Vulcan Materials K6ETT, K20ETT, K12ETT, ML-136068, ML-136069 User Manual

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SERVICE MANUAL

ELECTRIC COUNTER TOP

TILTING KETTLES

K6ETT ML-136067 K12ETT ML-136068 K20ETT ML-136069

K12ETT ON STAND

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.

Reproduction or other use of this Manual, without the express written consent of Vulcan, is prohibited.

For additional information on Vulcan-Hart or to locate an authorized parts and service prov ider in your area, visit our website at www.vulcanhart.com.

A product of VULCAN-HART LOUISVILLE, KY 40201-0696

F35496 (August 2009)

ELECTRIC COUNTER TOP TILTING KETTLES

TABLE OF CONTENTS

GENERAL ................................................................................3

Introduction ............................................................................3

Tools.................................................................................3

Specifications ..........................................................................4

REMOVAL AND REPLACEMENT OF PARTS ....................................................5

Covers and Panels .....................................................................5

Electrical Panel Components - Water Level Control, Transformer, Contactors and Temperature Control . . . 5

Bottom Components - Water Level Probe (LLCO), Temperature Sensor and Pressure Switch ...........6

Potentiometer..........................................................................6

Heating Element........................................................................ 7

Kettle Assembly ........................................................................8

Bearings .............................................................................11

Shaft Seal............................................................................ 12

Pivot Stop Pin......................................................................... 13

SERVICE PROCEDURES AND ADJUSTMENTS.................................................14

Temperature Controller Test ............................................................. 14

Potentiometer Test.....................................................................15

Thermocouple Test ..................................................................... 15

Heating Elements......................................................................16

Venting ..............................................................................17

Filling the Reservoir Jacket .............................................................. 17

ELECTRICAL OPERATION.................................................................. 19

Component Function ...................................................................19

Component Location ................................................................... 20

Water Level Control (WLC LLCO) .........................................................22

Sequence of Operation .................................................................. 23

Schematic Diagram ....................................................................24

Wiring Diagrams....................................................................... 25

TROUBLESHOOTING......................................................................27

F35496 (August 2009)

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ELECTRIC COUNTER TOP TILTING KETTLES - GENERAL

GENERAL

INTRODUCTION

General

The procedures in this manual apply to all models unless otherwise specified. The pictures and illustrations are of a model K6ETT countertop 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.

Countertop Tilting Kettles

The electric countertop tilting kettles are self contained two thirds jacketed kettles. 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

The 6 and 12 gallon kettles can be mounted to a counter top or optional stand. The 20 gallon kettle is a floor model mounted to its own stand.

Electric Countertop Tilting Kettles

K6ETT - 6 gallon K12ETT - 12 gallon K20ETT - 20 gallon

CONTROL PANEL

TOOLS

Standard

• Standard set of hand tools.

• Pipe thread sealant.

• VOM with an AC current tester (meter sensitivity should be at least 20,000 ohms per volt).

• Temperature meter (thermocouple type). Use for checking kettle temperature.

• 2 gallon container to hold drained reservoir

Special

• Torque wrench (ft-lbs) for tightening heating

• Lubriplate 630-AA Part No. 501687 for

• Loctite® ODC-Free Cleaner & Degreaser

• Loctite® 7471™ Primer N™ Part No. 544434-2.

• Loctite® 242™ Part No. 520228.

Page 3 of 28

jacket fluid.

element mounting bolts.

lubrication of tilt lock pivot stop pin.

(McMaster-Carr Part No. 66415A21) or equivalent fast drying, no residue cleaner.

F35496 (August 2009)

ELECTRIC COUNTER TOP TILTING KETTLES - GENERAL

SPECIFICATIONS

Reservoir Jacket Fluid

• Water - Use only distilled water for partial re-filling of the jacket (purchase locally).

• Dowfrost heat transfer fluid Part No. 558038 (5 gallon). Use during a complete re-fill of the jacket with new fluid. Refer to service procedures for volumes.

Electric

The kettle models listed in this manual, with exception of 480V steamers, are shipped pre-wired for 208/60/3 operation. Kettle heating element wiring change is required if connecting to 208/60/1, 240/60/1 or 240/60/3 electrical service.

ELECTRICAL SPECIFICATIONS

K6ETT

Volts Phase

208 1 7.50 36 12 58 12 58 240 1 10.0 42 16 67 16 67 208 3 7.5 22 12 33 12 33 240 3 10.0 26 16 39 16 39 480 3 7.50 9 12 14 12 14

Total

Amps

K12ETT K20ETT

Total

Amps

Total

Amps

*K6ETT only - Heating elements on 208/240VAC three phase machines are

not wired as a balanced load.

F35496 (August 2009)

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ELECTRIC COUNTER TOP TILTING KETTLES - REMOVAL AND REPLACEMENT OF PARTS

REMOVAL AND REPLACEMENT OF PARTS

COVERS AND PANELS

Control Box Cover

ELECTRICAL PANEL

COMPONENTS - WATER LEVEL

CONTROL, TRANSFORMER,

CONTACTORS AND

TEMPERATURE CONTROL

1. Remove CONTROL BOX COVER.

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.

