Groen AH-40 Service Manual

ii IMPORTANT INFORMATION IMPORTANT INFORMATIONii KEEP FOR OPERATORKEEP FOR OPERATORii IMPORTANT INFORMATIONIMPORTANT INFORMATION i

OPERATOR AND SERVICE MANUAL OM/SM-AH-CE

Part Number 128416 INTERNATIONAL

Model: AH-CE Mark

Steam Jacketed Kettle

Self-contained
Stainless Steel
Gas Heated
Floor Mounted
Stationary

KEEP THIS MANUAL WITH KETTLE DOCUMENTS. OPERATORS AND
TECHNICIANS SHOULD READ, UNDERSTAND AND FOLLOW WARNINGS AND
INSTRUCTIONS IN THIS MANUAL (THE SERVICE MANUAL AND THE OPERATOR
SECTIONS)

OPERATOR AND SERVICE MANUAL

Part Number 128416 Rev. B

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.

OM/SM-AH-CE

IMPORTANT — READ FIRST — IMPORTANT

IT IS MOST IMPORTANT THAT THESE INSTRUCTIONS AND THE OPERATOR AND SERVICE
MANUALS BE CONSULTED BEFORE INSTALLING AND COMMISSIONING THE APPLIANCE.
FAILURE TO COMPLY WITH SPECIFIED PROCEDURES MAY RESULT IN DAMAGE OR THE NEED

FOR A SERVICE CALL.

THESE APPLIANCES HAVE BEEN CE MARKED ON THE BASIS OF COMPLIANCE WITH THE GAS
APPLIANCE DIRECTIVE, EMC AND LOW VOLTAGE DIRECTIVE FOR THE COUNTRIES, GAS

TYPES AND PRESSURES AS STATED ON THE DATA PLATE.

THESE APPLIANCES MUST BE INSTALLED BY A COMPETENT PERSON IN CONFORMITY WITH
THE INSTALLATION AND SERVICING INSTRUCTIONS AND NATIONAL REGULATIONS IN FORCE

AT THE TIME. PARTICULAR ATTENTION MUST BE PAID TO THE FOLLOWING:

I. E. E. REGULATIONS FOR ELECTRICAL INSTALLATIONS
ELECTRICITY AT WORK REGULATIONS
GAS SAFETY (INSTALLATION AND USE) REGULATIONS
HEALTH AND SAFETY AT WORK ACT
LOCAL AND NATIONAL BUILDING REGULATIONS
FIRE PRECAUTIONS ACT

DETAILED RECOMMENDATIONS ARE CONTAINED IN INSTITUTE OF GAS ENGINEERS
PUBLISHED DOCUMENTS: IGE/UP/1, IGE/UP/2, BS6173 AND BE5440.

FURTHERMORE, IF A NEED ARISES TO CONVERT THE APPLIANCE FOR USE WITH ANOTHER
GAS, A COMPETENT PERSON MUST BE CONSULTED. THOSE PARTS WHICH HAVE BEEN
PROTECTED BY THE MANUFACTURER MUST NOT BE ADJUSTED BY THE USER.

USERS SHOULD BE CONVERSANT WITH THE APPROPRIATE PROVISIONS OF THE FIRE
PRECAUTIONS ACT AND THE REQUIREMENTS OF THE GAS SAFETY REGULATIONS. IN
PARTICULAR THEY SHOULD BE AWARE OF THE NEED FOR REGULAR SERVICING BY A
COMPETENT PERSON TO ENSURE THE CONTINUED SAFE AND EFFICIENT PERFORMANCE OF
THE APPLIANCE.

WARNING: TO PREVENT SHOCKS, ALL APPLIANCES GAS OR ELECTRIC, MUST BE

EARTHED.

UPON COMPLETION OF THE INSTALLATION, THE OWNERS MANUAL SHOULD BE HANDED TO
THE USERS AND THE INSTALLER SHOULD INSTRUCT THE RESPONSIBLE PERSON(S) IN THE
CORRECT OPERATION AND MAINTENANCE OF THE APPLIANCE.

THIS EQUIPMENT IS ONLY FOR PROFESSIONAL USE, AND SHALL BE OPERATED BY
QUALIFIED PERSONS. IT IS THE RESPONSIBILITY OF THE SUPERVISOR OR EQUIVALENT TO
ENSURE THAT USERS WEAR SUITABLE PROTECTIVE CLOTHING AND TO DRAW ATTENTION
TO THE FACT THAT, SOME PARTS WILL, BY NECESSITY, BECOME VERY HOT AND WILL
CAUSE BURNS IF TOUCHED ACCIDENTALLY.

WARNING: BEFORE REMOVING ANY PARTITION OR PANEL, ALWAYS TURN OFF THE

ELECTRIC POWER AND ALLOW THE FAN TO STOP ROTATING. BEFORE
WORKING ON ANY ELECTRICAL COMPONENT, DISCONNECT THE POWER
SOURCE FROM THE UNIT.

NOTE: IT IS IMPORTANT THAT THE END-USER ROUTINELY EXAMINE THE FLUE

OUTLET ON A REGULAR BASIS. DEBRIS COVERING THE FLUE OUTLET CAN
CAUSE A POTENTIALLY HAZARDOUS CONDITION. REMOVE ANY FOREIGN
MATERIAL BEFORE USING THIS PIECE OF EQUIPMENT.

WARNINGS AND CAUTIONS PROVIDED IN THIS OPERATOR AND SERVICE MANUAL MUST BE
COMPLIED WITH.

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2

OM/SM-AH-CE

TABLE OF CONTENTS

Section Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Model Numbers, Net Weights & Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

1.2 Siting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

1.3 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

1.4 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

1.5 Electrical Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

1.6 Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

1.7 Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

1.8 Total Gas Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

1.9 Injector Diameters-Natural and Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

1.10 Gas Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

1.11 Burner Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

2 Assembly and Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

2.2 Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

2.3 Electrical Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

2.4 Jacket Water Level/Jacket Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

2.5 Pre-Commissioning Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

2.6 Instruction to Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

3 Servicing and Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.1 Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.2 Jacket Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.3 Jacket Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.4 Water Treatment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.5 Removal of Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.6 Removal of Spark Ignition Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.7 Removal of Low Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.8 Removal of Gas Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.9 ON/OFF Switch and Reset Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.10 Removal of Neons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.11 Removal of Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.12 Removal of Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.13 Low Water Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.14 Removal of The Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.15 Pilot Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.16 Removal of Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.17 Removal of Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.18 Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.19 Filling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.20 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5 User Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5.1 Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5.2 Lighting and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.3 Cleaning and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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Introduction

These Appliances have been CE marked on
the basis of compliance with the Gas
Appliance Directive, EMC and Low Voltage
Directive for the Countries, Gas Types and
Pressures as stated on the Data Plate

.

These appliances MUST BE installed by a
competent person in conformity with the
INSTALLATION AND SERVICING
INSTRUCTIONS and National Regulations in
force at the time. Particular attention MUST be
paid to the following:

CC I.E.E. Regulations for Electrical

Installations

CC Electricity at Work Regulations
CC Gas Safety (Installation & Use)

Regulations

CC Health and Safety at Work Act

C Fire Precautions Act
C Local and National Building

Regulations

Furthermore, if a need arises to convert the
Appliance for use with another gas, a competent
person must be consulted. Parts which have
been protected by the manufacturer MUST NOT
be adjusted by the User.

Users should be conversant with appropriate
provisions of the Fire Precautions Act and the
requirements of the Gas Safety Regulations. In
particular they should be aware of the need for
regular servicing by a competent person to
ensure the continued safe and efficient
performance of the Appliance.

Upon completion of the installation, the Owners
Manual should be handed to the users and the
installer should instruct responsible person(s) in
the correct operation and maintenance of the
Appliance.

