Groen AE-1-60 Service Manual

OPERATOR MANUAL

IMPORTANT INFORMATION, KEEP FOR OPERATOR

This manual provides information for:

MODELS AH/1E Domestic

STEAM JACKETED KETTLE WITH STANDARD ELECTRONIC IGNITION

·Self-Contained

·Gas 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.

POST IN A PROMINENT LOCATION

Instructions to be followed in the event user smells gas. This information shall be obtained by consulting your local gas supplier. As a minimum, turn off the gas and call your gas company and your authorized service agent. Evacuate all personnel from the area.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Readtheinstallation,operatingandmaintenanceinstructions thoroughly before installing or servicing this equipment.

NOTIFY CARRIER OF DAMAGE AT ONCE

It is the responsibility of the consignee to inspect the container upon receipt of same and to determine the possibility of any damage, including concealed damage. Unified Brands suggests that if you are suspicious of damage to make a notation on the delivery receipt. It will be the responsibility of the consignee to file a claim with the carrier. We recommend that you do so at once.

Manufacture Service/Questions 888-994-7636.

Information contained in this document is known to be current and accurate at the time of printing/creation. Unified Brands recommends referencing our product line websites, unifiedbrands.net, for the most updated product information and specifications.

1055 Mendell Davis Drive Jackson, MS 39272 888-994-7636, fax [phone] unifiedbrands.net

PART NUMBER 121051, REV. H (08/12)

		IMPORTANT - READ FIRST - IMPORTANT
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.
WARNING:		THE UNIT MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH GAS AND
		ELECTRICITY.
WARNING:		UNIT MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE CODES.
CAUTION:		TO AVOID DAMAGING PARTS OF THE BURNER SYSTEM UNDERNEATH THE KETTLE, LIFT THE
		UNIT ONLY BY THE RING BENEATH THE OUTER PORTION OF THE BODY.
WARNING:		DO NOT ATTACH THE UNIT TO A TYPE “B” VENT. IT COULD CAUSE FIRE OR PROPERTY DAMAGE.
WARNING:		DO NOT CONNECT ANY PIPING TO THE SAFETY VALVE. IT MUST BE FREE TO VENT STEAM AS
		NEEDED. TO AVOID BURNS FROM THE VENTED STEAM THE VALVE DISCHARGE SHOULD POINT
		DOWN. IMPROPER INSTALLATION WILL VOID WARRANTY.
WARNING:		FAILURE TO PERIODICALLY CHECK SAFETY VALVE OPERATION COULD RESULT IN PERSONAL
		INJURY AND/OR DAMAGE TO EQUIPMENT.
WARNING:		WHEN TESTING, AVOID EXPOSURE TO THE STEAM BLOWING OUT OF THE SAFETY VALVE.
		DIRECT CONTACT COULD RESULT IN SEVERE BURNS.
DANGER:		ELECTRICALLY GROUND THE UNIT AT THE TERMINAL PROVIDED. FAILURE TO GROUND THE
		UNIT COULD RESULT IN ELECTROCUTION AND DEATH.
CAUTION:		BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE OPERATING INSTRUCTIONS,
		CAUTIONS AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL.
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, BOILING AND SAFE PRODUCT TRANSFER.
CAUTION:		KEEP FLOORS IN FRONT OF KETTLE WORK AREA CLEAN AND DRY. IF SPILLS OCCUR, CLEAN
		IMMEDIATELY TO AVOID SLIPS OR FALLS.
WARNING:		KEEP WATER AND SOLUTIONS OUT OF CONTROLS AND BURNERS. NEVER SPRAY OR HOSE
		DOWN THE CONTROL CONSOLE, ELECTRICAL CONNECTIONS, ETC.
CAUTION:		MOST CLEANERS ARE HARMFUL TO THE SKIN, EYES, MUCOUS MEMBRANES AND CLOTHING.
		TAKE PRECAUTIONS: WEAR RUBBER GLOVES, GOGGLES OR FACE SHIELD AND PROTECTIVE
		CLOTHING. CAREFULLY READ WARNINGS AND FOLLOW DIRECTIONS ON CLEANER LABELS.
NOTICE:		NEVER LEAVE A SANITIZER IN CONTACT WITH STAINLESS STEEL SURFACES LONGER THAN 10
		MINUTES. LONGER CONTACT CAN CAUSE CORROSION AND PITTING.
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
		AND CLOSE THE MAIN GAS VALVE. ALLOW FIVE MINUTES FOR GAS TO VENT.
CAUTION:		USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY AUTHORIZED
		DISTRIBUTORS CAN CAUSE OPERATOR INJURY AND DAMAGE TO THE EQUIPMENT, AND WILL
		VOID ALL WARRANTIES.
2	OM-AH/1

