Groen DEE/4-20, DEE-CE Series, DEE/4-60, DEE/4-40 Operator's Manual

OPERATOR MANUAL

IMPORTANT INFORMATION, KEEP FOR OPERATOR

This manual provides information for:

MODEL DEE-CE International
STEAM JACKETED KETTLE

· Self Contained

· Stainless Steel

· Floor Mounted

· Electrically Heated

· 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 ammable vapors
and liquids in the vicinity of this or any other appliance.

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. Unied 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 127730, REV. C (01/15)

1055 Mendell Davis Drive

Jackson, MS 39272

888-994-7636, fax [phone]

unifiedbrands.net

IMPORTANT - READ FIRST - IMPORTANT

REGULATIONS AND SAFETY PRECAUTIONS:
THESE APPLIANCES HAVE BEEN CE MARKED ON THE BASIS OF COMPLIANCE WITH THE EMC AND LOW
VOLTAGE DIRECTIVE. 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
HEALTH AND SAFETY AT WORK ACT
FIRE PRECAUTIONS ACT
LOCAL AND NATIONAL BUILDING REGULATIONS

THOSE 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.
IN PARTICULAR THEY SHOULD BE AWARE OF THE NEED FOR REGULAR SERVICING BY A COMPETENT
PERSON TO ENSURE CONTINUED SAFE AND EFFICIENT APPLIANCE PERFORMANCE.

WARNING: TO PREVENT SHOCKS, APPLIANCES WHETHER GAS OR ELECTRIC, MUST BE EARTHED.

UPON COMPLETION OF INSTALLATION, THE OWNERS MANUAL SHOULD BE HANDED TO 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 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.

UNLESS OTHERWISE STATED, PARTS WHICH HAVE BEEN PROTECTED BY THE MANUFACTURER ARE
NOT TO BE ADJUSTED BY THE INSTALLER.

BEFORE ATTEMPTING ANY SERVICING, ENSURE THAT THE ELECTRICAL SUPPLY IS DISCONNECTED.

WARNING: THE UNIT MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH ELECTRICITY.

IMPROPER INSTALLATION CAN RESULT IN INJURY TO PERSONNEL AND/OR DAMAGE TO
EQUIPMENT. THE UNIT MUST BE INSTALLED IN ACCORDANCE WITH APPLICABLE CODES.

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

WARNING: TO AVOID DAMAGE OR INJURY, FOLLOW THE WIRING DIAGRAM EXACTLY WHEN CONNECTING A

UNIT.

WARNING: BEFORE CLEANING THE OUTSIDE OF THE KETTLE, DISCONNECT ELECTRIC POWER . KEEP

WATER AND SOLUTIONS OUT OF CONTROLS AND ELECTRICAL COMPONENTS.

NOTICE: DO NOT USE ANY DE-GREASER THAT CONTAINS POTASSIUM HYDROXIDE OR SODIUM

HYDROXIDE OR THAT IS ALKALINE.

WARNING: USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY GROEN OR

THEIR AUTHORIZED DISTRIBUTOR VOIDS ALL WARRANTIES AND CAN RESULT IN BODILY
INJURY TO THE OPERATOR AND DAMAGE THE EQUIPMENT. SERVICE BY OTHER THAN
FACTORYAUTHORIZED PERSONNEL WILL VOID ALL WARRANTIES.

WARNING: HIGH VOLTAGE EXISTS INSIDE CONTROL COMPARTMENTS. DISCONNECT FROM BRANCH

BEFORE SERVICING. FAILURE TO DO SO CAN RESULT IN SERIOUS INJURY OR DEATH.

2 OM-DEE/4

Table of Contents

Important Operator Warnings .........................................................page 2

Equipment Description ................................................................. page 4

Inspection and Unpacking ............................................................ page 5

Installation .................................................................................... page 6

Initial Start-Up ............................................................................... page 7

Operation ................................................................................... page 8-9

Sequence of Operation .............................................................. page 10

Cleaning .................................................................................. page 11-12

Maintenance ........................................................................... page 13-15

Troubleshooting ...................................................................... page 16-17

Parts List ................................................................................. page 18-20

Wiring Diagram ............................................................................ page 21

Service Log ................................................................................. page 22

OM-DEE/4 3

Equipment Description

The Groen DEE/4 is a floor-mounted, tilting, steam jacketed kettle with a
thermostatically controlled, selfcontained, electrically-heated steam supply and
appropriate controls, mounted on a sturdy base. The Model DEE/4 is available in 20,
40 or 60 gallon capacities.