This equipment is ONLY FOR PROFESSIONAL
USE, and shall be operated by QUALIFIED
persons. It is the responsibility of the Supervisor
or equivalent to ensure that users wear
SUITABLE PROTECTIVE CLOTHING and to
draw attention to the fact that, some parts will,
by necessity, become VERY HOT and will
cause burns if touched accidentally.

The Groen Steam Jacketed Kettle you have just
purchased has been handcrafted from the finest
materials, meticulously inspected, and carefully
tested to ensure that you receive the best
possible product. With reasonable care and
periodic maintenance, it will provide years of
faithful service. It is recommended that you
establish a timetable for periodic maintenance
as outlined in this manual.

Section 1

Installation

UNLESS OTHERWISE STATED, PARTS PROTECTED BY THE MANUFACTURER ARE NOT TO BE
ADJUSTED BY THE INSTALLER.

1.1 Model Numbers, Net Weights and Dimensions

MODEL WIDTH DEPTH HEIGHT WEIGHT CAPACITY

mm (in.) mm (in.) mm (in.) kg (lbs.) Liters

AH-20

933 (36.7) 991 (38.9) 1016 (39.9) 213 (468) 75.7

AH-40

972 (38.1) 1143 (44.9) 1067 (41.9) 282 (620) 151.4

AH-60

1041 (40.9) 1245 (48.9) 1245 (48.9) 432 (950) 227

AH-80

1080 (42.4) 1295 (50.9) 1410 (55.4) 486 (1070) 303

WARNING
THE UNIT MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH ELECTRICITY AND
GAS. IMPROPER INSTALLATION CAN CAUSE INJURY TO PERSONNEL AND/OR DAMAGE T

O

EQUIPMENT. THE UNIT MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE CODES

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1.2 Siting 1.5 Electrical Supply

Install the appliance on a level floor in a well-lit This unit is designed for connection to fixed
and draught-free position. Install the appliance in wiring. A suitably rated isolating switch with
accordance with local and/or national regulations contact separation of at least 3 mm on both poles
as listed in this manual. must be fitted to the installation and the wiring

1.3 Installing Clearances

Minimum clearances of 150 mm from the sides of
the appliance and 150 mm from the rear of the
appliance are required if the appliance is installed
next to combustible surfaces.

Allow 1000 mm minimum clearance between the
top rim of kettle and any overlying surface.

1.4 Ventilation

The unit must be installed in an adequately
ventilated room with provision for an adequate air
supply. The area around the appliance must be
cleared of all combustible material. For multiple
installations requirements for individual units
should be added together. Installation must
comply with applicable regulations. A competent
installer must be employed.

CAUTION

THE APPLIANCE FLUE DISCHARGE

S
VERTICALLY FROM THE TOP OF THE UNIT.
IT MUST NOT BE DIRECTLY CONNECTED TO
A FLUE, MECHANICAL EXTRACTION
SYSTEM, OR DUCTING LEADING OUTSID

E
TH

E BUILDING. THE APPLIANCE IS BEST

DISCHARGED UNDER AN OPEN CANOP

Y
CONNECTED TO A VENTILATING SYSTEM

.

Recommendations for ventilation for catering natural and propane gases without any
appliances are given in BS 5440:2 and are shown conversion.
in the table below.

Equipment

Ventilation Rate

m³/Min ft³/Min

Range 17 600

Pastry Oven 17 600

Fryer 26 900

Grill 17 600

Steak Grill 26 900

Boiling Pan 17 600

Steamer 17 600

Sterilizing Sink 14 500

Bains Marie 11 400

Tea/Coffee Machine 8.5-14 300-500

executed in accordance with the regulations listed
in this manual.

Cable entry is at the lower rear on right hand side
of the appliance. Access to the terminals is
gained by removing relevant panels as described
in Section 3.5 of this manual.

Provide 230 VAC, 50 Hz, 1 Phase, service. Rated
input: 0.17 Amps, or 40 Watts. The electrical
schematic is located in the service compartment
and in this manual.

WARNING

THIS APPLIANCE MUST BE EARTHED.

1.6 Gas Supply

The incoming service must be of sufficient size to
supply full rate without excessive pressure drop.
A gas meter is connected to the service pipe by
the Gas Supplier. Any existing meter should be
checked by the Gas Supplier to ensure that the
meter is of adequate capacity to pass the required
rate of gas for the kettle in addition to any other
gas equipment installed.

The appliance governor is incorporated in the gas
control valve which is situated in the control
cabinet.

The control valve governor is suitable for both

Installation pipe work should be fitted in
accordance with IEGE/UP/2. The pipe work
should not be smaller than the gas inlet
connection on the kettle, i.e. Rp ½ (½”B.S.P.)

An isolating cock must be located close to the
appliance to allow shut down during an
emergency or servicing. The installation must be
tested for gas soundness and purged as specified
in IGE/UP/1.

1.7 Water Supply

Not applicable to these appliances.

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1.8 Total Gas Rate NOTE: With reference to the gas rate, pressure

Model (G20& (G31)

Natural Propane

G25) KW KW

Natural Propane
BTU/hr BTU/hr

AH-20 22 75,100 22 75,100
AH-40 25 85,300 22 75,100

AH-60 &

AH-80

40 136,500 40 136,500

1.9 Injector Diameters-Natural & Propane Gas

Model Gas G20 Gas G25 Gas G31

Natural Natural Propane

(mm) (mm) (mm)

No. of

Orifices

(Injectors)

AH-20 4.39 4.70 2.64 1
AH-40 4.57 4.90 2.64

1

AH-60 &

AH-80

5.94 6.75 3.57

1

1.10 Gas Pressure Adjustment

A pressure test point is fitted on the burner
manifold and on the gas control valve.

Model AH-20 AH-40

AH-60 &

AH-80

NATURAL
GAS G20

mbar 8.75 8.75 8.75
in. WC 3.5 3.5 3.5

NATURAL
GAS G25

mbar 8.75 8.75 7.0
in. WC 3.5 3.5 2.8

PROPANE
GAS G31

mbar 25 25 25
in. WC 10 10 10

adjustments and conversions, this appliance is
CE-approved for use with the following gases:

a) G20 natural gas may be supplied to the

appliance in Austria, Belgium, Denmark,
Finland, France, Germany, Greece, Iceland,
Ireland, Italy, Luxembourg, Norway, Portugal,
Spain, Sweden, Switzerland and the United
Kingdom.

b) G25 natural gas may be supplied to the

appliance in Belgium, France and the
Netherlands.

c) G31 propane gas may be supplied to the

appliance in France, Germany, Ireland, the
Netherlands, Portugal, Spain, Switzerland,
and the United Kingdom.

Use of the appliance with non-approved gases in a
listed country, or use in other countries will void CE
certification.

1.11 Burner Adjustment

The burner has a primary air adjustment. The gap
should be 1/4" (6.35 mm) to 3/8" (9.53 mm).

Section 2

Assembly and Commissioning

2.1 Assembly 2.3 Electrical Supply

a) Unpack the appliance. Before commissioning the appliance, ensure that the

b) Place on a firm, level floor. Adjust and fix relevant regulations. (Paragraph 1.5)

feet.

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.

2.2 Gas Supply

Connect the unit to the gas supply and test for gas
soundness. For the part of the integral gas supply
down stream of the gas valve, leak detection
spray or some solution may be used with the
burners lit.

Caution: Ensure that the pan contains liquid when
the burners are alight.

electrical installation has been carried out to the

THIS APPLIANCE MUST BE EARTHED.

2.4 Jacket Water Level/Jacket Pressure

a) Ensure the water level is correct in the jacket, by

confirming that the level is between the marks on
the gauge glass. If the water is low, follow the
instructions under "Jacket Filling" in the servicing
section of this manual.

b) Check the pressure gauge. If the gauge does not

show 20 or more inches of vacuum (that is, a
reading of 20 to 30 below zero) see "Jacket
Vacuum" in the servicing section of this manual.

