Vulcan-Hart K20Gl, k20GLT, K40GLT, K40GL, K80GLT User Manual
...
SERVICE MANUAL
K Series Gas Kettles 2/3 Jacketed
Stationary and Tilting
K20GL ML-136090
K40GL ML-136091
K60GL ML-136092
K20GLT ML-136094
K40GLT ML-136095
K60GLT ML-136096
K40GL Shown
- NOTICE -
This Manual is prepared for the use of trained Vulcan Service
Technicians and should not be used by those not properly
qualified.
This manual is not intended to be all encompassing. If you have
not attended a Vulcan Service School for this product, you should
read, in its entirety, the repair procedure you wish to perform to
determine if you have the necessary tools, instruments and skills
required to perform the procedure. Procedures for which you do
not have the necessary tools, instruments and skills should be
performed by a trained Vulcan Service Technician.
The reproduction, transfer, sale or other use of this Manual,
without the express written consent of Vulcan, is prohibited.
This manual has been provided to you by ITW Food Equipment
Group LLC ("ITW FEG") without charge and remains the property
of ITW FEG, and by accepting this manual you agree that you will
return it to ITW FEG promptly upon its request for such return at
any time in the future.
A product of Vulcan-Hart 3600 North Point Blvd Baltimore, MD 21222
F45461 Rev. A (0713)
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting
TABLE OF CONTENTS
GENERAL .................................................................................................. 4
INTRODUCTION ....................................................................................... 4
MODELS COVERED ................................................................................... 4
CONTROL PANEL ..................................................................................... 5
TOOLS ................................................................................................. 5
SPECIFICATIONS ...................................................................................... 5
OPERATION, CLEANING AND MAINTAINENCE ........................................................ 6
REMOVAL AND REPLACEMENT OF PARTS ............................................................... 7
CONTROL BOX COVER (TILTING) ..................................................................... 7
CORNER & REAR PANELS (TILTING) .................................................................. 7
SIDE & REAR PANELS (STATIONARY) ................................................................ 7
BOTTOM COVER ...................................................................................... 8
ELECTRICAL PANEL COMPONENTS .................................................................. 8
CONTROL BOX (TILTING) ......................................................................... 8
KETTLE CONTROL AREA .......................................................................... 8
PRESSURE SWITCH (1PAS) ........................................................................... 9
GAS VALVE ............................................................................................ 9
BLOWER ............................................................................................. 10
BURNER .............................................................................................. 11
SPARK IGNITOR ...................................................................................... 12
GAS SHUT-OFF VALVE (1SOL) - TILTING MODELS ONLY ............................................ 13
GEAR REDUCER - MANUAL TILTING MODELS ....................................................... 13
ELECTRICAL PANEL COMPONENTS - POWER TILTING OPTION ONLY ............................. 14
TILT SWITCH (2S) - POWER TILTING OPTION ONLY ................................................. 14
DOWN LIMIT SWITCH (3S) - POWER TILTING OPTION ONLY ........................................ 15
DC TILT MOTOR - POWER TILTING OPTION ONLY .................................................. 15
GEAR REDUCER - POWER TILTING OPTION ONLY .................................................. 16
SERVICE PROCEDURES AND ADJUSTMENTS ........................................................... 18
TEMPERATURE CONTROLLER TEST ................................................................ 18
POTENTIOMETER TEST .............................................................................. 19
THERMOCOUPLE TEST .............................................................................. 19
VENTING ............................................................................................. 19
FILLING THE RESERVOIR JACKET ................................................................... 21
PARTIAL REFILL .................................................................................. 21
