Operators Manual
Installation, Operation & Service
Gas Table Top Kettles
MODELS:
KGT-6-T
KGT-12-T
For models built after July 2002
™
Cleveland
Enodis
1333 East 179th St., Cleveland, Ohio, U.S.A. 44110
Phone: (216) 481-4900 Fax: (216) 481-3782
Visit our web site at www.clevelandrange.com
SE95010 Rev. 9
FOR THE USER
IMPORTANT!
PRIOR TO REMOVING ANY FITTINGS ENSURE
KETTLE IS AT ROOM TEMPERATURE AND
PRESSURE GAUGE IS SHOWING ZERO OR LESS PRESSURE.
FOR YOUR SAFETY
DO NOT STORE OR USE
GASOLINE OR ANY OTHER
FLAMMABLE LIQUIDS AND
VAPOURS IN THE VICINITY
OF THIS OR ANY OTHER
APPLIANCE.
WARNING: Improper installation,
adjustment, alteration, service or
maintenance can cause property
damage, injury or death. Read the
installation and operating
instructions thoroughly before
installing or servicing this
equipment.
IMPORTANT
POST IN A PROMINENT LOCATION, INSTRUCTIONS TO BE FOLLOWED IN THE EVENT
THE USER SMELLS GAS. THIS INFORMATION SHALL BE OBTAINED BY CONSULTING
YOUR LOCAL GAS SUPPLIER.
KEEP APPLIANCE AREA FREE AND CLEAR FROM COMBUSTIBLES.
DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATION AIR.
ALL SERVICE MUST BE PERFORMED BY A QUALIFIED CLEVELAND RANGE
TECHNICIAN.
RETAIN THIS MANUAL FOR YOUR REFERENCE.
INSTALLATION
INSPECTION
CLEARANCE REQUIREMENTS
Before unpacking visually inspect the unit for evidence
of damage during shipping.
CLEARANCE REQUIREMENTS TO COMBUSTIBLE
AND NONCOMBUSTIBLE SURFACES.
If damage is noticed, do not unpack the unit, follow
shipping damage instructions.
SHIPPING DAMAGE
INSTRUCTIONS
If shipping damage to the unit is discovered or
suspected, observe the following guidelines in
preparing a shipping damage claim.
1. Write down a description of the damage or the
reason for suspecting damage as soon as it is
discovered. This will help in filling out the claim
forms later.
Model #
Back
Left Side
Right Side
KGT-6-T
4”
0
0
KGT-12-T
4”
0
0
NOTE: To prevent removal of unit for servicing, allow
sufficient room on right hand side for servicing.
ASSEMBLY
2 3/8" - 6 gallon
1 3/8" - 12 gallon
14 1/2"
2
2. As soon as damage is discovered or suspected,
notify the carrier that delivered the shipment.
3. Arrange for the carrier's representative to examine
the damage.
10"
14 5/8"
4. Fill out all carrier claims forms and have the
examining carrier sign and date each form.
GENERAL
Installation of the kettle must be accomplished by
qualified installation personnel working to all applicable
local and national codes. Improper installation of
product could cause injury or damage.
This equipment is built to comply with applicable
standards for manufacturers. Included among those
approval agencies are: UL, A.G.A., NSF, ASME/N.Bd.,
CSA, CGA, ETL, and others. Many local codes exist,
and it is the responsibility of the owner/installer to
comply with these codes.
Observe all clearance requirements to provide proper
make-up air flow. Do not obstruct the flow of combustion
and ventilation air. Check rating plate to ensure that
kettle has been equipped to operate with the type of
gas available at the installation.
Dimensions and clearance specifications are shown on
the specification sheet and in the Clearance
Requirements section.
24" - 6 gallon
27" - 12 gallon
Base Mounting Diagram
Table-top models must be positioned on a firm, level
stand (Cleveland ST-28 recommended), or existing
counter top, and bolted in place. These models are
supplied with four threaded mounting bushings welded to
the underside of the base. An optional support stand with
level adjustable legs is available. Once the kettle is
secure, screw tilt handle into the threaded hole provided
at the right side of kettle.
GAS
ENSURE THE GAS SUPPLY MATCHES THE
KETTLE'S REQUIREMENTS AS STATED ON THE
RATING PLATE.
It is recommended that a sediment trap (drip leg) be
installed in the gas supply line. If the gas pressure
exceeds 14” water column, a pressure regulator must
be installed, to provide a maximum of 14” water column
gas pressure to the gas control valve.
Connect the gas line to the manual valve located at the
rear of the control box.
Installation must be in accordance with local codes and/or
the National Fuel Gas Code ANSI Z223.1 Latest Edition
(USA) or the latest Installation Codes for Gas Burning
Appliances and Equipment CAN/ CGA B149.1 and CAN/
CGA B149.2 (Canada). Use a gas pipe joint compound
which is resistant to L.P. gas. Test all pipe joints for leaks
with soap and water solution. Ensure that the gas pressure
regulator is set for the manifold pressure indicated on the
gas rating plate.
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 test pressures in
excess of 1/2 psi (3.45 kPa). 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 1/2 psi (3.45 kPa).
ELECTRICAL
ENSURE THE ELECTRICAL SUPPLY MATCHES THE
KETTLE'S REQUIREMENTS AS STATED ON THE RATING
LABEL.
A cord and plug are supplied with the unit. Simply plug the
unit into any grounded outlet rated for a minimum of 10
amps. The wiring diagram is located on the back of the
console access panel.
WARNING: Electrical Grounding Instructions.
This unit 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.
Standard supply voltage is 115 volts A.C., however, optional
A.C. voltages can be supplied on special order. A separate
fused disconnect switch must be supplied and installed in
the high voltage electrical supply line. The kettle when
installed, must be electrically installed and grounded in
accordance with local codes, or in the absence of local
codes, with National Electrical Code, ANSI/NFPA 70-1990
(USA) or the Canadian Electrical Code, CSA C22.2, Part 1
(Canada).
VENTILATION
Gas fired kettles are only to be installed under a ventilation
hood in a room which has provisions for adequate make up
air. Further information can be obtained by referring to the
U.S.A. National Fire Protection Associations NFPA96
regulations. These standards have also been adopted by
the National Building Code in Canada.
INSTALLATION CHECKS
Although the kettle has been thoroughly tested before
leaving the factory, the installer is responsible for
ensuring the proper operation of kettle once installed.
DO NOT ATTEMPT TO OPERATE THIS APPLIANCE
DURING A POWER FAILURE.
KEEP APPLIANCE AND AREA FREE AND CLEAR OF
COMBUSTIBLES.
1. Supply power to the kettle by placing the fused
disconnect switch to the "ON" position.
2. Unit has been thoroughly checked for gas leaks at
the factory however the installer should check all
connections using soap bubble or gas detector for
any leaks which may have resulted from shipping or
installation.