IMPORTANT - READ FIRST - IMPORTANT

WARNING: KEEP AREA AROUND KETTLE FREE AND CLEAR OF ALL COMBUSTIBLE MATERIALS. FAILURE TO DO SO COULD RESULT IN FIRE OR PROPERTY DAMAGE.

CAUTION: HEATING AN EMPTY KETTLE MAY CAUSE THE RELEASE OF STEAM FROM THE SAFETY VALVE.

CAUTION: UNIT WEIGHS 470 TO 1120 LB (212 TO 509 KG). FOR SAFE HANDLING, INSTALLER SHOULD OBTAIN HELP AS NEEDED, OR EMPLOY APPROPRIATE MATERIALS HANDLING EQUIPMENT (SUCH AS A FORKLIFT, DOLLY, OR PALLET JACK) TO REMOVE THE UNIT FROM THE SKID AND MOVE IT TO THE PLACE OF INSTALLATION.

WARNING: THIS UNIT IS DESIGNED FOR COMMERCIAL USE. NEVER USE HOME OR RESIDENTIAL GRADE GAS CONNECTIONS. THEY DO NOT MEET COMMERCIAL GAS CODES AND COULD BE HAZARDOUS.

IMPORTANT: SERVICE PERFORMED BY OTHER THAN FACTORY AUTHORIZED PERSONNEL WILL VOID WARRANTIES.

OM-AH/1 3

Table of Contents

Important Operator Warnings	.....................................................page 2-3
References ...................................................................................	page 4
Equipment Description ...............................................................	page 5-6
Inspection and Unpacking ...........................................................	page 7
Installation ..................................................................................	page 8-9
Initial Start-Up ..............................................................................	page 10
Operation ...............................................................................	page 11-12
Sequence of Operation ..............................................................	page 13
Cleaning ..................................................................................	page 14-15
Maintenance ...........................................................................	page 16-17
Troubleshooting ......................................................................	page 18-19
Parts List .................................................................................	page 20-26
Electrical Schematic ....................................................................	page 27
Service Log .................................................................................	page 28

References

CSA AMERICA INC

8501 East Pleasant Valley Road

Cleveland, Ohio 44131

ANSI Z83.11

NSF INTERNATIONAL

798 N. Dixboro Rd.

P.O. Box 130140

Ann Arbor, Michigan 48113-0140

NSF/ANSI 4

NATIONAL FIRE PROTECTION ASSOCIATION

60 Battery March Park

Quincy, Massachusetts 02269

NFPA/70 The National Electrical Code

NFPA/54 Installation Gas Appliances & Piping

AMERICAN NATIONAL STANDARDS INST., INC

1430 Broadway

New York, New York 10018

Z223.1-1984 National Fuel Gas Code

Z21.30 Installation of Gas Appliances & Piping

4 OM-AH/1

Equipment Description

AH/1 steam kettles are stainless steel, floor mounted kettles with a self-contained steam source heated by gas. A closed steam jacket covers the lower portion of the kettle. Heat from the gas burner boils water in the jacket to produce steam under pressure. To ignite the burners, the kettle uses electronic spark ignition.

The kettles are stationary (non-tilting). Liquids can be removed through the tangent draw-off valve.

Exposed surfaces are stainless steel. Insulated sheathing protects the kettle body, and a housing encloses the controls. Three tubular legs support the unit. Bullet feet adjust to level the kettle.

