Cleveland Range HA-MKGL-60-CC-T, HA-MKGL-100-CC, HA-MKGL-60-T, HA-MKGL-80, HA-MKGL-80-T User Manual

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Page 1

Operators Manual

Installation, Operation & Service

GAS MIXING KETTLES

HORIZONTAL AGITATOR

MODEL: HA-MKGL-60 HA-MKGL-60-T

HA-MKGL-80 HA-MKGL-80-T HA-MKGL-100 HA-MKGL-100-T

HA-MKGL-60-CC HA-MKGL-60-CC-T HA-MKGL-80-CC HA-MKGL-80-CC-T HA-MKGL-100-CC HA-MKGL-100-CC-T

™

Clev eland

Enodis

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

Phone: (216) 481-4900 Fax: (216) 481-3782 Visit our web site at www.clevelandrange.com

SE95022 Rev. 5

Page 2

FOR THE USER

WARNING: Improper installation,

adjustment, alteration, service or maintenance can cause property

damage, injury or death. Read the

installation and operating

instructions thoroughly before

installing or servicing this

equipment.

FOR YOUR SAFETY

DO NOT STORE OR USE GASOLINE

OR ANY OTHER

FLAMMABLE LIQUIDS AND

VAPOURS IN THE VICINITY

OF THIS OR ANY OTHER

APPLIANCE.

IMPORTANT!

ENSURE KETTLE IS AT ROOM TEMPERATURE AND

PRESSURE GAUGE IS SHOWING ZERO OR LESS PRESSURE

PRIOR TO REMOVING ANY FITTINGS.

IMPORTANT

The following points are to insure the safe installation and operation of this equipment:

• Insure all gas and electrical supplies match rating plate and electrical stickers.

• Observe all clearance requirements.

• Disconnect the electrical power supply to the appliance before cleaning or servicing unit.

• All service must be performed by a qualified Cleveland Range Technician.

• Do not obstruct the flow of combustion and ventilation air.

The installation and connection must comply with current local codes, or in the absence of local codes, with CAN/CGA-B149.1 and .2 installation code or with the national fuel gas code, ANSI Z223.1-L988.

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

The appliance and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig. (3.45 kpa).

The appliance must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig. (3.45 kpa).

RETAIN THIS MANUAL FOR YOUR REFERENCE.

Page 3

For your safety

DANGER

Keep clear of pressure relief discharge.

IMPORTANT

Inspect unit daily for proper operation.

CAUTION

Surfaces may be extremely hot! Use protective equipment.

Keep hands away from moving parts and pinch points.

Do not fill kettle above recommended level marked on outside of kettle.

Wear protective equipment when discharging hot product.

Do not lean on or place objects on kettle lip.

SERVICING

Shut off power at main fuse disconnect prior to servicing.

GAS APPLIANCES

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

Stand clear of product discharge path when discharging hot product.

Ensure kettle is at room

temperature and pressure gauge is showing zero or less prior to removing any fittings.

Keep appliance and area free and clear of combustibles.

Page 4

GENERAL

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

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

Observe all clearance requirements to provide proper makeup air flow as well as sufficient clearance for servicing.

Dimensions and clearance specifications are shown on the specification sheet and in the Clearance Requirements section. Do not install kick plates or otherwise obstruct the flow of combustion and ventilation air.

Check rating plate to ensure that kettle has been equipped to operate with the type of gas available at the installation.

VENTILATION

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

Building Code in Canada.

INSPECTION

Before unpacking visually inspect the unit for evidence of damage during shipping. If damage is noticed, do not unpack the unit, follow shipping damage

instructions.

SHIPPING DAMAGE INSTRUCTIONS

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

1. Write down a description of the damage or the reason for suspecting damage as soon as it is discovered. This will help in filling out the claim forms later.

2. As soon as damage is discovered or suspected, notify the carrier that delivered the shipment.

3. Arrange for the carrier's representative to examine the damage.

4. Fill out all carrier claims forms and have the examining carrier sign and date each form.

CLEARANCE REQUIREMENTS

This unit must be installed in accordance with the clearances shown on the rating label which is adhered to the unit.

FOR YOUR SAFETY. Keep the appliance area free and clear of combustible materials.

KETTLE

1. When removing the kettle from the platform, handle

with care to prevent scratching or any other damage. It is imperative that the kettle be level before bolting to the floor. This will prevent any twist or out of roundness to the kettle and will stop deflection of the agitator. Make sure the kettle is securely bolted to the floor and follow the procedure listed below:

⇒ Raise the flange on the leg under the motor so that it sets freely (stationary kettles only).

⇒ Position the kettle in its permanent location, check clearances and level the kettle by turning the adjustable feet.

⇒ Lower the flange or flanges under the motor channel. Over adjustment, whether up or down, could cause misalignment and cause damage to the agitator drive shaft and hub (stationary kettles only).

2. Next you must check the alignment of the drive shaft for a uniform clearance between the hub and the shaft. In order to check for clearance you must remove the seal cover plate and pull the seal back. you can check the distance for clearance by using a wire feeler gauge.

3. If adjustment is required for side direction, loosen the motor bolts, center the shaft and retighten.

If vertical alignment is needed, loosen the motor bolts and add a shim to raise or remove a shim to lower. Retighten bolts. When this is complete, check to see if the agitator shaft coupling slides freely for easy removal of the agitator.

4. Once positioned and leveled, permanently secure the kettle’s flanged feet to the floor using 1/2 x 2 I/2 inch lag bolts and floor anchors (supplied by the installer). Two bolts per leg are required to secure each of the flanged feet.

INSTALLATION

Page 5

GAS

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

Connect the gas supply piping to the input side of the gas control valve. Location and pressure data are shown on the specification sheet.

Installation must be in accordance with local codes and/or the National Fuel Gas Code ANSI Z223.1-1988 (USA) or the Installation Codes for Gas Burning Appliances and Equipment CANI B149.1 and B149.2 (Canada). Use a gas pipe joint compound which is resistant to L.P. gas. Test all pipe joints for leaks with soap and water solution. Ensure that the gas pressure regulator is set for the manifold pressure indicated on the gas rating plate.

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

ELECTRICAL

Electrical installation must be in accordance with local codes and/or the National Electric Code ANSI/NFPA 701990 (USA) or the Canadian Electrical Code CSA Standard C22.1 (Canada). The kettle must be electrically grounded by the installer.

A separate fused disconnect switch must be supplied and installed in the high voltage electrical supply line.

The wire gauge size and electric supply must match the power requirements specified on the kettle’s rating plate. The waterproof conduit enclosed permanent copper wiring must be adequate to carry the required current at the rated voltage. Refer to the specification sheet or rating label for electrical specifications and location of electrical connections.

Remove the screws securing the component cover (located to the left rear side of kettle), and remove the cover. A wiring diagram is affixed to the inside of the cover. Feed conduit enclosed permanent copper wiring through the cut-out in the bottom of the console and fasten to the terminal block. Fasten the ground wire to the ground lugs connected to the frame, beside the terminal block. Replace the console cover and secure it

with the screws.

WATER

The sealed jacket of the gas-fired kettle is precharged with the correct amount of a water-based formula, and therefore, no water connection is required to the kettle

jacket.

CLEANING

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

WARRANTY

Our Company supports a worldwide network of Maintenance and Repair Centres. Contact your nearest Maintenance and Repair Centre for replacement parts, service, or information regarding the proper maintenance and repair of your cooking equipment

In order to preserve the various agency safety certification (UL, A.G.A., NSF, ASME/Ntl. Bd., etc.), only factory-supplied replacement parts should be used. The use of other than factory supplied replacement parts will void warranty.

Page 6

SPECIFICATION DRAWING STATIONARY MODELS

ELECTRICAL SUPPLY

VOLTS: 208/240

PHASE: 3

AMPS: 15

FREQ: 60 HZ

APPROVALS

AGA CGA NSF

GAS SUPPLY (PIPING 3/4" NPT)

TYPE: NAT or LP

BTU PER CU. FT.:

1000 (NAT), 2500 (LP)

SUPPLY PRESSURE:

4" to 14" W.C.

BTU RATINGS:

190,000 per hour

AIR SUPPLY (PIPING 1/2" NPT)

PRESSURE:

90 - 100 PSI (only required for optional 3" dia. piston draw-off valve)

HOT & COLD

H C

WATER

1/2" NPT CONNECTION

40-60 PSI PRESSURE

CLEARANCE

RIGHT: 3", LEFT: 3" REAR: 5" (ALLOW 12" SPACE MINIMUM ON LEFT SIDE FOR SERVICE)

APPROX. SHIPPING WEIGHTS

60 GAL -

1010 LBS. 458 KG.

80 GAL -

1120 LBS. 508 KG.

100 GAL -

1325 LBS. 601 KG.

7 3/4"

RIM BAR

3 HP ELECTRIC MOTOR

WALL

12"

RECOMMENDED

FLOOR DRAIN

28" L

A I.D.

16"

H C

5 1/2"

(MAX. ADJUSTMENT)

5/8"Ø,

2 HOLES ON

4" B.C.D.

3/8"

SOLID

FOOT DETAIL

SPRING ASSIST

COVER (FULLY

OPEN AT 90 )

WALL

(COVER

FULLY OPEN)

3" DIA. BUTTERFLY VALVE

RECOMMENDED FLOOR SLOPE 1 INCH PER 4 FEET

6" RECOMMENDED

FLOOR DRAIN

PIPE DRAIN RECOMMENDED MINIMUM VALVE SIZE PLUS 1"

13"

DIMENSIONS

MODEL

HA-MKGL-60-TCC

HA-MKGL-80-TCC

HA-MKGL-100-TCC

NOTES: CLEVELAND RANGE EQUIPMENT IS BUILT TO COMPLY WITH APPLICABLE STANDARDS FOR MANUFACTURERS. INCLUDED AMONG THOSE APPROVAL AGENCIES ARE: UL, A.G.A., NSF, ASME/N.BD., CSA, CGA, ETL, AND OTHERS.