2.5 Pre-Commissioning Check

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a) Prior to operation, clean kettle pan with hot f) Remove governor cap screw on gas control

water and detergent. Rinse thoroughly. valve. See figure for governor position on valve.

b) Remove all literature and packing materials g) Governor is suitable for natural and propane gas.

from the interior and exterior of the unit.

c) Ensure the open end or the elbow at the governor turret clockwise, or anti-clockwise to

safety valve outlet is pointed down. If not, turn reduce pressure. Check the burner pressure
the elbow to the correct position. See Safety again after 15 minutes and adjust if necessary.
Valve Operation Instructions on Page 8.

2.5.1 Lighting Sequence

From Initial Start Up:

a) Put a small amount of water in the kettle pan.

b) Ensure gas and electricity mains are “on.”

c) Switch the toggle switch to the "on" position.

d) Turn thermostat dial to desired setting.

e) Observe that the burners ignite by the pilot

lamp illuminating.

f) If the unit does not ignite, it will lock-out. Turn

the unit off and wait for one or two minutes
before again attempting to switch it on.

g) Press reset lock-out switch and repeat steps

(b) to (e).

h) To switch unit off, flip toggle (On/Off) switch

to the “off” position.

i) Turn gas and electricity mains off.

2.5.2 Setting The Gas Pressure

a) Check gas pressure during commissioning.

Connect a pressure gauge to the pressure test
point on the burner manifold or the gas control
valve. See figure for test points.

b) When checking pressure at gas valve test

points, undo the screw a half turn and slip
tube over the nipple.

c) Turn the main gas and electricity supplies on.

d) Light the burners (Paragraph 2.5.1).

e) Remove screws securing control cabinet side

panel. (Paragraph 3.5).

h) To increase pressure turn the screw inside the

i) Disconnect pressure gauge from the test point.

j) Re-seal the pressure test point and test for gas

soundness.

k) Replace governor cap screw, lid and panels.

2.5.3 Checking Performance of Controls

a) Light the unit (Paragraph 2.5.1). Check that the

controls produce a healthy spark from the
electrode to the earthing post and that ignition is
smooth and without delay.

b) Turn thermostat off and then on. Check that

burners go out when switched off and ignite
smoothly and quickly when switched back on.
Repeat several times.

c) If the unit fails to respond as described above

contact an authorized Groen service agent.

2.6 Instruction to Installer

IMPORTANT
After installing and commissioning the
appliance, the installer should hand the user's
instructions to the user or purchaser. Ensure that
the instructions for lighting, turning off, correct
use and cleaning are properly understood.
Emphasis should be made with regard to the
location of the main gas isolating valve. The
emergency shut down procedure should be
demonstrated.

OM/SM-AH-CE

7

AVOID STEAMAVOID STEAM
CONTACTCONTACT

OM/SM-AH-CE

Section 3

Servicing and Conversion

IMPORTANT

BEFORE ATTEMPTING ANY SERVICING, ENSURE THAT THE ISOLATING COCK IS TURNED OFF
AND CANNOT BE INADVERTENTLY TURNED ON, AND THAT THE ELECTRICITY SUPPLY IS
DISCONNECTED.

AFTER ANY MAINTENANCE TASK, CHECK THE APPLIANCE TO ENSURE THAT IT PERFORMS
CORRECTLY AND CARRY OUT ANY NECESSARY ADJUSTMENTS AS DETAILED IN SECTION 1.

ALWAYS CHECK FOR GAS SOUNDNESS AFTER CARRYING OUT ANY SERVICING OR
EXCHANGE OF GAS CARRYING COMPONENTS !

NOTE

: When replacing wiring connections refer to the wiring diagram on the unit and in this manual.

After Servicing

a) Test for gas soundness as specified in

IGE/UP1 as appropriate after any gas
connection has been disturbed.

b) Check for correct operation, as appropriate

(see commissioning of appliance).

Regular Servicing Procedures

The following must be serviced at regular
intervals. To achieve topmost performance and maximum

Burners

The burner should be cleaned periodically to
maintain maximum performance. The burner is
best cleaned with a wire brush, taking care not
to damage the burner head.

The injector orifice should be cleaned with a
wooden splinter. Metal reamers may distort or
increase the orifice size and should be avoided.

Safety Valve

At least once every two months the safety valve
must be checked. When the gauge pressure is
about five PSIG, lift the valve enough to vent
steam, then quickly let it snap back into place.

WARNING

AVOID ANY EXPOSURE TO THE STEA

M

BLOWING OUT OF THE SAFETY VALVE.

This procedure should be explained to the user,
as it is to be carried out at least twice a month.
Safety procedures and requirements should also
be explained to the user when carrying out the
procedure.

Safety Valve Operating Instructions

If adding water to a boiler, DO NOT ALLOW
water to flow through safety valve as sediment
or debris may be deposited on seating surface.

service life, it is necessary to maintain a proper
pressure margin between set pressure of the
safety valve and equipment operating pressure.

The minimum required pressure margin for this
type of valve is 10% of the safety relief valve
set pressure, but not less than five Pounds per
Square Inch, Gauge (PSIG). UNDER NO

CIRCUMSTANCES SHOULD THIS MARGIN
BE LESS THAN FIVE PSIG.! Failure to

maintain this margin may result in water leakage
past the seat and an accumulation of deposits
on the seating surface. Excessive deposits may
prevent the valve from operating properly, and a
dangerous pressure build-up and equipment
rupture may result.

Maintenance and Testing

CAUTION

! Before testing, make certain

discharge pipe is properly connected to valve
outlet and arranged to contain and safely
dispose of boiler discharge (see “Installation
Instructions”).

Under normal operating conditions a “try lever
test” must be performed every two months.
Under severe service conditions, or if corrosion
and/or deposits are noticed within the valve

OM/SM-AH-CE

8

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body, testing must be performed more often. A e. Use pipe compound sparingly, or tape, on
“try lever test” must also be performed at the external threads only.
end of any non-service period.

Test at or near maximum operating pressure by
holding the test lever fully open for at least five
seconds to flush the valve seat free of sediment
and debris. Release the lever and let the valve
snap shut. If lift lever does not activate, or there
is no evidence of discharge, discontinue use of
equipment immediately and contact a licensed
contractor or qualified service personnel.

Neither Conbraco Industries, Inc. nor its agents
assume any liability for valves improperly
installed or maintained.

This quality Conbraco safety relief valve, with
proper installation, use, and maintenance, will
provide many years of reliable service and
protection against excessive pressure build-up
of water/steam. Use of this valve for any other
purpose or media places all responsibility upon
the user. Before installing valve or operating
equipment to which it is installed, read
instructions carefully. Always wear proper
safety equipment.

INSTALLATION OF SAFETY VALVE

10-100, 10-200, 10-300, 10-500, & 10-600

Series

a. Installation must be performed by qualified

service personnel only.

b. The Btu/hr or lb/hr rating of this valve must

equal or exceed that of the equipment to
which it is attached.

c. DO NOT use this valve on a coal or wood

boiler having an uncontrolled heat input.

d. Ensure that all connections, including the

valve inlet, are clean and free from any
foreign material.

f. DO NOT USE A PIPE WRENCH! Use

proper type and size wrench on wrench
pads only.

g. This valve must be mounted in a vertical,

upright position directly to a clean, tapped
opening in the top of the boiler or
equipment. Under no circumstances should
there be a flow restriction or valve of any
type between the safety relief valve and the
pressure vessel.

h. WARNING!

During operation this valve
may discharge large amounts of steam
and/or hot water. Therefore, to reduce the
potential for bodily injury and property
damage, a discharge line MUST

be installed

that:

1) is connected from the valve outlet with

no intervening valve and directed
downward to a safe point of discharge

2) allows complete drainage of both the

valve and the discharge line.

