Groen DH-1-40 Service Manual

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IMPORTANT INFORMATION• KEEP FOR OPERATOR• IMPORTANT INFORMATION
OPERATOR MANUAL OM-DH
Part Number 121050-Rev A. DOMESTIC
MODEL: DH
Steam Jacketed Kettle
[with Standard Electronic Ignition]
Model DH-40 With Optional Counter-balanced Cover
T H I S 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.
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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.
WARNING: KETTLE MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH
ELECTRICITY AND PLUMBING. IMPROPER INSTALLATION CAN RESULT IN INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT.
DANGER: ELECTRICALLY GROUND THE UNIT AT THE TERMINAL PROVIDED. FAILURE TO
GROUND UNIT COULD RESULT IN ELECTROCUTION AND DEATH.
WARNING: DO NOT CONNECT ANY PIPING TO THE POP SAFETY VALVE. THE VALVE MUST
BE FREE TO VENT STEAM AS NEEDED. THE ELBOW ATTACHED TO THE SAFETY VALVE SHOULD POINT TO THE FLOOR. IMPROPER INSTALLATION WILL VOID WARRANTY.
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 THE KETTLE.
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) USE CONTAINER DEEP ENOUGH TO CONTAIN AND MINIMIZE SPLASHING.
2) PLACE CONTAINER ON STABLE, FLAT SURFACE, AS CLOSE TO KETTLE AS POSSIBLE.
3) DO NOT OVER FILL 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 SAFETY VALVE, AVOID ANY EXPOSURE TO THE STEAM
BLOWING OUT OF THE SAFETY VALVE. DIRECT CONTACT WITH STEAM COULD RESULT IN SEVERE BURNS.
WARNING: TO AVOID INJURY, READ AND FOLLOW ALL PRECAUTIONS STATED ON THE
LABEL OF THE WATER TREATMENT COMPOUND.
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WARNING: BEFORE REPLACING ANY PARTS, DISCONNECT THE UNIT FROM THE ELECTRIC
POWER SUPPLY AND CLOSE THE MAIN GAS VALVE. ALLOW FIVE MINUTES FOR UNBURNED GAS TO VENT.
WARNING: KEEP WATER AND SOLUTIONS OUT OF CONTROLS AND ELECTRICAL
EQUIPMENT. NEVER SPRAY OR HOSE THE SUPPORT HOUSING OR ELECTRICAL CONNECTIONS.
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 THEIR AUTHORIZED SERVICE AGENTS 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 & UNPACKING ........................................... 6
INSTALLATION ...................................................... 7
OPERATION ........................................................ 9
SEQUENCE OF OPERATION .......................................... 11
MAINTENANCE .................................................... 12
CLEANING ......................................................... 15
TROUBLESHOOTING ................................................ 17
PARTS LISTS ....................................................... 19
DIAGRAMS & SCHEMATICS ........................................... 21
MAINTENANCE LOG ................................................. 22
REFERENCES ...................................................... 23
WARRANTY ........................................................ 24
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Equipment Description
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The Groen DH is a floor-mounted, tilting, steam jacketed kettle with a thermostatically controlled, self-contained, gas-heated steam source and appropriate controls, mounted on a sturdy base. The Model DH is available in 20, 40 or 60 gallon capacities.
The body of the DH 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 which is ASME shop inspected and registered with the national board for working pressures up to 50 PSI. Kettle finish is 180 emery grit on the inside and bright high buff polish on the outside.
The kettle is 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. Standard DHT units include a two inch tangent draw-off valve.
The self-contained steam source is heated by propane or natural gas. Ignition is electronic.
The kettle is charged at the factory with chemically pure water which contains rust inhibitors. The steam source provides kettle temperatures of 150º to approximately 295ºF (65 to 150ºC). Unit controls include a thermostat, pressure gauge, safety valve, pressure limit control, low water cut-off, power switch and gas regulator valve. The gas supply shuts off automatically when the kettle is tilted.
The unit must be specified for use with natural or propane gas. Service connections for gas and electricity are required. Standard power supply is 115 Volt. Alternate voltages (208V or 240V) are available.
KETTLE CHARACTERISTICS
DH-20 DHT-20 DH/1-40 DHT/1-40 DH-60 DHT-60
Kettle Capacity Tangent drawoff No Yes No Yes No Yes Jacket Capacity Kettle Body
Diameter Base Width Base Front to
Back Firing Rate - per
hour Energy into
Product per hr.
20 gal
(75 ltr)
5 gal.
(19 ltr)
20 in.
(508 mm)
35 in.
(889 mm)
29
(736 mm)
72,000 BTU 72,000 BTU 100,000 BTU 100,000 BTU 150,000 BTU 150,000 BTU
44,140 BTU 44,140 BTU 65,000 BTU 65,000 BTU 93,000 BTU 93,000 BTU
20 gal. (75 ltr)
5 gal.
