent to the controller.

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

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

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

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

■ The 12VDC relay will close until the unit reaches temperature

3. With the contacts of the relay closed, 120VAC is

sent to the blower and primary coil of the 120VAC/24VAC transformer.

■ From the secondary of the 24VAC transformer power is sent to the normally open contacts of the air switch.

■ When the air from the blower closes the air switch, 24VAC is sent to the Th terminal of the ignition module.

4. With both 120VAC (at L1 and L2) and 24VAC (at

Gnd and Th) to the ignition module then 120VAC will be sent to the surface igniter.

5. After the ignition module has been energized for 24

seconds the module will send 24VAC to the gas valve.

■ The gas will touch the hot igniter and ignite.

■ The kettle will build pressure until the controller is

satisfied by the thermistor at the setting of the potentiometer.

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

TROUBLESHOOTING GUIDES (continued)

PROBLEM:

KGL

Kettle Won't

Heat

Does red light

come on when unit

is first turned on?

Does red light go

off shortly after

unit is turned on?

Yes

Add water to

jacket of Kettle.

With the

potentiometer set

at 10, is 12 VDC at

the coil of the

relay?

Yes

Is 16 VAC

measured across

Pins 9 and 10 on

the controller?

Yes

Is 16 VAC at the

secondary side of

the transformer?

Replace

the on/off

switch (toggle

or rotary).

Yes

Is there Power to

the primary of the

transformer?

Replace the transformer.

Yes

Supply power

to the kettle.

Does the relay pull

in?

Yes

Replace the

relay.

Is there power to

the blower?

Yes

With the high limit

temporarily bypassed, is power at the

blower?

Replace the

high limit.

Yes

Replace the wire to the blower.

Is there power to

the ignition

transformer?

Is there 24 VAC at

the secondary of

the ignition

transformer?

Is there 24 VAC to

the igniton

module?

Yes

Does the blower

turn?

Replace

blower.

Yes

Replace the

DC relay.

Replace the

ignition

transformer

Replace the air

switch.

Is there 120 VAC

to the igniter?

Yes

Replace

ignition

module.

Does the ignitor

glow?

Yes

Replace the

ignitor.

Does the gas

valve get 24 VAC

20 sec. after the

ignitor is

energized?

Yes

Does the gas

valve open?

Yes

Replace gas

valve

Yes No

TROUBLESHOOTING GUIDES (continued)

PROBLEM:

KGL

Kettle Not

Hot Enough

ith kettle pot

empty and

temperature knob

et at 10, is the

emperature of the

surface of the pot

260 degrees?

nit is

operating

properly

Yes

hen unit is cold (room temp) is the p

ressure gauge in

the green?

ent the kettle per i

nstructions in

the manual.

When the unit is

calling for heat

(the green light is

on), is there flame

at the burner?

s the resistance of

the thermister 100,000 ohms +10% at room

temperature?

Yes

Replace the

thermister.

Is the

potentiometer

resistance 50,000

ohms at low and 0

ohms at high?

Yes

eplace

ontroller.

Yes

Replace the

potentiometer.

Does the kettle

eat at all?

Yes

See Problem:

ettle won't

eat.

Is the blower

turning?

Replace the

igh limit?

s there voltage to

the blower?

Replace the

lower

Replace the air

switch

PROBLEM: KGL Kettle Has Delayed Ignition

Delayed Igniton

Is the gas

pressure to the

burner 3.5" W.C.?

Adjust or

replace the gas

Valve.

Does the ignior

glow evenly

Replace ignitor.

Yes

Does the gas

valve get 24 VAC

20 seconds after

the ignitor is

energized?

Replace the

ignition

module.

Is the blower

turning?

Replace blower

and air switch.

Replace burner

Yes

TROUBLESHOOTING GUIDES (continued)

PROBLEM:

KGL Kettle

Gets Too

Hot

With the kettle empty and the

temperature set at

10, is the surface

temp 260-265

degrees?

The

kettle is working

properly.

Yes

Does the kettle

continue to call for

heat (green light

stays on) when

the kettle reaches

260-265 degrees?

Is there supply

voltage to the coil

of the gas valve?

Replace the

gas valve.

Is there any DC

voltage to the coil

of the relay?

Replace the

Relay

Yes

Replace the

controller

Yes

Is the resistance of

;the thermister

00,000 ohms +

10% at room

temperature?

Yes

Replace the

thermister.

Is the resistance of

the potentiometer

50,000 ohms at

the low setting and

0 ohms at high?