3. Before turning the kettle on, read the
vacuum/pressure gauge. The gauge's needle
should be in the green zone. If the needle is in the
"VENT AIR" zone, follow air venting procedure.
4. Place the kettle's power on/off switch to the "ON"
position.
5. Turn the temperature control knob to "MIN .". The green
LED light should remain lit, indicating the burner is lit,
until the set temperature is reached. Then the green
light will cycle on and off, indicating the burner is
cycling on and off to maintain temperature.
6. Tilt the kettle forward. The red "LOW WATER" light
should be lit when the kettle is in a tilted position.
This light indicates that the burner has automatically
been shut off by the kettle's safety circuit. This is a
normal condition when the kettle is in a tilted
position.
7. Raise the kettle to the upright position. The red "low
water" light should go out when the kettle is upright.
If the red light remains lit in the upright position, it
indicates a low water condition, and water must be
added to the reservoir before the kettle can be
operated. Refer to the "Reservoir Fill Procedures", on
the kettle's label, for details.
8. Turn the temperature control knob to "MAX." and
allow the kettle to preheat. The green light should
remain on until the set temperature is reached. Then
the green light will cycle ON and OFF, indicating the
burner is cycling ON and OFF to maintain
temperature.
CLEANING
WATER
The sealed jacket of the gas-fired kettle is precharged with
the correct amount of a water-based formula, and therefore,
no water connection is required to the kettle jacket. The
kettle can be equipped with optional hot and cold water
taps, the taps require 1/2" copper tubing as supply lines.
After installation the kettle must be thoroughly cleaned
and sanitized prior to cooking. See complete cleaning
instructions in this manual.
OPERATING INSTRUCTIONS
1
9
2
3
4
5
6
7
8
General Parts Drawing
ITEM #
DESCRIPTION
FUNCTION
1.
Tilting Handle
Used for tilting the kettle.
2.
Vacuum/Pressure Gauge
Indicate steam pressure in PSI inside steam jacket as well as
vacuum in inches of mercury.
3.
Pressure Relief Valve
This valve is used to vent the kettle and in the unlikely event there is
an excess steam build-up in the jacket, this valve opens
automatically to relieve this pressure.
4.
Heat Indicator Light (Green)
When lit, indicates that the kettle's burner is on.
Cycles ON-OFF with burner.
5.
Low Water Indicator Light (Red)
When lit, indicates that the kettle is low on water and will not operate
in this condition (see Reservoir Fill Procedures).
6.
Ignition Failure Indicator Light
(Amber)
Indicates failure of heating system to ignite.
7.
On-Off Switch/
Solid State Temperature
Control
Turns kettle ON/OFF and allows the operator to adjust the kettle
temperature in increments from 1 (Min.) to 10 (Max.).
(see Temperature Range Chart in the Operating Instructions
section).
8.
Marine Lock
Prevents unit from accidental tilting.
9.
Water Level Sight Glass
Displays water level in steam jacket.
OPERATING THE KETTLE
NOTE: Do not fill kettle above
recommended level marked on
outside of kettle.
DO NOT ATTEMPT TO OPERATE THIS APPLIANCE
DURING A POWER FAILURE.
KEEP APPLIANCE AND AREA FREE AND CLEAR OF
COMBUSTIBLES.
DO NOT LEAN ON OR PLACE OBJECTS ON KETTLE
LIP. SERIOUS INJURY COULD RESULT IF KETTLE
TIPPED OVER, SPILLING HOT CONTENTS.
1.
2.
Before turning kettle on, read the Vacuum/Pressure
Gauge (2). The gauges needle should be in the
green zone. Once heated, the kettle's normal
maximum operating pressure is approximately 1012 psi while cooking a water base product.
Ensure that the electrical service to the kettle is
turned on at the fused disconnect switch.
Temperature
Control
Setting
Approximate
Product Temperature
°F
°C
MIN.
120
49
1.
130
54
2.
145
63
3.
160
71
4.
170
77
5.
185
85
6.
195
91
7.
210
99
8.
230
110
9.
245
118
MAX.
265
130
NOTE: Certain combinations of ingredients will
result in temperature variations
Temperature Range Chart
NOTE: The Low Water Indicator Light (Red) (5) should not
be lit during kettle operation. This light indicates that the
burners have been automatically shut off by the kettle's safety
circuit. It is normal for the red light to come on when the kettle
is in a tilted position..
5.
When cooking is completed turn ON/OFF
Switch/Solid State Temperature Control (7) to the
"OFF' position.
NOTE: A five minute complete shut-of period is
required before relighting.
6.
Pour the contents of the kettle into an appropriate
container by tilting the kettle forward. Care should
be taken to pour slowly enough to avoid splashing
off the product.
NOTE: As with cleaning food soil from any cookware, an
important part of kettle cleaning is to prevent food from
drying on. For this reason, cleaning should be completed
immediately after cooked foods are removed.
APPROXIMATE BOILING TIMES
The accompanying chart shows approximate times
required for electric kettles of various capacities to boil
water. The ON/OFF Switch/Solid State Temperature
Control (7) must be set at “10” (Max.) throughout the
heat-up period. Water will boil about 1/3 faster if the
kettle is filled only to the outer steam jacket’s welded
seam resulting in a kettle filled to 2/3 capacity.
Kettle Capacity
6 gallon/23 litre
12 gallon/45 litre
Approximate Boiling Times
3.
Preheat the kettle by turning the ON/OFF
Switch/Solid State Temperature Control (7) to the
desired temperature setting (see above
"Temperature Range Chart"). The Heat Indicator
Light (Green) (4) will remain lit, indicating the
burner is on, until the temperature setting is
reached. When the green light goes off, the
burners are off, and preheating is complete.
NOTE: When cooking egg and milk products, the kettle
should not be preheated, as products of this nature adhere to
hot cooking surfaces. These types of food should be placed in
the kettle before heating is begun.
4.
Place food product into the kettle. The Heat
Indicator Light (Green) (4) will cycle on and off
indicating the burners are cycling on and off to
maintain the set temperature.
Minutes
20
25
MARINE LOCK
Your unit is equipped with a marine
lock to prevent accidental tilting.
The following procedure should be
used to tilt the kettle.
2.
3.
Hold the latch down to unlock tilting mechanism.
Pull the handle to tilt kettle.
4.
To lock, return the kettle to its upright position and
push handle back.
NOTE: Inspect lock daily to ensure it is free moving
and does not bind or stick. Clean lock if necessary
(see Cleaning Instructions below for details).
1. Grasp the tilt handle.
CLEANING INSTRUCTIONS
CAUTION
SURFACES MAY
BE EXTREMELY HOT!
CARE AND CLEANING
Cooking equipment must be cleaned regularly to
maintain its fast, efficient cooking performance and
to ensure its continued safe, reliable operation. The
best time to clean is shortly after each use (allow
unit to cool to a safe temperature).
