Groen TDBC-20 Service Manual

IMPORTANT INFORMATION

IMPORTANT INFORMATION IMPORTANT INFORMATION

KEEP FOR OPERATOR

KEEP FOR OPERATORKEEP FOR OPERATOR

IMPORTANT INFORMATION

IMPORTANT INFORMATIONIMPORTANT INFORMATION

OPERATOR MANUAL OM-TDB

Models: TDB and TDBC

Steam Jacketed Kettle

Self-Contained Electrically heated Table top mounted Tilting

CITSEMODA veR 575731 rebmuN traP

Model TDB

Model TDBC

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

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

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, MANUAL.

WA RNING: THIS UNIT IS INTENDED FO R USE IN THE CO MMERCIAL HE ATING, COOKING AND

HOLDING O F WATER AND F O O D PRODUCTS, PE R THE INSTRUCTIO NS CONTAINED IN THIS MANUAL. ANY OTHER US E COULD RESUL T IN SERIOUS PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT AND WILL VOID WARRANTY.

WA RNING: KETTLE MUS T BE INSTALLE D BY P ERSONNEL QUAL IFIED TO WORK WITH

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

DA NG ER: ELECTRI CAL LY GROUND THE UNIT AT THE TERM INAL PRO VIDED. FAIL URE TO

GROUND UNIT COULD RESULT IN ELECTROCUTION AND DEATH.

WA RNING: A VOID ALL DIRECT CONTACT WITH HOT EQUIPMENT SURFACES . DIRE CT SKIN

CONTACT COULD RESULT IN SEVERE BURNS.

WA RNING: A VOID ALL DIRECT CONTACT WITH HOT FOOD OR WATER IN THE KETTLE.

DIRECT CONTACT COULD RESULT IN SEVERE BURNS.

CA UTION: DO NOT OVER FILL THE KETTLE WHE N CO OKING, HO L DING OR CLE ANING.

KEEP LIQUIDS A MI NI MUM OF 2-3” (5-8 cm) BELOW THE KETTLE BODY RIM TO A L L O W CL EARANCE FOR STIRRING, BOILING AND SAF E PRODUCT TRANSFER.

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

PRODUCT WHEN ADDI NG INGREDIENTS, STIRRING OR TRA NSFERRING PRODUCT TO A NO THE R CONTAINER.

WA RNING: DO NOT STA ND O N O R AP PLY UNNECESSARY WEIGHT OR PRESSURE ON THE

KETTLE FRONT OR POURING LIP. THI S COULD RESUL T IN OVERL O AD AND FAILURE OF THE TILT MECHANI SM, AND POSSIBLE SERIOUS INJURY AND BURNS TO THE OPERATOR AND OTHERS.

WA RNING: WHEN TILTING KETTLE FOR P RO DUCT TRANSFE R:

1) WEAR PROTECTIVE OVEN MITT AND PROTECTIVE APRON.

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

3) PLACE CONTA INER ON S TABLE , FLAT SURFACE, AS CLOSE TO KETTLE AS POSSIBLE.

4) STAND TO LEF T OR RIGHT SI DE OF KETTLE (DEP ENDING ON TILTING HA NDL E PLACEMENT) WHIL E POURING . DO NOT STAND DI RECTLY IN POUR PATH OF HOT CONTENTS.

5) POUR SLOWLY, MAINTAIN CONTROL OF KETTLE BODY HANDLE AT ALL TIMES, AND RETURN KE TTLE BODY TO UP RIGHT POS ITION AF TE R CONTAINER IS FILLED OR TRANS F ER IS CO MPLE TE .

6) DO NOT OVER FILL CONTA INER. AVOID DIRECT SKIN CONTA CT WITH HOT CONTAINER AND ITS CONTENTS.

