Keating Of Chicago 2009 User Manual

1-800-KEATING
www.keatingofchicago.com
Users Manual
CUSTOM PASTA®SYSTEM ELECTRIC SERIES 2009
READ AND SAVE THIS MANUAL FOR FUTURE REFERENCE.
SECTION I: I NTRODUCTION . . . . . . . . . . .. . . . . . . . . . . . . . 1
SECTION II: INSTALLATION
SHIPMENT AND TRANSIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
A. POSITIONING, LEVELING, & RESTRAINING DEVICES . . . . .4
B. ELECTRICAL CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
C. WATER & DRAIN CONNECTION . . . . . . . . . . . . . . . . . . . . . . . .4
SECTION I II: OPE RATION
FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
THERMOSTATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
CONTROL PANEL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
THE AUTO-FILL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
COOKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
DRAINING & CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
ELECTRONIC (DIGITAL) TIMERS . . . . . . . . . . . . . . . . . . . . . . . . .7-8
SECTION IV: MAI NTENANCE
WARRANTY REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9
AUTO-FILL & SAFETY SHUT OFF . . . . . . . . . . . . . . . . . . . . . . . . . . .9
SENSOR TUBE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
SECTION V: SERVICE DIAGNOSIS
AUTO-FILL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
COOKER HEATING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . . . . . .11-12
SECTION VI: PARTS LIST
ORDERING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
CONTROL PANEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
SECTION VI I: WIR ING DIAGRAM S
14" ELECTRIC PASTA WITHOUT TIMERS . . . . . . . . . . . . . . . . . .15
14” ELECTRIC PASTA WITH DIGITAL TIMERS . . . . . . . . . . . . . .16
14" ELECTRIC PASTA WITH 138 (BLACK DIAL) TIMERS . . . .17
14” ELECTRIC PASTA WITH
BASKET-LIFT & DIGITAL TIMERS . . . . . . . . . . . . . . . . . . . . . . . . . .18
18" & 20" ELECTRIC PASTA WITH
(BLACK DIAL) 138 TIMERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
18" ELECTRIC PASTA, 2-THERMOSTATS
WITHOUT TIMERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
24” ELECTRIC PASTA WITH DIGITAL TIMERS . . . . . . . . . . . . . .21
WARRANTY
KEATING WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
CONTENTS:
IMPORTANT:
Keep a copy of your bill of sale. The date on the bill establishes the warranty period should service be required. If service is performed, it is in your interest to obtain and keep all receipts. Keating Custom Pasta Systems
®
are not intended for household use.
This Owner’s Guide provides specific operating and service instructions for your model. Use the Custom Pasta Systems
®
only as instructed in this Service Manual.
PastaElectric
03/11
part# 024763
RECORD THE MODEL AND SERIAL
NUMBERS OF THIS CUSTOM PASTA
®
SYSTEM IN THE SPACES PROVIDED.
SERIAL NO. ______________________________
MODE L NO. _____________________________
KEEP THESE NUMBERS FOR FUTURE RE FER ENCE.
i
This operating, installation, and service manual should be given to the user. The operator of the Custom Pasta
System should be familiar with the functions and operation of the cooker. This manual must be kept in a prominent, easily reachable location near the Pasta System.
POST THIS LABEL IN A
PROMINENT LOCATION ON
YOUR UNIT
Using any parts other than genuine, Keating of Chicago, Inc. factory
manufactured part relieves the manufacturer of all warrant and liability.
Keating of Chicago, Inc. manufacturer reserves the right to change
specifications at any time.
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.
FOR YOUR SAFETY
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
WARNING
Improper installation
can cause damage,
injury or death.
ShockBurnsGas
WARNING
Do not store flammable
liquids near this or any
other appliance.
1
I INTRODUCTION
Instructions in this manual should be read thoroughly before attempting to operate this Keating Electric Pasta Cooker. All installation and service on Keating Equipment must be performed by qualified, certified, licensed and/or authorized installation or service personnel.
Operating information for Keating equipment has been prepared for use by qualified and/or authorized personnel.
Keating equipment is made in the U.S.A. and has American sizes of hardware. All meteric conversions are approximate.
GENERAL
Keating Electric Custom Pasta™Systems are designed to give maximum production efficiency, delivering high quality food products. The following design features are incorporated in Keating Pasta Electric Systems.
STANDARD FEATURES
Highly polished stainless steel vessel
Highly polished stainless steel front
Highly polished stainless steel elements
Highly polished stainless steel thermostat bulb
Highly polished stainless steel Hi-Limit sensor
Grid screen over elements
Automatic water fill with manual override
Water solenoid and indicating light
Starch overflow
Two electronic timers
Low water safety shutoff
1" full port front drain valve on 14; 1
1
/4" for 18 and larger
High temperature limit control with manual reset
Patented accurate temperature control system ±2°F
Ideal 35" working height
One pair of perforated split baskets or one bulk basket
Patented dual thermostat system
Indicating lights for pilot and secondary thermostat on
STANDARD ACCESSORIES
Keating Klenzer Sample
Drain clean out rod
Sensor Cleaning Brush
STANDARD PASTA SYSTEMS
Sizes: 14” to 24”
Water capacity 51/2 to 24 gallons
24” Pasta System can cook 6 lbs. of dry pasta per load up to 110 lbs. per hour
NSF certified
ETL Certified listed
ETL Sanitation Certified listed
MODEL VARIATIONS
Basket-Lift Model: Basket-Lift Model Pasta Systems
come with all the same features as the standard models. The Basket-Lift mechanism lowers the baskets of food into the water when the timer button is pressed and raises the baskets when the cooking cycle is complete. Split baskets are required for these models.
SPECIFICATIONS
MODEL kW @ 240V
AMPS
SHIP WT.
3P 1P
14 15.5 32-56-32 65 140 lbs
18 21.4 52-52-52 89 215 lbs.
20 21.4 52-52-52 89 235 lbs.
24 28.6 79-79-52 119 285 lbs.
MODEL CAPACITY HEIGHT DEPTH WIDTH
14 7 gal. 461/2" 311/8" 153/8"
18 10 gal. 461/2
"
331/8
"
193/8
"
20 17 gal. 461/2" 351/8" 213/8"
24 24 gal. 461/2" 391/8" 253/8"
SAFETY PRECAUTIONS
THIS SYMBOL WARNS YOU THAT SERIOUS BURNS OR OTHER INJURIES MAY RESULT IF SAFETY INSTRUCTIONS ARE NOT FOLLOWED.
This service manual should be retained in a safe place for future reference. The installation of your new Pasta System must conform to local codes and with the current National Electrical Codes and regulations as applicable.
Your ventilation hood, when installed, must conform to the current standards.
No frame or restriction shall be constructed around the Custom Pasta System that will restrict air movement into the Pasta System or prevent proper ventilation.
You must maintain this appliance free and clear from combustibles.
Adequate clearance for servicing and proper operation must be maintained. Your pasta system is designed to be serviced from the front.
Keating Custom Pasta
Systems are not intended for household use. Installation in household voids warranty.
ALWAYS instruct new employees on proper pasta system operation.
A Custom Pasta System™should be operated ONLY by properly trained personnel.
ALWAYS turn pasta system off each night.
ALWAYS turn pasta system off at customer power panel before servicing.
NEVER leave a pasta system unattended during operation.
NEVER move a pasta system when full of hot water.
NEVER introduce objects or liquids into pasta system, while operational, which are not designed or made for cooking.
THIS CUSTOM PASTA™SYSTEM MAY NOT BE ALTERED, MODIFIED OR CHANGED IN ANY WAY.
IF THE EQUIPMENT IS NOT INSTALLED, OPERATED AND MAINTAINED IN ACCORDANCE WITH THE ABOVE, CONCENTRATIONS OF CARBON MONOXIDE IN EXCESS OF THE ESTABLISHED LIMITS COULD BE PRESENT IN THE KITCHEN ENVIRONMENT.
ALL PERSONNEL IN THE WORK PLACE WHO MAY BE SUBJECT TO ANY EXPOSURE OF CARBON MONOXIDE MUST BE WARNED OF SUCH POSSIBLE EXPOSURE. THIS WARNING SHOULD BE CONVEYED IN A MANNER SO THAT IT IS CLEARLY UNDERSTOOD BY THE EMPLOYEE, AND THE EMPLOYEE SHOULD BE ASKED IF IN FACT HE OR SHE UNDERSTANDS THE CORRECT METHOD OF OPERATION OF THE EQUIPMENT AND THAT A RISK OF EXPOSURE EXISTS IF THE EQUIPMENT IS OPERATED IMPROPERLY.
IF NOT INSTALLED, OPERATED AND MAINTAINED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS, THIS PRODUCT COULD EXPOSE YOU TO SUBSTANCES IN FUEL OR IN FUEL COMBUSTION WHICH CAN CAUSE DEATH OR SERIOUS ILLNESS AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
2
WARNING
Improper installation
can cause damage,
injury or death.