The body of the DEE/4 Kettle is constructed of stainless steel, welded into one solid
piece. The kettle is furnished with a reinforced rim and a butterfly shaped pouring lip.
It has a steam jacket rated for working pressures up to 345 kPa (50 psi). Kettle finish
is 180 emery grit on the inside and bright semi-deluxe on the outside.

The kettle can be tilted with a hand crank to pour out its contents. Stainless steel
panels enclose the controls and the base. Four stainless steel, tubular legs support the
unit. Bullet feet on each of the legs can be adjusted to level the kettle.

A built-in steam generator, sized for the kettle capacity and heated by electricity, delivers
steam into the jacket. “Airless” operation of the steam jacket permits uniform, efficient
heating at temperatures as low as 65.5°C (150°F) and as high as 148°C (298°F) In
addition to the adjustable thermostat for operating control, the unit has a tilt cut-off
switch, low water cut-off, safety valve, and high-limit pressure switch as safety features.

CE units have three lights on the Control Panel. The green POWER light comes on
when the unit is turned on. It indicates that power is being supplied to the unit. The
amber HEAT light comes on when heating elements are heating the kettle. The red
LOW WATER light will come on when water level in the jacket falls below acceptable
operating levels. Refer to the section on Jacket Filling and Water Treatment (Page 14).

A single electrical connection is required for installation. The unit may be ordered for
use with 230 VAC, 1 Phase, 50 Hz, or 400 VAC, 3 Phase, 50 Hz power.

KETTLE CHARACTERISTICS

Unit DEE/4-20 DEE/4-40 DEE/4-60

230 Volt - 1 Phase

400 Volt - 3 Phase

a. Connect the appropriate wiring as described in the wiring diagram located on the

inside of the control console. A copy is also provided at the rear of this manual.

b. Equipotential terminal - In accordance with national regulations the unit has been

fitted with an equipotential terminal.

57 Amperes 96 Amperes 96 Amperes

57 Amperes 96 Amperes 96 Amperes

4 OM-DEE/4

Optional equipment available with DEE/4 kettles:

1. 2” diameter tangent draw-off valve (factoryinstalled)

2. Lift-off cover

3. Counterbalanced cover (factory-installed)

4. TRI-BC basket cooking system

5. Water fill faucets

6. Kettle brush kit

Inspection & Unpacking

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.

CAUTION

THIS UNIT IS VERY HEAVY. INSTALLER

SHOULD OBTAIN HELP AS NEEDED TO LIFT

THIS WEIGHT SAFELY

The unit will arrive in a heavy shipping crate and will be bolted or banded to a skid.
Immediately upon receipt, inspect the crate carefully for exterior damage.

Thoroughly inspect the unit for concealed damage. Report any shipping damage or
incorrect shipments to the delivery agent.

Write down the model number, serial number, and installation date, and retain this
information for future reference. Space for these entries is provided at the top of the
Service Log at the back of this manual. Keep this manual on file and available for
operators to use.

When installation is to begin, carefully cut any straps which hold the unit on the skid.
Lift the unit straight up off the skid. Examine packing materials to be sure loose parts
are not discarded with the materials.

Pressure/Vacuum

Pressure/Vacuum
Gauge

Gauge

Water Gauge

Water Gauge
Glass

Glass

Rear View

Safety

Safety

Valve

Valve

OM-DEE/4 5

Installation

WARNING

INSTALLATION OF THE KETTLE MUST BE

DONE BY PERSONNEL QUALIFIED TO

WORK WITH ELECTRICITY. IMPROPER

INSTALLATION CAN RESULT IN INJURY

TO PERSONNEL AND/OR DAMAGE TO

EQUIPMENT.

CAUTION

ELECTRICALLY GROUND THE UNIT AT

THE TERMINAL PROVIDED. FAILURE TO

GROUND THE UNIT COULD RESULT IN

ELECTROCUTION AND DEATH.

The Groen Kettle is provided with complete internal wiring and is ready for immediate
connection. Wiring diagrams are provided in this manual and on the inside of the
control housing service panel. Any mechanical or electrical changes must be approved
by Groen’s Food Service Engineering Department.

The completed unit has been operated at the factory to test all controls and heater
elements.

A. Placement

1. Set the kettle in place and level it by turning the bullet feet to adjust leg
length. Allow clearance around the unit for cleaning, maintenance and
service.

B. Initial Checks

1. Confirm that the jacket water level is above the mid point of sight glass.
If the level is low, follow the instructions under “Jacket Filling and Water
Treatment,” Page 14.

2. The open end of the elbow on the outlet of the safety valve must face
downward. If it does not, turn it to the correct position.

C. Providing Power

1. Provide electrical power specified on the equipment electrical
information plate. Observe all local and national codes, and all
regulations in force at the time of installation.

