Groen capkold DH-400L, capcold DH/INA/2-100 Operator's Manual
OPERATOR MANUAL
IMPORTANT INFORMATION, KEEP FOR OPERATOR
This manual provides information for:
MODEL DH/INA/2-100
STEAM JACKETED
KETTLE
· Self-Contained
· Gas Heated
· Floor Mounted
· Tilting
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.
NOTIFY CARRIER OF DAMAGE AT ONCE
It is the responsibility of the consignee to inspect the container upon receipt of
same and to determine the possibility of any damage, including concealed dam-
age. Unied Brands suggests that if you are suspicious of damage to make a
notation on the delivery receipt. It will be the responsibility of the consignee to le
a claim with the carrier. We recommend that you do so at once.
Manufacture Service/Questions 888-994-7636.
Information contained in this document is known to be current and accurate at the time
of printing/creation. Unified Brands recommends referencing our product line websites,
unifiedbrands.net, for the most updated product information and specifications.
PART NUMBER 176302, REV. A (01/18)
1055 Mendell Davis Drive
Jackson, MS 39272
888-994-7636, fax 888-864-7636
unifiedbrands.net
IMPORTANT - READ FIRST - IMPORTANT
WARNING: FAILURE TO DISCONNECT POWER BEFORE SERVICING COULD RESULT IN ELECTROCUTION AND
DEATH.
WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE
PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENANCE
INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.
WARNING: DO NOT PLACE HANDS, TOOLS OR HOSES IN KETTLE WHILE AGITATOR IS MOVING. AGITATOR CAN
BE JOGGED WHILE KETTLE IS TILTED.
WARNING: THE UNIT MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH ELECTRICITY AND
PLUMBING. UNIT MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE CODES.
WARNING: DO NOT ATTACH THE UNIT TO A TYPE “B” VENT. IT COULD CAUSE FIRE OR PROPERTY DAMAGE.
WARNING: DO NOT CONNECT ANY PIPING TO THE SAFETY VALVE. IT MUST BE FREE TO VENT STEAM AS
NEEDED. TO AVOID BURNS FROM THE VENTED STEAM THE VALVE DISCHARGE SHOULD POINT
DOWNWARD.
DANGER: ELECTRICALLY GROUND THE UNIT AT THE TERMINAL PROVIDED. FAILURE TO GROUND THE UNIT
COULD RESULT IN ELECTROCUTION AND DEATH.
CAUTION: BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE OPERATING INSTRUCTIONS,
CAUTIONS AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL.
CAUTION: DO NOT OVERFILL THE KETTLE WHEN COOKING, HOLDING OR CLEANING. KEEP LIQUIDS A
MINIMUM OF 2-3” (5-8 CM) BELOW THE KETTLE BODY RIM TO ALLOW CLEARANCE FOR STIRRING,
BOILING AND SAFE TRANSFER OF PRODUCT.
CAUTION: KEEP FLOORS IN FRONT OF KETTLE WORK AREA CLEAN AND DRY. IF SPILLS OCCUR, CLEAN
IMMEDIATELY TO AVOID SLIPS OR FALLS.
WARNING: KEEP WATER AND SOLUTIONS OUT OF CONTROLS AND BURNERS. NEVER SPRAY OR HOSE DOWN
THE CONTROL CONSOLE, ELECTRICAL CONNECTIONS, ETC.
CAUTION: MOST CLEANERS ARE HARMFUL TO THE SKIN, EYES, MUCOUS MEMBRANES AND CLOTHING. TAKE
PRECAUTIONS: WEAR RUBBER GLOVES, GOGGLES OR FACE SHIELD AND PROTECTIVE CLOTHING.
CAREFULLY READ WARNINGS AND FOLLOW DIRECTIONS ON CLEANER LABELS .
NOTICE: NEVER LEAVE A SANITIZER IN CONTACT WITH STAINLESS STEEL SURFACES LONGER THAN 10
MINUTES. LONGER CONTACT CAN CAUSE CORROSION.
WARNING: FAILURE TO PERIODICALLY CHECK SAFETY VALVE OPERATION COULD RESULT IN PERSONAL
INJURY AND/OR DAMAGE TO EQUIPMENT.
