Groen AHS-40 Service Manual
ıııı IMPORTANT INFORMATION
IMPORTANT INFORMATIONı
IMPORTANT INFORMATION IMPORTANT INFORMATION
Model: AHS
Low Height Steam Jacketed Kettle
[with Standard Electronic Ignition]
Self-contained
Stainless Steel
Gas Heated
Floor Mounted
Stationary
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IMPORTANT INFORMATION
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MPORTANT INFORMATIONMPORTANT INFORMATION
SHA-MOLAUNAM ROTAREPO
CITSEMODA .veR - 919731 rebmuN traP
Model AHS
THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE. READ, UNDERSTAND
AND FOLLOW THE INSTRUCTIONS AND WARNINGS CONTAINED IN THIS MANUAL.
FOR YOUR SAFETY
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND
LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE .
POST IN A PROMINENT LOCATION
INSTRUCTIONS TO BE FOLLOWED IN THE EVENT USER SMELLS GAS. THIS
INFORMATION SHALL BE OBTAINED BY CONSULTING YOUR LOCAL GAS
SUPPLIER. AS A MINIMUM, TURN OFF THE GAS AND CALL YOUR GAS COMPANY
AND YOUR AUTHORIZED SERVICE AGENT. EVACUATE ALL PERSONNEL FROM
THE AREA.
WARNING
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR
MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS THOROUGHLY
BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.
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-AHS
IMPORTANT — READ FIRST — IMPORTANT
WARNING: FAILURE TO DISCONNECT POWER BEFORE SERVICING COULD RESULT IN
ELECTROCUTION AND DEATH.
WARNING: THIS UNIT IS INTENDED FOR USE IN THE COMMERCIAL HEATING, COOKING AND
HOLDING OF WATER AND FOOD PRODUCTS, PER THE INSTRUCTIONS CONTAINED
IN THIS MAUAL. ANY OTHER USE COULD RESULT IN SERIOUS PERSONAL INJURY
WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE
WARNING: THE UNIT MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH GAS,
CAUTION: TO AVOID DAMAGING PARTS OF THE BURNER SYSTEM UNDERNEATH THE KETTLE, LIFT
WARNING: DO NOT ATTACH THE UNIT TO A TYPE “B” VENT. IT COULD CAUSE FIRE OR PROPERTY
WARNING: DO NOT CONNECT ANY PIPING TO THE PRESSURE RELIEF VALVE. IT MUST BE
DANGER: ELECTRICALLY GROUND THE UNIT AT THE TERMINAL PROVIDED. FAILURE TO GROUND
CAUTION: BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE OPERATING
CAUTION: DO NOT OVERFILL THE KETTLE WHEN COOKING, HOLDING OR CLEANING. KEEP
CAUTION: KEEP FLOORS IN FRONT OF KETTLE WORK AREA CLEAN AND DRY. IF SPILLS OCCUR,
WARNING: KEEP WATER AND SOLUTIONS OUT OF CONTROLS AND BURNERS. NEVER USE A HIGH
CAUTION: MOST CLEANERS ARE HARMFUL TO THE SKIN, EYES, MUCOUS MEMBRANES AND
IMPORTANT: DO
NOTICE:
WARNING:
WARNING: WHEN TESTING, AVOID EXPOSURE TO THE STEAM BLOWING OUT OF THE PRESSURE
WARNING: TO AVOID INJURY, READ AND FOLLOW ALL PRECAUTIONS STATED ON THE LABEL OF
WARNING: BEFORE REPLACING ANY PARTS, DISCONNECT THE UNIT FROM THE ELECTRIC POWER
CAUTION: USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY GROEN OR
WARNING: KEEP AREA AROUND KETTLE FREE AND CLEAR OF ALL COMBUSTIBLE MATERIALS.
CAUTION: HEATING AN EMPTY KETTLE MAY CAUSE THE RELEASE OF STEAM FROM THE PRESSURE
IMPORTANT: SERVICE PERFORMED BY OTHER THAN FACTORY AUTHORIZED PERSONNEL WILL VOID
OR DAMAGE TO THE EQUIPMENT AND WILL VOID WARRANTY.
CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION,
OPERATING AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR
SERVICING THIS EQUIPMENT.
ELECTRICITY AND PLUMBING. UNIT MUST BE INSTALLED IN ACCORDANCE WITH ALL
APPLICABLE CODES.
THE UNIT ONLY BY THE RING BENEATH THE OUTER PORTION OF THE BODY.
