Groen AE-1-100 Installation Manual

P IMPORTANT INFORMATION P KEEP FOR OPERATOR P IMPORTANT INFORMATION P

OPERATOR MANUAL OM-EE & AE/1

Part Number 121019 DOMESTIC

MODEL: EE & AE/1

Steam Jacketed Kettle

Self-Contained Electrically heated Floor mounted Stationary

THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE. READ, UNDERSTAND AND FOLLOW THE INSTRUCTIONS AND WARNINGS CONTAINED IN THIS MANUAL.

FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

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IMPORTANT — READ FIRST — IMPORTANT

CAUTION: BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE OPERATING

INSTRUCTIONS, CAUTIONS, AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL.

WARNING: THIS UNIT IS INTENDED FOR USE IN THE COMMERCIAL HEATING, COOKING AND

HOLDING OF WATER AND FOOD PRODUCTS, PER THE INSTRUCTIONS CONTAINED IN THIS MANUAL. ANY OTHER USE COULD RESULT IN SERIOUS PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT AND WILL VOID WARRANTY.

WARNING: KETTLE MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH

ELECTRICITY. IMPROPER INSTALLATION CAN RESULT IN INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT.

DANGER: ELECTRICALLY GROUND THE UNIT AT THE TERMINAL PROVIDED. FAILURE TO

GROUND UNIT COULD RESULT IN ELECTROCUTION AND DEATH.

WARNING: AVOID ALL DIRECT CONTACT WITH HOT EQUIPMENT SURFACES. DIRECT SKIN

CONTACT COULD RESULT IN SEVERE BURNS.

WARNING: AVOID ALL DIRECT CONTACT WITH HOT FOOD OR WATER IN THE KETTLE.

DIRECT CONTACT COULD RESULT IN SEVERE BURNS.

CAUTION: DO NOT OVER FILL THE KETTLE WHEN COOKING, HOLDING OR CLEANING.

KEEP LIQUIDS A MINIMUM OF 2-3” (5-8 cm) BELOW THE KETTLE BODY RIM TO ALLOW CLEARANCE FOR STIRRING, AND BOILING.

WARNING: TAKE SPECIAL CARE TO AVOID CONTACT WITH HOT KETTLE BODY OR HOT

PRODUCT WHEN ADDING OR STIRRING INGREDIENTS.

CAUTION: KEEP FLOORS IN FRONT OF KETTLE WORK AREA CLEAN AND DRY. IF SPILLS

OCCUR, CLEAN IMMEDIATELY, TO AVOID SLIPS OR FALLS.

WARNING: FAILURE TO CHECK SAFETY VALVE OPERATION PERIODICALLY COULD RESULT

IN PERSONAL INJURY AND/OR DAMAGE TO EQUIPMENT.

WARNING: WHEN TESTING, AVOID ANY EXPOSURE TO THE STEAM BLOWING OUT OF THE

SAFETY VALVE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS.

WARNING: TO AVOID INJURY, READ AND FOLLOW ALL PRECAUTIONS STATED ON THE

LABEL OF THE WATER TREATMENT COMPOUND.

WARNING: BEFORE REPLACING ANY PARTS, DISCONNECT THE UNIT FROM THE ELECTRIC

POWER SUPPLY.

WARNING: KEEP WATER AND SOLUTIONS OUT OF CONTROLS AND ELECTRICAL

EQUIPMENT. NEVER SPRAY OR HOSE THE SUPPORT HOUSING OR ELECTRICAL CONNECTIONS.

CAUTION: MOST CLEANERS ARE HARMFUL TO THE SKIN, EYES, MUCOUS MEMBRANES

AND CLOTHING. PRECAUTIONS SHOULD BE TAKEN. WEAR RUBBER GLOVES, GOGGLES OR FACE SHIELD AND PROTECTIVE CLOTHING. CAREFULLY READ THE WARNINGS AND FOLLOW THE DIRECTIONS ON THE LABEL OF THE CLEANER TO BE USED.

CAUTION: USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY GROEN

OR THEIR AUTHORIZED DISTRIBUTORS CAN CAUSE OPERATOR INJURY AND DAMAGE TO THE EQUIPMENT, AND WILL VOID ALL WARRANTIES.

IMPORTANT: SERVICE PERFORMED BY OTHER THAN FACTORY AUTHORIZED PERSONNEL

WILL VOID WARRANTIES.

