Cleveland Range KGL-100, KGL-40-SH, KGL-40-T, KGL-60-SH, KGL-40 User Manual

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Page 1

Operators Manual

Installation, Operation & Service

Gas Floor Model Kettles

MODELS:

Stationary -

KGL-40, KGL-60, KGL-80, KGL-100

Tilting -

KGL-40-T, KGL-60-T, KGL-80-T

Short Series -

KGL-40-SH, KGL-60-SH, KGL-40-TSH

KGL-40

KGL-40-T

KGL-40SH

SE95003-1 Rev. 1

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

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.

IMPOR

TANT

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

TABLE OF CONTENTS

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

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

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

Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

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

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

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

Specification Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Operating Instructions Operating Controls & Indicators Drawing . . . . . . . . . . . . . . . . . . . 7

Operating the Kettle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Approximate Boiling Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Cleaning Instructions Care & Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Recommended Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Service Parts Wrap Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Pressure Relief Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Hinge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Electrical Component Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Trunnion Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Tangent Draw-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Gas Control Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16

Gear Box Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-18

Console Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Maintenance Inspection and Maintenance Checklist . . . . . . . . . . . . . . . . . . . . 20

Kettle Safety Inspection Checklist . . . . . . . . . . . . . . . . . . . . . 21-22

Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Hinge Adjustment Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Operating Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-26

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Kettle Won't Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Kettle Not Hot Enough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Kettle Gets too Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Kettle Venting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Vacuum Leak Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Repairing Leaks in Steam Jacketed Kettle Fittings . . . . . . . . . . . 27

Reservoir Fill Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Pressure Relief Valve Periodic Testing . . . . . . . . . . . . . . . . . . . . . 29

Calibrating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Kettle Jacket Filling & Draining Procedures . . . . . . . . . . . . . . . . 30

Gas Kettle Orifice Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Field Conversion Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-36

Symbols Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-38

Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Page 4

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.

Page 5

ELECTRICAL

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

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

WARNING: Electrical Grounding Instructions. This unit is equipped with a three-prong (grounding)

plug for your protection against shock hazard and should be plugged directly into a properly grounded three-prong receptacle. Do not cut or remove the grounding prong from this plug. Standard supply voltage is 115 volts A.C., however, optional A.C. voltages can be supplied on special order. A separate fused disconnect switch must be supplied and installed in the high voltage electrical supply line. The kettle when installed, must be electrically installed and grounded in accordance with local codes, or in the absence of local codes, with National Electrical Code, ANSI/NFPA 70-1990 (USA) or the Canadian Electrical Code, CSA C22.2, Part 1 (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.

CLEANING

After installation the kettle must be thoroughly cleaned and sanitized prior to cooking. See CLEANING INSTRUCTIONS (page #9) for detailed infor mation and

suggested cleaners.

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 (page #28).

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.

Page 6

Specification Drawing -

Stationary, KGL-40, KGL-60, KGL-80, KGL-100

NOTES:

Cleveland Range reserves right of design improvement or modification, as warranted. Many regional, state and local codes exist and it is the responsibility of the owner and installer to comply with the codes. Installation of backflow preventers, vacuum breakers and other specific code requirements is the responsibility of the owner and installer. Cleveland Range equipment is built to comply with applicable standards for manufacturers. Included among those approval agencies are U.L., A.G.A., NSF, ASME/N.Bd., CSA, CGA, ETL and others.

1/2" dia. Soft Copper Tubing (each) When ordered with optional faucet.

WATERELECTRIC

120V-1 Phase, 60 Hz, 10 amps

GAS CLEARANCE

RIGHT = 3" LEFT = 3" REAR = 3"

Allow 6" space minimum from rear and sides when located near combustible walls. 12" recommended on right side for service

NATURAL PROPANE

Piping: 3/4" N.P.T. Piping: 3/4" N.P.T.

Supply pressure: Supply pressure:

4.00" W.C. minimum 4.00" W.C. minimum

14.00" W.C. maximum 14.00" W.C. maximum

Manufacturer must be notified if unit will be operated above 2,000 ft. altitude.

B.T.U. RATING

40 gal. 140,000

60 gal. 80 gal. 190,000

100 gal.

DIMENSIONS

GALS./ LITERS ABCDEFGHJKLMNOPST I.D.

40 IN 35 1/8 37 32 1/4 40 1/2 9 1/4 16 71 1/2 9 9/16 17 3/4

25 15/16

10 3/8 18 5/8 26 7/8 28 1/2 4 5/8 24 1/2 26

150 mm 893 940 820 1029 235 407 1817 243 451 659 264 474 683 724 118 648 661 60 IN 38 1/4 39 34 1/4 43 1/2 8 3/4 14 1/4 75 8 15/16 19 1/8 29 5/16 10 3/8 18 5/8 27 7/8 30 1/4 5 1/4 27 29 1/2

225 mm 972 991 870 1105 223 362 1905 228 486 745 264 474 709 769 134 686 750 80 IN 41 5/8 42 3/8 35 1/2 45 1/2 8 3/4 15 1/2 79 9 1/4 20 3/4 32 1/4 10 3/8 18 5/8 29 5/8 31 1/2 6 5/8 29 33