DAMAGE.
FREE TO VENT TO VENT STEAM AS NEEDED. TO AVOID BURNS FROM THE VENTED STEAM
THE VALVE DISCHARGE SHOULD POINT DOWN. IMPROPER INSTALLATION WILL VOID
WARRANTY.
THE UNIT COULD RESULT IN ELECTROCUTION AND DEATH.
INSTRUCTIONS, CAUTIONS AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL.
LIQUIDS A MINIMUM OF 2-3" (5-8 CM) BELOW THE KETTLE BODY RIM TO ALLOW
CLEARANCE FOR STIRRING, BOILING AND SAFE TRANSFER OF PRODUCT.
CLEAN IMMEDIATELY TO AVOID SLIPS OR FALLS.
PRESSURE HOSE TO CLEAn THE KETTLE SURFACES.
CLOTHING. TAKE PRECAUTIONS: WEAR RUBBER GLOVES, GOGGLES OR FACE
SHIELD AND PROTECTIVE CLOTHING. CAREFULLY READ WARNINGS AND FOLLOW
DIRECTIONS ON CLEANER LABELS .
NOT MIX PARTS OF DIFFERENT DRAW-OFF VALVES DURING WASHING. PARTS
ARE NOT INTERCHANGEABLE.
NEVER LEAVE A SANITIZER IN CONTACT WITH STAINLESS STEEL SURFACES LONGER
THAN 10 MINUTES. LONGER CONTACT CAN CAUSE CORROSION.
FAILURE TO PERIODICALLY CHECK PRESSURE RELIEF VALVE OPERATION COULD RESULT
IN PERSONAL INJURY AND/OR DAMAGE TO EQUIPMENT.
RELIEF VALVE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS.
THE WATER TREATMENT COMPOUND.
SUPPLY AND CLOSE THE MAIN GAS VALVE. ALLOW FIVE MINUTES FOR GAS TO VENT.
AUTHORIZED DISTRIBUTORS CAN CAUSE INJURY TO THE OPERATOR AND DAMAGE TO
THE EQUIPMENT AND WILL VOID ALL WARRANTIES.
FAILURE TO DO SO COULD RESULT IN FIRE OR PROPERTY DAMAGE.
RELIEF VALVE.
ALL WARRANTIES.
2
OM-AHS
Table of Contents
INSTALLER AND OPERATOR WARNINGS ......................................2
REFERENCES .............................................................3
EQUIPMENT DESCRIPTION .................................................4
INSPECTION & UNPACKING . . . ..............................................5
INSTALLATION & START-UP .................................................6
OPERATION ..............................................................8
SEQUENCE OF OPERATION ................................................10
CLEANING ...............................................................11
MAINTENANCE ...........................................................12
TROUBLESHOOTING .....................................................14
PARTS LISTS. . . ..........................................................16
ELECTRICAL SCHEMATIC..
................................................22
SERVICE LOG ............................................................23
WARRANTY..............................................................24
References
CSA International
8501 East Pleasant Valley Road
Cleveland, Ohio 44131
NATIONAL SANITATION FOUNDATION
3475 Plymouth Rd.
Ann Arbor, Michigan 48106
KLENZADE SALES CENTER ECOLAB. Inc.
370 Wabasha
St. Paul, Minnesota 55102
ZEP MANUFACTURING CO.
1310-T Seaboard Industrial Blvd.
Atlanta, Georgia 30318
AMERICAN NAT’L STANDARDS INST., INC.
1430 Broadway
New York, New York 10018
Z223.1-1984 - National Fuel Gas Code
Z21.30 - Installation of Gas Appliances & Piping
NATIONAL FIRE PROTECTION ASSOCIATION
60 Battery March Park
Quincy, Massachusetts 02269
NFPA/54 - Installation Gas Appliances & Piping
NFPA/70 - The National Electrical Code
3
OM-AHS
Equipment Description
Groen AHS steam kettles are stainless steel, floor
mounted kettles with a self-contained steam source
heated by gas. A closed steam jacket covers the
lower
b of the kettle. Heat from the gas burner boils
water in the jacket to produce steam under
pressure. To ignite the burners, Model AHS uses
electronic spark ignition.
The kettles are stationary (non-tilting). Liquids can
be removed through the tangent draw-off valve.
Exposed surfaces are stainless steel. Insulated
sheathing protects the kettle body, and a housing
encloses the controls. Three tubular legs support
the unit. Bullet feet adjust to level the kettle.