CAUTIONS, AND SAFETY INSTRUCTIONS CONTAINED IN THIS

CAUTION: KEEP

WA RNING: FAILURE TO CHECK PRES SURE RELIEF VAL VE OPE RATION PERIODI CAL L Y

WARNING: WHEN TESTING, AVOID ANY EXPOSURE TO THE STEAM BLOWING OUT OF THE

WA RNING: TO AVOID INJURY, READ AND FOL L O W ALL PRECAUTIO NS STATE D ON THE

WARNING: BEFORE REPLACING ANY PARTS, DISCONNECT THE UNIT FROM THE ELECTRIC

FLOORS IN FRONT OF KETTLE WORK AREA CLEAN AND DRY. IF SPILLS

OCCUR,

COULD RESULT IN PERS O NAL INJURY AND/OR DAMAGE TO EQUIPM ENT.

PRESSURE RELIEF VA LVE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS.

LABEL OF THE WATER TREATMENT COMP O UND.

POWER SUPPLY.

CLEAN IMMEDIATELY, TO AVOID SLIPS OR FALLS.

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IMPORTANT — READ FIRST — IMPORTANT

WARNING: KEEP WATER AND SOLUTIONS OUT OF CONTROLS AND ELECTRICA L

EQUIPMENT. NEVER USE A HIGH PRESSURE HOSE TO CLEAN KETTLE SURFACES.

CA UTION: MOST CLEANERS ARE HARMFUL TO THE SKIN, EYES, MUCO US MEMBRANES

A ND CL O THING. PRECA UTIONS SHO UL D BE TAKEN. WEAR RUBBER GLOVES, GOGGLES OR FA CE S HIELD AND PROTECTIVE CLOTHING. CAREFULLY READ THE WA RNINGS AND F OL L O W THE DIRECTIONS ON THE LABEL O F THE CLEANER TO BE US ED.

CAUTION: USE

IMPORTANT: SERVICE PERFORMED BY OTHER THAN FACTORY AUTHORIZED PERSONNEL

OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY GROEN

THEIR AUTHORIZED DISTRIBUTORS CAN CAUSE OPERATOR INJURY AND

DAMAGE TO THE EQUIPMENT, AND WILL VOID ALL WARRANTIES.

WILL VOID WARRANTI ES.

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Table of Contents

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

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

INSPECTION & UNPACKING ............................................................. 6

INSTALLATION......................................................................... 7

INITIAL START-UP ...................................................................... 9

OPERATION .......................................................................... 10

SEQUENCE OF OPERATION ............................................................ 12

MAINTENANCE ....................................................................... 13

COMPONENT REPLACEMENT .......................................................... 16

CLEANING............................................................................ 18

TROUBLESHOOTING .................................................................. 20

PARTS LISTS ......................................................................... 21

SCHEMATICS ......................................................................... 30

SERVICE LOG ........................................................................ 32

REFERENCES ........................................................................ 33

WARRANTY .......................................................................... 34

Equipment Description

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The Groen TDB and TDBC are table top, tilting, steam jacketed kettles with a thermostatically controlled, self-contained, electrically-heat ed steam supply and appropriate controls, mounted on a sturdy base. Models TDB and TDBC are avai lable in 20 or 40 - quart capacity.

The body of the TDB and TDBC Kettle is constructed of stainless steel, w elded i nto one solid piece. The kettle is furnished with a reinforced rim and a butterfly shaped pouring lip. It has a steam jacket rated for a design pressure of 50 PSIG. K ettle finis h is 180 emery gri t on the inside and bright s emi-deluxe on the outs ide. A tilt handle on the TDB kettle and a handwheel crank on the TDBC kettle allows the operator to manually tilt the kettle body in a controlled manner. Pouring height accepts pans up to four inches hi gh on a table top.

A built-in steam generator, sized for the kettle capacity and heated by electricity , delivers steam into the jacket. “A irless” operation of the steam jacket permits uniform, efficient heat ing at temperatures as low as 150°F and as high as 295°F. I n additi on t o the adjustable thermostat for operating control, the unit has a tilt cut-off switch, low water cut-off, pressure relief valve, and high-limit pres sure switch as safety features. A heating indicator li ght, pressure gauge, and sight glass are provided for monitoring kett le operation.

A single electrical connecti on is requi red for installation. The unit may be ordered for use with 208/ 240 or 480 volt power. All kettles are wired for 208 volt, three-phase operat ion. For 240 volt, t hree-phase OR single-phase conversion, see the wiri ng diagrams and installation inst ructions i n this manual.