3) is independently supported and securely

anchored so as to avoid applied stress
on the valve.

4) is as short and straight as possible.

5) terminates freely to atmosphere where

any discharge will be clearly visible and
is at no risk of freezing.

6) terminates with a plain end that is not

threaded.

7) is constructed of a material suitable for

exposure to temperatures of 375º F or
greater

8) is, over its entire length, of a pipe size

equal to or greater than that of the valve
outlet.

Use only schedule 40 pipe for discharge.
(Do not use schedule 80, extra strong pipe
or connections). DO NOT CAP, PLUG, OR

OTHERWISE OBSTRUCT DISCHARGE
PIPE OUTLET!

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9

OM/SM-AH-CE

i. See appropriate ASME Boiler and Pressure

Vessel Code for additional installation
instructions.

3.1 Conversion — NOTE: See Para 1.9

and 1.10 (Page 6) for important gas proper level, either because water was lost as
conversion information. VERIFY steam during venting or because treated water
THE TYPE OF GAS TO BE USED. In was lost by draining.
the countries listed in Paragraph 1.10
all conversions must be for approved The procedure for adding water is as follows:
gas

.

To change the type of gas used (e.g. G20 to
G25 or G31 or the like), change the following:

Burner injector
Pilot orifice
Pressure setting
Data Plate

The governor spring does not need to be
changed- only the pressure setting.

3.2 Jacket Vacuum

When the kettle is cold, a reading that is
positive or near zero on the pressure/vacuum
gauge indicates excess air in the jacket. Air in
the jacket slows down the heating of the kettle.

To remove air:

a. Light the unit (see Section 2.5.1).

b. When the pressure/vacuum gauge reaches

a positive reading of five PSIG, release air
and steam by lifting the lever on the safety
valve for about 1 second. Repeat this
process a few times, then let the valve snap
back into the closed position.

See detailed Instructions on Page 8 pertaining
to Safety Valve installation and operation.

WARNING

AVOID ANY EXPOSURE TO THE STEA

M

BLOWING OUT OF THE SAFETY VALVE.

3.3 Jacket Filling

The jacket has been charged at the factory with
the proper amount of treated distilled water. You
may need to restore the jacket water to its

a. If you are replacing water lost as steam use

distilled water. If you are replacing treated
water that was removed from the jacket,
prepare more as directed below.

b. Allow the kettle to cool completely. Using

the proper sized spanner, remove the pipe
plug from above the globe valve.

c. Open the globe valve and pour distilled or

treated water in the pipe plug orifice. (See
“Water Treatment Procedure,” Paragraph

3.4). Hold the safety valve open while you
pour, to let air escape from the jacket.

d. Air introduced to the jacket during the filling

operation must be removed to obtain
efficient heating. (See "Jacket Vacuum"
section 3.2).

See detailed Instructions on Page 8 pertaining
to Safety Valve installation and operation.

3.4 Water Treatment Procedure

WARNING

REA

D AND FOLLOW ALL PRECAUTIONS

STATED ON THE LABEL OF THE WATE

R

TREATMENT COMPOUND TO AVOI

D

INJURY.

a. Fill the mixing container with the measured

amount of water required. (See Table). Use
distilled water only.

Model Capacity

Kettle

Capacity

Jacket

(Approx)

AH-20 75.7 Liters 17 Liters

AH-40 151.4 Liters 26.5 Liters

AH-60 227.1 Liters 35.9 Liters

AH-80 302.8 Liters 43.5 Liters

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10

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b. Hang a strip of pH test paper on the rim of c. Replace in reverse order.

the container, with about 3 cm of the strip
extending below the surface of the water. Ensure the low water level control is correctly

c. Measure the water treatment compound you

will be using. (One way is to add the
compound to the water from a small
measuring cup).

d. Stir the water continuously, while you slowly

add water treatment compound, until the
water reaches a pH between 10.5 and 11.5.
Judge the pH by frequently comparing the
color of the test strip with the color chart
provided in the pH test kit.

e. Record the exact amounts of water and

treatment compound used. These amounts
may be used again, if the same sources of
water and compound are employed to refill
the jacket in the future. However, it is
advisable to check the pH every time water
is prepared for the jacket.

f. For optimum performance, use correctly

treated, distilled water.

3.5 Removal of Control Panel

a. Remove the two screws at the panel base.

b. Remove panel

c. Replace in reverse order.

3.6 Removal of Spark Ignition Module ­(Turn the gas and electricity mains off)

a. Remove control panel (Paragraph 3.5).

b. Disconnect electrical leads from spark

ignition module.

c. Remove retaining screws securing spark

ignition module.

d. Withdraw spark ignition module from

supporting bracket.

e. Replace in reverse order.

3.7 Removal of Low Water Level Control
(Turn the gas and electricity mains off)

a. Remove control panel (Paragraph 3.5)

b. Remove low water level control from its

base by undoing the two retaining clips.

oriented when repositioned.

3.8 Removal of Gas Control Valve - (Turn the
gas and electricity mains off)

a. Remove control panel (Paragraph 3.5)

b. Disconnect electrical leads from control

valve.

c. Undo fittings on each side of control valve.

d. Remove mounting screws from valve.

e. Remove control valve from control cabinet.

f. Replace in reverse order.

3.9 Removal of ON/OFF Switch and Reset
Button - (Turn the gas and electricity

mains off)

a. Remove control panel (Paragraph 3.5).

b. Disconnect electrical leads from the On/Off

switch or reset button.

c. Undo and remove retaining collar which

secures the On/Off switch to the outer
surface of the control cabinet, and the reset
button to its inner surface.

d. Withdraw the On/Off switch or the reset

button as required.

e. Replace in reverse order.

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11

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3.10 Removal of Neons - (Turn the gas
and electricity mains off)

a. Remove control panel (Paragraph 3.5).

b. Disconnect the electrical leads to the neon.

c. Undo and remove the retaining collar which

secures the neon to the control cabinet.

d. Withdraw the neon from the control cabinet.

e. Replace in reverse order.

3.11 Removal of Thermostat - (Turn the
gas and electricity mains off)

a. Remove control panel (Paragraph 3.5).

b. Tilt the kettle slightly to move the water in

the jacket away from the Phial Boss
connection.

c. Undo the Phial Boss connection and

remove the thermostat Phial from the
jacket.

d. Remove thermostat control knob and

disconnect electrical leads.

e. Remove the two mounting screws that

secure the thermostat to the control
cabinet.

f. Replace in reverse order. Ensure that an

adequate sealant is used to seal the
thermostat Phial Boss.

WARNING

ENSURE THAT THE OTHER ELECTRICA

L

LEADS AND CONNECTIONS SITUATED I

N

THE KETTLE BASE DO NOT GET WET

.

REMOVE THEM IF REQUIRED.

Important: If water is lost during thermostat
removal replace as described in Paragraph

3.3, Jacket Filling.

Always refer to wiring diagram when
reconnecting electrical leads. (See Page 23).

3.12 Removal of Pressure Switch - (Turn
the gas and electricity mains off)

a. Remove control panel (Paragraph 3.5).

b. Disconnect the electrical leads from the

pressure switch.

c. Tilt the kettle slightly to move the water in

the jacket away from the pressure switch
pipe fitting.

d. Remove and withdraw the pressure switch

from the fitting.

e. Replace in reverse order.

f. Once the pressure switch is in place, ensure

that the jacket water level is correct. See
Paragraph 3.3, Jacket Fillings.