INSTALLATIONS OF BACK FLOW PREVENTERS, VACUUM BREAKERS AND OTHER SPECIFIC CODE REQUIREMENTS ARE THE RESPONSIBILITY OF THE OWNER AND INSTALLER. ALL VERTICAL DIMENSIONS SHOWN ARE MINIMUM. FEET ARE ADJUSTABLE TO +1" MAXIMUM. MANUFACTURER MUST BE NOTIFIED IF UNIT WILL BE OPERATING ABOVE 2000' ALTITUDE. CONSULT FACTORY FOR MANUFACTURED GAS.

Cleveland Range reserves right of design improvement or modification, as warranted.

29 1/2"

33"

35 1/2"

48 1/4"

51 3/4"

54 1/4"

61 5/8"

65 3/8"

68 3/8"

46 3/4"

52"

55"

93"

98"

104"

27 3/4"

30 3/4"

32 3/4"

42"

45 11/16"

48 3/16"

30 5/8"

33 5/8"

35 5/8"

78"

84"

95 5/8"

10 3/8"

11 7/16"

11 5/8"

53"

57"

66"

19 1/4"

20 3/4"

22"

5" MIN

CLEARANCE

24 1/2"

26 3/16"

27 5/8"

Page 7

SPECIFICATION DRAWING TILTING MODELS

ELECTRICAL SUPPLY

VOLTS: 208/240

PHASE: 3

AMPS: 15

FREQ: 60 HZ

APPROVALS

AGA CGA NSF

3" REF.

GAS SUPPLY (PIPING 3/4" NPT)

TYPE: NAT or LP

BTU PER CU. FT.:

1000 (NAT), 2500 (LP)

SUPPLY PRESSURE:

4" to 14" W.C.

BTU RATINGS:

190,000 per hour

M M

WALL

PNP

AIR SUPPLY (PIPING 1/2" NPT)

PRESSURE:

90 - 100 PSI (only required for optional 3" dia. piston draw-off valve)

HOT & COLD

H C

WATER

1/2" NPT CONNECTION

40-60 PSI PRESSURE

10 3/8

12" X 24"

RECOMMENDED FLOOR DRAIN

CLEARANCE

RIGHT: 3", LEFT: 3" REAR: 3" (ALLOW 12" SPACE MINIMUM ON LEFT SIDE FOR SERVICE)

18 3/8Q

H C

APPROX. SHIPPING WEIGHTS

60 GAL -

940 LBS. 428 KG.

80 GAL -

1030 LBS. 469 KG.

100 GAL -

1110 LBS. 505 KG.

5 1/2"

(MAX. ADJUSTMENT)

SOLID

FOOT DETAIL

5/8"Ø, 2 HOLES ON

4" B.C.D.

3/8"

SPRING ASSIST

COVER (FULLY

OPEN AT 90 )

RIM BAR

3 HP ELECTRIC MOTOR

A I.D.

H C

WALL

RECOMMENDED FLOOR SLOPE 1 INCH PER 4 FEET

8 3/4"

3" DIA. BUTTERFLY VALVE

6" RECOMMENDED

13"

FLOOR DRAIN

PIPE DRAIN RECOMMENDED MINIMUM VALVE SIZE PLUS 1"

CLEARANCE

DIMENSIONS

MODEL

HA-MKGL-60-CC

HA-MKGL-80-CC

HA-MKGL-100-CC

NOTES: CLEVELAND RANGE EQUIPMENT IS BUILT TO COMPLY WITH APPLICABLE STANDARDS FOR MANUFACTURERS. INCLUDED AMONG THOSE APPROVAL AGENCIES ARE: UL, A.G.A., NSF, ASME/N.BD., CSA, CGA, ETL, AND OTHERS.

29 1/2"

33"

35 1/2"

48 1/4"

51 3/4"

54 1/4"

50"

58"

60 1/2"

36 1/2"

39"

40 3/4"

83"

90"

96"

13 1/8"

14 7/8"

16 1/8"

34 5/8"

35 15/16"

37 1/8"

23 7/8"

24 5/8"

25 1/4"

19 1/8"

20 7/8"

22 1/8"

10 3/32"

11 17/32"

12 3/4"

24"

26"

27 1/4"

9 3/4"

11"

(COVER

FULLY OPEN)

3" MIN

17 7/8"

18 5/8"

19 1/4"

Cleveland Range reserves right of design improvement or modification, as warranted.

Page 8

OPERATING INSTRUCTIONS

21 3

NOTE:

Location of switches may vary dependant on customers specific options

Red Low Water Indicator Light

When lit, in the upright position, indicates kettle gas burner has cut out and unit requires more water. Occasional pulsing of this light is normal.

Green Heat Indicator Light

When lit, indicates gas burner is on; cycles on-off with solid state controls.

Solid State Temperature Control Knob / On-Off Toggle Switch

Controls electrical power to kettle. and allows operator to select kettle heat increments from minimum, 1-10. A setting of 7 or higher will boil water

Amber Ignition Failure Indicator Light

Indicates failure of heating system to ignite (Used prior to July 2004)

Agitator Stop Button

Stops agitator in case of emergency

Agitator Start Switch

Starts agitator. Agitator power control switch must be ON

Agitator Power Switch

Allows power to agitator. When not in use, turn control power OFF

Agitator Speed Control Switch

Turn clockwise until desired speed is reached

Power tilt control switch

Tilts kettle for pouring; some kettles have manual hand tilt

Reset circuit breaker

Protects power tilt system from overload. Push to reset

Water Meter Digital Counter (not shown)

Location may vary dependant on customer's specific options

0123

Fill Interrupt Switch

Interrupts water fill cycle

Potable Fill Water Switch

Selects hot or cold water

Fill Cycle Switch

Start/continue cycle switch

Product Discharge Valve Switch

Toggle momentary switch to desired valve opening

Temperature Sensor

Senses temperature of product

Automatic Dump Valve

Empties kettle of either food product or wash water

Sight Glass

For checking water level of kettle jacket

Vacuum /Pressure Gauge

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

Gas Shut-Off Valve

Air Quick Connect

Push yellow tab down to release air pressure before disconnecting air hose

Kettle Filler Nozzle

Page 9

General

WARNING:

Do not attempt to operate this appliance during a power failure. Keep appliance and area free and clear of combustibles.

Before turning kettle on, ensure that following conditions exist:

• If you are cooking an egg or milk product, do not pre-heat kettle.

• The vacuum/pressure gauge needle is in green zone; if it is not and is in "vent air" zone, call your service agent to repair leak.

• The electrical service to kettle is turned on

NOTE:

The kettle should be sanitized prior to the daily

production run - see CLEANING INSTRUCTIONS .

Mixing ("AGITATOR ")

WARNING:

•

Never add product to kettle while agitator is running.

•

Do not put hands in kettle.

•

Watch for loose clothing near agitator.

1. Turn "SPEED CONTROL" to "0".

2. Switch agitator to "ON".

3. Push agitator "START" to initiate mixing.

4. Turn "SPEED CONTROL" to desired mixing speed.

5. To stop mixing action, push agitator stop button.

NOTE:

Mixing speed depends on the product consistency. The faster the mixing speed the more damage may be done to fragile product.

Heating (General Notes)

• The green light cycles on and off, indicating that

burners are cycling to maintain set temperature.

• The red "low water" light should not be lit during operation. This light indicates that water level is critically low and that gas burners have automatically shut off. Before further use, refer to RESERVOIR FILL INSTRUCTIONS for adding distilled water.

• Occasional flashing of the red "low water" light is ok while kettle is heating.

Manual Heating

1. Switch "POWER" to "ON".

2. Turn temperature control knob to desired setting.

3. Switch "CONTROLLER" to "BYPASS".

4. After closing discharge valve, place product in kettle.

Automatic Heating

1. Switch "CONTROLLER" to "ACTIVE".

2. Turn temperature control knob to "10".

3. Continually push function key " " until "OFF" is

displayed.

4. Push and hold key " " or " " until desired temperature is set.

To Start:

push function key

" " until "CtrL" is displayed.

6. Push down key " ".

To Stop:

push function key

" " until "OFF" is displayed.

8. Push down key " ".

9. After closing discharge valve, place product in kettle.

Emptying the Kettle

1. To open automatic dump valve:

• Turn PRODUCT DISCHARGE VALVE switch

clockwise to JOG TO OPEN. Release switch to the HOLD position when desired valve opening is achieved.

• To close valve, turn switch counterclockwise to CLOSED position.

2. To avoid splashing, slowly empty kettle contents into an appropriate container by partially opening dump valve.

NOTE:

When pumping with a Metering Filling Station the speed of the agitator arm must be sufficient to suspend the heavier items in the mix in order to achieve an even distribution in your packaged items.

Immediately clean kettle as outlined in CLEANING INSTRUCTIONS on page.

Water Meter

1. Switch "POTABLE FILL WATER" to "HOT" or "COLD".

2. Set required volume by first pushing the " " key

until the digit you want to change is flashing in the lower display. Then use the " " key to change the value of the selected digit.

When all digits are set, press the "ENT" key.

3. Locate delivery spout over kettle.

4. Turn switch to "RESET". Delivery will start at "0" and

stop at preset volume.

5. To stop delivery at any time, turn "FILL INTERRUPT"

switch to " ● ".

6. To complete delivery after interrupting, turn switch

"FILL CYCLE" to "CONTINUE".

Page 10

CARE AND CLEANING

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

WARNINGS

➩ Do not use detergents or

cleansers that are chloride based or contain quaternary salt.

➩ Do not use a metal bristle

brush or scraper.

➩ Steel wool should never be

used for cleaning the stainless steel.

➩ Unit should never be cleaned

with a high pressure spray hose.

➩

Do not leave water sitting in unit when not in use.

Stagnant

Water

High Pressure

Spray Hose

Chloride Cleaners

Steel Pads

Wire Brush &

CLEANING INSTRUCTIONS

CAUTION

SURFACES MAY

BE EXTREMELY HOT!