A one piece dome cover is hinged to the kettle on
the AHS. Covers for 40 gallon kettles are supplied
with counterbalancing spring actuators to hold the
covers in the fully open or closed position.
Controls provided include the ON/OFF switch, to
control electric power for the unit, and the
thermostat, to set the cooking temperature. The
automatic controls and a brief description of each
are as follows.
a. Gas pressure regulator: Protects the unit from
high pressure in the gas supply line
b. Automatic gas valves: Allow gas into the
burners as needed
c. Pressure limit switch: Turns off the burner when
jacket pressure reaches 27 PSI. Lights the
burner when pressure drops to 22 PSI.
d. Safety valve: Lets steam out of the jacket if the
steam pressure exceeds 30 PSI.
e. Low-water cutoff: Turns off the burner if the
water level in the jacket gets too low for safe
operation
Instruments also are provided to show what is
happening inside the unit. These are:
a. Water level sight glass: Indicates whether there
is enough water in the steam jacket.
b. Pressure/vacuum gauge: Shows steam
pressure, and whether too much air has entered
the jacket.
c. Heating indicator light: Indicates that the kettle
is being heated.
d. Power on indicator light: Glows when the unit is
turned on.
e. Low water indicator light: Lights to show that
jacket water needs to be replenished.
The kettle body is welded into one piece and has a
rim reinforced by a rectangular bar. The interior and
exterior of the kettle is polished to a 180 emery grit
finish. The unit is ASME shop inspected and
registered with the National Board for working
pressures up to 30 PSI.
The standard 2 inch tangent draw-off is a 316
stainless steel, compression disc valve. A
removable strainer with ¼ inch holes keeps pieces
of product from entering the draw-off during
cooking.
The jacket is filled at the factory with water
containing rust inhibitors. The kettle can operate at
steam pressures up to 30 PSI, which provide
temperatures of 150ºF (65ºC) to approximately
250ºF (121ºC). This range allows warming,
simmering, boiling, or braising.
For AHS kettles, options include:
a. Larger (3 inch) draw-off *
Natural
Gas
c inch
Propane
Gas
b. Solid disc strainer or strainer with
perforations
c. WaterFill faucet
d. Automatic, metered water filler (Gallon Master)
e. TRI-BC basket
f. Kettle brush kit
g. Gallon etch marks*
h. Flanged feet
i. 316 stainless steel liner (for high acid products)*
j. Powered agitators (TA/3 or INA/2)*
* Factory installed options
KETTLE CHARACTERISTICS
Firing Rate, BTU/hour
Kettle Ignition
AHS-40 Spark 115,000 115,000
AH/1E-40 Spark 100,000 85,000
AH/1E-60 Spark 145,000 145,000
AH/1E-80 Spark 145,000 145,000
AH/1E-100 Spark 145,000 145,000
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OM-AHS
KETTLE CHARACTERISTICS
Model
AHS-40
AH/1E-40
AH/1E-60
AH/1E-80
AH/1E-100
Kettle
Capacity
Gallons
(Liters)
40(150) 7(26.5) 26 (660) 22 (559)
40 (150) 7 (26.5) 26 (660) 22(559)
60 (225) 9.5 (36) 30 (762) 25 (635) 41 (1041.4) 49 (1244.6) 49 (1244.6)
80 (300) 11.5 (43.5) 32 (813) 29 (737)
100 (375) 11.5 (43.5) 32 (813) 35 (889)
Jacket
Capacity
Gallons
(Liters)
Kettle
Diameter
Inches
(Millimeters)
Kettle
Depth
Inches
(Millimeters)
Overall
Width
Inches
(Millimeters)
38.25
(971.55)
38.25
(971.55)
42.5
(1079.4)
42.5
(1079.4)
Front-to-
Back,
Inches
(Millimeters)
45 (1143) 38.6 (981)
45 (1143) 42 (1066.8)
51 (1295.4)
51 (1295.4)
Rim Height
Inches
(Millimeters)
55.5
(1409.7)
61.5
(1562.1)
Inspection & Unpacking
WARNING
THIS UNIT MUST BE INSTALLED BY PERSONNEL WHO ARE QUALIFIED TO WORK WITH ELECTRICITY
AND PLUMBING. IMPROPER INSTALLATION CAN CAUSE INJURY TO PERSONNEL AND/OR DAMAGE
TO THE EQUIPMENT. THE UNIT MUST BE INSTALLED IN ACCORDANCE WITH APPLICABLE CODES.