A one piece dome cover is hinged to the kettle on the 20-gallon model. Covers for 40, 60, 80, and 100-gallon kettles are supplied with counterbalancing spring actuators to hold the covers in the fully open or closed position.

Controls provided include the ON/OFF switch, to control electric power for the unit, and the thermostat, to set the cooking temperature. The automatic controls and a brief description of each are as follows.

1.Gas pressure regulator: Protects the unit from high pressure in the gas supply line.

2.Automatic gas valves: Allow gas into the burners as needed.

3.Pressure limit switch: Turns off the burner when jacket pressure reaches 27 PSI. Lights the burner when pressure drops to 22 PSI.

4.Safety valve: Lets steam out of the jacket if the steam pressure exceeds 30 PSI.

5.Low-water cutoff: Turns off the burner if the water level in the jacket gets too low for safe operation.

Instruments also are provided to show what is happening inside the unit. These are:

1.Water level sight glass: Indicates whether there is enough water in the steam jacket.

2.Pressure/vacuum gauge: Shows steam pressure, and whether too much air has entered the jacket.

3.Heating indicator light: Indicates that the kettle is being heated.

4.Power on indicator light: Glows when the unit is turned on.

5.Low water indicator light: Lights to show that jacket water needs to be replenished.

OM-AH/1 5

Equipment Description

The kettle body is welded into one piece and has a rim reinforced by a rectangular bar. The interior and exterior of the kettle is polished to a 180 emery grit finish. The unit is ASME shop inspected and registered with the National Board for working pressures up to 30 PSI.

The standard 2 inch tangent draw-off is a 316 stainless steel, compression disc valve. A removable strainer with 1/4 inch holes keeps pieces of product from entering the draw-off during cooking.

The jacket is filled at the factory with water containing rust inhibitors. The kettle can operate at steam pressures up to 30 PSI, which provide temperatures of 150°F (65°C) to approximately 270°F (135°C). This range allows warming, simmering, boiling, or braising.

For the kettles, options include:

1.Larger (3 inch) draw-off

2.Solid disc strainer or strainer with 1/8 inch perforations

3.Water fill faucets

4.Basket inserts

5.Kettle brush kit

6.Gallon etch marks

7.Flanged feet

		Kettle	Jacket	Kettle	Kettle
	Model			Inside		Overall Width	Front-to-Back	Rim Height
		Capacity	Capacity		Depth
				Diameter
	AH/1E-20	20 Gallon	4-1/2 Gallon	20 inches	18 inches	36-3/4 inches	39 inches	40 inches
		(75 liter)	(17 liter)	(508 mm)	(457 mm)	(934 mm)	(991 mm)	(1016 mm)
	AH/1E-40	40 Gallon	7 Gallon	26 inches	22 inches	38-1/4 inches	45 inches	42 inches
		(150 liter)	(26.5 liter)	(660 mm)	(559 mm)	(972 mm)	(1143 mm)	(1067 mm)
	AH/1E-60	60 Gallon	9-1.2 Gallon	30 inches	25 inches	41 inches	49 inches	49 inches
		(225 liter)	(36 liter)	(762 mm)	(635 mm)	(1041 mm)	(1245 mm)	(1245 mm)
	AH/1E-80	80 Gallon	11-1/2 Gallon	32 inches	29 inches	42-1/2 inches	51 inches	55-1/2 inches
		(300 liter)	(43.5 liter)	(813 mm)	(737 mm)	(1080 mm)	(1295 mm)	(1410 mm)
	AH/1E-100	100 Gallon	11-1/2 Gallon	32 inches	35 inches	42-1/2 inches	51 inches	61-1/2 inches
		(375 liter)	(43.5 liter)	(813 mm)	(889 mm)	(1080 mm)	(1295 mm)	(1562 mm)
	Model	Ignition	FIRING RATE, BTU/HOUR
			Natural Gas	Propane Gas
	AH/1E-20	Spark	85,000	85,000
	AH/1E-40	Spark	100,000	85,000
	AH/1E-60	Spark	145,000	145,000
	AH/1E-80	Spark	145,000	145,000
	AH/1E-100	Spark	145,000	145,000

6 OM-AH/1

Inspection & Unpacking

WARNING

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

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.

