Cleveland Range KGT-25, KGL-25-T, KCL-25-T, KGL-25, KGT-25-T User Manual

Page 1
SE95052
Operators Manual
Installation, Operation & Service
Gas 25 Gallon Kettle
MODELS: KGL-25 KGL-25-T
KGT-25-T
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
Enodis
Page 2
FOR THE USER
IMPOR
TANT
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.
KEEP APPLIANCE AREA FREE AND CLEAR FROM COMBUSTIBLES.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATION AIR.
ALL SERVICE MUST BE PERFORMED BY A QUALIFIED CLEVELAND RANGE TECHNICIAN.
RETAIN THIS MANUAL FOR YOUR REFERENCE.
WARNING: Improper installation,
adjustment, alteration, service or maintenance can cause property
damage, injury or death. Read the
installation operating and maintenance instructions
thoroughly before installing or
servicing this equipment.
FOR YOUR SAFETY
DO NOT STORE OR USE
GASOLINE OR ANY OTHER
FLAMMABLE LIQUIDS AND VAPOURS IN THE VICINITY
OF THIS OR ANY OTHER
APPLIANCE.
IMPORTANT!
ENSURE KETTLE IS AT ROOM TEMPERATURE AND
PRESSURE GAUGE IS SHOWING ZERO OR LESS PRESSURE
PRIOR TO REMOVING ANY FITTINGS.
Page 3
TABLE OF CONTENTS
Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Shipping Damage Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Specification Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Operating Instructions General Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operating the Kettle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Approximate Boiling Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cleaning Instructions Care & Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Recommended Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Service Parts Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Faucet Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Burner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2" Tangent Draw-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Assembly - Tilting Models . . . . . . . . . . . . . . . . . . . . . 12-14
- Stationary Models. . . . . . . . . . . . . . . . . . . 15-16
Console Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hinge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Maintenance Inspection & Maintenance Check List . . . . . . . . . . . . . . . . . . . . . 19
Safety Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21
- Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Safety Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Low Water Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Operating Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hinge Adjustment Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Calibrating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pressure Relief Valve Periodic Testing Procedure. . . . . . . . . . . . . 23
Reservoir Fill Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Kettle Jacket Filling & Draining Procedures . . . . . . . . . . . . . . . . 25
Kettle Venting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Vacuum Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Repairing Leaks in Steam Jacketed Kettle Fittings . . . . . . . . . . . . 27
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Sequences of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-31
Symbol Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-33
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1
INSPECTION
Before unpacking visually inspect the unit for evidence of damage during shipping.
If damage is noticed, do not unpack the unit, follow shipping damage instructions.
SHIPPING DAMAGE INSTRUCTIONS
If shipping damage to the unit is discovered or suspected, observe the following guidelines in preparing a shipping damage claim.
1. Write down a description of the damage or the reason for suspecting damage as soon as it is discovered. This will help in filling out the claim forms later.
2. As soon as damage is discovered or suspected, notify the carrier that delivered the shipment.
3. Arrange for the carrier's representative to examine the damage.
4. Fill out all carrier claims forms and have the examining carrier sign and date each form.
GENERAL
Installation of the kettle must be accomplished by qualified installation personnel working to all applicable local and national codes. Improper installation of product could cause injury or damage.
This equipment is built to comply with applicable standards for manufacturers. Included among those approval agencies are: UL, A.G.A., NSF, ASME/N.Bd., CSA, CGA, ETL, and others. Many local codes exist, and it is the responsibility of the owner/installer to comply with these codes.
Observe all clearance requirements to provide proper make-up air flow. Do not obstruct the flow of combustion and ventilation air. Check rating plate to ensure that kettle has been equipped to operate with the type of gas available at the installation.
Dimensions and clearance specifications are shown on the SPECIFICATION DRAWING (see page #3-4).
CLEARANCE REQUIREMENTS
FOR CLEARANCE REQUIREMENTS (TO COMBUSTIBLE AND NONCOMBUSTIBLE WALLS) AND ASSEMBLY DETAILS REFER TO SPECIFICATION DRAWING ON PAGE #3.
INSTALLATION
Note: For clearance requirements, suggested
drain location and assembly details refer to "SPECIFICATION DRAWING" on page #3.
1. Position the unit in it's permanent location, and level the unit by turning the adjustable feet.
2. Once positioned and leveled, permanently secure the unit's flanged feet to the floor using 5/16" lag bolts and floor anchors (supplied by the installer). Three bolts are required to secure each of the flanged feet.
3. Seal joints of flanged feet with a silicone sealant.
GAS
ENSURE THE GAS SUPPLY MATCHES THE KETTLE'S REQUIREMENTS AS STATED ON THE RATING PLATE.
It is recommended that a sediment trap (drip leg) be installed in the gas supply line. If the gas pressure exceeds 14” water column, a pressure regulator must be installed, to provide a maximum of 14” water column gas pressure to the gas control valve.
Connect the gas line to the manual valve located at the rear of the control box.
Installation must be in accordance with local codes and/or the National Fuel Gas Code ANSI Z223.1 Latest Edition (USA) or the latest Installation Codes for Gas Burning Appliances and Equipment CAN/ CGA B149.1 and CAN/ CGA B149.2 (Canada). Use a gas pipe joint compound which is resistant to L.P. gas. Test all pipe joints for leaks with soap and water solution. Ensure that the gas pressure regulator is set for the manifold pressure indicated on the gas rating plate.
The appliance and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.45 kPa). The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.45 kPa).
INSTALLATION
FLANGED FOOT DETAIL
4 7/8" (124mm)
120 120
7/16"Ø, 3 HOLES
ON 3 1/8" (80mm) B.C.D.
(REAR LEGS ONLY)
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2
ELECTRICAL
ENSURE THE ELECTRICAL SUPPLY MATCHES THE KETTLE'S REQUIREMENTS AS STATED ON THE RATING LABEL.
A cord and plug are supplied with the unit. Simply plug the unit into any grounded outlet rated for a minimum of 10 amps. See GENERAL ASSEMBLY (pages #12-16) drawings for location of wiring diagram.
WARNING: Electrical Grounding Instructions.