WARNINGS
➩
Do not use detergents or cleansers
that are chloride based or contain
quaternary salt.
Chloride Cleaners
➩
Do not use a metal bristle brush or
scraper.
Wire Brush &
Scrapers
➩
Steel wool should never be used
for cleaning the stainless steel.
Steel Pads
➩
Unit should never be cleaned with
a high pressure spray hose.
High Pressure
Spray Hose
➩
Do not leave water sitting in unit
when not in use.
Stagnant
Water
CLEANING INSTRUCTIONS
1.
2.
Turn unit off.
Remove drain screen (if applicable). Thoroughly wash and
rinse the screen either in a sink or a dishwasher.
3. Prepare a warm water and mild detergent solution in the
unit.
4. Remove food soil using a nylon brush.
5. Loosen food which is stuck by allowing it to soak at a low
temperature setting.
6. Drain unit.
7. Rinse interior thoroughly.
8. If the unit is equipped with a Tangent Draw-Off Valve,
clean as follows:
a) Disassemble the draw-off valve first by turning the
valve knob counter-clockwise, then turning the large
hex nut counter-clockwise until the valve stem is free
of the valve body.
b) In a sink, wash and rinse the inside of the valve body
using a nylon brush.
c) Use a nylon brush to clean tangent draw-off tube.
d) Rinse with fresh water.
e) Reassemble the draw-off valve by reversing the
procedure for disassembly. The valve's hex nut should
be hand tight only.
9. If the unit is equipped with a Butterfly Valve, clean as
follows:
a) Place valve in open position.
b) Wash using a warm water and mild detergent solution.
c) Remove food deposits using a nylon brush.
d) Rinse with fresh water.
e) Leave valve open when unit is not in use.
10. Using mild soapy water and a damp sponge, wash the
exterior, rinse, and dry.
NOTES
➩ For more difficult cleaning applications one of the following
can be used: alcohol, baking soda, vinegar, or a solution of
ammonia in water.
➩ Leave the cover off when the kettle is not in use.
➩ For more detailed instructions refer to the Nafem Stainless Steel
Equipment Care and Cleaning manual (supplied with unit).
STAINLESS STEEL EQUIPMENT CARE AND CLEANING
(Suppied courtesy of Nafem. For more information visit their web site at www.nafem.org)
Contrary to popular belief, stainless steels ARE susceptible to rusting.
4. Treat your water.
Though this is not always practical, softening hard water can do much
to reduce deposits. There are certain filters that can be installed to
remove distasteful and corrosive elements. To insure proper water
treatment, call a treatment specialist.
Corrosion on metals is everywhere. It is recognized quickly on iron and
steel as unsightly yellow/orange rust. Such metals are called “active”
because they actively corrode in a natural environment when their atoms
combine with oxygen to form rust.
Stainless steels are passive metals because they contain other metals, like
chromium, nickel and manganese that stabilize the atoms. 400 series
stainless steels are called ferritic, contain chromium, and are magnetic;
300 series stainless steels are called austenitic, contain chromium and
nickel; and 200 series stainless, also austenitic, contains manganese,
nitrogen and carbon. Austenitic types of stainless are not magnetic, and
generally provide greater resistance to corrosion than ferritic types.
With 12-30 percent chromium, an invisible passive film covers the steel’s
surface acting as a shield against corrosion. As long as the film is intact
and not broken or contaminated, the metal is passive and stain-less. If the
passive film of stainless steel has been broken, equipment starts to
corrode. At its end, it rusts.
5. Keep your food equipment clean.
Use alkaline, alkaline chlorinated or non-chloride cleaners at
recommended strength. Clean frequently to avoid build-up of hard,
stubborn stains. If you boil water in stainless steel equipment,
remember the single most likely cause of damage is chlorides in the
water. Heating cleaners that contain chlorides have a similar effect.
6. Rinse, rinse, rinse.
If chlorinated cleaners are used, rinse and wipe equipment and
supplies dry immediately. The sooner you wipe off standing water,
especially when it contains cleaning agents, the better. After wiping
equipment down, allow it to air dry; oxygen helps maintain the
stainless steel’s passivity film.
Enemies of Stainless Steel
There are three basic things which can break down stainless steel’s
passivity layer and allow corrosion to occur.
7. Never use hydrochloric acid (muriatic acid) on stainless steel.
8. Regularly restore/passivate stainless steel.
1. Mechanical abrasion
2. Deposits and water
Recommended cleaners for specific situations
3. Chlorides
Job
Cleaning Agent
Comments
Mechanical abrasion means those things that will scratch a steel surface.
Steel pads, wire brushes and scrapers are prime examples.
Routine cleaning
Soap, ammonia,
detergent, Medallion
Apply with cloth or sponge
Fingerprints & smears
Arcal 20, Lac-O-Nu
Ecoshine
Provides barrier film
Stubborn stains &
discoloration
Cameo, Talc, Zud,
First Impression
Rub in direction of polish lines
Grease & fatty acids,
blood, burnt-on-foods
Easy-off, De-Grease
It Oven Aid
Excellent removal on all finishes
Grease & oil
Any good
commercial detergent
Apply with sponge or cloth
Restoration/Passivation
Benefit, Super Sheen
Water comes out of the faucet in varying degrees of hardness. Depending
on what part of the country you live in, you may have hard or soft water.
Hard water may leave spots, and when heated leave deposits behind that
if left to sit, will break down the passive layer and rust stainless steel. Other
deposits from food preparation and service must be properly removed.
Chlorides are found nearly everywhere. They are in water, food and table
salt. One of the worst chloride perpetrators can come from household and
industrial cleaners.
So what does all this mean? Don’t Despair!
Here are a few steps that can help prevent stainless steel rust.
1. Use the proper tools.
When cleaning stainless steel products, use non-abrasive tools. Soft
cloths and plastic scouring pads will not harm steel’s passive layer.
Stainless steel pads also can be used but the scrubbing motion must
be in the direction of the manufacturers’ polishing marks.
2. Clean with the polish lines.
Some stainless steel comes with visible polishing lines or “grain.”
When visible lines are present, always scrub in a motion parallel to the
lines. When the grain cannot be seen, play it safe and use a soft cloth
or plastic scouring pad.
Review
1. Stainless steels rust when passivity (film-shield) breaks down as a
result of scrapes, scratches, deposits and chlorides.
2. Stainless steel rust starts with pits and cracks.
3. Use the proper tools. Do not use steel pads, wire brushes or scrapers
to clean stainless steel.
4. Use non-chlorinated cleaners at recommended concentrations. Use
only chloride- free cleaners.
5. Soften your water. Use filters and softeners whenever possible.
6. Wipe off cleaning agent(s) and standing water as soon as possible.
Prolonged contact causes eventual problems.
