? IMPORTANT INFORMATION? KEEP FOR OPERATOR? IMPORTANT INFORMATION ?
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)
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.
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 |
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:
CI.E.E. Regulations for Electrical Installations
CElectricity at Work Regulations
CGas Safety (Installation & Use) Regulations
CHealth and Safety at Work Act
CFire Precautions Act
CLocal 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 TO EQUIPMENT. THE UNIT MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE CODES
4
1.2 Siting
Install the appliance on a level floor in a well-lit and draught-free position. Install the appliance in accordance with local and/or national regulations as listed in this manual.
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 DISCHARGES VERTICALLY FROM THE TOP OF THE UNIT. IT MUST NOT BE DIRECTLY CONNECTED TO A FLUE, MECHANICAL EXTRACTION SYSTEM, OR DUCTING LEADING OUTSIDE THE BUILDING. THE APPLIANCE IS BEST DISCHARGED UNDER AN OPEN CANOPY CONNECTED TO A VENTILATING SYSTEM.
Recommendations for ventilation for catering appliances are given in BS 5440:2 and are shown 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 |
|
|
|
|
|
OM/SM-AH-CE
1.5 Electrical Supply
This unit is designed for connection to fixed wiring. A suitably rated isolating switch with contact separation of at least 3 mm on both poles must be fitted to the installation and the wiring 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 natural and propane gases without any conversion.
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.
5
OM/SM-AH-CE
1.8 Total Gas Rate
Model |
Natural |
Natural |
Propane |
Propane |
|
(G20& |
BTU/hr |
(G31) |
BTU/hr |
||
|
G25) KW |
KW |
|||
AH-20 |
22 |
75,100 |
22 |
75,100 |
|
AH-40 |
25 |
85,300 |
22 |
75,100 |
|
AH-60 & |
40 |
136,500 |
40 |
136,500 |
|
AH-80 |
|||||
|
|
|
|
||
1.9 Injector Diameters-Natural & Propane Gas |
|||||
|
Natural |
Natural |
Propane |
No. of |
|
Model |
Gas G20 |
Gas G25 |
Gas G31 |
Orifices |
|
|
(mm) |
(mm) |
(mm) |
(Injectors) |
|
AH-20 |
4.39 |
4.70 |
2.64 |
1 |
|
AH-40 |
4.57 |
4.90 |
2.64 |
1 |
|
AH-60 & |
5.94 |
6.75 |
3.57 |
1 |
|
AH-80 |
|||||
|
|
|
|
||
1.10Gas 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 |
mbar |
8.75 |
8.75 |
8.75 |
GAS G20 |
in. WC |
3.5 |
3.5 |
3.5 |
NATURAL |
mbar |
8.75 |
8.75 |
7.0 |
GAS G25 |
in. WC |
3.5 |
3.5 |
2.8 |
PROPANE |
mbar |
25 |
25 |
25 |
GAS G31 |
in. WC |
10 |
10 |
10 |
NOTE: With reference to the gas rate, pressure 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
a)Unpack the appliance.
b)Place on a firm, level floor. Adjust and fix 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.
2.3Electrical Supply
Before commissioning the appliance, ensure that the electrical installation has been carried out to the relevant regulations. (Paragraph 1.5)
THIS APPLIANCE MUST BE EARTHED.
2.4Jacket 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.
2.5Pre-Commissioning Check
6
a)Prior to operation, clean kettle pan with hot water and detergent. Rinse thoroughly.
b)Remove all literature and packing materials from the interior and exterior of the unit.
c)Ensure the open end or the elbow at the safety valve outlet is pointed down. If not, turn the elbow to the correct position. See Safety Valve Operation Instructions on Page 8.
2.5.1Lighting 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.
2.5.2Setting 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).
OM/SM-AH-CE
f)Remove governor cap screw on gas control valve. See figure for governor position on valve.
g)Governor is suitable for natural and propane gas.
h)To increase pressure turn the screw inside the governor turret clockwise, or anti-clockwise to reduce pressure. Check the burner pressure again after 15 minutes and adjust if necessary.
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.
2.5.3Checking 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.
2.6Instruction 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.
7
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.
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.
AVOID STEAM
CONTACT
WARNING
AVOID ANY EXPOSURE TO THE STEAM 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.
To achieve topmost performance and maximum 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
8
body, testing must be performed more often. A “try lever test” must also be performed at the 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.
OM/SM-AH-CE
e.Use pipe compound sparingly, or tape, on external threads only.
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!
9
OM/SM-AH-CE
i.See appropriate ASME Boiler and Pressure Vessel Code for additional installation instructions.
3.1Conversion — NOTE: See Para 1.9 and 1.10 (Page 6) for important gas conversion information. VERIFY
THE TYPE OF GAS TO BE USED. In the countries listed in Paragraph 1.10 all conversions must be for approved 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 changedonly the pressure setting.
3.2Jacket 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 STEAM BLOWING OUT OF THE SAFETY VALVE.
3.3Jacket 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 proper level, either because water was lost as steam during venting or because treated water was lost by draining.
The procedure for adding water is as follows:
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
READ AND FOLLOW ALL PRECAUTIONS STATED ON THE LABEL OF THE WATER TREATMENT COMPOUND TO AVOID INJURY.
a.Fill the mixing container with the measured amount of water required. (See Table). Use distilled water only.
|
Kettle |
Jacket |
|
Model |
Capacity |
||
Capacity |
|||
|
(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 |
|
|
|
|
10
Loading...