This unit is equipped with a three-prong (grounding) plug for your protection against shock hazard and should be plugged directly into a properly grounded three-prong receptacle. Do not cut or remove the grounding prong from this plug. Standard supply voltage is 115 volts A.C., however, optional A.C. voltages can be supplied on special order. A separate fused disconnect switch must be supplied and installed in the high voltage electrical supply line. The kettle when installed, must be electrically installed and grounded in accordance with local codes, or in the absence of local codes, with National Electrical Code, ANSI/NFPA 70-1990 (USA) or the Canadian Electrical Code, CSA C22.2, Part 1 (Canada).
VENTILATION
Gas fired kettles are only to be installed under a ventilation hood in a room which has provisions for adequate make up air. Further information can be obtained by referring to the U.S.A. National Fire Protection Associations NFPA96 regulations. These standards have also been adopted by the National Building Code in Canada.
WATER
The sealed jacket of the gas-fired kettle is precharged with the correct amount of a water-based formula, and therefore, no water connection is required to the kettle jacket. The kettle can be equipped with optional hot and cold water taps, the taps require 1/2" copper tubing as supply lines.
INSTALLATION CHECKS
Although the kettle has been thoroughly tested before leaving the factory, the installer is responsible for ensuring the proper operation of kettle once installed.
DO NOT ATTEMPT TO OPERATE THIS APPLIANCE DURING A POWER FAILURE.
KEEP APPLIANCE AND AREA FREE AND CLEAR OF COMBUSTIBLES.
1. Before turning the kettle on, read the vacuum/pressure gauge. The gauge's needle should be in the green zone. If the needle is in the "VENT AIR" zone, follow air venting procedure.
2. Supply power to the kettle by placing the fused disconnect switch to the "ON" position.
3. Turn on main gas supply to unit. Open the kettle's shut-off valve (located at back of console).
4. Turn the temperature control knob to "1" (Min.). The green LED light should remain lit, indicating the burner is lit, until the set temperature is reached. Then the green light will cycle on and off, indicating the burner is cycling on and off to maintain temperature.
5. Tilt the kettle forward. The red "LOW WATER" light should be lit when the kettle is in a tilted position. This light indicates that the burner has automatically been shut off by the kettle's safety circuit. This is a normal condition when the kettle is in a tilted position.
6. Raise the kettle to the upright position. The red "LOW WATER" light should go out when the kettle is upright. If the red light remains lit in the upright position, it indicates a low water condition, and water must be added to the reservoir before the kettle can be operated. Refer to the "RESERVOIR FILL PROCEDURES", on page #19.
7. Turn the temperature control knob to "10" (Max.) and allow the kettle to preheat. The green light should remain on until the set temperature is reached. Then the green light will cycle ON and OFF, indicating the burner is cycling ON and OFF to maintain temperature.
CLEANING
After installation the kettle must be thoroughly cleaned and sanitized prior to cooking. See CLEANING INSTRUCTIONS (page #7) for detailed information and suggested cleaners.
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3
SPECIFICATION DRAWING
- TILTING MODELS
NOTES
SPECIFICATIONS
FLANGED
FOOT DETAIL
FOOT LOCATION &
FLOOR DRAIN DETAIL
OVERALL DEPTH
Page 7
4
SPECIFICATIONS NOTES
FOOT LOCATION &
FLOOR DRAIN DETAIL
FLANGED
FOOT DETAIL
9/16"
14
mm
120º TYP
1" (25
mm)
MAX. ADJUSTMENT
1 5/8" (42 mm)
Ø
7/16" (11 mm)
Ø
3 HOLES ON
3 1/8" (80
mm)
Ø
B.C.D.
4 7/8"
124
Ø mm
SPECIFICATION DRAWING
- STATIONARY MODELS
Page 8
5
OPERATING INSTRUCTIONS
ITEM # DESCRIPTION FUNCTION
1. Tilt Wheel (tilting models only) Used for tilting the kettle.
2. Vacuum/Pressure Gauge Indicate steam pressure in PSI inside steam jacket as well as
vacuum in inches of mercury.
3. Pressure Relief Valve This valve is used to vent the kettle and in the unlikely event there is an excess steam build-up in the jacket, this valve opens automatically to relieve this pressure.
4. Low Water Indicator Light (Red) When lit, indicates that the kettle is low on water and will not operate in this condition (see RESERVOIR FILL PROCEDURES on page #24).
5. On-Off Switch/ Turns kettle ON/OFF and allows the operator to adjust the kettle
Solid State Temperature temperature in increments from 1 (Min.) to 10 (Max.). Control (see TEMPERATURE RANGE CHART on page #6).
6. Heat Indicator Light (Green) When lit, indicates that the kettle's burner is on. Cycles ON-OFF with burner.
7. Water Level Sight Glass Displays water level in steam jacket.
8. Ignition Failure Indicator Light Indicates failure of heating system to ignite.
(Amber)
9. Tangent Draw-Off Valve Used for draining product or wash water from kettle. It is supplied as standard equipment on stationary kettles and is optional on tilting kettles
.
General Parts Drawing
2
3
1
7
4
5
6
8
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6
OPERATING THE KETTLE
DO NOT ATTEMPT TO OPERATE THIS APPLIANCE DURING A POWER FAILURE.
KEEP APPLIANCE AND AREA FREE AND CLEAR OF COMBUSTIBLES.
DO NOT LEAN ON OR PLACE OBJECTS ON KETTLE LIP. SERIOUS INJURY COULD RESULT IF KETTLE TIPPED OVER, SPILLING HOT CONTENTS.
1. Before turning kettle on, read the Vacuum/Pressure
Gauge (2). The gauges needle should be in the green zone. If the needle is in the "VENT AIR" zone, refer to the Kettle Venting Instructions (page #21). Any air that may be present will increase cooking times. Once heated, the kettle's normal maximum operating pressure is approximately 10­12 psi while cooking a water base product.
2. Ensure that the electrical service to the kettle is
turned on at the fused disconnect switch.
Temperature Range Chart
3. Preheat the kettle by turning the
ON/OFF
Switch/Solid State Temperature Control
(5) to the desired temperature setting (see above, TEMPERATURE RANGE CHART). The Heat Indicator Light (Green) (6) will remain lit, indicating the burner is on, until the temperature setting is reached. When the green light goes off, the burners are off, and preheating is complete.
NOTE: When cooking egg and milk products, the kettle should not be preheated, as products of this nature adhere to hot cooking surfaces. These types of food should be placed in the kettle before heating is begun.