COMPLETE DRAINING AND REFILL .............................................................. 21
BLOWER INLET PRESSURE CHECK ................................................................. 22
GAS VALVE/BLOWER INLET PRESSURE CHECK .................................................... 23
TO ADJUST: ...................................................................................... 23
SPARK IGNITION TEST ............................................................................... 24
FLAME SENSE CURRENT TEST ...................................................................... 24
IGNITION CONTROL MODULE TEST ................................................................. 25
TILT SWITCH (2S) ADJUSTMENT - MANUAL TILTING MODELS ...................................... 26
KETTLE TILT ADJUSTMENT - MANUAL TILTING MODELS ........................................... 26
TILT SWITCH (2S) ADJUSTMENT - POWER TILTING OPTION ONLY ................................. 27
DOWN LIMIT SWITCH (3S) ADJUSTMENT - POWER TILTING OPTION ONLY ......................... 28
DC TILT MOTOR CONTROLLER TEST - POWER TILTING OPTION ONLY ............................ 28
ELECTRICAL OPERATION ................................................................................ 30
COMPONENT FUNCTION (STATIONARY & TILTING MODELS) ....................................... 30
COMPONENT FUNCTION (POWER TILTING OPTION) ................................................ 31
COMPONENT LOCATION (STATIONARY & TILTING MODELS) ....................................... 32
SEQUENCE OF OPERATION (KETTLE CONTROL CIRCUIT) ......................................... 35
SEQUENCE OF OPERATION (POWER TILTING OPTION) ............................................ 37
SCHEMATIC DIAGRAM (STATIONARY & TILTING MODELS) ......................................... 39
SCHEMATIC DIAGRAM (POWER TILTING OPTION) .................................................. 40
F45461 Rev. A (0713) Page 2 of 44
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting
TROUBLESHOOTING ..................................................................................... 41
STATIONARY & TILTING - GENERAL ................................................................. 41
POWER TILTING OPTION ONLY ...................................................................... 43
© VULCAN 2013
Page 3 of 44 F45461 Rev. A (0713)
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - GENERAL
GENERAL
INTRODUCTION
General
The procedures in this manual apply to all models unless otherwise specified. The pictures and illustrations are of
a model K40GLT floor model tilting kettle unless otherwise noted. All information and specifications contained in
this manual are based on the latest product information available at the time of printing.
K Series - Tilting Kettles
The tilting kettles models are offered with a manual tilt mechanism as standard and are available with an optional
power tilt to automatically lower and raise the kettle. Kettles with the power tilt option can still be operated manually
using the crank handle as needed.
K Series - Floor Model Kettles
The 2/3 jacketed gas kettles are self contained. The lower two thirds of the kettle bowl is a double wall stainless
steel construction that provides a reservoir for a solution of heat transfer fluid and distilled water for improved heating
of the kettle contents. The kettles are used to prepare a variety of liquid or semi-liquid food products such as soups,
stews and sauces.
MODELS COVERED
All K Series kettles are mounted to the floor using legs with flanged feet for anchoring.
Model Type Gallons Quarts
K20GL Stationary 20 80
K40GL Stationary 40 160
K60GL Stationary 60 240
K20GLT Tilting 20 80
K40GLT Tilting 40 160
K60GLT Tilting 60 240
F45461 Rev. A (0713) Page 4 of 44
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - GENERAL
CONTROL PANEL
Fig. 1
• Dowfrost™ heat transfer fluid Part No. 558038 (5
gallon). Refer to FILLING THE RESERVOIR
JACKET for volumes.
• Distilled water only for re-filling of the jacket
(purchase locally). Refer to FILLING THE
RESERVOIR JACKET for volumes.
SPECIFICATIONS
Electric
• 120VAC / 60HZ / 1 phase
• 5 amp rating.
• Supplied with 6 foot power cord and 3-prong
grounding plug (proper ground required).
NOTE: Machines with electronic ignition systems
should be connected to a standard 120VAC electrical
outlet rather than a ground fault circuit interrupter
(GFCI) if possible. Machines connected to certain
GFCI circuits may repeatedly nuisance trip the GFCI.
If the machine must be connected to a GFCI, use Part
No. 913053 (Pass and Seymour) approved by
engineering for use with electronic ignition systems.
Gas Supply
TOOLS
Standard
• Standard set of hand tools.
• Pipe thread sealant (must be resistant to the
action of propane gases).
• VOM with an AC current tester (meter sensitivity
should be at least 20,000 ohms per volt).
• Temperature meter (thermocouple type) for
checking kettle temperature.
• Manometer capable of reading at least 16" W.C.
of gas pressure.
• Container that is capable of holding at least 8
gallons of drained reservoir jacket fluid.
Special
• Torque wrench capable of tightening combustion
chamber mountings nuts to 30 ft-lbs.
• 36mm socket to remove sight glass for jacket
fluid draining.
• Requires U-inclined (Grainger P/N 3T294) or
digital (Grainger P/N 1XFW2) manometer for
measuring gas pressures and blower air
pressures.
NOTICE The gas supply pressure must not exceed
14” WC (½ PSI). Pressures higher than 14” WC will
damage the equipment’s gas controls and is not
covered under warranty. If the supply pressure
exceeds 14” WC an additional supply line regulator
rated for the supply line pressure (inches WC),
nominal pressure (OUT), and gas flow for the kettle
BTU rating must be installed.
Span gas technology enables "field adjustable
manifold pressure" from natural to propane gas or
propane to natural. All kettles shipped for natural gas
at sea level atmospheric pressure. Requires a UInclined or digital manometer. See TOOLS.
Refer to F35461 Installation & Operation Manual for
specific instructions on GAS CONNECTIONS and
GAS AND ALTITUDE ADJUSTMENTS. A combustion
anaylizer is required for gas type conversions and
altitude adjustments as outlined in these procedures.
Page 5 of 44 F45461 Rev. A (0713)
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - GENERAL
GAS SUPPLY PRESSURES
GAS TYPE Manifold (in W.C.) NOMINAL (in W.C.) MIN (in W.C.) MAX (in W.C.)
Natural
Propane
* Low Speed – Blower operates at low speed during trial for ignition (approximately 7 seconds). Ignition
is successful and burner lights. Blower switches to high speed for normal operation approximately 8
seconds later (total time delay of 15 sec. to high speed) and runs until set point temperature is satisfied.
Cycle repeats upon call for heat.
Kettle Rating
All models listed on front cover have an input BTU rating of 100,000 BTU/HR.
Low Speed * - 0.27 to 0.30
7 5 14
High Speed - 1.91 to 1.98
Low Speed * - 0.27 to 0.30
11 11 13
High Speed - 1.91 to 1.98
OPERATION, CLEANING AND MAINTAINENCE
Refer to F35461 Installation & Operation Manual for specific instructions. The manual includes:
• A page from the Stainless Steel Care and Cleaning Guide for proper care and cleaning of stainless steel.
• Draw-Off Valve and Plug Valve dissassembly & cleaning instructions.
F45461 Rev. A (0713) Page 6 of 44
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS
REMOVAL AND REPLACEMENT OF PARTS
CONTROL BOX COVER (TILTING)
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
NOTE: Remove screws from cover where indicated.
NOTE: On kettles with manual tilt or power tilt option,
the control box height is now taller (as shown) to
acomodate additional tilt components. The cover is
held in place using the same number of screws.
K20GLT Manual Tilt Shown
CORNER & REAR PANELS
(TILTING)
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
K20GLT Manual Tilt Shown
SIDE & REAR PANELS
(STATIONARY)
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
NOTE: Remove screws from panel where indicated.
NOTE: Remove screws from panel where indicated.
Page 7 of 44 F45461 Rev. A (0713)
K20GL Shown
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS
BOTTOM COVER
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
NOTE: Remove screws from cover where indicated.
• Tilting models - tilt kettle to empty contents and
gain access to bottom components.
• Stationary models - use draw off valve to empty
contents.
• Raise the kettle for easier access to the
bottom components as necessary. Support
the kettle in some manner (2x4 blocks etc.)
while work is being performed.
panel components are mounted in the kettle control
area.
CONTROL BOX (TILTING)
1. Remove CONTROL BOX COVER (TILTING).
2. Disconnect lead wires from component being
replaced.
3. Remove screws securing the component to
panel.
4. Reverse procedure to install and check for proper
operation.
NOTE: Ensure J1 jumper is installed on temperature
controller.