WARNING: WHEN TESTING, AVOID EXPOSURE TO THE STEAM BLOWING OUT OF THE SAFETY VALVE. DIRECT
CONTACT COULD RESULT IN SEVERE BURNS.
WARNING: TO AVOID INJURY, READ AND FOLLOW ALL PRECAUTIONS STATED ON THE LABEL OF THE WATER
TREATMENT COMPOUND.
WARNING: BEFORE REPLACING ANY PARTS, DISCONNECT THE UNIT FROM THE ELECTRIC POWER SUPPLY
AND CLOSE THE MAIN GAS VALVE. ALLOW FIVE MINUTES FOR GAS TO VENT.
CAUTION: USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY GROEN OR AUTHORIZED
DISTRIBUTORS CAN CAUSE INJURY TO THE OPERATOR AND DAMAGE TO THE EQUIPMENT AND
WILL VOID ALL WARRANTIES.
2 OM-DH/INA/2-100
IMPORTANT - READ FIRST - IMPORTANT
WARNING: KEEP AREA AROUND KETTLE FREE AND CLEAR OF ALL COMBUSTIBLE MATERIALS. FAILURE TO DO
SO COULD RESULT IN FIRE OR PROPERTY DAMAGE.
CAUTION: HEATING AN EMPTY KETTLE MAY CAUSE THE RELEASE OF STEAM FROM THE SAFETY VALVE.
IMPORTANT: SERVICE PERFORMED BY OTHER THAN FACTORY AUTHORIZED PERSONNEL WILL VOID ALL
WARRANTIES.
OM-DH/INA/2-100 3
Table of Contents
Important Operator Warnings ....................................................page 2-3
References.................................................................................... page 4
Equipment Description.................................................................. page 5
Inspection and Unpacking ......................................................... page 6-7
Installation .................................................................................. page 8-9
Initial Start-Up............................................................................... page 10
Operation ................................................................................ page 11-16
Cleaning........................................................................................ page 17
Maintenance............................................................................ page 18-20
Sequence of Operation ............................................................... page 21
Troubleshooting...................................................................... page 22-23
Part Lists ............................................................................ page 24-36
Wiring Diagram ............................................................................ page 37
Service Log ................................................................................. page 39
References
KLENZADE SALES CENTER
ECOLAB. Inc.
370 Wabasha
St. Paul, Minnesota 55102
800/352-5326 or 612/293-2233
NATIONAL FIRE PROTECTION ASSOCIATION
60 Battery March Park
Quincy, Massachusetts 02269
NFPA/54 Installation of Gas Appliances &
Gas Piping
NFPA/70 The National Electrical Code
NSF INTERNATIONAL
789 N. Dixboro Rd.
P.O. Box 130140
Ann Arbor, Michigan 48113
UNDERWRITERS LABORATORIES, INC.
333 Pngsten Road
Northbrook, Illinois 60062
4 OM-DH/INA/2-100
ZEP MANUFACTURING CO.
1310-T Seaboard Industrial Blvd.
Atlanta, Georgia 30318
Equipment Description
Model Ignition
DH-400L
Capacity
Diameter
Overall Width
Overall
Front-to-Back
Rim Height
Electronic 360,000 360,000
FIRING RATE,
BTU/HOUR
Natural
Gas
100 gallons
34” (86 cm)
64¼” (163 cm)
54” (137 cm)
54¼” (138 cm)
Propane
Gas
Groen Model DH-400L is a stainless steel, steam jacketed, floor mounted, tilting kettle
with a self-contained, gas heated steam source. The kettle body is welded into one
piece and furnished with a reinforced bar rim and welded “butterfly” pouring lip. The
interior of the kettle is polished to a 180 emery grit finish and the exterior given a
uniform Number 3 finish.
The unit is ASME shop-inspected and is registered with the National Board for working
pressures up to 50 PSI. Kettle supports mount directly to the floor by use of lag bolts.
A power tilt feature is standard. Options available include: “Gallon Master” metering
system, product outlet strainer, and a power-assist cover, and a digital time-temperature
recorder.
The self-contained steam source is heated by either propane or natural gas. The
ignition system is spark or standing pilot. The kettle is charged at the factory with
chemically pure water containing corrosion inhibitors. The steam source provides kettle
temperatures of 150 to approximately 280ºF. Controls for the unit include a thermostat,
pressure gauge, water level glass, safety valve, pressure limit control, low water cutoff,
gas regulator valve, and a printed circuit board that monitors product temperature. The
gas supply shuts down automatically when the kettle is tilted. The agitator operates only
in partial rotation mode when the kettle is tilted.
