Cleveland PDM-3J User Manual

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Cleveland Range

UNITED STATES

CANADA

REPAIR MANUAL

PEM24/36/48-2/3J PEM160/200/250/300-2/3J

PDL/PDM/PDP-2/3J Model NO. PSM-2/3J

Cleveland Range, Inc.

1333 East 179th St. Cleveland, Ohio 44110

Phone: (216) 481-4900 • FAX: (216) 481-3782

Garland Commercial Ranges • 1777 Kamato Rd. Mississauga Ontario CN L4W 1X4

Phone: (416) 624-0260 • FAX: (416) 624-0623

PS-01

Installation Instructions For Steam Generators, Steamers, Steamer/Kettles: Gas — Electric — Steam Coil

Installation Instructions For All Models

1) These instructions must be retained by the owner/user for future reference. For installation only in noncombustible locations. Gas units

are only to be installed in areas that have provisions for adequate air supply.

2) Position: For proper operation and drainage, steam generator must be level. It must be set near a floor drain. Attach 1 1/2" piping all drain

connections to carry exhaust steam away from the cabinet. Ends of drain lines must vent to atmosphere to avoid back pressure. Allow a MINIMUM of 6" clearance to the rear and sides of the equipment. The surrounding area must be free and clear of combustibles.

3) Install in accordance with local codes and/or the National Electric Code ANSI/NFPA No. 70-1984. Installation in Canada shall be in accordance with the Canadian Electric Code CSA Standard C22-1. A unit that is connected to electricity must be grounded. A wiring diagram is provided inside the relay box.

4) Connect supply lines for 140° — 160° hot water, and cold water, to the unit. Water pressure must be maintained between 35 and 60 psi. Locations.and presswre data are shown on the connection drawing. Long hot water lines should be at least 1/2" IPS. Flush water supply lines thoroughly before connecting. Use water which is low in total solids content and low in gas content, to prevent internal scaling, pitting and corrosion of the steam generator and carry-over of minerals into the steam.Water which is fit to drink can still contain highly detrimental impurities. Refer to Water Quality Requirements page.

5) Turn on water supply to steam generator. Water valve is inside of base.

6) Connect fuel supply.

FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or are, other appliance.

For Steam Coil Steam Generators —

— Connect steam supply: Location is shown on the connection drawing. Incoming steam pressure must be regulated between 35 and 45 psi (30 — 45 psi for pressure steamers). Install a Strainer ahead of the regulating valve. Flush line thoroughly before connecting.

— Connect the outlet end of the steam coil to an inverted bucket trap. Fill trap with water before installing.

— Connect electricity if unit is equipped with electrical controls. Permanent connection is required. Junction box

location is shown on the connection drawing. Unit must be electrically grounded by the installer.

For Gas Fired Generators —

— Post in a prominent location, instructions to be followed in the event the user smells gas. This information shall be obtained by consulting the local gas supplier.

— Connect gas: Location and pressure data are shown on the connection drawing. Installation shall be in accordance with local codes, or in the absence of local codes, with the National Fuel Gas Code. ANSI Z223.1 —1984. Installation in Canada shall be in accordance with Installation Codes for Gas Burning Appliances and Equipment B149.1 and B149.2. Use a gas pipe joint compound which is resistant to LP gas. Test all pipe joints for leaks with soap and water solution. Allow 12 inch clearance on right side of all Gas Fired Steam Generator models for servicing gas burners and for proper operation. This 12" clearance also provides adequate air openings into the combustion chamber. Never obstruct the flow of combustion and ventilation air. The appliance and its individual shutoff 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 psig (3.45 kPa). The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressure equal to or less than 1/2 psig (3.45 kPa).

— Connect electricity if unit is equipped with electrical controls. Permanent 115V connection is required. Junction box

location is shown on the connection drawing. Unit must be electrically grounded by the installer.

— Lighting and Shutdown Instructions: Rip electrical switch on. Open water valve. Open gas valve. Slightly depress

and turn control knob to "off" for 5 minutes before lighting gas. Turn control knob to "pilot", depress it completely and light pilot burner. Continue to hold knob in for about 60 seconds, then release. Pilot burner is lighted through hole in panel at bottom of steam generator. Never leave panel off as this will damage controls. Turn control knob to "on". Depress electrical "reset" switch for main burner ignition. Burners will not light without water in the steam generator. For main burner off. with pilot on, turn control knob to "pilot". For main and pilot burner off, slightly depress and turn control knob to "off". Flip electrical switch off.

For Electrical Steam Generators

— Connect electric power. Location is shown on the connection drawing. Provide connection as required by your unit. Electric supply must match power requirements specified on data plate attached to base. Wiring must be adequate to carry required current at rated voltage. A separate fused disconnect must be supplied and installed. Unit must be electrically grounded by the installer.

CLEVELAND RANGE CO., 1333 EAST 179th ST., CLEVELAND, OHIO 44110

1086 LITHO IN U.S.A. Manufacturer reserves right of design improvement or modification, as warranted.

7) Turn on electricity at control circuit switch on steamer console. A red light glows when electricity is on. If water level is correct, steam

generator will operate by pressing the "reset" button. Heaters will not work without water in the steam generator This manual reset button must be pressed to start up the generator initially, and to restart the steam generator after every shut oft. or power interruption. No attempt should be made to operate the equipment during a power failure.

8) Check to make sure that the water in the sight; gauge glass automatically stays at about 2/3 full when the unit is started up

9)When installation is complete and tree of leaks, refer to Operating Procedures sheet Instructions For Steam

Generator Care

Protect your steam generator, prolong its life and preserve its performance by giving it the required daily attention, on a regular schedule. Follow servicing instructions for your steam generator which are printed on Data Sheet 260-LC in your Owner s Manual, and also on an adhesive label attached to the unit To obtain an additional data sheet or label carrying servicing instructions, write to the Cleveland Range Company.

No work should be done on the steam generator while it is pressurized or hot Service of the steam generator should only be

WARNING

performed by a trained and experienced service technician, thoroughly familiar with servicing steam generators. When maintenance or repairs are required, contact a local food service equipment service agency, or call the factory, or a factory representative, for the name and address of one in your area.

Steam Generator (Boiler) Safety

Rigid regulations govern the design and construction of a boiler. However, the responsibility for the safe and efficient operation of a boiler shifts to the owner/user after the boiler leaves the factory.

A sound boiler, if improperly installed, or if improperly maintained, or if improperly repaired, will create a dangerous situation

and may cause injury to personnel. Most states, provinces and some cities have a boiler safety law. Many underwriters require that their clients' boilers comply with these boiler safety laws. These safety laws call for action by the boiler manufacturer and action by the boiler owner / user. As a manufacturer. The Cleveland Range Company delivers steam generators built to the ASME Boiler Code. Section IV. which have been inspected by a National Board inspector. Also. each Cleveland Range Company boiler is built to comply with the boiler safety law of the state to which it is sent

Safe and Efficient Boiler Operation Depends on Proper Installation Install the boiler in compliance with following regulations, where they apply:

— The National Fuel Gas Code. ANSI Z223-1-1984 — The local and municipal building code (plumbing and electrical)

--Installation Codes for Gas Burning Appliances and — The state and city boiler laws Equipment B149.1 and 8149.2

— The Cleveland Range Company Installation Instruc- — The recommendations of the owner/user's underwriters

tions

— The National Electrical Code ANSI / NPPA No. 70-1984

The water for the boiler should be analyzed by a reputable boiler water specialist, to see if the quality will permit safe and efficient boiler operation. Water treatment is becoming increasingly necessary because the quality of water sources is deteriorating, although treatment will not be required in every case. A boiler will not operate properly for very long if the water causes boiler corrosion or scale. Even water which is safe to drink may be detrimental to a boiler. Refer to Water Quality Requirements page for details. Safety Requires Periodic Inspection and Maintenance

Any leaks around the boiler's hand hole plate must be quickly stopped. Small leaks, if unchecked, cause corrosion and

pitting on the boiler face, around the hand hole gasket making it unsealable.

Application of undue stress on the parts that are used to seal the boiler's hand hole opening, in an attempt to seal an unsealable. opening, by sledging the handle of the wrench, by increasing the leverage of the wrench by a length of pipe. or by other means, is dangerous because it may result in the breakage of parts, or injury. No attempts should be made to

tighten up the nut on the retaining stud beyond the recommended 15 foot pounds of torque.

When a repair affecting the safety of the boiler is necessary, call a National Board Inspector for consultation and advice as to the best method of making the repair, so that the completed work will get his approval. Repairs to the boiler must

conform to the applicable provisions in the ASME Code or the National Board Rules for Repairs.

A boiler will last many years before it has to be retired from service. Periodic inspection will reveal the approaching

retirement time. It is better to schedule a convenient replacement time than to wait for the boiler to fail.

When a boiler older than 10 years is replaced, the entire steam generator base assembly should be replaced for a

number of reasons:

— Replacement parts become increasingly difficult to obtain for older controls. — Dependable performance of the new controls can be assured for a longer time — The new steam generator, including controls, will comply with the latest industry and safety standards.

CLEVELAND RANGE CO, 1333 EAST 179th ST., CLEVELAND, OHIO 44110

1086 LITHO IN U.S.A. Manufacturer reserves right of design improvement or modification, as warranted.

PRESSURE STEAMER OPERATING INSTRUCTIONS

NOTE: These instructions pertain to steamers equipped with self-contained steam generators (boilers). For steamers directconnected to a remote (in-house) steam source, disregard those instructions which are directly and solely related to the selfcontained steam generator. These instructions are to be retained by the owner/user for future reference. 1A. Open the cabinet base door and close the drain valve if it is open.

B Make sure the hot and cold water supply valves are open

C. For steamers equipped with a gas-fired steam generator (boiler) follow the lighting instructions noted on the instruction label displayed on the unit before continuing to instruction in item 2.

2. Flip the toggle switch on from of the cabinet console to "ON". The red console light should then glow and the boiler will automatically begin filling with water (if it is not already full).

3. After approximately five minutes (after water appears in the sight gauge), depress the "START" reset button on the console. This will energize the electric healer elements or ignite the gas burners. This cannot be accomplished until the boiler is full of water.

4 in approximately 15 minutes you will notice the console's steam pressure gauge register 5 pounds. (10 pounds if the boiler

is also supplying steam to a kettle. The upper pressure gauge will register 5 pounds.) You can now preheat the cooking compartments.

5 Compartments should be preheated before use and should be kept hot between loads. If a kettle and steamer are to be used

at the same time, always heat the kettle unit first. When kettle contents begin to simmer, preheat the steamer compartments. When pressure on the boiler gauge returns to 10 pounds, cooking may begin in the steamer

6. Close and latch door securely. Turn bar handle clockwise until the door gasket just touches the compartment face

7. Start steam supply by pulling steam valve handle out. If fitted with automatic timer, set timer for 5 minutes. At the start, compartment thermostatic traps should release air and wet steam for about two minutes, then shut off.

8. Seal compartment door by turning bar handle clockwise just until steam leakage stops. DO NOT OVERTIGHTEN

9. At the completion of the 5 minute preheating cycle, push steam valve slowly in, to avoid boilovers. This shuts off the steam supply and also depressurizes and drains the compartment. If fitted with an automatic timer, the steam shuts off automatically and a bell rings when the timer reaches zero. Setting the timer to "Off" stops the bell.

10. To open compartment door, turn bar handle counter-clockwise and delatch.

11. Cooking can now begin by following the above operating steps #6 through #10, but setting the timer tor the required

cooking time. At the end of a cooking cycle 40 minutes long or longer, or when defrosting frozen foods, wait at least two minutes for the compartments) to depressurize and drain before opening the compartment door.

CAUTION: After each cooking cycle, ensure that all water is draining, and not accumulating in the compartment. Should a drain become obstructed, it must be cleared before attempting to cook in that compartment.

12. At the end of each day's operation, flip the console toggle switch to the "Blowdown" position, open the door in the cabinet base and open the boiler drain valve, (red handle). This "Blowdown" drains the boiler and helps to keep it dean. When the boiler is empty, flip the console toggle switch to the "OFF" position and dose the boiler drain valve.

13. It is recommended that the boiler be refilled with water after the "Blowdown" is performed. This can be accomplished by flipping the toggle switch to the "ON" position for a period of five minutes and then returning the switch to the "OFF" position.

TO PROLONG LIFE AND MINIMIZE SERVICE REQUIREMENTS

1. Blow down the steam generator daily.

2. A periodic boiler inspection must be performed by a qualified serviceman to prolong its life and to minimize service calls.

3. At the end of each day's operation, wash the pan slides, drain screen covers, door gaskets, and compartment interiors with

mild detergent and warm water. Thoroughly rinse with dean water. Rinse water should drain freely through the compartment drain openings. if it does not the drain must be cleaned before using the steamer.

4. Once a week, flush each compartment drain with a food service equipment drain cleaner and a deliming solution

5. Once every three months, shut off the water supply (hot and cold), and clean the water line strainers.

6. Compartment thermostatic traps can be disassembled and cleaned, by hand or in a mechanical dishwasher. This procedure is recommended if the traps act sluggishly, as they may if contaminated by grease or other film. If cleaning fails to restore the trap's proper functioning, replace the trap. For more detailed thermostatic trap servicing instructions, refer to Data Sheet 260-LH.

LITHO IN U.S.A. 0388

CLEVELAND RANGE, INC., 1333 EAST 179th ST., CLEVELAND, OHIO 44110

Manufacturer reserves right of design improvement or modification, as warranted.

7 Shelves, drain screens, and pan slides are stainless steel, and car be washed safely in a mechanical dishwasher.

8. Exterior Care: Allow steamer to cool before washing. Use the same cleaners and cleaning procedures as for other kitchen surfaces of stainless steel and aluminum. Mild soapy water, with a clear water rinse, is recommended. Do not allow water to run into electrical controls. Always turn off equipment power before using water to wash equipment.

9 Compartment Door Care:

3 When doors are closed for preheating or cooking, turn bar handle just enough to stop steam leakage. Over-tightening

shortens gasket life. a. When doors are open or unlatched, do not turn bar handle b. Always leave compartment doors ajar when not in use, to extend gasket Iife and to prevent gaskets from adhering to the

steamer. Unnecessary compression of a gasket shorten its life. c Keep bar handle screws clean. Lubricate frequently but not excessively. d. Door gaskets provide many months of service when care is taken to operate doors properly. When a gasket finally wears

and does not maintain an effective seal, it must be replaced. Door gaskets can be replaced easily without special tools or

cement, and the steamer may be used immediately afterwards. Remove the old gasket and clean the channel, being careful

not to damage the channel. The new gasket can then be pressed into place. Insert the gasket in the comers of the channel

first, adjusting the slack evenly between the comers. Then work from the corners to the center. Ridges hold the gasket

firmly. The gasket is designed to be oversize, so once it is compressed into the door's channel, it remains firmly in place.