300 mm 1058 1077 902 1156 223 394 2007 235 528 820 264 474 753 801 169 737 839 100 IN 44 43 1/2 36 1/2 47 1/2 8 3/4 15 1/2 83 1/2 9 1/8 21 7/8 34 5/8 10 3/8 18 5/8 31 1/4 32 1/2 7 1/2 30 1/2 35 1/2

375 mm 1118 1105 928 1207 22.3 394 2121 232 556 880 264 474 794 826 191 775 902

3 (77 mm)

FLOOR DRAIN 12" (305

mm) WIDE x

12" (305

75º

mm) LONG

3" (77 mm) MINIMUM CLEARANCE

(COVER

OPEN)

UNIT SHOWN WITH OPTIONAL 2" TANGENT DRAW-OFF VALVE, SPRING ASSIST COVER AND HOT & COLD WATER FAUCET.

Page 7

Specification Drawing -

Tilting, KGL-40-T, KGL-60-T, KGL-80-T

NOTES:

Cleveland Range reserves right of design improvement or modification, as warranted. Many regional, state and local codes exist and it is the responsibility of the owner and installer to comply with the codes. Installation of backflow preventers, vacuum breakers and other specific codr requirements is the responsibility of the owner and installer. Cleveland Range equipment is built to comply with applicable standards for manufacturers. Included among those approval agencies are U.L., A.G.A., NSF, ASME/N.Bd., CSA, CGA, ETL and others.

1/2" dia. Soft Copper Tubing (each)

When ordered with optional faucet.

WATERELECTRIC

120V-1 Phase, 60 Hz, 10 amps

GAS CLEARANCE

RIGHT = 0" LEFT = 0" REAR = 3"

Allow 6" space minimum from rear and sides when located near combustible walls. 12" recommended on right side for service

NATURAL PROPANE

Piping: 3/4" N.P.T. Piping: 3/4" N.P.T.

Supply pressure: Supply pressure:

4.00" W.C. minimum 4.00" W.C. minimum

14.00" W.C. maximum 14.00" W.C. maximum

Manufacturer must be notified if unit will be operated above 2,000 ft. altitude.

B.T.U. RATING

40 gal. 140,000

60 gal. 80 gal. 190,000

100 gal.

DIMENSIONS

GALS./ LITERS ABCDEFGHJKLMNOPQS I.D.

40 IN 45 3/4 42 1/2 38 35 9 42 1/4 71 40 1/2 15 1/2 23 1/4 19 35 3/4 4 3/8 24 33 63 26 150 mm 1163 108 966 889 229 1074 1804 1029 394 591 483 909 112 610 839 1601 661

60 IN 49 3/8 46 41 1/2 37 11 3/4 47 1/4 75 43 3/4 15 1/4 24 1/2 22 39 3/8 6 28 37 68 29 1/2 225 mm 1255 1169 1055 940 299 1201 1905 1112 388 623 559 1001 153 712 940 1728 750

80 IN 53 49 44 1/2 39 14 3/4 51 78 44 3/4 14 25 25 43 7 30 40 72 33 300 mm 1347 1245 1131 991 375 1296 1982 1137 356 635 635 1093 178 762 1016 1829 839

2 1/4" (57 mm) REF

2 1/2"

(64 mm)

3" (77 mm) REF

2 1/2"

(64 mm)

4 1/8"

7/16" (11 mm)

3 HOLES ON

3 1/8" (80

mm)

B.C.D.

1 5/8" (42 mm)

4 7/8"

124

Ø mm

120º TYP

(105 mm)

VALVE OPENING

HANDWHEEL REPLACED

BY SWITCH FOR

POWER TILT OPTION

1" (25

mm)

MAX. ADJUSTMENT

FLANGED FOOT DETAIL

9/16"

S I.D.

4" (102 mm)

RECOMMENDED

FLOOR SLOPE

1" (26 mm) per 4' (1220 mm)

PIPE DRAIN RECOMMENDED

min. valve size plus 1" (26 mm)

3" (77 mm) MIN.

UNIT SHOWN WITH OPTIONAL 2" TANGENT DRAW-OFF VALVE, SPRING ASSIST COVER AND HOT & COLD WATER FAUCET.

CLEARANCE

Page 8

Specification Drawing -

Short Series, KGL-40-SH, KGL-60-SH,

NOTES:

DIMENSIONS

MODEL NO A B C D E F G H J K L M N P Q S T

KGL-40SH IN 33 41.6 43.3 37.5 69 15.5 7.3 6.7 11 28 35.5 8.2 21.6 11.5 20.8 43.5 23

mm 838 1056 1099 953 1752 394 185 170 279 711 902 208 549 292 528 1105 584

KGL-60SH IN 33.5 44 43.5 37.5 71 12.1 7.3 5.5 12.6 30.5 35.5 8.2 22.2 13.7 22.1 44.5 24.5

mm 850 1117 1104 953 1803 307 185 140 320 775 902 208 564 348 561 1130 622

GAS ELECTRIC WATER CLEARANCE

NATURAL PROPANE BTU RATING 120V-1Phase, 60 Hz.

