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.
OM/SM-AH-CE
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
OM/SM-AH-CE
3
OM/SM-AH-CE
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
OM/SM-AH-CE
4
OM/SM-AH-CE
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.
OM/SM-AH-CE
5
OM/SM-AH-CE
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
OM/SM-AH-CE
6
OM/SM-AH-CE
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
OM/SM-AH-CE
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!
OM/SM-AH-CE
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
OM/SM-AH-CE
10
Loading...