PRESSURE STEAMER SAFETY

FOR YOUR SAFETY

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

Being the owner of a steamer carries with it the responsibility for keeping it in as safe a condition as when it was shipped from the factory. Safe steamer operation dictates that every pressure steamer must have the following safety inspection at least every 12 months.

1 Steam Valve Linkages

Have a qualified serviceman examine the steam valve linkages which are attached to the inlet and exhaust valves' operating handles on the left side of the steamer. This pivoted linkage, which is attached to both the steam inlet valve and the steam exhaust valve, must prevent the door's latch from disengaging from its catch when the steamer compartment is pressurized. It is important that the linkage operates as described so that the steamer door cannot be opened when the compartment is pressurized.

It is also important that when the steam valve is closed, the exhaust valve should open. The proper operation of the steam inlet valve and the steam exhaust valve should be confirmed and observed white the steam is on.

2. Pressure Gauge Check each pressure gauge. Gauge pointer must return to zero when the steam generator is shut down. Look

for signs of water, rust, corrosion, or scale, inside the pressure gauge A faulty pressure gauge should be replaced immediately

3. Door Gaskets

Inspect and replace compartment door gaskets once a year, or sooner if they are torn or hardened. The use of a hardened gasket produces undue stress in the parts which comprise the door enclosure and may result in breakage and injury.

4. Compartment Thermostatic Trap

Observe compartment thermostatic traps for proper operation. A good compartment trap, at start-up of a cooking cycle, is normally open and releases air and wet steam briskly for a few minutes, then holds steam within compartment If brisk venting doesn't begin immediately at start-up, or if brisk venting continues without stopping, and the compartment trap is over a year old, it should be cleaned, or a new one installed. Refer to data sheet 260-LH for details.

5. Compartment Steam Exhaust Valves and Drain Valves

Make sure that the compartment steam exhaust valves, and the drain lines attached to them, are free of food build-up internally and are venting freely to the atmosphere. If drain lines from other steam-consuming equipment. have been connected to the drain line from the steamer, the other drain lines should be disconnected. Never operate a compartment without the drain screen cover in place.

6. Refer to separate data sheets for steam generator operation, maintenance, and safety procedures.

WARNING

Service of steam cooking equipment should only be performed by a trained and experienced service technician, thoroughly familiar with servicing steam equipment. No work should be performed on the steamer while it is pressurized or hot Be sure all energy sources are shut off before the start of any work When maintenance or repairs are required, contact a local food service equipment service agency, or call the factory, or a factory representative, for the name and address of one in your area.

CLEVELAND RANGE, INC., 1333 EAST 179th ST., CLEVELAND, OHIO 44110

Manufacturer reserves right of design improvement or modification, as warranted.

PRESSURE STEAMERS: THERMOSTATIC TRAP AND

COMPARTMENT DOOR GASKET REPLACEMENT

The thermostatic trap and door gasket on your steamer stop the escape of steam from the compartment during operation Steam leakage from either source will cause loss of pressure which will result in longer cooking time, wasted steam and excessive condensation.

To keep your steamer operating at peak efficiency, thermostatic traps and compartment door gaskets require periodic replacement. Frequency of replacement varies from one piece of equipment to another depending on the amount of usage, and frequency and quality of maintenance.

A normal thermostatic trap at startup releases air and wet steam briskly for the first few minutes, then holds steam within the compartment. During cooking, the trap will also release accumulated condensate and a small amount of air. If brisk venting doesn't begin immediately at startup or if brisk venting continues for much longer than two minutes and the compartment trap is over a year old. it should be cleaned, or removed and a new one installed.

A compartment trap less than a year old may act sluggishly only because it is contaminated by grease and other film. To remove a thermostatic trap, unscrew the union nut as shown on the

sketch. To clean the trap, unscrew the threaded diaphragm cover from the body and wash the entire assembly. A more thorough cleaning can be accomplished by removing and disassembling the trap, and washing the entire assembly in a mechanical dishwasher. With proper tools, the threaded diaphragm cover can be unscrewed from the body, and the thermostatic diaphragm can be unscrewed from the

diaphragm cover. If the trap does not work properly after thorough cleaning. install a new one. If the steamer is used heavily for cooking foods contain ing large amounts of fat or starch, periodic cleaning is recommended as a routine procedure.

Replace the gaskets on compartment doors once a year, or sooner if they are torn or hardened. Door gaskets can be replaced easily without special tools or cement, and the steamer may be

used immediately afterwards. Remove the old gasket and clean the channel, being careful not to damage the channel. The new gasket can then be pressed into place. Insert the gasket in the comers of the channel first adjusting the slack evenly between the corners. Then work from the comers to the center. Ridges hold the gasket firmly. The gasket is designed to be oversize, so once it is compressed into the door's channel, it remains firmly in place.

COMPARTMENT THERMOSTATIC TRAP

COMPARTMENT DOOR GASKET REPLACEMENT

WARNING

Service of steam cooking equipment should only be performed by a trained and experienced service technician, thoroughly familiar with servicing steam equipment. No work should be performed on the steamer while it is pressurized or hot. Be sure all energy sources are shut off before the start of any work. When maintenance or repairs are required, contact a local food service equipment service agency, or call the factory, or a factory representative, for the name and address at one in your area.

CLEVELAND RANGE CO., 1333 EAST 179th ST., CLEVELAND, OHIO 44110

Manufacturer reserves right of design improvement or modification, as warranted.

LITHO IN U.S.A.

MECHANICAL COMPARTMENT CONTROLS MODEL J PRESSURE

STEAMERS-JAN. 1982 THRU PRESENT

MECHANICAL COMPARTMENT CONTROLS MODEL J PRESSURE

2 22130

Valve. Safely,

PSI 3 70411

Tee, Special 3/4"

22140

Air Vent

42276

Inlet Manifold Ass'y.

—2-

Compt.

—

Mech. "J", Less Valves

42277

Inlet Manifold Ass'y,

—3-

Compt,

—

Mech. "J", Less Valves

07173

Gauge. Pressure. Rear Mount,

0-30

PSI

7 42288

Exhaust Manifold Ass'y.

—2-

Compt, Model "J". Less Valves

42289

Exhaust Manifold Ass'y.

—3-

Compt,, Model "J

", Less Valves

8 02146

"Y"Bend

9 05263

Ell,3/4

Radiator Union

20551

Thermostatic Trap

—

Plain End

11 05252

Ell, 1/2" Street

22213

Valve,

Bullerlly, Exhaust Steam

14 41100

Drain Cover Screen

A 43765

Bus

hing Ass'y.,

40679

Linkage Ass'y., Model "J"

42697

Conversion Kit, Inlet Valve

—

"J" Mech., Includes:

1/2" Inlet Steam Valve,1/3" Street Elbow,1/2" x

Nipple,1/2" x 2 1/4"

Special Nipple,

(2)

Locknuts,

(2)

Sealing Washers

D 40710

Conversio

n Kit, Exhaust Valve, Includes:

Exhaust Steam Valve,

(2) 1"

x 3/4" Bushings,

3/4" Close Nipple, Drain

Cover Screen.

STEAMERS-JAN. 1982 THRU PRESENT

REFERENCE NUMBER

1 4065O Pull Rod Handle

12 22212

PART NUMBER DESCRIPTION

Valve, 1/2" Ball, Inlet Steam

NOTE: FOR SAFETY PURPOSES, DRAIN SCREEN COVER MUST BE IN PLACE WHEN OPERATING EQUIPMENT.

AUTOMATIC COMPARTMENT CONTROLS

MODEL J PRESSURE STEAMERS-DEC. 1977

THRU PRESENT

AUTOMATIC COMPARTMENT CONTROLS MODEL J PRESSURE

Ftng..

(2) 1/2" Close Nipples,

1/2"

2 1/4

Special Nipple,

1/2" x

STEAMERS-DEC. 1977 THRU PRESENT

REFERENCE NUMBER PART NUMBER DESCRIPTION

1 40860 Pull Rod Handle 2 22130 Valve, Safely. 8 PSI 3 70411 Tee, Special 3/4" 4 22140 Air Vent 5 42296 Inlet Manifold Ass'y.—2-Compt.—Auto "J", Less Valves

42297 Intel Manifold Ass'y.—3-Compt.—Auto "J", Less Valves 6 22115 Valve,1/2" Steam Inlet Solenoid 7 03278 Valve, Steam By-Pass 8 42288 Exhaust Manifold Ass'y.—2-Compt., Model "J", Less Valves

42289 Exhaust Manifold Ass'y.—3-Comt„ Model "J", Less Valves 9 43764 "Y" Bend—with 1/4" Tapped Hole 10 05263 Ell, 3/4" Radiator Union 11 20551 Thermostalic Trap—Plain End 12 22199 1/4" Solenoid Valve, Auto Exhaust, 115 Volt, For Use With 40518 Timer

22185 1/4" Solenoid Valve, Auto Exhaust, 115 Volt, For Use With 40540 Timer 13 07172 Gauge, Pressure, Bottom Mount, 0-30 PSI 14 40518 Timer, 60 MIn, Mechanical (Mfg. #70000) 15 19977 Switch—SPST 16 12161 Light, Signal 17 07173 Gauge, Pressure, Rear Mount, 0-30 PSI 18 41350 Buzzer 19 40540 Timer, 105 MIn. (Mfg 601) 20 22212 Valve, 1/2" Ball, Inlet Steam 21 22213 Valve, 1" Butterlly. Exhaust Steam 22 41100 Drain Cover Screen A 43765 Bushing Ass'y., B 40879 Linkage Ass'y., Model "J" C 40712 Conversion Kit, Inlet Valve—"J" Auto, Includes;

1/2 Inlet Steam Valve,1/2" Street Elbow, 3/8" Tube Ftng , 3/8 — 90° Tube

D 40710 Conversion Kit, Exhaust Valve, Includes:

NOTE: FOR SAFETY PURPOSES, DRAIN SCREEN COVER MUST BE IN PLACE WHEN OPERATING EQUIPMENT

3/8" x 12" Tube, (2) Locknuts, (2) Sealing Washers

1" Exhaust Steam Valve, (2) 1" x 3/4" Bushings, 3/4" Close Nipple, Drain Cover Screen.

MODEL J DOOR AND DOOR ARM ASSEMBLY

1 253021

Door Arm W/Bushings, Polished

2 02568

Door Ann Hinge Bushing

Required)

41370

Standard Door Arm Screw With Ball

(1" x 8

thread)

41371

Oversize Door Arm Screw W

ith Ball (1 3/32" x

thread)

081001

Screw Handle Bar, Polished

16305

Pin 6 15250

Oil Cup

41360

Striker Plate and Pin

43723

Door Hanger w/Screws and Washers

Required)

53035

Door Ann Insert. Stainless

04162

Polished Aluminum Door, Les

s Gasket

07136

Door Gasket

— Rubber

68140

Retainer, Yoke Hanger

Required)

19228

Screw

23182

Washer

122001

Door Ann Latch, Chrome Plated

163141

Door Arm Latch Pin, Chrome Plated

18306

Retainer Clip,

Required)

023001

Doo

r Ann Hinge Post Bolt (Upper)

— Concentric Type

— 19

023061

Door Ann Hinge Post Bolt (Lower)

— Eccentric Type

— 20

14643

Nut, For Lower Hinge Post Bolt

23181

Shim Washers

REFERENCE NUMBER

PART NUMBER DESCRIPTION

CLEVELAND RANGE CO., 1333 EAST 179th ST., CLEVELAND, OHIO 44110

Manufacturer reserves right of design improvement or modification, as warranted.

MODELS B, C, F, K PRESSURE STEAMERS DOOR

25304

Door Arm With Bushings

— Model F

K, Polished

02568

Door Ann Hinge Bushing

quired)

41370

Standard Door Ann Screw With Ball

(1" x 8

thread)

41371

Oversize Door Arm Screw With Ball 1 3/32" x

thread)

081001

Screw Handle Bar, Polished

16305

Pin 6 15250

Oil Cup

122011

Door Ann Latch

— Model B, C,

F Chrome Plated

122021

Door Ann Latch

— Model K Chrome Plated

101018

Door Ann Latch Pin

— Model B, C, F,

K Brass

163101

Door Ann Latch Pin

— Model B, C, F,

K Chrome Plated

081031

Door Retainer

— Model B, C, F,

K Chrome Plated

19291

Screw

041631

Doo

r, Model B Polished

04164

Door, Model C Polished

04165

Door, Model F

K Polished

07132

Door Gasket

— Rubber, Model B

07134

Door Gasket

— Rubber, Model C, F, K

023001

Door Arm Hinge Post Bolt (Upper)

— Concentric Type

— 14

023061

Door Ann

Hinge Post Bolt (Lower)

— Eccentric Type

— 15

14643

Nut, For Lower Hinge Post Bolt

16 23181

Shim Washer

17 40547

60 Minute Bell Timer Assembly

08601

Timer Housing

— Model B

C Polished (Not Available)

AND DOOR ARM ASSEMBLY

REFERENCE NUMBER

1 25303 Door Ann With Bushings — Model B & C, Polished

PART NUMBER DESCRIPTION

08606 Timer Housing — Model F Polished (Not Available)

CLEVELAND RANGE CO., 1333 EAST 179th ST., CLEVELAND, OHIO 44110

Manufacturer reserves right of design improvement or modification, as warranted

MODELS J AND K PRESSURE STEAMER

SLIDE SETS

REFERENCE NUMBER PART NUMBER DESCRIPTION

1 41440 Pan Support Slide Set, Model J Complete

41442 Pan Support Slide Set, Model K Complete

2 41430 Right or Left Side Slide Rack. 2 Per Compt Req'd. Model J

41432 Right or Left Side Slide Rack, 2 Per Compt Req'd, Model K

3 41435 Center Slide Rack Model J, 1 Req'd Per Compt

41437 Center Slide Rack Model K, 1 Req'd Per Compt

4 19909 Replacement Top Studs (Screw-In) J or K (Set of 6)

CLEVELAND RANGE, INC., 1333 EAST 179th ST., CLEVELAND, OHIO 44110

Manufacturer reserves right of design improvement or modification, as warranted.

START-UP MAINTENANCE PROCEDURES — STEAM GENERATOR

IMPORTANT: These instructions must be

followed in order to prevent premature failure of

the steam generator.

START -UP:

1) Open the cabinet base door and close the drain valve if it is open. (Red handle lever marked "blowdown".)

2) Rip the toggle switch on front of the cabinet console to "ON" (up position). The red console light should then glow and water will automatically begin filling the generator.

3) When the water level in the sight gauge glass (on the generator) reaches approximately 2/3 full (after approximately five minutes), depress the "ON" reset button or the console. This will energize the electric heater elements or ignite the gas burner, If the sight gauge glass shows no stabilized water level, i.e.. the gauge glass is completely empty or completely filled, have the generator serviced.