(19 ltr)
20 in.
(508 mm)
35 in.
(889 mm)
29
(736 mm)
40 gal.
(150 ltr)
6 gal.
(22¾ ltr)
26 in.
(660 mcm)
47 in.
(1194 mm)
29
(736 mm)
40 gal.
(150 ltr)
6 gal.
(22¾ ltr)
26 in.
(660 mm)
47 in.
(1194 mm)
29
(736 mm)
60 gal.
(225 ltr)
14 gal. (53 ltr)
30 in.
(762 mm)
47 in.
(1194 mm)
29
(736 mm)
60 gal.
(225 ltr)
14 gal. (53 ltr)
30 in.
(762 mm)
47 in.
(1194 mm)
29
(736 mm)
Options available with listed models are:
1. Two inch tangent drawoff*
2. Strainers, solid disk, ¼ or c inch holes
3. No. 31 lift-off cover
4. No. 51 counterbalanced cover w/actuator*
* Factory-installed options
5. Basket Inserts (Tri-BC)
6. Water fill faucets with swing spout
7. Kettle Brush Kit
8. Stainless steel liner*
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Inspection & Unpacking
The unit will arrive in a heavy shipping carton and will be bolted or banded to a skid. Immediately upon receipt, inspect the carton carefully for exterior damage.
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.
Carefully cut any polyester straps around the carton and detach the sides of the box from the skid. Pull the carton up off the unit.
Thoroughly inspect the unit for hidden 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.
CAUTION THIS UNIT WEIGHS BETWEEN 535 AND 880 POUNDS (245 TO 400 Kg) DEPENDING ON SIZE. INSTALLER SHOULD USE PROPER EQUIPMENT TO LIFT SAFELY.
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.
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Installation
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For efficient performance the DH kettle must be installed in a well-ventilated area. Items which might restrict or obstruct the flow of air for combustion and ventilation must be removed. The area directly around the appliance must be free of combustible materials.
WARNING THE KETTLE MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH ELECTRICITY AND PLUMBING. IMPROPER INSTALLATION CAN RESULT IN INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT.
1. Installation on combustible floors is allowed. Rear clearance of 10 inches and six inches at both sides is required for both combustible and non-combustible construction.
2. Installation under a vent hood is recommended. Consult local codes.
3. Set the kettle in place and level it using a spirit level on the bar rim, by turning the bullet feet to adjust leg length. Allow clearance around the unit for cleaning, maintenance and service.
4. Complete the piping to the gas service main with ½” line or approved equivalent.
5. For standard units, provide 115 vac, 60 Hz, single phase 5 AMP electrical service. The unit may also be ordered for alternate electric service of 208 VAC or 240 VAC. Observe local codes and/or The National Electrical Code in accordance with ANSI/NFPA 70 - (current edition). Use the wiring diagram inside the service panel and at the rear of this manual.
soap solution or other suitable leak detector should be employed.
9. Confirm that the jacket water level is between the gauge glass markers. If the level is low, follow instructions under “Jacket Filling and Water Treatment,” Page 13.
10. 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.
The open end of the pop safety valve elbow must face downward.
WARNING DO NOT CONNECT ANY PIPING TO THE POP SAFETY VALVE. THE VALVE MUST BE FREE TO VENT STEAM AS NEEDED. IMPROPER INSTALLATION WILL VOID THE WARRANTY!
THE ELBOW ATTACHED TO THE SAFETY VALVE MUST POINT TO THE FLOOR.
6. Bring electrical service through the entrance at the rear of the support housing with a ½ inch conduit connector. Make a watertight connection with the incoming lines.
DANGER ELECTRICALLY GROUND THE UNIT AT THE TERMINAL PROVIDED. FAILURE TO GROUND UNIT COULD RESULT IN ELECTROCUTION AND DEATH.
7. Electrically ground the unit at the terminal provided.
8. After the kettle has been connected to the gas supply, check all gas joints for leaks. DO NOT USE FLAME TO CHECK FOR LEAKS. A thick
11. The appliance and its individual shut-off valve must be disconnected from the gas supply piping system during any testing at pressures in excess of ½ PSI (3.45 kPa). The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing at or less than ½ PSI (3.45 kPa).
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Now that the kettle has been installed, you should test to ensure that it is operating correctly.
1. Remove 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 1-2 quarts of water into the kettle.
6. Following “To Start Kettle” instructions in the “Operation” section (Page 9), begin heating the water at the highest thermostat setting. The heat indicator light should come on, and heating should continue until the water boils.
(For units with optional tangent draw-off). Assemble the tangent draw-off by placing the large nut over the draw-off valve and inserting it into the draw-off tube. ONLY HAND-TIGHTEN THE NUT to complete installation.
When attaching the draw-off valve hand­tighten the nut.
