Groen D, DT, DL, DLT, MW/D Operation Manual

...

IMPORTANT INFORMATION � KEEP FOR OPERATOR � IMPORTANT INFORMATION

OPERATOR MANUAL

OPERATOR MANUAL OM-D

Part Number 121007 Rev. B

Part Number 121007, Rev. B DOMESTIC

MODELS: D, DT, DL, DLT,

MW/D, MW/DT Steam Jacketed Kettles

Stainless Steel Direct steam heated Tilting

Model DL

Model D

THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE. READ, UNDERSTAND AND FOLLOW THE INSTRUCTIONS AND WARNINGS CONTAINED IN THIS MANUAL.

WARNING DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

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IMPORTANT — READ FIRST — IMPORTANT

CAUTION: BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE

OPERATING INSTRUCTIONS, CAUTIONS, AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL.

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 MANUAL. ANY OTHER USE COULD RESULT IN SERIOUS PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT AND WILL VOID WARRANTY.

CAUTION: SHIPPING STRAPS ARE UNDER TENSION AND CAN SNAP BACK WHEN

CUT.

CAUTION: UNIT WEIGHS 190 TO 270 LBS (85 TO 125 KG). FOR SAFE HANDLING,

INSTALLER SHOULD GET HELP AS NEEDED, OR USE MATERIALS HANDLING EQUIPMENT (E.G., FORK LIFT, DOLLY OR PALLET JACK) TO REMOVE THE UNIT FROM THE SKID AND MOVE IT TO THE PLACE OF INSTALLATION.

WARNING: KETTLES MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK

WITH PLUMBING. IMPROPER INSTALLATION CAN RESULT IN INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT.

WARNING: AVOID ANY EXPOSURE TO ESCAPING STEAM. STEAM CAN CAUSE

SEVERE BURNS.

WARNING: TAKE EXTREME CARE TO KEEP HOT CONTENTS FROM SPILLING OR

SPLASHING ON ANYONE. DO NOT STAND DIRECTLY IN FRONT OF KETTLE BODIES WHEN THEY ARE BEING TILTED.

WARNING: AVOID ALL DIRECT CONTACT WITH HOT EQUIPMENT SURFACES. DIRECT

SKIN CONTACT COULD RESULT IN SEVERE BURNS.

WARNING: AVOID ALL DIRECT CONTACT WITH HOT FOOD OR WATER IN KETTLES.

DIRECT CONTACT COULD RESULT IN SEVERE BURNS.

CAUTION: DO NOT OVER FILL 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 PRODUCT TRANSFER.

WARNING: TAKE SPECIAL CARE TO AVOID CONTACT WITH HOT KETTLE BODY OR

HOT PRODUCT WHEN ADDING INGREDIENTS, STIRRING OR TRANSFERRING PRODUCT TO ANOTHER CONTAINER.

WARNING: WHEN TILTING KETTLE FOR PRODUCT TRANSFER:

1) WEAR PROTECTIVE OVEN MITT AND PROTECTIVE APRON.

2) USE CONTAINER DEEP ENOUGH TO CONTAIN AND MINIMIZE PRODUCT SPLASHING.

3) PLACE CONTAINER ON STABLE, FLAT SURFACE, AS CLOSE TO KETTLE AS POSSIBLE.

4) STAND TO LEFT OR RIGHT SIDE OF KETTLE (DEPENDING ON TILTING HANDLE PLACEMENT) WHILE POURING. DO NOT STAND DIRECTLY IN POUR PATH OF HOT CONTENTS.

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IMPORTANT — READ FIRST — IMPORTANT

5) POUR SLOWLY, MAINTAIN CONTROL OF KETTLE BODY HANDLE AT ALL TIMES, AND RETURN KETTLE BODY TO UPRIGHT POSITION AFTER CONTAINER IS FILLED OR TRANSFER IS COMPLETE.