The unit must be specified for use with natural or propane gas. Service connections
are required for gas, electric, air (if the air-operated valve is specified), water (if Gallon
Master metering is specified).
Left Stanchion
Kettle Body Assembly Fill Spout
Sight Glass Power-Aid Hinge
Touch Screen Control Flue Stack, Combustion Chamber
Right Stanchion and Burner Assemblies
OM-DH/INA/2-100 5
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.
WARNING
SHIPPING CHANNELS (BRACES) ARE VERY
HEAVY. USE PROPER LIFTING AND HANDLING
EQUIPMENT FOR MOVEMENT.
CAUTION
WATCH OUT FOR NAILS AND SPLINTERS
WHILE DISMANTLING THE SHIPPING CRATE.
CAUTION
UNIT HASAN APPROXIMATE SHIPPING
WEIGHT OF 1600 LBS. (727 KG.). FOR SAFE
HANDLING, INSTALLER SHOULD OBTAIN
PROFESSIONAL RIGGING HELP AS NEEDED
AND USE MATERIAL HANDLING EQUIPMENT
(SUCH AS A FORKLIFT, OVERHEAD HOIST, OR
PALLET JACKS) TO REMOVE THE UNIT FROM
THE SKID AND MOVE IT TO ITS PLACE OF
INSTALLATION.
The unit is delivered completely assembled, on a heavy skid surrounded by a wooden
crate. Immediately upon receipt, inspect the unit for damage. Report any shipping damage
or an incorrect shipment to the delivery agent.
Write down the model number, serial number, and installation date of your unit, and keep
this information for future reference. Space for these entries is provided at the top of the
Service Log provided at the rear of this manual. The unit is anchored to two metal shipping
channels (braces) which may be discarded after installation. Carefully unbolt one side of
shipping channel. Position the kettle and remove second shipping channel.
The unit is delivered crated and
bolted to a heavy skid.
Two heavy shipping channels
(braces) anchor the unit for
shipment.
Shipping Channels (Braces)
When installation is to begin, unbolt the unit from the skid, and lift the unit straight up and
off the skid.
WARNING
TO AVOID DAMAGE OR INJURY, FOLLOW THE
ELECTRICAL SCHEMATIC EXACTLY WHEN
CONNECTING THE UNIT.
6 OM-DH/INA/2-100
UTILITY REQUIREMENTS
1. Electrical Supply Connection-3 Phase Operation Only
a. The panel must be removed to gain access to the electrical supply connection.
Open the wiring and control panel by unscrewing the eight screws which hold it in
place. Grasp the panel by the base at the bottom edge. While lifting the panel, swing
its bottom toward you. Set the panel aside.
b. Supply Voltage: The unit must operate at the rated nameplate voltage, plus or minus
10 percent.
c. Wiring Information: Refer to the electrical schematic for wiring information. A copy
of the schematic is found inside the control panel and at the rear of this manual.
d. Terminal Block: The terminal block for incoming power is located at the back of the
control compartment. The ground terminal is located next to the terminal block. The
unit must have a separate ground wire for safe operation.
e. High Voltage safety
Inspection & Unpacking
f. Branch Circuit Protection: Each conductor must have over-current protection. Refer
to the label on the back of the unit for the proper wire type and size. Connections to
the unit must be watertight.
We strongly recommend that the Kettle have its own branch circuit protection.
Current and power demands for the different voltage units are as follows:
Gas and Water Connections are on the
back of the left stanchion.
Maximum Voltage Three Phase Current, Per Line
208 Volts
240 Volts
480 Volts
7 AMP
7 AMP
3.5 AMP
2. Water Connection(s)
Install a check valve in the incoming cold water line, if required by local plumbing
codes. Water pressure in the line should be between 30 and 60 PSIG (210 and 420
kPa). A ¾ NPT connector is needed to attach the water supply to the water inlet valve.
The minimum recommended water feed line diameter is ½ inch (13mm). Do not allow
the connection to leak, no matter how slowly. THE INSTALLER MUST PROVIDE THE
CHECK VALVE (ANTI-SYPHON DEVICE) IF REQUIRED BY LOCAL CODES.