2. Bringing the electrical service through the entrance at the rear of the
support housing with one inch conduit, making a watertight connection
with the incoming lines. Observe all local and national codes, and all
regulations in force at the time of installation.

3. Electrically earth the unit at the terminal provided.

6 OM-DEE/4

Check the following to confirm that your DEE/4 kettle is properly installed:

• Room for cleaning and servicing

• The kettle is level

• The correct amount of water is in the kettle jacket

• Safety valve is pointed down

• Unit is connected with a waterproof supply of the proper voltage, phase and
amperage rating

KETTLE CHARACTERISTICS

Unit DEE/4-20 DEE/4-40 DEE/4-60

230 Volt - 1 Phase

400 Volt - 3 Phase

57 Amperes 96 Amperes 96 Amperes

57 Amperes 96 Amperes 96 Amperes

Initial Start-Up

IMPORTANT
BE SURE ALL OPERATORS READ,
UNDERSTAND AND FOLLOW THE

OPERATING INSTRUCTIONS, CAUTIONS

AND SAFETY INSTRUCTIONS CONTAINED

IN THIS MANUAL.

WARNING

AVOID ALL DIRECT CONTACT WITH HOT

SURFACES. DIRECT SKIN CONTACT COULD

RESULT IN SEVERE BURNS.

AVOID ALL DIRECT CONTACT WITH HOT

FOOD OR WATER IN THE KETTLE. DIRECT

CONTACT COULD RESULT IN SEVERE BURNS.

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

. DIRECT SKIN CONTACT

1. Remove all literature and packing materials from inside and outside of the unit.

2. If the unit is equipped with a draw-off valve (product outlet), clean out any
material which might clog or damage the draw-off.

3. Confirm that the tilting mechanism is operating properly by tilting the kettle
through its full range. Then return the kettle to the upright position.

4. Turn on the electrical service to the unit.

5. Pour 2-4 liters of water into the kettle.

6. Following “To Start Kettle” instructions in the “Operation” section of this
manual, begin heating the water at the highest thermostat setting. The heating
indicator light should come on immediately, and heating should continue until
the water boils.

7. To shut down the unit, turn the thermostat dial to “0” and the power switch to
OFF.

PROPER
WATER LEVEL

Each day, confirm the jacket water

level by checking the water gauge.

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

OM-DEE/4 7

Operation

WARNING

WHEN TILTING KETTLE

1) WEAR PROTECTIVE OVEN MITT AND
PROTECTIVE APRON.

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

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

POSSIBLE.

4) STAND TO RIGHT OF KETTLE WHILE

POURING—NOT DIRECTLY IN POUR PATH

OF HOT CONTENTS.

5) POUR SLOWLY, MAINTAINING CONTROL

OF KETTLE, AND RETURN KETTLE BODY TO

UPRIGHT POSITION AFTER CONTAINER IS

FILLED OR TRANSFER IS COMPLETE.

6) DO NOT OVERFILL CONTAINER. AVOID

SKIN CONTACT WITH HOT CONTAINER AND

ITS CONTENTS.

CE units have three lights on the Control Panel. The green POWER light comes on
when the unit is turned on. It indicates that power is being supplied to the unit. The
amber HEAT light comes on when heating elements are heating the kettle. The red
LOW WATER light will come on when water level in the jacket falls below acceptable
operating levels. Refer to the section on Jacket Filling and Water Treatment (Page 14).

A. To Start Kettle

1. EVERY DAY make sure that the jacket water level is between the
markers on the gauge glass. If the level is too low, see “Jacket Filling
and Water Treatment” on page 14.

2. Check the pressure gauge. If the gauge does not show 20 to 30 inches
of vacuum (that is a reading of 20 to 30 below 0 atmospheric pressure),
see “Jacket Vacuum” on page 14.

3. Turn on the electrical power to the unit by setting the power switch to
ON. The green POWER indicator should light.

4. Turn the thermostat to desired setting. The amber HEAT indicator light
will come on. Cycling of the light on and off the shows that the kettle is
being held at the set temperature. Once in each cycle the contactors in
the support housing will make a clicking sound. This is normal.

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.

B. To Transfer Product or Empty Kettle

1. The kettle is tilted by means of the crank on the front of the control
housing. The kettle remains in the position to which tilted until cranked
again.

2. Product may also be transferred by means of the optional draw-off valve

if the kettle is so equipped.

C. Common Accessories

1. LIft-Off Cover or Counterbalanced Cover
As with stock pot cooking, an optional cover can speed up the heating of

water and food products. A cover helps retain heat and reduces the heat
and humidity released into the kitchen. Using a cover can reduce some
product cook times and help maintain the temperature, color and texture
of products being held or simmered for longer periods.