4) In approximately ten minutes you will notice the steam pressure gauge, on the console, register the steam pressure contained inside the generator.

5) Cooking may now begin. Refer to "Cooking" and "Operating Procedure" data sheets for specific instruc tions.

MAINTENANCE:

1) At the end of each day's operation, while the generator is pressurized, flip the console toggle switch to the "Blowdown " position, open the door in the cabinet base and open the generator's drain valve, (red handle). This "Blowdown" procedure drains the water out of the generator and helps to prevent lime scale formation. When the generator is empty, flip the console toggle switch to the "OFF" position and dose the generator's drain valve. It is recommended that the generator be refilled with water after the "Blowdown" is performed. This can be accomplished by flipping the toggle switch to the "ON" position for a period of five minutes and then returning the switch to the "OFF" position.

CAUTION: Service on the generator should only be performed by a trained and experienced service technician, thoroughly familiar with servicing steam generators. No work should be done on the steam generator while it is pressurized or hot. Be sure all energy sources are shut oft before the start of any work.

2) Even though the "Blowdown" is performed faithfully each day, it will still be necessary to periodically inspect the inside of the generator. The generators hand hole plate should be removed at regular intervals, so that it and the inside can be inspected. The hand hole plate should be cleaned and examined each time it is removed. If the hand hole plate is chipped or cracked, or over three years old. install a new one. Replace the corrosion resistor(s) if necessary, and chemically de scale the generator if it is coated with lime scale. A new hand hole gasket should always be installed.

3) It will be necessary to periodically have scale accumulations removed from the inside of the steam generator. by a qualified service technician. Generator descaling instructions are provided on a separate data sheet Failure to periodically remove scale from the inside of the generator will result in greatly reduced generator life.

4) Every steam generator is equipped with at least one corrosion resistor to reduce generator shell corrosion and scaling. This corrosion resistor is sacrificial and must be replaced at regular intervals just before it is entirely consumed. In areas where the water is very hard. the feedwater must also be treated to remove the harmful mineral content Refer to separate data sheets for corrosion resistor servicing instructions, feed water treatment information. and hand hole plate servicing instructions.

5) Check the safety valve once a week while steam generator is pressurized. Test by pulling safety valve extension wire. Valve must open freely and snap closed when released. If it does not or if it drips constantly, a new safety valve is needed.

6) If the steam generator is to be left idle for three months or more, it should be drained and dried out and the hand hole plate left on.

7) Water level in the sight gauge normally should be about 2/3 full. This level is maintained automatically. Refer to separate data sheet or either mechanical or water fill servicing instructions.

8) If gas fired. the lighting instructions are on the AGA rating plate. Pilot burner is lit through hole in panel at bottom of steam generator. This panel should never be left off as this will damage the controls. Burners will not light without water in the steam generator.

CLEVELAND RANGE CO., 1333 EAST 179th ST., CLEVELAND, OHIO 44110

Manufacuter reserves right of design improvement or modification, as warranted.

WATER QUALITY REQUIREMENTS — STEAM

GENERATOR PROTECTION AND MAINTENANCE

A steam generator, or broiler, unlike other types of water-using kitchen equipment, distills the water in order to make steam. Nearly all feed-water sources contain dissolved minerals in varying degrees of concentration. As this water is boiled, pure steam rises from it's surface, upward to the cooking compartment(s), leaving minerals behind that can become harmful to the steam generator. If minerals are allowed to accumulate inside t he steam generator, they will solidify as a scale. Then, malfunctioning will occur, and serious equipment damage may result.

The use of good quality generator feed water is the responsibility

of the owner/user. The use of poor quality feed water could void equipment warranties. The minimum treatment required in most areas is water softening,although local water conditions may require more intensive pretreatment than simply a water softener.

Scale problems occur when feed water is high in hardness,total

dissolved solids,silica,and alkalinity. Watersoftening will only reduce the water's hardness, which is the presence of dissolved salts of magnesium and calcium. Water softening will not affect the multitude of other minerals found in most water supplies. Because generator scale is the result of of the precipitation of many minerals. the best property to control, for the generator feed water, is total dissolved solids, not just hardness.

The recommended minimum water quality standards, wheter untreated or pre-treated, based upon 10 hours of use per day, and a Daily Blowdown, are as follows:

TOTAL DISSOLVED SOLIDS — less than 60 parts per million TOTAL ALKALINITY less than 27 parts per million SILICA less than 13 parts per million

pH FACTOR greater than 7.5

Consult a local water treatment specialist for an on-the-premises water analysis and tor recommendations concerning steam generator feed water treatment (If required). in order to remove or reduce harmful concentrations of minerals.

If the recommended water quality requirements are met without supplemental treatment, or if treatment is applied, resulting in teed water quality meeting the prescribed standards, the steam Generator will need to be blown down only once each day. In addition, the inside of the generator requires an inspection (for excessive lime accumulation and consumed corrosion resistors) only once every six months. Replace the corrosion resistors s) ana chemically descale the generator as required.

If a pre-treatment unit cannot be installed and the recommended water quality requirements are not met. the following procedures should be followed, in order to achieve maximum steam generator service life. The steam generator should be blown down after each 6 hours of use. Have the steam generator inspected, inside ana outside, by a qualified technician every 3 months. If the corrosion resistor(s) is totally, or nearly consumed. replace it. If the inside of the generator is heavily coated with scale, have if chemically descaled by a qualified service technician

INSTRUCTIONS FOR CHEMICALLY DESCALING STEAM GENERATORS.

WARNING: Steam under pressure may cause serious injury and bodily harm when it is accidently or carelessly released. Improper handeling of acid could cause serious, permanent injury. Therefore, service of the steam generator should only be performed by trained and experienced personnel, thoroughly familiar with servicing generators.

There are a number of commercial descaling chemicals available. produced by various manufacturers. Those utilizing a sulfamic acid base. which can be identified py its powdered form, are safe and compatible with our food preparation equipment, It is imperative that the acid used for descaling be FDA approved, for use in food preparation equipment. Various manufacturers may include additional chemicals to increase potency and therfore, Instructions for a specific brand should be followed— carefully. If instructions are not provided with the deliming chemical you purchase. the following general guidelines— may be followed.

WARNING: Exercise care when handeling acid. Avoid contact with skin, eyes, or clothing. Wear safety glasses or face shield, along with rubber gloves and rubber apron In case of exposure to clothing, remove clothing and flush with water. In case of exposure to skin or eyes, flush with water tor 15 minutes end get immediate medical attention. Don not take internally. Keep out of reach of children.

Be sure the generator has been drained, depres-surized, and is cool. Open the hand hole access plate on me front of the generator place approximately 8-10 pounds of sulfamic acid inside the generator. Put a new hand note gasket on the hand hole plate, and replace the hand hole plate, tightening the bar and nut assembly to a maximum of 15 foot pounds torque. The generator must be completely filled with hot water (fill the generator beyond its normal, automatic fill point of 2/3 up in (he sight gauge). On mechanical fill generators. this can be accomplished by adding weight to the float. or removing the float, and regulating the fill level with a hand valve in the water supply plumbing. On electric fill generators (with probes), this can be accomplished by temporarily jumpering terminals #3 & #4 of the water control relay. Turn the main on-off toggle switch to the "ON" position, then turn the switch to the "OFF" position when the generator is completely filled. Let the solution stand for several hours, then flush with water Rinse with a solution of bicarbonate of soda to neutralize any acid residue, and again, flush with water.

CAUTION: Never tighten the hand hole plate nut when the steam generator is in use, hot or otherwise pressurized. Never tighten nut over 15 pounds torque. Overtightening may cause uneven stress, which may result in the weakening and possible breakage of the plate.

CLEVELAND RANGE CO., -1333 EAST 179th ST.. CLEVELAND, OHIO 44110

Manuafcturer reserves right of design improvement or modification as warranted.

MAINTENANCE INSTRUCTIONS FOR

Distribution of hard water in the

0-60 parts per

million

WARNING: Steam under pressure may cause

serious Injury and bodily harm when It is acciden tally or carelessly released. Therefore, service of the steam generator should only be performed by trained and experienced personnel, thoroughly familiar with servicing steam generators.

CAUTION: Never work on the steam generator when

It is hot or pressurized.

Every steam generator shipped is equipped with at least one corrosion resistor (cathodic). The larger capacity steam generators will have two corrosion resistors

The hand hole plate and gasket on your steam genera tor stops the escape of steam through the hand hole opening during operation.

1) Turn of all energy sources to steam generator. Drain steam generator

2) Remove hand hole cover plate from steam generator.

3) Hang corrosion resistor from the right side of the front stay rod. away from the probes. Clean scale and rust off a portion of the stay rod. so the hanger will rest on the bright, bare metal

4) Re-install the hand hole plate, along with a new gasket.

The hand hole plate should be cleaned and examined every time it is removed. If the hand hole plate is chipped or cracked, or over three years old. install a new one. Because continuous use and possible abuse cause metal fatigue which weakens the hand hole plate. a new one should be installed at least every three years.

CAUTION: Never tighten the hand hole plate nut when steam generator is in use, hot, or otherwise pressurized. Never tighten nut over 15 footpounds torque. Overtightening may cause uneven stress, which may result In the weakening and possible

breakage of the plate.

U.S. is shown on map. right. Areas shown in black have hardest water, while relatively soft water is found in white areas. Shaded areas require supplemental teed water treatment to remove or to reduce the hardness.

This map is a general representation and exceptions do exist. Consult a local water treatment

specialist for a water sample test.

60-120 parts per million 120-180 parts per million above 180 parts per million

Manufacturer reserves right of design improvement or modification as warrantee

STEAM GENERATORS

(EXCEPT THOSE EQUIPPED WITH TWO PROBES)

Replace the gasket whenever the hand hole plate is removed or replaced. Keep a spare gasket on hand at all times.

Replace the gasket at least once a year. or sooner if it is cracked, torn or hardened.

Leakage of water past the hand hole plate should not be allowed to continue, as this will cause pitting of the metal in contact with the gasket.

5) After re-installing the hand hole plate, close the steam generator drain valve. Turn on energy sources.

6) Start up and operate steam generator long enough to observe that it is operating properly.

The corrosion resistor is sacrificial and must be replaced at regular intervals just before it is entirely consumed. Frequency of replacement can only be established by a regular inspection for how much of the protector remains and whether scaling or pitting has begun. Scaling indicates a very hard water condition Pitting indicates an excess acid condition. In either case. more protectors or more frequent replacement of them is necessary. The best way to reduce servicing time and to assure long generator life is to provide feed water that is low in solids content and low in gas content. Water that is fit to drink can still be high in impurities that are highly detrimental to a steam generator Consult a water treatment specialist in your area for recommendations concerning steam generator feed water treatment.

Under average conditions, the corrosion resistor provides about six months of service. An average condition would meet each of the following tests:

1) Less than 8 hours of steam generation a day.

2) One generator blowdown every day.

3) Moderately hard water. Less than 85 ppm.

4) Water containing less than 60 ppm Total Dissolved Solids.

CLEVELAND RANGE CO., 1333 EAST 179th ST., CLEVELAND, OHIO 44110

STEAM GENERATOR (BOILER) IDENTIFICATION

SERVICE NOTE

The above drawings showing the sight gauge location and method of mounting are tor assisting in determining the proper part number tor replacement generators. When ordering, please provide both the proper part number and the equipment's serial number.

STEAM GENERATOR (2 PROBE TYPE) MAINTENANCE PROCEDURES

CAUTION: Service on the generator must be performed only by a trained and experienced service technician, thoroughly familiar with servicing steam generators. No work should be done on the steam generator while it is pressurized or hot. Be sure all energy sources are shut off before the start of any work.

The steam generator must be drained under pressure (blowdown) after a maximum of 8 hours of use. If the generator's feedwater contains more than 300 parts per million of total dissolved solids, the generator must have a blowdown after each 4-6 hours of use. "Blowdown" means the generator must be drained under pressure.

THE GENERATOR "BLOWDOWN" IS PERFORMED BY SHUTTING OFF THE UNITS RED-LIGHTED "POWER" SWITCH WHILE THE GENERATOR IS AT NORMAL OPERATING PRESSURE- WHEN THE BOTTOM OF THE "POWER" ROCKER SWITCH IS PUSHED, ITS RED LIGHT GOES OUT. AND THE DRAIN VALVE AUTOMATICALLY OPENS. DRAINING THE GENERATOR- AN AUTOMATICALLY-TIMED SOLENOID VALVE WILL FLUSH THE DRAIN FOR 3 MINUTES. THEN SHUT OFF. AFTER 3 MINUTES, THE UNIT CAN BE RESTARTED.

Even though the "Blowdown" is performed faithfully each day. it will still be necessary to have a qualified service technician periodically inspect the inside of the generator for scaling or pitting. The generator's hand hole plate should be removed at regular intervals, so that it and the inside of the generator can be inspected The hand hole plate should be cleaned and examined each time it is removed. If the hand hole plate is chipped or cracked, or over three years old, install a new one. A new hand hole gasket should always be installed.

Scaling indicates a high concentration of dissolved minerals in the feed water. Pitting indicates an excess acid condition. The best way to reduce servicing time and to assure a long generator life is to provide feed water that is low in mineral content arid low in gas content Water that is fit to drink can still be high in impurities that are highly detrimental to a steam generator. Consult the state department of water for an on the premises water analysis and for recommendations concerning steam generator feed water treatment (if required), in order to remove or reduce harmful concentrations of minerals.

CAUTION: Never tighten the hand hole plate nut when the steam generator is in use, hot, or otherwise pressurized. Never tighten nut over 15 foot-pounds torque. Overtightening may cause uneven stress, which may result in the weakening and possible breakage of the plate.

The "Blowdown" procedure will not completely remove the mineral deposits that adhere to the top of the generator.

It will be necessary to periodically have scale accumulations removed from the inside of the steam generator by a qualified service technician. Only a U.S.D.A. approved acid cleaner should be used to descale the generator.

Descaling should be done once a year, but in poor water (highly mineralized) areas it may be needed two or three times a year.

Failure to periodically remove scale from the inside of the generator will result in greatly reduced generator life.

Check the safety valve once a month while the steam generator is pressurized- Test by pulling the safety valve lever. The valve must open freely and snap closed when released- If it does not, or if it drips constantly, a new safety valve is needed.

If the steam generator is to be left idle for three months or more. it should be drained and dried out and the hand hole plate left off.

CLEVELAND RANGE, INC. 1333 EAST 179th ST., CLEVELAND, OHIO 44110

0485 LITHO IN U.S.A. Manufacturer reserves right of design improvement or modification, as warranted.

WATER QUALITY REQUIREMENTS — 2-PROBE

TYPE STEAM GENERATOR PROTECTION

AND MAINTENANCE

A steam generator, or boiler, unlike other types of water-using kitchen equipment, distills the water in order to make steam. Nearly all feed-water sources contain dissolved minerals in varying degrees of concentration. As this water is boiled, pure steam rises from its surface, upward to the cooking compartments), leaving minerals behind, that can become harmful to the steam generator. If minerals are allowed to accumulate inside the steam generator, they will solidify as a scale. Then, malfunctioning will occur, and serious equipment damage may result.