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Table of Contents

IMPORTANT OPERATOR WARNINGS ................................... 2

EQUIPMENT DESCRIPTION ............................................ 4

INSPECTION & UNPACKING ........................................... 5

INSTALLATION ...................................................... 6

INITIAL START-UP ................................................... 7

OPERATION ........................................................ 8

SEQUENCE OF OPERATION ........................................... 9

MAINTENANCE .................................................... 10

CLEANING ......................................................... 12

TROUBLESHOOTING ................................................ 13

PARTS LISTS ....................................................... 15

SCHEMATICS ...................................................... 16

REFERENCES ...................................................... 25

MAINTENANCE LOG ................................................. 26

WARRANTY ........................................................ 27

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Equipment Description

Groen Model EE and AE/1 are floor-mounted, tilting, steam-jacketed kettles which have thermostatically controlled, self-contained, electrically-heated steam supplies and appropriate controls, mounted on a sturdy base. Heat produced by electric heating elements boils water in a reservoir below the jacket to produce steam under pressure. AE/1 models were manufactured and supplied by Groen through

1987. AE/1 kettles have half the Kilowatt input of corresponding EE models, and heat more slowly.

The kettle is surrounded by air-insulated stainless steel sheathing. Stainless steel panels enclose all of the controls. Three stainless steel, tubular legs support the unit. EE and AE/1 kettles are available in 20, 40, 60, 80 and 100 gallon capacities. Kettle bodies are welded into one piece. Models are all equipped with a sanitary tangent draw-off (product faucet) valve and a stainless steel strainer. This standard draw-off is two inches in diameter, and uses a compression disc valve. The unit is controlled with a thermostat, which turns electric power on or off, and sets the cooking temperature. Instruments are provided to show what is happening inside the unit:

• Water gauge glass: shows the level of water within the steam jacket

• Pressure/vacuum gauge: shows the steam pressure and if there is air in the jacket

• Indicator lamp: Lights when the kettle is being heated

Automatic controls within the unit:

• Contactor: Controlled by the thermostat, turns heating element power on or off

• Low-water cutoff: Turns off power to keep heating elements from overheating if water loss exposes them above the water level.

• Safety valve: Releases steam if jacket pressure gets too high

The jacket is filled at the factory with water that contains rust inhibitors. When air is removed from the jacket, the kettle efficiently provides a uniform heating temperature range of 150 to approximately 270oF (65 to 132oC). This range allows the kettle to be used for warming, simmering, boiling or braising.

The interior of the kettle is polished to a 180 emery grit finish and the exterior is given a uniform Number 4 finish. The unit is ASME shop inspected and registered with the National Board for working pressures up to 30 PSI.

Optional equipment for the EE and AE kettles includes:

• Three inch draw-off valve

• c” perforated or solid disc strainer

• Basket inserts (TRI-BC)

• Water fill faucets

• Automatic water filler

• Kettle brush kit

• 316 stainless steel liner

Capacity Diameter Rim Height Total Width Front to Back

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KETTLE CHARACTERISTICS

EE-20, AE/1-20 EE-40, AE/1-40 EE-60, AE/1-60 EE-80, AE/1-80 EE-100, AE/1-100

20 gal (75 l) 40 gal (150l) 60 gal (226l) 80 gal (300L) 100 gal (378l) 26 in (66 cm) 32 in (81 cm) 36 in (91 cm) 38 in (96.5 cm) 38 in (96.5 cm) 37 in (94 cm) 37 in (94 cm) 40 in (102 cm) 44 in (112 cm) 44 in (112 cm) 26 in (66 cm) 32 in (81 cm) 36 in (91 cm) 38 in (96.5 cm) 38 in (96.5 cm)

38¼ in (97 cm) 48¼ in (123 cm) 47¼ in (120 cm) 49¼ in (125 cm) 49¼ in (125 cm)

Inspection & Unpacking

The unit will arrive in a heavy shipping carton and will be banded to a skid. Immediately upon receipt, inspect the carton carefully for exterior damage.

CAUTION

SHIPPING STRAPS ARE UNDER TENSION AND CAN SNAP BACK WHEN CUT. TAKE CARE TO AVOID PERSONAL INJURY OR DAMAGE TO THE UNIT BY STAPLES LEFT IN THE WALLS OF THE CARTON.

Carefully cut any polyester straps around the carton and detach the sides of the box from the skid. Pull the carton up off the unit.

Thoroughly inspect the unit for concealed damage. Report any shipping damage or

Write down the model number, serial number, and installation date, and retain this information for future reference. Space for these entries is provided at the top of the Service Log at the back of this manual. Keep this manual on file and available for operators to use.

CAUTION

THIS UNIT IS VERY HEAVY. INSTALLER SHOULD OBTAIN HELP AS NEEDED TO LIFT THIS WEIGHT SAFELY.

