Cleveland KGT-6-T Service Manual

INSTALLATION, OPERATION AND SERVICE MANUAL

GAS TABLE TOP KETTLE -

MODEL: KGT-6-T

KGT-12-T

CLEVELAND RANGE INC.

1333 East 179th St. Cleveland, Ohio U.S.A. 44110 Toll Free 1-800-338-2204

SE95010 Rev.3

FOR THE USER

IMPORTANT

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

ALL SERVICE MUST BE PERFORMED BY A QUALIFIED CLEVELAND RANGE TECHNICIAN.

RETAIN THIS MANUAL FOR YOUR REFERENCE.

WARNING: Improper installation,

adjustment, alteration, service or maintenance can cause property

damage, injury or death. Read the

installation operating and maintenance instructions

thoroughly before installing or

servicing this equipment.

FOR YOUR SAFETY

DO NOT STORE OR USE

GASOLINE OR ANY OTHER

FLAMMABLE LIQUIDS AND VAPOURS IN THE VICINITY

OF THIS OR ANY OTHER

APPLIANCE.

TABLE OF CONTENTS

Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

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

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

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

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

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

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

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

Operating Instructions General Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Operating the Kettle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Marine Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Cleaning Instructions Care & Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Marine Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Service Parts Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Faucet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Main Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Component Mounting Bracket Assembly. . . . . . . . . . . . . . . . . . . . 9

Piping Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Maintenance Inspection & Maintenance Check List . . . . . . . . . . . . . . . . . . . . 11

Calibrating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Vacuum Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Pressure Relief Valve Periodic Testing Procedure . . . . . . . . . . . . 12

Reservoir Fill Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Kettle Venting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Repairing Leaks in Steam Jacketed Kettle Fittings . . . . . . . . . . . 14

Kettle Jacket Filling & Draining Procedures . . . . . . . . . . . . . . . 15

Operating Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Field Conversion Instructions -

Natural Gas to Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . 17

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

INSPECTION

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

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

SHIPPING DAMAGE INSTRUCTIONS

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

1. Write down a description of the damage or the

reason for suspecting damage as soon as it is discovered. This will help in filling out the claim forms later.

2. As soon as damage is discovered or suspected,

notify the carrier that delivered the shipment.

3. Arrange for the carrier's representative to examine

the damage.

4. Fill out all carrier claims forms and have the

examining carrier sign and date each form.

GENERAL

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

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

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

Dimensions and clearance specifications are shown on the specification sheet and in the Clearance Requirements section.

CLEARANCE REQUIREMENTS

CLEARANCE REQUIREMENTS TO COMBUSTIBLE AND NONCOMBUSTIBLE SURFACES.

NOTE: To prevent removal of unit for servicing, allow sufficient room on right hand side for servicing.

ASSEMBLY

Base Mounting Diagram

Table-top models must be positioned on a firm, level stand, or existing counter top, and bolted in place. These models are supplied with four threaded mounting bushings welded to the underside of the base. An optional support stand with level adjustable legs is available. Once the kettle is secure, screw tilt handle into the threaded hole provided at the right side of kettle.

GAS

ENSURE THE GAS SUPPLY MATCHES THE KETTLE'S REQUIREMENTS AS STATED ON THE RATING PLATE.

It is recommended that a sediment trap (drip leg) be installed in the gas supply line. If the gas pressure exceeds 14” water column, a pressure regulator must be installed, to provide a maximum of 14” water column gas pressure to the gas control valve.

Connect the gas line to the manual valve located at the rear of the control box.

Model # Back Left Side Right Side

KGT-16-T 4” 0 0 KGT-12-T 4” 0 0

INSTALLATION

1 1/4"

10"

3 1/4"

14 1/2" 2 1/4"

14 1/2"

24" (6 gallon)

27" (12 gallon)

Installation must be in accordance with local codes and/or the National Fuel Gas Code ANSI Z223.1 Latest Edition (USA) or the latest Installation Codes for Gas Burning Appliances and Equipment CAN/ CGA B149.1 and CAN/ CGA B149.2 (Canada). Use a gas pipe joint compound which is resistant to L.P. gas. Test all pipe joints for leaks with soap and water solution. Ensure that the gas pressure regulator is set for the manifold pressure indicated on the gas rating plate.

The appliance and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.45 kPa). The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.45 kPa).

ELECTRICAL

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

A cord and plug are supplied with the unit. Simply plug the unit into any grounded outlet rated for a minimum of 10 amps. The wiring diagram is located on the back of the console access panel.

WARNING: Electrical Grounding Instructions.