ShockBurnsGas
3
II INSTALLATION
This Custom Pasta™System MUST be installed, inspected, calibrated and serviced by qualified and/or certified and/or licensed service personnel – you may void your Keating warranty if installation is not completed per current local, national and Keating specifications. Contact your dealer for assistance.
DAMAGE DURING SHIPMENT
The Custom Pasta™System has been assembled, tested and inspected at the factory. Upon arrival, the complete Pasta System should be checked for any damage that may have occurred during shipment.
IF EQUIPMENT ARRIVES DAMAGED
Keating does not assume responsibility for loss or damage incurred in transit.
IMPORTANT
This merchandise has been thoroughly inspected and carefully packed before leaving our plant. Responsibility for its safe delivery was assumed by the carrier at the time of shipment. Claims for loss or damage to the contents should, therefore, be made upon the carrier, as follows:
CONCEALED LOSS OR DAMAGE
Concealed loss or damage means loss or damage which does not become apparent until the merchandise has been unpacked. The contents may be damaged in transit due to rough handling even though the carton may not show external damage. When the damage is discovered upon unpacking, make a written request for inspection by the carrier’s agent within fifteen days of the delivery date. Then file a claim with the carrier since such damage is the carrier’s responsibility. By following these instructions carefully, we guarantee our full support of your claims to protect you against loss from concealed damage.
VISIBLE LOSS OR DAMAGE
Any external evidence of loss or damage must be noted on the freight bill or express receipt, and signed by the carrier’s agent. Failure to adequately describe such external evidence of loss or damage may result in the carrier refusing to honor a damage claim. The form required to file such a claim will be supplied by the carrier.
DO NOT RETURN DAMAGED MERCHANDISE TO KEATING. FILE YOUR CLAIM AS ABOVE.
IT MAY BE NECESSARY TO INSTALL A BACK FLOW OR CHECK VALVE ON THE WATER SUPPLY LINE TO THE PASTA COOKER. CHECK WITH EITHER YOUR LOCAL WATER OR HEALTH DEPARTMENT TO DETERMINE IF THIS IS NECESSARY IN YOUR SPECIFIC AREA.
DROP-IN PASTA COUNTER
CUTOUT/INSTALLATION
INSTALLATION NOTES
1. Minimum of 130 sq. in. unobstructed vent area near pasta cooker required for combustion.
2. All Drop-In Pasta must be 16” from any open flame.
3. Pasta must be located no more than 5” from counter top front.
4. Cabinet must be reinforced to support full weight of past in use (pasta, water, food, etc.).
5. Pasta cooker must be properly ventilated and located under an exhaust hood.
DROPPING THE PASTA COOKER INTO THE
It is only necessary to place the pasta cooker in such a position that the front edge overlaps the front raised edge of the opening.
COUNTER TOP
WARNING
Improper installation
can cause damage,
injury or death.
ShockBurnsGas
4
Push the fryer forward as far as it will go holding the fryer on approximately a 15° angle, and then drop the rear of the pasta cooker into its proper position lowering it down gently so you do not deform the table or equipment stand.
POSITIONING
The pasta cooker must be no closer than 6" from any combustible material. When placed under an exhaust hood with a fire retardant system it must comply with ANSI/UL 507-(Latest Edition) and ANSI/NFPA 96­(Latest Edition). No frame or restriction can be constructed around the lower part of the pasta cooker that would restrict ventilation or air movement into the pasta cooker. You must insure adequate air supply to the pasta cooker.
Adequate clearance for servicing and proper operation must be maintained. Your pasta cooker is designed to be serviced from the front. Do not place a pasta cooker next to a deep fat fryer. Hot oil and water can cause an unstable condition creating a hazardous situation.
LEVELING
The Pasta System will operate at its highest efficiency when properly leveled. Place a level on Pasta System vessel from side to side. For Pasta Systems on legs, the bottom foot of the leg is adjustable. Turn counter clockwise to decrease height or clockwise to increase height until level. For Pasta Systems on casters, the casters are adjustable by loosening the jam nut and turning the caster in or out. When the desired level is reached, tighten the jam nut. Adjustments of more than
3
/4" are not recommended on any caster. The same procedure should be followed to level the Pasta System from front to back.
