Intek ELTM-100 Installation Manual

INSTALLATION AND OPERATION

MANUAL

ELECTRIC SELF GENERATING SINGLE AND TWIN STEAM MIXER KETTLE

MODELS: ELTM-40 & ELTM-40-2

ELTM-60 & ELTM-60-2 ELTM-80 & ELTM-80-2 ELTM-100 & ELTM-100-2

CROWN FOOD SERVICE EQUIPMENT LTD.

70 OAKDALE ROAD, DOWNSVIEW (TORONTO), ONTARIO, CANADA, M3N 1V9

TELEPHONE: (416) 746-2358, FAX: (416) 746-8324

PART NUMBER 10041R2 1 2008-08-11

PRINTED IN CANADA

INSTALLATION AND OPERATION MANUAL, ELECTRIC SELF GENERATING SINGLE AND

TWIN STEAM MIXER KETTLE, MODELS ELTM-40 TO 100 AND ELTM 40-2 TO 100-2

IMPORTANT NOTES FOR INSTALLATION AND OPERATION

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

WARNING: Improper installation, operation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operating and maintenance instructions thoroughly before installing, operating or servicing this equipment.

Adequate clearances must be maintained for safe and proper operation.

Intended for commercial use only. Not for household use.

This manual should be retained for future reference.

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INSTALLATION AND OPERATION MANUAL, ELECTRIC SELF GENERATING SINGLE AND

TWIN STEAM MIXER KETTLE, MODELS ELTM-40 TO 100 AND ELTM 40-2 TO 100-2

TABLE OF CONTENTS

DESCRIPTION PAGE

Important Notes for Installation and Operation ....................................2

1.0 Service Connections ....................................................4

2.0 Introduction ...........................................................6

3.0 Installation Instructions ...................................................9

4.0 Operation Instructions ..................................................11

5.0 Cleaning Instructions ...................................................15

6.0 Maintenance .........................................................19

7.0 Troubleshooting .......................................................22

Appendix A, Material Safety Data Sheet - Hydraulic Unit ............................28

Appendix B, Material Safety Data Sheet - Kettle ..................................33

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INSTALLATION AND OPERATION MANUAL, ELECTRIC SELF GENERATING SINGLE AND

TWIN STEAM MIXER KETTLE, MODELS ELTM-40 TO 100 AND ELTM 40-2 TO 100-2

1.0 SERVICE CONNECTIONS

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INSTALLATION AND OPERATION MANUAL, ELECTRIC SELF GENERATING SINGLE AND

TWIN STEAM MIXER KETTLE, MODELS ELTM-40 TO 100 AND ELTM 40-2 TO 100-2

1.0 SERVICE CONNECTIONS (Continued)

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INSTALLATION AND OPERATION MANUAL, ELECTRIC SELF GENERATING SINGLE AND

TWIN STEAM MIXER KETTLE, MODELS ELTM-40 TO 100 AND ELTM 40-2 TO 100-2

2.0 INTRODUCTION

DESCRIPTION

All electrically powered kettles described and referred to in this manual are pressure vessels of a double-wall construction forming a sealed jacket (chamber) enveloping the lower two thirds of the kettle bowl surface.

The kettle bowl is the container for the food product which ideally should be a liquid or semiliquid consistency to achieve complete contact with the bowl surface. Food products will fully absorb the heat transmitted through that surface from the pressurized steam generated in the kettle jacket.

The jacket is intended to function as a self contained sealed chamber with a permanent solution of water and antifreeze sufficient not only to immerse and thereby protect replaceable electric heating elements, but also provide the steam source during the steam generating process.

The heating elements are thermostatically controlled to provide precise temperatures throughout the range from slow simmer to rolling boil.

All tilting kettles are intended to be permanently floor mounted on legs with adjustable flanged feet.

A sealed stainless steel tilt mechanism permits the kettle to tilt forward a full 90° for complete emptying. The tilting mechanism is self locking for positive stop action.

MIXER FEATURES

CAPACITIES

All models are suffixed with either -40, -60, -80 or -100 to indicate the capacity of that kettle in US gallons. Models with the suffix -2 indicate a twin model. Thus a unit with suffix -40-2 has two 40 gallon kettles, one on each side of the mixer console. An ELTM-40 indicates a single 40 gallon kettle two thirds jacketed electrically powered steam kettle.

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INSTALLATION AND OPERATION MANUAL, ELECTRIC SELF GENERATING SINGLE AND

TWIN STEAM MIXER KETTLE, MODELS ELTM-40 TO 100 AND ELTM 40-2 TO 100-2

2.0 INTRODUCTION

FUNCTIONING MODE

All electrically powered self steam generating kettles consist of a jacket containing a permanent solution of water and antifreeze sufficient to completely immerse and protect replaceable electric heating elements.

To minimize tampering, the Safety Valve is plumbed toward the rear of the kettle jacket. Should any component malfunction and cause the pressure in the jacket to reach the rated pressure of the kettle, this protective device will open automatically and release excessive pressurized steam.