If the unit functions as described it is ready for use. If it does not function as described, contact your local Groen Certified Service Agency.
Each day confirm the jacket water
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level by checking the water gauge.
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Operation
A. Controls
Operator controls for the DH kettle are:
1. Manual gas valve (on gas line behind the unit), which controls the supply of gas from the main to the unit.
2. On-Off (Toggle) Switch. This controls the supply of electric power to the control circuits.
3. Thermostat dial, which turns the thermostat on or off, and sets the kettle temperature.
4. Tilting crank, used to tilt the kettle body.
5. Indicator Lights to alert operator of unit conditions:
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a. Power On Indicator - shows that the unit is
turned on
b. Heat Indicator - indicates that main gas is on
to produce steam in the kettle jacket.
c. Low Water indicator - shows that jacket
water is low
6. Unit gas pressure regulator adjustment - located behind the access door in the kettle skirt.
B. Operating Procedure
1. To Start Kettle: a. 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 13.
b. Check the pressure gauge. If the gauge does
not show 20 to 30 inches of mercury (Hg) vacuum (that is a reading of 20 to 30 below 0 atmospheric pressure), see “Jacket Vacuum” on page 13.
to maintain the set temperature. The heat indicator light will come on.
3) If the unit does not light, turn it off and wait five minutes. Then follow the instructions again.
2 To Empty Kettle:
a. To tilt the body of the kettle forward, turn the
hand crank on the front of the cabinet counter-clockwise. The body will stay in the position it holds when you stop cranking. To return the kettle body to its upright position, turn the crank clockwise.
b. Product may also be transferred by means of
the optional draw-off valve, if the kettle is so equipped.
3. To Shut Down Kettle: a. Turn thermostat dial to OFF. b. Turn toggle switch to OFF.
4. For a prolonged shut-down:
c. Do not attempt to light any burner with a
flame.Turn the manual gas valve ON (align handle with gas line).
1) Turn toggle (on-off) switch ON. The electronic ignition will attempt to light the pilot for 90 seconds, or until it is lit. Once lit, proceed to step two.
2) Turn thermostat to desired setting. The main gas burner will ignite, and will cycle
a. Follow the procedure above. b. Turn the manual gas valve off (handle at
right angles to gas line).
c. Disconnect electric power from the unit.
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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.
5. If power fails:
a. Do not attempt to operate the unit until
electric power is restored.
b. When power comes back on, follow
directions “To Start Kettle,” above.
WARNING AVOID ALL DIRECT CONTACT WITH HOT SURFACES AND HOT FOOD OR WATER IN THE KETTLE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS.
When removing a lift-off cover:
a. Firmly grasp the handle, and lift the rear
edge (farthest from operator) 1-2” (3-5 cm) to allow steam and water vapor to escape. Wait 2-3 seconds.
b. Tilt cover to 45-60° angle to allow any hot
condensate or product to roll off cover back into kettle.
c. Remove cover, ensuring that remaining hot
condensate or product does not drip on operator, floor or work surfaces.
d. Place cover on safe, flat, sanitary, out-of-the-
way surface, or return to kettle.
CAUTION DO NOT TILT KETTLE WITH LIFT-OFF COVER IN PLACE. COVER MAY SLIDE OFF, CAUSING INJURY TO OPERATOR.
C. Use of Common Accessories
1. Lift-Off or Counterbalanced Cover As with stock pot cooking, an optional cover can
speed up the heating of water and food products. It helps retain heat and reduces the heat and humidity in the kitchen. A cover can reduce some product cook times and help maintain the temperature, color and texture of products 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 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.
2. Basket Insert An optional kettle basket insert set (Tri-BC) will
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, (approx. ¼” (6 mm). This includes rice and small pasta shapes.
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 OFF, and with cold water in the kettle.
CAUTION DO NOT OVERFILL THE KETTLE WHEN COOKING, HOLDING OR CLEANING. KEEP LIQUIDS AT LEAST 2-3” (5-8 cm) BELOW THE KETTLE RIM TO ALLOW CLEARANCE FOR STIRRING, BOILING AND SAFE PRODUCT TRANSFER.
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WARNING AVOID ALL DIRECT CONTACT WITH HOT FOOD OR WATER IN THE KETTLE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS.
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.
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admit gas to the main burner, where it is ignited by the pilot flame. When the kettle reaches the set temperature, the thermostat switch opens. This stops the signal to the gas control valve and shuts off gas to the main burner. The pilot flame remains lit. When the kettle cools below the set temperature, the thermostat switch closes and starts another cycle. On and off cycling continues and maintains the kettle at the desired temperature. This action is indicated by the Heat indicator light.
The kettle has the following safety features in addition to the 90-second ignition timer:
1. Low water cutoff relay that will shut off gas supplies to all burners until the jacket water level is corrected.
2. High limit pressure switch, set to open at about 46 PSI and to shut down the burners until jacket pressure is decreased.