The unit arrives completely assembled, except for the
TDO valve, flue stack and flue elbow which are usually
packed separately and shipped inside the kettle.. The
unit is strapped on a skid in a heavy box. Inspect the
box carefully for damage. Open the container and
check the unit for hidden damage. Report shipping
damage or shipment errors to the delivery agent.
Write down the model number, serial number, and
installation date for your unit at the top of the
Maintenance and Service Log at the back of this
manual. Keep the manual on file and available for
operators to use.
To remove the kettle from the box, cut any straps from
around the box. Detach the box sides from the skid.
Pull the box up off the unit, taking care to avoid damage
or injury from any staples left in the box walls. When
installation is to begin, cut the straps holding the kettle
to the skid, and lift the kettle straight up off the skid.
Examine the packing materials to make sure no loose
parts are discarded with the materials.
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.
UNIT WEIGHS FROM 468 LBS. (212 KG) TO 1120
LBS. (508 KG). FOR SAFE HANDLING,
INSTALLER SHOULD OBTAIN HELP AS NEEDED
AND USE MATERIAL HANDLING EQUIPMENT TO
REMOVE THE UNIT FROM THE SKID AND MOVE
IT TO ITS PLACE OF INSTALLATION.
Once the kettle is unpacked, the tangent draw-off
valve is easily attached, as shown below. The large
nut which attaches the valve to the kettle should be
hand tightened only.
Assemble and attach the tangent draw-off valve after the kettle is unpacked.
5
OM-AHS
WARNING
THE KETTLE MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH ELECTRICITY AND
PLUMBING. IMPROPER INSTALLATION CAN CAUSE INJURY TO PERSONNEL AND/OR DAMAGE TO THE
EQUIPMENT.
THIS UNIT IS FOR COMMERCIAL USE. NEVER USE HOME OR RESIDENTIAL GRADE GAS CONNECTIONS.
THEY DO NOT MEET GAS CODES AND COULD BE HAZARDOUS.
Installation and Initial Start-Up
A. Installation
The unit should be installed in a ventilated room for
efficient performance. items which may obstruct or
restrict the flow of air for combustion and ventilation
must be removed. The area directly around the
appliance must be cleared of all combustible materials.
1. Installation requires connection with gas and
electrical services. See items 8 to 14 for details.
2. To protect the unit from damage, leave it on the
shipping pallet until the time of installation. When
installation is to begin, cut the straps holding the
kettle, and hoist the kettle straight up off the skid.
NOTICE
To avoid damaging parts of the burner system
underneath the kettle, LIFT THE UNIT ONLY BY THE
RING beneath the outer portion of the body.
3.
Unit is for use only on non-combustible floors.
4.
Install the unit with a minimum clearance to
combustible and non-combustible construction of two
inches at the sides and four inches at rear. Also leave
enough room for cleaning, maintenance, and service.
5. The flue stack and flue elbow shipped with the kettle
is the correct height and shape to give maximum
performance. Install the flue stack and flue elbow as
shown on the sketch below.
Unit must be installed under a ventilation hood only.
Installation of a ventaling hood should comply with
local codes and/or ANSI/NFOA-96 Latest Edition.
Also, local codes may require that the kettle be
electrically interlocked to shut off the gas supply
and prevent the operation of the unit if the
exhaust fan is not operating or if the fire
suppression system is activated. Failure to
follow these instructions can cause bodily injury
and/or property damage.
6. To level the unit, adjust leg length by turning the
bullet feet
7. Make sure the water level is correct in the
jacket, by confirming that the level is between
the marks on the gauge glass. If the water level
is low, follow the instructions under “Jacket
Filling” in the “Maintenance” Section of this
manual.
CAUTION
DO NOT CONNECT ANY PIPING TO THIS
PRESSURE RELIEF VALVE. IT MUST BE FREE
TO VENT STEAM AS NEEDED. ELBOW SHOULD
POINT DOWN TOWARD FLOOR. IMPROPER
INSTALLATION WILL VOID WARRANTY!
8. To protect personnel from steam coming out of
the pressure relief valve, the open end of the
elbow at the outlet must be directed down. If it
is not, turn the elbow to the correct postion.
flue stack
flue elbow
WARNING
DO NOT ATTACH THE UNIT TO A TYPE “B” VENT.
FAILURE COULD RESULT IN FIRE OR PROPERTY
DAMAGE.