KETTLE CHARACTERISTICS

TDB-20 and TDBC-20 TDB-40 and TDBC-40 Kettle Capacit y 20 qts. 18.8 liters 40 qts . 37.6 liters Jacket Capacity 7 qt s . 6.6 liters 9 qts. 8.5 liters Diameter 14” 36 cm 16-1/2” 42 cm Depth 11” 28 cm 14-1/4” 36 cm K.W. at 208 V 6.3 10.8 K.W. at 240 V 8.4 14.4 K.W. at 480 V 6.3 12.0 Base Width 24” 60 cm 28” 60 cm Base Depth 16” 41 cm 16” 41 cm

Options available include:

1. Kit, cover and holder (P/N 139805, 20 quart - P/N 139806, 40 quart).

2. One-piece, lift-off cover (P/N 128003, 20 quart - P/N 128002, 40 quart).

3. Holder for Lift-off cover (P/ N 133837).

4. Basket i nsert (P/N 001159, 20 quart - P/N 001161, 40 quart).

5. Rice Strainer (P/N 005187, 20 quart - P/N 005186, 40 quart).

6. Stand that s upports the uni t and holds a pan in position for filling (Model TS-9).

7. Water fill swing faucet.

8. 316 stainless steel int erior (must be ordered wi th origi nal equipment order).

9. Agitators wi th motor drives (must be ordered wit h original equi pment order).

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Inspection & Unpacking

The unit will arrive in a heavy shi pping carton and will be attached to a s kid. Immediately upon receipt, inspect the cart on 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 TH E WAL LS O F THE C ARTON.

Carefully cut the polyes t er straps around the carton and detach the sides of the box from the skid. P ull the carton up off the unit.

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 provi ded at the top of the Service Log at t he back of this manual. Keep this manual on file and avai lable for operators t o use.

For TDB units, attach the tilt handle (normally shipped inside t he ket t le) by carefully threading it into the socket on the trunnion support. Be careful to avoid cross-threading the fine threads on the trunnion.

CAUTION THIS UNIT WEIGHS 140 TO 163 LB. (64 TO 74 KG). INSTALLER SHOULD OBTAIN HELP AS NEEDED TO LIFT THIS WEIGHT SAFELY.

When installation is to begi n, carefully cut the straps w hich hold the unit on t he s kid. Lift the unit straight up off the skid. Examine packing materials to be sure loose parts are not discarded with the materials.

NOTE: After handle installation on the ri ght hand side, retain the hardw are supplied wi th the unit for left hand installation.

Installation

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The Groen Kettle is provided with complete internal wiring. It is ready for immediate connection. A wiri ng diagram is provided i n this manual and on the inside of the control housing service panel. Any mechanical or electrical changes must be approved i n by Groen’s Food Service Engineering Department.

WARNING INSTALLATION OF THE KETTLE MUST BE DONE BY A CERTIFIED ELECTRICIAN OR GROEN AUTHORIZED REPRESENTATIVE QU ALIFIED TO WO RK WIT H E LEC TR ICIT Y . IMPROPER INSTALLATION CAN RESULT IN INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT.

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

1. Set the kettle in place and level it. The base should be securely fast ened to a table or work surface. Four 3/8”-16 N.C. threaded couplings are provided i n the base of unit. Installation under a ventilation hood is recommended.

2. Once the unit is anchored to a mounting surface, apply a small bead of silicone caulk around the perimeter of the kettle base and seal the joint.

3. Provide electrical power as s pecified on the electrical information plate attached t o the equipment. Observe local codes and/or The National Electrical Code i n accordance with ANSI/NFPA 70 - (current edition).

4. Standard equipment is shipped ready for 208V, 3-phase or 480V, 3-phase operation. Refer t o the wiring diagram located on the inside cover of the control box and the inst ruct ions below for conversion to si ngle-phase operation. A jumper wire and “conversion” label are included wit h the unit. They can be found in a plastic bag attached to the trunnion assembly ins ide the control box.