1/2"

diameter RIGHT = 0"

Piping

3/4"

N.P.T. Piping

3/4"

N.P.T. 190,000 10 amps Soft Copper LEFT = 0"

Supply pressure Supply pressure Tubing each REAR = 0"

4.00" W.C. Min. 11.00" W.C. Min. When ordered Allow 6" space min.

14.00" W.C. Max. 14.00" W.C. Max. with optional from rear and sides

faucet When located near

combustible walls

RECOMMENDED

FLOOR SLOPE

1" (26 mm) per 4' (1220 mm)

PIPE DRAIN RECOMMENDED min. valve size plus 1" (26 mm)

4" (102 mm)

RECOMMENDED

mm)

4 7/8"

124

Ø mm

120º TYP

9/16"

7/16" (11 mm)

3 HOLES ON

3 1/8" (80

mm)

B.C.D.

1 5/8" (42 mm)

1" (25

MAX. ADJUSTMENT

FLANGED FOOT DETAIL

Page 9

Specification Drawing -

Short Series, KGL-40-TSH

NOTES:

SPECIFICATIONS

7/16" (11 mm)

3 1/8" (80

1 5/8" (42 mm)

MAX. ADJUSTMENT

3 HOLES ON

mm)

B.C.D.

1" (25

mm)

FLANGED

FOOT DETAIL

4 7/8"

124

Ø mm

120º TYP

9/16"

FOOT LOCATION &

FLOOR DRAIN DETAIL

NOTES

Page 10

OPERATING INSTRUCTIONS

3 4

9 6

ITEM # DESCRIPTION FUNCTION

1. 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 #28.

2. On-Off Switch/ Turns kettle ON/OFF and allows the operator to adjust the kettle Solid State temperature in increments from 1 (Min.) to 10 (Max.). Temperature Control (see the TEMPERATURE RANGE CHART on page #8).

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

Cycles ON-OFF with burner.

4. Ignition Failure Indicator Light Indicates failure of heating system to ignite. (Amber)

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

vacuum in inches of mercury.

6. Pressure Relief Valve This valve is used to vent the kettle and in the unlikely event there is (not shown) an excess steam build-up in the jacket, this valve opens

automatically to relieve this pressure.

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

8. Tilt Wheel Used for tilting the kettle on hand tilt models. In power tilt models

there is a toggle switch in same location.

9. Flue

10. 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

Operating Controls & Indicators

Page 11

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.

IF YOU ARE COOKING AN EGG OR MILK PRODUCT, DO NOT PRE-HEAT KETTLE.

1. Before turning kettle on, read the Vacuum/Pressure

Gauge (5). The gauges needle should be in the green zone. If the needle is in the " VENT AIR" zone, refer to the KETTLE VENTING INSTRUCTIONS (page #27). Any air that may be present will increase cooking times. Once heated, the kettle's normal maximum operating pressure is approximately 10-12 psi while cooking a water base product.

2. 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

(2) to the desired temperature setting (see above "Temperature Range Chart"). The Heat Indicator Light (Green) (3) 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 green Heat Indicator Light (3) 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 red Low Water Indicator Light (1) 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 #28 for details.

5. When cooking is completed tur n

On/Off Switch/Solid

State Temperature Control

(2) 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 #9) for detailed kettle washing procedures.

APPROXIMATE BOILING TIMES

The accompanying chart shows approximate times required for gas kettles of various capacities to boil water with the lid open. The

ON/OFF Switch/Solid State

Temperature Control

(2) must be set at “10” 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

KGL, KGL-T

40 gallon 35 60 gallon 47 80 gallon 60 100 gallon 75

KGL-SH, KGL-TSH

60 gallon 27 80 gallon 34

Temperature Approximate

Control Product Temperature Setting °F °C

1. 120 49

2. 135 57

3. 150 66

4. 165 74

5. 180 82

6. 195 91

7. 210 99

8. 225 107

9. 245 118

10. 265 130

NOTE: Certain combinations of ingredients will

result in temperature variations

Page 12

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 (2) 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 counterclockwise 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.

CLEANING INSTRUCTIONS

Page 13

WRAP COVERS

KETTLE TOP FRONT LEFT SIDE RIGHT SIDE BACK

KGL-40 KE01479-X KE53483-4 KE54253-X KE01432-X KE02186-1 KGL-60 KE01479-1 KE53483-5 KE54253-1 KE01432-1 KE02186-2 KGL-80 KE01479-2 KE53483-6 KE54253-2 KE01432-2 KE02186-3 KGL-100 KE01479-3 KE53483-7 KE54253-3 KE01432-3 KE02186-4 KGL-40-T KE01479-X KE53483-X KE54253-X KE01432-X KE02186-1 KGL-60-T KE01479-1 KE53483-1 KE54253-1 KE01432-1 KE02186-2 KGL-80-T KE01479-2 KE53483-2 KE54253-2 KE01432-2 KE02186-3 KGL-40-SH KE01479-4 KE53483-6 KE54253-2 KE01432-2 KE02186-3 KGL-60-SH KE01479-5 KE53483-7 KE54253-3 KE01432-3 KE02186-4 KGL-40-TSH KE01479-4 KE53483-2 KE54253-2 KE01432-2 KE02186-3

SERVICE PARTS

BACK

TOP

LEFT SIDE

FRONT

RIGHT SIDE

Page 14

PRESSURE RELIEF ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY.