6) DO NOT OVERFILL CONTAINER. AVOID DIRECT SKIN CONTACT WITH HOT CONTAINER AND ITS CONTENTS.

CAUTION: KEEP FLOORS IN FRONT OF KETTLE WORK AREA CLEAN AND DRY. IF

SPILLS OCCUR, CLEAN IMMEDIATELY, TO AVOID SLIPS OR FALLS.

WARNING: FAILURE TO CHECK SAFETY VALVE OPERATION PERIODICALLY COULD

RESULT IN PERSONAL INJURY AND/OR DAMAGE TO EQUIPMENT.

WARNING: WHEN TESTING, AVOID ANY 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.

CAUTION: MOST CLEANERS ARE HARMFUL TO THE SKIN, EYES, MUCOUS

MEMBRANES AND CLOTHING. PRECAUTIONS SHOULD BE TAKEN. WEAR RUBBER GLOVES, GOGGLES OR FACE SHIELD AND PROTECTIVE CLOTHING. CAREFULLY READ THE WARNINGS AND FOLLOW THE DIRECTIONS ON THE LABEL OF THE CLEANER TO BE USED.

CAUTION: USE

OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY

GROEN

OR ITS AUTHORIZED DISTRIBUTORS CAN CAUSE OPERATOR INJURY AND DAMAGE TO THE EQUIPMENT, AND WILL VOID ALL WARRANTIES.

IMPORTANT: SERVICE PERFORMED BY OTHER THAN FACTORY AUTHORIZED

PERSONNEL WILL VOID WARRANTIES.

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Table of Contents

IMPORTANT OPERATOR WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

EQUIPMENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INSPECTION AND UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

DIAGRAMS & SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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Equipment Description

A. All Models

The Groen D Series are deep type, tilting kettles with direct steam-heated 2/3 jackets. The stainless steel kettles have welded, reinforced rims and butterfly shaped pouring lips. The liner and pouring lip of all kettles are 316 stainless steel. They are ASME shop-inspected, and are registered with the National Board. The kettles have a 180 emery grit interior finish and a bright semi-deluxe exterior finish.

Every unit requires a remote steam source. The steam supply is controlled by an inlet valve, and enters the jacket through one trunnion directly into the jacket. Steam pressure forces condensate out a dip tube through the other trunnion. Both steam and condensate lines are concealed within the support structures of the various models. The tale at bottom right shows the standard kettle sizes for each model.

These kettles operate safely and efficiently at various steam pressures above five PSI, with upper pressure limits assured by the provided safety valve. Operation also requires a globe valve on the steam inlet and a strainer, steam trap, and check valve on the condensate outlet. These may be ordered from Groen as optional equipment.

D Series kettles are emptied by tilting, but optional tangent draw-offs are available. The standard draw-off is two inch outer diameter stainless steel, with compression disc valve and a removable stainless steel strainer that has 1/4 inch perforations. Strainers with 1/8 inch or no perforations are also available. The table on the bottom right shows the sizes of draw-offs which can be furnished with each model. When equipped with a tangent draw-off the designation “T” is added to the model designation.

The kettles in this series employ a worm and gear tilting mechanism, which is completely enclosed.

D Series kettles are mounted in three ways. Model D is suspended in a stainless steel yoke on a pedestal base. The outer circumference of the base is flanged down for proper sealing to the floor. Model DL is supported by a tubular, stainless steel tri-leg frame with adjustable floor flanges. The wall-mounted model MW/D has a supporting frame enclosed in a stainless steel, drip-proof housing. The frame must hang on an in-wall carrier which may be purchased as an option.