Be sure the handle is secure on the lift-off cover before using. ALWAYS

use the handle to place or remove cover from the kettle. Wear protective
oven mitts and a protective apron.

When putting a lift-off cover on the kettle, position it on top of kettle rim,

with its flat edge facing the pouring lip.

8 OM-DEE/4

Operation

WARNING

AVOID ALL DIRECT CONTACT WITH HOT

SURFACES. DIRECT SKIN CONTACT COULD

RESULT IN SEVERE BURNS.

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 TILT KETTLE WITH LIFT-OFF

COVER IN PLACE. COVER MAY SLIDE OFF,

CAUSING INJURY TO OPERATOR.

CAUTION

KEEP FLOORS IN FRONT OF THE KETTLE

WORK AREA CLEAN AND DRY. IF SPILLS

OCCUR, CLEAN AT ONCE TO AVOID

SLIPS OR FALLS.

Kettle Model Max Capacity

DEE/4-20 75 Liters
DEE/4-40 150 Liters
DEE/4-60 225 Liters

When removing a lift-off cover:
a. Firmly grasp the handle
b. Lift rear edge (farthest from operator) 1-2” (3-5 cm) to allow
steam and water vapor to escape the cooking vessel. Wait 2-3
seconds.
c. Tilt cover to 45-60° angle to allow any hot condensate or product
to roll off cover back into kettle.
d. Remove cover, ensuring that any remaining hot condensate or
product does not drip on operator, floor or work surfaces.
e. Place cover on safe, flat, sanitary, out-of-the-way surface, or

return to kettle.

2. Basket Insert
An optional kettle basket insert set can assist in cooking water-boiled

products including eggs, potatoes, vegetables, shell fish, pasta and rice.
The nylon mesh liner must be used for products smaller than the basket
mesh size, (approximately 1/4”, 6mm). This includes rice and small pasta
shapes. Tips for use:
a. Allow for displacement of the three baskets and product. This

may mean only half filling the kettle. Test baskets and product
displacement with the kettle power switch and thermostat turned

off, and with cold water in the kettle.
b. Load baskets on a level, stable work surface.
c. Lift loaded baskets with both hands. Get help from another
person if the basket is too heavy for safe handling.
d. Slowly lower product into kettle and securely hook basket to the
“Y” frame.
e. When removing baskets with cooked product, lift straight up,

ensuring basket bottoms clear the kettle rim and pouring lip. Wear

protective oven mitts and protective apron.
f. Allow hot water to fully drain from product before moving basket

away from the kettle. Do not rest baskets on kettle rim or pouring

lip. If baskets are too heavy for individual to lift and safely move,

get help. Remove product immediately from basket into another

container, being sure to avoid contact with hot product and hot

basket or...
g. Place baskets with food on a stable, flat surface, inside a solid

steamer or bake pan,to catch any remaining hot water draining

from product.

OM-DEE/4 9

Sequence of Operation

The following “action-reaction” outline is provided to help understand how the kettle
works.

When the operator starts up the kettle by turning on the power switch and by turning
the operating thermostat dial from “0” to a desired setting, the thermostat switch
closes and the green POWER lamp comes on. This also lights up the amber HEAT
indicator light and causes the contactors to close, allowing power to flow to heating
elements.

When the temperature of the steam jacket reaches the value corresponding to the
dial setting, the thermostat switch opens. This turns off the HEAT indicator light and
causes the contactors to open, stopping the power to the heaters.

As soon as the thermostat senses that the kettle is cooking below the set point, the
thermostat switch closes, the HEAT indicator light comes on, the contactors close,
and the heaters come on again. On-off cycling continues, keeping the kettle at the set
temperature.

This is why the HEAT indicator light cycles on and off during normal operation. Every
time the kettle is tilted, the tilt cut-off switch interrupts the power supply to the
heaters, so that the heating elements will not operate while not submerged in the
jacket water.

If steam pressure greater than 345 kPa (50 psi) is generated in the jacket, the safety
valve will open and relieve the excess pressure.

If the jacket water level gets too low before the heating elements overheat, the high­limit control will open and shut off power to the elements until the kettle cools.

Setting the operating thermostat dial to “0” shuts down the heating circuits. Turning
the power switch to OFF shuts down all heating and control circuits.

10 OM-DEE/4

Cleaning

WARNING

KEEP WATER AND SOLUTIONS OUT OF

CONTROLS AND ELECTRICAL EQUIPMENT.