PRESSURE RELIEF VALVE ASSEMBLIES

1. KE01450 FOR ASME KETTLES (INCLUDES #2-6) 1 KE01450-1 FOR CE KETTLES (INCLUDES #2-6) 1

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

3. FI00151 STREET ELBOW, 90°, 1/2", BRASS 2

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

SAFETY VALVES

5. KE54941-5 1/2" FPT, 50 PSI., FOR ASME KETTLES 1 KE54941-31 1/2" FPT, 50 PSI., FOR CE KETTLE 1

6. KE54223 BLOW DOWN TUBE 1

7. KE54864 ACCESS PANEL 1

8. FA11518-4 THUMB SCREW, 10-32 X 1/2" L 1

Page 15

HINGE ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY.

1. - 11 SE00120-1 HINGE ASSEMBLY - KGL-40/T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SE00120-2 KGL-60/T, KGL-80/T, KGL-40-T/SH . . . . . . . . . . . . . . . .1

SE00120-3 KGL-100/T, KGL-60-T/SH . . . . . . . . . . . . . . . . . . . . . . . .1

1. KE50882 HINGE BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. KE51217 HINGE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3. KE50121-2 HINGE SPRING - KGL-40/T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50121-1 KGL-60/T, KGL-80/T, KGL-100/T,

KGL-40-T/SH,KGL-60-T/SH . . . . . . . . . . . . . . . . . . . . . . . .1

4. KE50823-1 HINGE PIN - KGL-40/T, KGL-60/T, KGL-80/T, KGL-40-T/SH . . . . . . . . . .1

KE50823-2 KGL-100/T, KGL-60-T/SH . . . . . . . . . . . . . . . . . . . . . . . . . .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

1312

Page 16

ELECTRICAL COMPONENT BOX

ITEM ON. PART NO. DESCRIPTION QTY.

KE01422 ELECTRICAL CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53439 COMPONENT BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53440 COVER, COMPONENT BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53599-1 GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1. KE53838-27 TRANSFORMER, 120-14V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

2. KE54833-3 SNAP-IN BUSHING, 0.875" DIA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3. KE53469 IGNITION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4. KE00458 KETTLE SOLID STATE CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50303 BRACKET, SOLID STATE CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5. KE50753-7 RELAY, 120V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50753-8 RELAY, 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

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

8. KE53436 AIR PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53432 AIR PRESSURE SWITCH BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

SIGHT GLASS

ITEM ON. PART NO. DESCRIPTION QTY.

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

2. KE52871 GASKET . . . . . . . . . . . . . . . . . 1

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

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

Page 17

TRUNNION ASSEMBLY

ITEM PART DESCRIPTION QTY. NO. NO.

1. KE00354 TRUNNION BEARING ASSEMBLY . . . . . .1

2. KE00351 TRUNNION BEARING ASSEMBLY . . . . . .1

3. KE51711 ROLLER BEARING . . . . . . . . . . . . . . . . . 2

4. KE51571-1 SPHERICAL WASHER . . . . . . . . . . . . . . . .1

5. FA95081-3 BOLT, 5/16-18 X 1/2" . . . . . . . . . . . . . . . . .1

6. KE51886 GREASE NIPPLE . . . . . . . . . . . . . . . . . . . .1

TANGENT DRAW-OFF VALVE

ITEM NO. PART NO. DESCRIPTION QTY.

1. - 7. TD-2 DRAW-OFF ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TD-3 DRAW-OFF ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1. FA95049 WING NUT, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FA21050 ACCORN NUT, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FA21501-1 ACCORN NUT, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. KE52755 KNOB, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SE50018 KNOB, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3. KE52754 HEX NUT, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SE50016 HEX NUT, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4. KE52753 RETAINER, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SE50013 RETAINER, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5. KE52752 PISTON, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

107487 PISTON, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6. FA05002-24 "O" RING, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FA05002-38 "O" RING, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7. KE50972-B VALVE BODY, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

KE50973-B VALVE BODY, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

For the following units

with covers KGL-40-T

KGL-60-T KGL-80-T

3 4 5

For the following units with or with-out covers

KGL-40-TSH For the following units

with-out covers KGL-40 KGL-80 KGL-40-SH

KGL-60 KGL-100 KGL-60-SH

Page 18

GAS CONTROL ASSEMBLY

31 32 33 34

6 4

13 14

Stationary Models

Tilting

Models

Air Blower Primary

Air Orifice

Secondary

Air

Orifice

Gas Orifice

Ignitor

Burner

Gas Valve

Shut-Off Valve

Page 19

GAS CONTROL ASSEMBLY

ITEM ON. PART NO. DESCRIPTION QTY.