Other options include:

1. No. 31 lift-off cover (for kettles smaller than 60 gallons)

2. No. 51 cover with counter-balancing actuator (for 40 gallon and larger kettles)

3. Fill faucets with swing spout

4. Gallon Master water meter

5. TRI-BC basket cooking system

6. Kettle brush kit

7. Operating pressures up to 90 PSIG

Standard Capacities, Gallons

Model 20 40 60 80 100

��

DT ��

DL, DLT ��

MW/D, MW/DT ��

Optional Draw-Offs Available*

Model

1½” 2" 3"

DT: 20 or 40 Gallon

��

DLT: All Sizes ��

MW/DT: All Sizes ��

*2" or 3" only

provided on current production

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Inspection and Unpacking

The kettle will arrive completely assembled and wrapped in protective plastic, strapped and bolted on a heavy skid, enclosed in a three-wall cardboard crate. (80 gallon and larger kettles are in wooden crates.) Immediately on receipt remove the box and plastic wrap, and inspect the unit for damage. Report any damage or an incorrect shipment to the delivery agent.

Write down the model number, serial number and installation date, and keep this information for future reference. Space for these entries is provided at the top of the Service Log in the back of this manual.

CAUTION

SHIPPING STRAPS ARE UNDER TENSION AND CAN SNAP BACK WHEN CUT.

CAUTION

AVOID NAILS AND SPLINTERS WHEN REMOVING KETTLES FROM WOODEN CRATES. WEAR SAFETY GLASSES.

CAUTION

UNIT WEIGHS 215 TO 295 LBS (98 TO 134 KG). FOR SAFE HANDLING, INSTALLER SHOULD GET HELP AS NEEDED, OR USE MATERIALS HANDLING EQUIPMENT (e.g., FORK LIFT, DOLLY OR PALLET JACK) TO REMOVE THE UNIT FROM THE SKID AND PLACE IT FOR INSTALLATION.

When installation is to begin, cut the straps holding the unit on the skid. Lift the unit straight up off of the skid.

Installation

WARNING

THIS UNIT MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH PLUMBING. IMPROPER INSTALLATION CAN CAUSE INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT.

A. All Models

1. Installation under a ventilation hood is recommended. Consult local codes.

2. Install and anchor the kettle on a level surface.

3. If the steam supply pressure is greater than the maximum working pressure stamped on the nameplate, you must install a pressure reducing valve in the steam supply line near the kettle.

4. Connect the steam supply line to the steam inlet fitting. Include a steam control valve and an appropriate safety valve. To obtain the full heating capability of the kettle, the steam supply line must be as large as the steam inlet fitting.

5. The safety valve is preset to relieve jacket pressure that exceeds its rated limit. Do not try to adjust the valve setting, and do not

allow the valve outlet or lever to be blocked.

6. Connect the kettle condensate return line to the boiler return line, or to a drain. A suitable steam trap, strainer, and check valve must be installed. (See piping diagram, Page 18).

7. Any mechanical change must be approved by the Groen Food Service Engineering Department.

B. Floor Mounted Models

1. Install the unit on a level surface. Ensure that there is adequate clearance at the sides and rear, as required by the specification drawings. Anchor the pedestal or legs securely to the floor.

2. Apply a continuous bead of clear silicone sealant (No. 732 or equivalent) to the junction between the pedestal or leg flange and the surface, as shown in the illustration

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For proper sanitation, continuous seal is required between pedestals or flanges and the mounting surface.

below. Fill all cracks and crevices, and wipe excess away.

C. Cold Water Cooling Option

D. Wall Mounted Models

1. Install a “chair carrier” in the wall to which the unit will be attached, following the instructions pertaining to anchoring and location. See diagram on page 19.

2. Stub in the steam supply line and condensate return line so that they will be aligned with the appropriate fittings when the unit is mounted.

3. Mount the unit on the protruding studs of the

chair carrier.

4. Apply a continuous bead of clear silicone sealant (No. 732 or equivalent) to the junction between the frame housing and the wall. Fill all cracks and crevices, and wipe away the excess.

Initial Start-Up

IMPORTANT

BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE OPERATING INSTRUCTIONS, CAUTIONS, AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL.

Now that the kettle has been installed, you should test it to ensure that it is operating correctly.

1. Remove all literature and packing materials from inside and outside of the unit. Clean out any material that might clog the tangent draw-off valve, if present.