DO NOT USE A HIGH PRESSURE HOSE TO

CLEAN THE CONTROL CONSOLE,

ELECTRICAL CONNECTIONS, ETC.

CAUTION

NEVER LEAVE A CHLORINE SANITIZER

IN CONTACT WITH STAINLESS STEEL

SURFACES FOR LONGER THAN 30
MINUTES. LONGER CONTACT CAN

CAUSE CORROSION.

CAUTION
MOST CLEANERS ARE HARMFUL TO THE
SKIN, EYES, MUCOUS MEMBRANES AND

CLOTHING. PRECAUTIONS SHOULD BE

TAKEN TO WEAR RUBBER GLOVES,

GOGGLES OR FACE SHIELD AND
PROTECTIVE CLOTHING. CAREFULLY
READ THE WARNINGS AND FOLLOW

LABEL DIRECTIONS.

A. Suggested Cleaning Supplies

1. Cleaner, such as Klenzade HC-10 or HC-32 from ECOLAB, Inc.

2. Kettle brushes in good condition.

3. Sanitizer such as Klenzade XY-12.

4. Film remover such as Klenzade LC-30.

B. Precautions

Before any cleaning operation, shut off the kettle by turning the thermostat
dial to “0” and the power switch to OFF, then shut off all electric power to the

unit at a remote switch, such as the circuit breaker.

C. Procedure

1. Clean food contact surfaces as soon as possible after use, preferably
while the kettle is still warm. If the unit is in continuous use, clean
and sanitize inside and outside at least once every 12 hours.

2. Scrape and flush out large amounts of food residues. Be careful not
to scratch the kettle with metal implements. Close the draw-off.

3. Prepare a solution of the detergent/cleaning compound as instructed
by the supplier. Clean the unit thoroughly. A cloth moistened with
cleaning solution can be used to clean controls, housing, electrical
conduit, etc.

Use a brush, sponge, cloth, plastic or

rubber scraper, or plastic wool to clean.

Don’t use metal implements

or steel wool when cleaning.

4. Rinse the kettle thoroughly with hot water. Then drain completely.

5. Disassemble the tangent draw-off valve. Clean the draw-off port and
each valve part with a brush.

6. Rinse the kettle and draw-off valve parts thoroughly with hot water,
then drain completely.

7. When you reassemble the draw-off valve, HAND-TIGHTEN the nut
which holds it in place.

8. As part of the daily cleaning program, clean soiled external and
internal surfaces. Remember to check the sides of the unit and
control housing.

9. To remove burned-on foods, use a brush, sponge, cloth, plastic or
rubber scraper, or plastic wool along with the cleaning solution. To
reduce effort required in washing, let the detergent solution sit in the
kettle for a few minutes and soak into the residue. Do NOT use
abrasive materials or metal tools that might scratch the surface.
Scratches make the surface harder to clean and provide places for
bacteria to grow. Do not use steel wool, which will leave particles in
the surface and cause eventual corrosion and pitting.

10. The outside of the unit may be polished with a recognized stainless
steel cleaner or hot water and detergent.

OM-DEE/4 11

Cleaning

CAUTION

NEVER LEAVE A CHLORINE SANITIZER

IN CONTACT WITH STAINLESS STEEL

SURFACES FOR LONGER THAN 30
MINUTES. LONGER CONTACT CAN

CAUSE CORROSION.

11. When the equipment needs to be sanitized, use a sanitizing solution
equivalent to one that supplies 200 parts per million chlorine. Obtain
advice on the best sanitizing agent from your supplier of sanitizing
products. Following the suppliers instructions, apply the sanitizing agent
after the unit has been cleaned and drained. Rinse off the sanitizer
thoroughly.

12. It is recommended that each piece of equipment be sanitized just before
use.

13. If there is difficulty removing mineral deposits or a film left by hard
water or food residues, clean the kettle thoroughly and then use a
deliming agent, in accordance with the manufacturer’s directions. Rinse
and drain the unit before further use.

14. If cleaning problems persist, contact your cleaning product supplier for
assistance. The supplier has a trained technical staff with laboratory
facilities to serve you.

12 OM-DEE/4

Maintenance

WARNING

WHEN TESTING, AVOID ANY EXPOSURE TO

THE STEAM BLOWING OUT OF THE SAFETY

VALVE. DIRECT CONTACT COULD RESULT IN

SEVERE BURNS.

WARNING

DISCONNECT ELECTRICAL POWER FROM

THE UNIT BEFORE ATTEMPTING TO

GREASE THE TRUNNION BEARINGS.

WARNING

TO AVOID INJURY, READ AND FOLLOW ALL

PRECAUTIONS STATED ON THE LABEL OF

THE WATER TREATMENT COMPOUND.