When installation is to begin, carefully cut any straps which hold the unit on the skid. Lift the unit straight up off the skid. Examine packing materials to be sure that loose parts are not discarded with the materials.

The unit will arrive in a heavy carton.

incorrect shipments to the delivery agent.

Inside it will be banded to a skid.

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Installation

The Groen Kettle is provided with complete internal wiring and is ready for immediate connection. Wiring diagrams are provided in this manual and on the inside of the control housing service panel. Any mechanical or electrical changes must be approved by Groen’s Food Service Engineering Department.

WARNING INSTALLATION OF THE KETTLE MUST BE DONE BY PERSONNEL QUALIFIED TO WORK WITH ELECTRICITY. IMPROPER INSTALLATION CAN RESULT IN INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT.

The completed unit has been operated at the factory to test all controls and heater elements.

1. Set the kettle in place and level it by turning the bullet feet to adjust leg length. Allow clearance around the unit for cleaning, maintenance and service.

2. Confirm that the jacket water level is above the mid point of the gauge glass. If the level is low, follow the instructions under “Jacket Filling and Water Treatment,” Page 11.

3. The open end of the elbow on the outlet of the safety valve must face downward. If it does not, turn it to the correct position.

4. Provide electrical power specified on the equipment electrical information plate. Observe local codes and/or The National Electrical Code in accordance with ANSI/NFPA 70 - (current edition).

5. The equipment is shipped ready for three phase operation. Refer to the wiring diagram for single phase operation.

6. Bringing the electrical service through the entrance at the rear of the support housing with one inch conduit, making a watertight connection with the incoming lines. Observe local codes and/or the National Electrical Code in compliance with ANSI/NFPA 70 (latest edition). When there is a choice between applicable codes, Groen recommends following the more stringent code. (A BX connection is not recommended.)

DANGER ELECTRICALLY GROUND THE UNIT AT THE TERMINAL PROVIDED. FAILURE TO GROUND UNIT COULD RESULT IN ELECTROCUTION AND DEATH.

7. Electrically ground the unit at the terminal provided.

8. Check the following to confirm that your kettle is properly installed:

• Room for cleaning and servicing

• The kettle is level

• The correct amount of water is in the

kettle jacket

• Safety valve is pointed down

• Unit is connected with a waterproof

electric power supply of the proper voltage, phase and amperage rating

ELECTRICAL SPECIFICATIONS*

EE-20 EE-40 EE-60 EE-80 EE-100

KW AMP KW AMP KW AMP KW AMP KW AMP

208 Volts 11 30 22 60 32 90 32 90 32 90 240 Volts 12 29 24 58 36 87 36 87 36 87 480 Volts 12 14 24 28 36 44 36 44 36 44

AE/1-20 AE/1-40 AE/1-60 AE/1-80 AE/1-100

208 Volts 5.6 16 11 30 16 46 16 46 16 46 240 Volts 6.0 14 12 29 18 43 18 43 18 43 480 Volts — — 12 14 16 20 16 20 16 20

*All three phase. Single phase is also available, except on EE-60, 80 and 100.

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Initial Start-Up

IMPORTANT: BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE OPERATING INSTRUCTIONS, CAUTIONS AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL.

Now that the kettle has been installed, you should test it to ensure that the unit is operating correctly.

1. Remove all literature and packing materials from inside and outside of the unit.

2. Clean out any material which might clog or damage the draw-off (product outlet).

3. Install the draw-off valve (packed separately) by sliding the assembly into the tangent and hand-tightening the large stainless steel nut.

3. Turn on the electrical service to the unit.

WARNING AVOID ALL DIRECT CONTACT WITH HOT SURFACES. DIRECT SKIN CONTACT COULD RESULT IN SEVERE BURNS.

AVOID ALL DIRECT CONTACT WITH HOT FOOD OR WATER IN THE KETTLE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS.

4. Pour water into the kettle until it is about six inches deep (150 mm).

5. Test draw-off valve operation by opening it all the way, then closing it before all the water runs out.

6. Following “To Start Kettle” instructions in the “Operation” section of this manual, begin heating the water at the highest thermostat setting. The heating indicator light should come on immediately, and heating should continue until the water boils.

7. To shut down the unit, turn the thermostat dial to “OFF”.

If the unit functions as described above, it is ready for use. If the unit does not function as described, contact your local Groen Certified Service Agency.

Be sure that the pressure/vacuum gauge shows at least 20 inches of vacuum.

Each day, confirm the jacket water level by checking the water gauge.

Slide the assembly into the tangent and hand-tighten the large stainless steel nut.

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The operator controls kettle heating with the thermostat dial. The dial turns heating element power on or off and sets the kettle operating temperature.