The use of good quality generator feed water is the responsibility of the owner/user. The use of poor quality feed wat er could void equipment warranties. The minimum treatment required in most areas is water softening, although local water conditions may require more in tensive pretreatment than simply a water softener.

Scale problems occur when feed water is high in hardness, total dissolved solids, silica and alkalinity. Water softening will only reduce the water's hardness, which is the presence of dissolved salts of magnesium and calcium. Water softening will not affect the multitude of other minerals found in most water supplies. Because generator scale is the result of the precipitation of many minerals, the best property to control, for generator feed water, is total dissolved solids, not just hardness.

The recommended minimum water quality standards. whether untreated or pre-treated, based upon 8 hours of use per day. and a Daily Blowdown , are as follows:

TOTAL DISSOLVED SOLIDS less than 60 parts per million TOTAL ALKALINITY less than 27 parts per million

SILICA less than 13 parts per million pH FACTOR greater man 7.5

Consult the state department of water or a local water treatment specialist for an on-the-premises water analy sis and for recommendations concerning steam generator teed water treatment (if required), in order to remove or reduce harmful concentrations of minerals.

If the recommended water quality requirements are met without supplemental treatment or if treatment is applied. resulting in feed water quality meeting the prescribed standards, the steam generator will need to be blown down only once every 8 hours. In addition, the inside of the generator requires an inspection (for excessive lime accumulation) only once every six months. Chemically descale the generator as required.

If a pre-treatment unit cannot be installed, and the recommended water quality requirements are not met the following procedures should be followed, in order to achieve maximum steam generator service life. The steam generator should be blown down after each 4-6 hours of use, have the steam generator inspected, inside and outside, by a qualified technician every three months. If the inside of the generator is heavily coated with scale, have it chemically descaled by a qualified service technician.

INSTRUCTIONS FOR CHEMICALLY DESCALING

2-PROBE TYPE STEAM GENERATORS

WARNING: Steam under pressure may cause serious injury and bodily harm when it is accidentally or carelessly released. Improper handling of acid could cause serious, permanent injury. Therefore, service of the steam generator should only be performed by trained and experienced personnel, thoroughly familiar with servicing generators.

There are a number of commercial descaling chemicals available, produced by various manufacturers. Those utilizing a sulfamic acid base, which can be identified by its powdered form. are safe and compatible with our food preparation equipment It is imperative that the acid used for descaling be FDA approved, for use in food preparation equipment Various manufacturers may include additional chemicals to increase potency, and therefore. instructions for a specific brand should be followed carefully. If instructions are not provided with the deliming chemical you purchase, the following general guidelines may be followed.

WARNING: Exercise care when handling acid. Avoid contact with skin, eyes, or clothing. Wear safety glasses or face shield, along with rubber gloves and rubber apron. In case of exposure to clothing, remove clothing and flush with water. In case of exposure to skin or eyes, flush with water for 15 minutes and get immediate medical attention. Do not take internally. Keep out of the reach of children.

Be sure the generator has been drained, de -pressurized. and is cool. Open the hand hole access plate on the front of the generator and place approximately 8-10 pounds of sulfamic acid inside the generator. Put a new hand hole gasket on the hand hole plate, and replace the hand hole plate, tightening the bar and nut assembly to a maximum of 15 foot pounds torque. The generator must be com- pletely filled with water (fill t he generator beyond its normal, automatic fill point of 2/3 up in the sight gauge). This can be accomplished by temporarily disconnecting the wire from the water level probe at the water level control board. The board is marked "HI" at this connection point Turn the main on-off rocker switch to the "ON" position, then close the manual water feed valve when the generator is completely filled. Leave the on-off rocker switch in the "on" position to prevent the generator from automatically draining. Reconnect the probe wire to the "HI" terminal of the water level control board. Let the solution stand for several hours, then flush with water. Rinse with a solution of bicarbonate of soda to neutralize any acid residue, and again, flush with water. Be sure to reconnect the wire to the water level control board and to open the manual water teed valve.

CAUTION: Never tighten the hand hole plate nut when the steam generator is in use, hot, or otherwise pressurized. Never tighten nut over 15 toot-pounds torque. Overtightening may cause uneven stress, which may result in the weakening and possible breakage of the plate.

Descaling Procedure for Two-Probe Steam Generators

The steam generator should be descaled at least once a month, depending on scale buildup. If you have serious steam generator scale buildup, install a water treatment system for the steamer. Cleveland Range recommends use of the descaling kit, part number 40891, which consists of powdered sulfamic acid. Full descaling may take several hours, or more than one add process. Perform des caling until all scale buildup is cleaned out.

(50-50). Mis and add water if necessary to form slurry. Scoop up slurry and wash residue down drain with excess water. Wash site with soda ash solution.

WARNING

The powdered sulfamic acid in descaling kit 40891 can be harmful if not handled properly. Follow these basic safety rules for handling and using add.

Follow hazard and leak cleanup procedures on add container label. If the label is not readable or has been removed, refer to the following hazard and emergency instructions as a minimum safety precaution.

THESE INSTRUCTIONS ARE FOR USE WITH

POWDERED SULFAMIC ACID ONLY.

• Health Hazard Data, Effects of Overexposore - Product is extremely irritating to the eyes and may result in eye burns. Product is severely irritating to skin and can result in skin burns; repeated or prolonged contact with more dilute solutions may result in dermatitis. Aerosol mist or vapors are irritating to respiratory tract, eyes and throat. Prolonged exposure to high concentration may result in pulmonary edema If ingested, may result in abdominal hemorrhage with severe abdominal pain, nausea, vomiting or loss of consciousness; necrosis of stomach and gastrointestinal tract may also occur.

• Emergency and First Aid Procedures - In case of eye contact, immediately flush eyes with plenty of water for at least 15 minutes. Seek medical aid. In case of skin contact immediately wash with soap and plenty of water for at least 15 minutes while removing contaminated clothing. Seek medical aid. If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give oxygen. Seek medical aid. If swallowed, do not induce vomiting. Give large quantities of water- Seek medical aid. Never give anything by mouth to an unconscious person.

•Spill or Leak Procedures - Contain spill Cover the

contaminated surface with sodium bicarbonate or a soda ash-slaked lime mixture

Wear protective clothing when mixing or applying chemical cleaners . Wear rubber gloves, mask and approved cup-type goggles.

Avoid breathing fumes. If add comes in contact with skin, flush immediately with large quantities of cold water. Remove contaminated clothing.

If chemical contacts eyes, flush with cold water for a minimum of 15 minutes. Get immediate medical attention.

If chemical is swallowed or ingested, follow instructions on the chemical container. Get immediate medical attention.

CAUTION

Do not scrape heating elements with a solid tool.

If the steamer is turned off, energize the steamer by pressing the POWER switch to on. Allow time for the steam generator to fill (3 to 4 minutes). This assures that blowdown occurs.

1. Press the POWER switch to off.

2. Press the TIMED/MANUAL switch to TIMED. Set timer to 0.

3. After completion of blowdown (3 minutes), turn off power at the main disconnect switch.

4. Allow time for the steam generator and compart ment to cool down.

Descaling Procedure (continued)

5. Turn off power at main disconnect switch.

6. Remove handhole plate.

7. Pour powdered sulfamic add into the steam gen- erator.

8. Replace handhole plate.

9. Turn water off at manual 1/4-inch ball valve on base.

10. Remove control box cover.

11. Disconnect black probe wire from water board.

12. Turn power on at the main disconnect switch.

13. Turn POWER switch on base unit to on.

14. Turn water on at manual 1/4-inch ball valve.

15. Let steam generator fill to proper level (2/3 the way up the sight glass), then turn off the manual fill valve to stop generator fill

16. Start steam generator heat cycle. Let generator heat up until it is hot to the touch.

17. When the steam generator is hot turn off the gas package valve.

18. Turn on the generator fill. manual valve and, while holding open the safety valve (pop off valve), let the generator keep filling until water comes out the safety valve.

19. Turn off the manual ball valve to the fill assembly

20. Let steam generator descale overnight or for any eight (8) hour period.

After eight hour period:

21. Drain the generator with the manual 3/4-inch ball valve.

22. Turn off electric power at the main disconnect switch.

23. Remove handhole plate.

24. Pour in neutralizer (3 or 4 tablespoons of baking soda).

25. Install handhole plate and tighten the bar and nut assembly to a maximum of 15 foot pounds torque.

26- Close the 3/4-inch manual drain valve.

27. Open 1/4-inch manual ball valve to fill assembly. 28- Turn electrical power on at main disconnect switch.

29. Turn POWER switch on base unit to on. 30- Let unit fill until water comes out the safety valve.

31. Close 1/4-inch manual ball valve on fill assembly.

32. Let unit set for 5 minutes.

33. Open the 3/4-inch drain valve to blow down and drain the steamer.

34. Turn POWER switch on base unit to off.

35. Turn power off at the main disconnect switch

36. Reconnect black probe wire to water board.

37. Replace control box cover.

38. Turn on manual ball valve to fill assembly.

39. Close 3/4-inch drain ball valve.

40.Turn power on at the main disconnect switch.

41. Turn POWER switch on base unit to on.

42. An amber light on the STEAM switch will light when the water reaches the low cut -off probe.

43. Turn. on the STEAM switch to start the steam generator for a test.

44. When pressure reaches 9 psi on the pressure gage located on the steam generator console, open the manual drain valve to blow down the generator under pressure and test the low water cut -off.

45. Close the manual drain valve.

46. Refill generator and when amber light comes on, turn on the steam switch to start the steam generator for a test.

47. When the unit reaches 9 psi, turn off POWER switch on console to test blowdown.

48. After blowdown has completed, refill generator and restart heat cycle.

49. Unit is now ready for use.

SERVICING INSTRUCTIONS STEAM PRESSURE ADJUSTMENTS

WARNING: Adjustments must be made only by trained and experienced service personnel.

Normally there is no need to make pressure adjustments on a new steamer, because the proper settings are made at the factory. In some cases however, the factory setting may shift due to shaking in transit, and resetting will be required after installation. The factory pressure settings shown on the accompanying chart should never be exceeded.

For Gas and Electric Steam Generator

Steam pressure is controlled with two pressure switches, located toward the upper-front of the cabinet, either to the extreme left or extreme right

The left switch is the operating pressure switch. This switch controls the pressure in the steam generator, which is the pressure indicated on the steam generator pressure gauge. The right switch is a high-limit, pressure safety control. It

breaks an electric circuit to shut off the energy source if the steam pressure rises above a safe level. Each switch has a screw on top of the case, to permit the pressure set point to be adjusted without removing the cover. The correct settings are shown in the accompanying chart The pressure switch indicator scale is for reference only. Actual pressure should be read on the pressure gauge, and the pressure switch adjusted to produce the proper pressure gauge reading.

Some models may also have a pressure reducing valve to control the pressure in the steam line to the steamer. The adjustment of this is discussed further on.

For Steam Coil Steam Generator

The steam supply to steam coil generators is controlled by one of two methods. Steam generator pressure may be controlled by a pilot operated pressure regulating valve. The steam generator pressure can be adjusted by turning the adjusting collar, identified on the sketch. A steel rod is provided to turn the collar. The correct settings are shown in the accompanying chart.

On steam coil generators equipped with an electric solenoid valve to control the steam supply to the steam generator, one or two pressure switches control the steam generator pressure. To adjust the switch(es), turn the screw on the top of the case to achieve the pressure reading shown in the accompanying chart.

Pressure Reducing Valve — Adjustment and Care A screw at the top of the valve body, as shown on the sketch, permits the pressure set point to

be adjusted. The locknut must be loosened before adjustment is made, and tightened after. Turning adjustment screw into housing raises pressure. If excessively high or tow pressure can't be corrected by adjustment, install a new valve.

To eliminate erratic performance, the internal steam strainer should be cleaned periodically The strainer can be reached by unscrewing the large hex head plug at the bottom of the valve body.

(CONTINUED ON THE REVERSE SIDE)

GAUGE PRESSURE READING WITH HO STEAM FLOW (STATIC PRESSURE)

Self-Contained Steam Generator Direct-Connect

Gas or Electric

Self-Contained

Steam Coil Generator

(To "House" Steam Supply)

Equipment

Steam Generator Only

5 PSI

Pressure Steamer N/A 5 psi 10 psi N/A 5 psi 5 psi N/A

Pressure Steamer

With Any Kettle(s))

Steam Generator Only

10 PSI

Kettle Only—All N/A 10 psi 15 psi N/A N/A N/A 20psi

Convection Steamer. Super Steamcraft. or "D" Series Defroster With or Without Kettles

Steamer's

Pressure

Reducing

Valve

N/A 5 psi 10 psi N/A 5 psi N/A N/A

5 psi 10 psi 15 psi 5 psi 10 psi 5 psi 20 psi

N/A 10 psi 15 psi N/A 10psi N/A N/A

N/A 10 psi 15 psi N/A 10 psi 10 psi 20 psi

Operating

Pressure

Switch

High Limit

Safety

Pressure

Switch

Steamer's

Pressure

Reducing

Valve

Pressure

Regulating

Valve or

Pressure

Switch

Steamer's

Pressure

Reducing

Valve

Kettle's

Pressure

Reducing

Valve

PROBE SYSTEM: ELECTRIC WATER FILL AND

SERVICING

INSTRUCTIONS

ELECTRIC LOW WATER FUEL CUT OFF FOR STEAM GENERATOR — 3 PROBE TYPE

WARNING: Service of the steam generator must be performed only

During operation of the steam generator, the water level is maintained automatically by unequal length probe extensions inside The probes and extensions must be Kept clean ana free of scale deposits in order to function properly

The probe extensions are sensors in a control system which monitors and maintains the water level between the end of the short probe extension and the end of the intermediate extension.

by trained and experienced service technicians.

The long probe, called "Low Water." is a safety sensor which shuts off the fuel supply if there is insufficient water in the steam generator.

Since the control system is all electric and these parts don't move or wear. they can be expected to have a long life. If they do malfunction, it is generally because untreated hard feedwater is being used in the steam generator. This forms scale on the submerged ends of the probe extensions and on the top horizontal surfaces of the probes. After this scale is removed, the parts will function properly.

To eliminate the cause of scaling, refer to separate data sheets for feedwater treatment information and corrosion protector servicing instructions. Probes and probe extensions should be wiped clean each time the corrosion protector is replaced.

Erratic operation may result from loose connections on either end of the probe. The external end of the probe has a nut to hold the wiring terminal snugly to the probe. This nut, if loose, may be tightened, firmly but gently. Too much torque will turn the center piece of the probe and misalign the attached probe extension inside, causing the probe to become inoperative.