CAUTION

BEFORE ANY ELECTRICAL CONVERSION,

VERIFY THA T THE BRANCH CIRCUIT

WIRING IS ADEQUATE TO HANDLE ANY

INCREASE AMPERAGE REQUIRE MENTS.

REFER TO THE ELECTRICAL

SPECIFICATIONS LISTED BELOW.

a. For conversion from 208V, 3-phase to

208V or 240V 1-phase OR 480V, 3-phase to 480V, 1-phase:

i. Verify that the branch circuit w iring is

adequate for any increased amperage requirements (see table on page 8).

ii. For 240V 1-phase only, enlarge

electrical inlet opening for 1" condui t fitting. Use a 1" sealtite conduit fitting.

iii. 1-phase requires tw o jumper wires.

One jumper wire exists on t he terminal block for 3-phase input. The second jumper wire is located in a plastic bag i nside the control box.

iv. Attach jumper wire to terminal block

as per wi ring diagram for 1-phase supply.

v. For 240V 1-phase only

from 208V tab on control transformer and insert on 240V tab (See Photo #1).

vi . Complete “conversion label”

(supplied in bag) and adhere it to t he control box near t he UL dat aplate.

b. For conversion from 208V, 3-phase to

240V, 3-phase: i. Verify that the branch circuit w iring is

adequate for any increased amperage requirements (see table on page 8).

ii. Pull lead from 208V tab on control

transformer and insert on 240V tab. (See Photo #1)

iii. Complete “conversion label”

(supplied in bag and adhere it to t he control box near t he UL dataplate).

, pull lead

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c. For conversi on from 480V, 3-phase t o

460V, 3-phase: i. Verify that the branch circuit w iring is

adequate for any increase amperage requirements (see table on page 8).

ii. Complete “conversion label”

(supplied in bag and adhere it to t he control box near t he UL dataplate).

5. Bring incoming electrical service through the conduit fitting (for 240V 1-phase, a new one inch condui t fitti ng is requi red) at the rear of the support hous ing, making a watertight connection w ith the incoming lines. A BX style connection is not recommended.

TDB / TDBC SUPPLY WIRE REQUIREMENTS

THWN (75°) / THHN (90°) COPPER ONLY

DANGER ELECTRI CALLY GROUND THE UNIT A T THE TERMINAL PROVIDED. FAILURE TO GROUND UNIT COULD RESULT IN ELECTROCUTI ON AND DEATH.

6. Confirm that the jacket wat er level is at or just above mid point of sight glass (new models). If the level is low, follow the instruct ions under “Jacket Fi lli ng and Water Treatment” in the “Mai ntenance” section of the manual.

7. Ensure that the open end of the elbow on the outlet of the press ure reli ef valve is directed downward.

TDB-20, TDBC-20 TDB-40, TDBC-40

VOLTAGE AMPS

208V 1 PH

3 PH

240V 1 PH

3 PH 460V 3 PH 7.3 14 460V 3 PH 14 12 480V 1 PH

3 PH

31 18

35 20

SUPPLY

WIRE

14 14

VOLTAGE AMPS

208V 1 PH

3 PH

240V 1 PH

3 PH

480V 1 PH

3 PH

52 30

60 35

25 15

SUPPLY

WIRE

6 8

4 8

10 12

Photo #1

Pull lead fro m 208V tab and insert on 240V tab .

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Initial Start-Up

IMPORTANT: BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE OPERATING INSTRUCTI O NS, CAUTIONS, AND SAFE TY INSTRUCTIONS CONTAINED IN THIS MANUAL.

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

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

2. Turn on the electrical service to the unit.

3. Pour 1-2 quarts of water int o t he ket tle.

4. Following “To St art Kettle” ins tructions in the “Operation” section of this manual, begin heating the water at t he highest thermostat setting. The heati ng indicator light should come on immediately, and heating should continue until the w ater boils.

5. To shut down t he unit, turn the thermostat dial to “OFF”.

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.

If the uni t functions as des cribed above, it is ready for use. If the unit does not functi on as intended, first recheck power supply connections and, if necessary, contact your local Groen Certifi ed Service Agency.

WARNING

A simple turn of the thermostat controls the Groen

TDB and TDBC kettle.