CAUTION
DO NOT USE KETTLE WITHOUT GROEN
SUPPLIED FLUESTACK & ELBOW INSTALLED.
FLUE RISER, 17 INCHES HIGH MUST BE
ATTACHED HERE. NOT SUITABLE FOR
CONNECTION TO TYPE B GAS VENT.
DANGER ELECTRICALLY GROUND THE UNIT
AT THE TERMINAL PROVIDED. FAILURE TO
GROUND UNIT COULD RESULT IN
ELECTROCUTION AND DEATH.
Provide 115 VAC, 60 HZ, 1 PH, 15 AMP
9.
electrical service for standard unit. Unit may be
equipped for alternate electrical service of 208
VAC or 240 VAC, as ordered. Use 1/2 inch
waterproof conduit and waterproof connections.
Observe local codes and/or The National
Electrical Code in accordance with ANSI/NFPA
70 - latest edition. AN ELECTRICAL GROUND
IS REQUIRED. The electrical schematic is
located on the inside of the service panel.
In Canada, provide electrical service in
accordance with the Canadian Electrical Code,
6
CSA C22.2 Part 1 and/or local codes.
10. The internal gas lines of the unit were cleaned and
closed off with a gas cock before the unit was
shipped from the factory. Free all external gas lines
of lint, dirt, metal chips, sealant, grease, oil, and
other contaminants, before you connect the lines to
the kettle.
11. Connect the gas cock of the kettle to the gas service
main with 3/4 inch IPS line or approved equivalent
12. Installation must conform with local codes, or in the
absence of local codes, with the National Fuel Gas
Code, ANSI Z 223.1-1988 (or latest edition). The
unit should be installed in an adequately ventilated
room with a provision for adequate air supply. The
best ventilation will utilize a vent hood and exhaust
fan with no direct connection between the vent duct
and the flue. Do NOT obstruct the flue or vent duct
after installation.
In Canada, the installation must conform to the
CAN/CGA B149 Installation Codes for Gas Burning
Appliances and Equipment and/or local codes.
13. Adequate space for proper service and operation is
required. Do NOT block any air intake spacings to
the combustion chamber or obstruct the air flow by
piling or stacking anything near the kettle.
OM-AHS
a. Unit installed on non combustible floor.
Enough room between the kettle and nearby
b.
objects for cleaning and service.
c. Minimum clearance of 2 inches from sides and
4" rear clearance.
d.
Unit installed under a ventalation hood.
e.
Kettle Level
Correct amount of water in the jacket.
f.
g. Safety valve outlet pointed down.
h. Connected with a waterproof, 115 volt, 15 amp
supply of electric power in accordance with
electrical codes.
i. Gas lines cleaned before connection.
j. Gas connected with 3/4 inch pipe or equivalent.
k. Gas lin joints checked for leaks.
l.
No obstruction to air supply or venting.
B.
Initial Start-Up
After the kettle has been installed, the installer
should test to ensure that it is operating correctly.
1. Remove literature and packing materials from
inside and outside of the unit.
2. Install the TDO valve handle.
3. Put a small amount of water into the kettle.
14. After the kettle has been connected to the gas
supply, all gas line joints must be checked for leaks.
DO NOT USE A FLAME TO CHECK FOR LEAKS.
A thick soap solution or other suitable leak detector
should be employed.
15. PRESSURE TEST WARNING
a) Test pressure exceeding 1/2 PSIG (3.45 kPa).
During pressure testing of the gas supply piping
system at pressures exceeding 1/2 PSIG, the
appliance and its idividual shutoff valve must be
disconnected from the gas supply piping system.
b) Test pressure equal to or less than 1/2 PSIG
(3.45kPa.) During pressure testing of the gas
gas supply piping system at pressures equal
to or less than 1/2 PSIG, the kettle must be
isolated from the gas supply piping system
closing its individual manual shutoff valve
16. Check the following points to confirm that your
AHS kettle has been installed properly.
4. Verify that kettle water level is normal and that
kettle is holding vacuum in jacket. Correct if not.
(See operating instructions to correct)
Make sure the supplies of gas and electric
5.
power are on.
6. Follow the Start Kettle Heating instructions in the
Operation section of this manual. Begin heating
the water at the highest thermostat setting. The
indicator light should come on and heating
should continue until the water boils.
7. To turn off the unit, follow “To Stop Kettle
Heating” in “Operating Instructions,” below.
If the kettle functions as described, it is ready for
use. If the unit does not operate as designed,
contact authorized Groen Service Agent.
7
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