Always refer to wiring diagram when
reconnecting electrical leads. (See Page 23)

3.13 Low Water Level Sensor - (Turn the
gas and electricity mains off)

a. Remove control panel (Paragraph 3.5).

b. Disconnect the electrical lead from the

water level sensor.

c. Tilt the kettle slightly to move the water in

the jacket away from the sensor coupling on
the jacket

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12

OM/SM-AH-CE

d. Remove the low water sensor from the g. Once the burners ignite, ensure that the

jacket. sparking sequence stops and the burners

e. Replace in reverse order.

f. Ensure a suitable sealant is used to seal the not remain lit, then adjustment to the

low water level sensor coupling. sparking or sensing electrode is required.

g. Once the low water level sensor is in place,

check the jacket water level. See Paragraph

3.3, Jacket Fillings.

3.14 Removal of Burners - (Turn the gas
and electricity mains off)

a. Undo union on gas pipe to burner manifold. glass.

b. Remove the two retaining nuts securing the c. Replace with new pressure gauge ensuring

burner manifold to the combustion chamber. that an adequate sealing compound is used.

c. Carefully support the weight of the burner d. Once the pressure gauge has been

manifold and lower the assembly to a safe replaced, the kettle jacket will need to be
position. vented. See Paragraph 3.2, Jacket

d. The burner is accessible and the orifice can

be changed as required.

e. Replace in reverse order.

Always check for gas soundness when any part
of the gas circuit has been disturbed.

3.15 Removal of Pilot Assembly
(Spark/Sensing Electrodes) - (Turn
the gas and electricity mains off)

a. Undo the compression fitting on the pilot

line attached to the burner.

b. Remove the two retaining screws securing

the spark electrode/pilot bracket on the
burner.

c. Withdraw the pilot assembly from the burner

chamber. The pilot orifice can now be
changed as required

d. Disconnect the high temperature lead wire

connection to the sparking electrode or the
sensing electrode as required.

e. Replace in reverse order.

f. Ensure that there is an adequate spark at

the sparking electrode and that the burners
light smoothly and without delay.

remain lit.

h. If the burners do not light, or ignite but do

3.16 Removal of Pressure Gauge - (Turn
the gas and electricity mains off)

a. Remove control panel (Paragraph 3.5).

b. Using the correctly sized spanner remove

the pressure gauge from the top of the sight

Vacuum.

3.17 Removal of Sight Glass - (Turn the
gas and electricity mains off)

a. Remove control panel (Paragraph 3.5).

b. Remove sight glass protection bars.

c. Undo top and bottom compression fittings.

d. Allow the water in the sight glass to drain.

e. Remove the sight glass.

f. Replace in reverse order.

g. Once the sight glass has been replaced,

the lost jacket water needs to be replaced.
See Paragraph 3.3. Jacket Filling.

3.18 Removal of Safety Valve - (Turn the
gas and electricity mains off)

See detailed Instructions on Page 8 pertaining
to Safety Valve installation and operation.

a. Remove the elbow from the safety valve.

b. Remove the safety valve from kettle jacket

pipework.

c. Replace in reverse order

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13

OM/SM-AH-CE

d. Ensure an adequate sealing compound is d. Once the fill valve has been replaced the

used to seal the safety valve. jacket will need to be vented. See Section

e) Once the safety valve has been replaced

the jacket will need to be vented. See
Paragraph 3.2 Jacket Vacuum.

3.19 Removal of Filling Valve - (Turn the
gas and electricity mains off)

a. Remove filling valve from kettle jacket

pipework. c. Replace fuse (identical to fuse removed

b. Replace in reverse order. d. Replace in reverse order.

c. Ensure adequate sealing compound is used

to seal the valve.

3.2 Jacket Vacuum.

3.20 Fuse Replacement - (Turn the gas
and electricity mains off)

a. Remove control panel (Paragraph 3.5).

b. Remove fuse from vertical fuse holder.

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OM/SM-AH-CE

4. Troubleshooting

Your Groen kettle is designed to operate smoothly and efficiently if properly maintained. However, the
following are checks to make in the event of a problem. Wiring diagrams are inside the service panel.

USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY GROEN OR THEIR
AUTHORIZED DISTRIBUTORS CAN CAUSE INJURY TO THE OPERATOR AND DAMAGE TO THE
EQUIPMENT AND WILL VOID ALL WARRANTIES.

SYMPTOM WHO WHAT TO CHECK

Burners will not light. User a. Is main gas valve open (handle in line with gas

pipe)?
b. Gas supply to your building.
c. Is electric power turned on at the circuit breaker or

fuse box, and is power being supplied to the

appliance
d. Thermostat operation.

Kettle continues heating after it User a. Thermostat dial setting.
reaches the desired temperature.

Auth b. Thermostat calibration.

Y

Service c. Thermostat operation. Thermostat should click when
Rep Only the dial is rotated above and below a setting.

Y

Kettle stops heating before it User a. Thermostat dial setting.
reaches the desired temperature.

Auth b. Thermostat calibration.

Y

Service c. Thermostat. Thermostat should click when the dial is
Rep Only rotated above and below a setting.

Y

Kettle heats slowly User a. Air in jacket - pressure/vacuum gauge (20 to 30

below zero when the kettle is cold?)

Safety valve pops. User a. Air in jacket - pressure/vacuum gauge (20 to 30

below zero when the kettle is cold?)
b. Whether kettle was being heated while empty.

Auth c. If high pressure limit switch is set too high.

Y

Service d. Thermostat. Thermostat should click when the dial
Rep Only is rotated above and below a setting.

Y

e. Safety valve. If valve pops below 300 PSIG,

replace.

Y

System does not produce a spark Auth a. Thermostat: close the contacts if they are open

Y

Service b. AC voltage between terminals “1" and “GR.” If it is
Rep Only not 230 Volt, check the high limit switch, which

should be closed.

Y

c. That the high tension cable is firmly attached and in

good condition. If cracked or brittle, replace the

pilot.

Y

e. Electrode ceramic for crack or break.

Y

f. Replace the electronic spark ignition module.

Y

Spark is present but the pilot will not Auth a. That the gas valve is opening.Y

light. Service b. That pressure meets the control manufacturer’s

Rep Only specifications.

Y

c. For gas at the pilot. If it is not flowing:

(1) Check pilot gas line for kinks or obstructions.

Y

(2) Clean orifice, if necessary.

Y

(3) Replace the pilot valve.

Y

Pilot lights, but main burner will not Auth a. That the gas pressure meets the control
come on and spark does not stay Service manufacturer’s specifications.

Y

on. Rep Only b. Replace electric module

Y

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15

OM/SM-AH-CE

SYMPTOM WHO WHAT TO CHECK

Pilot lights, but main burner will not Auth a. Sensor cable, to make certain that there are secure
come on, the spark stays on. Service attachments to terminal “13" and the sensor.

Y

Rep Only b. Sensor ceramic for cracks.

Y

c. That cable is not grounded out. If it is, correct the

ground.

Y

d. Sensor cable for continuity and condition of

insulation.

Y

e. (1) Check the gas pressure.

Y

(2) Clean the pilot Assembly.

Y

(3) Tighten mechanical and electrical connections.

Y

OM/SM-AH-CE

16

OM/SM-AH-CE

5. User Instructions

Regulations and Safety Precautions

These Appliances have been CE marked on the
basis of compliance with the Gas Appliance
Directive, EMC and Low Voltage Directive for
the Countries, Gas Types and Pressures as
stated on the Data Plate.

These appliances MUST BE installed by a
competent person in compliance with the
INSTALLATION AND SERVICING
INSTRUCTIONS and National Regulations in
force at the time. Particular attention MUST be
paid to the following:

I.E.E. Regulations for Electrical
Installations
Electricity at Work Regulations
Gas Safety (Installation & Use)
Regulations
Health and Safety at Work Act

Furthermore, if a need arises to convert the
appliance for use with another gas, a competent
person must be consulted. Those parts which
have been protected by the manufacturer MUST
NOT be adjusted by the User.

Users should be conversant with the appropriate
provisions of the Fire Precautions Act and the
requirements of the Gas Safety Regulations. In
particular the need for regular servicing by a
competent person to ensure the continued safe
and efficient performance of the Appliance.