Figure 2-1
RESTRAINING DEVICES
On Custom Pasta
System installations with casters, casters and jam nuts must be completely tightened. Adequate means must also be provided to limit the movement of the appliance without depending on the connector, the quick-disconnect device or its associated piping to limit the appliance movement.
Connectors must comply with ANSI Z21.69/CAN1 CAN/CGA 6.16 (latest edition) for connectors for movable gas appliances. Quick-disconnect devices must comply with ANSI Z21.41/CAN 1 6.9 (or latest edition) standard for quick-disconnect devices for use with gas fuel as applicable.
IF DISCONNECTION OF THE RESTRAINT IS NECESSARY, IT MUST BE RECONNECTED WHEN THE CUSTOM PASTA
SYSTEM IS RETURNED TO
ITS ORIGINALLY INSTALLED POSITION.
ELECTRICAL CONNECTION
Your pasta cooker has been ordered in either 1 phase or 3 phase by your dealer. All electrical connections should be made by a licensed electrician. If necessary this unit can be field changed from 1 phase to 3 phase or from 3 phase to 1 phase. Have a qualified electrician refer to the wiring diagram.
ALL ELECTRICAL WIRING LEADING TO THE PASTA COOKER MUST CONFORM TO LOCAL CODES. BE SURE THE ON/OFF SWITCH IS IN THE OFF POSITION BEFORE TURNING THE POWER ON TO THE PASTA COOKER.
WATER AND DRAIN CONNECTION
The water is to be connected to the 3/8" female pipe connection on the cabinet back, for auto-fill and the optional faucet.
Make sure this and all other connections do not leak. Check your water pressure. The auto-fill system is not designed to handle pressure greater than 60 psi. Any pressure greater than this can damage the auto-fill solenoid or cause the system to fail. If the pressure is greater than 60 psi a pressure regulator should be added. The water temperature must not exceed 150°F (65.6°C). Hot or warm water is not needed due to the instant recovery of the Custom Pasta™System.
If during operation the boil is killed when water automatically enters the pasta cooker, turn the water pressure down until the water is added without killing the boil. The drain terminates within inches of the floor and is designed for the standard dump to drain opening.
CLEARANCES
Combustible Construction
Non-Combustible
Construction
Back 6" 0"
Right Side 6" 0"
Left Side 6" 0"
Caster
Leg
NOTICE
Restraining devices
required.
5
In most cases the health department will not allow a direct connection between the cooker drain and the floor receptical. Contact your local health department for specific information in your area.
III OPERATION
FILLING
NOTE: Before filling the Pasta System make certain the vessel is sanitized, dry and the drain valve is completely closed.
Figure 3-1
Manual Water Fill Level
When the water fill toggle switch (located between the green and blue indicating lights) is turned on, the Pasta System vessel automatically will be filled to the proper level. If the vessel is being manually filled with water from a faucet or through the manual fill button, fill to just below the overflow deck. The black manual fill button is located to the right of the blue water fill indicating light.
THERMOSTATS
The Keating pasta cooker has two thermostats. This is to allow maximum control of the boil. The system is designed so that both thermostats will function together when called for but one thermostat will act as primary and hold the water at a rolling boil during cooking as well as idle time. The two thermostats allow the user to have complete control over the cooking process.
The right side thermostat will only activate if the left side thermostat is active. From a cold start all elements and thermostats will be on and heat the water to a rolling boil. Once the water has reached a rolling boil the right side (secondary) thermostat will turn off and the left side thermostat (primary) will hold the water at a rolling boil. When product to be cooked is dropped into the pasta cooker the drop in temperature depends on the temperature spread between the two thermostats as determined by the user.
If adding product does not turn on the secondary thermostat and the water falls below a rolling boil, increase the setting slightly on the secondary thermostat. It is not recommended that there be less than a twenty degree difference between the two
thermostats. Having less than a twenty degree difference will increase the possibility of a boil over and cause the pasta cooker to short cycle. The recommended starting temperatures for the cooker are 212°F (98.8°C) for the primary and 190°F (87.8°C) for the secondary thermostat. Using these settings with the knowledge of the operation of this system, the user can fine tune the settings to fit his specific operation.
CONTROL PANEL FEATURES
Figure 3-2
Custom Pasta System Electric Control Panel
AMBER–shows the power is on.
GREEN–shows the secondary (right)
thermostat is calling for heat from the center element(s).
BLUE–shows water is filling into the
Pasta System vessel through the Pasta System water solenoid valve.
NOTE: The black manual water fill button is located to
the right of the blue indicating light.