4. Place food product into the kettle. The Heat Indicator Light (Green) (6) will cycle on and off indicating the burners are cycling on and off to maintain the set temperature.
NOTE: Do not fill kettle above recommended level marked on outside of kettle.
NOTE: The Low Water Indicator Light (Red) (4) should not be lit during kettle operation. This light indicates that the burners have been automatically shut off by the kettle's safety circuit. It is normal for the red light to come on when the kettle is in a tilted position. However, the kettle cannot be operated when the red light remains lit while the kettle is in the upright position. This indicates a low water condition, and water must be added to the reservoir. Refer to Reservoir Fill Procedures on page #19 of this manual for details.
5. When cooking is completed turn
ON/OFF
Switch/Solid State Temperature Control
(5) to the
"OFF' position.
NOTE: A five minute complete shut-of period is required before relighting.
6. Pour the contents of the kettle into an appropriate container by tilting the kettle forward. Care should be taken to pour slowly enough to avoid splashing off the product.
NOTE: As with cleaning food soil from any cookware, an important part of kettle cleaning is to prevent food from drying on. For this reason, cleaning should be completed immediately after cooked foods are removed. Refer to the Cleaning Instructions (page #6) for detailed kettle washing procedures.
APPROXIMATE BOILING TIMES
The accompanying chart shows approximate times required for electric kettles of various capacities to boil water. The
ON/OFF Switch/Solid State Temperature
Control
(5) must be set at “10” (Max.) throughout the heat-up period. Water will boil about 1/3 faster if the kettle is filled only to the outer steam jacket’s welded seam resulting in a kettle filled to 2/3 capacity.
Approximate Boiling Times
Kettle Capacity Minutes
25 gallon 37
Temperature Approximate
Control Product Temperature Setting °F °C
MIN. 120 49
1. 130 54
2. 145 63
3. 160 71
4. 170 77
5. 185 85
6. 195 91
7. 210 99
8. 230 110
9. 245 118
MAX. 265 130
NOTE: Certain combinations of ingredients will
result in temperature variations
Page 10
CARE AND CLEANING
Your kettle must be cleaned regularly to maintain its fast, efficient cooking performance, and to ensure its continued safe, reliable operation.
WARNING: Do not use chloride base detergents. There is a growing number of non-chloride cleaners available. If unsure of the cleaners chlorine content consult the supplier. Also avoid cleaners containing quaternary salt as they can cause the stainless steel to pit and rust.
WARNING: If any gaskets or seals are found defective, replace or repair immediately. (See Service Parts Drawings for part identification.)
1. Place the kettle's On-Off Switch/Solid State
Temperature Control (5) to the "OFF" position.
2. Prepare a warm water and mild detergent solution
in the kettle.
3.
Remove food soil inside the kettle using a nylon brush.
WARNING: Do not use a metal
bristle brush or scraper, as this may
permanently damage the kettle's
stainless steel surface.
4. Loosen food which is stuck to the kettle by allowing
it to soak at a low temperature setting.
5. If the kettle is equipped with a draw-off valve, it
should be cleaned as follows:
a) Remove drain screen from bottom of kettle.
Thoroughly wash and rinse the screen either in a sink or a dishwasher, then replace it into the kettle.
b) Disassemble the draw-off valve first by turning
the valve knob counter-clockwise, then turning the large hex nut counter-clockwise until the valve stem is free of the valve body.
c) In a sink, wash and rinse the inside of the
valve body using a nylon brush.
d) Reassemble the draw-off valve by reversing
the procedure for disassembly. The valve's hex nut should be hand tight only.
6. Rinse kettle interior thoroughly, then drain the rinse water. Do not leave water sitting in unit when not in use.
7. Using mild soapy water and a damp sponge, wash the exterior of the kettle, rinse, and dry.
NOTE: For more difficult cleaning applications one of the following can be used: alcohol, baking soda, vinegar, or a solution of ammonia in water.
Avoid the use of chloride cleansers, which may damage the kettle's stainless steel surface.
WARNING: Steel wool should never be used for cleaning the cooking chamber of the kettle. Particles of steel wool become embedded in the cooking surface and rust, which may corrode the stainless steel.
NOTE: Unit should not be cleaned with a water jet.
8. Leave the cover off when the kettle is not in use.
Job Cleaning Agent Comments
Routine Cleaning Soap, Ammonia Apply with cloth or
Detergent, Medallion sponge
Fingerprints Arcal 20, Lac-O-Nu Provides barrier film & Smears Ecoshine
Stubborn Stains Cameo, Talc, Zud Rub in direction & Discolouration First Impression of polish lines
Grease & Fatty Acids, Easy-Off, De-Grease It Excellent removal Blood, Burnt-On Foods Oven Aid on all finishes
Grease & Oil Any good commercial Apply with sponge
detergent or cloth
Restoration/ Benefit, Super Sheen Passivation
RECOMMENDED CLEANERS FOR SPECIFIC SITUATIONS
7
CLEANING INSTRUCTIONS
Chloride Cleaners
Steel Pads
Wire Brush & Scrapers
Page 11
8
FAUCET ASSEMBLY
(optional)
ITEM PART DESCRIPTION QTY. NO. NO.
1.
33//44"" SSPPOOUUTT
KE50825-7 FOR STATIONARY KETTLES . . . . . . . . . . .1
KE50825-2 FOR TILTING KETTLES . . . . . . . . . . . . . . .1
2. FA95022 RETAINING RING . . . . . . . . . . . . . . . . . . . .1
3. FA05002-19 "O" RING . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4. KE51736 LONG FAUCET NUT . . . . . . . . . . . . . . . . .1
5. SE50020 HOT WATER STEM ASSEMBLY . . . . . . . . .1
(DOUBLE PANTRY ONLY)
6. SE50021 COLD WATER STEM ASSEMBLY . . . . . . . .1
7. KE51401 SINGLE PANTRY BODY . . . . . . . . . . . . . . .1
(C/W ITEM NO. 6)
8. KE50335 ADAPTER WASHER . . . . . . . . . . . . . . . . . .1
(SINGLE PANTRY ONLY)
9. KE51403 DOUBLE PANTRY BODY . . . . . . . . . . . . . .1
(C/W ITEM NO. 5&6)
10. SK00395-1 FAUCET MOUNTING BRACKET . . . . . . . .1
11. FA11258 HEX CAP SCREW . . . . . . . . . . . . . . . . . . .2
12. FA30505-1 WASHER . . . . . . . . . . . . . . . . . . . . . . . . . .2
13. FA21008 HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . .2
14. SE50447 WASHER HORSESHOE . . . . . . . . . . . . . . .1
SERVICE PARTS
WARRANTY
Our Company supports a worldwide network of Maintenance and Repair Centers. 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, NSF, ASME/Ntl. Bd., etc.), only factory­supplied replacement parts should be used. The use of other than factory supplied replacement parts will void warranty.