Inside the steam generator, the screw which holds the probe extension to the probe may be loose, allowing the probe extension to swing or rest against some part of the steam generator. This can be corrected by removing the hand hole plate and reaching inside to align and hold the probe extensions vertically while tightening the screws.

To Service the Probes or the Probe Extensions

1) Turn off all utilities and fuel to steam generator. Drain Steam generator.

CAUTI ON: Never work on the steam generator when it is hot or pressurized.

2) Remove probe cover on outside of steam generator to expose probe terminals. Examine for loose wiring terminals.

3) Remove hand hole cover plate from steam generator. See separate data sheet for instructions.

4) Remove probe extensions from probes on inside of steam generator, clean off scale, and re-install. Or, install new probe extensions if preferred.

5) Remove scale from the probe (see sketch above). Do not use an abrasive on the teflon insulator. If the old probe needs replacement, install a new one.

(CONTINUED ON THE REVERSE SIDE)

SERVICING PROBE SYSTEM: ELECTRIC WATER FILL AND INSTRUCTIONS ELECTRIC LOW WATER FUEL CUT OFF FOR STEAM GENERATOR-- 3 PROBE TYPE

6) Assemble probe extensions to probes on inside of steam generator so they hang vertically, parallel to each other- Malfunctioning will occur if an extension touches any part of the steam generator or another probe extension

7) If insulation on electrical wires to the probe snows signs of being broken, cut or deteriorated, the wires should be replaced.

8) Connect wire terminals on outside of steam generator to probe terminals as follows:

Red wire to the shortest probe. Turns water off Black wire to the intermediate probe: Turns water on. White wire to the longest probe- Shuts off fuel (low water safety fuel shut-off).

9) Re-install hand hole plate and install a new gasket.

The hand hole plate should be cleaned and examined each time it is removed. If the plate is chipped or cracked, it should be replaced immediately. Because continuous use and possible abuse can cause metal fatigue which weakens the hand hole plate, a new one should be installed at least every three years. Replace the gasket at least once a year —or sooner if it is cracked or hardened.

10) Replace probe cover and check to make sure that the cover does not contact probes.

11) Close steam generator drain valve. Turn on utilities and fuel supply to steam generator.

12) Operate and observe steam generator long enough to insure that it is functioning properly

Low Water Fuel Cut Off Test Proper operation of the "Low Water" probe extension should be checked periodically, by someone who is thoroughly familiar with the equipment.

To Test: Open the drain of the steam generator while fuel is on. When the water has drained below the "Low Water" probe, the fuel should shut off automatically. Indication of fuel shut off should occur just as the water level in the sight gauge drops from view. If it does, close the drain, allow the steam generator to refill, and resume normal operations, if the fuel does not shut off. immediately turn the on-off toggle switch to the "off" position, and follow the steps outlined under "To Service the Probes or the Probe Extensions" as given on the reverse side of this sheet. For specific information pertaining to the operation of the electric water fill controls, and electric low water safety fuel cut-off, refer to the following data sheets:

Electric Steam Generators Gas-Fired Steam Generators Steam Coil (electric operated) Generators

STANDING PILOT-IGNITION TYPE GAS CONTROLS FOR GAS-FIRED STEAM GENERATORS

CAUTION: The following procedures, as well as other work on the gas controls, should be performed only by a trained and experienced service technician, thoroughly familiar with gas controls.

Built in gas controls assure sate and automatic operation of the pilot and main burners of the steam Generator The controls consist of a pilot generator (thermocouple; and a unit called the combination gas control. This latter unit consists of a gas

valve operator and servo gas pressure regulator. Generally, there is no need to make an adjustment to any portion of the gas system. The main burner orifices and the pilot burner orifice installed at the factory are correct for the kind of gas specified on the purchase order. Also. the primary air supply to the main

burner is properly adjusted for complete combustion.

Lighting and Shutdown Instructions

Flip electrical switch on. Open water valve. Open gas valve. Slightly depress and turn control knob to "off" for 5 minutes before lighting gas. Turn-control knob to "pilot," depress it completely and light pilot burner. Continue to hold knob in for about 60 seconds, then release. Pilot burner is lighted through hole in panel at bottom of steam generator Never leave panel off, as this will damage controls. Turn control knob to "on". Depress electrical switch for main burner ignition. Burners will not light without water in the steam generator. For main burner off. with pilot on, turn control knob to "pilot". For main and pilot burner off, slightly depress and turn control knob to "off". Flip electrical switch off.

Occasionally, due to regional differences in the gas supply, the pilot burner flame may require

adjustment. A normal flame is mostly blue and steady, and

envelops 3/8" to 1/2 of the tip of the pilot generator, as illustrated at right.

The pilot gas adjusting screw can be found under a cover screw located near the gas control knob, illustrated below.

To adjust the pilot flame:

1) Remove the pilot adjustment cover screw.

2) Turn PILOT FLOW ADJUSTMENT SCREW clockwise to decrease or counterclockwise increase pilot flame.

3) WARNING: Be sure to replace cover screw after adjustment to prevent possible gas leakage.

Electrical connections in the pilot generator circuit must be clean and secure. Because the pilot generator operates in a severe environment, it may eventually need a replacement The time before replacement will vary from one piece of equipment to another, depending on the amount of usage. The pilot generator (thermocouple) should generate 450-750 MV in an open circuit condition. When a malfunction is traceable to the combination gas control unit. it is recommended that the entire unit be replaced with a new one, rather than attempting repairs to the old unit.

WARNING: To prevent the danger of possible gas leakage, the installer must be a trained and experienced service technician, thoroughly familiar with gas controls.

HOW THE ELECTRIC (WARRICK RELAY) WATER LEVEL CONTROLS OPERATE — ON GAS FIRED STEAM GENERATORS (WITH 3 PROBES)

Inside Cleveland Range Co. boilers which have electric water level controls, there are three probe extensions vertically oriented above the water with their lower ends positioned at various levels.

Water is admitted to the boiler and is shut off in response to the water level sensed by the tips of the short and the medium length probe extensions. The electncal conductance of the water is used in this system for controlling its level.

The third probe extension is a low water safety cutout sensor and operates on the same principle.

Operation Sequence — Water Level Control Assume an empty boiler. To fill. dose Switch S for the

following operations:

1) Solenoid SV² is energized allowing the boiler to fill with water at the same time the primary circuit of Transformer T²is also energized.

2) The boiler will continue to fill until the water level reaches the Water Off probe extension completing the T² secondary circuit and energizing Relay Coil RC².

3) When Relay Coil RC² is energized the normally closed contact opens, de-energizing Solenoid SV²

stopping the water fill. The normally open contact is closed, completing the circuit to the Water On probe.

When the water boils away below the end of the Water On probe extension the following occurs:

1) The secondary circuit of Transformer T² is broken and the Relay Coil RC² is de energized.

2) When Relay Coil RC² is de-energized the normally open contact opens, breaking the circuit to the Water Off probe extension. And. the normally closed contact closes, energizing Solenoid SV² allowing the boiler to fill as in Step 2 above.

Operation — Low Water Safety Cutout When Switch S is dosed the following operations

Occur:

1) The primary circuit of Transformer T² is energized.

2) When the water level reaches the low water safety cutout probe extension and the momentary reset switch is manually dosed. Relay Coil RC² is energized.

3) When Relay Coil RC², is energized the normally open contacts close, completing the low water safety circuit through Contacts 7 and 8 and completing the circuit through Contacts 3 and 4. completing the 750 millivolt pilot generator circuit and allowing the gas control package valve to operate.

if the water level drops below the Low Water Safety Cutout probe extension, the following occurs:

1) The secondary circuit of Transformer T² is broken and the Relay Coil RC, is de-energized. Contacts 7 and 8 and 3 and 4 open. breaking the 750 millivolt circuit

which shuts oft the flow of gas to the burnersThe burners will not operate until water level in the boiler

is normal and the reset switch is operated.

Operation-Boiler Drain Condenser

To activate the Boiler Drain Condenser System dose switch S by placing toggle in the down position.

To drain boiler, open boiler drain ball valve. The heat from the boiler drain water will close the normally open thermal switch TS and energize the condenser solenoid valve SV³ To de-activate the Boiler Drain Condenser System open switch S by moving toggle to center off position.

HOW THE ELECTRIC (WARRICK RELAY) WATER LEVEL CONTROLS OPERATE — ON ELECTRIC STEAM GENERATORS (WITH 3 PROBES)

Inside Cleveland Range Co. boilers which have electric water level controls, there are three probe extensions vertically oriented above the water with their lower ends positioned at various levels. Water is admitted to the boiler and is shut off in response to the water level sensed by the tips of the short and the medium length probe extensions. The electrical conductance of the water is used in this system for controlling its level.

The third probe extension is a low water safety cutout sensor and operates on the same principle.

Operation Sequence — Water Level Control Assume an empty boiler. To fill dose Switch S for the following operations:

1) Solenoid SV² is energized allowing the boiler to fill with water at the same time the primary circuit of Transformer T² is also energized.

2) The boiler will continue to fill until the water level reaches the Water Off probe extension completing the T, secondary circuit, and energizing Relay Coil RC².

3) When Relay Coil RC² is energized the normally closed contact opens, de-energizing Solenoid SV², stopping the water fill. The normally open contact is closed, completing the circuit to the Water On probe.

When the water boils away below the end of the Water On probe extension the following occurs:

1) The secondary Circuit of Transformer T² is broken and the Relay Coil RC, is de energized.

Operation — Low Water Safely Cutout When Switch S is closed the following operations occur

1) The primary circuit of Transformer T² is energized.

2) When the water level reaches the low water safety cutout probe extension and the momentary reset switch is manually closed. Relay Coil RC² is energized.

3) When Relay Coil RC, is energized the normally open contacts close, completing the low water safety circuit through Contacts 7 and 8. and completing the circuit through Contacts 3 and 4, energizing Contactor Coil C which closes the heater circuit.

If the water level drops below the Low Water Safety Cutout probe extension, the following occurs:

1) The secondary circuit of Transformer T² is broken and

the Relay Coil RC² is de-energized. Contacts 7 and 8 and 3 and 4 open. breaking the circuits to Contactor C. thereby turning off the heaters.

ELECTRIC STEAM GENERATOR (BOILER) ASSEMBLY - 3 PROBE TYPE

24KW, 36KW, & 48KW (2, 3, & 4 HEATER ELEMENTS) — 1968 to PRESENT

ELECTRIC STEAM GENERATOR (BOILER) ASSEMBLY

NUMBER

1/4

1/4"

1/2"

1/4

3/4'

24KW, 36KW, & 48KW (2, 3, & 4 HEATER ELEMENTS) -

REFERENCE

20A

43936 43936

43895 40445 07108 23132 07302 40462 101467 40421 43748 07106 08165 08166 08167 08214 08215 08216 08175 08176 08177 07128 07115 53250 03504 03514 03276 22102 44095 19870 03509 03506 20533 02193 02196

20535 03202 19947 22130 22131 19968 19944 19967 12161 12169 07173 07168 03277 22140 40471 52568 22122 19945 22104 19979 22106

PART

DESCRIPTION

Boiler shell only. with legs, hand hole plate assembly, mounting studs tor 3 square-flanged heater elements. Boiler shell (43937) above, also including two corrosion resistors, sight gauge, three probes and extensions with cover box. Corrosion resistor, with hanger. Water gauge set with glass. Fibre washer (2 required) Gauge glass washer (2 required). Glass only 6" long. Probe with lock washer and screw. Probe extension set (3). Hand hole plate ass'y.. including bar. nut. and gasket. Hand hole plate-only. Hand hole gasket, flat. 4" x 6" oval. Electric immersion heater, with gasket. 3" flange. 12KW. 208/220 volt, 3 phase. Electric immersion heater, with gasket. 3" flange. 12KW. 230/240 volt, 3 phase. Electric immersion heater, with gasket. 3" flange. 12KW, 440/480 volt. 3 phase. Electric immersion heater, with gasket, 3" flange. 12KW. 208/220 volt. 1 phase. Electric immersion heater, with gasket. 3" flange. 12KW, 230/240 volt. 1 phase. Electric immersion heater, with gasket. 3" flange. 12KW, 440/480 volt. 1 phase. Electric immersion heater, with gasket, 2 1/2' flange, 12KW, 208/220 volt. 3 phase. Electric immersion heater, with gasket, 2 1/2' flange, 12KW, 230/240 volt. 3 phase. Electric immersion heater, with gasket. 2% ' flange, 12KW, 440/480 volt, 3 phase. Heater gasket — 3" square. Heater gasket — 2 1/2 square. Probe cover. Water control relay. 115 volt (1D1DO). Low water cut-off relay, 115 volt, (1C1DO).

ball valve water supply shutoff.

check valve. water feed solenoid valve

line strainer. Contactor — 50 amp. Contactor — 75 amp. Transformer, 75VA, (All. except Convection Steamers). Heavy duty terminal block — use with more than one contactor (125 amp size) Heavy duty terminal block — use with more than one contactor (250 amp size). 24KW, 220 volt. single phase and 48KW. 208 220 & 240 volt. three phase. Transformer, 150VA, (Convection Steamers only). Circuit breaker for 20535. Pressure switch (Models after 1-70). Safety valve — 8 psi Safety valve — 15 psi Reset switch. On-Off power switch. 115/220 volt DPST (before 1-78). On-Off power switch, 115 volt 3PDT (after 1-78) and all auto blowdown. Signal light, 115/220 volt, 1" Signal light, 115/220 volt, 1/2' (Pressure Steamers only). Steam pressure gauge, rear mount. 0-30 psi, 2 1/2. Steam pressure gauge, rear mount, 0-30 psi, 2" (Pressure Steamers only) Generator drain valve — ball type. Air vent. Control enclosure. Cover, control enclosure.

pressure reducing valve, 3-15 psi output (optional). Float switch with gasket — low water cut off (California only). 1/4' solenoid valve — boiler condenser water supply. Thermal switch — boiler condenser. Valve, solenoid. 1/2" boiler auto blowdown, 115 volt (optional)

- 3 PROBE TYPE 1968 to PRESENT

CLEVELAND RANGE CO, 1333 EAST 179th ST., CLEVELAND, OHIO 44110

Manufacturer reserves right of design improvement or modification, as warranted.