WARNING

TO PREVENT SHOCKS, ALL APPLIANCE

S

WHETHER GAS OR ELECTRIC, MUST B

E

EARTHED.

Upon receipt of the User's Instruction manual,
the installer should instruct the responsible
person(s) of the correct operation and
maintenance of the Appliance.

This equipment is ONLY FOR PROFESSIONAL
USE, and shall be operated by QUALIFIED
persons. It is the responsibility of the Supervisor
or equivalent to ensure that users wear
SUITABLE PROTECTIVE CLOTHING and to
draw attention to the fact that, some parts will,
by necessity, become VERY HOT and will cause
burns if touched accidentally.

5.1

Equipment Description

5.1.1 General The kettle is charged at the factory with treated,

Groen AH models are stainless steel, steam- temperatures of 65° C to 134° C. Controls for the
jacketed, floor mounted, stationary kettles with a unit include a thermostat, pressure gauge, gauge
self-contained, gas heated steam source. The glass, safety valve, pressure limit control, low
kettle body is welded into one piece and is water cut-off, on/off switch, and a multi­sheathed in stainless steel and insulated with functional gas control valve.
fiber bat insulation. The interior and exterior are
given a bright buff finish. Service connections are required for gas and

The unit is ASME shop inspected and registered Paragraph 3.4 - Water Treatment.
with the National Board for working pressure up
to 30 PSIG. Kettle controls are contained in an IMPORTANT
enclosed stainless steel enclosure. The unit rests
on tubular legs with adjustable ball feet. AH Prior to operation, clean out the kettle pan
kettles come standard with stainless steel covers thoroughly using hot water and detergent.
and two inch (five cm) sanitary tangent draw-off Rinse out and dry completely.
valve.

The self-contained steam source is heated by
propane or natural gas. Ignition is by electronic
spark.

distilled water. The steam source provides kettle

230-V, single phase 50-Hz electricity. See

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17

OM/SM-AH-CE

The gas burners are protected by an
electronic flame failure device which
incorporates automatic ignition of the
burners and instant shut-off of the gas
supply to the burners should a gas supply
interruption occur.

Options available with listed models are:

1. Three inch (7.6 cm) tangent draw-off
valve. (Factory-installed option)

2. Basket inserts.

3. Water filler with swing spout and
bracket.

4. Kettle brush kit.

5.1.2 Operational and Maintenance Safety

CAUTION

BE SURE ALL OPERATORS READ

,

UNDERSTAND AND FOLLOW OPERATIN

G

INSTRUCTIONS, CAUTIONS AND SAFET

Y

INSTRUCTIONS IN THIS MANUAL.

WARNING

INSTALLATION OF THE UNIT MUST B

E

DONE BY PERSONNEL QUALIFIED T

O

WORK WITH ELECTRICITY, GAS AN

D

PLUMBING IN ACCORDANCE WITH AL

L

APPLICABLE CODES.

BEFORE REPLACING ANY PARTS

,

DISCONNECT THE UNIT FROM TH

E

ELECTRIC POWER SUPPLY AND CLOS

E

THE MAIN GAS COCK. ALLOW FIV

E

MINUTES FOR UNBURNED GAS TO VENT.

TO PREVENT SHOCKS, ALL APPLIANCE

S

WHETHER GAS OR ELECTRIC, MUST B

E

EARTHED.

5.2 Lighting and Operation

5.2.1 Initial Kettle Lighting and Operational require venting. (This will require a
Readiness Check service call).

After the AH Kettle has been installed according 6. Switch the On/Off switch to the "On"
to service and installation instructions, perform position. The "power on" neon will
initial start-up as a test to ensure that the unit is illuminate.
operating correctly. Follow the steps below.
Refer to the picture for identification of AH 7. Turn the thermostat dial to the required
controls and indicators. setting.

1. Remove all literature and packing 8. After 10-15 seconds the burners should
material from the interior and exterior of light. The "burners on" neon will
the unit. illuminate.

2. Make sure gas and electricity supplies 9. In the event the burners do not light, or
are switched on. go out as indicated by the illumination of

3. Ensure that the kettle is filled with water off. Wait approx 1 minute. Press lockout
before lighting. reset switch and repeat steps (4) to (8).

4. Check the water level in the jacket. The
level should be between the lines on the
gauge glass. If the level is low, the
jacket water level will be required to be
topped up. (This will require a service
call).

5. Check the pressure gauge. If the gauge
does not show sufficient vacuum (that is,
20 to 30 below zero), the jacket will

the lockout indicating neon, turn the unit

WARNING

AVOID CONTACT WITH THE FLUE

.

SURFACES ARE VERY HOT AND WIL

L

CAUSE BURNS.

DO NOT OBSTRUCT FLUE EXHAUS

T

OPENING.

OM/SM-AH-CE

18

POWER ON

HEAT

LOCKOUT

ON

OFF

RESET

POWER

POWER
ON NEON

BURNERS
ON NEON

LOCKOUT
INDICATING
NEON

THERMOSTAT

POWER ON
SWITCH

LOCKOUT
RESET
SWITCH

OM/SM-AH-CE

Controls on the AH-CE model are easy to
understand and use.

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19

HOTHOT

SURFACESURFACE

S

OM/SM-AH-CE

5.2.2 To Shut Down Kettle 1. Low-water cutoff relay that will shut off

1. Turn the thermostat dial to the Off water level is corrected.
position.

2. Switch the On/Off switch to the Off about 27 PSIG and shut down the
position. burners until jacket pressure is

3. For a prolonged shut down follow steps
1 and 2, and turn the gas and electricity 3. Pop safety valve, which will release
supplies off. steam if the jacket pressure exceeds 30

5.2.3 Filling the Kettle

Prior to operation of the unit, clean out the kettle Safety Valve installation and operation.
pan thoroughly, using hot water and detergent.

Kettle Capacities: the thermostat switch opens, stopping the signal

Model Capacity

AH-20 75.7 Liters
AH-40 151.4 Liters
AH-60 227.1 Liters
AH-80 302.8 Liters

Note that these are maximum capacities. Groen
recommends that no more than 80% of the
maximum capacity be used during operation.

5.2.4 Users Thermostat

The thermostat provides automatic control of the
Kettle Jacket temperature at selected settings to
a maximum of 134° C.

5.2.5 Sequence of Operation

The following "sequence of operation" outline is
provided to help the user understand the
functioning of the unit.

When the operator sets the desired temperature
on the thermostat dial, the thermostat switch
closes and sends a signal which (1) starts the
spark and (2) opens the automatic valve for the
burners. The spark ignites the burner on low
flow. The flame completes a circuit at the
sensing probe and sends a signal that causes
the spark to shut off and the automatic valve to
open to full flow once a flame has been
detected. If a flame is not detected within 15
seconds the gas is automatically cut off and the
appliance is locked out. The unit can only be re­lit once the reset button has been pressed.

In addition to the lockout timer, safety features
include:

the gas supply to all burners until the

2. High pressure switch, set to open at

decreased.

PSIG.

See detailed Instructions on Page 8 pertaining to

When the kettle reaches the set temperature,

to the gas control valve and causing the valve to
shut off all gas flow. When the kettle cools below
the set temperature, the thermostat switch
closes and starts another heating cycle. On-off
cycling continues and maintains the kettle at the
desired temperature.

5.2.6 To Empty Kettle

Turn the handle on the tangent draw off valve
anti-clockwise. After approximately 3½ turns the
valve handle can be pulled forward and full flow
achieved. To close the tangent draw off valve,
push the valve handle inward until the threads
on the valve stem engage. Turn the handle
clockwise until the valve is closed. Do not over
tighten the valve since over-tightening may
damage the valve seat.