3. Use alkaline, alkaline chlorinated or non-chloride containing cleaners.
While many traditional cleaners are loaded with chlorides, the industry
is providing an ever-increasing choice of non-chloride cleaners. If you
are not sure of chloride content in the cleaner used, contact your cleaner
supplier. If your present cleaner contains chlorides, ask your supplier if
they have an alternative. Avoid cleaners containing quaternary salts; it
also can attack stainless steel and cause pitting and rusting.
To learn more about chloride-stress corrosion and how to prevent it,
contact the equipment manufacturer or cleaning materials supplier.
Developed by Packer Engineering, Naperville, Ill., an independent testing
laboratory.
SERVICE PARTS
WARRANTY
Our Company supports a worldwide network of Maintenance and Repair Centers. Contact your nearest Maintenance and
Repair Centre for replacement parts, service, or information regarding the proper maintenance and repair of your cooking
equipment
In order to preserve the various agency safety certification (UL, NSF, ASME/Ntl. Bd., etc.), only factory-supplied
replacement parts should be used. The use of other than factory supplied replacement parts will void warranty.
FAUCET ASSEMBLY
1
2
1
3
4
2
ITEM PART
#
#
DESCRIPTION . . . . . . .QTY.
1.
KE50825-2
3/4" Spout . . . . . . . . . . . . . . . . . . . . . .1
2.
FA95022
Retaining Ring . . . . . . . . . . . . . . . . . .1
3.
FA05002-19
"O" Ring . . . . . . . . . . . . . . . . . . . . . . .1
4.
KE51736
Long Faucet Nut . . . . . . . . . . . . . . . . .1
5.
SE50020
Hot Water Stem Assembly . . . . . . . . .1
5
3
6
4
6
10
7
11
9
8
(Double Pantry only)
12
13
6.
SE50021
Cold Water Stem Assembly . . . . . . . .1
7.
KE51401
Single Pantry Body . . . . . . . . . . . . . . .1
10
(c/w Item # 6)
8.
KE50335
Adapter Washer . . . . . . . . . . . . . . . . .1
(Single Pantry only)
9.
KE51403
Double Pantry Body . . . . . . . . . . . . . .1
(c/w Item # 5&6)
10.
KE54159
Faucet Mounting Bracket . . . . . . . . . .1
11.
FA11258
Hex Cap Screw . . . . . . . . . . . . . . . . .2
12.
FA30505
Washer . . . . . . . . . . . . . . . . . . . . . . . .2
13.
FA21008
Hex Nut . . . . . . . . . . . . . . . . . . . . . . . .2
14.
SE50447
Washer Horseshoe . . . . . . . . . . . . . . .1
11
12
13
14
CONSOLE COMPONENTS
(used after June 2005)
14
Consol Gasket
KE600284-2
15
7
1
3
2
4
10
12
11
13
19
6
5
9
8
16
20 21
17
18
ITEM #
PART #
DESCRIPTION
1.
2.
3.
4.
4.
5.
6.
7.
8.
KE600545
KE50753-7
KE00458
KE50303-2
KE50303-1
FA11145
FA15018-7
FA11091
KE53838-20
KE53838-18
KE53838-27
KE53838-21
KE53469-2
KE600567
FA21006
FA15018-8
KE54309
KE54308-1
KE600566
FA11256
WHKGT-2
FA95074
FA31010
FA21026
COMPONENT MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SOLID STATE CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BLACK BOX BRACKET (USE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BLACK BOX BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SCREW, #10-32 X 3/8 S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SCREW, ZINC PLATED, #6-32 X 1/4 SEMS HEAD . . . . . . . . . . . . . . . . . . . . . . 2
MACHINE SCREW, PHILIPS HEAD, #8-32 x 3/8 . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSFORMER, 120/24V OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TRANSFORMER, 240/24V OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TRANSFORMER, 120/14V OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TRANSFORMER, 240/16V OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
IGNITION CONROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BRACKET, IGNITION MODULE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HEX NUT, SS, #10-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SCREW, ZINC PLATED, #6-32 X 3/4 SEMS PHILIPS HEAD . . . . . . . . . . . . . . . 4
LOW VOLTAGE LEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HI VOLTAGE LEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
RUBBER GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SCREW, 1/4-20 X 1/2 HEX CAP S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
NYLON ANCHOR NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
WASHER, SPRING LOCK, HELICAL, 3/8” . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
HEX NUT, 3/8-19, PLATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
QTY.
CONSOLE COMPONENTS
(used prior to June 2005)
7
9
11
10
2
4
12
5
8
6
3
1
16
14 15
13
ITEM #
PART #
DESCRIPTION
1-8
1.
2.
3.
4.
5.
6.
7.
KE01928-3
KE01927-2
KE50753-7
KE00458
KE50303-2
FA11089
FA11052
KE53838-27
KE53838-21
KE53838-20
KE53838-18
KE53469-2
FA10245
KE54308-3
KE54309
WHKGT
KE600252
KE90424
FA95062
COMPONENT PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
COMPONENT MOUNTING PLATE WELDMENT . . . . . . . . . . . . . . . . . . . . . . . . .1
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SOLID STATE CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
BLACK BOX BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SCREW, #8-32X1/4 LG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
SCREW, #6-32X1/2 LG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
TRANSFORMER, 120/14V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TRANSFORMER, 240/16V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TRANSFORMER, 120/24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TRANSFORMER, 240/24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
IGNITION CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SCREWS #8-32 X1" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
HI VOLT LEAD ASS'Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
LOW VOLT LEAD ASS'Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
CONSOLE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SCREW, SS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8.
9.
10.
11.
12.
13.
14.
15.
16.
QTY.
TRUNNION ASSEMBLY
(used after June 2005)
1
3
7
2
4
3
8
9
5
6
5
ITEM #
PART #
DESCRIPTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
FA21024
FA31030
KE600343
FA11323
KE01917-1
FA95007-11
FA05002-49
FA05002-45
KE54434-1
HEX NUT, SS, 5/16-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HELICAL SPRING LOCK WASHER, SS, 5/16" DIA. . . . . . . . . . . . . . . . . . . . . . . 4
BARTITE SEALING WASHER, 5/16" DIA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HEX CAP SCREW, 5/16-18 X 3/4" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TRUNNION HOUSING PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
O-RING, A-228, 2 7/8" x 3 1/8" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
O-RING, A-228, 2 1/4" x 2 1/2" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TRUNNION WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TRUNNION ASSEMBLY
(used prior to June 2005)
QTY.
1
2
3
OVERHEAD
VIEW
ITEM #
PART #
DESCRIPTION
QTY.
1.
2.
3.
FA05002-45
KE54434-1
FA95007-11
"O" RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TRUNNION WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SWITCHES & INDICATORS
(used after June 2005)
5
6
4
1
2
3
6
5
7
8
4
9
3
7
8
10
2
1
60-B
05
KE60
OFF
9
ITEM #
PART #
DESCRIPTION
QTY.