1. KE53441 BLOWER, 115V, 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

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

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

3. KE54239 CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4. KE01426-4 MIXING CHAMBER, 40 GALLON KETTLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

KE01426-2 MIXING CHAMBER, 80 GALLON KETTLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE01426-3 MIXING CHAMBER, 100 GALLON KETTLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5. KE53523 1/4” TUBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6. KE53402 AIR ORIFICE, 40 GALLON KETTLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53402-1 AIR ORIFICE, 60 - 100 GALLON KETTLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53402-2 AIR ORIFICE, 40 GALLON KETTLES (FOR FRANCE ONLY) . . . . . . . . . . . . . . . . . . . . . . .1

KE53402-3 AIR ORIFICE, 60 - 100 GALLON KETTLES (FOR FRANCE ONLY) . . . . . . . . . . . . . . . . . .1

7. KE01449 BLOWER MOUNTING PIPE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8. KE53618 SIGHT GLASS GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

10. KE53619 SIGHT GLASS RETAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11. KE00515 THERMISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

13. KE53437 IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

14. KE53570 GASKET FOR IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

15. FI05257 SHUT-OFF COCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

16. FI05213 PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

17. KE53422 SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

19.

GAS ORIFICES:

KE53403-4 NATURAL GAS - SEA LEVEL UP TO 2000', 40 GALLON KETTLES . . . . . . . . . . . . . . . . .1

KE53403-5 PROPANE GAS - SEA LEVEL UP TO 2000', 40 GALLON KETTLES . . . . . . . . . . . . . . . . .1

KE53403-6 NATURAL GAS - SEA LEVEL UP TO 2000', 60 - 100 GALLON KETTLES . . . . . . . . . . . . .1

KE53403-7 PROPANE GAS - SEA LEVEL UP TO 2000', 60 - 100 GALLON KETTLES . . . . . . . . . . . .1

KE53403-8 NATURAL GAS - 2000' UP TO 4000', 40 GALLON KETTLES . . . . . . . . . . . . . . . . . . . . . .1

KE53403-9 PROPANE GAS - 2000' UP TO 4000', 40 GALLON KETTLES . . . . . . . . . . . . . . . . . . . . . .1

KE53403-10 NATURAL GAS - 2000' UP TO 4000', 60 - 100 GALLON KETTLES . . . . . . . . . . . . . . . . . .1

KE53403-11 PROPANE GAS - 2000' TO 4000', 60 - 100 GALLON KETTLES . . . . . . . . . . . . . . . . . . . .1

KE53403-12 NATURAL GAS - 4000' UP TO 6000', 40 GALLON KETTLES . . . . . . . . . . . . . . . . . . . . . .1

KE53403-13 PROPANE GAS - 4000' UP TO 6000', 40 GALLON KETTLES . . . . . . . . . . . . . . . . . . . . . .1

KE53403-10 NATURAL GAS - 4000' UP TO 6000', 60 - 100 GALLON KETTLES . . . . . . . . . . . . . . . . . .1

KE53403-14 PROPANE GAS - 4000' UP TO 6000', 60 - 100 GALLON KETTLES . . . . . . . . . . . . . . . . .1

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

21. FI05226-4 NIPPLE, 1/2" NPT, 5 5/16" LONG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

22. FI00073 UNION, 1/2" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

23. FI00133 ELBOW, 1/2", STREET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

24. KE93909 STRIP, TO HOLD BLOWER DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

25. FI00040-1 ELBOW, 1/2" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

26. FI00579 NIPPLE, 1/2" NPT, 4" LONG, KGL-60-T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FI05226-2 NIPPLE, 1/2" NPT, 4" LONG, KGL-80-T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

27. KE55004-3 RETAINING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

28. FI00573 NIPPLE, 1/2" NPT, 1 1/8" LONG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

29. FI05231 BUSHING, 3/4 - 1/2" NPT FLUSH, BLACK IRON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

30. F01518-1 GAS SHUT-OFF VALVE, 3/4" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

31. FI05226 NIPPLE, 1/2" NPT, 8" LONG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

32. FI05222 SWIVEL ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

33. FI05223 SPECIAL NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

34. KE02053 GAS VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

35. KE53515 GAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

36. FI00607 NIPPLE, 3/4" NPT, 1 1/2" LONG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Page 20

GEARBOX ASSEMBLY

254226 27 28

Page 21

GEARBOX ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY.