When the Power Switch is turned ON and the Temperature Control (Thermostat) Knob dialed, the TEMPERATURE pilot light will ignite and contactors will close to allow power to the elements. Steam generation will commence and continue until the preselected temperature is reached, at which point the contactors open, cutting off power to heating the elements. The TEMPERATURE pilot light will then extinguish. When the temperature of the water in the jacket drops slightly, the cycle will repeat itself thus making it possible to maintain any selected precise cooking mode temperature.

The temperature required for the cooking process to function adequately must be greater than the boiling point of the liquid food product. Further, the higher the temperature, the greater the steam pressure attained in the jacket and consequently the quicker the cooking process. For example, steam pressurized at 30 p.s.i. attains a temperature of 274º Fahrenheit.

Since air is an unsuitable media through which heat may be transferred, it has been removed from the kettle jacket during testing at the factory. The Pressure Gauge should indicate vacuum in the jacket in green zone on the gauge (approximately 20 - 25 inches Hg) when the kettle is cold or has been inoperative for some time. The kettle jacket is intended to function at all times as a completely sealed self-contained chamber and it is especially advisable not to trip the safety relief valve during inoperative periods since this will break the vacuum seal and allow air to enter the kettle jacket.

The Temperature Controls (thermostats) used in these kettles have been calibrated to prevent the heating elements from generating steam pressure that would exceed the rated working pressure of the kettle. In the unlikely event that the Temperature Control fails and the heating elements remain energized, the Safety Valve will blow and release the excessive pressure and steam from the jacket, consequently lowering the water level in the jacket. The Safety Probe sensing depletion of the water level in the kettle jacket will not only activate the LOW WATER level indicator pilot light, but also signal the Liquid Level Control to switch off power and deenergize the circuit to the heating elements (preventing element burn outs) until the water level is adequately replenished.

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INSTALLATION AND OPERATION MANUAL, ELECTRIC SELF GENERATING SINGLE AND

TWIN STEAM MIXER KETTLE, MODELS ELTM-40 TO 100 AND ELTM 40-2 TO 100-2

FUNCTIONING MODE (Continued)

The mixer is a variable speed unit powered by a 5 hp electric motor driving a hydraulic pump. Two heavy duty hydraulic motors drive the primary scraper/agitator and secondary high speed mixer. Both are removable without tools for cleaning. They are housed in a stainless steel bridge that is power tilt and swings 140° out of the way for tilting the kettles(s). Once the bridge has been lifted the agitators cannot be operated as a safety switch is activated. Bridge may now be moved out of the way or if a twin mixer, moved to the other kettle. The speed control is located on the front panel and may be set to the desired speed by turning. The maximum speed will not exceed 54 RPM on the smallest kettle and 40 RPM on the largest.

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INSTALLATION AND OPERATION MANUAL, ELECTRIC SELF GENERATING SINGLE AND

TWIN STEAM MIXER KETTLE, MODELS ELTM-40 TO 100 AND ELTM 40-2 TO 100-2

3.0 INSTALLATION INSTRUCTIONS UNPACKING

Immediately after unpacking, check for possible shipping damage. If the kettle is found to be damaged, save the packaging material and contact the carrier within 15 days of delivery.

INSTALLATION

Before installing, verify that the electrical service agrees with the specifications on the rating plate located on the right side of the tilt console. If the supply and equipment requirements do not agree, contact your dealer or Crown Food Service Equipment Ltd.

The kettle must be installed in accordance with State and/or local codes. In the USA, the National Electrical Code, ANSI/NFPA-70 (latest edition). In Canada, the Canadian Electrical Code, Part 1, CSA Standard C22.1 (latest edition).

1. Select a location to provide drainage for kettle pour path when tilted and for butterfly valve if so equipped. Allow sufficient rear clearance from wall for access to rear service panel on hydraulic console.

2. Level unit. With kettle in the upright position, place a carpenter’s level on top of the kettle and turn the adjustable feet to level kettle side-to-side and front to back. Mark hole locations on floor through anchoring holes provided in flanged adjustable feet.

3. Remove unit and drill holes where marked and insert expansion shields to accommodate 5/16" size lag bolts.

4. Reposition unit. Re-level kettle by making necessary adjustments on flanged feet.

5. Bolt down unit and seal with Silastic or equivalent sealing compound. Sealant must be applied not only to bolt heads but also around flanges making contact with the floor surface to fulfil NSF requirements. Wipe off excess sealant immediately.

6. Connect water drain line from cooling system to drain or return line.

7. Connect cold water supply line for cooling system as indicated in bottom of hydraulic console.

8. The relief valve on the kettles(s) must not be adjusted or closed off as they are set to relieve excess pressure in the kettle(s).

9. Do not make any adjustments to the hydraulic system as it has been set at the factory.

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INSTALLATION AND OPERATION MANUAL, ELECTRIC SELF GENERATING SINGLE AND

TWIN STEAM MIXER KETTLE, MODELS ELTM-40 TO 100 AND ELTM 40-2 TO 100-2

3.0 INSTALLATION INSTRUCTIONS

ELECTRICAL CONNECTIONS

A control box with a power supply equivalent to the electrical rating of the unit should be located nearby. A waterproof electrical connection for the power supply to the unit must be provided.