Bottom Cover

F35496 (August 2009)Page 5 of 28

ELECTRIC COUNTER TOP TILTING KETTLES - REMOVAL AND REPLACEMENT OF PARTS

BOTTOM COMPONENTS -

WATER LEVEL PROBE (LLCO),

TEMPERATURE SENSOR AND

PRESSURE SWITCH

1. Open pressure relief valve until reservoir jacket is completely vented.

2. Remove BOTTOM COVER.

3. Disconnect lead wires from component being replaced.

4. If removing pressure switch: A. Disconnect compression fitting from elbow

near the pressure switch.

B. Remove top nut on brass fitting to remove

pressure switch from mounting bracket.

POTENTIOMETER

1. Remove CONTROL BOX COVER.

2. Disconnect potentiometer wire from temperature control.

3. Pull temperature dial from potentiometer shaft and remove seal nut.

5. Remove component from bottom of kettle.

6. Reverse procedure to install.

7. Remove air from reservoir jacket as outlined under VENTING procedure.

8. Check for proper operation.

NOTE: Pressure switch setting is fixed and should not be adjusted. Clean threads and apply pipe thread sealant when replacing pressure switch, water level probe or temperature sensor.

4. Remove potentiometer from control panel.

5. Reverse procedure to install and check for proper operation.

NOTE: When installing, ensure potentiometer alignment tab is seated in positioning bracket.

F35496 (August 2009) Page 6 of 28

ELECTRIC COUNTER TOP TILTING KETTLES - REMOVAL AND REPLACEMENT OF PARTS

HEATING ELEMENT

1. Open pressure relief valve until reservoir jacket is completely vented.

2. Tilt kettle to expose the heater access cover.

3. Remove three screws where indicated. Loosen remaining screw and allow cover to rotate out of way.

6. Reverse procedure to install. Use a new heating element seal whenever installing heating element. Torque mounting bolts to 40 ft-lbs and tighten in an alternating pattern.

7. Remove air from reservoir jacket as outlined under VENTING.

8. Check for proper operation and leaks around heating element.

NOTE: On K6ETT only, element lengths are staggered to fit the contour of the kettle bottom. Install with the shortest element toward the bottom of kettle.

4. Note lead wire locations and disconnect wires from heating element.

5. Remove mounting bolts securing heating element to kettle.

F35496 (August 2009)Page 7 of 28

ELECTRIC COUNTER TOP TILTING KETTLES - REMOVAL AND REPLACEMENT OF PARTS

KETTLE ASSEMBLY

Removal

1. Place kettle in full upright position.

2. Support kettle using 2x4 blocks of wood.

8. Remove outer bearing from support shaft.

3. Remove CONTROL BOX COVER.

4. Disconnect thermocouple lead wires from temperature control and the 4 pin wiring harness connector.

5. Note lead wire locations and disconnect from load side of contactors.

6. Remove wire tie securing lead wire bundle to control box.

7. Remove three set screws on pivot stop collar. Access third screw thru the slot in top of control box.

9. On K20ETT only. A. Remove two bolts securing kettle tilt stop

to base.

B. Remove kettle support cover.

F35496 (August 2009) Page 8 of 28

ELECTRIC COUNTER TOP TILTING KETTLES - REMOVAL AND REPLACEMENT OF PARTS

11. If re-installing kettle assembly, proceed to Installation in this section. If installing a replacement kettle assembly, remove components as outlined below from old kettle assembly for re-use.

A. Open pressure relief valve until reservoir

jacket is completely vented.

B. Place kettle on floor with the pressure relief

valve and reservoir jacket fill elbow facing

up. C. Remove BOTTOM COVER. D. Remove WATER LEVEL PROBE. E. Position kettle assembly to drain fluid into

container. Remove 1/2" pipe plug from the

reservoir jacket fill elbow to facilitate

draining. F. Remove TEMPERATURE SENSOR AND

PRESSURE SWITCH including

condensate coil.

C. Remove kettle support and bearing

housing assembly from support shaft.

G. Remove pressure relief valve assembly

plumbing and reservoir jacket fill elbow.

10. Pull kettle assembly away from control box to disengage support shaft from inner bearing and pivot stop collar. Slide kettle onto the 2x4 blocks.

H. Remove HEATING ELEMENT. I. Install all removed components onto

replacement kettle. Clean threads and apply sealant before re-installing pipe fittings.

Installation NOTE: Bearings and shaft seal are self aligning for

easy installation. Bearings do not require lubrication.

1. Place kettle assembly on 2x4 blocks and align support shaft to shaft seal. Pull lead wire bundle thru shaft seal and inner bearing.

A. Pull lead wire bundle thru inner bearing

and pivot stop collar during removal.

NOTE: If support shaft of kettle assembly does not easily disengage, apply force between control box housing and kettle assembly to release pivot stop collar. The support shaft should slide out of inner bearing easily.

2. Push kettle assembly support shaft thru shaft seal and inner bearing.

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