3. Gas Connection
Connect 1 NPT gas line to the gas inlet valve on the rear of the left stanchion. Be sure
that the gas supply meets the following criteria:
Natural Gas Propane
Minimum
Maximum
7” W.C. 11” W.C.
10” W.C. 14” W.C.
OM-DH/INA/2-100 7
Installation
WARNING
THIS UNIT IS FOR COMMERCIAL USE.
NEVER USE HOME OR RESIDENTIAL
GRADE GAS CONNECTIONS.
THEY DO NOT MEET GAS CODES AND
COULD BE HAZARDOUS.
WARNING
DO NOT ATTACH THE UNIT TO A TYPE “B”
VENT. FAILURE COULD RESULT IN FIRE OR
PROPERTY DAMAGE.
Recommended shim size.
The unit should be installed in a well-ventilated room on non-combustible flooring.
Anything which might obstruct or restrict the flow of air for combustion and ventilation
must be removed. The area directly around the appliance must be free of combustible
materials.
1. Installation requires connection with air, gas, water and electric services. See items
8 to 14 for details.
2. To protect the unit from damage, leave it on the shipping pallet until installation. When
ready to start installation, disassemble the shipping crate, unbolt the stanchions,
disconnect the shipping channels (braces) and raise the unit straight up off the skid.
Do not lift the kettle at the heat exchanger. Lifting the kettle at the heat exchanger
could damage the unit.
3. Install the unit with at least 22 inches clearance from the back walls. Also leave
enough room for easy cleaning, maintenance, and service.
4. Do not alter the kettle in any way. Any mechanical, electrical, or gas change must be
approved by the Groen Food Service Engineering Department.
5. Level the unit as follows:
The stanchions are each supplied with a drip tray in which the angle frame is placed.
Steel leveling shims (not included, supplied by installer) are placed between the drip
tray and frame so that the drip tray will be flush with the floor, as shown.
Don’t lift here
8 OM-DH/INA/2-100
Start with the right stanchion and level it as shown in the sketch. Once the right
stanchion is levelled and properly anchored front to rear, level the left stanchion front
to rear and side to side.
Level the entire unit side to side by placing a four foot carpenter’s level on the kettle
rim. Once the rim is level from side to side, rotate the level to check front to back.
Shim the left stanchion in the same manner as the right, and anchor the equipment
firmly to the floor through the shims.
6. Make sure the jacket water level is correct by confirming that it is in the middle of
the bulls-eye sight glass at the front of the kettle. If the water level is low, follow the
instructions under “Jacket Filling” in the “Maintenance” Section of this manual.
7. To protect personnel from steam coming from the safety valve, the open end of the
elbow at the outlet must be directed downward. If it is not, turn the elbow to the
correct position.
8. INSTALL:
Check valve in the incoming cold water line, if required by local plumbing codes, as
described in Paragraph 2, page 6.
Installation
WARNING
DO NOT CONNECT ANY PIPING TO THE POP
SAFETY VALVE. IT MUST BE FREE TO VENT
STEAM AS NEEDED. THE ELBOW SHOULD
POINT DOWN TOWARD FLOOR. IMPROPER
INSTALLATION WILL VOID WARRANTY.
DANGER
ELECTRICALLY GROUND THE UNIT AT THE
TERMINAL PROVIDED. FAILURE TO
GROUND UNIT COULD CAUSE
ELECTROCUTION AND DEATH.
9. Provide electrical service per Paragraph 1, Electrical Supply Connecton in the
Inspection and Unpacking, Requirements Section, Page 6. Use ½ inch waterproof
conduit and waterproof connections. Observe local Codes and/or The National
Electrical Code in accordance with ANSI/NFPA 70 - latest edition. AN ELECTRICAL
GROUND IS REQUIRED. The electrical schematic is located on the inside of the
service panel. In Canada, provide electrical service in accordance with the Canadian
Electrical code, CSA C22.1 Part 1 and/or local codes.
10. The internal gas lines of the unit were cleaned and closed with a gas cock before
the unit was shipped from the factory. Ensure that external gas lines are free of lint,
dirt, metal chips, sealant, grease, oil or other contaminants, before you connect the
line to the kettle.