ELECTRIC STEAM GENERATOR (BOILER) ASSEMBLY 18KW, 27KW, and

36KW (3 ELEMENTS — 6, 9, or 12KW EACH) — PRIOR TO 1968

REFERENCE NUMBER PART NUMBER DESCRIPTION 1 40425 Hand Hole Plate Assembly

16650 Hand Hole Plate Only 2 07116 Hand Hole Gasket 3 40446 Water Gauge Set With Glass

07108 Fiber Washer (2 Required)

23132 Gauge Glass Washer (2 Required) 4 07301 Glass Only — l0 1/2 Long 5 43720 Water Regulator Valve Assembly 6 06300 Float Only 7 43740 Float Arm and Block Assembly 8 02411 Float Pivot Bracket 9 23130 Sealing Washer 10 43735 Float Plunger Assembly. 3 1/2 11 16833 Plunger Disc 12 43724 Water Regulator Valve Sub-Assembly 13 43895 Corrosion Resistor 14 22130 Safety Valve — 8 psi

22131 Safety Valve — 15 psi 15 22140 Air Vent 16 16820 17 19947 Pressure Switch 18 12161 Signal Light. 115/220 Volt 19 19944 On-Off Power Switch. 115/220 Volt DPST 20 03503 Contactor tor Side Heater. 50 amp. 208/240 Volt Coil

03505 Contactor tor Side Heater. 75 amp. 208/240 Volt Coil 21 20532 Transformer — Optional (480/240/120 Volt Only) 22 08170 Electric Immersion Heater. Screw Type. 6KW. 208 Volt

08171 Electric immersion Heater. Screw Type. 6KW. 240 Volt

08184 Electric Immersion Heater. Screw Type. 6KW. 480 Volt

08172 Electric Immersion Heater. Screw Type. 9KW. 208 Volt

08180 Electric Immersion Heater. Screw Type. 9KW. 240 Volt

08185 Electric Immersion Heater. Screw Type. 9KW. 480 Volt

08182 Electric Immersion Heater. Screw Type. 12KW. 208 Volt

08181 Electric Immersion Heater. Screw Type. 12KW. 240 Volt

08183 Electric Immersion Heater. Screw Type. 12KW. 480 Volt 23 08201 Heater. Screw Type. With Thermostat 6KW. 208 Volt (Not Available)*

08200 Heater. Screw Type. With Thermostat 6KW. 240 Volt

08204 Heater. Screw Type. With Thermostat 6KW. 480 Volt

08203 Heater. Screw Type. With Thermostat 9KW. 208 Volt (Not Available)*

08202 Heater. Screw Type. With Thermostat 9KW. 240 Volt (Not Available)*

08205 Heater. Screw Type. With Thermostat 9KW. 480 Volt (Not Available)* 24 19945 Float Switch With Gasket — Low Water Cut-Off

Pigtail. 1/4" ips

• Consult factory for conversion to a low water cut-off float switch type of safety circuit.

STEAM COIL GENERATOR (BOILER) ASSEMBLY

2 PROBE TYPE

STEAM COIL GENERATOR (BOILER) ASSEMBLY 2 PROBE

1 43977

Steam Coil Boiler Shell with Legs, Sight Gauge, Steam

TYPE

REFERENCE NUMBER PART NUMBER DESCRIPTION

Coil, Hand Hole Plate Assembly, 2 Probes and

Extensions with Cover Box. 2 100636 Hand Hole Plate Assembly 2a 16545 Hand Hole Plate Only 3 07116 Hand Hole Gasket 4 40401 Steam Coil Assembly 5 14612 1/4" Brass Locknut 6 23135 3 1/4" Square Rat Washer 7 14611 1/4" Steel Locknut 8 40446 Water Gauge Set with Glass

07108 Fiber Washer (2 required)

23132 Gauge Glass Washer (2 required) 9 07301 Glass Only—10 1/2" Long 10 52305 Probe Cover Box 11 40462 Probe with Lockwasher and Screw 12 101466 Probe Extension Set (2) 13 22130 Safety Valve—8 psi

22131 Safety Valve—15 psi 14 22232 Safety Valve—55 psi 15 03277 3/4" Ball Valve 16 22193 3/4" Steam Solenoid Valve 17 19872 3/4" Line Strainer 18 20555 3/4" Bucket Trap 19 19870 1/4" Line Strainer 20 06226 Brass Elbow, 90°, Special 21 22223 Solenoid Valve. Water Feed 22 22102 Check Valve. 1/4" 23 03276 1/4" Ball Valve. Water Supply Shut Off 24 22221 Solenoid Valve, Boiler Drain 25 03277 3/4" Ball Valve, Manual Drain 26 03616 Reducing Bell 27 13252 Drain Manifold 28 05292 Street Elbow, 90° 29 05238 Elbow, 90° 30 23198 Control Board, Water Level and LWCO 31 44165 Terminal Block, 4-pole 32 03525 Relay Socket 33 03524 Relay 34 20478 Interval Timer, 3 Minute 35 19947 Pressure Switch 36 19993 DPDT Power Switch 37 19994 SPST Momentary Contact Reset Switch 38 07168 Pressure Gauge, Back Mount, 0-30 psi 39 07166 Pressure Gauge, Back Mount, 0-100 psi 40 45006 Low Water Cut Off Assembly (California Only) 41 41943 LWCO Mounting Plate (California Only) 42 07128 Gasket (California Only) 43 05253 Brass Street Elbow (California Only) 44 02623 1/2 "-1/4" Brass Reducing Bushing (California Only) 45 19995 Float Switch, LWCO (California Only)

ELECTRIC STEAM GENERATOR (BOILER) ASSEMBLY - 2

PROBE TYPE

1 43894 Elect

ric Boiler Shell only. with legs. hand hole

08216 Heater,

12 KW. 440/480

volt, 1 phase

flanged heater elements

10 07128 Heater Gasket

44149 Electric Boiler

Shell

(43894)

above, also include

16546 3- Block-Off Plate

18 KW, 27 KW, 36 KW, & 48 KW (2, 3, & 4 HEATER ELEMENTS)

REFERENCE

NUMBER

2 40421 Hand Hole Plate Assembly including oar. nut. 13 19947 Pressure Switch 2a 43748 Hand Hole Plate only

3 07106

5 101466 Probe Extension Set (set of two) 17 03525 Relay Socket 6 52305 Probe Cover Box 18 44168 Terminal Block. 2 pole 7 40445 Water Gauge Set with Glass 19 03202 Circuit Breaker, 1 amp

8 07302 Gauge Glass Only. 6' long 22 22102 9 08235 Heater. 9 KW. 208 volt. 3 phase 23 03276 1/4 " Ban Valve, water supply shut-off

PART

NUMBER

40462 Probe 16 03524 Relay

07108 Fibre Washer (2 required) 20 20478 interval Timer. 3 minute 23132 Gauge Glass Washer (2 required) 21 20535 Transformer. 150 VA

08236 Heater. 9 KW. 220/240 volt. 3 phase 24 08237 Healer. 9 KW. 440/480 volt 3 phase 25 19870 Line Strainer. 1/4 " 08234 Healer. 9 KW. 600 volt. 3 phase 26 03277 3/4" Ball Valve, manual drain 08241 Healer. 9 KW. 208 volt. 1 phase 27 22221 Solenoid Valve. boiler dram 08242 Heater. 9 KW. 220/240 volt 1 phase 28 13252 Drain Manifold 08243 Heater. 9 KW. 440/480 volt 1 phase 29 45006 Low Water Cut-Off Assembly (California only) 08244 Healer. 9 KW. 600 volt. 1 phase 30 41943 LWCO Mounting Plate (California only) 08165 Heater. 12 KW. 208/220 volt. 3 phase 31 05253 Brass Street Elbow (California only) 08166 Heater. 12 KW. 230/240 volt. 3 phase 32 02623 08167 Heater. 12 KW. 440/480 volt. 3 phase 33 19995 Float Switch. LWCO (California only 08163 Heater. 12 KW. 600 volt. 3 phase 34 19993 DPDT Power switch 08214 Heater. 12 KW. 208/220 volt. 1 phase 35 19994 SPST Momentary contact reset switch 08215 Heater. 12 KW. 230/240 volt. 1 phase 36 07167 Pressure gauge. 0-30 psi. 1 1/2"

DESCRIPTION REFERENCE

plate assembly, mounting studs tor 3' square

ing sigh t gauge, two probes and extensions with 12 22131 15 psi Safety Valve cow box.

and gasket. 14 03509 Contactor 50 amp Hand Hole Gasket. 4' x 6' oval

NUMBER

15 23198 Control Board, water level ana LWCO

PART NUMBER

08217 Heater. 12 KW. 600 volt. 1 phase

22130 8 psi Safety Valve

03506 Contactor. 75 amp

22223

DESCRIPTION

Check valve, 3/4. •

Solenoid Valve, water feed

Reducing Bushing. 1/2" - 1/4' (California only)

Manufacturer reserves right of design improvement or modification, as warranted.

HEATER AND CONTACTOR WIRING SCHEMATICS FOR SOLID

STATE ELECTRIC STEAM GENERATORS

Electric Models

Electric Models with Secondary Low Water Cutoff Built to California Code

GAS STEAM GENERATOR (BOILER) ASSEMBLY - NO PROBES

100,000 BTU (2 BURNER) & 150,000 BTU (3 BURNER)

GAS STEAM GENERATOR (BOILER) ASSEMBLY — NO PROBES

100,000 BTU (2 BURNER) & 150,000 BTU (3 BURNER)

REFERENCE

NUMBER

2 40425 Hand Hole Plate Assembly Including Bar. Nut. Gasket, and Hand Hole Plate 2a 16545 Hand Hole Plate Only 3 07116 Hand Hole Gasket 4 43895 Corrosion Resistor 5 40446 Water Gauge Set With Glass

6 07301 Glass Only —10 1/2" Long 8 06300 Float Only

9 43740 Float Arm and Block Assembly 10 02411 Float Pivot Bracket 11 23130 Sealing Washer 12 43735 13 16833 Plunger Disc 14 43724 Water Regulator Valve Sub-Assembly 15 22112 Water Shut Off Angle Valve 16 22150 17 16621 Fusible Plug With Bushing 18 19945 Float Switch With Gasket—Low Water Cut-Off 19 02498 Main Gas Burner—24" Long

20 15453 Main Burner Orifice—Natural Gas 21 19632 Orifice Holder (After 7/76) 22 63150 Gas Manifold —100,000 BTU—2 Burner 23 22182 1/2 Combination Natural Gas Control Valve 24 43651 Pilot Generator Assembly With 02505 Burner. 20410 Thermocouple. 52449 Bracket and 15460

25 20410 Pilot Thermocouple 26 02505 Pilot Burner—Natural Gas

27 15460 Pilot Burner Orifice—Natural Gas 28 52449 Pilot Bracket (After 7/76)

28A 52450 Pilot Bracket (Before 7/76) 29 07173 Pressure Gauge. Rear Mount—0 to 30 psi 30 19967 On-Off Power Switch. 115/220 Volt. 3 PDT 31 19968 Reset Switch 32 12161 Signal Light 115/220 Volt 33 19947 Pressure Switch 34 22140 Air Vent 35 22130 Safety Valve—8 psi

36 22122 3/4" Pressure Reducing Valve. 3-15 psi Output (Optional) 37 69934 Rear Baffle and Burner Support —100.000 BTU—2 Burner

38 52171 Burner Compartment Front Baffle —100.000 BTU—2 Burner 39 70920 Twister

PART

NUMBER 40300 Boiler Shell Only. With Legs, Studs. Hand Hole Plate Assembly, and Top Flue Bracket.

40307 Boiler Shell Only With Clip Locks. Studs. Hand Hole Plate Assembly, and Top Flue Bracket. 43826 Boiler Shell 40300 Above. Also Including One Corrosion Resistor, Sight Gauge. Low Water Cut-Off

43828 Boiler Shell 40307 Above. Also Including One Corrosion Resistor. Sight Gauge, Low Water Cut-Off

07108 Fiber Washers (2 Req'd.) 23132 Gauge Glass Washers (2 Req'd.)

43720 Water Regulator Valve Assembly

02499 Main Gas Burner—20" Long 02501 Main Gas Burner Used on Units Built Before 7/76 (not shown). Replace With Burner 02498 (24"

15450 Main Burner Orifice—LP Gas 19631 Orifice Holder (Before 7/76) 63151 Gas Manifold —150,000 BTU—3 Burner 22096 1/2" Combination LP Gas Control Valve

43653 Pilot Generator Assembly with 02523 Burner. 20410 Thermocouple. 52449 Bracket, and 15461

02523 Pilot Burner—LP Gas 15461 Pilot Burner Orifice—LP Gas

22131 Safety Valve—15 psi 69935 Rear Baffle and Burner Support —150.000 BTU—3 Burner

52172 Burner Compartment Front Baffle —150.000 BTU—3 Burner

DESCRIPTION

Switch, and Water Regulator Switch, and Water Regulator.

Float Plunger Assembly. 3 1/2"

Long) or 02499 (20" Long). 1963 Orifice Holder, and One 52450 Pilot Bracket (If Pilot's Burner is Replaced.)

Orifice. Orifice.

GAS STEAM GENERATOR (BOILER) ASSEMBLY — 3 PROBE TYPE

210,000 BTU (5 BURNERS)

GAS STEAM GENERATOR (BOILER) ASSEMBLY — 3 PROBE TYPE

REFERENCE

PART

1 40302

Boiler Shell Only. With Legs, Studs. Hand Hole Plate Assembly, and Top Flue Bracket.

40309

Boiler Sh

ell Only, With Angle Iron Mounting Bar, Studs. Hand Hole Plate Assembly, and

Top Flue Bracket.

43632

Boiler Shell

40302

Above. Also Including: Two Corrosion Resistors. Sight Gauge, Three

Probes and Extensions With Cover Box.

43833

Boiler Sh

ell

40309

Above, Also Including: Two Corrosion Resistors, Sight Gauge. Three

Probes and Extensions With Cover Box.

40425

Hand Hole Plate Assembly Including Bar. Nut, and Gasket

16545

Hand Hole Plate Only

07116

Hand Hole Gasket

43895

Corro

sion Resistor

Req'd.)

40446

Water Gauge Set With Glass

07108

Fiber Washers

Req'd.)

23132

Gauge Glass Washers

Req'd.)

07301

Glass Only,

10 1/2" Long

40462

Probe With Lockwasher and Screw

40455

Probe Extension Set

52350

Probe Co

ver 10 19870

1/4" Line Strainer

44095

02499

Main Gas Burner

02500

Main Gas Burner Used on Units Built Before

7/76

(Not Shown). Replace With Burner

02498

—

24"

Long or

02499

—

20"

Long,

19632

—

Orifice Holder, and O

52450

—

Pilot Bracket (If Pilot's Burner Is Replaced.)

15453

Main Burner Orifice

—

Natural Gas

15450

Main Burner Orifice

—

LP Gas

19632

Orifice Holder (After

7/76)

19631

Orifice Holder (Before

7/76)

63152

Gas Manifold

—

210,000 BTU

—5 Burn

er 16 22183

3/4" Combination Natural Gas Control Valve

16A 22189

3/4" Combination LP Gas Control Valve

17 43651

Pilot Generator Assembly With

02505

Burner.

20410

Thermocouple,

52449

Bracket, and

15460

Orifice.

43653

Pilot Generator Assembly With

02523

Burner,

20410

Thermocouple.