WARNING

ELECTRIC POWER ALWAYS SHOULD BE

SHUT OFF BEFORE WORK IS DONE ON

INTERNAL COMPONENTS.

CAUTION
BEFORE YOU HEAT THE KETTLE AGAIN
FOR ANY PURPOSE, TURN THE ELBOW

BACK CLOCKWISE UNTIL THE OPENING

FACES DOWNWARD.

NOTICE: Contact an authorized representative when repairs are required.

A Maintenance & Service Log is provided at the back of this manual. Each time
maintenance is performed on your kettle, enter the date on which the work was done,
what was done, and who did it. Keep this manual on file and available for operators to
use. Periodic inspection will minimize equipment down time and increase the efficiency of
operation. The following points should be checked:

1. Check the pressure/vacuum gauge everyday. The gauge should show a vacuum of
20 to 30 inches mercury (Hg), when the kettle is cold. If it does not, see “Jacket
Vacuum” on page 14.

2. Also check the jacket water level every day. It should be between the markers on
the gauge glass. If the level is low, see “Jacket Filling and Water Treatment” on
page 14.

3. Test the safety valve at least twice each month. Test the valve with the kettle
operating at 105 kPa (15 psi), by holding the test lever for at least 5 seconds. Then
release the lever and let the valve snap shut. If the lever does not activate, or there
is no evidence of discharge, or the valve leaks, stop using the kettle and contact a
qualified service representative.

4. Keep electrical wiring and connections in good condition.

5. Keep the inside of the control console clean and dry.

6. 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.

Make sure that the open

end of the elbow on the

pressure relief valve is

directed downward.

Test the safety valve at least twice monthly.

The pressure gauge
should show a vacuum of
20 to 30 inches when the

kettle is cold.

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 34.5 kPa
(5 psi). UNDER NO CIRCUMSTANCES SHOULD THIS MARGIN BE LESS THAN 34.5
kPa (5 psi). Failure to maintain this operating 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.

7. Lubrication (Gears)
The gear housing has fittings for proper lubrication of moving parts. Because the
gears do not run in oil, periodic lubrication with grease is necessary. Frequency of
lubrication will depend on operating conditions, but it should be performed at least
once every six months. It is recommended that a Number Two grade LGI lithium
grease be used. Add grease through the Zerk fittings on the gear housing until
grease flows out of the bearings around the trunnion shaft. Place a liberal amount
of grease on the gear to cover the arc that is in contact with the worm gear.

OM-DEE/4 13

Maintenance

CAUTION

KEEP GREASE AWAY FROM ELECTRICAL

PARTS LOCATED NEAR THE GEARS.

WARNING

TO AVOID INJURY, READ AND FOLLOW ALL

PRECAUTIONS STATED ON THE LABEL OF

THE WATER TREATMENT COMPOUND.

CAUTION
BEFORE YOU HEAT THE KETTLE AGAIN
FOR ANY PURPOSE, TURN THE ELBOW

BACK CLOCKWISE UNTIL THE OPENING

FACES DOWNWARD.

WARNING

ELECTRIC POWER ALWAYS SHOULD BE

SHUT OFF BEFORE WORK IS DONE ON

INTERNAL COMPONENTS.

WARNING

DISCONNECT ELECTRICAL POWER FROM

THE UNIT BEFORE ATTEMPTING TO GREASE

THE TRUNNION BEARINGS.

8. Jacket Vacuum/Removing Air from Jacket
When the kettle is cold, a positive pressure reading on the pressure/vacuum gauge

or a reading near zero indicates that there is air in the jacket. Air in the jacket acts
as an insulator, and slows kettle heating.

To remove air:
a. Start the unit. (Be sure there is water or product in the kettle when heating).
b. When the pressure/vacuum gauge reaches a positive pressure reading of

34.5 kPa (5 psi), release the trapped air and steam by pulling up or out on
the safety valve lever or ring for about 1 second. Repeat this step, then let
the pull ring or valve lever snap back into the closed position.

9. Jacket Filling and Water Treatment
The jacket was charged at the factory with the proper amount of treated water. You
may need to restore this water, either because it was lost as venting steam or by
draining.
a. If you are replacing water lost as steam, use distilled water. If you are
replacing treated water that ran out of the jacket, prepare more treated
water as directed in “Water Treatment Procedure.”
b. Allow the kettle to cool. Turn the elbow on the safety valve counterclockwise
(to avoid thread damage) until the opening of the elbow faces upward.
c. Open the safety valve and pour the water or treated water in at the elbow
until the water level rises to a point between the marks on the gauge glass.

d. Air introduced to the jacket during filling must be removed to obtain
efficient heating. See “Jacket Vacuum.”