1
2
1
2
3
4
8
10
11
12
13
3
4
5
6
6
10
7
11
12
13
9
14
Page 12
9
ITEM NO. PART NO. DESCRIPTION QTY.
1. KE01927-1 COMPONENT MOUNTING PLATE (STATIONARY MODELS) . . . . . . . . . . . . . . .1
KE01927 COMPONENT MOUNTING PLATE (TILTING MODELS) . . . . . . . . . . . . . . . . . . .1
2. KE50753-7 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3. KE00458 SSK CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4. KE50303 ELECTRONIC BOX HOLDER (STATIONARY MODELS) . . . . . . . . . . . . . . . . . . .1
KE52548 ELECTRONIC BOX HOLDER (TILTING MODELS) . . . . . . . . . . . . . . . . . . . . . . .1
5. FA11089 SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
6. FA11052 SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
9. FA32004 TOOTH LOCKWASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
10. FA32005 TOOTH LOCKWASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
11.* KE53469-2 IGNITION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12.* FA10245 SCREW (8-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
13.* FA20004 HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
FOR 120V OPTION
7. KE53838-20 TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8. KE53838-27 TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
FOR 240V OPTION
7. KE53838-18 TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8. KE53838-21 TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
* LOCATED IN GEARBOX ON GAS MODELS
COMPONENT MOUNTING PLATES
STATIONARY MODELS
TILTING MODELS
43 5 1110 12
10 13
2
5
9
1 7 8
1
8 7 4
3 5 10
2 6 9
Page 13
10
ITEM NO. PART NO. DESCRIPTION QTY.
1. KE54897-1 MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. KE54890-1 IGNITION GUARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3. FA11144 SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
4. KE54881-1 BOTTOM COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5. KE54894-1 HOLDER, BOTTOM COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6. KE54895-3 INSULATION ON TOP OF COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7. KE01500-2 BURNER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8. KE01500-4 BURNER WITHOUT IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9. KE02195-1 BURNER PAN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
10. KE54895-2 INSULATION BETWEEN BOTTOM COVER & BURNER ASSEMBLY . . . . . . . . .2
11. KE54895-4 INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12. KE53406-21 GAS ORIFICE, NATURAL GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
KE53406-18 GAS ORIFICE, LP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
13. FI05134-1 COMPRESSION FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
14. FI00565-6 NIPPLE 3/8 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
15. KE53437-1 IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
16. FA11145 SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
17. KE54775 IGNITOR POSITION HOLDING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
BURNER ASSEMBLY
711
8
10
2151617 3
1 4 5 6
1412
13
9
Page 14
11
2" TANGENT DRAW-OFF VALVE
ITEM NO. PART NO. DESCRIPTION QTY.
1. - 7. KE50972-B DRAW-OFF ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1. FA95049 WING NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. KE527551 KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3. KE52754 HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4. KE52753 RETAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5. KE52752 PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6. FA00111 "O" RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7. KE52751 VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
7
6
5
4
3
2
1
Page 15
12
ITEM NO. PART NO. DESCRIPTION QTY.
1. KE00099 ADJUSTABLE FOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. KE51723-1 SAFETY VALVE (50 PSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3. KE50429-3 PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4. KE54852-1 BRACKET FOR SAFETY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5. KE529773 LID FOR GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6. KE00508 HANDWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7. KE54821-8 SUPPLY CORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8. CHS-KGL-25-T SPRING HINGE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9. KE00351 TRUNNION BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
10. FI05321-1 NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
11. KE54667-3 BURNER TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12. FI05134-1 COMPRESSION FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
GENERAL ASSEMBLY
- TILTING MODELS (pg. 1 of 3)
62
3 2
4
60
VIEW "G"
MANIFOLD & BURNER TUBE PIPING DETAIL
55 56 57
8
5
60 L5
10 13
12 11 12 14
L2 L3
6
9
L4
7
L1
161
G
Page 16
13
13. FI05198-5 COMPRESSION ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
14. FI00565-6 NIPPLE 3/8 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
15. FI05222 SWIVEL ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
16. FI05231 FLUSH BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
17. FI05223 SPECIAL NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
18. KE02053 GAS VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
19. FI00607 CLOSE NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
20. F01518-1 GAS SHUT OFF VALVE
GAS OPTIONS
:
KE54618-1 PRESSURE REGULATOR (PROPANE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE54618-2 PRESSURE REGULATOR (NATURAL GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
21. F105226-12 NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
22. FI00040 ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GENERAL ASSEMBLY
- TILTING MODELS (pg. 2 of 3)
26
25
28
27
30
29
BB
23 24
CC
16 172221 18 19 20
15
3837 39 40 41 36 42 43 45 43 42
44
46 47 48 49 50
58 53 59
31 32 33 34 35
516052 53 54
Page 17
14
23. FA19177 HEX SOCKET SET SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
24. FA20047 JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
25. KE50294-1 MERCURY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
26. KE54456-1 MERCURY SWITCH BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
27. KE50295-1 CLIP FOR MERCURY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28. FA11396 HEX HEAD BOLT (3/8-24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
29. FA31031 SPLIT LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
30. FA15018-7 SCREW 6-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
31. KE52833 WORM GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
32. FA10772 SOCKET HEAD CAP SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
33. FA20030 JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
34. FA95007-4 RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
35. FA95055-1 SQUARE KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
36. KE50315 WORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
37. KE51730 TILT SHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
38. FA31010 SPLIT LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
39. FA20030 HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
40. KE503752 TILT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
41. FA95005 TENSION PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
42. KE52193 THRUST BEARING SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
43. KE52191 ROLLER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
44. KE52192 THRUST WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
45. FA30088 WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
46. FA95008 JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
47. KE53469-2 IGNITION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
48. FA10245 SCREW (8-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
49. FA20004 HEX NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
50. FA32005 TOOTH LOCKWASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
51. KE53390 GAS VALVE MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
52. FA10367 BINDING HEAD SCREW (10-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
53. FA32006 TOOTH LOCKWASHER (J10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
54. FA20007 MACHINE SCREW NUT (10-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
55. KE53316 SAFETY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
56. KE00515 THERMISTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
57. KE50556-1 LOW WATER PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
58. KE01928-1 COMPONENT MOUNTING PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .1
(see COMPONENT MOUNTING PLATES on page #9)
59. FA20006 MACHINE SCREW NUT (10-24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
60. FA11145 SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
61. KE54833-2 SNAP-IN BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
62. KE54468 WATER LEVEL SIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
LABELS
L1. KE95555-5 OPERATING INSTRUCTION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
L2. KE95552 RATING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
L3. KE95551 GAS KETTLE LABEL GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
L4. KE95040 DIRECTION OF TILT LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
L5. KE90424 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GENERAL ASSEMBLY
- TILTING MODELS (pg. 3 of 3)
Page 18
15
GENERAL ASSEMBLY
- STATIONARY MODELS (pg. 1 of 2)
34
11 13
12
531
7 8 10
21
A
6
7 9
14 15 16
10 L1
VIEW "A"
COMPONENT MOUNTING BOX
WITH LID REMOVED
L3
25
27
26
28 29 28 30
4
19 20
VIEW "B"
MANIFOLD & BURNER
TUBE PIPING DETAIL
322 3
33
17242325 18
L4
L2
B
22
1
Page 19
16
ITEM NO. PART NO. DESCRIPTION QTY.
