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

SE95052

Operators Manual

Installation, Operation & Service

Gas 25 Gallon Kettle

MODELS: KGL-25 KGL-25-T

KGT-25-T

KGT-25

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

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.

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

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)

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.

SPECIFICATION DRAWING

- TILTING MODELS

NOTES

SPECIFICATIONS

FLANGED

FOOT DETAIL

FOOT LOCATION &

FLOOR DRAIN DETAIL

OVERALL DEPTH

SPECIFICATIONS NOTES

FOOT LOCATION &

FLOOR DRAIN DETAIL

FLANGED

FOOT DETAIL

9/16"

120º TYP

1" (25

mm)

MAX. ADJUSTMENT

1 5/8" (42 mm)

7/16" (11 mm)

3 HOLES ON

3 1/8" (80

mm)

B.C.D.

4 7/8"

124

Ø mm

SPECIFICATION DRAWING

- STATIONARY MODELS

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

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

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.

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

CLEANING INSTRUCTIONS

Chloride Cleaners

Steel Pads

Wire Brush & Scrapers

FAUCET ASSEMBLY

(optional)

ITEM PART DESCRIPTION QTY. NO. NO.

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.

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