CAUTION

NEVER LEAVE A CHLORINE SANITIZER

IN CONTACT WITH STAINLESS STEEL

SURFACES FOR LONGER THAN 30
MINUTES. LONGER CONTACT CAN

CAUSE CORROSION.

10. Water Treatment Procedure
a. Obtain water treatment compound and a pH test kit from your

authorized parts distributor.
b. Fill a mixing container with the measured amount of water required.
(See table). Use distilled water only.

Kettle Model Jacket Capacity

DEE/4-20 9.5 Liters
DEE/4-40 13.2 Liters
DEE/4-60 15.1 Liters

c. Hang a strip of pH test paper on the rim of the container, with about
25 mm of the strip below the surface of the water.
d. Measure the water treatment compound. One way to do this is to add
the compound from a measuring cup.
e. Stir the water continuously, while you slowly add treatment compound,
until the water has a pH between 10.5 and 11.5. Judge the pH by
frequently comparing the test strip color with the color chart provided in
the test kit. If you are color blind use an electroanalytical instrument to
measure the pH level or have a person who is not color blind read the
test strip color level.
f. As you add water to the jacket, check water level to ensure that it
is between minimum and maximum marks on gauge. Stop adding water
when it reaches the maximum marker on the gauge.

14 OM-DEE/4

Maintenance

g. Record the exact amounts of water and treatment compound needed.
These amounts may be used again, if the same water sources and
compound are used. However, it is best to check the pH each time
treated water is prepared.

11. Installation of Safety Valve
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.
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. 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 174°C (375°F) or greater.

8. is, over its entire length, of a size equal to or greater than the
valve outlet.

i. 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!

j. See appropriate ASME Boiler and Pressure Vessel Code for additional

installation instructions.

OM-DEE/4 15

Troubleshooting

Your kettle is designed to operate smoothly and efficiently if properly maintained. However, the following is a list of checks to make
in the event of a problem. Wiring diagrams are furnished inside the service panel. X indicates items which must be performed by
an authorized technician. USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY THE MANUFACTURER OR AN

AUTHORIZED DISTRIBUTOR CAN CAUSE INJURY TO THE OPERATOR AND DAMAGE TO THE EQUIPMENT AND WILL VOID ALL
WARRANTIES.

SYMPTOM WHO WHAT TO CHECK

Kettle will not heat and
heating indicator will not
come on.

Kettle will not heat but
heating indicator comes
on.

Kettle continues heating
after it reaches the desired
temperature.

Kettle stops heating before
it reaches the desired
temperature.

Kettle heats slowly. User a. For air in the jacket. See “Jacket Vacuum” in the “Maintenance”

User a. Electric power supply to the unit.

b. Water level in jacket.

Authorized

Service Rep Only

User a. For air in the jacket. See “Jacket Vacuum” in the “Maintenance”

Authorized

Service Rep Only

User a. Thermostat dial setting.

Authorized

Service Rep Only

User a. Thermostat dial setting.

Authorized

Service Rep Only

c. Control circuit fuses. Replace a blown fuse only with a fuse of the
same AMP rating. X
d. For loose or broken wires. X
e. Tilt cut-off switch. X f. That pressure switch is open. X
g. Operation of variable thermostat. X h. Low water cuttoff. X

section of this manual.

b. Contactor. X
c. Heater elements with ohmmeter for ground short or open element.
If element is defective, call Service. X

b. Thermostat circuit for short. X
c. Thermostat operation. The thermostat should click when the dial
is rotated to settings above and below the temperature of the kettle.
X
d. Contactor, to determine whether it is energized or stuck. X

b. Thermostat calibration. X
c. Thermostat operation. The thermostat should click when the dial
is rotated above and below the setting for the temperature of the
kettle. X

section of this manual.

Authorized

Service Rep Only

Safety valve pops. User a. For air in the jacket. See “Jacket Vacuum” in the “Maintenance”

Authorized

Service Rep Only

16 OM-DEE/4

b. Heater elements with ohmmeter for ground short or open
element. If an element is defective, call service. X
c. Voltage of main power source. X

section of this manual.
b. Whether kettle was being heated empty when valve popped.

c. Pressure switch setting. X
d. Thermostat operation. Thermostat should click when the dial
is rotated above and below the setting for the temperature of the
kettle. X
e. Safety valve. If the valve pops at pressures below 24 PSI, replace
it. X
f. Contactor, to determine whether it is de-energized. X

Troubleshooting

SYMPTOM WHO WHAT TO CHECK

Safety valve leaks a small
amount of steam when
the kettle is operating.