This unit is equipped with a three-prong (grounding) plug for your protection against shock hazard and should be plugged directly into a properly grounded three-prong receptacle. Do not cut or remove the grounding prong from this plug. Standard supply voltage is 115 volts A.C., however, optional A.C. voltages can be supplied on special order. A separate fused disconnect switch must be supplied and installed in the high voltage electrical supply line. The kettle when installed, must be electrically installed and grounded in accordance with local codes, or in the absence of local codes, with National Electrical Code, ANSI/NFPA 7-1990 (USA) or the Canadian Electrical Code, CSA C22.1, Part 1 (Canada).

VENTILATION

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

WATER

The sealed jacket of the gas-fired kettle is precharged with the correct amount of a water-based 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.

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

KEEP APPLIANCE AND AREA FREE AND CLEAR OF COMBUSTIBLES.

1. Supply power to the kettle by placing the fused

disconnect switch to the "ON" position.

2. Before turning the kettle on, read the

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

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

position.

4. Turn the temperature control knob to "MIN .". The green

LED light should remain lit, indicating the burner is lit, until the set temperature is reached. Then the green light will cycle on and off, indicating the burner is cycling on and off to maintain temperature.

5. Tilt the kettle forward. The red "LOW WATER" light

should be lit when the kettle is in a tilted position. This light indicates that the burner has automatically been shut off by the kettle's safety circuit. This is a normal condition when the kettle is in a tilted position.

6. Raise the kettle to the upright position. The red "low

water" light should go out when the kettle is upright. If the red light remains lit in the upright position, it indicates a low water condition, and water must be added to the reservoir before the kettle can be operated. Refer to the "Reservoir Fill Procedures", on 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. Then the green light will cycle ON and OFF, indicating the burner is cycling ON and OFF to maintain temperature.

CLEANING

After installation the kettle must be thoroughly cleaned and sanitized prior to cooking. See complete cleaning instructions in this manual (page 5).

OPERATING INSTRUCTIONS

General Parts Drawing

ITEM # DESCRIPTION FUNCTION

1. On-Off Toggle Switch Controls electrical power to kettle.

2. Solid State Temperature This control allows the operator to adjust the kettle temperature in

Control Knob increments from MIN. to MAX. (see Temperature Range Chart on

page 4 of this manual.

3. Heat Indicator Light (Green) When lit, indicates that the kettle burner is on.

Cycles ON-OFF with burner.

4. Low Water Indicator Light (Red) When lit, indicates that the kettle is low on water and will not operate

in this condition (see Reservoir Fill Procedures on page 13 of this manual).

5. Vacuum/Pressure Gauge Indicate steam pressure in PSI inside steam jacket as well as

vacuum in inches of mercury.

6. Pressure Relief Valve This valve is used to vent the kettle and in the unlikely event there is

an excess steam build-up in the jacket, this valve opens automatically to relieve this pressure.

7. Plug Nut Plug nut is used for refilling the kettle with water (see "Kettle Venting

Instructions" and "Reservoir Fill Procedures" on pages 13 and 14 of this manual).

8. Tilting Handle Used for tilting the kettle.

9. Marine Lock Prevents unit from accidental tilting.

10. Water Level Sight Glass Displays water level in steam jacket.

8 7 6

4 3

OPERATING THE KETTLE

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

KEEP APPLIANCE AND AREA FREE AND CLEAR OF COMBUSTIBLES.

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

1. Before turning kettle on, read the Vacuum/Pressure Gauge (5). 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. Place the kettle's On-Off Toggle Switch (1) to the "ON" position.

Temperature Range Chart

3. Preheat the kettle by turning the Solid State Temperature Control Knob (2) to the desired temperature setting (see Temperature Range Chart on page 4). The Heat Indicator Light (Green) (3) 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.

4. Place food product into the kettle. The green

light will cycle on and off indicating the burner is cycling on and off to maintain the set temperature.

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.

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

5. When cooking is completed place On-Off Toggle Switch (1) to the "OFF' position.

NOTE: A five minute complete shut-of period is required before relighting.

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

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

MARINE LOCK

If your unit is equipped with a marine lock to prevent accidental tilting, the following procedure should be used to tilt the kettle.

1. Grasp the tilt handle with your right hand.

2. Push the marine lock button down with your

left hand to unlock tilting mechanism.

3. Pull the handle to tilt kettle.

4. When you return the kettle to its upright

position the marine lock will latch automatically.

Temperature Approximate

Control Product Temperature Setting °F °C

MIN. 120 49

1. 130 54

2. 145 63

3. 160 71

4. 170 77

5. 185 85

6. 195 91

7. 210 99

8. 230 110

9. 245 118

MAX.

265 130

NOTE: Certain combinations of ingredients will

result in temperature variations

+ 14 hidden pages