WARNING

WHEN EMPTYING THE KETTLE B

E
CAREFUL TO KEEP HOT CONTENTS FROM
SPILLING. AVOID DIRECT SKIN CONTACT.
ENSURE PEOPLE ARE KEPT AWAY FRO

M

THE KETTLE WHEN EMPTYING IT.

5.2.7 Power Failure

If power to the unit fails, do not attempt to
operate the appliance until the electricity supply
is reestablished.

When the power comes back on, follow the
steps in Paragraph 5.2.1 (Initial Kettle Lighting
and Operational Readiness Check.)

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Do not use metal implements or steel wool.

Use a brush, sponge, cloth, plastic or rubber
to remove materials stuck to the surface.

5.3 Cleaning and Maintenance

IMPORTANT
Disconnect the electricity supply before
any cleaning is undertaken. The
appliance must not be cleaned with a jet
of water, nor steam-cleaned.

5.3.1 Suggested Tools

1. Detergent and sanitizing agent, or a
combination cleaning - sanitizing
agent.

2. Long handled and short handled
kettle brushes.

5.3.2 Precautions

Before cleaning, shut off the burner by
turning the thermostat dial to "OFF". If water
or cleaning/sanitizing solution will be
sprayed, shut off all electric power to the
unit at a remote switch such as the circuit
breaker.

WARNING
KEEP WATER AND SOLUTIONS OUT OF
CONTROLS. NEVER SPRAY OR HOS

E

DOWN THE CONTROL CONSOLE.

5.3.3 Procedure

1. Clean all food contact surfaces as soon
as possible after use, preferably while
the kettle is still hot. If the unit is in
continuous use, thoroughly clean and
sanitize both interior and exterior at

least once every 12 hours.

2. Scrape and flush out large amounts of
food residues. Be careful not to scratch
the kettle with metal implements.

3. Prepare a solution of the detergent/
cleaning compound as instructed by the
supplier. Clean the unit thoroughly. A
cloth moistened with cleaning solution
may be used to clean controls, control
housings and electrical conduits.

4. As part of the daily cleaning program,
clean all external and internal surfaces
that may have been soiled. Remember
to check such parts as the underside of
the kettle and control housing.

5. To remove materials stuck to the
equipment, use a brush, sponge, cloth,

plastic or rubber scraper, or plastic wool
along with the detergent solution. To
minimize the effort required in washing,
let the detergent solution sit in the kettle
and soak into the residue, or briefly heat
the detergent solution.

Do not use any abrasive materials or
metal implement that might scratch the
surface because scratches make the
surface hard to clean and provide places
for bacteria to grow. DO NOT use steel
wool, which may leave particles
imbedded in the surface and cause
eventual corrosion and pitting.

6. The exterior of the unit may be polished
with a recognized stainless steel cleaner
or with water and detergent.

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7. When equipment needs to be sanitized, 5.3.4 Safety Precautions

use a solution equivalent to one that
supplies 200 parts per million available A stopcock will be fitted in the gas pipe
chlorine. Obtain advice on the best supplying the appliance. The user must be
sanitizing agent from your products familiar with its location and operation so that it
supplier. Follow the supplier’s may be turned off in an emergency. If there is a
instructions and apply the agent after the smell of gas, turn off the gas, ventilate the area
unit has been cleaned and drained. and call the gas supplier. Do not search for gas
Thoroughly rinse off the sanitizing agent. leaks with naked flames.

CAUTION

NEVER LEAVE A CHLORINE SANITIZIN

G

AGENT IN CONTACT WITH STAINLES

S

STEEL SURFACES LONGER THAN 3

0

MINUTES. LONGER CONTACT CAUSE

S

CORROSION.

8. It is recommended that the unit be
sanitized before use.

9. If there is difficulty removing mineral
deposits or a film left by hard water or
food residue, clean the kettle thoroughly.
Then use a de-liming agent, such as
Groen Delimer Descaler (P/N 114800) or
Lime-Away from EcoLab, Inc, in
accordance with the manufacturer's
directions. Rinse and drain the unit
before further use.

10. If especially difficult cleaning problems
persist, contact your cleaning product
supplier for assistance.

5.3.5 Service/Periodic Maintenance

A Maintenance and Service Log is included in
this manual. Each time maintenance is
performed on your Groen equipment, enter the
date on which it was done, what was done, and
who did it. Keep the manual, its warranty and the
log near the unit. Periodic inspection can
minimize equipment down time and increase the
efficiency of operation. The following points
should be checked regularly.

1. The pressure/vacuum gauge should
show a vacuum of 20 to 30 inches when
the kettle is cold. If it does not, the unit
requires servicing.

2. The jacket water level should be
between the marks on the gauge glass.
If it is not, the unit requires servicing.

3. Keep electrical wiring in good condition.

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23

OM/SM-AH-CE

Parts Lists

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24

OM/SM-AH-CE

Parts Lists

Key Description Part No. Key Description Part No.

7 Foot, Adjustable Bullet 013275 43 Switch Push Button (momentary) 122003
9 Bracket Burner Support, AH/1-60, -80 000388 44 Thermostat 012313

9 Bracket Burner Support, AH/1-20, -40 000336 45 Thermostat Adapter (shaft bushing) 107172
10 Bracket Burner Head AH/1-60, -80 000389 46 Screw, Rnd Hd slotted 8-32 x 3/8 lg 009697
10 Bracket Burner Head AH/1-20, -40 000337 47 Knob, Thermostat 122000

11* Burner Assy. (Natural G20) (80 60) 117730A 48 Electrical Panel Assembly 117732
11* Burner Assy. (Natural G20) (40) 117795A 50 Label, Wiring Diagram 113077
11* Burner Assy. (Natural G20) (20) 117731A Wire Harness ** 117727
11* Burner Assy. (Natural G25) (80 60) 117730C 54 Water Level Electrode 074665
11* Burner Assy. (Natural G25) (40) 117795C 56 Boot Electrode 010390
11* Burner Assy. (Natural G25) (20) 117731C 57 Pressure Switch, High Limit 108559
11* Burner Assy. (Propane G31) (80, 60) 117730B 58 TDO Kit replacement parts 100573
11* Burner Assy. (Propane G31) (40) 117795B 58a Valve Stem 009048
11* Burner Assy. (Propane G31) (20) 117731B 58b Bonnet 009047
11* Burner Injector (Natural G20) (80 60) 000399 58c O-Ring 009034
11* Burner Injector (Natural G20) (40) 000280 58d Hex Nut 009354
11* Burner Injector (Natural G20) (20) 000480 58e Handle 009029
11* Burner Injector (Natural G25) (80 60) 127386 58f Wing Nut 009028
11* Burner Injector (Natural G25) (40) 127385 59 Bracket, Faucet Mounting 009054
11* Burner Injector (Natural G25) (20) 127384 61 Data Plate, CE Mark Kettles 114504
11* Burner Injector (PropaneG31) (80 60) 000403 62 Nameplate, Groen, Large 055450
11* Burner Injector (Propane G31) (40) 000281 68 Cover Assy w/Power Aid AH/1-80

** 047694

11* Burner Injector (Propane G31) (20) 000281 68 Cover Assy w/Power Aid AH/1-60** 049884

13 Radiation Shield Assy, AH/1-60, -80 000445 68 Cover Assy w/Power Aid AH/1-40** 067417
13 Radiation Shield Assy, AH/1-20, -40 000448 68 Cover Assy w/Power Aid AH/1-20** 047695
17 Cover Panel, AH/1-80 117721 Users Manual** 122039
17 Cover Panel, AH/1-60 117720 71 Assembly, Equipotential Terminal 122021
17 Cover Panel, AH/1-40 117719 73 Wire Assembly, Supplementary 122013
17 Cover Panel, AH/1-20 117718 74 Wire Assembly, Flame Rod 122034
21 Insulator, Pilot Burner Access 008201 79 Adapter 1/2” BSPT (M) x1/2"NPT (F) 116392
22 Door, Pilot Burner Access 004035 80 Pilot Ignition Controller 113060
23 Hinge, Pilot Door 004114 81 Liquid Level Control Relay 117737
32 Safety Valve & Water Fill Assembly 097010 82 Liquid Level Control Relay Base 117738
33 Plate with Chain Assembly 008332 83 Terminal Block 003119
34 Water Gauge Fitting 004071 84 Fuse (Three Amp) 079965
37 Sight tube, 5/8” Diameter x 4-3/4” lg 008742 85 Fuse Block 077854
38 Pressure Gauge 2-1/2“dia (dual scale) 084208 86 Pilot Burner & Orifice Assy (Natural) 117704
39 Overlay, Panel 117716+ 87 Pilot Burner & Orifice Assy (Propane) 117705
40 Switch, Toggle, DPST 122004 88 Pilot Burner Mounting Bracket 004425
41 Light Indicator Red, 240V 116381 89 Water Treatment Kit 110324
42 Light Indicator, Amber 240V 116382

*NOTE: See Para 1.10 (Page 6) for permissible conversions.