1. KE00099 ADJUSTABLE FOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2. KE01928-2 COMPONENT MOUNTING PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .1
(see COMPONENT MOUNTING PLATES on page #9)
3. FA20006 MACHINE SCREW NUT (10-24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4. FA32006 TOOTH LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5. KE54991-1 LID (COMPONENT BOX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6. KE54991-2 LID (SIDE BOX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7. FA95074 ANCHOR NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
8. KE54846-4 GASKET (COMPONENT BOX LID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9. KE54846-5 GASKET (SIDEBOX LID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
10. FA95031 PAN HEAD PHILLIPS DRIVE SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
11. KE50429-3 PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12. KE54852-1 BRACKET FOR SAFETY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
13. KE54941-6 SAFETY VALVE (50 PSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
14. KE53316 SAFETY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
15. KE00515 THERMISTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
16. KE50556-1 LOW WATER PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
17. KE02053 GAS VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
18. FA10360 SCREW PAN HEAD PHILLIPS (10-32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
19. F01518-1 GAS SHUT OFF VALVE (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GAS OPTIONS
:
KE54618-1 PRESSURE REGULATOR (PROPANE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE54618-2 PRESSURE REGULATOR (NATURAL GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
20. FI00607 CLOSE NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
21. KE54821-8 SUPPLY CORD (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
22. KE54833-2 SNAP IN BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
23. FA00152 STREET ELBOW (3/4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
24. FI00355 BUSHING (3/4 X 3/8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
25. FI00565-3 NIPPLE (3/8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
26. FI05198-5 COMPRESSION ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
27. FI00265 COUPLING (3/8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
28. FI05134-1 COMPRESSION FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
29. KE54667-4 BURNER TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
30. FI00565-6 NIPPLE (3/8 NPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
31. KE51238 CORD CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
32. CHS-25 SPRING HINGE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
33. FA11145 SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
34. KE54468 WATER LEVEL SIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
LABELS
L1. KE90424 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
L2. KE95555-5 OPERATING INSTRUCTION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
L3. KE95552 RATING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
L4. KE95551 LABEL SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GENERAL ASSEMBLY
- TILTING MODELS (pg. 2 of 2)
Page 20
17
CONSOLE CONTROLS
ITEM NO. PART NO. DESCRIPTION QTY.
1. SE00114 POTENTIOMETER WITH ON/OFF SWITCH, C/W ITEM #2 . . . . . . . . . . . . . . . . .1
2. KE51005 RUBBER BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3. KE50569-1 KNOB, POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4. KE50567-1 L.E.D., RED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5. KE50568-1 L.E.D., GREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6. KE50567-2 L.E.D., AMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7. FA05002-18 "O" RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2
3
76
5 7
1
4 7
8
Page 21
18
HINGE ASSEMBLY
ITEM NO. PART NO. DESCRIPTION QTY.
1. - 11 SE00120-1 Hinge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1. KE50882 Hinge Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. KE51217 Hinge Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3. KE50121-2 Hinge Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4. KE50823-1 Hinge Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5. KE50824 Hinge Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6. KE50819-1 Hinge End Piece, LHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7. KE50820 Hinge Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8. KE50819 Hinge End Piece, RHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9. FA11284 Screw, Socket Head, 1/4-20 x 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
10. FA11507 Cutting Screw, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
11. KE54907-10 Plug Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12. KE50151-12 Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
13. Cover Handle (specify model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9
4
7
11
8
6
10
1
9
5
1312
32
Page 22
19
MAINTENANCE
ALL SERVICE MUST BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN.
Cleveland Range equipment requires little preventative maintenance. We do however provide the following
chart as a guideline for inspection and maintenance to keep your unit functioning at 100%.
INSPECTION AND MAINTENANCE CHECKLIST
The following check should be completed every six months or more frequently if unit is in a high volume facility.
WARNING: It is imperative that damaged seals be repaired immediately to prevent equipment failure and/or damage.
ITEM CHECK
HAND WHEEL
(tilting models only) Check hand wheel for tightness. If loose tighten allen screw.
LUBRICATION
(tilting models only) Check that kettle tilts smoothly. Grease trunnion housings and
gear/worm assembly every three months as recommended in LUBRICATION PROCEDURE on page #22.
GEAR/WORM Inspect for play. Tighten Allen screws if required.
PRESSURE GAUGE Check that the gauge does not have moisture on its inside face.
Replace if moisture is present.
Check that the gauge shows a vacuum (needle is well into the Green zone) when cold and shows between 25-40 psi when unit is hot. If not follow VACUUM LEAK TEST on page #26.