K20GLT Manual Tilt Shown
ELECTRICAL PANEL
COMPONENTS
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Control Box - K Series Tilting Kettle
KETTLE CONTROL AREA
1. Remove CORNER PANEL (TILTING) or SIDE
PANEL (STATIONARY).
2. Disconnect lead wires from component being
replaced.
3. Remove fastener securing the component to
panel.
A. If installing blower speed control, ensure
switches SW1, SW2 & SW4 are properly set
as shown in Blower Speed Control - Switch
Settings picture in this procedure.
4. Reverse procedure to install and check for proper
operation.
NOTE: Pictures show the electrical panel
components for a tilting kettle (control box & kettle
control area). On a stationary kettle, all the electrical
F45461 Rev. A (0713) Page 8 of 44
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS
5. Remove air from reservoir jacket as outlined
under VENTING procedure.
6. Check for proper operation.
NOTE: Pressure switch setting is fixed and should not
be adjusted.
Kettle Control Area - K Series Tilting Kettles
Blower Speed Control - Switch Settings
PRESSURE SWITCH (1PAS)
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Open pressure relief valve until reservoir jacket
is completely vented.
2. Remove CORNER PANEL (TILTING) or SIDE
PANEL (STATIONARY).
Fig. 9
GAS VALVE
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Shut off the gas before servicing the
unit.
All gas joints disturbed during
servicing must be checked for leaks. Check with a
soap and water solution (bubbles). Do not use an open
flame.
1. Remove
(TILTING) or SIDE & REAR PANELS
(STATIONARY).
2. Remove electrical connector from gas valve.
3. Disconnect gas line from gas valve.
4. Remove gas valve from blower.
CORNER & REAR PANELS
3. Remove pressure switch from tubing.
4. Reverse procedure to install.
Page 9 of 44 F45461 Rev. A (0713)
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS
Fig. 10
5. Remove piping from gas valve inlet and install on
replacement valve. Ensure the factory tags that
are wired to the piping remain installed.
NOTE: Replacement gas valve contains valve plate,
orifice and o-ring already assembled. The gas valve/
blower design allows natural and propane gas kettles
to use the same orifice size. Labels for gas type are
also included.
4. Remove electrical connectors (2) from blower.
5. Remove blower from kettle at burner manifold.
Fig. 11
Clean pipe threads and apply thread
sealant that is suitable for use with propane gas.
6. Reverse procedure to install.
7. Affix the appropriate gas label (natural or
propane) on top of gas valve.
8. Perform
PRESSURE CHECK.
GAS VALVE/BLOWER INLET
BLOWER
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove
2. Remove BOTTOM COVER.
3. Separate burner manifold compression fitting on
gas supply tube (feeding burner).
GAS VALVE from blower.
Fig. 12
A. Remove blower from burner manifold (4
screws).
B. Remove swirl plate (3 screws) and blower
plate (2 screws) from blower intake.
F45461 Rev. A (0713) Page 10 of 44
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS
Fig. 14
Fig. 13
6. Reverse procedure to install replacement blower
and check for proper operation.
6. Remove combustion chamber cover from bottom
of kettle.
NOTE: Install replacement blower gasket as
necessary.
BURNER
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Shut off the gas before servicing the
unit.
All gas joints disturbed during
servicing must be checked for leaks. Check with a
soap and water solution (bubbles). Do not use an open
flame.
1. Remove
2. Remove clips securing insulation to bottom of
kettle.
A. Gently remove insulation and save for
BOTTOM COVER.
reuse.
Fig. 15
7. Note alignment of pipe elbow connected to
burner. Remove elbow from burner.
8. Remove burner from combustion chamber cover.
3. Disconnect spark ignitor lead wires at the ignition
module.
4. Separate compression nuts on gas supply tube.
5. Loosen gas manifold mounting nuts and remove
gas supply tube from the fittings.
Page 11 of 44 F45461 Rev. A (0713)
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS
Fig. 16
9. Reverse procedure to install replacement burner
and check for proper operation.