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.
Sequence of Operation
The following “action-reaction” outline is provided to help understand how the DH kettle works.
1. When the power switch is turned on, it starts the spark igniter and opens the automatic valve for the pilot burner. The spark ignites a pilot flame, which heats the sensor. The sensor then sends a signal to turn off the spark. The flame thereafter acts as a standing pilot until the power is turned off.
3. Pop safety valve, which will release steam if jacket pressure exceeds 50 PSI.
4. Tilt switch, which shuts off all burners when the kettle is tilted.
5. Gas pressure regulator built into the gas control valve.
2. If the pilot flame is not sensed within 90 seconds after spark begins, a timer shuts down the entire operation. To attempt a second trial for ignition, turn off the power switch. Check the gas supply valves and wait five minutes before trying again by switching power on. If you cannot establish a pilot flame in four tries, close all valves, turn off the power, and contact an authorized Groen Service Agency.
3. When the operator sets a temperature on the thermostat, it causes the automatic valve to
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Maintenance
NOTICE: Contact Groen or an authorized Groen Service Agent when repairs are required.
1. Periodic Maintenance
A Maintenance & Service Log is provided at the back of this manual with the warranty information. Each time maintenance is performed on your Groen 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:
kettle is cold. If it does not, see “Jacket Vacuum” on page 13.
b. 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 13.
c. Test the safety valve at least twice each
month. With the kettle operating at five psi (105 kPa), pull the test lever and let it snap back to its closed position. If there is little discharge (mostly air), and the pressure gauge drops back to zero PSI, allow the pressure to build back to five PSI and repeat the procedure. (Tip: Using a screwdriver or other implement to pull the ring will help you avoid contact with the steam.)
d. If the valve does not activate, or there is no
evidence of discharge, or the valve leaks, stop using the kettle and contact a qualified Groen service representative.
The pressure gauge should show a vacuum of 20 to 30 inches of mercury (Hg) and the water level should be between the markers when the kettle is cold.
WARNING WHEN TESTING, AVOID ANY EXPOSURE TO THE STEAM BLOWING OUT OF THE SAFETY VALVE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS.
e. Keep the primary burner gas jet air inlets
free of dust and lint.
f. The pilot flame should be blue. It should
envelop about ½ inch (12 mm) of the flame sensor tip.
g. The gear housing has fittings for lubrication
of moving parts. The gears do not run in oil, so periodic lubrication with grease is necessary.
h. Frequency of lubrication depends on
operating conditions, but it should be done at least once every six months.
i. Use a #2 grade LGI lithium grease to add
grease through Zerk fittings on gear housing until it flows out of the bearings around the trunnion shaft.
a. Check the pressure/vacuum gauge every
day. The gauge should show a vacuum of 20 to 30 inches mercury (Hg), when the
i. Place liberal amounts of grease on the gear
to cover the arc that is in contact with the worm gear.
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Add grease through Zerk Fittings.
j. Keep electrical wiring and connections in
good condition.
k. Keep the inside of the control console clean
and dry.
l. Keep burner slots clean.
2. 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.
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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 five PSI, release the trapped air and steam by pulling up the safety valve ring for about five seconds. Repeat this step three or four times. Then let the pull ring snap back into the closed position.
c. If there is little discharge (mostly air), and the
pressure gauge drops back to zero PSI, allow the pressure to build back to five PSI and repeat the procedure.
d. Once steam has been vented from the
jacket as described in b, above, remove the hot water from the kettle and replace it with cold. This will condense steam in the kettle jacket, and the pressure gauge should show a reading of 20 to 30 inches mercury (Hg) below zero. If it does not, or if the vacuum is leaking down, contact a Groen authorized service agency to correct the problem.
3. 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. 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,” below.
To remove air:
Liberally grease the wheel where it contacts the worm gear.
Allow the kettle to cool completely. The
procedure will be easier with the kettle under vacuum ( pressure gauge reading below zero).
Test the safety valve at least twice monthly.
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a. Make sure the fill valve is closed, and
remove the square head pipe plug with open-ended wrench or crescent wrench.
b. Position a funnel in the opening and fill it with
properly treated water.
c. Slowly open the fill valve to allow water to be
sucked into the jacket. Quickly close the valve to prevent air from entering.
d. Check water level in the jacket to ensure
that it is between minimum and maximum marks on glass.
e. Close the valve and reinstall the square-
head pipe plug.
f. Reestablish the jacket vacuum as described
in Paragraph 2, above, if the pressure gauge does not show a negative reading of 20 to 30 inches mercury (Hg).
4. Water Treatment Procedure
a. Obtain water treatment compound and a pH
test kit from your Groen Service Agent.