CLEANING INSTRUCTIONS

1. Turn unit off.

2. Remove drain screen (if applicable). Thoroughly

wash and rinse the screen either in a sink or a dishwasher.

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

4. Remove food soil using a nylon brush.

5. Loosen food which is stuck by allowing it to soak at

a low temperature setting.

6. Drain unit.

7. Rinse interior thoroughly.

8. If the unit is equipped with a Tangent Draw-Off

Valve, clean as follows:

a) Disassemble the draw-off valve first by turning

the valve knob counter-clockwise, then turning the large hex nut counter-clockwise until the valve stem is free of the valve body.

b) In a sink, wash and rinse the inside of the valve

body using a nylon brush.

Use a nylon brush to clean tangent draw-off tube.

d) Rinse with fresh water.

e) Reassemble the draw-off valve by reversing the

procedure for disassembly. The valve's hex nut should be hand tight only.

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

a) Place valve in open position.

b) Wash using a warm water and mild detergent

solution.

c) Remove food deposits using a nylon brush.

d) Rinse with fresh water.

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

10 . Using mild soapy water and a damp sponge, wash

the exterior, rinse, and dry.

NOTES

➩ For more difficult cleaning applications one of the

following can be used: alcohol, baking soda, vinegar, or a solution of ammonia in water.

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

➩ For more detailed instructions refer to the Nafem

Stainless Steel Equipment Care and Cleaning manual (supplied with unit).

Page 11

STAINLESS STEEL EQUIPMENT CARE AND CLEANING

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

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

Corrosion on metals is everywhere. It is recognized quickly on iron and steel as unsightly yellow/orange rust. Such metals are called “active” because they actively corrode in a natural environment when their atoms combine with oxygen to form rust.

Stainless steels are passive metals because they contain other metals, like chromium, nickel and manganese that stabilize the atoms. 400 series stainless steels are called ferritic, contain chromium, and are magnetic; 300 series stainless steels are called austenitic, contain chromium and nickel; and 200 series stainless, also austenitic, contains manganese, nitrogen and carbon. Austenitic types of stainless are not magnetic, and generally provide greater resistance to corrosion than ferritic types.

With 12-30 percent chromium, an invisible passive film covers the steel’s surface acting as a shield against corrosion. As long as the film is intact and not broken or contaminated, the metal is passive and stain-less. If the passive film of stainless steel has been broken, equipment starts to corrode. At its end, it rusts.

Enemies of Stainless Steel

There are three basic things which can break down stainless steel’s passivity layer and allow corrosion to occur.

1. Mechanical abrasion

2. Deposits and water

3. Chlorides

Mechanical abrasion means those things that will scratch a steel surface. Steel pads, wire brushes and scrapers are prime examples.

Water comes out of the faucet in varying degrees of hardness. Depending on what part of the country you live in, you may have hard or soft water. Hard water may leave spots, and when heated leave deposits behind that if left to sit, will break down the passive layer and rust stainless steel. Other deposits from food preparation and service must be properly removed.

Chlorides are found nearly everywhere. They are in water, food and table salt. One of the worst chloride perpetrators can come from household and industrial cleaners.

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

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

Use the proper tools.

When cleaning stainless steel products, use non-abrasive tools. Soft cloths and plastic scouring pads will not harm steel’s passive layer. Stainless steel pads also can be used but the scrubbing motion must be in the direction of the manufacturers’ polishing marks.

Clean with the polish lines.

Some stainless steel comes with visible polishing lines or “grain.” When visible lines are present, always scrub in a motion parallel to the lines. When the grain cannot be seen, play it safe and use a soft cloth or plastic scouring pad.

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

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

Treat your water.

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

to reduce deposits. There are certain filters that can be installed to remove distasteful and corrosive elements. To insure proper water treatment, call a treatment specialist.

Keep your food equipment clean.

Use alkaline, alkaline chlorinated or non-chloride cleaners at recommended strength. Clean frequently to avoid build-up of hard, stubborn stains. If you boil water in stainless steel equipment, remember the single most likely cause of damage is chlorides in the water. Heating cleaners that contain chlorides have a similar effect.

Rinse, rinse, rinse.

If chlorinated cleaners are used, rinse and wipe equipment and supplies dry immediately. The sooner you wipe off standing water, especially when it contains cleaning agents, the better. After wiping equipment down, allow it to air dry; oxygen helps maintain the stainless steel’s passivity film.

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

Regularly restore/passivate stainless steel.

Recommended cleaners for specific situations

Job Cleaning Agent Comments

Routine cleaning Soap, ammonia, Apply with cloth or sponge

detergent, Medallion

Fingerprints & smears Arcal 20, Lac-O-Nu Provides barrier film

Ecoshine

Stubborn stains & Cameo, Talc, Zud, Rub in direction of polish lines discoloration First Impression

Grease & fatty acids, Easy-off, De-Grease Excellent removal on all finishes blood, burnt-on-foods It Oven Aid

Grease & oil Any good Apply with sponge or cloth

commercial detergent

Restoration/Passivation Benefit, Super Sheen

Review

1. Stainless steels rust when passivity (film-shield) breaks down as a result of scrapes, scratches, deposits and chlorides.

2. Stainless steel rust starts with pits and cracks.

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

to clean stainless steel.

4. Use non-chlorinated cleaners at recommended concentrations. Use only chloride- free cleaners.

5. Soften your water. Use filters and softeners whenever possible.

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

Prolonged contact causes eventual problems.

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

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

Page 12

PRODUCT VALVE

Daily

- clean product valve as follows:

Open product valve.

Disconnect air hoses.

Remove air cylinder.

Remove valve tee.

Remove all O-rings.

Clean air cylinder, do not submerge in water. Wipe clean and sanitize.

Clean and sanitize tee and O-rings.

Grease and reinstall O-rings.

Reinstall tee to kettle outlet.

10.

Reinstall air cylinder to bottom of tee.

11.

Reconnect air hoses.

12.

Close valve and check for alignment.

SCRAPER BLADES

To remove and clean scraper blades:

1. Remove scraper blades using the tool to release

the spring from the retaining pin and sliding the blade off the shaft.

2. Place parts in a pan of warm water to soak.

3. Clean in a sink, using a warm water and mild

detergent solution.

4. Rinse with fresh water.

5. Allow to dry thoroughly on a flat, clean surface.

AIR HOSE

AIR CYLINDER

AIR HOSE

OPEN POSITION

CLOSED POSTITION

0-RING

CLAMP

0-RING

VALVE TEE

0-RING

CLAMP

KETTLE OUTLET

KETTLE

Scraper

blade

Back stop

Pin A Pin B

Spring

To Remove Scraper Blade

1. Insert tool that is provided as shown in Fig. 2.

2. Pull up on spring arm until arm clears groove in Pin B.

3. Spring is now disengaged, gently release spring to remove

scraper blade.

To Install Scraper Blade

1. Slide scraper blade and spring onto Pin A as shown in Fig. 1.

2. Hook spring arm and pull up.

3. Using tool, engage spring arm into groove on Pin B.

Scraper blade is now in place.

Tool

Fig. 2 Fig. 3Fig. 1

Page 13

AGITATOR

To remove and clean agitator (two-person

job):

Removing Agitator

1. Remove scraper blades.

2. Rotate agitator until pull pin is on top side.

3. Turn power OFF.

4. Pull pin out.

5. Slide coupling toward kettle wall, and carefully lift

agitator pulling back to lift out.

6. Clean in a sink, using a warm water and mild detergent solution.

7. Rinse with fresh water.

AGITATOR BUSHING

With agitator out, remove bushing by:

1. Remove bushing

by turning 1/4 turn and pulling away from the kettle wall.

2. Clean, rinse and

sanitize bushing and bushing mounting area.

3. Lubricate metal surfaces with food safe grease.

4. Install bushing by locating retaining pin and sliding

bushing on.

5. Rotate to lock into position.

QUAD RING

To clean agitator quad ring:

Cleaning Quad Ring

1. Remove retaining knobs.

2. Slide shaft seal retainer plate and quad ring away

from kettle body.

3. Clean quad ring, shaft, and seal retainer plate with clean cloth.

4. Rinse with fresh.

5. Apply light coat of food safe grease to both sides

of the quad ring.

6. Slide quad ring back into original position, making sure it does not twist.

7. Slide retainer plate back toward kettle, replacing retaining knobs.

8. Tighten with hand pressure only.

Agitator shaft

Coupling

Quad ring

Seal retainer plate

Retaining knobs

Slot

Bushing

Retaining

Agitator

Shaft

Page 14

Agitator

Shaft

1 2 3

4 5 76

SCRAPER BLADES

ITEM NO. PART NO. DESCRIPTION QTY.

1. KE54602 SCRAPER BLADE . . . . . . . . . . . . . . .7

2. KE54608 SPRING . . . . . . . . . . . . . . . . . . . . . . .7

3. KE01976 SPRING REMOVAL TOOL . . . . . . . . 1

AGITATOR SEAL ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY.

1. KE01911 RETAINING KNOBS . . . . . 3

2. KE54592 SEAL RETAINER PLATE . . 1

3. FA05002-8 "O" RING . . . . . . . . . . . . . . 1

4. KE54594 PIN . . . . . . . . . . . . . . . . . . 1

5. KE54583 COUPLING . . . . . . . . . . . . 1

6. KE54593 IDLER PIN . . . . . . . . . . . . 1

7. KE54590 BUSHING . . . . . . . . . . . . . 1

OPERATING CONTROLS

ITEM NO. PART NO. DESCRIPTION QTY.

1. KE54531 AGITATOR STOP . . . . . . . . . . . . . . . . . . . . . . 1

2. KE54530 AGITATOR START . . . . . . . . . . . . . . . . . . . . . 1

3. KE54529 POWER ON/OFF SWITCH . . . . . . . . . . . . . . . 1

4. KE54532 SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . 1

SERVICE PARTS

Page 15

PRESSURE RELIEF ASSEMBLY

4 3 1

ITEM NO. PART NO. DESCRIPTION QTY.