2. Pour a small amount of water into the kettle.

3. Open the steam inlet valve.

4. When the water begins to boil, inspect all of the fittings to ensure that there are no leaks.

5. Check the safety valve by lifting its lever far enough to let steam escape. Then let it snap back into place to reseat the valve so that it will not leak.

6. Shut down the unit by closing the steam inlet valve.

7. Operate the tilting mechanism and drawoff valve to confirm that they function through the whole range of normal operation.

If the unit functions as described above, it is ready for use. If the unit does not function as intended, contact your local Groen Certified Service Agency.

WARNING

AVOID ANY EXPOSURE TO ESCAPING STEAM, WHICH CAN CAUSE SEVERE BURNS.

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Operation

Before operating a cold kettle, open the petcock at the bottom of the jacket to drain any water left by condensing steam. Close the petcock before you open the steam inlet valve. Draining this water decreases the “hammering” you hear when steam enters a cold jacket.

To heat the kettle, open the steam inlet valve. Adjusting the inlet valve allows the operator to control the heating rate. Opening the valve more allows steam to flow into the jacket faster, and thereby heats the product faster.

The kettle operates efficiently with steam pressures from five PSI to the maximum working pressure for which the kettle was designed. The maximum allowable pressure is stamped on the kettle nameplate. It is 25 PSI for standard units.

WARNING

AVOID EXPOSURE TO ESCAPING STEAM, WHICH CAN CAUSE SEVERE BURNS.

Once a day, while there is still steam pressure in the jacket, bleed off any entrapped air and double check the operation of the safety valve. Pull out on its chain, or lift the lever far enough to let steam escape. Then let it snap back into place to reseat the valve so that it will not leak.

Tilting the Kettle

To transfer product or empty the kettle: turn the handwheel counterclockwise. The kettle will hold its position when you stop turning the wheel.

If the tilting mechanism seems to be locked, do not use force to free the kettle. Call for assistance from your Groen Certified Service Agency, or refer to the Troubleshooting section of this manual.

WARNING

AVOID ALL DIRECT CONTACT WITH HOT FOOD OR WATER IN THE KETTLE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS.

TAKE SPECIAL CARE TO AVOID CONTACT WITH HOT KETTLE BODY OR HOT PRODUCT, WHEN ADDING INGREDIENTS, STIRRING OR TRANSFERRING PRODUCT TO ANOTHER CONTAINER.

CAUTION

DO NOT OVERFILL THE KETTLE WHEN COOKING, HOLDING OR CLEANING. KEEP LIQUIDS AT LEAST 2-3” (5-8 cm) BELOW THE KETTLE BODY RIM TO ALLOW CLEARANCE FOR STIRRING, BOILING PRODUCT AND SAFE TRANSFER.

WARNING

WHEN TILTING KETTLE FOR PRODUCT FOR PRODUCT TRANSFER:

1) WEAR PROTECTIVE OVEN MITT AND PROTECTIVE APRON.

2) USE CONTAINER DEEP ENOUGH TO CONTAIN AND MINIMIZE PRODUCT SPLASHING.

3) PLACE CONTAINER ON STABLE, FLAT SURFACE, AS CLOSE TO KETTLE AS POSSIBLE.

4) STAND TO LEFT OR RIGHT SIDE OF KETTLE WHILE POURING – NOT DIRECTLY IN POUR PATH OF HOT CONTENTS.

5) POUR SLOWLY, MAINTAIN CONTROL OF KETTLE AT ALL TIMES, AND RETURN KETTLE BODY TO UPRIGHT POSITION AFTER CONTAINER IS FILLED OR TRANSFER IS COMPLETE.

6) DO NOT OVERFILL CONTAINER. AVOID DIRECT SKIN CONTACT WITH HOT CONTAINER AND ITS CONTENTS.

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+ 16 hidden pages

Groen D, DT, DL, DLT, MW/D Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual