Intek GL-40E Installation Manual
INSTALLATION AND OPERATION
MANUAL
GAS KETTLES
MODELS: GL-20E
GL-40E
GL-60E
CROWN FOOD SERVICE EQUIPMENT LTD.
70 OAKDALE ROAD, DOWNSVIEW, (TORONTO), ONTARIO, M3N 1V9
TELEPHONE: (416) 746-2358, FAX: (416) 746-8324
PART NUMBER 10125R2 1 2006-06-13
PRINTED IN CANADA
INSTALLATION AND OPERATION MANUAL, GAS KETTLES, GL-20E, 40E, GL-60E
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.
FOR YOUR SAFETY: Do not store or use gasoline or other
flammable vapours or liquids in the vicinity of this or any other
appliance.
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.
PURCHASER: Instructions to be followed in the event that the operator of this
appliance smells gas must be posted in a prominent location. This information
shall be obtained by consulting the local gas supplier.
Do not obstruct the flow of combustion and ventilation air.
Keep the appliance area free and clear from combustibles.
Adequate clearances must be maintained for servicing and proper operation.
Do not attempt to operate this unit in the event of a power failure.
Intended for commercial use only. Not for household use.
This manual should be retained for future reference.
PART NUMBER 10125R2 2 2006-06-13
INSTALLATION AND OPERATION MANUAL, GAS KETTLES, GL-20E, GL-40E, GL-60E
TABLE OF CONTENTS
DESCRIPTION PAGE
Important Notes for Installation and Operation ....................................2
1.0 Service Connections ....................................................4
2.0 Installation ............................................................5
3.0 Performance Check ....................................................10
4.0 Operation ............................................................11
5.0 Maintenance .........................................................17
6.0 Service ..............................................................22
Adjustments .............................................................24
Troubleshooting ..........................................................30
Appendix ‘A’, Material Safety Data Sheet .......................................32
PART NUMBER 10125R2 3 2006-06-13
INSTALLATION AND OPERATION MANUAL, GAS KETTLES, GL-20E, GL-40E, GL-60E
1.0 SERVICE CONNECTIONS
PART NUMBER 10125R2 4 2006-06-13
INSTALLATION AND OPERATION MANUAL, GAS KETTLES, GL-20E, GL-40E, GL-60E
2.0 INSTALLATION
INSTALLATION CODES AND STANDARDS
Installation must conform with local codes, or in the absence of local codes, with the National
Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code,
CSA B149.1, as applicable.
1. The appliance and its individual shut off valve must be disconnected from the gas supply
piping system during any pressure testing of that system at pressures in excess of ½ psi
(3.5 kPa).
2. The appliance must be isolated from the gas supply piping system by closing its individual
manual shut off valve during any pressure testing of the gas supply piping system at test
pressures equal to or less than ½ psi (3.5 kPa).
Electrical grounding must be provided in accordance with local codes, or in the absence of local
codes, with the National Electrical Code, ANSI/NFPA 70, or the Canadian Electrical Code, CSA
C22.2, as applicable.
The electrical diagram is located on the inside of the console control cover.
EXHAUST FANS AND CANOPIES: Canopies are set over ranges, ovens and kettles for
ventilation purposes. It is recommended that a canopy extend 6" past appliance and be located
7.5 feet from the floor. Filters should be installed at an angle of 45 degrees or more with the
horizontal. This position prevents dripping of grease and facilitates collecting the run-off grease
in a drip pan, usually installed with the filter. A strong exhaust fan tends to create a vacuum in
the room and may interfere with burner performance or may extinguish pilot flames. Makeup
air openings approximately equal to the fan area will relieve such vacuum. In case of
unsatisfactory performance on any appliance, check operation with exhaust fan in the “OFF”
position.
WALL EXHAUST FAN: The exhaust fan should be installed at least 2 feet above the vent
opening at the top of the unit.
CLEARANCES: Adequate clearance must be provided in aisle and at the side and back.
Adequate clearances for air openings into the combustion chamber must be provided, as well
as for serviceability.
SIDES - 6 INCHES
BACK - 2 INCHES AT FLUE BOX
FLOORS - 6 INCH LEGS OR 8 INCH LEGS
All units must be installed in such a manner that the flow of combustion and ventilation air are
not obstructed. Provisions for an adequate air supply must also be provided. Do not obstruct
the lower front or right side of the unit, as combustion air enters through these areas. The
bottom of the control area must also remain unobstructed.
PART NUMBER 10125R2 5 2006-06-13
INSTALLATION AND OPERATION MANUAL, GAS KETTLES, GL-20E, GL-40E, GL-60E
2.0 INSTALLATION (Continued)
TO INSTALL
1. Uncrate carefully. Report any hidden freight damage to the freight company immediately.
2. Set the unit in place. Be certain to maintain minimum clearances as stated above.
3. To level the unit use a spirit level in all directions on the top of the kettle (lid up).
1. Units with legs - adjust the bottom foot on each leg to overcome an uneven floor.
2. Units with casters - loosen the locking nuts, turn casters in or out as required and
tighten locking nuts.
4. Be certain to leave adequate clearances for cleaning, maintenance and service.
5. The pressure relief valve is located at the left rear of the unit. This area should be kept
clear and should not be in an area where operators will normally stand. The elbow on the
relief valve should be turned toward the floor. A maximum 3 foot, 3/4" diameter pipe may
be used to extend to the floor, but must not be piped directly to a drain. It must vent to the
atmosphere.
6. Check the pressure gauge on the front panel before operating. If the pressure gauge does
not indicate green vacuum zone (below 0 psi), see “Re-establishing Vacuum” section under
SERVICE, after completing installation instructions.
GAS CONNECTION
The serial plate on the lower right side of the unit indicates the type of gas your unit is equipped
to burn. Do NOT connect to any other gas type.
A 1" NPT line is provided at the rear for the connection. Each unit is equipped with an internal
pressure regulator which is set for 4" W.C. manifold pressure for natural gas and 10" W.C. for
propane gas. Use 1/8" pipe tap on the burner manifold for checking pressure.
An adequate gas supply is imperative. Undersized or low pressure lines will restrict the volume
of gas required for satisfactory performance. A steady pressure, minimum 6" W.C. for natural
gas and minimum 11" W.C. for propane gas, is recommended. With all units operating
simultaneously, the manifold pressure on all units should not show any appreciable drop.
Fluctuations of more than 25% on natural gas, and 10% on propane gas, will create pilot
problems and affect burner operating characteristics. Contact your gas company for correct
supply line sizes.
PART NUMBER 10125R2 6 2006-06-13
INSTALLATION AND OPERATION MANUAL, GAS KETTLES, GL-20E, GL-40E, GL-60E
2.0 INSTALLATION (Continued)
Purge the supply line to clean out any dust, dirt, or other foreign matter before connecting the
line to the unit. It is recommended that an individual manual shut off valve be installed in the
gas supply line to the unit. Use pipe joint compound which is suitable for use with LP gas on all
threaded connections. Test pipe connections thoroughly for gas leaks.
WARNING: All connections must be checked for leaks, after the unit
has been put in operation. Use soapy water only for testing on all
gases. Never use an open flame to check for gas leaks.
NOTICE: If applicable, the vent line from the gas appliance pressure regulator
shall be installed to the outdoors in accordance with local codes or, in the
absence of local codes, with the National Fuel Gas Code, ANSI Z223.1/NFPA 54,
or the Natural Gas and Propane Installation Code CSA B149.1, as applicable.
NOTICE: If this equipment is being installed at over 2,000 feet altitude and was
not so specified on order, contact service department. Failure to install with
proper orifice sizing may void the warranty.
WATER CONNECTION
On units equipped with an optional water fill valve connect a water line (minimum 1/4") to the
valve with a 1/4" NPT female fitting. Units with dual (hot and cold) valves must have the hot
water line connected to side with the hot water valve (red) and cold water line to the cold water
valve (blue). Plastic or rubber hose is not recommended, as it may melt against the hot kettle
side.
PART NUMBER 10125R2 7 2006-06-13
INSTALLATION AND OPERATION MANUAL, GAS KETTLES, GL-20E, GL-40E, GL-60E
2.0 INSTALLATION (Continued)
WARNING: For an appliance equipped with casters, the installation
shall be made with a connector that complies with the standard for
connectors for moveable gas appliances, ANSI Z21.69-CSA 6.16
and a quick-disconnect device that complies with the standard
for quick-disconnect devices for use with gas fuel, ANSI Z21.41CSA 6.9; adequate means must be provided to limit the movement
of the appliance without depending on the connector and the quick
disconnect device or its associated piping to limit the appliance
movement; the location where the restraining means may be
attached to the appliance is on bottom of unit directly below relief
valve.
If the unit is also equipped with an optional water fill valve it too
must be installed with a flexible water supply tube, a quick
disconnect and strain relief.
WARNING: Do not connect the appliance to the electrical supply
until after the gas connection has been made.
1. 120 VAC - 60 Hz - Single Phase.
Units with this electrical rating are factory supplied with a three-wire cord and three-prong
plug which fits any standard 120V, three-prong grounded receptacle. A separate 15 amp
supply is needed for each unit.
PART NUMBER 10125R2 8 2006-06-13
INSTALLATION AND OPERATION MANUAL, GAS KETTLES, GL-20E, GL-40E, GL-60E
2.0 INSTALLATION (Continued)
WARNING: ELECTRICAL GROUNDING INSTRUCTIONS
This appliance is equipped with a three-prong (grounding) plug for
your protection against shock hazard and should be plugged
directly into a properly grounded three-prong receptacle. Do not cut
or remove the grounding prong from this plug. (120V units only).
2. 208/240 VAC - 60 Hz - Single and Three Phase.