1. FA05049 MALE CONNECTOR, 1/2" PIPE - 1/4" TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. FI00151 STREET ELBOW, 1/2" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

3. FI00178 TEE, 1/2" FPT, BRASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4. KE54941-5 SAFETY VALVE, 50 PSI, 1/2" (NORTH AMERICA) . . . . . . . . . . . . . . . . . . . . . . .1

KE54941-31 SAFETY VALVE, 50 PSI, 1/2", (EUROPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5. KE54223 BLOW DOWN TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SIGHT GLASS

ITEM ON. PART NO. DESCRIPTION QTY.

1. KE50955 RETAINING COVER . . . . . . . . 1

2. KE52871 WASHER . . . . . . . . . . . . . . . . 1

3. KE51053-1 SIGHT GLASS . . . . . . . . . . . . 1

4. FA05002-30 ”O” RING . . . . . . . . . . . . . . . . 1

Page 16

HINGE ASSEMBLY

1312

ITEM NO. PART NO. DESCRIPTION QTY.

Hinge Assembly

1. - 11 KE50597-1 25 - 40 Gallon, 20 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50597-2 60 - 80 Gallon, 30 - 40 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50597-3 100 - 150 Gallon, 60 - 100 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . .1

KE50597-4 KDM-60, KDM-60-T, Cook Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50597-5 KDL-200, KDL-250, KDL-150-F, KDL-250-F . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1. KE50822 Hinge Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. KE51217 Hinge Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3. KE50121-2 Hinge Spring Light - for KE50597-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50121-1 Hinge Spring Heavy - for KE50597-1, KE50597-3, KE50597-4, KE50597-5, . .1

4. KE50823-1 Hinge Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5. KE50824 Hinge Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6. KE50819-1 Hinge End Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7. KE50820 Hinge Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8. KE50819 Hinge End Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9. FA11284 Screw, Socket Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

10. FA11507 Cutting Screw, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

11. SK50418 Plug Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12. KE50151-2 Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

13. Cover Handle (specify model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Page 17

WATER METER ASSEMBLY

ITEM ON. PART NO. DESCRIPTION QTY.

1. FI00096 3/4 BRASS UNION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2. F100629-2 3/4 NPT X 2 112 BRASS NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

3. FI00063 3/4 NPT BRASS ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

4. F100629-36 3/4 NPT CLOSE BRASS NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

5. KE55228 U-BOLT, 1/4-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

6. KE54834-4 SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

7. KE02290 MOUNTING PLATE ASSY, HOT COLD WM . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8. R00179 3/4 NPT BRASS FEMALE TEE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9. FI00365 3/4 X 1 REDUCING BRASS ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

10. FI00267 3/4 NPT BRASS COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11. FA21008 S.S. NUT 1/4-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

12. KE54336 GALLON METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE54336-1 QUART METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE52002-1 LITER METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Page 18

FLUSH PISTON VALVE

(USED PRIOR TO 2003)

ITEM NO. PART NO. DESCRIPTION QTY.

T40430 Valve Assembly (includes parts 1 - 16) . . . . . . . . . . . . . . . . . . . . . . . . .1

1. FA05000 "O" Ring, Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. KE52345 Piston Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3. KE52346 Air seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4. KE52347 Sani-Clamp Seal, 4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5. KE52344 Sani-Clamp, 4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6. FA05002-22 "O" Ring, Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

7. FA05002-21 "O" Ring, Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

8. KE52315 Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9. KE52335 Compression Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10.-13. SE00040 Supply Hose Assembly, Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10. KE52341 Hose Barb, 1/8” x 1/4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

11. KE52340 Supply Hose, 8” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12. KE52342 Hose Barb, 1/4” x 1/4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

13. KE52338 Quick Connect Male End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

14. KE52327 Piston Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

15. KE52328 Piston Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

16. KE52314 Bottom Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Rev 2

Page 19

ITEM ON. PART NO. DESCRIPTION QTY.

1. KE55210 WELD RING, KETTLE BOTTOM OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2. FI05144-3 SANI CLAMP, 3” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3. KE52154-4 GASKET, SANI CLAMP, 3” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4. KE02291 COMPLETE ACTUATOR AND DISCHARGE VALVE ASSEMBLY . . . . . . . . . . . . 1

INCLUDES PARTS 5. - 13.

5. KE55248 BUNA-N O-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6. KE55249 REPLACEABLE S.S. PLUNGER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7. KE55250 BUNA-N O-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8. KE55251 1/8 NPT S.S. HYDRAULIC CLOSE NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

9. KE55252 MALE S.S. QUICK DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10. KE55253 AIR OPERATED CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11. KE55254 FEMALE S.S. QUICK DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12. FA05002-53 BUNA-N O-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

13. KE55256 FEMALE S.S. QUICK DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

14. KE54924 TEMPERATURE SENSOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15. FA05002-46 O-RING, FOOD GRADE, SIZE A0123, EPDM E 692-75 . . . . . . . . . . . . . . . . . . 1

16. KE52154-3 GASKET, SANI CLAMP, 1 1/2” WHITE TEFLON . . . . . . . . . . . . . . . . . . . . . . . . . 1

TEMPERATURE

SENSOR

AIR VALVE ASSEMBLY

FPVA-3

FLUSH PISTON VALVE & TEMPERATURE SENSOR ASSEMBLIES

(USED AFTER TO 2003)

Page 20

GEARMOTOR - ELECTRICAL ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY.

1. KE53838-2 TRANSFORMER, 200-240V/440-480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. KE50750-2 CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3. KE51139-1 FUSE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

4. KE52936-18 15A FUSE, KLKR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

5. PR50003 TERMINAL BLOCK

6. PR50005 TERMINAL BLOCK BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7. KE54528 A.C. INVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8. KE54527-1 GEAR MOTOR, 200V/340V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE54527-2 GEAR MOTOR, 230V/460V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Page 21

KETTLE - ELECTRICAL COMPONENTS

ITEM ON. PART NO. DESCRIPTION QTY.

1. KE53838-19 TRANSFORMER, 120-16V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53444 TRANSFORMER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. KE54833-3 BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3. KE02372 IGNITION MODULE, PRIOR TO SEPT. 2004 . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53469-4 IGNITION MODULE, SEPT. 2004 AND AFTER . . . . . . . . . . . . . . . . . . . . . . . . . .1

4. KE00458 SOLID STATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50303 SOLID STATE CONTROL BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5. KE50753-7 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6. KE55069-6 SAFETY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7. FI05050 BRASS NUT #7/16-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8. KE02400 AIR SWITCH, PRIOR TO SEPT. 2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE55453-1 AIR SWITCH, SEPT. 2004 AND AFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9. KE53838-20 TRANSFORMER 120-24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Page 22

KETTLE - GAS COMPONENTS

10 26

Page 23

ITEM ON. PART NO. DESCRIPTION QTY.

1. KE53617 SIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. KE53437 IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3. KE50556-2 WATER LEVEL PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4. KE00515 THERMISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5. FI05213 PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6. FA05002-4 “O” RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7. KE53422 SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8. GAS ORIFICE:

KE53403-6 NATURAL GAS - SEA LEVEL TO 2000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53403-7 PROPANE GAS - SEA LEVEL TO 2000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53403-10 NATURAL GAS - 2000' TO 4000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53403-11 PROPANE GAS - 2000' TO 4000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53403-10 NATURAL GAS - 4000' TO 6000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53403-14 PROPANE GAS - 4000' TO 6000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53403-17 NATURAL GAS - 6000' TO 8000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53403-18 PROPANE GAS - 6000' TO 8000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53403-17 NATURAL GAS - 8000' TO 10,000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53403-22 PROPANE GAS - 8000' TO 10,000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9. FA05002-29 “O” RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10. KE50568-1 L.E.D. GREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11. KE50567-1 L.E.D. RED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12. TEMPERATURE CONTROL ASSEMBLY:

KE50569-1 KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SE00114 POTENTIOMETER WITH ON/OFF SWITCH, C/W SEAL . . . . . . . . . . . . . . . . . . .1

KE51005 SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

13. KE50429-2 PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

14. KE53441 BLOWER, 110 V, 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

15. KE53441-1 BLOWER, 220 V, 50 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

16. KE01426-1 MIXING CHAMBER, 60 GALLON KETTLES . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

17. KE53402-1 AIR ORIFICE, 190K BTU BURNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

18. FI05212 PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

19. KE95087-1 OPERATING INSTRUCTION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

20. KE50567-2 L.E.D. AMBER (USED PRIOR TO JULY 2004) . . . . . . . . . . . . . . . . . . . . . . . . . .1

21. KE02274 CAPACITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

22. KE53618 SIGHT GLASS GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

23. KE53619 SIGHT GLASS RETAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

24. KE53570 GASKET FOR IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

25. KE54420 AIR INTAKE WASHER (NATURAL GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE54420-1 AIR INTAKE WASHER (PROPANE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

26. FA05002-18 "O" RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Page 24

CONTROL BOX - ELECTRICAL

For front panel control switches see SIDE BOX - TILT MECHANISM & SWITCHES. CONTROL BOX - WATER METER & CHART RECORDER.

1612

3938

2928

3231

2625

9 9B9C

SAFETY SWITCH ASSEMBLY FRONT VIEW

SAFETY SWITCH

ASSEMBLY -

SIDE

VIEW

13 17 18 10 16 11 12 13

DOOR GASKET

Page 25

ITEM ON. PART NO. DESCRIPTION QTY.

1. KE55287-1 PANEL, REMOTE CONTROL, DUAL FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE55187-2 PANEL, REMOTE CONTROL, DUAL WALL . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE55287-3 PANEL, REMOTE CONTROL SINGLE FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE55287-4 PANEL, REMOTE CONTROL, SINGLE WALL . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. KE55284-1 COMPONENT MOUNTING PLATE DUAL PANEL . . . . . . . . . . . . . . . . . . . . . . . .1

KE55284-2 COMPONENT MOUNTING PLATE SINGLE PANEL . . . . . . . . . . . . . . . . . . . . . .1

3. KE55286-1 MOUNTING BRACKET, INCOMING, DUAL PANEL . . . . . . . . . . . . . . . . . . . . . .1

KE55286-2 MOUNTING BRACKET, INCOMING, SINGLE PANEL . . . . . . . . . . . . . . . . . . . .1

4. KE54860 FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

5. KE55283 VENT COVER PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

6. KE55288-1 MOUNTING RAIL, DUAL CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE55288-2 MOUNTING RAIL SINGLE CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . .1

7. KE55298 MOTOR PROTECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1

8. KE50750-4 CONTACTOR, 230 VAC, 50 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50750-2 CONTACTOR, 230 VAC, 30 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9. KE55297-1 SAFETY INTERLOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9B. KE55297-2 TOTALLY FLEXIBLE ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9C. KE55297-3 GD2 STANDARD ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10. KE55285 MOUNTING BRACKET, DOOR INTERLOCK SWITCH . . . . . . . . . . . . . . . . . . . .1

11. FA40000-15 WELD STUD, #10-32 X 1/2, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

12. FA21007 HEX NUT, #10-32, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

13. FA32006 TOOTH LOCK WASHER, #10, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

14. FA11091 SCREW, #8-32 X 3/8, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

15. FA21004 NUT, #8-32, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

16. FA11146 SCREW, #10-32 X 1/2, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11/8

17. FA40000-14 WELD STUD, #10-24 X 3/4, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

18. FA21006 HEX NUT, #10-24, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

19. KE55271 LABEL, REMOTE CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1

20. KE55292-1 LABEL TERMINAL STRIP REMOTE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

21. KE55292-4 LABEL TERMINAL STRIP REMOTE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

22. KE55292-3 LABEL, TERMINAL STRIP, REMOTE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . .1

23. KE50753-10 RELAY, 120 V HOT COLD WATER BYPASS . . . . . . . . . . . . . . . . . . . . . . . . . . .6/3

24. KE52106 TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4/2

25. KE50377 TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

26. KE50376 TERMINAL BLOCK END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

27. KE50374 TERMINAL BLOCK MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1

28. SK50055-1 TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14/7

29. SK50054-1 TERMINAL BLOCK END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4/2

30. KE54761-2 TERMINAL BLOCK MOUNTING RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1

31. SK50054-2 TERMINAL BLOCK END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4/2

32. KE54761 TERMINAL BLOCK MOUNTING RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

33. KE90425-1 WIRING DIAGRAM, DUAL REMOTE CONTROL PANEL . . . . . . . . . . . . . . . . . .1

KE90425-2 WIRING DIAGRAM, SINGLE REMOTE CONTROL PANEL . . . . . . . . . . . . . . . . .1

34. KE90401-2 WIRING DIAGRAM, DUAL WATER METER OPTION . . . . . . . . . . . . . . . . . . . . .1

35. KE55232 WIRING DIAGRAM, 3" AIR VALVE OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

36. KE54528 AC INVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1

37. KE53838-2 TRANSFORMER, 200- 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1

38. KE52936-18 FUSE, 15 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6/3

39. KE51139-1 FUSE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6/3

40. KE50750-2 CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1

Page 26

CONTROL BOX WATER METER & CHART RECORDER

ITEM NO. PART NO. DESCRIPTION QTY.

1. KE53257 Digital Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. SE50354 Pen Tip, red (pkg. of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3. SE50354 Pen Tip, green (pkg. of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4. KE003209-1 Switch Assembly, On/Off - Maintained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5. KE003209-1 Switch Assembly, On/Off - Maintained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

6. KE003209-6 Momentary Spring Return Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7. KE003209-7 Momentary Spring Return Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .2

8. KE53136-1 Chart Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

NOTES: For units built prior to December 2006,

the complete switch assembly must be ordered.

EMPTY

WATER METER

START

CONTINUE RESET

EMPTY

START

OFF ON

EMPTY

MAIN POWER

EMPTY

BYPASS ACTIVEOFF ON

EMPTY

INTERRUPT

EMPTY

INDEX

Contactor CartridgesCapacitor

INCLUDED WITH

ALL SWITCHES.

PART NO.

KE52074 KE603208-9 KE603208-8

Page 27

ITEM NO. PART NO. DESCRIPTION QTY.

1. FA05166 QUICK CONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. KE54280 SLIDE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I

3. FA30512 SPACER WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4. FA32500 TOOTH LOCK WASHER 7/8" DIA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5. KE52697 NUT 1/2 NPS BRASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I

6. KE52931 AIR FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7. F100178 TEE 1/2 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8. FI00351 BUSHING 1/2 MIP X 1/4 FIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9. FI05318 HOSE BARB 90° ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

10. FI00151 90° STREET ELBOW 1/2 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11. FA30090 WASHER 15/16 ID X 1 3/4 OD X 1/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12. 7100595-8 NIPPLE 1/2 NPT X 4 1/2" LONG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

13. KE55238 FILTER-REGULATOR-LUBRICATOR BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . .1

14. F105220-1 GEAR CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

15. FA21006 10-24 S.S. NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

16. KE532177 PNEUMATIC HOSE 1/4 I.D. X 31" L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

17. KE532176 PNEUMATIC HOSE 1/4 I.D. X 12 1/2" L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

18. FA30000 FLAT WASHER #10, ZINC PLATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

19. KE02292 AIR SOLENOID ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

20. KE50555-3 GROMMET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

21. FA21008 1/4-20 NUT S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

22. FA30002 FLAT WASHER 1/4 DIA., ZINC PLATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

4671211

14 9 13 21 22 9

1716

1815

RTV ALL AROUND

(NOT SHOWN)

SIDE BOX PNEUMATICS

Page 28

ITEM NO. PART NO. DESCRIPTION QTY.

1. KE50579-1 CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FA00012 "O" RING, CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50580 WATER RESISTANT BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. KE603208-4 TILT SWITCH OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3. KE51730 TILT SHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4. KE54531 AGITATOR STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5.* KE54530 AGITATOR START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6.* KE54529 POWER ON/OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7.* KE54532 SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8. KE01889 MICRO SWITCH TRIGGER/SEGMENT GEAR WELDMENT . . . . . . . . . . . . . . . .1

2322

25 26 27 28

GAS CONNECTIONGAS CONNECTION

SEE PNEUMATIC

COMPONENTS DRAWING

SEE PNEUMATIC

COMPONENTS DRAWING

SIDE BOX TILT MECHANISM & SWITCHES

Page 29

9. FA10772 SOCKET HD. CAP SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

10. FA20048 JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

11. FA95007-4 RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12. FA95055-1 SQUARE KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

13. FA19201 HEX SOCKET SET SCREW 3/8-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

14. KE54644 TILT SHAFT, MANUAL TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE52836-2 TILT SHAFT, POWER TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

15. KE50315 WORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

16. FA95005 TENSION PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

17. KE52193-1 THRUST BEARING SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

18. KE52192 THRUST WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

19. KE52191 ROLLER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

20. FA30088 WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

21. FA95008 JAM NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

22. KE50582 CPLG. ONTARIO BELTING #G-100 5/8 BORE . . . . . . . . . . . . . . . . . . . . . . . . . .2

23. FA95055-6 SQUARE KEY 3/16 X 3/16 X 1" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

24. KE50583 RUBBER INSERT, ONTARIO BELTING "BUNA N" . . . . . . . . . . . . . . . . . . . . . . . .1

25. KE52832-1 MOTOR "BODINE" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

26. FA10487 HEX HD SCREW 1/4-20 X 1" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

27. FA31008 SPLIT LOCKWASHER 1/4" DIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

28. FA20026 HEX NUT 1/4 - 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

29. KE50473 GROUND LUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

30. FO1518-1 GAS SHUT-OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

31. KE02053 COMBINATION GAS VALVE NATURAL GAS . . . . . . . . . . . . . . . . . . . . . . . . . . .1

32. FI05223-1 SPECIAL NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

33. FI05222 SWIVEL ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

34. FI05231 FLUSH BUSHING 3/4M TO1/2F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

35. FI05226-11 NIPPLE 1/2 X 10" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

36. KE51007 MICRO SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

37. FA10139 MACHINE SCREW #6-32 X 1" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

38. KE50498 MICRO SWITCH INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

39. FA32004 TOOTH LOCK WASHER #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

40. KE603208-7 CONTACT SECTION HOLDER (LATCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

41. KE603208-9 CONTACT BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

42. KE50581 BRIDGE RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

43. KE54535 EDGE CONNECTOR (11 PIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

44. KE50753-10 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

45. KE54491 LID FOR GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

46. KE53599-8 GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

47. KE53599-9 GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

48. FA95062 PAN HD. PHILLIPS SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

49. FA95074 NYLON ANCHOR NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

50. FA19177 HEX SOCKET SET SCREW 5/16-24 X 1" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

51. FA20047 JAM NUT 5/16-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

52. KE54606 GAS VALVE LOCKWASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

53. KE003209-9 SWITCH, JOG TO OPEN AIR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

54.* KE003209-6 SWITCH, FILL INTERRUPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

55. * KE003209-2 SWITCH, HOT/COLD SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

56.* KE003209-3 SWITCH, FILL CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

* SWITCHES MAY BE LOCATED ON REMOTE CONTROL PANEL.

Page 30

MAINTENANCE

INSPECTION AND MAINTENANCE CHECKLIST

Cleveland Range equipment requires little preventative maintenance. We do however provide the following chart as a guide line for inspection and maintenance to keep your unit functioning at 100%.

MONTHLY INSPECTION



Inspect all switches for damage. Replace rubber boots or switches as required.



Check that the automatic dump valve works fully and smoothly and no air leaks are evident.



Check that the 3 way regulator shuts off the incoming air and completely vacates the air from the air hose to the metering filling station.



Tilt kettle and check for smooth operation in both directions.



Inspect gear and worm assembly in gear box for play - tighten Allen screws if required.