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Model TDBC

Operation

The operator controls kettle heating with the thermostat dial. The dial turns heating element electric power on or off and sets the operating temperature of the kettle.

A. To Start Kettle

1. EVERY DAY make sure that t he jacke t water level i s above the mid-point of the round sight glass. If the l e vel is too low, see “Jacket Filling” and “Water Treatment” on page 14 of this manual.

2. Check the press ure gauge. If the gauge does not show 20 to 30 inches of vacuum (that is, a reading of 20 to 30 below 0), see “Jacket Vacuum” on page 13 of this manual.

3. Turn on the electrical power to the unit.

4. Turn the thermostat dial to the desired setting. The heating indicator light indicates that the kettle is heating, and cy cling of the light on and off indicates that the kettle is being h e ld at the set temperature. Once in each cycle the contactors in the support housing will make a clicking sound. This is normal.

Model TDB

B. To Transfer Product or Empty Kettle:

TDB: The kettle is designed an d

manufactured to be tilted i n a controll e d manner. Grasp the insulated plastic ball firmly. Maintain a firm grip on handle when tilting, while keeping kettle body i n a tilted pos ition and when SLOWLY return ing the kettle body to an upright position. DO NOT release kettle hand le when kettle is partly tilted. It will impact in either the upri ght or fully tilted position and may cause burns.

TDBC: The kettle is tilted using its crank ti lt

hand wheel. Turning the crank clockwise t ilts the kettle; counter-clockwise returns i t to an upright positi on. The kett le will remain in any cranked positi on.

WARNING

AVOID ALL DIRECT CONTACT WITH HOT SURFACES. DIRECT SKIN CONTACT COULD RESULT IN SEVERE BURNS.

AVOID ALL DIRECT CONTACT WITH HOT FOOD OR W ATER IN THE KETTLE. DIRE CT CONTACT COULD RESULT IN SEVERE BURNS.

On TDB and TDBC units, the jacket water l evel is

shown in a sight gl ass on the kettle body.

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 A L L O W CL EARANCE FOR STIRRING, BOILING PRODUCT AND SAFE TRANSFER.

WARNING

WHEN TILTING KETTLE FOR PRODUCT TRANSFER:

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) S TAND TO LEFT OR RIGHT OF KE TTLE

(DEPENDING ON HANDLE PLACEMENT) WHILE POURING — NOT DIRECTLY IN POUR PATH OF HOT CONTENTS.

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 CON TAINER. AVOID

DIRECT SKIN CONTACT WITH HOT CONTAINER AND ITS CONTENTS.

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Wear protectiv e oven mitts and a protective apron.

When putting the cover on the kettle, positio n it on top of kett le rim, with its flat edge facing the pouring lip.

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.

When removing cover:

a) Firmly grasp plastic handle b) Lift rear

2” (3-5 cm) to allow any steam and water vapor to es cape t he cooking vessel. Wait 2-3 seconds.

c) Tilt cover to 45-60° angle and allow any

hot condensate or product to roll off cover b ack into ke ttle.

edge (farthest from operator) 1-

CAUTION KEEP FLOOR S IN FRONT OF T HE KET TLE WORK AREA CLEAN AND DRY. IF SPILLS OCCUR, CLEAN AT ONCE TO AVOID SLIPS OR FALLS.

Common Accessories

1. Li ft Off Cover As with stock pot cooki ng, an optional lift off cover can speed up the heating of water and food products. A cover helps retain heat in the cooking vessel and reduces the amount of heat and humidity released into the kitchen. Use of a cover can reduce some product cook times and help maintain the temperature, color and texture of products bei ng held or simmered for extended peri ods.

Make sure the plast ic ball handle is secure on the lift off cover before us ing. ALWAYS use the plastic handle to place or remove cover from the kettle.

Lift the rear of the l id first.

d) Remove cover, ensuri ng that any

remaining hot condensate or product does not drip on operator, floor or work surfaces.

e) Place cover on safe, flat, sani t ary, out-

of-the-way surface, or return to kett le rim. Cover may also be placed in the optional holder for the cover as shown in the photograph.

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