Units with this electrical rating are factory equipped with a transformer. To connect supply
wires remove cover from transformer box at right rear of unit. Route supply wires and
ground wire through the hole in the cover with a strain relief fitting. Connect wires to the
primary transformer terminals as required by your power supply voltage. Connect ground
wire to ground lug. Replace cover. Three-phase units are wired as above, using only two
supply wires. The third supply wire is not connected and must be properly terminated.
3. 220 VAC - 50 Hz - Single Phase.
Units equipped with this voltage rating should be wired exactly as in (2) above.
PART NUMBER 10125R2 9 2006-06-13
INSTALLATION AND OPERATION MANUAL, GAS KETTLES, GL-20E, GL-40E, GL-60E
3.0 PERFORMANCE CHECK
The following items should be checked before or within the first 30 days of operation by a
qualified service technician.
1. Verify correct gas type.
2. Verify correct voltage, cycle and phase.
3. Gas pressure.
4. Internal gas connections.
5. Internal electrical connections.
6. Pilots - adjustment and ignition.
7. Burners - adjustment and ignition.
8. Thermostat - cycle for operation check.
9. Supply valve - check for operation.
10. Check hinge and lid assembly.
11. Draw-off valve - check operation.
12. Advise user on cleaning procedures.
PART NUMBER 10125R2 10 2006-06-13
INSTALLATION AND OPERATION MANUAL, GAS KETTLES, GL-20E, GL-40E, GL-60E
4.0 OPERATION
Contact the factory, the factory representative or a local service company to
perform maintenance and repairs should the appliance malfunction.
WARNING: In the event of main burner ignition failure, a 5 minute
purge period must be observed prior to re-establishing ignition
source.
WARNING: In the event you smell gas, shut down equipment at the
main shut off valve and contact the local gas company or gas
supplier for service.
CAUTION: If you smell gas during the lighting procedure,
immediately shut off the gas supply until the leak has been
corrected.
GAS CONTROL INSTRUCTIONS:
Appliance does not require “Lighting” the pilot with a flame.
A. START-UP
1. Turn thermostat to “OFF” position and power switch to “OFF” position.
2. Open control panel access door located on right side at bottom.
3. Turn dial on combination control to “ON” position by rotating control knob
counterclockwise. (NOTE: Any gas service valves exterior to the unit should be open.)
4. Turn “POWER” switch to “ON” position.
5. Set “COOK TEMP” to desired setting. The red “COOKING” pilot will be on until desired
setting has been reached.
6. At this time the spark igniter will begin sparking at the pilot until the pilot is ignited, or for
ninety seconds (an audible clicking sound will be evident).
PART NUMBER 10125R2 11 2006-06-13
INSTALLATION AND OPERATION MANUAL, GAS KETTLES, GL-20E, GL-40E, GL-60E
4.0 OPERATION (Continued)
GAS CONTROL INSTRUCTIONS: (Continued)
7. When the pilot is ignited the spark igniter will automatically stop and within 15 seconds
main burner gas will come on. If ignition does not occur, after a total of ninety
seconds, the unit will lockout, shutting off all gas although the spark igniter will
continue to spark. New installations (where there may be a considerable amount of air
in the gas line) may require the unit to be turned off and immediately back on
numerous times after each lockout period until the air is purged from the gas line.
B. SHUTDOWN
1. STANDBY
1. Place power on switch and thermostat to “OFF” position.
2. COMPLETE
1. Place power on switch and thermostat to “OFF” position.
2. Turn dial on combination control from “ON” position to “OFF” position.
3. Turn any main gas service valves supplying gas to “OFF” position.
C. RELIGHTING
1. Turn power switch to “ON” position.
It should be noted that the pilot and electronic ignition do not cycle with the thermostat. A
standing pilot is automatically established and monitored each time the power switch is turned
ON. If the pilot is ever extinguished by a momentary external interruption, the spark igniter will
automatically relight it without disturbing the cooking cycle, unless lockout occurs.
PART NUMBER 10125R2 12 2006-06-13
INSTALLATION AND OPERATION MANUAL, GAS KETTLES, GL-20E, GL-40E, GL-60E
4.0 OPERATION (Continued)
SPARK IGNITER FAILURE:
In the event the spark igniter module fails the unit may still be operated by carefully following
these instructions.
1. Turn thermostat to OFF position; completely counterclockwise.
2. Turn power switch to OFF position.
3. WAIT A MINIMUM OF 5 MINUTES BEFORE PROCEEDING.
4. Turn dial on combination control to ON position (if not already on).
5. Turn power switch to ON position.
6. Wait two minutes and ten seconds and then immediately light pilot with long match or taper.
7. After 10 - 15 seconds gas valve will allow main burner gas to flow when thermostat is turned
on.
8. The pilot will now stay ignited as long as the power switch remains ON. If power switch is
turned OFF, repeat the above instructions. It is intended that the unit be operated in this
manner only in emergency situations and only while it is attended (do not leave pilot lit
overnight; shut off power switch). A qualified serviceman must be called promptly.
PART NUMBER 10125R2 13 2006-06-13
Loading...