52449

Bracket, and

15461

Orifice.

20410

Pilot Thermocouple

02505

Pilot Burner

—

Natural Gas

02523

Pilot Burner

—

LP Gas

15460

Pilot Burner Orifice

—

Natural Gas

15461

Pilot Burner Orifice

—

LP Gas

52449

Pilot Bracket (After

7/76)

21A 52450

Pilot Bracket (Before

7/76)

52177

Burner Compartment Front Baffle

69933

Burner Compartment Rear Baffle

07173

Pressure Gauge, Rear Mount

—0 to

psi 25 19941

On-Off Power Switch.

115/220

Volt, 4 PDT 26 19

968 Reset Switch

12161

Signal Light

115/220

Volt 28 19947

Pressure Switch

22140

Air Vent

22130

Safety Valve

—8 psi 22131

Safety Valve

—15 psi 31 22122

3/4" Pressure Reducing Valve.

3-15

psi Output (Optional)

32 19945

Float Switch With Gaske

t—Low Water Cut

Off 33 03504

Water Control Relay.

115

Volt

D1DO)

03514

Low Water

Cut-Off

Relay,

115

Volt (1C1DO)

22150

16621

Fusible Plug With Bushing

70920

Twister

210,000 BTU (5 BURNERS)

NUMBER

DESCRIPTION

GAS STEAM GENERATOR (BOILER) ASSEMBLY — 3 PROBE TYPE

160,000 BTU (3 BURNER) & 200,000 BTU (4 BURNER)

GAS STEAM GENERATOR (BOILER) ASSEMBLY — 3 PROBE TYPE 160,000 BTU

REFERENCE

PART

DESCRIPTION

1 43872

Boiler shell only. with legs, studs, hand hole plate assembly, and top flue bracket

40298

Boil

er shell

43872

above, also including two corrosion resistors, sight gauge, insulation panels, top flue

collector with insulation and cover plate, three probes and extensions with cover box.

40421

Hand hole plate assembly, including bar. nut and gas

ket 2A 43748

Hand hole plate only.

07106

Hand hole gasket flat

4x6

oval. 4 43941

Left side insulating panel assembly

43943

Right side insulating panel assembly

56320

Top flue collector.

40115

Top insulation baffle assembly (flat).

40116

Top insulation baffle assembly (with flange).

42360

Internal flue riser assembly.

40462

Probe with lock washer and screw.

40455

Probe extension set

(3). 11 52350

Probe cover.

43895

Corrosion resistor.

40445

Water gauge set with glass.

07108

Fibre washer

required).

23132

Gauge glass washer

required).

07302

Glass only

— 6" long.

43851

burner front baffle assembly

— Natural Gas.

43855

burner front baffle assembly

— LP. Gas.

43852

burner front baffle assembly

— Natural Gas.

43856

burner front baffle assembly

— LP. Gas.

41365

burner rear burner support (after

7-76).

69952

burner rear burner support (before

7-76). 18 41366

burner rear burner support (after

7-76).

69953

burner rear burner su

pport (before

7-76). 19 19870

1/4" line strainer.

44095

1/2"

water feed solenoid valve.

22102

1/4" check valve.

03276

1/4" ball valve

— water supply shut

off. 23 03277

Generator drain valve

— bail type.

02499

Main gas burner.

15453

Main burner orifice

— Natural Gas.

15450

Main burner orifice

— LP. Gas.

40901

Gas manifold assembly

— 3

burner (after

7-76).

40905

Gas manifold assembly

— 3

burner (before

7-76). 27 40902

Gas manifold assembly

— 4

burner (after

7-76).

40906

Gas

manifold assembly

— 4

burner (before

7-76). 28 19632

Orifice holder (after

7-76).

19631

Orifice holder (before

7-76). 29 43651

Pilot generator assembly with

02505

burner.

20410

thermocouple.

52449

bracket, and

15460

orifice.

43653

Pilot generator

assembly with

02523

burner.

20410

thermocouple,

52449

bracket, and

15461

orifice.

20410

Pilot thermocouple.

02505

Pilot burner

— Natural Gas

02523

Pilot burner

— LP. Gas.

52449

Pilot bracket

15460

Pilot burner orifice

— Natural Gas.

15461

Pilot burner orifice

— LP. Gas.

22182

1/2

" combination gas control valve

— Natural Gas.

34A 22096

1/2 combination gas control valve

— LP. Gas.

22122

3/4 pressure reducing valve,

3-15

psi output (optional).

22130

Safety valve

— 8

psi.

22131

Safety valve

— 15

psi. 37 22140

Air vent

19947

Pressure switch.

03514

Low water cut

off relay.

115

volt. (1C1DO).

03504

Water control relay.

115

volt. (1D1DO).

07173

Steam pressure gauge, rear mount

0-30

psi. 42 19967

On-

Off power s

witch.

115/220

volt. 3 PDT. 43 19968

Reset switch.

12161

Signal light.

115/220

volt 45 19945

Float switch with gasket

— low water cut

off (California only).

46 22104

1/4 solenoid valve

— boiler condenser water supply.

47 19979

Thermal switch

— boil

er condenser.

22106

Valve, solenoid.

1/2" boiler auto blowdown,

115

volt (optional).

05263

Radiator Ell.

/4 union.

(3 BURNER) & 200,000 BTU (4 BURNER)

GAS STEAM GENERATOR (BOILER) ASSEMBLY — 3 PROBE TYPE

250,000 BTU (5 BURNERS) & 300,000 BTU (6 BURNERS)

GAS STEAM GENERATOR (BOILER) ASSEMBLY — 3 PROBE TYPE

REFERENCE

NUMBER

PART

NUMBER

1 43873

Boiler shell only. with legs. Studs. tend hole plate assembly, and top flue bracket

40297

Boiler shell

43873

above, also including two corrosion resistors, sight gauge, insulation panels. top flue

collector with insulation and cover plate, three probes and extensions with cover box

40421

Hand hole Plate Assembly including bar.

nut ana gasket

43748

Hand hole plate only

07106

Hand hole gasket, flat

4x6

oval. 4 43942

Left side insulating panel assembly

43943

Right side insulating panel assembly

56321

Top flue collector.

40117

Top insulation baffle assembly (flat).

40118

Top insulation baffle assembly (with flange)

42361

Internal flue riser assembly.

40462

Probe with lock washer and screw

40455

Probe extension set

(3). 11 - 52350

Probe Cover.

43895

Corrosion resistor.

40445

Water gauge set with

glass

07108

Fiber washer

Required).

23132

Gauge glass washer

Required)

07302

Glass Only

— 6"

long. 15 43853

5 burner front baffle assembly

— Natural Gas

43857

5 burner front baffle assembly

— L.P. Gas.

43854

6 burner front baffle a

ssembly

— Natural Gas

43858

6 burner front baffle assembly

— L.P. Gas.

41367

5 burner rear burner support (after

7-76).

69954

5 burner rear burner support (before

7-76). 18 41368

6 burner rear burner support (after

7-76).

69955

6 burner rear

burner support (before

7-76). 19 19870

1/4" line strainer.

44095

1/2" water feed solenoid valve.

22102

1/4" check valve.

03276

1/4 ball valve

— water supply shut off.

02499

Main gas burner.

15453

Main burner orifice

— Natural Gas

450 Main burner orifice

— L.P.

Gas 25 19632

Orifice Holder (after

7-76).

19631

Orifice Holder (before

7-76) 26 03277

Generator drain valve

— ball type.

40903

Gas manifold assembly

— 5

burner (after

7-76).

40907

Gas manifold assembly

— 5

burner

(before

7-76). 28 40904

Gas manifold assembly

— 6

burner (after

7-76).

40908

Gas manifold assembly

— 6

burner (before

7-76). 29 43652

Pilot generator assembly with

02505

burner.

20411

thermocouple, and

52449

bracket

20411

Pilot thermocouple.

31 02505 Pilot burner

— Natural Gas.

02523

Pilot burner

— L.P.

Gas- 32

52449

Pilot bracket.

22183

3/4 combination gas control valve

— Natural Gas.

33A 22189

3/4" combination gas control valve

— L.P.

Gas. 34 15460

Pilot burner orifice

— Natural Gas.

15461

Pilot burner orifice

— L.P.

Gas. 35 22122

3/4 pressure reducing valve.

3-15

psi output (optional).

22130

Safety valve

— 8

psi.

22131

Safety valve

— 15

psi. 37 22140

Air Vent

19947

Pressure Switch.

03514

Low water cut

off relay.

115

volt.

C1DO).

03504

Water control relay.

115

volt, (1D1DO).

07173

Steam pressure gauge, rear mount.

0-30

psi 42 19967

On-

Off power switch.

115/220

volt, 3 PDT.

19968

Reset switch.

12161

Signal light,

115/220

volt. 45 19945

Float switch

with gasket

— low water cut off (California only).

22104

1/4" solenoid valve

— boiler condenser water supply.

19979

Thermal switch

— boiler condenser.

22106

Valve, solenoid.

1/2" boiler auto blowdown.

115

volt (optional).

05263

Radiator E

ll. 3/4" union.

250,000 BTU (5 BURNERS) & 300,000 BTU (6 BURNERS)

DESCRIPTION

WIRING DIAGRAM FOR 100,000 and 150.000 BTU STEAM GENERATORS, WITH PILOT IGNITION,

WIRING DIAGRAM FOR 210,000 BTU STEAM GENERATORS, WITH PILOT IGNITION, WITH

WITH AND WITHOUT SAFETY RESET CIRCUIT

MANUAL SAFETY RESET CIRCUIT

WIRING DIAGRAM FOR 100,000 and 150,000 BTU STEAM GENERATORS. WITH PILOT IGNITION,

WITH MECHANICAL LOW-WATER FUEL CUTOFF, WITH AND WITHOUT SAFETY RESET CIRCUIT

GAS STEAM GENERATOR (BOILER) ASSEMBLY - 2 PROBE TYPE SMALL: 100,000 BTU (2 Burners) & 200,000 BTU (4 burners) LARGE: 250,000 BTU (5 burners) & 300,000 BTU (6 burners)

GAS STEAM GENERATOR (BOILER) ASSEMBLY - 2 PROBE TYPE

BTU). with

SMALL: 100,000 BTU (2 Burners) & 200,000 BTU (4 burners) LARGE: 250,000 BTU (5 burners) & 300,000 BTU (6 burners)

REFERENCE

NUMBER

2 40421 2a 43748 Hand hole plate only 20 05101 Ignitor electrode 3 07106 Hand hole gasket. 4' x 6" oval 21 40918 Gas manifold. 2-burner 4 40462 Probe 5 101466 Probe extension set (set of two) 6 52305 Probe cover box 7 40445 Water gauge set with glass 22 52602 Manifold alignment bracket

8 07302 Gauge glass only. 6" long 9 44043 Left side insulation panel assembly 25 02497 Burner

10 44042 Right side insulation panel assembly 28 20478 Interal timer. 3 minute

13 44134 2-bumer front baffle assembly - natural gas 38 22221 Solenoid valve, boiler drain

14 44153 2-burner rear burner support 46 19993 DPDT Power switch

PART NUMBER

43898 Small boiler. shell only (100.000/200.000

43899 44173 Small boiler shell (43898) above, also includ 17 22228 Gas control valve, natural gas. small boiler

44172 72

07108 Fibre washer (2 required) 23 19632 Orifice holder 23132 Gauge glass washer (2 required) 24 15453 Burner orifice, natural gas

440431 Left side insulation panel assembly for LP 26 03546 Spark ignition control module

440421 Right side insulation panel assembly (or LP 29 44164 Terminal block. 4 pole 42398 Top flue collector with insulation, for small 31 03524 Relay 42399 Top flue collector with insulation, lor large 32 23198 Control board. water level and IWCO 42360 Internal flue riser assembly for small boiler 34 42361 Internal flue riser assembly for large boiler 36

44135 4-burner from baffle assembly - natural gas 39 13252 Drain manifold 40840 5-bumer front baffle assembly - natural gas 40 40842 6-bumer front baffle assembly - natural gas 41 41943 LWCO mounting plate (California only)

44150 44170

44171 Left side burner baffle assembly for L.P. gas -

44155 4-bumer rear burner support 47 19994 SPST Momentary contact reset switch

DESCRIPTION REFERENCE

BTU). with legs. studs. hand hole plate assembly and top flue bracket. 15 22130 Safety valve. 8 psi

Large boiler shell only (250.000/300.000

assembly, and top flue bracket 16 19947 Pressure switch ing insulation panels, lop flue collector with

insulation sight gauge, two probes and extensions with cover box - Large boiler shell (43899) above, also includ

ing insulation panels, top flue collector with insulation, sight gauge, two probes and extensions

Hand hole plate assembly including bar. nut. and

gas - 100,000/200,000 BTU boiler only 27 20528 24 volt transformer

gas - 100.000/200.000 BTU boiler only 30 03525 Relay socket boiler (100.000/200.000 BTU) boiler (250.000/300.000 BTU) 33 (100,000/200,000 BTU) 35 22223 Solenoid valve. water teed (250.000/300.000 BTU) 37 03277 3/4' Ball valve, manual drain

Front burner baffle assembly for LP. gas -

100.000/200.000 BTU boiler only (not shown)

Right side burner baffle assembly for LP. gas •

100.000/200.000 BTU boiler only (not shown)

100.000/200.000 BTU boiler only (not shown) 45 19995 Float switch. IWCO (California only)

NUMBER

18 44169 Ignitor cable 19 44096 Ignitor box assembly with ignitor

42 07128 Gasket (California only)

43 44

48 07167 Pressure gauge. 0-30 psi. 1 1/2"

PART NUMBER DESCRIPTION 44156 5-burner rear burner support

44157 6-burner rear burner support 22131 Safety valve. 15 psi

(100.000/200.000 BTU)

22230 Gas control, valve. natural gas. large boiler

(250/300,000 BTU) 22231 Gas control valve. LP. gas. small and

large boilers (100,000/200,000 and

250.000/300.000 BTU)

40920 Gas manifold. 4-burner 40921 Gas manifold. 5-burner 40922 Gas manifold, 6-burner

15450 Burner orifice. LP. gas

22102 Check valve. 1/4 03276 1/4' Ball valve, water supply shut off

19870 Line strainer. 1/4

45006 Low water cut-off assembly (California

05253 Brass street elbow (California only) 02623 1/2' - 1/4" Brass reducing bushing

Gas Models

Gas Models with Secondary Low Water Cutoff

STEAM COIL GENERATOR (BOILER) ASSEMBLY

WITH VARIOUS CONTROL OPTIONS

(INCLUDES BOILERS EQUIPPED WITH 0, 1, or 3 PROBES)

STEAM COIL GENERATOR (BOILER) ASSEMBLY WITH VARIOUS

3/4" Steam solenoid valve

CONTROL OPTIONS

(INCLUDES BOILERS EQUIPPED WITH 0, 1, or 3 PROBES)

REFERENCE NUMBER

2 100636 Hand note plate assembly, incl. bar. nut. and gasket 3 07116 Hand note gasket

4 40401 Steam coil assembly 5 14612 1 1/4" Brass locknut 6 23135 3 1/4" Square flat washer 7 14611 1 1/4" Steel locknut 8 40446 Water gauge set with glass

9 07301 Glass only -10% * long 10 43720 Water regulator valve assembly (used before

11 06300 Float only 12 43740 Float arm and block assembly 13 100655 Float pivot bracket 14 23130 Sealing washer 15 43735 Float plunger assembly 16 16833 Plunger disc 17 43724 Water regulator valve sub-assembly (seat) 18 40462* Probe with lockwasher and screw REFERENCE PART

NUMBER Number

PART NUMBER

43700 Steam coil boiler shell with legs. sight gauge.

43782 Steam coil boiler shell (43700) above, also in

439881 Steam coil boiler shell only. with legs and hand

43989 Steam coil boiler shell (43988) above. also

16545 Hand note plate only

07108 Fibre Washer (2 required) 23132 Gauge Glass Washer (2 required)

DESCRIPTION

water regulator, steam coil. one corrosion resistor, hand hole plate assembly. (For use with mechanical pressure regulating valve for controlling the steam supply.)

cluding one probe and extension with cover box. tor electric operation of the steam supply con trols (solenoid valve in lieu of the mechanical pressure regulating valve).

hole plate assembly. (Equipped with 3 probe holes, for use with electrically controlled water and steam supplies).

including sight gauge, steam coil. 3 probes and extensions with cover box (for use with electrically controlled water and steam supplies).