WARNING TO AVOID INJURY, READ AND FOLLOW ALL PRECAUTIONS ON THE LABEL OF THE WATER TREATMENT COMPOUND.
b. Fill a mixing container with the measured
amount of water required. (See table). Distilled water is recommended.
and maximum marks on glass. Stop adding water when it reaches the maximum marker on the gauge.
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.
5. Component Replacement
WARNING BEFORE REPLACING ANY PARTS, DISCONNECT THE UNIT FROM THE ELECTRIC POWER SUPPLY AND CLOSE THE MAIN GAS VALVE. ALLOW FIVE MINUTES FOR UNBURNED GAS TO VENT.
When component replacement involves breaking a gas pipe connection, check the new connection with soap solution or an appropriate leak detector. DO
NOT USE A FLAME TO TEST FOR LEAKS.
Internal wiring is marked as shown on the circuit schematic drawings (inside control housing and in this manual). Be sure that new components are wired in the same manner as old components. An examination of the circuit schematic shows that the safety components are wired in series. In most cases, a faulty component may be isolated with a jumper wire to verify that the component is faulty. If this determination is made, contact a certified Groen Service Agency for assistance.
Kettle Model
DH-20, DHT-20 2½ Gallons
DH/1-40, DHT/1-40 3½ Gallons
DH-60, DHT-60 4 Gallons
c. Hang a strip of pH test paper on the rim of
the container, with about 1 inch 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.
f. As you add water to the jacket, check water
level to ensure that it is between minimum
Approximate Jacket
Capacity
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Cleaning
OM-DH
1. Suggested Cleaning Supplies:
a. Cleaner, such as Klenzade HC-10 or HC-32
from ECOLAB, Inc.
b. Kettle brushes in good condition. c. Sanitizer such as Klenzade XY-12.
d. Film remover such as Klenzade LC-30.
2. Precautions
Before cleaning, shut off the kettle by turning the thermostat dial to “OFF,” and shut off all electric power to the unit at a remote switch, such as the circuit breaker.
WARNING
KEEP WATER AND SOLUTIONS AWAY FROM CONTROLS AND ELECTRICAL EQUIPMENT. NEVER SPRAY THE SUPPORT HOUSING OR ELECTRICAL CONNECTIONS.
d. Model DHT only: Disassemble the tangent
draw-off valve. Clean the draw-off port and each valve part with a brush.
CAUTION DO NOT MIX PARTS OF DIFFERENT DRAW­OFF VALVE ASSEMBLIES. THE PARTS ARE NOT INTERCHANGEABLE.
e. Rinse the kettle and draw-off valve parts
thoroughly with hot water, then drain completely.
f. When you reassemble the draw-off valve,
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. READ THE WARNINGS AND FOLLOW THE DIRECTIONS ON THE LABEL OF THE CLEANER CAREFULLY
3. Procedure
a. Clean food-contact surfaces as soon as
possible after use. If the unit is in continuous use, thoroughly clean and sanitize the interior and exterior at least once every 12 hours.
b. Scrape and flush out food residues. Be
careful not to scratch the kettle with metal implements. (For DHT models only: After flushing the kettle, close the draw-off valve.)
c. Prepare a hot 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, housings, and electrical conduits.
When attaching the draw-off valve, just hand­tighten the nut.
hand-tighten the nut which holds it in place.
g. As part of the daily cleaning program, clean
soiled external and internal surfaces. Remember to check the sides of the unit and control housing.
h. To remove burnt on foods, use a brush,
sponge, cloth, plastic or rubber scraper, or plastic wool with the cleaning solution. To reduce effort required in washing, let the detergent solution sit in the kettle 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 may leave particles in the surface and cause eventual corrosion and pitting.
i. The outside of the unit may be polished with
a stainless steel cleaner such as “Zepper” from Zep Manufacturing Co.
j. When equipment needs to be sanitized, use
a solution equivalent to one that supplies
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OM-DH
200 parts per million available chlorine. Obtain advice on sanitizing agents from your supplier of sanitizing products.
j. Following the supplier’s instructions, apply
the agent after the unit has been cleaned and drained. Rinse off the sanitizer thoroughly.
NOTICE NEVER LEAVE A CHLORINE SANITIZER IN CONTACT WITH STAINLESS STEEL SURFACES LONGER THAN 30 MINUTES. LONGER CONTACT CAN CAUSE STAINING AND CORROSION.
k. It is recommended that each piece of
equipment be sanitized just before use.
l. 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, like Groen Delimer/Descaler (Part Number 114800) or Lime-Away from Ecolab, in accordance with the manufacturer’s directions. Rinse and drain the unit before further use.
m. If cleaning problems persist, contact your
cleaning product representative for assistance. The supplier has a trained technical staff with laboratory facilities to serve you.
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OM-DH
Troubleshooting
Your Groen 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 and in this manual. If an item on the list is followed by Y, the work should be done by a qualified service
representative.