Apply pipe thread sealant to burner
threads that is suitable for use with propane gas.
NOTE: Torque mounting nuts for combustion
chamber cover to 30 ft-lb.
SPARK IGNITOR
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Remove
CORNER PANEL (STATIONARY).
2. Disconnect spark ignitor lead wires at ignition
module.
3. Remove BOTTOM COVER.
CONTROL BOX COVER (TILTING) or
Fig. 17
6. Ensure spark gap between ignitor electrode and
ground rod is approximately 1/8". If necessary,
adjust as outline under SPARK IGNITION TEST
Step 8C.
7. Reverse procedure to install and check for proper
operation.
4. Remove clips holding insulation against
combustion chamber cover.
5. Remove spark ignitor from combustion chamber
cover.
F45461 Rev. A (0713) Page 12 of 44
Fig. 18
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS
GAS SHUT-OFF VALVE (1SOL) -
TILTING MODELS ONLY
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Shut off the gas before servicing the
unit.
All gas joints disturbed during
servicing must be checked for leaks. Check with a
soap and water solution (bubbles). Do not use an open
flame.
1. Remove CONTROL BOX COVER (TILTING).
2. Disconnect lead wires for gas shut-off valve
(1SOL) at terminal strip in control box.
3. Remove piping from inlet side of valve.
4. Remove threaded plug (NPT) from the ½” swivel
fitting secured to end of pivot shaft.
GEAR REDUCER - MANUAL
TILTING MODELS
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Shut off the gas before servicing the
unit.
All gas joints disturbed during
servicing must be checked for leaks. Check with a
soap and water solution (bubbles). Do not use an open
flame.
1. Place kettle in the fully upright position and
remove crank handle.
2. Support kettle from the bottom in some manner
(2x4 etc). Raise it slightly to take the kettle arm
weight off gear reducer.
3. Remove GAS SHUT-OFF VALVE (1SOL) TILTING MODELS ONLY.
K20GLT Manual Tilt Shown
5. Remove gas shut-off valve from control box.
6. Remove piping from outlet side of valve.
7. Reverse procedure to install replacement gas
shut-off valve and check for proper operation.
Clean pipe threads and apply thread
sealant that is suitable for use with propane gases.
4. Remove tilt switch (2S) from bracket leaving the
lead wires connected.
5. Remove bolts securing gear reducer and control
box to kettle frame.
Fig. 20
6. Pull gear reducer away from kettle by working it
off the kettle arm until free. Note that the kettle
arm is keyed.
NOTE: Control box can be moved as necessary for
ease of gear reducer removal.
7. Remove reducer shaft extension from gear
reducer shaft.
Page 13 of 44 F45461 Rev. A (0713)
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS
2. Disconnect lead wires from component being
replaced.
3. Remove screws securing the component to
panel.
4. Reverse procedure to install and check for proper
operation.
Fig. 21
8. Remove positive stop plate from gear reducer.
Note that the positive stop shaft is keyed.
Fig. 22
9. Reverse procedure to install replacement gear
reducer.
10. Perform KETTLE TILT ADJUSTMENT MANUAL TILTING MODELS to check for proper
operation.
ELECTRICAL PANEL
COMPONENTS - POWER TILTING
OPTION ONLY
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
Fig. 23
TILT SWITCH (2S) - POWER
TILTING OPTION ONLY
Disconnect the
electrical power to the machine and
follow lockout / tagout procedures.
1. Place kettle in the fully upright position.
2. Remove
3. Note lead wire locations and disconnect from tilt
switch (2S).
4. Remove adjustment screws (2) securring switch
bracket to mounting plate.
5. Remove mounting nuts and screws (2) securring
tilt switch (2S) to bracket.
6. Reverse procedure to install tilt switch (2S).
7. Perform TILT SWITCH (2S) ADJUSTMENT POWER TILTING OPTION ONLY.
CONTROL BOX COVER (TILTING).
1. Remove
F45461 Rev. A (0713) Page 14 of 44
CONTROL BOX COVER (TILTING).
Loading...