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

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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.

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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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