WARNING BEFORE REPLACING ANY PARTS, DISCONNECT THE UNIT FROM THE ELECTRIC POWER SUPPLY AND CLOSE THE MAIN GAS VALVE. ALLOW FIVE MINUTES FOR UNBURNED GAS TO VENT.
CAUTION USEING REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY GROEN OR THEIR AUTHORIZED DISTRIBUTOR CAN CAUSE OPERATOR INJURY AND EQUIPMENT DAMAGE AND WILL VOID ALL WARRANTIES.
SYMPTOM WHO WHAT TO CHECK
Kettle is hard to tilt. User a. Gears for foreign materials, and lubrication.
Auth Service Rep Only
Kettle continues heating after it reaches desired temperature.
Kettle stops heating before it reaches the desired temperature.
Safety Valve pops open User a. For air in the jacket. See “Jacket Vacuum” in the Maintenance section.
Burners will not light. User a. That the main gas supply valve is open. (handle is in line with gas pipe).
System does not produce a spark Auth
User a. Thermostat dial setting. Auth
Service Rep Only
User a. Thermostat dial setting. Auth
Service Rep Only
Auth Service Rep Only
Auth Service Rep Only
Service Rep Only
Y indicates items which must be performed by an authorized technician.
b. Gears for alignment. Y c. Worm gears or broken gears. Y
b. Thermostat calibration.Y c. Thermostat operation. The thermostat should click when the dial is
rotated to settings above and below the temperature of the kettle.Y
b. Thermostat calibration.Y c. Thermostat operation. The thermostat should click when the dial is
rotated to settings above and below the temperature of the kettle.Y
b. Thermostat dial setting. c. For defective thermostat. The thermostat should click when the dial is
rotated to settings above and below the temperature of the kettle. If defective, replace.Y
d. For defective safety valve. If the valve pops at pressures below 49 PSI,
replace.Y
b. Gas supply to the building. c. That the kettle body is not tilted.
d. Thermostat operation. The thermostat should click when the dial is
rotated to settings above and below the temperature of the kettle.Y
f. That tilt limit switch is closed when body is not tilted.Y a. Thermostat, and close the contacts if they are open Y
b. AC voltage between terminals on secondary side of transformer. If it is
not 24 Volt, replace the transformer Y
c. That the high tension cable is firmly attached and in good condition. If
cracked or brittle, replace.Y d. Pilot electric ceramic for crack or break.Y e. Pilot spark gap. Regap.Y
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SYMPTOM WHO WHAT TO CHECK
Spark is present but the pilot will not light.
Pilot lights, but main burner will not come on and spark does not stay on.
Pilot lights, but main burner will not come on, the spark stays on.
Main burner comes on but will not stay on.
Auth Service Rep Only
Auth Service Rep Only
Auth Service Rep Only
Auth Service Rep Only
Y indicates items which must be performed by an authorized technician.
a. That the pilot valve is securely connected to terminals.Y b. For 24 VAC at terminals PV and PV/MV. If 24V is not present, replace
the ignition control module.Y b. That gas pressure is at least 3.5" W.C.(8.7818 :b).Y c. For gas at the pilot. If it is not flowing:
(1) Check the pilot gas line for kinks and obstructions.Y
(2) Clean orifice, if necessary.Y
(3) Check magnetic operator for pilot valve on gas valve. Repair or
replace as necessary.Y
d. That the pilot spark gap is located in the pilot gas stream. If not, adjust
or replace the pilot burner.Y e. For drafts. Shield the pilot burner, if necessary.Y
a. For 24 V between terminals PV and PV/MV. If 24V is not present,
replace the ignition control module.Y b. That gas pressure is at least 3.5" W.C.(8.7818 :b).Y c. Electrical connections of the main valve to terminals, to assure that they
are securely attached. Check magnetic operator for pilot valve on gas
valve. Repair or replace as necessary.Y a. Check for bad burner ground. If necessary, repair with high temperature
wire.Y b. Pilot burner ceramic insulator for cracks.Y c. That cable is not grounded out. If it is, correct the ground-out condition
or replace cable.Y d. For proper gas pressure.Y e. Clean pilot assembly, or replace if necessary.Y f. Tighten all mechanical and electrical connections.Y g. If the pilot flame is weak, increase pilot orifice size.Y h. Replace ignition control module.Y
a. Check burner ground for bad wire or connection. Replace if necessary
with high temperature wire.Y b. Check for low gas supply pressure. If necessary, replace ignition control
module.Y
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Electrical Schematic
OM-DH
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OM-DH
Parts List
To order parts, contact your Groen Certified Service Agency. Supply the model designation, part description, part number, quantity, and, where applicable, voltage and phase.
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OM-DH
Parts List
To order parts, contact your Groen Certified Service Agency. Supply the model designation, part description, part number, quantity, and, where applicable, voltage and phase.
Key Description Part No. Key Description Part No. Key Description Part No.