1.
2.
3.
4.
5.
6.
7.
8.
9.
KE55486-3
KE55486-2
KE55486-4
KE600537
FA21006
KE600560-B
SE00114
KE51005
KE50569-1
INDICATOR LIGHT, GREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INDICATOR LIGHT, RED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INDICATOR LIGHT, AMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BRACKET, LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
#10-24, HEX NUT, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
POTENTIOMETER WITH ON/OFF SWITCH, C/W ITEM #8 . . . . . . . . . . . . . . . . 1
ROTARY SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
KNOB, POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SWITCHES & INDICATORS
(used prior to June 2005)
8
4
5 6
5
3
2
1
5 7
ITEM #
PART #
DESCRIPTION
QTY.
1.
2.
3.
4.
5.
6.
7.
8.
SE00114
KE51005
KE50569-1
KE50567-1
FA05002-18
KE50567-3
KE50567-2
KE5555-5
POTENTIOMETER WITH ON/OFF SWITCH, C/W ITEM #2 . . . . . . . . . . . . . . . . .1
ROTARY SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KNOB, POTENTIOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
L.E.D., RED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
"O" RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
L.E.D., GREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
L.E.D., AMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
MAIN
COMPONENTS
2
1
22
7
8
23
24
4
28
3
KE54419-7 FLUE GASKET 12T
KE54419-6 FLUE GASKET 6T
17
18
19
SEE
FAUCET
DRAWING
KE50556-1 Water level probe
28
27
5
6
25
20 21
26
ITEM #
1.
2.
3.
4.
5.
6.
7.
8.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
PART #
SK50403
SK50434
FA95081-3
KE54247
KE02004-2
KE50474
KE50429-5
KE54941-5
KE54941-31
KE50151-1
KE54670-4
KE54670-2
KE54670-5
KE54670-3
FA30501-1
KE54435-4
FA11258
KE54821-8
KE54721-2
KE54468
KE55069-6
KE50294-1
KE00515
KE54246-3
DESCRIPTION
QTY.
BRONZE BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
BOLT, MODIFIED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HEX BOLT, 14-20 X 3/4" LG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
TRUNNION SUPPORT BAR AND BRACE ASSEMBLY . . . . . . . . . . . . . . . . . . . .1
FOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SAFETY VALVE, 50 PSI, 1/2" (NORTH AMERICA) . . . . . . . . . . . . . . . . . . . . . . .1
SAFETY VALVE, 50 PSI, 1/2", (EUROPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HANDLE, 6 GALLON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HANDLE, 12 GALLON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
FIBER WASHER FOR HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
FEED PIPE SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HEX CAP SCREW, 14-20 X 3/4" LG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ELECTRICAL CORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
CORD CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WATER LEVEL SIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SAFETY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
MERCURY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
THERMISTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE003672 Includes:
MARINE LOCK ASSEMBLY . . . . . . . . . . .KE54476
. . . . . . .SPACER
. . . . . . . . . . . . . . . . . . . . . . .1
FA11146 SCREW 10-32, SS
FA21007 NUT 10-32, SS
FA32006 LOCK WASHER #10
FA11258 BOLT, 1/4-20, SS
FA21008 NUT, 1/4-20, SS
FA31029 LOCK WASHER, 1/4", SS
KE54256-3 MARINE LOCK
PIPING ASSEMBLY
5
17
6
16
7
13
15
4
3
11
8
9
10
TO MAIN GAS
SUPPLY
14
1
2
PIPING ASSEMBLY (continued)
ITEM #
PART #
DESCRIPTION
1.
2.
KE01929-1
KE55240-8
KE55240-7
FI05163-1
FI05222-2
FEED PIPE ASS'Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GAS VALVE, NATURAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GAS VALVE, C/W L.P. CONVERSION KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
ADAPTER 1/2 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SWIVEL (USED AFTER JULY 2002)
SWIVEL REPLACEMENT KIT (USED PRIOR TO JULY 2002)
FOR KGT-12-T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
FOR KGT-6-T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
FOR KGT12TGB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
COMPRESSION FITTING (STRAIGHT) & NIPPLE ASS'Y . . . . . . . . . . . . . . . . . .1
BURNER TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
COMPRESSION ELBOW (LONG NUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
ORIFICE ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
ORIFICE SUPPORT BLOCK (KGT-6-T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
NIPPLE
USED AFTER JUNE 2005, 1/2" X 3 1/8" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
USED PRIOR TO JUNE 2005, 1/2'' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1/2'' BLACK IRON UNION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
BURNER ASSEMBLY (KGT-6-T), C/W IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . .1
BURNER ASSEMBLY (KGT-12-T), C/W IGNITOR . . . . . . . . . . . . . . . . . . . . . . . .1
BURNER ONLY (KGT-12-T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GAS SHUT OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GAS ORIFICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.
4.
5.
6.
7.
8.
9.
10.
KE002191-1
KE002191-2
KE002191-3
KE02012
KE54667-1
FI05198-5
KE54666
KE54700
QTY.
16.
17.
FI05226-14
FI00577
FI00073
KE01500-3
KE01500-2
K53653-2
F01518-1
SEE CHART
BELOW
KE53437-2
KE53437-1
FI05222-3
KETTLE
SIZE
ELEVATION ABOVE
SEA LEVEL
BTU'S/HR.
GAS TYPE
ORIFICE
SIZE "A"
PART NUMBER
SEA LEVEL
UP TO 2000'
2,000' UP TO 4,000'
34,000
4,000' UP TO 6,000'
30,700
6,000' UP TO 8,000'
29,200
8,000' UP TO 10,000'
27,700
SEA LEVEL
53,000
2,000' UP TO 4,000'
50,400
4,000' UP TO 6,000'
47,800
6,000' UP TO 8,000'
45,400
8,000' UP TO 10,000'
43,200
NATURAL
PROPANE
NATURAL
PROPANE
NATURAL
PROPANE
NATURAL
PROPANE
NATURAL
PROPANE
NATURAL
PROPANE
NATURAL
PROPANE
NATURAL
PROPANE
NATURAL
PROPANE
NATURAL
PROPANE
#36 (.1065")
1.75mm
#37(.1040")
1.70mm
#38 (.1015")
1.65mm
#39 (.0995")
1.6mm
#40 (.0980")
1.55mm
3.4mm
2.15mm
3.3mm
#45 (.0820)
3.2mm
2.05mm
3.1 mm
(.0780")
2.9mm
1.95mm
KE 53406-1
KE 53406-2
KE 53406-3
KE 53406-4
KE 53406-5
KE 53406-6
KE 53406-7
KE 53406-8
KE 53406-9
KE 53406-10
KE 53406-11
KE 53406-12
KE 53406-13
KE 53406-14
KE 53406-15
KE 53406-16
KE 53406-17
KE 53406-18
KE 53406-19
KE 53406-20
11.