Remove the back panel of the hydraulic console and make electrical connection per wiring diagram located inside the console in plastic bag attached to tank. A waterproof electrical connection from power supply to rear of hydraulic console must be provided.

Ground kettle to terminal provided in the hydraulic console. Once proper connections are made, replace the back panel on hydraulic console, turn power

ON and check for proper operation.

SERVICE CONNECTIONS

All internal wiring for the kettle and hydraulic power unit is complete. Connect water supply for cooling system as shown in Service Connections. If faucet is provided connect water supply and check for proper operation.

INSTALLATION CODES AND STANDARDS

Your electric mixing kettle must be installed in accordance with:

1. Provincial and local codes, or in the absence of local codes, with C.S.A. C22.1 Canadian Electrical Code, Part 1, or in the U.S.A., the National Electrical Code ANSI/NFPA-70 (latest edition).

2. ANSI NFPA Standard #96 “Vapour Removal from Cooking Equipment”, (latest edition), available from the National Fire Protection Association, Batterymarch Park, Quincy, MA,

02269.

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INSTALLATION AND OPERATION MANUAL, ELECTRIC SELF GENERATING SINGLE AND

TWIN STEAM MIXER KETTLE, MODELS ELTM-40 TO 100 AND ELTM 40-2 TO 100-2

4.0 OPERATION INSTRUCTIONS

WARNING: The kettle and its parts are hot. Use care when operating, cleaning and servicing the kettle.

KETTLE

Ensure that the external electrical service to kettle is on. Check pressure gauge for correct cold kettle reading. Reading should be in the green area of

the gauge indicating 25 - 30 In. Hg (630 - 730 mm Hg) of vacuum. If reading is not low enough, follow VENTING procedure in Troubleshooting section prior to using kettle.

Place power switch to ON position. Preheat kettle by placing thermostat knob at ‘10' and wait until TEMPERATURE light goes off.

NOTE: Preheating should not be used when cooking milk and egg food products which adhere to hot cooking surfaces. These foods should be placed into kettle before heating has begun.

Add food to be cooked into kettle. Place thermostat knob at required temperature setting from 1 to 10 coinciding with the following

table:

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INSTALLATION AND OPERATION MANUAL, ELECTRIC SELF GENERATING SINGLE AND

TWIN STEAM MIXER KETTLE, MODELS ELTM-40 TO 100 AND ELTM 40-2 TO 100-2

4.0 OPERATION INSTRUCTIONS (Continued)

THERMOSTAT SETTING APPROXIMATE (JACKET) TEMPERATURE

1 140° Fahrenheit 60°Celsius 2 155° Fahrenheit 68°Celsius 3 172° Fahrenheit 78° Celsius 4 187° Fahrenheit 86 °Celsius 5 205° Fahrenheit 96° Celsius 6 223° Fahrenheit 106° Celsius 7 240° Fahrenheit 116° Celsius 8 255° Fahrenheit 124° Celsius 9 271° Fahrenheit 133° Celsius

10 285° Fahrenheit 140° Celsius

When cooking is finished set thermostat knob and power switch to OFF position. Pour finished product from kettle using tilt handle. Be careful to avoid splashing. Add water to kettle for cleaning purposes. Wash kettle thoroughly. See CLEANING procedure, next section.

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INSTALLATION AND OPERATION MANUAL, ELECTRIC SELF GENERATING SINGLE AND

TWIN STEAM MIXER KETTLE, MODELS ELTM-40 TO 100 AND ELTM 40-2 TO 100-2

4.0 OPERATION INSTRUCTIONS

OPERATION OF MIXER UNIT

Power to operate the mixer unit is controlled by the “Main Power” switch located on the left side of the control panel. Ensure that mixer “speed” control is set to the “stop” position. Place switch in the “ON” position. Set the mixer switch, located beside the main power switch, to “ON” position. Note that the agitators should not be turning. The speed control has four basic settings which are: stop, slow, medium and fast. Set the speed control to the slow position and observe that the agitators begin to turn.

CAUTION: Never place hands inside kettle when agitators are in motion.

Increasing the speed setting on the control will increase the speed at which the agitators turn.

NOTE: Always start agitators at the slow speed and then gradually increase to the desired speed to avoid splashing or “throwing” the product over edge of kettle.

TO RAISE MIXER BRIDGE

To tilt kettle for emptying or to clean agitators, the mixer bridge will tilt hydraulically upward and manually swing clear of the kettle. To do this, first turn speed control to “STOP” and then turn mixer switch to “OFF”.

NOTE: Mixer agitator arms must be stopped at 90 degrees to the mixer bridge before raising the bridge. If the agitator arms do not stop in this position when speed selector is set to stop, then “jog” the selector on and off to achieve this position.

Push the “TILT” switch to the “RAISE” position and hold. Bridge will raise to maximum height. Bridge will stop at any position if the tilt switch is released and will remain in that position until switch is pushed to either raise or lower. When the bridge is fully raised it can be manually turned to the side to be clear of the kettle.

PART NUMBER 10041R2 13 2008-08-11

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