11. Connect the kettle gas cock to the gas service main using a 1” NPT gas connection.
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 well-ventilated room with a provision for adequate air supply. The best
ventilation will use a vent hood and exhaust fan with no direct connection between
the vent duct and the unit flue.
Do NOT obstruct the flue or vent duct after installation. In Canada, the installation
must conform with 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.
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 used.
15. The appliance and its individual shutoff valve must be disconnected from the gas
supply piping system during any pressure testing of that system at test pressures
in excess of ½ PSIG (3.48 kPa). The appliance must be isolated from the gas supply
piping system by closing its individual manual shutoff valve during any testing of the
gas system at pressures equal to or less than ½ PSIG (3.48 kPa).
16. Check the following to confirm that your kettle has been installed properly:
• Enough room between the kettle and nearby objects for cleaning and service.
• Minimum clearance of 24 inches from sides and 24 from back.
• Unit vented to an exhaust hood.
• Kettle level.
• Correct amount of water in the jacket.
• Safety valve outlet pointed down.
• Connected with a waterproof electric power cable in accordance with Paragraph
1 Electrical Supply Connecton (above) and local electrical codes.
• Gas lines cleaned before connection.
• Gas connected with 1 NPT or larger.
• Gas line joints checked for leaks.
• No obstruction to air supply or venting.
• Gas lines (1 NPT) connected to supply.
• Water supply connection (¾”) completed.
OM-DH/INA/2-100 9
Initial Start-Up
After the kettle has been installed, the installer should test to ensure that the unit is
operating correctly.
1. Remove all literature and packing materials from the inside and outside of the unit.
Clean out any material that might clog or damage the product outlet.
2. Add 50 gallons (180 liters) of water to the kettle to provide sufficient product for
testing.
3. Make sure the supplies of gas and electric power are on.
4. Following “Start Kettle Heating” instructions in the “Operating Instructions” section
of this manual, begin heating the water at the highest thermostat setting. The pilot
lamp should come on as soon as you pull out the emergency stop and turn on power.
Heating should continue until the water boils.
5. 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 an authorized Groen Service agent.
10 OM-DH/INA/2-100
Operation
WARNING
ANY POTENTIAL USER OF THE EQUIPMENT
MUST BE TRAINED IN SAFE AND CORRECT
OPERATING PROCEDURES.
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 SAFETY VALVE.
CONTROLS
Refer to the drawing on the following page for identification and function of kettle
controls.
OPERATING INSTRUCTIONS
Refer to the drawing on the following page for identification and function of kettle
controls.
1. CHECK THE WATER LEVEL IN THE JACKET EVERY DAY. The level must be in the middle
of the bulls-eye sight glass. If the level is low, see “Jacket Filling” in the “Preventive
Maintenance” section of this manual.
2. With the kettle cold, check the pressure gauge. If it does not show 20 or more inches
of vacuum (a reading of 20 to 30 below 0), see “Jacket Vacuum” in the “Preventive
Maintenance” section of this manual.
3. Start Kettle Heating
a. Open main gas supply valve.
b. Pull OUT the emergency stop and turn ON the control power switch on the front
of the right stanchion.
c. The touch-screen control panel should be ON (if not, check that mains power is
connected to the unit and the mains circuit breaker is on).
OM-DH/INA/2-100 11
Operation
WARNING
DO NOT ATTEMPT TO LIGHT PILOT
MANUALLY WITH A FLAME.
4. Cooking Control
a. Touch the COOK CONTROL on the screen. The display will change to show the
main cooking control screen. This screen allows user to control kettle tilt, cooking
operation, water fill, turbo heat; and displays current product temperature in
degrees Celsius, desired cooking temperature in degrees Celsius; and lamp
status of the pilot, main gas vale, low fire burner and high fire burner.
b. Ensure kettle is tilted fully upright. If not, press TILT CONTROL on the screen.
The pop-up tilt control will appear. Press continuously on either TILT UP or TILT
DOWN until the kettle comes to a fully upright position. The tilt controls will turn
bright green when pressed and will go dark when released [Note: Press TILT
CONTROL to minimize the tilt feature on the screen.]
12 OM-DH/INA/2-100
c. The PILOT and MAIN indicators on the screen should show green.
d. Press FAUCET FILL on the screen. The pop-up faucet fill controls will appear.
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