13.
14.
15.
6
GAL
12
GAL
IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
“O” RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
32,300
MAINTENANCE
ALL SERVICE MUST BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN.
Cleveland Range equipment requires little preventative maintenance. We do however provide the following
chart as a guideline for inspection and maintenance to keep your unit functioning at 100%.
INSPECTION AND MAINTENANCE CHECK LIST
The following check should be completed every six months or more frequently if unit is in a high volume
facility.
WARNING: It is imperative that damaged seals be repaired immediately to prevent equipment failure
and/or damage.
ITEM
CHECK
SIDE Console seal
Insure there are six screws firmly holding down the cover. If not replace
screws and/or missing or worn nylon anchor nuts.
Bottom Cover Gasket
Check to see it is in place and is not cracked or split.
Tilt Handle
Check handle for tightness. If loose apply lock tight and reinstall.
Check handle knob is on end of handle and firmly tightened. If loose
apply lock tight and reinstall.
Pressure Gauge
Check that the gauge does not have moisture on its inside face.
Replace if moisture is present.
Check that the gauge shows a vacuum (needle is well into the Green
zone) when cold and shows between 25-40 psi when unit is hot. If not
follow Vacuum Leak Test.
Pressure Relief Valve
Check pressure relief valve as described in Pressure Relief Valve
Periodic Testing Procedure.
Temperature Check
Following Calibrating Procedure check the inner kettle surface
temperature with a digital surface thermometer and adjust if required.
CALIBRATING PROCEDURE
1.
Insure the unit has a vacuum before you begin
calibrating procedures. If unit requires venting refer
to Kettle Venting Instructions.
2.
Set On-Off Switch/Temperature Control to "10" (Max.).
3.
Allow the unit to cycle twice.
4.
Check temperature of the inner kettle surface with
a digital surface thermometer.
5.
Temperature should be between 260° F and 265° F.
6.
Using a screw driver adjust temperature by turning
the potentiometer on the black box. Turn very little.
Turn clockwise to INCREASES and counterclockwise to DECREASE temperature.
7.
Allow the unit to cycle twice.
8.
Check temperature of the inner kettle surface with
a digital surface thermometer.
WARNING: Kettle surface will be hot and steam will be
released during testing. Take necessary precautions
including the use of gloves and eye protection to
prevent personal injury.
1.
With the kettle empty, set On-Off Switch/Temperature
Control to "10" (Max.). Allow the kettle to heat until
the unit cycles off.
2.
Switch On-Off Switch/Temperature Control to "0" (Off)
and disconnect main power at fused disconnect switch.
3.
Stand to the side of the pressure relief valve
discharge tube and pull valve open for a maximum
of one second. Repeat test three to four times. Each
time the mechanism should move freely and be
accompanied by a rapid escape of steam.
9. Repeat steps 4. through 8. until unit is calibrated.
PRESSURE RELIEF VALVE
PERIODIC TESTING
PROCEDURE
Most insurance agencies require periodic testing of
DANGER: PRESSURE RELIEF
VALVE WILL EXHAUST HIGH
TEMPERATURE STEAM. CONTACT
WITH SKIN COULD RESULT IN
SERIOUS BURNS. KEEP FACE,
HANDS AND BODY CLEAR OF DISCHARGE.
DANGER: WORKING ON MACHINES
WITH POWER COULD RESULT IN
SEVERE ELECTRICAL SHOCK.
WARNING: IMPROPER REFILLING OF
KETTLE JACKET WILL RESULT IN
IRREVERSIBLE DAMAGE TO UNIT.
pressure relief valves used on pressure vessels. This
procedure will allow you to safely and quickly test your
kettle's pressure relief valve. We recommend this test be
performed twice a year.
NOTE: The following instruction is intended for use by
qualified service personnel.
If valve appears to be sticking replace pressure relief
valve.
If foreign material is discharged then drain kettle and
replace pressure relief valve.
See KETTLE JACKET CLEANOUT AND PASSIVATION
PROCEDURES for full instructions on the correct method
for refilling kettle jacket.
WARNING: Improper refilling of kettle jacket will result
in irreversible damage to unit.
NOTE: Rust inhibitor is purchased locally. Read
directions and do not exceed manufacturer's
recommendation (excessive rust inhibitor can also
cause solidification).
RESERVOIR FILL
PROCEDURES
C. Fill unit via Street Elbow
B.
Attach Street
Elbow
WARNING: IMPROPER REFILLING OF
KETTLE JACKET WILL RESULT IN
IRREVERSIBLE DAMAGE TO UNIT.
A.*
Remove
Pressure
Relief
Valve
The kettle's water level must be maintained at the
proper level. Under normal operating conditions, the
sealed water reservoir should never require the addition
of water.
If the red "low water" light comes on during use (while
the kettle is in an upright position), the water level has
reached a critically low level. The low water protection
control has automatically shut off the gas burner. The
following procedure must be completed before further
use:
*Important- Pull ring on Pressure Relief Valve
prior to removal to insure vessel is not pressurized.
Pressure Relief Valve/Gauge Assembly Drawing
DANGER: PRESSURE RELIEF
150
200
100
0
250
20
50
30
10
300
40
0
IR
NT A
VE
VALVE WILL EXHAUST HIGH
TEMPERATURE STEAM. CONTACT
WITH SKIN COULD RESULT IN
SERIOUS BURNS. KEEP FACE,
HANDS AND BODY CLEAR OF DISCHARGE.
50
60
psi
1. Ensure kettle is at room
temperature and pressure
gauge showing zero or less
pressure.
350
400
kPa
2. Shut off power to the kettle
at the fused disconnect
switch.
DANGER: WORKING ON MACHINES
WITH POWER COULD RESULT IN
SEVERE ELECTRICAL SHOCK.
3. Pull Pressure Relief Valve (A) open to insure vessel
is not pressurized.
4. Remove Pressure Relief Valve (A).
NOTE: Have a qualified service technician repair the
leakage problem and add water to the unit. Ensure that
the red "low water" light is on when the kettle is upright.
On tilting kettles, it is normal for the red light to come on
when the kettle is in a tilted position.
DISTILLED WATER REQUIREMENTS
Kettle
Capacity
When red “Low
Water Light” comes
on, add distilled water
6 gallon
70 ounces
12 gallon
120 ounces
5. Replace Pressure Relief Valve (A) with Street
Elbow (B).
Sight
Glass
6. Add distilled water (C) through the
Street Elbow (B), using a funnel if
necessary. Fill the unit to the high
level mark on the Sight Glass.
7. Apply a thread sealant (i.e. Teflon tape) to the
Pressure Relief Valve's (A) thread and replace.
8. Restore power to unit at the fused disconnect
switch.
9. The kettle must now be vented. (Refer to the
KETTLE VENTING INSTRUCTIONS).