Yes

Replace the

controller

Replace the

potentiometer

Yes

PROBLEM: Red Add Water LED Stays On

Does Red LED stay on after adding the proper

amount of distilled

water and rust inhibitor?

Add the proper

amount of distilled

water and rust

inhibitor.

Is the red LED on

with probe grounded?

Yes

Clean or

replace water

probe.

Does the red LED

stay on with a

jumper between

pins 5 and 7 on

the controller?

Yes

Replace the

wire harness in

the trunion.

Replace the

controller.

Yes

KETTLE SAFETY INSPECTION AND TESTING

260º - 270º MAXIMUM KETTLE TEMPERATURE

265º

✔



OFF

SAFETY VALVE INSTALLATION:

The above illustrations show the three variations of factory installed Safety Valves.

Modifications are unacceptable.

SAFETY THERMOSTAT:

Correct

Installation

Incorrect

Installations

robe

fully inserted i

n tube

Wiring is properly

connected

LOW WATER LEVEL PROBE:

Probe

Probe bypassed by running (A) an

✘

additional wire

roperly

attached

✔

Probe bypassed by (B) grounding the

✘

connecting wire

PRESSURE RELIEF VALVE TESTING

Probe removed

partially

Safety thermostat probe is not completely inserted into tubing.

2. Safety thermostat probe is removed from tubing.

3. Safety thermostat electrical connection is bypassed.

Probe removed

completely

OPERATING

THERMOSTAT:

If maximum temperature is not in this range (on empty kettle), refer to the “Calibrating Procedure”.

GAS KETTLE AIR SWITCH:

Correct Incorrect

Wiring is properly connected Switch electrically bypassed

Thermostat

electrically bypassed

260° - 270° F MAXIMUM KETTLE TEMPERATURE

Access

Panel

WARNING:

personal injury.

Pull Pressure Relief Valve Ring 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.

Replace access panel.

IMPORTANT:

If valve appears to be sticking replace pressure relief valve.

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

Use of gloves and eye protection to prevent

1. With the kettle empty, set On-

Off Switch/Temperature Control to "10" (Max.). Allow the kettle to heat until the unit cycles off.

Switch On-Off Switch/Temperature

Control to main power at fused disconnect switch.

3. Remove Access Panel at back

of main kettle console.

"0"

(Off) and disconnect

Pressure Relief Valve Ring

CALIBRATING PROCEDURE FREE AIR CALCULATION

OFF

Insert drager pump tube 4" down the center

olid State Temperature

ontrol Box

djustment

of the flue and take one sample each of Carbon Dioxide (CO2) and Carbon Monoxide (CO) and record results.

With results obtained for CO2 use chart to determine dilution factor for gas type used.

Enter these numbers in the following formula to determine the concentration of carbon monoxide in an air free sample of flue gas.

_____________

PPM)

(

__________________________

ilution Factor

______________

CO2

1. Insure the unit has a vacuum before you begin

calibrating procedures. If unit requires venting refer to KETTLE VENTING INSTRUCTIONS.

Set On-Off Switch/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 Solid State Temperature Control Box. Turn very little. Turn clockwise to INCREASES and counter-clockwise 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. through 8. until unit is calibrated.

Dilution Factor X CO (PPM) =

0,000

_____________________________

% Carbon Monoxide

Result must not exceed 0.08% carbon monoxide.

CARBON DIOXIDE IN FACTOR FACTOR

SAMPLE (PERCENT) PROPANE GAS NATURAL GAS

4.0 3.50 3.05

4.2 3.33 2.90

4.4 3.18 2.77

4.6 3.04 2.65

4.8 2.92 2.54

5.0 2.80 2.44

5.2 2.69 2.34

5.4 2.59 2.26

5.6 2.50 2.18

5.8 2.41 2.10

6.0 2.33 2.03

6.2 2.26 1.97

6.4 2.19 1.91

6.6 2.12 1.85

6.8 2.06 1.80

7.0 2.00 1.74

7.2 1.94 1.70

7.4 1.89 1.65

7.6 1.84 1.61

7.8 1.79 1.56

8.0 1.75 1.53

8.2 1.71 1.49

8.4 1.67 1.45

8.6 1.63 1.42

8.8 1.59 1.39

9.0 1.56 1.36

9.2 1.52 1.33

9.4 1.49 1.30

9.6 1.46 1.27

9.8 1.43 1.24

10.0 1.40 1.22

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