PRESSURE RELIEF VALVE Check pressure relief valve as described in PRESSURE RELIEF VALVE
TESTING PROCEDURE on page #22.
TEMPERATURE CHECK Following the CALIBRATING PROCEDURE on page #23, check the
inner kettle surface temperature with a digital surface thermometer and adjust if required.
ON/OFF SWITCH/ Check for damage. Replace if necessary.
TEMPERATURE CONTROL
SPRING ASSIST COVER Check cover is tightly secured to handle and insure spring is holding
cover up - adjust if required. Refer to HINGE ADJUSTMENT INSTRUCTIONS on page #22.
IMPORTANT!
ENSURE KETTLE IS AT ROOM TEMPERATURE AND
PRESSURE GAUGE IS SHOWING ZERO OR LESS PRESSURE
PRIOR TO REMOVING ANY FITTINGS.
Page 23
20
SAFETY INSPECTION CHECKLIST
-
TILTING MODELS (pg. 1 of 2)
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
1
2
3
4
Incorrect Installations
1
Safety valve has plug threaded into the discharge opening preventing any steam from escaping.
2
Safety valve’s tube diameter has been reduced.
3
Safety valve is sticking, frozen shut or plugged. To test, refer to page 23, PRESSURE RELIEF VALVE PERIODIC TESTING PROCEDURE.
4
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.
This illustrations show the correct configuration of a factory installed Safety Valves.
Any modifications are unacceptable.
Page 24
21
SAFETY THERMOST
AT:
Incorrect Installations
1
Safety thermostat probe is not completely inserted into tubing.
2
Safety thermostat probe is removed from tubing.
3
Safety thermostat electrical connection is bypassed.
Low W
ater 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 on page #23.
Operating Thermostat:
Probe bypassed by (B) grounding the connecting wire
(A)
(B)
SAFETY INSPECTION CHECKLIST
-
TILTING MODELS (pg. 2 of 2)
Probe fully inserted in tube
Wiring is properly
connected
123
Probe
removed
partially
Probe
removed
completely
Thermostat
electrically
bypassed
Page 25
22
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 grease nipple.
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
Adjusting
Screw
Worm Screw and Tilt Gear
Cross
Bar
Trunnion Housing
Grease Nipple
Page 26
23
CALIBRATING PROCEDURE
1. Insure the unit has a vacuum before you begin
calibrating procedures. If unit requires venting refer to Kettle VENTING INSTRUCTIONS on page #26.
2.
Set On-Off Switch/Temperature Control to "10" (Max.).
3. Allow the unit to cycle twice.
4. Check temperature of the inner kettle surface with
a digital surface thermometer.
5. Temperature should be between 260° F and 265° F.
6. Using a screw driver adjust temperature by turning
the potentiometer on the black box. Turn very little. Turn clockwise to INCREASES and counter­clockwise 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.
Pressure Relief Valve/Gauge Assembly Drawing
PRESSURE RELIEF VALVE PERIODIC TESTING PROCEDURE
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. Remove guard bracket from pressure relief valve/gauge assembly.
2. With the kettle empty, set On-Off Switch/Temperature Control to "10" (Max.). Allow the kettle to heat until the unit cycles off.
3.
Switch On-Off Switch/Temperature Control to "0"(Off) and disconnect main power at fused disconnect switch.
4. Stand to the side of the pressure relief valve discharge tube and pull valve 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.
5. Replace guard bracket from pressure relief valve/gauge assembly.
If valve appears to be sticking replace pressure relief valve.
If foreign material is discharged then drain kettle (see KETTLE JACKET FILLING & DRAINING PROCEDURES on page #25) and replace pressure relief valve.
See RESERVOIR FILL PROCEDURE (page #24) for full instructions on the correct method for refilling kettle jacket.
WARNING: Improper refilling of kettle jacket will result in irreversible damage to unit.
NOTE: Rust inhibitor is purchased locally. Read directions and do not exceed manufacturer's recommendation (excessive rust inhibitor can also cause solidification).
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.
Pressure Gauge
Pressure Relief Valve
Guard Bracket
Page 27
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 on page #25). 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).
DISTILLED WATER REQUIREMENTS
When red “Low When the reservoir is Kettle Water Light” comes completely empty, Capacity on, add distilled water add distilled water
25 gallon Approximately 1 gal. 4.4 gallon
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 Guard Bracket (A).
4. Pull Pressure Relief Valve (B) open to insure vessel
is not pressurized.
5. Remove Pressure Relief Valve (B).
6. Replace Pressure Relief Valve (B) with Street
Elbow (C).
7. Add distilled water (D) through the Street Elbow (C), 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 Pressure Relief Valve's (B) thread and replace.
9. Replace Guard Bracket (A).
10.
Restore power to unit at the fused disconnect switch.
11.
The kettle must now be vented. (Refer to the KETTLE VENTING INSTRUCTIONS on page #26).
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.
24
Sight Glass
WARNING: IMPROPER REFILLING OF
KETTLE JACKET WILL RESULT IN IRREVERSIBLE DAMAGE TO UNIT.
50
0
100
150
200
250
300
350
400
40
50
60
0
10
20
30
psi
kPa
V
E
N
T
A
I
R
Pressure Relief Valve/Gauge Assembly Drawing
D. Fill unit via Street Elbow
C.
Attach Street
Elbow
A. Remove
Guard Bracket
*Important-
Pull ring on Pressure Relief Valve
prior to removal to insure vessel is not pressurized.
*
B.
Remove
Pressure
Relief Valve
Page 28
25
Draining Procedure
1. Shut off gas supply.
2. Disconnect gas line and electrical connection.
3. Remove bolts holding kettle to table.
4. Pull ring on pressure relief valve to insure there is
no pressure within the kettle jacket.
5. Remove sight glass.
6. Tilt kettle on its side (sight glass down) and allow
to drain (pull ring on pressure relief valve to speed up draining).
7. Tilt kettle upright and refill with water. Tilt kettle again on its side and allow to drain. Repeat until water drains clear.
8. Apply a thread sealant (i.e. Teflon tape) to the sight glass threads and replace.
Refilling Unit (see RESERVOIR FILL
PROCEDURES on page #24 for details).
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.
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 (page #9) 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.
Refill Quantities
(water and corrosion inhibitor mixture)
Kettle Size U.S. Gallons Liters
25 gallon 4.4 16.6
WARNING: IMPROPER REFILLING OF
KETTLE JACKET WILL RESULT IN IRREVERSIBLE DAMAGE TO UNIT.
Sight Glass
DANGER: EXTREMELY
HOT SURFACES.
WORK ONLY ON COLD
KETTLE.
Page 29
KETTLE VENTING INSTRUCTIONS
1. Remove guard bracket from
pressure relief valve/gauge assembly.
2.
Set On-Off Switch/Temperature Control to to "10 " (Max.), heat the empty kettle until unit cycles off.
3. Vent kettle by pulling safety valve ring 8-10 times in short 2-3 second blasts with a 5 second interval between pulls.
NOTE: If unit cycles ON, stop venting and wait for kettle to cycle OFF before continuing.
4.
Set On-Off Switch/Temperature Control to to "0" (Max.). 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.
5. Replace guard bracket from pressure relief valve/gauge assembly.
50
0
100
150
200
250
300
350
400
40
50
60
0
10
20
30
psi
kPa
V
E
N
T
A
I
R
50
0
100
150
200
250
300
350
400
40
50
60
0
10
20
30
psi
kPa
V
E
N
T
A
I
R
26
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 on page #27).
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.
C. Pressure Gauge.
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.
Pressure
Gauge
Pressure
Relief
Valve
Guard Bracket
Pressure Gauge
Pressure Relief Valve
Water Level Probe
6
5
4
3
2
1
10
OFF
7
8
9
Page 30
27
WIRING DIAGRAM
TABLE-TOP GAS KETTLE, 120-240 VOLTS KE90424-F
Page 31
28
SEQUENCE OF OPERATIONS
1. To turn the unit on, turn the switch to the on
position.
Power is sent to primary side of the 120vac/16vac transformer.
Power is sent to the normally closed high limit.
From the high limit power is sent to the normally
open contacts of the 12VDC relay.
2. From the secondary of the transformer 16VAC is sent to the controller.
Power is sent to the red LED (low water indicator light) from terminal 4 of the controller.
If the water probe is grounded through water the LED will go off.
If the water probe is not grounded the LED will remain on and the unit will not heat.
If the resistance of the thermistor is higher than the setting of the potentiometer( the unit is calling for heat) then 16VDC is sent to the coil of the relay and the green LED (heat indicator light)
The 12VDC relay will close until the unit reaches temperature
3. With the contacts of the relay closed, power is sent to the 24 VAC transformer.
The transformer sends 24 VAC to the ignition module.
Ignition module sends 24 VAC to the Amber LED
The ignition module will send spark to the igniter
and 24 VAC to the gas valve.
With 24VAC to the gas valve the valve opens and gas is sent to the burner.
Spark and gas together cause ignition.
When this happens and the module reads at
least 0.7 micro amps DC within 4 seconds, the Amber light will go out and the 24 VAC will remain on the gas valve.
The unit will heat causing the water to boil and steam to be generated.
If the module does not see the 0.7 micro-amps in 4 seconds, the module will try again in 15 seconds. It will try 3 times then lock out.
4. The kettle will heat (build pressure) until the controller is satisfied by the thermistor at the setting of the potentiometer.
The controller will then turn off the heat circuit until the temperature of the kettle is below the setting.
When the temperature drops below the setting the controller will send 12 VDC to the relay and the heat circuit will be energized again.
5. To turn the unit off, place the switch in the off position.
Power will be removed from the controller and the heat circuit will de-energize.
Page 32
29
PROBLEM: KGL-25 Kettle Won't Heat
Replace
the on/off
switch (toggle
or rotary).
Replace the transformer.
Yes
Yes
Is 16 VAC at the
secondary side of
the transformer?
No
Is there 115 VAC
to the primary of the transformer?
No
Supply115 VAC to the
kettle.
Does red light
come on when unit
is first turned on?
Is 16 VAC
measured across
No
Pins 9 and 10 on
the controller?
Replace the
Replace the
high limit.
Replace the
transformer
No
relay.
ignition
Does red light go
Yes
off shortly after
unit is turned on?
potentiometer set
at 10, is 12 VDC at
Yes
the coil of the
Does the relay pull
No
Is there 115 VAC
to the primary of
No
transformer?
Is there 24 VAC to
No
Yes
With the
relay?
Yes
in?
Yes
the ignition
Yes
the ignition
Module?
Yes
Add water to
No
jacket of Kettle.
With a jumper
across pins 5 and
7 on the controller,
No
is there 12 VDC
across the coil of
the DC relay?
Does the
potentiomer have
a resistance of
50,000 ohms on
low and 0 ohms at
Does the probe
have a resistance
of 100,000 ohms +
10% at room temperature?
Replace Probe
Yes
high?
Yes
No
removed and the
No
probe, is 12 VDC measured across
the coil of the DC
No
Yes
Replace the
wire harness in
the trunion
No
With the jumper
probe wire
grounded at the
relay?
Yes
Add water
Replace the
potentiometer
Replace the
controller
No
Replace
the Ignition
module.
No
Is there 24 VAC to
the Gas valve for 4
Seconds?
Yes
Is there Gas to the
burner?
Yes
Is there Spark to
the ignitor for 4
seconds.
Yes
If there
is spark and gas to
the burner assmbly
there should be
flame. Check
alighnment.
No
Replace the
gas valve
Page 33
30
PROBLEM: KGL-25 Kettle Not Hot Enough
Does the kettle
heat at all?
Yes
With kettle pot
empty and
temperature knob
set at 10, is the
temperature of the
surface of the pot
260 degrees?
No
Yes
See Problem:
kettle won't heat.
Unit is
operating
properly
Yes
Vent the kettle per instructions in
the manual.
When unit is cold
(room temp) is the
No
pressure gauge in
the green?
When the unit is
calling for heat
(the green light is
on), is there flame
at the burner?
Is the resistance of
the thermister
100,000 ohms
+10% at room
temperature?
No
Yes
Yes
Is there 24 VAC to
Is there 115 VAC
to the primary of
No
No
Replace the
igniton
transformer
No
the ignition
module?
Yes
the ignition
module?
Replace the
thermister.
No
Replace the
high limit
Replace
controller.
Yes
ohms at low and 0
Yes
Is the
potentiometer
resistance 50,000
ohms at high?
No
Replace the
potentiometer.
Page 34
31
PROBLEM: KGL-25 Kettle Gets Too Hot
The
kettle is working
properly.
temperature set at
Yes
continue to call for
the kettle reaches
260-265 degrees?
With the kettle empty and the
10, is the surface
temp 260-265
degrees?
No
Does the kettle
heat (green light
stays on) when
No
Is the resistance of
Yes
100,000 ohms +
;the thermister
10% at room
temperature?
Yes
No
Replace the
thermister.
Is there 115 vac to
Replace the
gas valve.
Replace the
Relay
No
No
the primary of the
ignition
transformer?
Yes
Is there DC
voltage to the coil
of the relay?
Yes
Replace the
controller
PROBLEM: Red Add Water LED Stays On
Add the proper
amount of distilled
water and rust
inhibitor.
Does Red LED stay on after adding the proper
No
amount of distilled
water and rust inhibitor?
Is the resistance of
the potentiometer
50,000 ohms at
the low setting and
0 ohms at high?
Yes
Replace the
controller
No
Replace the
potentiometer
Clean or
replace water
probe.
Replace the
wire harness in
the trunion.
No
No
Yes
Is the red LED on
with probe
grounded?
Yes
Does the red LED
stay on with a
jumper between
pins 5 and 7 on
the controller?
Yes
Replace the
controller.
Page 35
32
ON MARCHE ENCENDIDO ACCESO AN
PAUSE, INTERRUPTION PAUSE, INTERRUPTION PAUSA, INTERRUPCION PAUSA, INTERRUZIONE PAUSE, UNTERBRECHUNG
RESET RÉENCLENCHER RECONECTAR RESET NULLSTELLEN
STOP OF ACTION ARRÊT DE L'ACTION PARAR FUNCIONAMIENTO ARRESTO OPERAZIONE FUNKTION STOPPEN
FAST STOP, EMERGENCY ARRÊT RAPIDE D'URGENCE PARADA RAPIDA, EMERGENCIA ARRESTO RAPIDO, EMERGENZA SCHNELLER STOPP, NOTFALL
RISK OF ELECTRICAL SHOCK DANGER DE SECOUSSE ÉLECTRIQUE PELIGRO DE ELECTROCHOQUE PERICOLO DI SCOSSA STROMSCHLAG-GEFAHR
SPLASHPROOF ANTIÉCLABOUSSURES A PRUEBA DE SALPICADURAS PROTETTO CONTRO GLI SPRUZZI SPRITZWASSERDICHT
DISCONNECT ELECTRICAL SUPPLY BEFORE WORKING ON KETTLE COUPER LE COURANT AVANT D'INTERVENIR SUR L'ÉQUIPEMENT DESCONECTAR LA ALIMENTACION ELECTRICA ANTES DE REALIZAR TRABAJOS EN EL EQUIPO DISINSERIRE LA CORRENTE PRIMA DI LAVORARE SULLA MACCHINA STROMVERSORGUNG AUSSCHALTEN, BEVOR AM GERÄT GEARBEITET WIRD
MAIN POWER ALIMENTATION ÉLECTRIQUE ALIMENTACION PRINCIPAL ALIMENTAZIONE HAUPTSTROM
OFF ARRÊT APAGADO SPENTO AUS
CONTINUE CONTINUER CONTINUAR CONTINUA WEITER
START OF ACTION DÉBUT DE L'ACTION INICIAR FUNCIONAMIENTO INIZIO OPERAZIONE FUNKTION STARTEN
FAST START DÉMARRAGE RAPIDE INICIO RAPIDO AVVIAMENTO RAPIDO SCHNELLER START
Symbol Legend
(page 1 of 2)
English French Spanish Italian German ❐ Chinese-Simplified Chinese-Traditional
Page 36
33
LOW WATER NIVEAU BAS DE L'EAU NIVEL DE AGUA BAJO LIVELLO BASSO WASSERSTAND NIEDRIG
IGNITION FAILURE PANNE D'ALLUMAGE FALLO DE ENCENDIDO MANCATA ACCENSIONE
ZÜNDUNGSFEHLER
COOLING REFROIDISSEMENT REFRIGERACION RAFFREDDAMENTO KÜHLUNG
MIXER BRIDGE PONT DU MÉLANGEUR PUENTE DE MEZCLADORA MENSOLA MESCOLATORE MISCHER-BRÜCKE
RIGHT KETTLE BOUILLOIRE DROITE HERVIDOR DERECHO BOLLITORE DESTRO RECHTER KOCHKESSEL
LIFT LEVER LEVANTAR SOLLEVARE HEBEN
DOWN BAS ABAJO GIÙ RUNTER
COLD WATER EAU FROIDE AGUA FRIA ACQUA FREDDA KALTES WASSER
AUTOMATIC TEMPERATURE CONTROL COMMANDE AUTOMATIQUE DE LA TEMPÉRATURE AJUSTE AUTOMATICO DE TEMPERATURA CONTROLLO AUTOMATICO TEMPERATURA AUTOMATISCHE TEMPERATURREGELUNG
BURNER AND/OR ELEMENT ENERGIZED BRÛLEUR ET/OU ÉLÉMENT ALLUMÉ QUEMADOR O ELEMENTO ENCENDIDO FIAMMA E/O ELEMENTO ATTIVATI BRENNER ODER ELEMENT EINGESCHALTET
HEATING ÉBULLITION CALEFACCION RISCALDAMENTO HEIZUNG
HEAT ADJUSTMENT RÉGLAGE DE LA CHALEUR REGULACION DE CALOR REGOLAZIONE RISCALDAMENTO WÄRMEREGULIERUNG
LEFT KETTLE BOUILLOIRE GAUCHE HERVIDOR IZQUIERDO BOLLITORE SINISTRO LINKER KOCHKESSEL
MIX MÉLANGER MEZCLAR MESCOLATURA MISCHEN
UP HAUT ARRIBA SU RAUF
HOT WATER EAU CHAUDE AGUA CALIENTE ACQUA CALDA HEISSES WASSER
Symbol Legend
(page 2 of 2)
English French Spanish Italian German ❐ Chinese-Simplified Chinese-Traditional
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