Inspect gasket material on covers for integrity.



Check spring assist covers for tightness to handle and insure spring is holding cover up - adjust if required. Refer to HINGE ADJUSTMENT INSTRUCTIONS.



When kettle is cold check that pressure gauge needle is in the green zone indicating a vacuum in kettle - if venting is required refer to KETTLE VENTING PROCEDURE.



Inspect mixer blades for cracks or other damage - replace as required. Refer to NEW SCRAPER BLADE INSTALLATION PROCEDURE.



Check quad ring and replace if required. Refer to QUAD RING REPLACEMENT PROCEDURE.



Inspect oiler in gear box and fill with oil if required. Refer to OILER FILLING PROCEDURE.



Inspect air filter cartridge and replace if required. Refer to AIR FILTER REPLACEMENT PROCEDURE.

SIX MONTH MAINTENANCE



Grease trunnion housings in gear box and on outboard bearings.



Test pressure relief valve. Refer to PRESSURE RELIEF VALVE TESTING PROCEDURE.

Page 31

OPERATING SEQUENCE - HEATING

QUICK CHECKS:

Potentiometer - Range 0 - 50K, Safety Thermostat - Normally Closed,

Thermistor - Range 0 - 100K, Water Level Probe - Must be submerged in water for burners to work

RESULT 2

Amber LED is illuminated. (Used prior to July 2004)

a/ Green LED illuminates. b/ 12 VDC relay contacts close.

a/ Air switch contacts close.

25 volts supplied to ignition module.

Within 20 seconds ignitor glows red.

a/ Burner ignites.

a/ If temperature drops in

chamber gas valve is deenergized within five seconds.

b/ Ignitor will try twice more to

light before locking out.

a/ Green LED turns off. b/ 12 VDC relay contacts open. c/ Blower turns off. d/

25 volt transformer de-energizes.

ACTION

Close main circuit breaker.

On/Off switch on kettle switched to ON.

Control box.

12 VDC relay contacts close.

Ignition module.

120 volts turned off to ignitor.

Temperature reached.

STEP

RESULT 1

120 volts is supplied by primary contactor to kettle On/Off switch and tilt relay contacts. Power supplied to tilt assembly.

120/16 volt transformer supplies power to control boxes.

A/ Requires grounded probe to

function (pin #5).

More that 6 volts at pin #2. Control box energizes 12 volt DC relay (pin #6).

A/ Blower energizes.

B/ 120/25 volt transformer energizes.

120 volt supplied to ignition module.

Supplies 120 volts to ignition.

A/ Gas valve is energized.

B/ Ignitor becomes sensor.

A/ Less than 6 volts at pin #2.

Control box de-energizes 12 volt DC relay (pin #6)

OPERATING SEQUENCE - AGITATOR

Three phase contactor closes to supply power to variable speed drive.

A/ Power to agitator motor.

A/ Motor speed increases.

a/ Indicator light is energized.

a/ Motor comes up to speed.

On/Off switch closed.

Start button momentarily depressed.

Speed control turned up.

OPERATING SEQUENCE - POWER TILT

A/ Relay 2 is energized.

A/ Power interrupted to down side

of tilt switch.

A/ Relay 1 is energized.

A/ Power interrupted to up side of

tilt switch.

a/ Tilt motor is energized.

a/ Relay de-energized. b/ Motor stops.

a/ Tilt motor is energized.

a/ Relay de-energized. b/ Motor stops.

Turn and hold tilt switch in down position.

Kettle tilts until limit switch is depressed.

Turn and hold tilt switch in up position.

Kettle tilts until limit switch is depressed.

Page 32

KETTLE SAFETY INSPECTION CHECKLIST

Regular inspection and maintenance of units is essential to obtain trouble free and safe operation of equipment. Inspections must include testing of the pressure relief valve and checks of the operating system to insure that it has not been altered.

No safety features designed into the equipment should ever be tampered with. Tampering with or bypassing controls is a very dangerous practice and unfortunately we have seen several cases of this. Following is a short list of the most common and the most dangerous alterations performed on kettles.

✘

Plug

✘

Tube diameter reduced

✘

Frozen, stuck, or plugged

✘

Plumbed to drain or water line

✔

Incorrect Installations

Safety valve has plug threaded into the

discharge opening preventing any steam from escaping.

Safety valve’s tube diameter has been

reduced.

Safety valve is sticking, frozen shut or plugged.

To test, refer to PRESSURE RELIEF VALVE PERIODIC TESTING.

Safety valve is plumbed to a drain or water

line creating back pressure and reducing flow.

SAFETY VALVE:

This illustrations show the correct configuration of a factory installed Safety Valves.

Any modifications are unacceptable.

Page 33

SAFETY THERMOSTAT:

✘

Probe

removed

partially

✘

Probe

removed

completely

✘

Thermostat

electrically

bypassed

✔

Probe fully inserted in tube

Wiring is properly

connected

123

Incorrect Installations

Safety thermostat

probe is not completely inserted into tubing.

Safety thermostat

probe is removed from tubing.

Safety thermostat

electrical connection is bypassed.

Low Water Level Probe:

Probe bypassed by running (A) an additional wire

Probe properly attached

260º - 270º MAXIMUM KETTLE TEMPERATURE

265º

✔

If maximum temperature is not in this range (on empty kettle), refer to the CALIBRATING PROCEDURE.

Operating Thermostat:

✔

✘

Probe bypassed by (B) grounding the connecting wire

✘

(A)

(B)

✘

Switch

electrically

bypassed

✔

Wiring is

properly

connected

Air Switch:

Incorrect

Installation

Page 34

NEW SCRAPER BLADE INSTALLATION PROCEDURE

Fig. 2 Fig. 3Fig. 1

Scraper

blade

Back stop

Move to

adjust

Move to

adjust

Trim corners or center to fit

Spring

QUAD RING REPLACEMENT PROCEDURE

1. Remove agitator as per cleaning instructions.

2. Remove hole cap, retaining bolt and retaining

washer.

3. Snap retaining ring out from seating inside motor.

4. Remove retaining knobs.

5. Slide seal retainer plate away from kettle.

6. Slide shaft away from kettle body to allow

clearance for removing quad ring.

7. Remove quad ring.

8. Slide new quad ring back into original position,

making sure it does not twist.

9. Apply light coat of food-safe grease.

10.

Slide retainer plate back toward kettle, replacing retaining knobs -tighten with hand pressure only.

11. Reassemble.

Retaining ring

Hole cap Retaining bolt

Retaining washer

Retaining

ring seat

Quad ring

Seal retainer plate

Retaining knobs

AIR FILTER REPLACEMENT PROCEDURE

1 Disconnect air supply and bleed system.

2. Remove cover on console (see SIDE BOX -

PNEUMATICS).

3. Check for filter location.

4. Push lever down

and rotate bowl/ guard assembly 1/8 turn.

5. Push down on bowl/guard assembly and remove.

6. Unscrew baffle and remove filter element, inspect and replace filter if required.

7. Replace filler cap and cover.

Deflector

Filter

Element

Baffle

Lever

Bowl/Guard

Assembly

LUBRICATION PROCEDURE

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

TRUNNION HOUSING, WORM SCREW AND TILT GEAR

These parts are accessed through the top cover of the console.

Apply grease to gear teeth. Check for

excessive play and adjust with adjusting screw located on top of cross bar.

KETTLE

TRUNNIONS

On the left hand side of the kettle there are two grease nipples on the top back portion of the trunnion housing. On the right hand side of the kettle you must remove the console cover to access the two grease nipples.

Trunnion Housing

Grease Nipple

Adjusting

Screw

Worm Screw and Tilt Gear

Cross

Bar

Page 35

PRODUCT VALVE

Replacing O-Rings

Open product valve.

Disconnect air hoses.

Remove air cylinder.

Remove valve tee.

Remove all O-rings, grease and reinstall new O-rings as required.

Reinstall tee to kettle outlet.

Reinstall air cylinder to bottom of tee.

Reconnect air hoses.

Close valve and check for alignment.

AIR HOSE

AIR CYLINDER

AIR HOSE

OPEN POSITION

CLOSED POSTITION

0-RING

CLAMP

0-RING

VALVE TEE

0-RING

CLAMP

KETTLE OUTLET

KETTLE

HINGE ADJUSTMENT INSTRUCTIONS

1. Insert 3/8" Allen wrench.

2. Turn clockwise to relieve tension on spring.

3. While tension is released remove one of the two

slotted screws.

4. To prevent Allen wrench from springing back abruptly while the second slotted screw is removed, insert a pin (approximately 1/8") in the hole where the first slotted screw was removed from.

5. Remove second slotted screw.

6. While holding Allen wrench remove pin.

7. Turn Allen wrench clockwise to tighten or

counter-clockwise to loosen tension to produce desired effect.

8. Re-insert pin in one of the two holes.

9. Tighten one slotted screw in the other hole (it

may be necessary to turn Allen wrench slightly to align holes).

10. Remove pin and repeat step number 9 for other slotted screw.

3/8" Allen wrench

BUSHING REPLACEMENT PROCEDURE

1. Remove agitator as per cleaning instructions.

2. Remove bushing by turning 1/4 turn and pulling

away from the kettle wall.

3. Lubricate metal surfaces with food safe grease.

4. Install new bushing by locating retaining pin and

sliding bushing on.

5. Rotate to lock into position.

6. Reassemble agitator.

OIL FILLING PROCEDURE

1. Disconnect air supply

and bleed system.

2. Remove cover on

console.

3. Check for oiler location.

4. Inspect oil level in bowl.

5. Remove filler cap.

6. Add mineral oil as

required.

7. Replace filler cap and

console cover.

Filler

Cap

Bowl

Page 36

KETTLE VENTING INSTRUCTIONS

1. Remove Access Panel from

back of main kettle console.

Turn kettle ON and set temperature control to 10, heat the empty kettle until unit cycles off.