THE AUTO-FILL SYSTEM
The water temperature must not exceed 120°F (48.8°C). Control of the water level is fully automatic with the auto-fill system. The water level is controlled by two circuit boards attached to the two water level sensors located on the front of the pot below the spashdeck. Once the water switch is turned to ON, the pasta cooker will start to fill with water. The heating elements will not turn on until the water level is above the bottom sensor. This is an automatic water safety built into every pasta cooker. This safety prevents the pasta cooker from accidental heat damage due to low or no water. The bottom sensor is the low water cut off. The top sensor is the water level control. Both sensors should be cleaned on a regular basis to prevent water deposits from interfering with the sensor reaction. Cleaning should be done with the brush up and down the sensor tube located on the right side of the splashdeck.
COOKING
Keating Electric Custom Pasta Systems are designed to provide maximum production efficiency and deliver high quality food products. Low-temperature cooking and highly polished stainless steel mean greater energy savings. Two thermostats are used to provide instant recovery and to save energy while water is boiling. The secondary (right)
6
thermostat calls for additional heat at start up or occasionally when water is added. Follow cooking procedures below for your model.
NOTE: Use of sodium chloride during the cooking process will have a detrimental effect on the cooker tank and will void the warranty.
OPERATION OF THIS PASTA SYSTEM SHOULD BE LIMITED TO PERSONNEL WHO HAVE BEEN THOROUGHLY TRAINED IN OPERATING PROCEDURES.
USE ONLY KEATING APPROVED BASKETS IN YOUR PASTA SYSTEM. NEVER OVERFILL BASKETS. DO NOT BANG BASKETS ON BASKET HANGERS OR PASTA SYSTEM VESSEL.
CARE SHOULD BE TAKEN WHEN LOWERING BASKETS INTO PASTA SYSTEM TO PREVENT SPLASHING HOT WATER FROM PASTA SYSTEM VESSEL.
NEVER LIFT BASKETS DIRECTLY OUT OF THE PASTA SYSTEM VESSEL WITHOUT DRAINING AS SEVERE INJURY MAY RESULT.
NOTE: For counter model Pasta Systems, always check the rear drain operating handle before attempting to use the Pasta System. A safety switch prevents the Pasta System from operating if the handle is not pushed in completely and latched.
A. Standard Pasta System
1. Fill Pasta System as described on page 6 – Filling.
2. Set primary (left) thermostat to 212°F(100°C) and secondary (right) thermostat to 190°F(87.8°C).
3. When the water starts boiling, lower baskets slowly into the hot water.
4. Set timer for left or right side basket, whichever is being lowered into water.
5. When timer sounds, lift basket out of water. Place on basket hanger rods on splashback of Pasta System to allow draining of excess water.
B. Basket-Lift Model
1. Fill Pasta System as described on page 6 – Filling.
2. Set primary (left) thermostat to 212°F(100°C) and secondary (right) thermostat to 190°F(87.8°C).
3. Fill basket(s) to proper level and place on upper basket hanger rods on splashback of Pasta System.
4. Set timers to desired cooking time using T1, T2 or T3 buttons. (For Programming Timers see pages 8-9).
5. Start the timer. Basket(s) will automatically lower into the Pasta System vessel.
6. When cooking cycle is complete, an audible alarm will sound and the basket(s) will raise automatically. Allow water to drain before removing.
DRAINING
ALWAYS SHUT THE PASTA SYSTEM OFF COMPLETELY BEFORE DRAINING. THE PASTA SYSTEM SHOULD BE DRAINED ONLY UNDER THE SUPERVISION OF PROPERLY TRAINED PERSONNEL.
1. Turn off Pasta System and open the door.
Figure 3-3
Drain, drain valve and overflow tubing
* Gas model shown
2. Slowly turn handle. The drain valve will be completely open after 1/4 turn.
CLEANING
When cleaning and boiling out your Pasta System, use white vinegar and Keating Klenzer to keep your Pasta System in top condition. Once your Pasta System vessel is clean, use Keating Klenzer, the finest dry stainless steel polish available, to restore your Keating Electric Pasta System’ exterior to its original luster.
Disconnect electric power source before cleaning.
To avoid damaging the Pasta System, do not power wash, spray or hose it down while cleaning.
1. Operator should be outfitted with proper attire including:
–Water and heat resistant gloves –Water and heat resistant apron –Safety goggles –Water and heat resistant footwear
2. Turn the Pasta System off.
3. Drain water from Pasta System.
Overflow
Drain
Handle
Drain
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