Keating Of Chicago Gas Custom Pasta System User Manual
CUSTOM
PASTA
™
SYSTEM
GAS
SERVICE
MANUAL
KEEP THIS MANUAL FOR TRAINING NEW PERSONNEL
1-800-KEATING
www.keatingofchicago.com
Gas Pasta 0107 9/07
i
This operating, installation, and service manual should be given to
the user. The operator of the 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
PROM INENT 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.
IMPORTANT
IN THE EVENT A GAS ODOR IS DETECTED, SHUT
DOWN UNITS AT MAIN SHUT OFF VALVE AND
CONTACT THE LOCAL GAS COMPANY OR GAS
SUPPLIER FOR SERVICE.
NOTICE
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
Do not store flammable
liquids near this or any
other appliance.
WARNING
Improper installation
can cause damage,
injury or death.
NOTICE
NOTICE
TABLE OF CONTENTS
SECTION I INTRODUCTION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . .1
Model Variations . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . .1-3
SECTION II INSTALLATION
Damage During Shipment . . . . . . . . . . . . . . . . . . . .3
Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Restraining Devices . . . . . . . . . . . . . . . . . . . . . . . . .4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . .5
Gas Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Check Gas Supply Pressure . . . . . . . . . . . . . . . . . .5
Special Notices . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Water and Drain Connections . . . . . . . . . . . . . . . . .6
SECTION III OPERATING THE PASTA SYSTEM
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Indicating Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Cooking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Electronic Timers . . . . . . . . . . . . . . . . . . . . . . . . .8-9
SECTION IV MAINTENANCE
Warranty Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . .9
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Water Auto-Fill System . . . . . . . . . . . . . . . . . . .10-11
SECTION V SERVICE DIAGNOSIS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Water Fill and Safety Shut-Off
Circuit Board and Sensor Check . . . . . . . . . . . . . .11
Trouble Shooting Chart . . . . . . . . . . . . . . . . . .12-13
SECTION VI PARTS LIST
Gas Pasta System Assembly I . . . . . . . . . . . . . . .14
Gas Pasta System Assembly II . . . . . . . . . . . . . . .15
Control Panel Assembly . . . . . . . . . . . . . . . . . . . .16
SECTION VII WIRING DIAGRAMS
Pasta System . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Auto-Lift Gas Pasta System . . . . . . . . . . . . . . . . .18
I INTRODUCTION
GENERAL
Keating Pasta Gas Systems are designed to give
maximum production efficiency, delivering high quality
food products. The following design features are
incorporated in Keating Pasta Gas Systems.
STANDARD FEATURES
Highly polished stainless steel vessel
Highly polished stainless steel front
Highly polished stainless steel heat transfer tubes
Highly polished stainless steel thermostat bulb
Highly polished stainless steel Hi-Limit sensor
Grid screen over heat transfer tubes
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
100% safety pilot shut off
3/4” gas connection on single Pasta System
One pair of split baskets or one perforated basket
Patented dual thermostat system
Indicating lights for pilot and secondary thermostat
on
STANDARD ACCESSORIES
Keating Klenzer Sample
Keating Sea Powder Sample
Drain clean out rod
Sensor Cleaning Brush
STANDARD PASTA SYSTEMS
Sizes: 14 to 24
Water capacity 5-1/2 to 17-1/2 gallons
24 Pasta System can cook 6 lbs. of dry pasta per
load up to 110 lbs. per hour
ETL Certified
ETL Santitation Certified
NSF Certified
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.
SAFETY
PRECAUTIONS
THIS SYMBOL WARNS YOU THAT SERIOUS BURNS
OR OTHER INJURIES MAY RESULT IF SAFETY
INSTRUCTIONS ARE NOT FOLLOWED.
KEATING PASTA SYSTEMS ARE NOT INTENDED FOR
USE WITH COOKING OIL.
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 or
in the absence of local codes, with the current
National Fuel Gas Code ANSI Z223.1/NFPA 54,
(latest edition) Natural Gas Installation
Code CAN/CGA-B149.1 or Propane Installation
Code CAN/CGA-B149.2.
Your ventilation hood, when installed, must
conform to the current ANSI/NFPA 96 (latest
edition).
No frame or restriction shall be constructed around
the Pasta System that will restrict air movement
into the Pasta System’s combustion area or
prevent proper ventilation.