1. KE52836-2 TILT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2. KE50315 WORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3. FA95005 TENSION PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4. KE52193 THRUST BEARING SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

5. KE52192 THRUST WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

6. KE52191 ROLLER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

7. FA30088 WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

8. FA95008 JAM NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

9. KE55057-4 LID FOR GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10. FA95062 PAN HD. PHILLIPS SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

11. KE00508 HANDWHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12. FA19501 HANDWHEEL ALLEN SCREW, HEX SOCKET . . . . . . . . . . . . . . . . . . . .2

13. KE51730 TILT SHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

14. FA19177 HEX SOCKET SET SCREW 5/16-24 X 1/2 . . . . . . . . . . . . . . . . . . . . . . .1

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

16. KE53137-3 MOMENTARY SWITCH ACTIVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

17. KE53184 CONTACT SECTION HOLDER (LATCH) . . . . . . . . . . . . . . . . . . . . . . . .1

18. KE53138-1 CONTACT BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

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

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

21. KE50579 CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

22. KE51007 MICRO SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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

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

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

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

24. FA95014 SQUARE KEY 3/16 X 3/16 X 1" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

26. KE52832 MOTOR "BODINE" #NSH-54RL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

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

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

30. KE517112 LEFT HAND BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

31. KE517111 RIGHT HAND BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

32. KE51712 GREASE NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

33. KE01889 MICRO SWITCH TRIGGER/WORM GEAR WELDMENT . . . . . . . . . . . . . . . . . . .1

34. FA10772 SOCKET HD. CAP SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

35. FA20048 JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

36. FA95050 RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

37. FA95055-1 SQUARE KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

39. KE50581 BRIDGE RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

41. KE50753-10 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

42. KE50473 GROUND LUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Page 22

CONSOLE CONTROLS

ITEM NO. PART NO. DESCRIPTION QTY.

1. KE50504 SWITCH, TOGGLE (USED PRIOR TO JANUARY 2000) . . . . . . . . . . . . . . . . . . .1

2. SK50062 RUBBER BOOT (USED PRIOR TO JANUARY 2000) . . . . . . . . . . . . . . . . . . . . .1

3. SE00114 POTENTIOMETER WITH ON/OFF SWITCH, C/W ITEM #4 . . . . . . . . . . . . . . . . .1

KE50988-2 POTENTIOMETER (USED PRIOR TO JANUARY 2000) . . . . . . . . . . . . . . . . . . .1

4. KE51005 RUBBER BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

5. KE50569-1 KNOB, POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6. KE50567-1 L.E.D., RED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7. KE50568-1 L.E.D., GREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8. KE50567-2 L.E.D., AMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

10. KE50429-2 PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11. KE5555-5-B LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE95457 LABEL (USED PRIOR TO JANUARY 2000) . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

100

150

200

250

300

350

400

psi

kPa

7 9

USED PRIOR TO JANUARY 2000

Page 23

MAINTENANCE

INSPECTION AND MAINTENANCE CHECKLIST

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 checks 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

KETTLE CONSOLE COVER Inspect gasket material for integrity. Replace if necessary.

Insure all screws are in place and firmly holding down the cover. If not replace/tighten screws.

HAND WHEEL

(hand tilt models only) Check hand wheel for tightness. If loose tighten allen screw.

TILTING

(tilting models only)

Check that kettle tilts smoothly. Grease as described in LUBRICATION PROCEDURE (page #23).

ON/OFF SWITCH/ Check for damage. Replace if necessary. TEMPERATURE CONTROL

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 PROCEDURE (page #27).

PRESSURE RELIEF VALVE Check pressure relief valve as described in PRESSURE RELIEF VALVE

TESTING PROCEDURE (page #29).

TEMPERATURE CHECK

Following CALIBRATING PROCEDURE (page #29) check the inner kettle surface temperature with a digital surface thermometer and adjust if required.

LUBRICATION Grease trunnion housings and gear/worm assembly as

recommended in LUBRICATION INSTRUCTIONS on page #23).

GEAR/WORM Inspect for play. Tighten Allen screws if required. ASSEMBLY

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 (page #23)

Page 24

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 page #29, 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 25

SAFETY THERMOSTAT:

✘

Probe

removed

partially

✘

Probe

removed

completely

Page 26

GENERAL

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

position.

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

■ Power is sent to the normally closed high limit.

■ From the high limit power is sent to the normally

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

2. From the secondary of the transfor mer 16VAC is

sent to the controller.

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

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

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

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

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

3. With the contacts of the relay closed, 120VAC is sent to the blower and primary coil of the 120VAC/24VAC transformer.

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

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

4. With both 120VAC (at L1 and L2) and 24VAC (at Gnd and Th) to the ignition module then 120VAC will be sent to the surface igniter.

5. After the ignition module has been energized for 24 seconds the module will send 24VAC to the gas valve.

■ The gas will touch the hot igniter and ignite.

■ The kettle will build pressure until the controller is

satisfied by the thermistor at the setting of the potentiometer.

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

TROUBLESHOOTING GUIDES

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

Page 27

TROUBLESHOOTING GUIDES (continued)

PROBLEM:

KGL

Kettle Won't

Heat

Does red light

come on when unit

is first turned on?

Does red light go

Yes

unit is turned on?

off shortly after

Add water to

jacket of Kettle.

Replace

the on/off

switch (toggle

or rotary).

Replace the transformer.

Yes

Is 16 VAC at the

secondary side of

the transformer?

Is there Power to

the primary of the

transformer?

Supply power

to the kettle.

measured across

Pins 9 and 10 on

Is 16 VAC

the controller?

Replace the

relay.