CAUTION

UNIT WEIGHS FROM 468 LBS (212 KG) TO 1120 LBS (508 KG). FOR SAFE HANDLING, INSTALLER SHOULD OBTAIN HELP AS NEEDED AND USE MATERIAL HANDLING EQUIPMENT TO REMOVE THE UNIT FROM THE SKID AND MOVE IT TO ITS PLACE OF INSTALLATION.

Assemble and attach the tangent draw-off valve after the kettle is unpacked.

The unit arrives completely assembled, except for the TDO valve and flue gas converter, which are usually packed separately and shipped inside the kettle.. The unit is strapped on a skid in a heavy box. Inspect the box carefully for damage. Open the container and check the unit for hidden damage. Report shipping damage or shipment errors to the delivery agent.

Write down the model number, serial number, and installation date for your unit at the top of the Maintenance and Service Log at the back of this manual. Keep the manual with the unit.

To remove the kettle from the box, cut any straps from around the box. Detach the box sides from the skid. Pull the box up off the unit, taking care to avoid damage or injury from any staples left in the box walls. When installation is to begin, cut the straps holding the kettle to the skid, and lift the kettle straight up off the skid. Examine the packing materials to make sure no loose parts are discarded with the materials.

Once the kettle is unpacked, the tangent draw-off valve is easily attached, as shown below. The large nut which attaches the valve to the kettle should be hand tightened only.

OM-AH/1 7

WARNING

THIS PRODUCT MUST BE INSTALLED BY A LICENSED PLUMBER OR GAS FITTER WHEN INSTALLED WITHIN THE COMMON WEALTH OF MASSACHUSETTS. IMPROPER INSTALLATION CAN CAUSE INJURY TO PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT. THIS UNIT IS FOR COMMERCIAL USE. NEVER USE HOME OR RESIDENTIAL GRADE GAS CONNECTIONS. THEY DO NOT MEET GAS CODES AND COULD BE HAZARDOUS.

NOTICE

TO AVOID DAMAGING PARTS OF THE BURNER SYSTEM UNDERNEATH THE KETTLE, LIFT THE UNIT ONLY BY THE RING BENEATH THE OUTER PORTION OF THE BODY.

CAUTION

DO NOT CONNECT ANY PIPING TO THE PRESSURE RELIEF SAFETY VALVE. IT MUST BE FREE TO VENT STEAM AS NEEDED. ELBOW SHOULD POINT DOWN TOWARD FLOOR. IMPROPER INSTALLATION WILL VOID WARRANTY!

DANGER

ELECTRICALLY GROUND THE UNIT

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

8 OM-AH/1

Installation

The unit should be installed in a ventilated room for efficient performance. Items which may obstruct or restrict the flow of air for combustion and ventilation must be removed. The area directly around the appliance must be cleared of all combustible materials.

1.Installation requires connection with gas and electrical services. See items 8 to 14 for details.

2.To protect the unit from damage, leave it on the shipping pallet until the time of installation. When installation is to begin, cut the straps holding the kettle, and hoist the kettle straight up off the skid.

3.Install the unit with a minimum clearance to combustible and non-combustible construction of six inches at the sides and six inches between the draft diverter and the wall. Also leave enough room for cleaning, maintenance, and service.

4.The draft diverter shipped with the kettle is the correct height and shape to give maximum performance. Install the draft diverter as shown on the figures at left. Securely fasten the screw to attach draft directly. Do not change the diverter in any way. Install the unit under a ventilation hood, or vent the flue directly to a masonry chimney. Put a hood at least several inches above the upper end of the draft diverter. Do not rest hood supports on the diverter. Installation of a ventilating hood should comply with local codes and/or ANSI/NFPA-96 Latest Edition. Also, local codes may require that the kettle be electrically interlocked to shut off the gas supply and prevent the operation of the unit if the exhaust fan is not operating or

if the fire suppression system is activated. Failure to follow these instructions can cause bodily injury and/or property damage.

5.To level the unit, adjust leg length by turning the bullet feet.