** Not Shown

OM/SM-AH-CE

25

30E

8 8

8

16

1

INSTALL WITH 1/2"BSPT THREADS
TOWARD GAS VALVE

9

5

1

13

TOWARD GAS VALVE

INSTALL WITH 1/2"BSPT THREADS

6

2

4

14

7

11

10

3

18

12

OM/SM-AH-CE

Gas Valve and Piping Assembly, AH/1-20

Parts Lists

Keyed to Parts Listing on Page 29

OM/SM-AH-CE

26

30E

8 8

8

16

3

12

13

1

INSTALL WITH 1/2"BSPT THREADS
TOWARD GAS VALVE

9

5

1

1

TOWARD GAS VALVE

INSTALL WITH 1/2"BSPT THREADS

5

2

4

14

7

11

10

B

C

18

OM/SM-AH-CE

Gas Valve and Piping Assembly, AH/1-40

Parts List

Keyed to Parts Listing on Page 29

OM/SM-AH-CE

27

8

2

1

8

1

9

9

14

13

1

7

12

30E

11

11

10

5

3

4

16

6

INSTALL WITH 1/2"BSPT THREAD
TOWARDS GAS VALVE

INSTALL WITH 1/2"BSPT THREAD
TOWARDS GAS VALVE

15 B

B

17

OM/SM-AH-CE

Gas Valve and Piping Assembly, AH/1-60, 1-80

Parts List

Keyed to Parts Listing on Page 29

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28

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Parts List

Key Description Part No. Key Description Part No.

1 90º Elbow 1/2” NPT (black) 008747 9 Bracket, Gas Valve Mounting (AH-20) 122080

2 Union 3/8” NPT (black) (AH-20) 005686 10 Screw, Phillips Pan Hd M5 x 10 mm 116388

2 Union 1/2” NPT (black) (AH-40 004186 11 Gas Valve 114505

2 Union elbow 1/2”NPT(black)(AH-60 80) 005495 12 Bushing Reducing 1/2” x 1/8" NPT 088290

3 Gas Test Nipple 117051 (black) (AH-40, 60, 80)

4 Cross, 1/2” NPT (black) (AH-20) 060241 12 Bushing Reducing 3/8”x 1/8" NPT 049943

4 Cross, 3/8” NPT (black) (AH-40,60,80) 097587 (AH-20)

5 Nipple 1/2” NPTx4"Lg. (black) 005554 13 Bushing Reducing 1/2”x 3/8" NPT 007442

6 Nipple 3/8” NPT x 4-1/2” Lg. (black) 005635 (AH-40)

(AH-20) 13 Bushing Reducing 1/2” x 1/8" NPT 088290

6 Nipple 1/2” NPTx4”Lg.(black)(AH-40) 005554 (AH-60,80)

6 Nipple1/2”NPTx5-1/2”Lg.(black) 010234 14 Bushing Reducing 3/8” x 1/4" NPT 013296

(AH-60, 80) (AH-20)

7 Nipple, 3/8” NPT, close (black) AH-20 007439 14 Bushing Reducing 1/2” x 1/4" NPT 008739

7 Nipple, 1/2” NPT, close (black) AH-40 008877 (AH-40)

7 Nipple, 1/2” NPT, 3"Lg (black) AH-60 005553 14 Bushing Reducing 1” x 1-1/2” NPT 002647

7 Nipple, 1/2” NPT, 4"Lg (black) AH-80 005554 (AH-60,80)

8 Nipple 1/2" NPT x 1/2” BSPT (brass) 116394 16 Nipple 1/2” NPT x 8 Lg. (black) 005557

9 Bracket, Gas Valve Mounting 117717 19 Adaptor 1/8” Female BSPP x 122087

(AH-40,60,80) 1/8” Male NPT

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Service Log

The Groen Steam Jacketed Kettle you have just purchased has been handcrafted from the finest materials,

meticulously inspected, and carefully tested to ensure that you receive the best possible product. With

reasonable care and periodic maintenance, it will provide years of faithful service. It is recommended that

you establish a timetable for periodic maintenance with an Authorized Groen Service Agency. Space has

been provided in the manual for a Maintenance & Service Log. Keep it up-to-date and on file.

Model

m _________________________________ Purchased From _________________________

Serial

m _________________________________ Location ________________________________

Date Purchased ___________________________ Date Installed ___________________________

Purchase Order

m _________________________ For Service Call __________________________

Date Service Performed Performed By

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30

Limited Warranty To Commercial Purchasers*

(for Areas Outside of the U.S. and Canada)

Groen Foodservice Equipment ("Groen Equipment") has been skillfully manufactured, carefully inspected

and packaged to meet rigid standards of excellence. Groen warrants its Equipment to be free from defects

in material and workmanship for ( 12) twelve months from date of installation or ( 18) eighteen months from

date of shipment with the following conditions and subject to the following limitations.

I. This parts warranty is limited to Groen Equipment sold to the original commercial purchaser/users

(but not original equipment manufacturers), at its original place of installation, in areas outside the
U.S. and Canada.

II. Damage during shipment is to be reported to the carrier, is not covered under this warranty, and is

the sole responsibility of the purchaser/user.

III. Groen, or an authorized service representative, will repair or replace parts, at Groen's sole election,

for any Groen Equipment, including but not limited to, draw-off valves, safety valves, gas and
electric components, found to be defective during the warranty period.

IV. This warranty does not cover boiler maintenance, calibration, or periodic adjustments as specified in

operating instructions or manuals, and consumable parts such as scraper blades, gaskets, packing,
etc., or labor costs incurred for removal of adjacent equipment or objects to gain access to Groen
Equipment. This warranty does not cover defects caused by improper installation, abuse, careless
operation, or improper maintenance of equipment. This warranty does not cover damage caused by
poor water quality or improper boiler maintenance.

v. THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED

OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE, EACH OF WHICH IS HEREBY EXPRESSLY DISCLAIMED.
THE REMEDIES DESCRIBED ABOVE ARE EXCLUSIVE AND IN NO EVENT SHALL GROEN BE
LIABLE FOR SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES FOR THE BREACH OR
DELAY IN PERFORMANCE OF THIS WARRANTY.

VI. Groen Equipment is for commercial use only. If sold as a component of another (O.E.M.)

manufacturer's equipment or if used as a consumer product, such Equipment is sold AS IS and
without any warranty.

* (Covers All Food Service Equipment Ordered After October 1,1995)

OM/SM-AH-CE

31

1055 Mendell Davis Drive
Jackson, Mississippi 39212
Telephone [phone]
FAX [phone]

OM/SM-AH-CE

OM/SM-AH-CE

Part Number 128416 Rev. B

Part Number 128416

Revised 4/99