A. To Start Kettle

1. EVERY DAY make sure the jacket water level is between the marks on the gauge glass. If the level is too low, see “Jacket Filling and Water Treatment” on page 11.

2. While the kettle is cold, check the pressure gauge. If the gauge does not show 20 to 30 inches of vacuum (that is, a reading of 20 to 30 below 0), see “Jacket Vacuum” on page 10.

3. Make sure that the strainer covers the draw-off valve outlet at the bottom of the kettle. This keeps food solids from collecting in the draw-off area.

4. Turn the thermostat dial to the desired setting. The indicator light will confirm that the kettle is heating. Cycling of the light on and off shows that the kettle is being held at the set temperature. Once

in each cycle contactors in the support housing will make a clicking sound. This is normal.

B. To Transfer Product or Empty Kettle:

1. The kettle is emptied by means of its draw-off valve, by ladling product out, or with the optional tri-basket insert.

Operation

CAUTION DO NOT OVERFILL THE KETTLE WHEN COOKING, HOLDING OR CLEANING. KEEP LIQUIDS AT LEAST 2-3” (5-8 cm) BELOW THE KETTLE BODY RIM TO ALLOW CLEARANCE FOR STIRRING, BOILING PRODUCT AND SAFE TRANSFER.

CAUTION KEEP FLOORS IN FRONT OF THE KETTLE WORK AREA CLEAN AND DRY. IF SPILLS OCCUR, CLEAN AT ONCE TO AVOID SLIPS OR FALLS.

2. Use of Optional Basket Insert The optional kettle basket insert set will

assist in cooking water-boiled products such as eggs, potatoes, vegetables, shell fish, pasta and rice. The nylon mesh liner must be used for products smaller than the basket mesh size, (approximately 1/4” (6 mm). This includes rice and small pasta shapes.

Tips For Use. a) Allow for displacement of the three

baskets and product. This may mean only filling the kettle half way. Test baskets and product displacement with the kettle OFF, and with cold water in the kettle.

WARNING OPEN THE KETTLE LID CAREFULLY TO AVOID STEAM WHICH MAY ESCAPE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS.

CAUTION

DO NOT OVERFILL THE KETTLE WHEN COOKING, HOLDING OR CLEANING. KEEP LIQUIDS AT LEAST 2-3” (5-8 cm) BELOW THE KETTLE RIM TO ALLOW CLEARANCE FOR STIRRING, BOILING AND SAFE PRODUCT TRANSFER.

WARNING AVOID ALL DIRECT CONTACT WITH HOT FOOD OR WATER IN THE KETTLE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS.

b) Load baskets on a level, stable work

surface.

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f) Allow hot water to fully drain from

product, before moving basket away from the kettle. Do not rest baskets on kettle rim or pouring lip. If baskets are too heavy for one individual to lift and safely move, get help. Remove product immediately from basket into another container, being sure to avoid contact with hot product and hot basket or.

g) Place baskets with food on a stable, flat

surface, inside a solid steamer or bake pan, to catch any remaining hot water draining from product.

c) Lift loaded baskets with both hands. Get

help from another person if the basket is too heavy for safe handling.

d) Slowly lower product into kettle and

securely hook the basket to the “Y” frame.

e) When removing baskets with cooked

product, lift straight up, ensuring basket bottoms clear the kettle rim. Wear protective oven mitts and protective apron.

. .

Sequence of Operation

The following “action-reaction” outline is provided to help the user understand how the equipment works.

When the operator starts up the kettle by turning the operating thermostat dial from “OFF” to a desired setting, the thermostat switch closes. This lights up the heating indicator light and causes the contactors to close, allowing power to flow to heating elements.

B. To Turn Off the Kettle

1. Turn the thermostat dial to “OFF.”

2. Before the unit is serviced, or if it will be off for a week or more:

a. Set the thermostat to “OFF.” b. Turn off electric power to the unit at the

circuit breaker or fuse.

switch closes, the heating indicator light comes on, the contactors close, and the heaters come on again. On-off cycling continues, keeping the kettle at the set temperature. This is why the heating indicator light cycles on and off during normal operation.

If steam pressure greater than 30 PSI is generated in the jacket, the safety valve will open and relieve the excess pressure.

When the temperature of the steam jacket reaches the value corresponding to the dial setting, the thermostat switch opens. This turns off the heating indicator light and causes the contactors to open, cutting the power to the heaters.

As soon as the thermostat senses that the kettle is cooling below the set point, the thermostat

If the jacket water level gets too low before the heating elements overheat, the high-limit control will open and shut off power to the elements until the kettle cools.

Setting the operating thermostat dial to “OFF” shuts down all control and heating circuits.

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