6.Make sure the water level is correct in the jacket, by confirming that the level is between the marks on the gauge glass. If the water level is low, follow the instructions under “Jacket Filling” in the “Maintenance” Section of this manual.

7.To protect personnel from steam coming out of the safety valve, the open end of the elbow at the outlet must be directed down. If it is not, turn the elbow to the correct position.

8.Provide 115 VAC, 60 HZ, 1 PH, 15 AMP electrical service for standard unit. Unit may be equipped for alternate electrical service of 208 VAC or 240 VAC, as ordered. Use 1/2 inch waterproof conduit and waterproof connections. Observe local codes and/or The National Electrical Code in accordance with ANSI/NFPA 70 - latest edition. AN ELECTRICAL GROUND IS REQUIRED. The electrical schematic is located on the inside of the service panel.

In Canada, provide electrical service in accordance with the Canadian Electrical Code, CSA C22.1 Part 1 and/or local codes.

9.The internal gas lines of the unit were cleaned and closed off with a gas cock before the unit was shipped from the factory. Free all external gas lines of lint, dirt, metal chips, sealant, grease, oil, and other contaminants, before you connect the lines to the kettle.

10.Connect the gas cock of the kettle to the gas service main with 3/4 inch IPS line or approved equivalent.

Installation

11.Installation must conform with local codes, or in the absence of local codes, with the National Fuel Gas Code, ANSI Z 223.1-1988 (or latest edition). The unit should be installed in an adequately ventilated room with a provision for adequate air supply. The best ventilation will utilize a vent hood and exhaust fan with no direct connection between the vent duct and the flue. Do NOT obstruct the flue or vent duct after installation.

In Canada, the installation must conform to the CAN/CGA B149 Installation Codes for Gas Burning Appliances and Equipment and/or local codes.

12.Adequate space for proper service and operation is required. No NOT block any air intake spacings to the combustion chamber or obstruct the air flow by piling or stacking anything near the kettle.

13.After the kettle has been connected to the gas supply, all gas line joints must be checked for leaks. DO NOT USE A FLAME TO CHECK FOR LEAKS. A thick soap solution or other suitable leak detector should be employed.

14.For a unit on casters, complete connection to the gas supply with connectors that comply with the standard for connectors for moveable gas appliances, ANSI Z21.69 - latest edition. Restrain movement of the unit by attaching a cable or chain to the eyelet (provided at the back of the frame) and anchoring the cable or chain to the wall or floor. Make the length and location of the cable such that the unit cannot pull on the gas connection while the cable is connected.

15.The appliance and its individual shutoff 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 (3.48 kPa). The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG (3.48 kPa).

16.Check the following points to confirm that your kettle has been installed properly. Any mechanical, electrical, or gas type change must be approved by the Food Service Engineering Department.

a.Enough room between the kettle and nearby objects for cleaning and service.

b.Minimum clearance of 6 inches from sides and 6 inches from draft diverter.

c.Unit vented to a hood or chimney (not attached to a vent).

d.Kettle level.

e.Correct amount of water in the jacket.

f.Pressure relief safety valve outlet pointed down.

g.Connected with a waterproof, 115 volt, 15 AMP supply of electric power in accordance with electrical codes.

h.Gas lines cleaned before connection.

i.Gas connected with 3/4 inch pipe or equivalent.

j.Gas line joints checked for leaks.

k.No obstruction to air supply or venting.

OM-AH/1 9

IMPORTANT

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

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.

10 OM-AH/1

Initial Start-Up

After kettle has been installed, the installer should test to ensure that it is operating correctly.

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

2.Install the TDO valve.

3.Put a small amount of water into the kettle.

4.Verify that kettle water level is normal and that kettle is holding vacuum in jacket. Correct if not.

5.Make sure the supplies of gas and electric power are on.

6.Follow the “Start Kettle Heating” instructions in the Operation section of this manual. Begin heating the water at the highest thermostat setting. The indicator light should come on and heating should continue until the water boils.

7.To turn off the unit, follow “To Stop Kettle Heating” in the Operation section.

If the kettle functions as described, if is read for use. If the unit does not operate as designed, contact authorized Service Agent.