Keating Pasta Systems are designed to operate on
the gas fuel specified on the serial plate and must
not be operated with another gas fuel. They
cannot be converted to another gas fuel by turning
or engaging a switch.
FOR YOUR SAFETY: Do not store
or use gasoline or other flammable
vapors and liquids in the vicinity of
this or any appliance.
You will post, in a prominent
location, instructions to be followed
in the event the user smells gas.
This information shall be obtained
from your local gas supplier. You
may use the yellow stick-on label temporarily until you
receive the data from your local gas supplier.
IMPORTANT: In the event a gas odor is detected, shut
down unit at main shut-off valve and contact the local
gas company or gas supplier for emergency service.
1
WARNING
WARNING
Do not store flammable
liquids near this or any
other appliance.
You must maintain this appliance free and clear
from combustibles.
You must maintain the following minimum
clearances from combustible and noncombustible
construction:
Adequate clearance for servicing and proper
operation must be maintained. Your Pasta System
is designed to be serviced from the front.
Keating commercial Pasta Systems are intended
for other than household use.
ALWAYS instruct new employees on proper Pasta
System operation.
ALWAYS turn Pasta System off each night.
ALWAYS disconnect fuel source before servicing.
NEVER use a Pasta System with cooking oil.
NEVER leave a Pasta System unattended during
operation.
Keating Pasta Systems are NOT intended for use
with cooking oil.
NEVER move a Pasta System with any hot water
in it.
NEVER introduce objects or liquids into Pasta
System, while operational, which are not designed
or made for cooking.
THIS COOKER MAY NOT BE ALTERED,
MODIFIED OR CHANGED IN ANY WAY.
The State of California enacted the California Safe
drinking water and Toxic Enforcement Act of 1986,
(Prop. 65), which “prohibits any person in the course of
doing business from knowingly and intentionally
exposing any individual to a chemical known to the
State of California to cause cancer or reproductive
toxicity without first giving clear and reasonable
warning to such individuals.” The Governor’s Scientific
Advisory Panel added carbon monoxide
to the list of
hazardous chemicals known to cause reproductive
harm.
In order to establish full compliance with Proposition
65, we attached a yellow warning label to each gas
fired Pasta System manufactured by Keating of
Chicago, Inc.
Carbon monoxide would not be present in
concentrations that would pose a “significant risk” to
the consumer when the equipment is installed,
operated and maintained as follows:
Installed in accordance with all local codes, or in
the absence of local codes, with the current
National Fuel Gas Code A223.1/NFPA54, Natural
Gas Installation CAN/CGA-B149.1 or Propane
Installation Code CAN/CGA-B149.2.
Installed under a properly designed operating
exhaust hood.
Connected to the type of gas for which the
appliance is manufactured.
Pressure regulator is installed in the appliance and
adjusted for the manifold pressure marked on the
serial plate.
If the inlet gas pressure exceeds 6" WC for natural
gas and 12" WC for Propane, an in-line pressure
regulator is required. In-line pressure regulators
are not supplied by Keating. They are to be
provided and installed by others as directed by
local codes.
Adequate air supply to the Pasta System.
The equipment is operated in the manner intended
using the proper utensils.
Keep the equipment clean and have it checked
periodically.
Burner air adjustments, mechanical maintenance
and repairs must be performed by qualified service
personnel.
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.
CLEARANCES
Combustible
Construction
Non-Combustible
Construction
Back 6" 0"
Right Side 6" 0"
Left Side 6" 0"
2
WARNING
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.
II INSTALLATION
This 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 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.
The carrier is responsible for all damage in transit
whether visible or concealed. Do not pay for the freight
bill until the Pasta System has been thoroughly checked
for damage. If concealed damage is found later, contact
the carrier immediately to file a claim.
What to do if equipment arrives damaged:
VISIBLE LOSS OR DAMAGE — Be certain to note this
on the freight or express receipt and have it signed by
the delivery person.
FILE CLAIM FOR DAMAGES IMMEDIATELY —
Regardless of extent of damage.
CONCEALED LOSS OR DAMAGE — If damage is
noticed when equipment is unpacked, notify the freight
company immediately, and file a “concealed damage
claim”. This MUST be done immediately. Be sure to
retain the shipping container for inspection.
Keating does not assume responsibility for Loss OR
Damage incurred in transit.
NOTE: Interstate commerce regulations require that
the claim must be initiated by the consignee within 10
days from the date it is received.
INSTALLATION
Installation must conform with local codes or, in
absence of local codes, with the current National Fuel
Gas Code Z223.1/NFPA 54, Natural Gas Installation
CAN/CGA - B149.1 or Propane Installation Code
CAN/CGA-B149.2.
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. ALL connections and placement must
comply with local and national codes. It is the
responsibility of the owner and local installer to comply
with these regulations when installing the Pasta
System.
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. The
pasta cooker will operate at highest efficiency when
properly leveled. Place a level across the cooker front
panel from left to right, and then front to rear. Screw the
adjustable bullet feet or casters in or out as necessary
until the cooker is as level as possible. Each leg is
adjustable to
3
/
4". Do not expose more than three
threads on the stem of the caster.
Counter model and floor model Pasta System cookers
must be restrained to prevent tipping when installed
in order to avoid splashing, spilling, etc. of hot liquid.
The restraining method may be a manner of installation
or by separate means.
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 increase height or clockwise to decrease
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.
CLEARANCES
Combustible
Construction
Non-Combustible
Construction
Back 6" 0"
Right Side 6" 0"
Left Side 6" 0"
WARNING
3
WARNING
Improper installation
can cause damage,
injury or death.
4
Figure 2-1
RESTRAINING
DEVICES
On 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 PASTA SYSTEM IS RETURNED TO ITS
ORIGINALLY INSTALLED POSITION.
SPECIFICATIONS
NOTE: The pipe size table shown is predicated on
the fact that this is the sole supply line for a single Pasta
System. If multiple Pasta Systems are to be connected,
consult your local gas utility for the proper gas pipe size.
NOTE: Fuel ratings for propane gas Pasta System
cookers in the U.S. may differ from natural gas models.
In Canada, propane ratings are the same as U.S.
natural gas ratings.
NOTE: Roughly half of all service calls result from
inadequate gas supply. Do not use pipe sizes smaller
than recommended in the table above.
GAS CONNECTION
HAVE YOUR PLUMBER OR GAS COMPANY
CHECK FOR LEAKS.
PIPE JOINT COMPOUNDS RESISTANT TO
PROPANE GASES MUST BE USED.
BEFORE OPERATING THIS PASTA SYSTEM,
CHECK PIPE JOINTS FOR LEAKS BY USING A
SOAP AND WATER SOLUTION OR SNIFFER
ONLY. DO NOT USE AN OPEN FLAME!
Figure 2-3
Main Gas and Water Supply Connection
FOR YOUR SAFETY: Do not store or
use gasoline or other flammable vapors
and liquids in the vicinity of this or any
other appliance.
You will post, in a prominent location,
instructions to be followed in the event
the user smells gas. This information
shall be obtained from your local gas
supplier. You may use the yellow stick-
on label enclosed
on page “i”
temporarily until
you receive the
data from your
local gas supplier.
Connect the Pasta
System to the main gas supply line at the rear of the Pasta
System. See figure 2-3 above.
The piping should be a minimum of 3/4" NPT supply pipe
for a single Pasta System at the burner manifold. Batteries
require larger supply lines. Installation must conform with
local codes, or in the absence of local codes, with the
current National Fuel Gas Code ANSI Z223.1/NFPA 54,
Natural Gas Installation Code CAN/CGA-B149.1 or
Propane Installation Code CAN/CGA-B149.2.
Caster
Gas
Supply
Water
Supply
Models
Total No.
of Burners
Water
Capacity
Fuel Input
(BTU/hr)**
Single Pasta System Supply Pipe Sizes
(For various pipe lengths)
Natural Gas
Propane (LP)
Gas
6' 12' 18' 24' 30'
14 CUSTOM PASTA SYSTEM 3 5.5 gal. 109K 109K
3
/4"3/4"3/4" 1" 1"
18 CUSTOM PASTA SYSTEM 4 8.5 gal. 135K 90K
3
/4"3/4" 1" 1" 1"
20 CUSTOM PASTA SYSTEM 4 13.5 gal. 135K 90K
3
/
4"
3
/4"1" 1" 1"
24 CUSTOM PASTA SYSTEM 5 17.5 gal. 165K 145K 1" 1" 1" 1" 1"
WARNING
WARNING
WARNING
Do not store flammable
liquids near this or any
other appliance.
5
A3/4" IPS manual gas valve is shipped with each single
Pasta System for field installation. Batteries have a
factory installed manual gas valve for each Pasta
System. The required gas pressure for proper operation
of each Pasta System is 4" water column (WC) for natural
gas and 10” water column (WC) for Propane gas at the
burner manifold. Remove the allen head test plug on the
gas valve and using a manometer to check pressure.
If the inlet gas pressure exceeds 7" WC for natural
gas and 11" WC for Propane, an in-line pressure
regulator is required. In-line pressure regulators are
not supplied by Keating. They are to be provided
and installed by others as directed by local codes.
NOTE: If more than one gas Pasta System is on the
same supply line, you may require a larger line. Consult
your local gas company to assure adequate volume and
pressure. Refer to serial plate for proper gas
requirements for your particular model.
ELECTRICAL
CONNECTION
The Keating Custom Pasta Gas
System is equipped with a 9'
neoprene covered, 3 wire electrical
cord with a three-pronged grounded
plug for protection against electrical
shock. This plug must be placed into a
120V properly grounded
three-pronged outlet (NEMA 5-15 or
5-20). For proper grounding
procedures see local codes or, in the
absence of local codes, the current National Electrical
Code ANSI/NFPA 70 or Canadian Electrical Code CAN
22.2 as applicable.
NOTE: The electrical wiring diagram for the Pasta
System is attached to the inside of the Pasta System
door and in Section VIII of this manual.
DO NOT CUT OR REMOVE THE GROUNDING
PRONG FROM THIS PLUG.
GAS LEAK TESTING
Prior to lighting your Pasta System:
1. Make sure all thermostats, switches and safety
valves are in the “OFF” position.
2. Turn main supply gas cock (Item 18, page 17) to
the “ON” position.
3. Have your plumber or gas company check for leaks
with a soap solution or sniffer. (NEVER check with
an open flame)
4. Have your plumber or gas company representative
light the constant pilot. (Not necessary if your Pasta
System has an optional spark ignitor.)
NOTE: It is estimated that half of all service calls
made on Keating Pasta Gas Systems result from an
inadequate gas supply. During installation, have a gas
company representative make certain that the Pasta
System is receiving adequate gas pressure and
volume.
PROPANE GAS MAY EVENTUALLY LOSE ITS ODOR
AND PRECAUTIONS SHOULD BE TAKEN TO
ASSURE THAT IT IS NOT PRESENT EVEN THOUGH
YOU DO NOT DETECT AN ODOR. IF THERE IS ANY
DOUBT, YOU SHOULD CALL YOUR LOCAL
PROPANE GAS SUPPLIER FOR ASSISTANCE.
CHECK GAS SUPPLY
PRESSURE
Special attention should be given to the supply pressure
and gas flow pressure at the supply connection to the
Pasta System. The nominal gas should be 4" WC for
natural gas and 10" WC for propane gas.
If the supply pressure is lower or higher than the rated
(nominal) pressure, then the reason should be
investigated and the gas supplier contacted.
If the supply is lower than 2 1/2" WC or higher than 6" WC
for natural gas or lower then 9” WC or higher than 12" WC
for propane gas, then the Pasta System should be shut
down and a service company or supplier notified. No
adjustments should be made and the Pasta System
should not be operated.
1. Turn off main gas supply valve.
2. Remove pressure measuring stud screw located at
the “out-flow” (closest to gas burner) of the gas
valve and attach a manometer.
3. Remove cover screw from the gas value pressure
adjustment valve.
4. Open main gas supply valve and start Pasta
System according to instructions with the
thermostat set at 190°F(87.8°C).
5. Once the Pasta System is in operation, adjust
pressure valve to 4" WC for natural gas and 10” WC
for propane gas.
6. Turn Pasta System off, close main gas supply
valve, remove manometer and tighten cover screw
into pressure measuring stud.
SPECIAL NOTICES
The Pasta System should be operated only in an area that
has good air circulation.
The Pasta System must be installed under an electrically
powered ventilating hood.
The operator should be properly trained to the functioning
of the Pasta System.
This instruction manual should be supplied the the operator.
WARNING
Plug into a properly
grounded three-prong
receptacle.
WARNING
WARNING
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