KETTLE JACKET CLEANOUT AND PASSIVATION PROCEDURES
The following procedure should be preformed at least once every three years to prevent possible corrosion
and ensure the optimum life of the kettle.
DANGER:
WARNING:
WORKING ON MACHINES WITH
POWER COULD RESULT IN SEVERE
ELECTRICAL SHOCK.
IMPROPER REFILLING OF KETTLE JACKET WILL
RESULT IN IRREVERSIBLE DAMAGE TO UNIT.
DANGER:
DANGER:
MOLYFILM 315 IS CORROSIVE, AVOID
CONTACT WITH SKIN AND EYES.
EXTREMELY HOT SURFACES.
WORK ONLY ON COLD KETTLE.
Remove
Pressure
Relief
Valve
DANGER:
AVOID INHALATION - VAPORS FROM
MOLYFILM 315 MAY BE HARMFUL OR FATAL.
DESCRIPTION - Molyfilm 315 inhibits corrosion in
stainless steel and copper. A pH buffer is present to
assist in maintaining the appropriate pH to assist in
corrosion inhibition.
DISPOSAL - Follow all Federal, State and local codes
when disposing of product.
Fill unit via Street Elbow
Sight
Glass
ImportantPull pressure relief valve
ring open to insure vessel
is not pressurized.
Flushing Procedure
1. Ensure kettle is at room temperature and
pressure gauge showing zero or less
pressure.
psi
2. Shut off and disconnect gas supply.
3. Remove electrical plug from power source.
4. Remove bolts holding kettle to tabletop/floor.
5. Pull ring on pressure relief valve to insure there
is no pressure within the kettle jacket.
6. Remove pressure relief valve.
7. Replace pressure relief valve with street elbow.
8. Remove sight glass.
9. Tilt kettle on its side (sight glass down) and allow to
drain. Flush out as much debris as possible with water.
10. Tilt kettle upright, apply a thread sealant (i.e. Teflon
tape) to the sight glass threads and replace.
11. Fill jacket via the street elbow with a mixture of water
and Molyfilm 315 (see REFILL QUANTITIES).
12. Remove street elbow.
13. Apply a thread sealant (i.e. Teflon tape) to the pressure
relief valve and replace.
14. Reconnect gas and electrical supplies.
15. Turn kettle on, vent and heat to high for 1/2 hour.
16. Cool and drain kettle as per above procedure.
150
200
100
0
250
20
50
10
30
300
40
0
IR
NT A
VE
SHELF LIFE - Molyfilm 315’s effectiveness will
diminish after three years.
Attach
Street
Elbow
50
60
350
400
kPa
REFILL QUANTITIES (ORDERING INFO: 1 Liter
Molyfilm 315 Rust Inhibitor - Part# KE600340-1)
IMPORTANT: To ensure satisfactory mixing follow the
MIXING / FILLING PROCEDURE described below.
Kettle Size
6 U.S. Gal.
12 U.S. Gal.
Volume of Water
U.S. Gal. Liters
1.6
5.8
2.2
8.3
Volume of Molyfilm 315
oz. cc (ml.)
2.1
61
3
88
MIXING / FILLING PROCEDURE
1. Refer to chart to determine the required volumes of
water and Molyfilm 315.
2. In a separate container mix 1/2 gallon of the required
volume of water with the total required volume of
Molyfilm 315.
3. Pour mixture into kettle.
4. Pour the remaining required volume of water into kettle.
DANGER:
PRESSURE RELIEF VALVE WILL
EXHAUST HIGH TEMPERATURE STEAM.
CONTACT WITH SKIN COULD RESULT IN
SERIOUS BURNS. KEEP FACE, HANDS
AND BODY CLEAR OF DISCHARGE.
Refilling Unit
1. Apply a thread sealant (i.e. Teflon tape) to the sight
glass threads and replace.
2. Fill kettle jacket with a mixture of water and Molyfilm
315 (see REFILL QUANTITIES chart).
3. Apply a thread sealant (i.e. Teflon tape) to the filler
plug threads and replace.
4. Turn kettle on and check for leaks at sight glass and
filler plug. See Vacuum Leak Test.
5. Vent kettle. See Kettle Venting Instructions for proper
procedure.
KETTLE VENTING
INSTRUCTIONS
150
200
100
250
20
50
30
10
0
50
IR
NT A
VE
Pressure
Gauge
Pressure
Gauge
Pressure
Relief
Valve
Pressure
Relief Valve
300
40
0
VACUUM LEAK TEST
PROCEDURE
60
350
400
psi
kPa
Water Level
Probe
The following venting procedure should be followed when the
Vacuum/Pressure Gauge needle is in the "VENT AIR" zone:
NOTE: Check for and eliminate leaks prior to venting (See
Repairing Leaks in Steam Jacketed Kettle Fittings.
DANGER: PRESSURE RELIEF
VALVE WILL EXHAUST HIGH
TEMPERATURE STEAM. CONTACT
WITH SKIN COULD RESULT IN
SERIOUS BURNS. KEEP FACE,
HANDS AND BODY CLEAR OF DISCHARGE.
If the kettle will not hold vacuum, test for leaks at:
A. Water Level Probe.
B. Pressure Relief Valve.
C. Pressure Gauge.
LEAK TEST PROCEDURE:
1. Heat kettle until unit cycles off.
DANGER: WORKING ON MACHINES
WITH POWER COULD RESULT IN
SEVERE ELECTRICAL SHOCK.
6
5
7
4
8
3
9
2
10
1
1. Turn kettle ON and set
Temperature Control to 10
(Max.), heat the empty kettle
until unit cycles off.
2. Vent kettle by pulling safety
valve ring 8-10 times in short
2-3 second blasts with a 5
second interval between pulls.
OFF
NOTE: If unit cycles ON, stop
venting and wait for kettle to
cycle OFF before continuing.
3. Turn kettle OFF. Add cold
water to kettle until its surface
temperature is below 100°F.
The pressure gauge needle
should be in the green zone,
indicating a vacuum in the
kettle’s jacket.
150
200
100
50
300
40
0
IR
NT A
VE
0
30
10
50
60
psi
3. Spread Bubble Type Leak Detector over suspected
areas and watch closely for bubbles.
4. Repair areas as required.
REPAIRING LEAKS IN STEAM
JACKETED KETTLE FITTINGS
If unit will not hold a vacuum the most likely cause is a
leak at one of the fittings.
Often, the easiest way to eliminate a leak is reseal the
suspect areas.
1. Water Level Probe
Remove,clean threads, apply teflon thread sealant
and reinstall.
2. Pressure Relief Valve
A/ Inspect for signs of leaks. Replace if required.
B/ Remove, clean threads, apply teflon thread
sealant and reinstall.
3. Pressure Gauge
250
20
2. Shut off power to the kettle at the fused disconnect
switch.
350
400
kPa
A/ Inspect face of gauge. If it contains moisture
on the inside of face replace.
WIRING
DIAGRAM
4
1
2
6
4
7
9
5
8
10
8
12
3
14
13
11
15
ITEM #
PART #
DESCRIPTION
1.
KE55486-2
KE50567-1
KE55486-3
KE50567-3
KE55486-2
KE50567-2
SE00114
KE00458
KE00515
KE50556-1
KE50753-7
KE50294-1
KE53838-27
KE53838-21
KE53437-1
KE55069-6
KE53469-2
KE53838-20
KE53838-18
KE55240-8
KE55240-7
L.E.D., RED (USED AFTER JUNE 2005)
L.E.D., RED (USED PRIOR TO JUNE 2005)
L.E.D., GREEN (USED AFTER JUNE 2005)
L.E.D., GREEN (USED PRIOR TO JUNE 2005)
L.E.D., AMBER (USED AFTER JUNE 2005)
L.E.D., AMBER (USED PRIOR TO JUNE 2005)
POTENTIOMETER WITH ON/OFF SWITCH, C/W RUBBER BOOT
SOLID STATE CONTROL BOX
THERMISTOR ASSEMBLY
WATER LEVEL PROBE
RELAY
MERCURY SWITCH
TRANSFORMER, 120/14V OPTION
TRANSFORMER, 240/16V OPTION
IGNITOR
SAFETY THERMOSTAT
IGNITION CONTROL #05-296466-151
TRANSFORMER, 120/24V OPTION
TRANSFORMER, 240/24V OPTION
GAS VALVE KIT, INCLUDES 1/2" NPT ELBOW ADAPTER (USED AFTER JUNE 2005)
GAS VALVE KIT, INCLUDES L.P. CONVERSION KIT (USED PRIOR TO JUNE 2005)
2
.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
14.
15.
OPERATING SEQUENCES
1.
Turn On-Off Switch/
Temperature Control Knob "ON"
*
*
*
*
14 volt transformer is energized and powers solid state control system.
Temperature knob is turned up and control box calls for heat.
Relay (RY-1) closes and powers 24 volt transformer.
Ignition control box is powered.
3.
Ignitor Sparks
*
*
Gas valve is energized.
Ignitor sparks and ignition occurs.
4.
Temperature Reached
*
*
*
*
Solid state controls senses temperature reached.
Relay (RY-1) opens and 24 volt transformer loses power.
Ignition control box is turned off.
Gas valve closes.
5.
Maintaining Temperature
*
*
*
*
Solid state controls senses temperature drop.
Relay (RY-1) closes and powers 24 volt transformer.
Ignitor control box is powered.
Steps three and four are repeated.
SOLID STATE CONTROL SEQUENCE
Our solid state controls consist of the following components.
On-Off Switch/
Temperature
Control Knob
(Potentiometer)
*
*
*
Provides or interrupts electrical power to the control system.
Rotate to change resistance from 0 to 50,000 ohms. This resistance is
compared to the resistance on the thermistor using a voltage comparator
circuit inside the control box.
If the resistance is lower than the thermistor resistance then the control box will
provide 14v dc to pin #8. The green indicator light illuminates and the control
relay (RY-1) is energized closed to provide power to the heating system.
Control Box
*
*
Analyzes inputs from water level probe, tilt switch, potentiometer, thermistor.
Energizes control relay (RY-1)
Water Level Probe
*
Senses water in jacket.
Tilt Switch
*
When kettle is in upright position tilt switch is closed to complete circuit
between pin #8, the relay (RY-1) and green indicator light.
Thermistor
*
The thermistor resistance decreases as temperature increases. When the
thermistor resistance equals the potentiometer then 14v dc is removed from
pin #8. The control relay (RY-1) returns to the normally open position.
Green LED Light
Indicates that the control box is calling for heat. Pin #8 powered.
Red LED Light
Indicates that the water level probe is not immersed in water. Not enough water
in the jacket or kettle tilted.
Relay (RY-1)
When energized allows the heating circuit to function. Electric elements or gas
burner system.
NOTES:
* A ground loop circuit must be established between kettle body, water in jacket, water level probe and
control box. If this loop is present, it indicates that there is sufficient water in the kettle for safe operation.
* If there is not sufficient water in the jacket then the loop is broken and the control box will prevent 14v DC
from being supplied to pin #8. The control relay (RY-1) will remain (or return) to the normally open
position and the unit cannot heat. The red LED light will be illuminated.
MARINE LOCK
TESTING
PROCEDURE
Marine Lock
(Latch)
Stop Pin on
Sidebox
Side to Side Play
Lockwasher
Locknut
Figure A
(Side View)
1. Check that lock clears stop pin on side box without
rubbing when kettle is tilted (Figure A).
Side Box
2. Check side to side play. Lock should remain fully
over stop pin when pushed to it's maximum side to
side play (Figure B).
3. Check that the kettle when pushed fully upright
moves the lock to a closed position. To check this:
A/ Hold the latch firmly in the unlocked position
while tilting the kettle back to an upright position.
B/ The kettle sidebox will force the lock into a new
position.
Shoulder Bolt
Figure B
(Top View)
Console
C/ Hold the lock in this position and try to tilt the
kettle forward. The latch should prevent the kettle
from tilting.
4. Check shoulder bolt is firmly seated against
console body.
5. Check on inside of console box that shoulder bolt
locknut is secure.
GAS VALVE REPLACEMENT KIT (Item # KE55240-7)
This kit includes a gas valve and a natural to propane conversion kit for the valve.
REPLACEMENT INSTRUCTIONS
Removal
Installation
13. Replace gas valve assembly and reconnect gas
lines and wiring to valve.
1.
Turn off power to unit a main breaker.
2.
Turn off main gas supply.
3.
Disconnect gas line on incoming side of kettle
shut-off valve.
4.
Remove shut-off valve.
5.
Remove piping support bracket.
Calibration
6.
Remove side panel.
7.
Remove wires from gas valve.
17. Connect a water column meter to the manifold side
of the gas valve.
8.
Undo the union on the gas line.
18. Turn unit on.
9.
Remove the two bolts located at the rear of the
console and remove gas valve assembly.
19. Check for gas leaks.
14. Turn gas supply back on.
15. Check for gas leaks.
16. Turn main power back on.
20. Natural Gas- set manifold pressure to 4.2 inches WC.
21. Propane Gas- set manifold pressure to 10 inches WC.
Gas Valve Replacement
10. If the unit is Propane, install the propane kit on the
new valve as per the instructions in the bag.
Closure
11. Remove the supply pipe from the old valve and
install on the new valve using pipe thread sealant
for the pipe threads.
23. Replace side panel.
12. Remove the four screws holding the outlet
plumbing assembly to the old valve and reinstall on
the new valve. Use a little "O"ring lube on elbow
seal to the gas valve.
22. Remove test equipment
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