3. Vent kettle by pulling Valve Ring eight to fifteen times, holding valve open for two seconds each time.

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

4. Turn kettle OFF. Add cold water to kettle until its surface temperature is below 100°F. The pressure gauge needle should be in the green zone, indicating a vacuum in the kettle’s jacket.

If needle is in the green zone then venting was successful. If not repeat procedure.

OFF

100

150

200

250

300

350

400

psi

kPa

100

150

200

250

300

350

400

psi

kPa

The following venting procedure

should be followed when the

Vacuum/Pressure Gauge needle

is in the "VENT AIR" zone:

NOTE: Check for and eliminate leaks prior to venting (See REPAIRING LEAKS IN STEAM JACKETED KETTLE FITTINGS).

DANGER: PRESSURE RELIEF

VALVE WILL EXHAUST HIGH TEMPERATURE STEAM. CONTACT WITH SKIN COULD RESULT IN SERIOUS BURNS. KEEP FACE,

HANDS AND BODY CLEAR OF DISCHARGE.

DANGER: WORKING ON MACHINES

WITH POWER COULD RESULT IN SEVERE ELECTRICAL SHOCK.

VACUUM LEAK TEST PROCEDURE

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

A. Water Level Probe.

B. Pressure Relief Valve/Pressure Gauge and

connecting plumbing.

C. Boiler Drain Cap.

D. Sight Glass.

LEAK TEST PROCEDURE:

1. Heat kettle until unit cycles off.

2. Shut off power to the kettle at the fused disconnect

switch.

3. Spread Bubble Type Leak Detector over suspected areas and watch closely for bubbles.

4. Repair areas as required.

REPAIRING LEAKS IN STEAM JACKETED KETTLE FITTINGS

If unit will not hold a vacuum the most likely cause is a leak at one of the fittings.

Often, the easiest way to eliminate a leak is reseal the suspect areas.

1. Water Level Probe

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

2. Pressure Relief Valve

A/ Inspect for signs of leaks. Replace if required.

B/ Remove, clean threads, apply teflon thread

sealant and reinstall.

3. Pressure Gauge

A/ Inspect face of gauge. If it contains moisture

on the inside of face replace.

B/ Check tightness of plumbing connection to pressure Gauge.

3. Sight Glass

A/ Check tightness of sight glass.

B/ Replace "O" ring if required.

Pressure

Relief Valve

Access

Panel

Valve

Ring

Page 37

RESERVOIR FILL PROCEDURES

The kettle's water level must be maintained at the proper level. Under normal operating conditions, the sealed water reservoir should never require the addition of water.

If the red "low water" light comes on during use (while the kettle is in an upright position), the water level has reached a critically low level. The low water protection control has automatically shut off the gas burner. The following procedure must be completed before further use:

NOTE: Have a qualified service technician repair the leakage problem and add water to the unit. Ensure that the red "low water" light is on when the kettle is upright. On tilting kettles, it is normal for the red light to come on when the kettle is in a tilted position.

CAUTION: Only distilled water should be used when adding water to a partially filled water reservoir (If unit is completely empty see KETTLE JACKET FILLING & DRAINING PROCEDURES). Local tap water conditions may cause kettle damage which is not covered under warranty. Rust inhibitor is purchased locally. Read directions and do not exceed manufacturer's recommendation (excessive rust inhibitor can also cause solidification).

1. Ensure kettle is at room temperature and pressure gauge showing zero or less pressure.

2. Shut off power to the kettle at the fused disconnect switch.

3. Remove Access Panel from back of main kettle console.

4. Pull Pressure Relief Valve Ring open to insure vessel is not pressurized.

5. Remove main kettle Console Cover.

6. Remove 1/4" copper tubing and reducer bushing.

7. Add distilled water using a funnel if necessary. Fill the unit to the high level mark on the Sight Glass.

8. Apply a thread sealant (i.e. Teflon tape) to the reducer bushing threads and replace.

9. Replace main kettle Console Cover and Access Panel.

10.

Restore power to unit at the fused disconnect switch.

11.

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

DANGER: PRESSURE RELIEF

VALVE WILL EXHAUST HIGH TEMPERATURE STEAM. CONTACT WITH SKIN COULD RESULT IN SERIOUS BURNS. KEEP FACE,

HANDS AND BODY CLEAR OF DISCHARGE.

DANGER: WORKING ON MACHINES

WITH POWER COULD RESULT IN SEVERE ELECTRICAL SHOCK.

WARNING: IMPROPER REFILLING OF

KETTLE JACKET WILL RESULT IN

IRREVERSIBLE DAMAGE TO UNIT.

100

150

200

250

300

350

400

psi

kPa

Pressure Relief Valve

Access

Panel

Valve

Ring

Pressure Relief Valve

Sight Glass

Important- Pull ring on Pressure Relief V

alve prior to removal to insure vessel is not pressurized.

Console

Cover

Page 38

PRESSURE RELIEF VALVE PERIODIC TESTING

Most insurance agencies require periodic testing of pressure relief valves used on pressure vessels. This procedure will allow you to safely and quickly test your kettle's pressure relief valve. We recommend this test be performed twice a year.

NOTE: The following instruction is intended for use by qualified service personnel.

WARNING: Kettle surface will be hot and steam will be released during testing. Take necessary precautions including the use of gloves and eye protection to prevent personal injury.

1. With the kettle empty, turn unit ON and set

temperature

control to 10

. Allow the kettle to heat until the unit cycles off.

2. Switch unit OFF and disconnect main power at fused disconnect switch.

3. Remove Access Panel at back of main kettle console.

4. Pull Pressure Relief Valve Ring open for a maximum of one second. Repeat test three to four times. Each time the mechanism should move freely and be accompanied by a rapid escape of steam

NOTES:

If valve appears to be sticking replace pressure relief valve.

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

See service bulletin (KETTLE JACKET FILLING AND DRAINING PROCEDURES) for full instructions on the correct method for draining and refilling kettle jacket.

WARNING: Improper refilling of kettle jacket will result in irreversible damage to unit.

5. Replace Access Panel.

6. Reconnect main power at fused disconnect switch..

CALIBRATING PROCEDURE

1. Insure the unit has a vacuum before you begin

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

2. Turn kettle ON and set temperature control to 10

3. Allow the unit to cycle twice.

4. Check temperature of the

inner kettle surface with a digital surface thermometer.

5. Temperature should be between 260°F and 265°F.

6. Using a screw driver adjust

temperature by turning the potentiometer on the Solid State

Temperature Control Box. Turn very little. Turn clockwise to INCREASES and counter-clockwise to DECREASE temperature.

7. Allow the unit to cycle twice.

8. Check temperature of the inner kettle surface with

a digital surface thermometer.

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

DANGER: PRESSURE RELIEF

VALVE WILL EXHAUST HIGH TEMPERATURE STEAM. CONTACT WITH SKIN COULD RESULT IN SERIOUS BURNS. KEEP FACE,

HANDS AND BODY CLEAR OF DISCHARGE.

DANGER: WORKING ON MACHINES

WITH POWER COULD RESULT IN SEVERE ELECTRICAL SHOCK.

Pressure Relief Valve

Access

Panel

Valve

Ring

Solid State Temperature

Control Box

Adjustment

Pot

OFF

Page 39

1. Remove Access Panel at back of main kettle console.

2. Pull pressure relief valve chain to ensure there is no

pressure within the kettle jacket.

3. Remove 1/4" copper tubing and reducer bushing.

4. Remove drain plug cap (located underneath the

kettle on the right rear). Allow kettle jacket to drain.

5. Replace filler plug and add water until it shows on sight glass. Remove Drain Plug cap and allow water to drain. Repeat until water drains clear.

Refilling Unit (see RESERVOIR FILL

PROCEDURES).

KETTLE JACKET FILLING & DRAINING PROCEDURES

Under normal circumstances the kettle does not require the draining of all fluid. If the red “low water” light is on, follow the RESERVOIR FILL PROCEDURES in this manual.

If unit must be drained follow the procedures described on the following pages.

Use only a mixture of water and rust inhibitor to refill kettle jacket (see instructions below).

Contact your local water treatment company and purchase rust inhibitor with the specifications described below.

Recommended Corrosion Inhibitors for Closed Systems

DESCRIPTION

Recommended for our units is a blend of SODIUM NITRITE and BORAX for corrosion inhibition of ferrous metals and axoles for copper and copper alloy corrosion protection. Product should be formulated for hot or cold closed recalculating water systems.

Source the chemicals stated above from your local water treatment company. Mix only with water and follow manufactures recommended mixing rate.

DISPOSAL OF INHIBITOR

Do not dispose of chemicals in any system which may discharge into water supplies used for drinking or washing or that could accidentally discharge into such systems, or into stream accessible to animals.

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

WARNING: IMPROPER REFILLING OF

KETTLE JACKET WILL RESULT IN

IRREVERSIBLE DAMAGE TO UNIT.

DANGER: EXTREMELY

HOT SURFACES.

WORK ONLY ON COLD

KETTLE.

DANGER: PRESSURE RELIEF

VALVE WILL EXHAUST HIGH TEMPERATURE STEAM. CONTACT WITH SKIN COULD RESULT IN SERIOUS BURNS. KEEP FACE,

HANDS AND BODY CLEAR OF DISCHARGE.

DANGER: WORKING ON MACHINES

WITH POWER COULD RESULT IN SEVERE ELECTRICAL SHOCK.

DANGER: EXTREMELY

HOT SURFACES.

WORK ONLY ON COLD

KETTLE.

WARNING: IMPROPER REFILLING OF

KETTLE JACKET WILL RESULT IN IRREVERSIBLE DAMAGE TO UNIT.

Pressure Relief Valve

Access

Panel

Valve

Ring

Drain Plug Location

Page 40

Note: Disconnect external power supply and shut off gas to unit prior to servicing.

1. Remove mixer arm leaving flat surface on drive shaft facing upwards.

Remove shaft end cap.