Kettle is hard to tilt. User a. For air in the jacket. See “Jacket Vacuum” in the “Maintenance”

User a. For contamination that prevents seating of valve. With full

pressure in the jacket, pull the lever all the way briefly to blow the
valve clean, then let the lever snap back to seat the valve.

Authorized

Service Rep Only

Authorized

Service Rep Only

a. Safety valve for defects. Replace any defective valve with an
identical valve. X

section of this manual.

a. Tilting gear and worm for contamination and for proper alignment
and lubrication. X

OM-DEE/4 17

Parts List

18 OM-DEE/4

Parts List

OM-DEE/4 19

Parts List

To order parts, contact your Authorized Service Agent. Supply the model designation, serial number, part description, part number,
quantity, and when applicable, voltage and phase.

KEY DESCRIPTION PART NO.

1 WATER-FILL PIPING ASSY 097007

2 SAFETY VALVE, 50 PSI 141360

3 STREET ELBOW, 1/2 NPT 004185

4 WATER LEVEL ASSY 065198

---- WATER LEVEL GLASS 008742

---- GLASS GUARD ROD 002981

---- COMPOUND PRESSURE GAUGE 084208

---- WATER LEVEL ELECTRODE 002170

5 KBA & TRUNNION, 20-GAL, NO TDO, 240V,

CE, 50 PSI

5 KBA & TRUNNION, 20-GAL, TDO, 240V,

CE, 50 PSI

5 KBA & TRUNNION, 40-GAL, NO TDO, 240V,

CE, 50 PSI

5 KBA & TRUNNION, 40-GAL, TDO, 240V,

CE, 50 PSI

5 KBA & TRUNNION, 60-GAL, NO TDO, 240V,

CE, 50 PSI

5 KBA & TRUNNION, 60-GAL, TDO, 240V,

CE, 50 PSI

6 OVERLAY, OPERATING INSTRUCTIONS 141367

7 OVERLAY, SWITCH & LAMPS 122055

8 THERMOSTAT 009730

9 TOGGLE SWITCH 122004

10 TERMINAL LUG, GROUND, 6-14 AWG 129714

11 LIMIT SWITCH 002982

12 CONTACTOR, 4-POLE 119811

13 TRANSFORMER, CE, 24V SEC 50VA 148899

14 RED LIGHT, INDICATOR, 24V 116383

14 AMBER LIGHT, INDICATOR, 24V 116384

14 GREEN LIGHT, INDICATOR, 24V 162846

15 TERMINAL BLOCK 4 POLE 85 AMP 088214

16 FUSE 3.0 AMP TYPE 3 AG 077853

17 FUSE HOLDER TYPE 3 AG 077854

18 WATER LEVEL BOARD ASSY 148323

19 PRESSURE SWITCH 096963

20 THERMOSTAT KNOB 122000

MS102860

MS102866

MS100869

MS100875

MS102912

MS102918

KEY DESCRIPTION PART NO.

---- EQUIPOTENTIAL TERMINAL ASSY 122021

---- WIRING HARNESS, POWER INPUT 141365

---- WIRING HARNESS, 24V CONTROLS EL
WIR0607

---- WIRING HARNESS, HEATERS EL
WIR0608

23 BULLET FOOT 013275

23 FLANGED FOOT 096569

24 CRANK HANDLE 013617

---- 1/4" ROLL PIN 012614

---- SHAFT 013624

---- WORM GEAR 012026

---- GEAR WHEEL, 92 TOOTH 013609

---- BALL BEARING 009765

---- BEARING SLEEVE 115268

---- KEY, 3/8" 001474

---- SET SCREW 009763

---- GREASE FITTING 012100

26 DRAWOFF VALVE 009046

27 SANITARY HEX NUT 009354

28 BONNET 009024

29 VALVE STEM 009048

30 RUBBER O-RING 009034

31 HANDLE 009029

32 WING NUT, 10-24 009028

---- PRISON VALVE HANDLE, STEM, BONNET,

HEX NUT AND LANYARD

33 STAND AND HOUSING, 20-GALLON 127795

33 STAND AND HOUSING, 40- 60-GALLON 147513

171281

x- Item not depicted/called out in drawing

20 OM-DEE/4

Wiring Diagram

OM-DEE/4 21

Service Log

Model No: Purchased From:

Serial No: Location:

Date Purchased: Date Installed:

Purchase Order No: For Service Call:

Date Maintenance Performed Performed By

22 OM-DEE/4

1055 Mendell Davis Drive • Jackson MS 39272

888-994-7636 • 601-372-3903 • Fax [phone]

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