Replace

blower.

potentiometer set

at 10, is 12 VDC at

Yes

the coil of the

Does the relay pull

Is there power to

the blower?

Does the blower

Yes

With the

relay?

Yes

in?

Yes

turn?

Yes

Replace the

high limit.

With the high limit

temporarily

bypassed, is

power at the

blower?

Yes

Replace the wire to the blower.

Replace

ignition

module.

Replace the

transformer

Is there 120 VAC

Does the ignitor

valve get 24 VAC

20 sec. after the

ignition

to the igniter?

Yes

glow?

Yes

Does the gas

ignitor is

energized?

Is there 24 VAC at

the secondary of

transformer?

Is there 24 VAC to

Yes

Replace the

Does the gas

Yes

valve open?

the ignition

Yes

the igniton

module?

ignitor.

Is there power to

Yes No

the ignition

transformer?

Replace the air

switch.

Replace gas

valve

Replace the

DC relay.

Page 28

TROUBLESHOOTING GUIDES (continued)

PROBLEM:

KGL

Kettle Not

Hot Enough

See Problem:

Kettle won't

heat.

Does the kettle

heat at all?

the kettle per instructions in

the manual.

Replace

controller.

Is the

potentiometer resistance 50,000 ohms at low and 0

ohms at high?

Vent

Yes

With kettle pot

Yes

temperature knob

set at 10, is the

temperature of the

surface of the pot

260 degrees?

When unit is cold

(room temp) is the

pressure gauge in

When the unit is

calling for heat

(the green light is

on), is there flame

at the burner?

Is the resistance of

the thermister

Yes

100,000 ohms

+10% at room

temperature?

empty and

the green?

Yes

Is there voltage to

Unit is

operating

properly

Replace the

high limit?

the blower?

Replace the

thermister.

Yes

Replace the

blower

Is the blower

turning?

Yes

Replace the air

switch

Delayed Igniton

Replace the

potentiometer.

PROBLEM: KGL Kettle Has Delayed Ignition

Replace ignitor.

Is the gas

pressure to the

burner 3.5" W.C.?

Adjust or

replace the gas

Valve.

Yes

Does the ignior

glow evenly

Yes

Does the gas

valve get 24 VAC

20 seconds after

the ignitor is

energized?

Replace the

ignition

module.

Yes

Replace blower

and air switch.

Is the blower

turning?

Yes

Replace burner

Page 29

TROUBLESHOOTING GUIDES (continued)

PROBLEM:

KGL Kettle

Gets Too

Hot

With the kettle

empty and the temperature set at

10, is the surface

temp 260-265

degrees?

The

kettle is working

properly.

Yes

Does the kettle

continue to call for

heat (green light

stays on) when the kettle reaches 260-265 degrees?

Is there supply voltage to the coil of the gas valve?

Replace the

gas valve.

Is there any DC

voltage to the coil

of the relay?

Replace the

Relay

Yes

Replace the

controller

Yes

Is the resistance of

;the thermister

100,000 ohms +

10% at room

temperature?

Yes

Replace the

thermister.

Is the resistance of

the potentiometer

50,000 ohms at

the low setting and

0 ohms at high?

Yes

Replace the

controller

Replace the

potentiometer

Yes

PROBLEM: Red Add Water LED Stays On

Does Red LED stay on after adding the proper

amount of distilled

water and rust inhibitor?

Add the proper

amount of distilled

water and rust

inhibitor.

Is the red LED on

with probe

grounded?

Yes

Clean or

replace water

probe.

Does the red LED

stay on with a

jumper between

pins 5 and 7 on

the controller?

Yes

Replace the

wire harness in

the trunion.

Replace the

controller.

Yes

Page 30

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.

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 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/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

OFF

Page 31

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 #30). 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 Console Cover and Access Panel.

4. Pull Pressure Relief Valve

Ring open to insure vessel is not pressurized.

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

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

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

8. Replace Console Cover and Access Panel.

9. Restore power to unit at the fused disconnect switch.

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

WARNING: IMPROPER REFILLING OF

KETTLE JACKET WILL RESULT IN

IRREVERSIBLE DAMAGE TO UNIT.

Page 32

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 necessar y 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 KETTLE JACKET FILLING AND DRAINING PROCEDURES on page #30 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 on page #27.

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. thr ough 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 33

3. Remove Console Cover and Access Panel.

4. Pull Pressure Relief Valve Ring open to insure

vessel is not pressurized.

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

6. Remove Drain Plug cap and allow water to drain.

7. Replace Drain Plug cap and add water until it

shows on sight glass.

8. Repeat steps 6 & 7 until water drains clear.

9. Apply a thread sealant (i.e. Teflon tape) to the Drain

Plug cap and replace.

10. Add distilled water and rust inhibitor using a funnel if necessary. Fill the unit to the high level mark on the Sight Glass.

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

12. Replace Console Cover and Access Panel.

13. Restore power to unit at the fused disconnect

switch.

14. The kettle must now be vented. (Refer to the KETTLE VENTING INSTRUCTIONS on page #27).

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 #28) 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 manufactur

es 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

Drain Plug Location

Valve

Ring

Console

Cover

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.

100

150

200

250

300

350

400

psi

kPa

Page 34

GAS KETTLE ORIFICE REPLACEMENT

Gas Orifice

Console Cover

"O" Ring

Spring

Plug

1. Remove Console Cover

2. Remove Plug and Spring

3. Remove Orifice

4. Replace with new Orifice and "O" ring

5. Replace Spring and Plug

6. Replace Console Cover

Kettles BTU's per Gas Water # of

Hour Type Column Orifices KGL-40, 140000 Natural Gas 3.5 1 KGL-40-T, 140000 Propane 3.5 1 KGL-60 to 100, KGL-60-T to 80-T,

190000 Natural Gas 3.5 1

KGL-40-TSH,

190000 Propane 3.5 1

KGL-40-F to 60-F, KGL-40-SH to 60-SH,

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 main kettle CONSOLE COVER.

4. Remove PLUG and SPRING.

5. Remove GAS ORIFICE and “O” RING.

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

7. Replace SPRING and PLUG.

8. Replace main kettle CONSOLE COVER.

9. Reconnect electrical supply.

Page 35

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 main kettle CONSOLE COVER.

4. Remove PLUG and SPRING.

5. Remove GAS ORIFICE and “O” RING.

6. Replace first with new “O” RING and then GAS

ORIFICE.

7. Replace SPRING and PLUG.

8. Replace main kettle CONSOLE COVER.

9. Reconnect electrical supply.

Conversion Parts Required

KGL-40

Part No. Description Quantity

KE95591 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

KE95591 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

CONSOLE COVER

NOTE: Changing the gas type requires a new Rating Label be affixed to the unit.

When ordering conversion parts, it is

essential to provide both the Model # and the Serial # of the unit in order to facilitate completion of this label in the factory.

Kettles BTU's per Gas Water # of

Hour Type Column Orifices KGL-40, 140000 Natural Gas 3.5 1 KGL-40-T, 140000 Propane 3.5 1 KGL-60 to 100, KGL-60-T to 80-T,

190000 Natural Gas 3.5 1

KGL-40-TSH,

190000 Propane 3.5 1

KGL-40-F to 60-F, KGL-40-SH to 60-SH,

PLUG

SPRING

GAS ORIFICE

“O” RING

Page 36

WIRING DIAGRAMS

Diagram #1:

Floor Gas Kettle (except KGL-25/T) 110-120 Volts, 60Hz

7 8

9 11

Page 37

Diagram #1 (continued): Floor Gas Kettle (except KGL-25/T) 110-120 Volts, 60Hz

ITEM NO. PART NO. DESCRIPTION QTY.

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

2 KE53436 AIR PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3 KE53441 BLOWER, 115V, 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

5 KE53437 IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

6 KE53515 GAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

7 KE50567-2 L.E.D., AMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

8 KE50567-1 L.E.D., RED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9 KE50568-1 L.E.D., GREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10 SE00114 POTENTIOMETER WITH ON/OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11 KE50753-7 RELAY, 120V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12 KE53838-20??? TRANSFORMER 120-24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

13 KE50753-10 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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

KE53137-3 MOMENTARY SWITCH ACTIVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53184 CONTACT SECTION HOLDER (LATCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

15 KE50581 BRIDGE RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

16 KE51007 MICRO SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

17 KE50579 CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

18 KE52832 MOTOR "BODINE" #NSH-54RL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

19 KE00458 KETTLE SOLID STATE CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

20 KE00458 KETTLE SOLID STATE CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Page 38

Diagram #2 (see Diagram #1 for common parts): Floor Gas Kettle (except KGL-25/T) 200-240 Volts, 60Hz

ITEM NO. PART NO. DESCRIPTION QTY.

21 KE53838-2 TRANSFORMER 120-24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

22 KE53441 BLOWER, 115V, 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Page 39

Diagram #3 (see Diagram #1 for common parts): Floor Gas Kettle (except KGL-25/T) 200-240 Volts, 50Hz

ITEM NO. PART NO. DESCRIPTION QTY.

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

24 KE53838-2 TRANSFORMER 120-24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

25 KE50753-8 RELAY, 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Page 40

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 41

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

✔

Page 42

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

KE00458 KETTLE SOLID STATE CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50753-7 RELAY, 120V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

SE00114 POTENTIOMETER WITH ON/OFF SWITCH, C/W ITEM #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50569-1 KNOB, POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

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

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

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

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

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

KE54941-5 1/2" FPT, 50 PSI., FOR ASME KETTLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE54941-31 1/2" FPT, 50 PSI., FOR CE KETTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53838-27 TRANSFORMER, 120-14V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53469 IGNITION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE00458 KETTLE SOLID STATE CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53436 AIR PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

KE52752 PISTON, TD-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SE50010 PISTON, TD-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

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

KE50567-2 L.E.D., AMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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

`KE53437 IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE02053 GAS VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53137-3 MOMENTARY SWITCH ACTIVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53184 CONTACT SECTION HOLDER (LATCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53138-1 CONTACT BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4