3. Remove shaft retaining bolt.

4. Remove shaft retaining ring.

HA DRIVE SHAFT REPLACEMENT PROCEDURE

Page 41

5. Gently hammer out shaft and remove.

6. Clean seal.

7. Grease seal with food grade grease.

8. Insert new shaft.

9. Push new shaft past retraining ring groove and

install retaining ring.

10. Tap shaft back to seat up against retaining ring.

11. Complete reassembly by reinstalling bolt and

end cap.

Page 42

NOTE: Use thread sealant compatible with propane gas on all threaded piping connections.

1. Disconnect electrical connection.

2. Shut off main gas supply and disconnect kettle from

supply line.

3. Remove TOP COVER.

4. Remove PLUG and SPRING.

5. Remove GAS ORIFICE and “O” RING.

6. Replace with new GAS ORIFICE and “O” RING.

7. Replace SPRING and PLUG.

8. Replace TOP COVER.

9. Place gas conversion label next to rating label.

10. Reconnect electrical supply.

Power Burner Gas Kettles

BTU's per Gas Water # of

Hour Type Column Orifices KGL-40, KGL-40-T,

140000 NAT 3.5 1

MKGL-40-T,

140000 LP 3.5 1

KGL-60 to 100, KGL-60-T to 80-T, KGL-40-TSH, 190000 NAT 3.5 1 KGL-40-F to 60-F, 190000 LP 3.5 1 KGL-40-SH to 60-SH, HA-MKGL-60 to 100, HA-MKGL-60 to 100-T

Conversion Parts Required

KGL-40

Part No. Description Quantity

KE95549 Conversion Label 1

KE54420-1 Air Intake Washer 1

KE53403-5 Gas Orifice 1

FA05002-29 “O” Ring 1

KGL-60 to 100

Part No. Description Quantity

KE95549 Conversion Label 1

KE54420-1 Air Intake Washer 1

KE53403-7 Gas Orifice 1

FA05002-29 “O” Ring 1

FIELD CONVERSION INSTRUCTIONS -

Natural Gas to Propane Gas

PLUG

SPRING

GAS ORIFICE

“O” RING

TOP COVER

Page 43

SPARE PARTS LIST

The following is a spare parts listing of parts that wear during normal us or are apt to be misplaced during normal operation. These parts should be kept on hand to prevent loss time due to a minor problem.

PART NUMBER DESCRIPTION QUANTITY

KE54602 SCRAPER BLADE 1

KE54608 SPRING 3

KE01911 RETAINING KNOBS 1

FA05002-8 "O" RING 3

KE54594 PIN 1

KE54834-4 SOLENOID VALVE 1

KE55248 BUNA-N O-RING 5

KE55255 BUNA-N O-RING 5

FA05002-46 O-RING, FOOD GRADE, SIZE A0123, EPDM E 692-75 5

KE52154-3 GASKET, SANI CLAMP, 1 1/2” WHITE TEFLON 5

KE55297-3 GD2 STANDARD ACTUATOR 1

KE52936-2 FUSE, 15 AMP 6

SE50354 PEN TIP, RED (PKG. OF 5) 1

SE50354 PEN TIP, GREEN (PKG. OF 5) 1

The following is a recommended list of space parts that may be required if the service agency is of some distance away or if down time must be kept to a minimum and spare parts are required for the service

agent on site.

PART NUMBER DESCRIPTION QUANTITY

KE54834-4 SOLENOID VALVE 1

KE55253 AIR OPERATED CYLINDER 1

KE53469-4 IGNITION MODULE 1

KE00458 SOLID STATE CONTROL 1

KE50753-7 RELAY 1

KE00515 THERMISTOR 1

KE50753-10 RELAY, 120 V HOT COLD WATER BYPASS 1

KE02274 CAPACITOR ASSEMBLY 3

KE603208-9 CONTACTOR CARTRIDGE, NORMALLY OPEN 2

KE603208-8 CONTACTOR CARTRIDGE, NORMALLY CLOSED 2

KE50753-10 RELAY 1

Page 44

AC INVERTER PROGRAMMING INSTRUCTIONS

The WFC Series AC Inverters come wired for external use and must be installed for use in a side panel control (See WIRING DIAGRAMS). Refer to owners manual for complete instructions and explanations. Manual used for the following was FORM 1094.

After installation is complete the inverter must be reprogrammed to Cleveland's modifications of the factory settings. All modifications are achieved in Access Level 2.

1. Turn agitator power on. The top four LED indicators will illuminate momentarily - wait for the three green LED's to go

out before proceeding.

2. Press the PROGram and SHIFT keys simultaneously to reach Access Level 2. The display display will now read:

3. Use the UP/DOWN arrow keys to select the program parameter for change.

4. Press the SHIFT key. The program number will blink indicating that that the data value may be changed.

5. Use the UP/DOWN arrow keys to select the new data code.

6. Press the ENTER key. The display will indicate **STORED** for one second, then revert to the normal parameter

display.

7. Press the PROGram key to exit the programming mode or the UP/DOWN keys to select an new parameter for

change.

PROGRAM CODE SUMMARY:

# Name Description Data Range Factory Setting Units Access Level Customer Setting

01 MODEL Model Number 0-65000 Note 1 --- 1

02 RVLVL Software Revision 0-640 Note 1 --- 2

03 IRAT Rated Current 2-200 Note 1 A 2

05 SERNO Serial Number 0-65000 --- --- 2

06 REP Repair Date 0-65000 --- --- 2

07 FLT3 Last Fault --- --- --- 1

08 FLT2 2nd Fault --- --- --- 2

09 FLT1 1st Fault --- --- --- 2

12 FOUT Output Frequency 0-400 --- Hz 1

13 VOUT Output Voltage 0-100 --- % 1

14 IOUT Output Current 0-650 --- A 1

15 LOAD Drive Load 0-200 --- % 1

16 TORQ Load Torque 0-200 --- % 1

17 TEMP Inverter Temp 2-105 --- C 1

18 TIME1 Total Run Time 0-65000 --- h 2

19 TIME2 Power On Hours 0-65000 --- h 2

21 MODE Input Mode 0-36 0 --- 1 4

24 FSEL Reference Select 0-18 0 --- 2

27 TLSEL Torque Limit Select 0-6 0 --- 2

31 FMIN Min. Frequency 0.00-400 0 Hz 1 14

32 FMAX Max. Frequency 20.00-400 60 Hz 1 70

33 F2 Preset Speed #2 - Jog 0.00-400 5 Hz 1

34 F3 Preset Speed #3 0.00-400 20 Hz 2

35 F4 Preset Speed #4 0.00-400 40 Hz 2

36 F5 Preset Speed #5 0.00-400 60 Hz 2

37 F6 Preset Speed #6 0.00-400 0 Hz 2

38 F7 Preset Speed #7 0.00-400 0 Hz 2

39 FTL Min. Frequency in Torque Limit 0.00-400 10 Hz 2

41 RSEL Ramp Selector 0-7 0 --- 2

42 ACC1 Acceleration Time #1 0.10-600 3 s 1 9

Page 45

43 DEC1 Deceleration Time #1 0.10-600 3 s 1 1

44 ACC2 Acceleration Time #2 0.10-600 1 s 2

45 DEC2 Deceleration Time #2 0.10-600 1 s 2

46 DECTL Torq. Limit Response Time 0.10-30 1 s 2

47 DCBRK DC Brake Time 0-5 0.2 s 2

48 DCVLT DC Brake voltage 0-15 Note1 % 2

51 VSEL V/Hz Characteristic Selector 0-5 0 --- 2 2

52 BOOST Torque Boost 0-25 Note 1 % 1 8

53 FKNEE V/Hz Knee Frequency 26-640 60 Hz 2 75

54 SKBND Skip Fresq. Hysteresis Band 0.20-20 1 Hz 2

55 SK1 Skip Frequency #1 0.00-400 0 Hz 2

56 SK2 Skip Frequency #2 0.00-400 0 Hz 2

57 SK3 Skip Frequency #3 0.00-400 0 Hz 2

58 SK4 Skip Frequency #4 0.00-400 0 Hz 2

59 MVOLT Rated Motor Voltage 185-480 Note 1 V 2

61 LTLF Load Torq. Limit Forward 5-150 150 % 2

62 LTLR Load Torq. Limit Reverse 5-150 150 % 2

63 RTLF Regenerative Torq. Limit FWD 5-110 80 % 2

64 RTLR Regenerative Torq. Limit REV 5-110 80 % 2

65 SLIP Slip Compensation 0-10* 0 % 1

66 STAB Current Stability 0-5 2 --- 2

67 TOL Timed Overload Trip Point 0-100 0 % 2 100

68 NRST Restart Number 0-8 0 --- 2

69 DRST Restart Delay 0-60* 0 s 2

6C TOLC Timed Overload Characteristic 0-7 0 --- 2

71 METER Analog Meter Output 0-7 1 --- 1

72 ST1 Auxiliary Output #1 0-11 6 --- 2

73 ST2 Auxiliary Output #2 0-11 3 --- 2

74 ST3 Auxiliary Output #3 0-11 7 --- 2

75 STR Auxiliary Relay (Fault) 0-11 2 --- 2 3

81 PRGNO Special Program Number 0-65000 0 --- 2 2

82 START Inverter Start Options 0-7 0 --- 2

83 PWM Carrier Frequency Selector 0-1 0 --- 2 1

84 DISP Display Option Full Setting 0-65000 0 --- 2

85 UNITS Display Units ALPHA RPM_1 --- 2

86 LANG Display Language 0-3 0 --- 2

87 ACODE Security Access Code 0-999 0 --- 2

A2 RATIO Master Slave Speed Ratio (Note 2) 50-2000 100 % 2

B1 OPTNO Option Board Number 0-6 0 --- 2

Cx CNTLx Event Control (1-9) BINARY (8) 0 --- 2

Ex ECNTx Event Counts (1-9) 0-65535 0 --- 2

Bolded areas indicate Cleveland modifications of factory settings.

Page 46

WIRING DIAGRAM - DUAL REMOTE

Page 47

WIRING DIAGRAM SINGLE REMOTE