Hardware, Final Assembly 117086 Screw, Socket Head 3/8-16 x 1-1/2 Lg 005097 Label Warning-Self Contained Kettles 098171
? Valve, Safety & Water Fill Assembly 005444 Washer Lock, 3/8" 005702 Valve, Gas, Manual Shut-Off 098458
Chain, Single Jack Link 003261 Nut, Hexagon 1/2-13 005705 Label, Warning, AGA 099961
? Safety Valve and Water Fill Assembly 097008 Washer, Lock 1/2" 005735
Valve, Safety, 50 PSI 097005 Nut, Hexagon 3/8-16 008214 Water Column Assembly 117088 Elbow, 90 degree Street 1/2 NPT 096905 Screw Hexagon Head 1/2-13 x 1-1/2 008679 Fittings, Sight Glass Assembly 002845 Elbow, 90 deg. Street 1/2 NPT black 004185 Guard Gas Rod Gauge 002981
Housing, Bearing Assembly 009762 Label, Maximum and Minimum 000558
Piping Water Fill Assembly 097007 Screw Set Socket 3/8-16 x 1/2 009763 Tube, Water Level 008742
Plug Pipe 1/2 NPT Brass 011146 Fitting Grease Straight 012100 Gauge, Compound Pressure w/dual 084208 Tee, 1/2 NPT 008772 Bearing, Ball 009765 Elbow, F 90 Deg 1/2 NPT x 1/2" tube 055634 Valve, Swing Check 1/2 NPT 004187 Gear, Worm 3/4" Bore 012026 Nut, Hex Cap 005470 Nipple, 1/2 NPT x Close black 008877 Washer, Shim 1-3/8" ID x 1-3/4 OD 012039 Bushing, Reducing 1/4" x 1/8" NPT 074872 Valve, Gate 1/2 NPT 004180 Screw Set Socket w/Nylon insert 012060 Plate, Caution 1-3/8" x 2-1/4" 008250 Pin Roll 1/4" Dia x 1-1/4" Long 012614 Assembly, Front Panel 123804 Tag, Water Supply 084083 Ring Internal Retaining 1-3/4" Shaft 013483 Light, Indicator, Amber, 24 VAC 116384 Washer, Plain 1/4" 005472 Gear 3" Bore 013609 Light, Indicator, Red, 24 VAC 116383 Screw, Flat Head 8-32 x 3/8" Lg 006006 Handle, Crank, 3/4" Bore 013617 Switch, SPST On/Off 006904 Clamp, Conduit 1/2" 006777 Shaft, Handwheel, 3/4" Dia x 13-1/2 013624 Overlay, Front Panel 123802 Coupler, Male Tab 007880 Spacer, 3" Sch 40 x 3/4" 013625 Clamp, Conduit 3/8" OD 008224 Shim, Trunnion 088246 A Stand and Housing Assembly 123813 Bracket, Faucet Mounting 009054 Shim, Trunnion 088247 Strap, Cable Ty-Wrap 011093 Shim, Trunnion 088248 B Gas Valve Piping & Bottom Comps. 127369 Nut, Hex, Keps 1/4-20 w/washer 012940 Nameplate, “Groen” 055450 Foot, Adjustable, Bullet 2"OD 013275 Bracket, Support 065382 C Burner and Flame Sensor Assembly 123814 Nameplate “Fill Jacket..” 026450 Bracket, Support Assy Gas Line 068132
Clamp, Conduit 1/2" 006777 D Combustion Chamber Assembly 122093
Tilt Mechanism Assembly 045752 Nut Hexagon Keps 1/4-20 012940
Bushing, Snap 3/4" x 1" Nylon 000453 Bracket Support 1/8"x3/4"x8-3/4" 068133 E Flue Stack Assembly 117034 Key, 3/8" Square x 1-3/8" Lg 001474 Swivel Joint 1/2" NPT 076680 Bar Square 3/8" 403511 Label, Warning 093614
See Following Pages for Assembly Parts
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OM-DH
Parts List
Stand and Housing Assembly
Key Description Part No. Key Description Part No. Key Description Part No.
A Stand and Housing Assembly 123813 5 Housing Cladding, DH-20 123810 9 1/2" Lock Washer 005735
1 Cabinet Side Panel 047882 5 Housing Cladding, DH-40 and 60 123811 10 Screw Truss #8-32 x 3/8 005764 2 Stand Cladding MS96694 6 Tray Liner 001475 11 Screw Truss #8-32 x 1-1/4 Lg. 071247 3 Base Assembly MS96698 7 Nut Hexagon 1/2-13 Heavy Duty 005705 12 Cabinet Cover 001465 4 Housing Weldment Assembly MS47332 8 Screw Hex Head Cap 1/2-13 x1-1/2 008679
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OM-DH
Parts List
To order parts, contact your Groen Certified Service Agency. Supply the model designation, part description, part number, quantity, and, where applicable, voltage and phase.
Gas Valve Piping and Bottom Components Assembly
Key Description Part No. Key Description Part No. Key Description Part No.
B Gas Valve Piping&BottomComps. 127369 9 Pressure Switch 1/4" 096963 20 Cover, Bottom 049801
1 Tube, Copper, 1/2" 007334 10 Connector 1/2 NPT Male 049093 2 Elbow, Female, 90 Deg. 1/2 NPT 055634 11 Gas Valve 123815 3 Thermostat, electric 009730 12 Bracket Support 065382 21 Cap Bottom Cover Plate 049003 4 Elbow, 90 Deg 1/2 NPT 008747 13 Screw, Pan Head #8-32 x 3/8" 005764 22 Gasket, Bottom Plate 007937 5 Nipple, 1/2 NPT x 2-1/2" Long 005552 14 Nut, Hexagon Kep 1/4 012940 23 Screw, 10-32x3/8, Hex 069773 6 Electrode, Water Level 002170 16 Bar 005440 24 Elbow, 1/8" NPT Male x 1/4" Tube 097195 7 Tee, 1/2 x 1/2 Tube x 3/8 MPT 074593 17 Clamp, Rigid Conduit 068687 25 Tube, Aluminum 1/4" OD x 32" 006796 8 Connector 1/4" NPT Female 097074 19 Boot Probe 101143
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OM-DH
Parts List
Burner and Flame Sensor Assembly
Flue Stack Assembly
24
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Parts List
To order parts, contact your Groen Certified Service Agency. Supply the model designation, part description, part number, quantity, and, where applicable, voltage and phase.
Key Description Part No. Key Description Part No.
C Burner and Flame Sensor Assly 123814 E Flue Stack Assembly 117034
1 Baffle Plate 123498 1 Flue, Top Section of Top Plate 117029 2 Washer Lock 005655 2 Flue, Bottom Section of Top Plate 117033 3 Nut Hex 005601 3 Flue, Front Section 117032 4 Burner Bracket Support 1017010 4 Flue, Main Body 117031 5 Burner Bracket 117013 5 Screw, Truss Head 072189 6 Burner Assembly 090644 7 Pilot Burner Assembly 123580
OM-DH
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OM-DH
Model No. _______________________________ Purchased From _________________________ Serial No. _______________________________ Location ________________________________ Date Purchased __________________________ Date Installed ___________________________ Purchase Order No. _______________________ For Service Call __________________________
Service Log
Date Service Performed Performed By
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Limited Warranty
To Commercial Purchasers *
(Domestic U.S., Hawaii & Canadian Sales Only)
Groen Foodservice Equipment ("Groen Equipment") has been skillfully manufactured, carefully inspected and packaged to meet rigid standards of excellence. Groen warrants its Equipment to be free from defects in material and workmanship for (12) twelve months with the following conditions and subject to the following limitations.
I. This parts and labor warranty is limited to Groen Equipment sold to the original commercial
purchaser/users (but not original equipment manufacturers), at its original place of installation in the continental United States, Hawaii and Canada.
II. Damage during shipment is to be reported to the carrier, is not covered under this warranty, and is the
sole responsibility of purchaser/user.
III. Groen, or an authorized service representative, will repair or replace, at Groen's sole election, any Groen
Equipment, including but not limited to, drawoff valves, safety valves, gas and electric components, found to be defective during the warranty period. As to warranty service in the territory described above, Groen will absorb labor and portal to portal transportation costs (time & mileage) for the first twelve (12) months from date of installation or fifteen (15) months from date of shipment from Groen.
IV. This warranty does not cover boiler maintenance, calibration, periodic adjustments as specified in
operating instructions or manuals, and consumable parts such as scraper blades, gaskets, packing, etc., or labor costs incurred for removal of adjacent equipment or objects to gain access to Groen Equipment. This warranty does not cover defects caused by improper installation, abuse, careless operation, or improper maintenance of equipment. This warranty does not cover damage caused by poor water quality or improper boiler maintenance.
V. THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR
IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, EACH OF WHICH IS HEREBY EXPRESSLY DISCLAIMED. THE REMEDIES DESCRIBED ABOVE ARE EXCLUSIVE AND IN NO EVENT SHALL GROEN BE LIABLE FOR SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES FOR THE BREACH OR DELAY IN PERFORMANCE OF THIS WARRANTY.
VI. Groen Equipment is for commercial use only. If sold as a component of another (O.E.M.) manufacturer's
equipment, or if used as a consumer product, such Equipment is sold AS IS and without any warranty.
* (Covers All Foodservice Equipment Ordered After October 1, 1995)
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1055 Mendell Davis Drive Jackson, Mississippi 39272 Telephone 601 373-3903 FAX 601 373-9587
OM-DH (Issued Jan 00)
Part Number 121050-Rev A
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