April, 1964)

DESCRIPTION

19 62453* Probe extension (for use only with single probe 20 101468 Probe extension set (3) (for use only with three

21 43895 Corrosion resistor (not used with 3 probe 22 22200 23 07169 Pressure gauge, bottom mount (0-100 psi)

24 03277 2S 22151 26 22193* 27 22140 Air vent 28 100075 Safety valve - 50 psi 29 22106 1/2" Solenoid valve, boiler auto blowdown. 115

30 22112 Water shut-off angle valve 31 19872 3/4" Line strainer 32 20555 3/4" Bucket trap

33 03276 1/4" Ball valve 34 22102 1/4" Check valve 35 44095" 1/2" Water teed solenoid valve 36 19870

37 07173 Pressure gauge, rear mount. 0-30 psi. 2 1/2"

07168 Pressure gauge, rear mount 0-30 psi. 2" (Pressure

38 19944* On - off power switch. 115/220 volt DPST 39 19968* Reset switch 40 12161- Signal light, 115/220 volt. 1"

12169* Signal light, 115/220 volt, 1/2" (Pressure Steamers

41 19947- Pressure switch 42 03514- Low water cut-off relay. 115 volt (1CIDO)

43 03504" Water control relay. 115 volt (1D1D0) 44 19020*** 3/4" Moisture separator (ball float trap) 45 19945* Float switch with gasket - tow water cut-off

boilers) probe boilers)

boilers) 3/4' Pressure reducing valve - 30 to 50 psi

(optional)

3/4" Ball valve 3/4" Steam control valve

volt (optional)

1/4' Line strainer

Steamers only)

only)

(California only)

*Required for electric steam control and electric low water cut-off safety circuit Through November 1982, these components were used

in lieu of the #22151 steam control valve as standard equipment on all 24" and 60" wide cabinets and all California units, but optional on 36" and 42" wide cabinets. After November 1982, the #22151 was not used and the electric controls became standard equipment on all steam coil generators.

**Required for electric (solenoid valve) water fill, used in lieu of the #43720 water regulator valve, beginning April 1984.

***Optional, if steam supply is wet.

STEAM COIL WIRING DIAGRAM

HOW THE ELECTRIC LOW WATER SAFETY SHUT -OFF OPERATES ON STEAM

COIL (ELECTRIC OPERATED) STEAM GENERATORS

Operation — Low Water Safety Shut-Off

When Switch S is closed the following operations occur:

1. The primary circuit of Transformer T is energized.

2. When the water level reaches the low water safety cutout probe extension and the momentary reset switch is manually closed, Relay Coil RC is energized.

3. When Relay Coil RC is energized, the normally open contacts close, completing the low water safety circuit through Contacts 7 and 6. and completing the circuit through Contacts 3 and 4, energizing Solenoid SV2, allowing steam to flow into the boiler's steam coil.

If the water level drops below the Low Water Safety Cutout probe extension, the following occurs:

1. The secondary circuit of Transformer T is broken and the Relay Coil RC is de-energized. Contacts 7 and 8 and 3 and 4 open, breaking the circuits to Solenoid SV2, thereby shutting off the flow of steam to the boiler's steam coil.

The steam Solenoid SV2 will not operate until water level in the boiler is normal and the reset switch is operated.

Operation — Boiler Drain Condenser To activate the Boiler Drain Condenser System close Switch S

by placing toggle in the down position. To drain the boiler, open the boiler drain ball valve. The heat from the boiler drain water will close the normally open Thermal

Switch TS and energize the condenser Solenoid Valve SV3. To deactivate the Boiler Drain Condenser System open Switch S by moving toggle to the center off position.

SERVICING INSTRUCTIONS — MECHANICAL WATER FILL

FOR STEAM GENERATOR

The water level in the sight gauge should normally be about 2/3 full. If it is not. then (1) the water valve may be scaled up or (2) the water valve plunger disc is in need of replacement or (3) the adjusting screw at the top of the valve plunger is set incorrectly or (4) the float needs to be replaced.

WARNING: Steam under pressure may cause serious injury and bodily harm when it is accidentally or carelessly released. Therefore, service of the steam generator should only be performed by trained and experienced personnel, thoroughly familiar with servicing steam generators.

To service the water valve:

1. Turn oft all utilities and fuel to steam generator. Drain steam generator.

CAUTION: Never work on the steam generator while It is hot or pressurized.

2. Remove hand hole plate from steam generator. Refer to separate data sheet for proper procedures and cautions.

3. (Inside the steam generator as shown on the diagram). Remove the float arm pivot screw. Disengage float arm assembly.

4. Lift out valve plunger disc and install new plunger disc.

5. Remove scale from valve seat and other internal valve surfaces.

6. Re-insert plunger in valve.

7. Install float arm assembly and check the adjustment. Float travel should be approximately 6 inches.

8. To increase the travel, turn adjusting screw clockwise. To decrease, reverse.

9. Re-install hand hole plate, never applying more than 15 ft./lbs. torque to the nut. The hand hole plate should be cleaned and examined every time it is removed. If the hand hole plate is chipped or cracked, or over three years old, install a new one. Because continuous use and possible abuse cause metal fatigue which weakens the hand hole plate, a new one should be installed at least every three years. Replace the gasket at least once a year or sooner if it is cracked or hardened. Replace the hand hole gasket when re-installing the hand hole plate.

10. Close steam generator drain valve. Turn on utilities and fuel.

11. Check the water level. Proper level in the sight gauge is about 2/3 full.

12. Start up and observe steam generator long enough to see that it is operating properly.

13. After the valve plunger disc is installed, order more to have spares on hand at all times.

If hard water scale created the problem, the use of more corrosion resistors or more frequent replacement of them is required. Refer to separate data sheets for maintenance instructions pertaining to scale problems.

Steam Coil Models

Steam Coil Models with Secondary Low Water Cutoff

WATER LEVEL CONTROL SYSTEM

TROUBLESHOOTING AND REPAIR

General Description of Operation:

The Cleveland Range water level control, P/N 23198, is designed to maintain operating water level in Cleveland Range steam generators and to ensure that the heat source is only operated when the generator water level is above a specified minimum level. The sensing technique for the control relies on the fact that tap water is conductive to electricity; if two metal electrodes are immersed in a bath of water, electric current can flow between the electrodes using the water as a conductor. Water is not a good conductor, like copper, but is conductive enough to be measured using appropriate electronic circuitry.

The Cleveland Range control is a two probe system having two metallic probes (LOW and HI) for sensing water in the generator; a COM terminal is placed on the tank. The LOW probe is placed so that it will come in contact with the water when the water level is just above the desired water level, enough to protect the heat source. If the water is of sufficient level and the LOW probe is in the water, a small electrical current provided by the level control electronics will flow between the probe and COM; this flow will be sensed by the electronics which in turn will activate the "HEAT" relay to apply AC power to the HEAT terminal on the control circuit board.

Similarly, the HI probe is located at the desired water level fill (above the LOW probe level) so that when the water level has reached the desired fill level electrical current will flow between the HI probe and COM. The action of this probe is reversed from the previous situation so that when water reaches the HI probe, the WATER fill relay is deactivated so that AC power to the WF is turned off. When the water level drops below the HI probe, the WF terminal will be re-energized after a five second delay. The time delay is to prevent bubbling or turbulence in the generator from chattering to WATER fill relay or the water valve solenoid.

The control runs on 120 vac and is transformer isolated so that the probes and the electronics are run at low voltage and are not common to the AC power line.

Note that in many Cleveland Range generators both sensing probes are inserted from the front top of the unit down into the generator. In this case, the LOW probe will be the longest and the HI probe will be the shortest.

STEP

TEST

RESULT

REMEDY

nect ohmmeter to control board power terminals. Is

(inoperative

A) SYMPTOMS OF WATER LEVEL CONTROL RELATED PROBLEMS:

1) Boiler overfills or floods

2) Boiler dry fires (system underfills or doesn't fill)

3) Boiler doesn't fill at all

4) Water fill solenoid chatter

5) Heater contactor chatter

6) Fills but cuts out on LOW WATER before filling again

7) Overfills but does not heat

8) Fills but does not heat

B) POSSIBLE CAUSES:

1) Inoperative water level control circuit board (P/N 23198)

2) Incorrect or damaged wiring to probes

3) Incorrect or damaged wiring from water leve l board to loads

4) Damaged probes

5) Probes snorted together

6) Scale build-up on probes

C) FAULT ISOLATION PROCEDURE:

Equipment Required: Volt/Ohmmeter (VOM) or Multimeter

1. Is power applied to the control circuit board? Measure L1-L2 at the board to be 120 VAC + 15V.

2. Remove two AC power wires from control board and con resistance between 100-1000 ohms?

3. Visually inspect probe wiring for damaged or broken wires or loose or missing terminals at either end. Is wiring visually OK?

Yes No

Go to Step #2 Correct external supply problem

Reconnect power and go to Step #3 Replace control board P/N 23198

transformer)

Go to Step #4 Replace wiring as required

Step

TEST

RESULT

REMEDY

Correct probe wiring as required (see

Temporarily disconnect the wire from the HTR

onnect the

trol

board. Measure the AC line voltage between the

trol board. Is

vac? NOTE: Digital meters may

nals on the control

board. Does the AC line voltage between the

vac (line

LOW wires and go to

terminals on the control board and short the

COM terminals together. Measure the AC

nals.

4. Are the following connections made correctly? Yes Go to Step #5

6. With HTR still disconnected, disc

7. Short the LOW and COM termi

A) COM input on board to boiler ground No

B) LO input on board to long length "LO" probe

C) HI input on board to short "HI" probe

terminal so that the heat source will not operate. Is the heat source off?

LOW wire at the LOW terminal of the con

HTR and L2 terminals on the con the voltage 0 read a few volts due to their high input impedance; this should be considered as 0 vac.

HTR and L2 terminals now read 120 voltage)?

Yes No

Yes

Figure 1)

Go to Step #6 Check heat source and wiring in cooker

Go to Step #7 Replace water level control P/N 23198

Reconnect HTR & Step #8

Replace water level control P/N 23198

8. Disconnect the wires from the HI and COM

HI & line voltage between the WF and L2 termi Is the voltage 0 vac?

Yes No

Go to Step #9 Replace water level control P/N 23198

Remove the short from the HI and COM terminals on the

erator. Disconnect the wires

disconnected

Disconnect the HI wire at the water sensing probe on the

STEP TEST RESULT REMEDY

9. control board. Does the AC line voltage between WF and L2 stay at 0 vac for about five seconds, then jump to 120 vac?

Yes

Reconnect El & COM wires and go to Step #10

Replace water level control P/N 23198

10. Drain all water form the gen from the LO, HI, & COM termi nals at the control board.

11. Disconnect the LO wire at the water sensing probe on

12. Reconnect the ohmmeter across each end of the

13. Connect an ohmmeter across the HI and COM wires

Connect an Ohmmeter across the LO and COM vires leading to the generator. Does the Ohmmeter read greater than 100,000 ohms?

the generator. Does the Ohmmeter connected in the previous step now read greater than 100,000 ohms?

LO wire. Does the ohmmeter read less than 10 ohms? No Replace wire

leading to the generator. Does the ohmmeter read greater than 100,000 ohms?

Yes Go to Step #12

No Go to Step #11

Yes No

Yes Go to Step #13

Yes No

Go to Step #12 Replace probe wiring

Go to Step #15 Go to Step #14

14. generator. Does the ohmmeter connected in the previous step now read greater than 100,000 ohms?

15. Reconnect the ohmmeter across each end of the disconnected HI wire. Does the ohmmeter read less than 10 ohms?

Yes No

Replace probe wiring Go to Step #16

Go to Step #16 Replace probe wiring

STEP TEST RESULT

REMEDY

16. Reconnect one lead of the ohmmeter to the COM wire at the control board and connect the other ohmmeter lead to generator ground. Does the ohmmeter read less than 10 ohms?

17. Reconnect the ohmmeter across the LOW terminal at the sensing probe & generator ground. Does the ohmmeter read greater than 100,000 ohms?

18. Reconnect the ohmmeter across the HI terminal at the sensing probe & generator ground. Does the ohmmeter read greater than 100,000 ohms?

19. Remove probe and check for scale buildup on or across probes. Replace probe assembly as required.

Yes

Yes No

Reconnect HI LOW & COM wires at control board only. Go to Step #17.

Replace probe wiring

Go to Step #18 Replace probe assembly

Go to Step #19 Replace probe assembly

FIGURE 1 TWO-PROBE & COMMON WATER LEVEL CONTROL

WIRING DIAGRAM ELECTRIC STEAM

WIRING DIAGRAM FOR ELECTRIC STEAM GENERATORS WITH

GENERATORS

ELECTRICAL LOW-WATER HEATER CUTOFF, WITHOUT MANUAL SAFETY RESET CIRCUIT PRIOR TO JANUARY, 1978

ELECTRICAL LOW-WATER HEATER CUTOFF. WITH MANUAL SAFETY RESET CIRCUIT AFTER JANUARY, 1978

0882 LITHO IN U.S.A

CLEVELAND RANGE CO., 1333 EAST 179th ST., CLEVELAND, OHIO 44110

Manufacturer reserves right of design improvement or modification, as warranted.

Cleveland PDM-3J User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual