Cleveland Range HA-MKDL-150-CC Hot Beverage Maker User Manual

Operators Manual
Installation, Operation & Service
GAS MIXING KETTLES
HORIZONTAL AGITATOR
MODEL:
HA-MKGL-60
HA-MKGL-80
HA-MKGL-100
HA-MKGL-60-T
HA-MKGL-80-T
HA-MKGL-100-T
HA-MKGL-60-CC
HA-MKGL-80-CC
HA-MKGL-100-CC
HA-MKGL-60-CC-T
HA-MKGL-80-CC-T
HA-MKGL-100-CC-T
™
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
SE95022 Rev. 5
FOR THE USER
IMPORTANT!
ENSURE KETTLE IS AT ROOM TEMPERATURE AND
PRESSURE GAUGE IS SHOWING ZERO OR LESS PRESSURE
PRIOR TO REMOVING ANY FITTINGS.
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
The following points are to insure the safe installation and operation of this equipment:
• Insure all gas and electrical supplies match rating plate and electrical stickers.
• Observe all clearance requirements.
• Disconnect the electrical power supply to the appliance before cleaning or servicing unit.
• All service must be performed by a qualified Cleveland Range Technician.
• Do not obstruct the flow of combustion and ventilation air.
The installation and connection must comply with current local codes, or in the absence of local codes, with
CAN/CGA-B149.1 and .2 installation code or with the national fuel gas code, ANSI Z223.1-L988.
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.
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 psig. (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
psig. (3.45 kpa).
RETAIN THIS MANUAL FOR YOUR REFERENCE.
For your safety
DANGER
Keep clear of pressure
relief discharge.
Keep hands away from
moving parts and pinch points.
IMPORTANT
Do not fill kettle above
recommended level
marked on outside of kettle.
Inspect unit daily for
proper operation.
CAUTION
Surfaces may be
extremely hot! Use
protective equipment.
Wear protective equipment
when discharging hot product.
Do not lean on or place
objects on kettle lip.
Stand clear of product
discharge path when
discharging hot product.
SERVICING
Shut off power at main
fuse disconnect prior
to servicing.
0
Ensure kettle is at room
temperature and pressure
gauge is showing zero or less
prior to removing any fittings.
GAS APPLIANCES
Do not attempt to operate
this appliance during a
power failure.
Keep appliance and area free
and clear of combustibles.
INSTALLATION
GENERAL
CLEARANCE REQUIREMENTS
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 unit must be installed in accordance with the
clearances shown on the rating label which is adhered
to the unit.
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 makeup air flow as well as sufficient clearance for servicing.
FOR YOUR SAFETY. Keep the appliance area free and
clear of combustible materials.
KETTLE
1.
Dimensions and clearance specifications are shown on the
specification sheet and in the Clearance Requirements
section. Do not install kick plates or otherwise 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.
⇒ Raise the flange on the leg under the motor so
that it sets freely (stationary kettles only).
⇒ Position the kettle in its permanent location,
check clearances and level the kettle by turning
the adjustable feet.
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.
⇒ Lower the flange or flanges under the motor
channel. Over adjustment, whether up or down,
could cause misalignment and cause damage to
the agitator drive shaft and hub (stationary kettles
only).
2.
Next you must check the alignment of the drive
shaft for a uniform clearance between the hub and
the shaft. In order to check for clearance you must
remove the seal cover plate and pull the seal back.
you can check the distance for clearance by using
a wire feeler gauge.
3.
If adjustment is required for side direction, loosen
the motor bolts, center the shaft and retighten.
INSPECTION
Before unpacking visually inspect the unit for evidence
of damage during shipping. If damage is noticed, do
not unpack the unit, follow shipping damage
instructions.
If vertical alignment is needed, loosen the motor
bolts and add a shim to raise or remove a shim to
lower. Retighten bolts. When this is complete,
check to see if the agitator shaft coupling slides
freely for easy removal of the agitator.
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.
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.
4. Fill out all carrier claims forms and have the
examining carrier sign and date each form.
When removing the kettle from the platform, handle
with care to prevent scratching or any other
damage. It is imperative that the kettle be level
before bolting to the floor. This will prevent any
twist or out of roundness to the kettle and will stop
deflection of the agitator. Make sure the kettle is
securely bolted to the floor and follow the
procedure listed below:
4.
Once positioned and leveled, permanently secure
the kettle’s flanged feet to the floor using 1/2 x 2 I/2
inch lag bolts and floor anchors (supplied by the
installer). Two bolts per leg are required to secure
each of the flanged feet.
GAS
WATER
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.
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.
Connect the gas supply piping to the input side of the
gas control valve. Location and pressure data are
shown on the specification sheet.
CLEANING
Installation must be in accordance with local codes
and/or the National Fuel Gas Code ANSI Z223.1-1988
(USA) or the Installation Codes for Gas Burning
Appliances and Equipment CANI B149.1 and 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
Electrical installation must be in accordance with local
codes and/or the National Electric Code ANSI/NFPA 701990 (USA) or the Canadian Electrical Code CSA
Standard C22.1 (Canada). The kettle must be
electrically grounded by the installer.
A separate fused disconnect switch must be supplied
and installed in the high voltage electrical supply line.
The wire gauge size and electric supply must match the
power requirements specified on the kettle’s rating
plate. The waterproof conduit enclosed permanent
copper wiring must be adequate to carry the required
current at the rated voltage. Refer to the specification
sheet or rating label for electrical specifications and
location of electrical connections.
Remove the screws securing the component cover
(located to the left rear side of kettle), and remove the
cover. A wiring diagram is affixed to the inside of the
cover. Feed conduit enclosed permanent copper wiring
through the cut-out in the bottom of the console and
fasten to the terminal block. Fasten the ground wire to
the ground lugs connected to the frame, beside the
terminal block. Replace the console cover and secure it
with the screws.
After installation the kettle must be thoroughly cleaned
and sanitized prior to cooking.
WARRANTY
Our Company supports a worldwide network of
Maintenance and Repair Centres. 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, A.G.A., 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.
SPECIFICATION DRAWING STATIONARY MODELS
ELECTRICAL
SUPPLY
GAS SUPPLY
(PIPING 3/4" NPT)
VOLTS: 208/240
TYPE: NAT or LP
PHASE: 3
BTU PER CU. FT.:
AMPS: 15
1000 (NAT), 2500 (LP)
FREQ:
60 HZ
APPROVALS
AGA
CGA
NSF
SUPPLY PRESSURE:
A AIR SUPPLY (PIPING 1/2" NPT)
APPROX.
SHIPPING
WEIGHTS
PRESSURE:
90 - 100 PSI
(only required for optional 3" dia.
piston draw-off valve)
H C HOT & COLD
WATER
4" to 14" W.C.
1/2" NPT CONNECTION
BTU RATINGS:
40-60 PSI PRESSURE
190,000 per hour
60 GAL 1010 LBS.
458 KG.
80 GAL 1120 LBS.
508 KG.
100 GAL 1325 LBS.
601 KG.
CLEARANCE
RIGHT: 3", LEFT: 3"
REAR: 5"
(ALLOW 12" SPACE
MINIMUM ON LEFT
SIDE FOR SERVICE)
G
WALL
7 3/4"
H C
H
F
A
5 1/2"
16"
J
5/8"Ø,
2 HOLES
ON
4" B.C.D.
2"
M
3/8"
12"
1" (MAX. ADJUSTMENT)
RECOMMENDED
FLOOR DRAIN
SOLID
FOOT DETAIL
L
SPRING ASSIST
COVER (FULLY
OPEN AT 90 )
WALL
28"
C
A I.D.
D
RIM BAR
E
(COVER
FULLY
OPEN)
3 HP
ELECTRIC
MOTOR
H C
B
A
A
RECOMMENDED FLOOR
SLOPE 1 INCH PER 4 FEET
S
6" RECOMMENDED
T
13"
FLOOR DRAIN
3" DIA. BUTTERFLY VALVE
5" MIN
CLEARANCE
PIPE DRAIN RECOMMENDED
MINIMUM VALVE SIZE PLUS 1"
DIMENSIONS
MODEL
A
B
C
D
E
F
G
H
J
L
M
S
T
29 1/2"
48 1/4"
61 5/8"
46 3/4"
93"
27 3/4"
42"
30 5/8"
78"
10 3/8"
53"
19 1/4"
24 1/2"
HA-MKGL-80-TCC
33"
51 3/4"
65 3/8"
52"
98"
30 3/4"
45 11/16"
33 5/8"
84"
11 7/16"
57"
20 3/4"
26 3/16"
HA-MKGL-100-TCC
35 1/2"
54 1/4"
68 3/8"
55"
104"
32 3/4"
48 3/16"
35 5/8"
95 5/8"
11 5/8"
66"
22"
27 5/8"
HA-MKGL-60-TCC
NOTES: CLEVELAND RANGE 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.
INSTALLATIONS OF BACK FLOW PREVENTERS, VACUUM BREAKERS AND OTHER SPECIFIC CODE REQUIREMENTS ARE THE RESPONSIBILITY OF THE OWNER AND INSTALLER.
ALL VERTICAL DIMENSIONS SHOWN ARE MINIMUM. FEET ARE ADJUSTABLE TO +1" MAXIMUM.
MANUFACTURER MUST BE NOTIFIED IF UNIT WILL BE OPERATING ABOVE 2000' ALTITUDE.
CONSULT FACTORY FOR MANUFACTURED GAS.
Cleveland Range reserves right of design improvement or modification, as warranted.
SPECIFICATION DRAWING TILTING MODELS
VOLTS: 208/240
TYPE: NAT or LP
PHASE: 3
BTU PER CU. FT.:
AMPS: 15
1000 (NAT), 2500 (LP)
FREQ:
60 HZ
CGA
NSF
APPROX.
SHIPPING
WEIGHTS
PRESSURE:
90 - 100 PSI
(only required for optional 3" dia.
piston draw-off valve)
H C HOT & COLD
WATER
SUPPLY PRESSURE:
APPROVALS
AGA
A AIR SUPPLY (PIPING 1/2" NPT)
GAS SUPPLY
(PIPING 3/4" NPT)
ELECTRICAL
SUPPLY
4" to 14" W.C.
1/2" NPT CONNECTION
BTU RATINGS:
40-60 PSI PRESSURE
190,000 per hour
CLEARANCE
RIGHT: 3", LEFT: 3"
REAR: 3"
(ALLOW 12" SPACE
MINIMUM ON LEFT
SIDE FOR SERVICE)
60 GAL 940 LBS.
428 KG.
80 GAL 1030 LBS.
469 KG.
100 GAL 1110 LBS.
505 KG.
L
M
3" REF.
M
5 1/2"
WALL
5/8"Ø,
2 HOLES
ON
4" B.C.D.
10 3/8
K
Q
18 3/8
2"
3/8"
G
1" (MAX. ADJUSTMENT)
SOLID
FOOT DETAIL
H C
F
CL
P
12" X 24"
P
RECOMMENDED
FLOOR DRAIN
N
WALL
SPRING ASSIST
COVER (FULLY
OPEN AT 90 )
C
D
A I.D.
RIM BAR
3 HP
ELECTRIC
MOTOR
E
(COVER
FULLY
OPEN)
H
C
H C
B
RECOMMENDED FLOOR
SLOPE 1 INCH PER 4 FEET
A
6" RECOMMENDED
8 3/4"
13"
FLOOR DRAIN
3" DIA. BUTTERFLY VALVE
3" MIN
CLEARANCE
PIPE DRAIN RECOMMENDED
MINIMUM VALVE SIZE PLUS 1"
DIMENSIONS
MODEL
A
B
C
D
E
F
G
K
L
M
N
P
Q
29 1/2"
48 1/4"
50"
36 1/2"
83"
13 1/8"
34 5/8"
23 7/8"
19 1/8"
10 3/32"
24"
9 3/4"
17 7/8"
HA-MKGL-80-CC
33"
51 3/4"
58"
39"
90"
14 7/8"
35 15/16"
24 5/8"
20 7/8"
11 17/32"
26"
9 3/4"
18 5/8"
HA-MKGL-100-CC
35 1/2"
54 1/4"
60 1/2"
40 3/4"
96"
16 1/8"
37 1/8"
25 1/4"
22 1/8"
12 3/4"
27 1/4"
11"
19 1/4"
HA-MKGL-60-CC
NOTES: CLEVELAND RANGE 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.
INSTALLATIONS OF BACK FLOW PREVENTERS, VACUUM BREAKERS AND OTHER SPECIFIC CODE REQUIREMENTS ARE THE RESPONSIBILITY OF THE OWNER AND INSTALLER.
ALL VERTICAL DIMENSIONS SHOWN ARE MINIMUM. FEET ARE ADJUSTABLE TO +1" MAXIMUM.
MANUFACTURER MUST BE NOTIFIED IF UNIT WILL BE OPERATING ABOVE 2000' ALTITUDE.
CONSULT FACTORY FOR MANUFACTURED GAS.
Cleveland Range reserves right of design improvement or modification, as warranted.
OPERATING INSTRUCTIONS
A
B
C
NOTE:
Location of
switches may
vary dependant
on customers
specific options
D
E
7
5
6
1
2
4
3
Red Low Water Indicator Light
When lit, in the upright position, indicates kettle gas
burner has cut out and unit requires more water.
Occasional pulsing of this light is normal.
A
Fill Interrupt Switch
Interrupts water fill cycle
Green Heat Indicator Light
When lit, indicates gas burner is on; cycles on-off with
solid state controls.
Solid State Temperature Control Knob /
On-Off Toggle Switch
Controls electrical power to kettle. and allows operator to
select kettle heat increments from minimum, 1-10.
A setting of 7 or higher will boil water
Amber Ignition Failure Indicator Light
Indicates failure of heating system to ignite
(Used prior to July 2004)
Agitator Stop Button
Stops agitator in case of emergency
B
0 1 2 3
Agitator Start Switch
Starts agitator. Agitator power control switch must be ON
Agitator Power Switch
Allows power to agitator. When not in use, turn control
power OFF
Agitator Speed Control Switch
Turn clockwise until desired speed is reached
Water Meter Digital Counter (not shown)
Location may vary dependant on customer's specific
options
Potable Fill Water Switch
Selects hot or cold water
D
Fill Cycle Switch
Start/continue cycle switch
Product Discharge Valve Switch
Toggle momentary switch to desired valve opening
E
1
Temperature Sensor
Senses temperature of product
2
Automatic Dump Valve
Empties kettle of either food product or wash water
3
Sight Glass
For checking water level of kettle jacket
4
Vacuum /Pressure Gauge
Indicates steam pressure inside steam jacket in PSI, as
well as vacuum in inches of mercury
5
Gas Shut-Off Valve
Power tilt control switch
Tilts kettle for pouring; some kettles have manual hand tilt
6
Air Quick Connect
Push yellow tab down to release air pressure before
disconnecting air hose
Reset circuit breaker
Protects power tilt system from overload. Push to reset
7
Kettle Filler Nozzle
C
General
WARNING: Do not attempt to operate this appliance
during a power failure. Keep appliance and area free and
clear of combustibles.
Automatic Heating
1.
Switch "CONTROLLER" to "ACTIVE".
2.
Turn temperature control knob to "10".
3.
Continually push function key "
displayed.
4.
Push and hold key "
temperature is set.
5.
To Start: push function key
Before turning kettle on, ensure that following
conditions exist:
• If you are cooking an egg or milk product, do not
pre-heat kettle.
• The vacuum/pressure gauge needle is in green
zone; if it is not and is in "vent air" zone, call your
service agent to repair leak.
• The electrical service to kettle is turned on
NOTE: The kettle should be sanitized prior to the daily
production run - see CLEANING INSTRUCTIONS .
Mixing ("AGITATOR ")
"
" or "
" until desired
" until "CtrL" is displayed.
6.
Push down key "
7.
To Stop: push function key
"
" until "OFF" is
".
" until "OFF" is displayed.
8.
Push down key "
9.
After closing discharge valve, place product in kettle.
".
WARNING:
• Never add product to kettle while agitator is running.
Emptying the Kettle
• Do not put hands in kettle.
1.
• Watch for loose clothing near agitator.
1.
Turn "SPEED CONTROL" to "0".
2.
Switch agitator to "ON".
3.
Push agitator "START" to initiate mixing.
4.
Turn "SPEED CONTROL" to desired mixing speed.
5.
To stop mixing action, push agitator stop button.
NOTE: Mixing speed depends on the product
consistency. The faster the mixing speed the more
damage may be done to fragile product.
Heating (General Notes)
• Turn PRODUCT DISCHARGE VALVE switch
clockwise to JOG TO OPEN. Release switch to the
HOLD position when desired valve opening is
achieved.
• To close valve, turn switch counterclockwise to
CLOSED position.
2.
To avoid splashing, slowly empty kettle contents into
an appropriate container by partially opening dump
valve.
NOTE: When pumping with a Metering Filling Station the
speed of the agitator arm must be sufficient to suspend
the heavier items in the mix in order to achieve an even
distribution in your packaged items.
3.
• The green light cycles on and off, indicating that
burners are cycling to maintain set temperature.
• The red "low water" light should not be lit during
operation. This light indicates that water level is
critically low and that gas burners have
automatically shut off. Before further use, refer to
RESERVOIR FILL INSTRUCTIONS for adding
distilled water.
To open automatic dump valve:
Immediately clean kettle as outlined in CLEANING
INSTRUCTIONS on page.
Water Meter
1.
Switch "POTABLE FILL WATER" to "HOT" or "COLD".
2.
Set required volume by first pushing the "
" key
until the digit you want to change is flashing in the
lower display. Then use the "
" key to change the
value of the selected digit.
• Occasional flashing of the red "low water" light is ok
while kettle is heating.
When all digits are set, press the "ENT" key.
Manual Heating
1.
Switch "POWER" to "ON".
2.
Turn temperature control knob to desired setting.
3.
Switch "CONTROLLER" to "BYPASS".
4.
After closing discharge valve, place product in kettle.
3.
Locate delivery spout over kettle.
4.
Turn switch to "RESET". Delivery will start at "0" and
stop at preset volume.
5.
To stop delivery at any time, turn "FILL INTERRUPT"
switch to " ● ".
6.
To complete delivery after interrupting, turn switch
"FILL CYCLE" to "CONTINUE".
CLEANING INSTRUCTIONS
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
➩
2. 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.
Do not use detergents or
cleansers that are chloride
based or contain quaternary
salt.
Chloride Cleaners
➩
1. Turn unit off.
Do not use a metal bristle
brush or scraper.
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.
Wire Brush &
➩
Steel wool should never be
used for cleaning the stainless
steel.
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.
Steel Pads
➩
c) Remove food deposits using a nylon brush.
Unit should never be cleaned
with a high pressure spray
hose.
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
High Pressure
Spray Hose
➩
Do not leave water sitting in unit
when not in use.
➩ 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.
Stagnant
Water
➩ 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)
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.
Contrary to popular belief, stainless steels ARE susceptible to rusting.
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.
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.
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.
7. Never use hydrochloric acid (muriatic acid) on stainless steel.
Enemies of Stainless Steel
8. Regularly restore/passivate stainless steel.
There are three basic things which can break down stainless steel’s
passivity layer and allow corrosion to occur.
Recommended cleaners for specific situations
1. Mechanical abrasion
Job
Cleaning Agent
Comments
2. Deposits and water
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
3. Chlorides
Mechanical abrasion means those things that will scratch a steel surface.
Steel pads, wire brushes and scrapers are prime examples.
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.
Review
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.
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.
4. Treat your water.
Though this is not always practical, softening hard water can do much
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.
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.
PRODUCT VALVE
SCRAPER BLADES
Daily - clean product valve as follows:
To remove and clean scraper blades:
Scraper
blade
KETTLE
KETTLE
OUTLET
Back stop
Pin A
Pin B
CLAMP
Spring
Tool
Fig. 1
0-RING
VALVE
TEE
0-RING
Fig. 2
Fig. 3
To Remove Scraper Blade
1. Insert tool that is provided as shown in Fig. 2.
2. Pull up on spring arm until arm clears groove in Pin B.
3. Spring is now disengaged, gently release spring to remove
scraper blade.
To Install Scraper Blade
1. Slide scraper blade and spring onto Pin A as shown in Fig. 1.
2. Hook spring arm and pull up.
3. Using tool, engage spring arm into groove on Pin B.
Scraper blade is now in place.
CLAMP
0-RING
CLOSED
POSTITION
OPEN
POSITION
AIR HOSE
AIR
CYLINDER
AIR HOSE
1.
Open product valve.
2.
Disconnect air hoses.
3.
Remove air cylinder.
4.
Remove valve tee.
5.
Remove all O-rings.
6.
Clean air cylinder, do not submerge in water. Wipe
clean and sanitize.
7.
Clean and sanitize tee and O-rings.
8.
Grease and reinstall O-rings.
9.
Reinstall tee to kettle outlet.
10. Reinstall air cylinder to bottom of tee.
11. Reconnect air hoses.
12. Close valve and check for alignment.
1.
Remove scraper blades using the tool to release
the spring from the retaining pin and sliding the
blade off the shaft.
2.
Place parts in a pan of warm water to soak.
3.
Clean in a sink, using a warm water and mild
detergent solution.
4.
Rinse with fresh water.
5.
Allow to dry thoroughly on a flat, clean surface.
AGITATOR
QUAD RING
To remove and clean agitator (two-person
To clean agitator quad ring:
job):
Quad ring
Seal retainer plate
Agitator shaft
Pin
Retaining knobs
Coupling
Cleaning Quad Ring
Removing Agitator
1.
Remove retaining knobs.
2.
Slide shaft seal retainer plate and quad ring away
from kettle body.
3.
Clean quad ring, shaft, and seal retainer plate with
clean cloth.
1.
Remove scraper blades.
2.
Rotate agitator until pull pin is on top side.
3.
Turn power OFF.
4.
Pull pin out.
4.
Rinse with fresh.
5.
Slide coupling toward kettle wall, and carefully lift
agitator pulling back to lift out.
5.
Apply light coat of food safe grease to both sides
of the quad ring.
6.
Clean in a sink, using a warm water and mild
detergent solution.
6.
Slide quad ring back into original position, making
sure it does not twist.
7.
Rinse with fresh water.
7.
Slide retainer plate back toward kettle, replacing
retaining knobs.
8.
Tighten with hand pressure only.
AGITATOR BUSHING
With agitator out, remove bushing by:
Bushing
Slot
1. Remove bushing
by turning 1/4 turn
and pulling away
from the kettle wall.
Agitator Retaining
pin
Shaft
2.
Clean, rinse and
sanitize bushing and bushing mounting area.
3.
Lubricate metal surfaces with food safe grease.
4.
Install bushing by locating retaining pin and sliding
bushing on.
5.
Rotate to lock into position.
SERVICE PARTS
SCRAPER BLADES
ITEM NO.
PART NO.
DESCRIPTION
QTY.
1.
KE54602
SCRAPER BLADE . . . . . . . . . . . . . . .7
2.
KE54608
SPRING . . . . . . . . . . . . . . . . . . . . . . .7
3.
KE01976
SPRING REMOVAL TOOL . . . . . . . . 1
1
3
2
AGITATOR SEAL ASSEMBLY
1
ITEM
NO.
PART NO.
DESCRIPTION
1.
KE01911
RETAINING KNOBS . . . . . 3
2.
KE54592
SEAL RETAINER PLATE . . 1
3.
FA05002-8
"O" RING . . . . . . . . . . . . . . 1
4.
KE54594
PIN . . . . . . . . . . . . . . . . . . 1
5.
KE54583
COUPLING . . . . . . . . . . . . 1
6.
KE54593
IDLER PIN . . . . . . . . . . . . 1
7.
KE54590
BUSHING . . . . . . . . . . . . . 1
2
3
4
QTY.
Agitator
Shaft
1
OPERATING CONTROLS
ITEM NO.
PART NO.
DESCRIPTION
QTY.
1.
KE54531
AGITATOR STOP . . . . . . . . . . . . . . . . . . . . . . 1
2.
KE54530
AGITATOR START . . . . . . . . . . . . . . . . . . . . . 1
3.
KE54529
POWER ON/OFF SWITCH . . . . . . . . . . . . . . . 1
4.
KE54532
SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . 1
2
3
4
5
6
7
PRESSURE RELIEF ASSEMBLY
4
3
1
5
2
ITEM NO.
PART NO.
DESCRIPTION
1.
FA05049
MALE CONNECTOR, 1/2" PIPE - 1/4" TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.
FI00151
STREET ELBOW, 1/2" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3.
FI00178
TEE, 1/2" FPT, BRASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4.
KE54941-5
SAFETY VALVE, 50 PSI, 1/2" (NORTH AMERICA) . . . . . . . . . . . . . . . . . . . . . . .1
KE54941-31
SAFETY VALVE, 50 PSI, 1/2", (EUROPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE54223
BLOW DOWN TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5.
QTY.
SIGHT GLASS
ITEM ON.
PART NO.
DESCRIPTION
QTY.
1.
KE50955
RETAINING COVER . . . . . . . . 1
2.
KE52871
WASHER . . . . . . . . . . . . . . . . 1
3.
KE51053-1
SIGHT GLASS . . . . . . . . . . . . 1
4.
FA05002-30
HI
LO
4
3
”O” RING . . . . . . . . . . . . . . . . 1
2
1
HINGE ASSEMBLY
9
4
7
11
8
6
10
1
9
5
12
ITEM NO.
PART NO.
DESCRIPTION
13
2
3
QTY.
Hinge Assembly
1. - 11
KE50597-1
25 - 40 Gallon, 20 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE50597-2
60 - 80 Gallon, 30 - 40 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE50597-3
100 - 150 Gallon, 60 - 100 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . .1
KE50597-4
KDM-60, KDM-60-T, Cook Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE50597-5
KDL-200, KDL-250, KDL-150-F, KDL-250-F . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.
KE50822
Hinge Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.
KE51217
Hinge Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.
KE50121-2
Hinge Spring Light - for KE50597-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE50121-1
Hinge Spring Heavy - for KE50597-1, KE50597-3, KE50597-4, KE50597-5, . .1
4.
KE50823-1
Hinge Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5.
KE50824
Hinge Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6.
KE50819-1
Hinge End Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7.
KE50820
Hinge Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8.
KE50819
Hinge End Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9.
FA11284
Screw, Socket Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
10.
FA11507
Cutting Screw,
11.
SK50418
Plug Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12.
KE50151-2
Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
13.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Cover Handle (specify model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WATER METER ASSEMBLY
12
9
10
4
2
8
4
3
2
1
6
4
7
3
2
1
ITEM ON.
PART NO.
DESCRIPTION
QTY.
1.
FI00096
3/4 BRASS UNION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.
F100629-2
3/4 NPT X 2 112 BRASS NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.
FI00063
3/4 NPT BRASS ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
4.
F100629-36
3/4 NPT CLOSE BRASS NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
5.
KE55228
U-BOLT, 1/4-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
6.
KE54834-4
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
7.
KE02290
MOUNTING PLATE ASSY, HOT COLD WM . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8.
R00179
3/4 NPT BRASS FEMALE TEE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9.
FI00365
3/4 X 1 REDUCING BRASS ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
10.
FI00267
3/4 NPT BRASS COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
11.
FA21008
S.S. NUT 1/4-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
12.
KE54336
GALLON METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE54336-1
QUART METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE52002-1
LITER METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
FLUSH PISTON VALVE
ITEM NO.
(USED PRIOR TO 2003)
PART NO.
DESCRIPTION
QTY.
T40430
Valve Assembly (includes parts 1 - 16) . . . . . . . . . . . . . . . . . . . . . . . . .1
1.
FA05000
"O" Ring, Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.
KE52345
Piston Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.
KE52346
Air seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4.
KE52347
Sani-Clamp Seal, 4”
5.
KE52344
Sani-Clamp, 4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6.
FA05002-22
"O" Ring, Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
7.
FA05002-21
"O" Ring, Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
8.
KE52315
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9.
10.-13.
KE52335
SE00040
Compression Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Supply Hose Assembly, Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
10.
KE52341
Hose Barb, 1/8” x 1/4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
11.
KE52340
Supply Hose, 8” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12.
KE52342
Hose Barb, 1/4” x 1/4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
13.
KE52338
Quick Connect Male End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
14.
KE52327
Piston Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
15.
KE52328
Piston Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
16.
KE52314
Bottom Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Rev 2
FLUSH PISTON VALVE
& TEMPERATURE
SENSOR ASSEMBLIES
(USED AFTER TO 2003)
12
13
4
15
14
16
12
AIR VALVE
ASSEMBLY
FPVA-3
1
5
2
6
3
7
8
9
10
TEMPERATURE
SENSOR
8
11
ITEM ON.
PART NO.
DESCRIPTION
QTY.
1.
KE55210
WELD RING, KETTLE BOTTOM OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.
FI05144-3
SANI CLAMP, 3” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.
KE52154-4
GASKET, SANI CLAMP, 3” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4.
KE02291
COMPLETE ACTUATOR AND DISCHARGE VALVE ASSEMBLY . . . . . . . . . . . . 1
INCLUDES PARTS 5. - 13.
5.
KE55248
BUNA-N O-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6.
KE55249
REPLACEABLE S.S. PLUNGER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7.
KE55250
BUNA-N O-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8.
KE55251
1/8 NPT S.S. HYDRAULIC CLOSE NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
9.
KE55252
MALE S.S. QUICK DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
10.
KE55253
AIR OPERATED CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
11.
KE55254
FEMALE S.S. QUICK DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12.
FA05002-53
BUNA-N O-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
13.
KE55256
FEMALE S.S. QUICK DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
14.
KE54924
TEMPERATURE SENSOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
15.
FA05002-46
O-RING, FOOD GRADE, SIZE A0123, EPDM E 692-75 . . . . . . . . . . . . . . . . . . 1
16.
KE52154-3
GASKET, SANI CLAMP, 1 1/2” WHITE TEFLON . . . . . . . . . . . . . . . . . . . . . . . . . 1
GEARMOTOR - ELECTRICAL ASSEMBLY
8
1
7
2
3
4
5
6
ITEM NO.
PART NO.
DESCRIPTION
QTY.
1.
KE53838-2
TRANSFORMER, 200-240V/440-480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.
KE50750-2
CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.
KE51139-1
FUSE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
4.
KE52936-18
15A FUSE, KLKR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
5.
PR50003
TERMINAL BLOCK
6.
PR50005
TERMINAL BLOCK BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7.
KE54528
A.C. INVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8.
KE54527-1
GEAR MOTOR, 200V/340V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE54527-2
GEAR MOTOR, 230V/460V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KETTLE - ELECTRICAL COMPONENTS
ITEM ON.
PART NO.
DESCRIPTION
QTY.
1.
KE53838-19
TRANSFORMER, 120-16V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE53444
TRANSFORMER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.
KE54833-3
BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.
KE02372
IGNITION MODULE, PRIOR TO SEPT. 2004 . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE53469-4
IGNITION MODULE, SEPT. 2004 AND AFTER . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE00458
SOLID STATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE50303
SOLID STATE CONTROL BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5.
KE50753-7
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6.
KE55069-6
SAFETY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7.
FI05050
BRASS NUT #7/16-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8.
KE02400
AIR SWITCH, PRIOR TO SEPT. 2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4.
9.
KE55453-1
AIR SWITCH, SEPT. 2004 AND AFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE53838-20
TRANSFORMER 120-24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KETTLE - GAS COMPONENTS
14
25
5
6
7
8
9
21
15
16
4
17
19
11 26
3
10 26
13
18
1
12
20 26
22
2
24
23
ITEM ON.
PART NO.
DESCRIPTION
QTY.
1.
KE53617
SIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.
KE53437
IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.
KE50556-2
WATER LEVEL PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4.
KE00515
THERMISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5.
FI05213
PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6.
FA05002-4
“O” RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7.
KE53422
SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8.
GAS ORIFICE:
KE53403-6
NATURAL GAS - SEA LEVEL TO 2000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE53403-7
PROPANE GAS - SEA LEVEL TO 2000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE53403-10
NATURAL GAS - 2000' TO 4000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE53403-11
PROPANE GAS - 2000' TO 4000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE53403-10
NATURAL GAS - 4000' TO 6000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE53403-14
PROPANE GAS - 4000' TO 6000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE53403-17
NATURAL GAS - 6000' TO 8000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE53403-18
PROPANE GAS - 6000' TO 8000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE53403-17
NATURAL GAS - 8000' TO 10,000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE53403-22
PROPANE GAS - 8000' TO 10,000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9.
FA05002-29
“O” RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
10.
KE50568-1
L.E.D. GREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
11.
KE50567-1
L.E.D. RED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12.
TEMPERATURE CONTROL ASSEMBLY:
KE50569-1
KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SE00114
POTENTIOMETER WITH ON/OFF SWITCH, C/W SEAL . . . . . . . . . . . . . . . . . . .1
KE51005
SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
13.
KE50429-2
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
14.
KE53441
BLOWER, 110 V, 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
15.
KE53441-1
BLOWER, 220 V, 50 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
16.
KE01426-1
MIXING CHAMBER, 60 GALLON KETTLES . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
17.
KE53402-1
AIR ORIFICE, 190K BTU BURNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
18.
FI05212
PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
19.
KE95087-1
OPERATING INSTRUCTION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
20.
KE50567-2
L.E.D. AMBER (USED PRIOR TO JULY 2004) . . . . . . . . . . . . . . . . . . . . . . . . . .1
21.
KE02274
CAPACITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
22.
KE53618
SIGHT GLASS GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
23.
KE53619
SIGHT GLASS RETAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
24.
KE53570
GASKET FOR IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
25.
KE54420
AIR INTAKE WASHER (NATURAL GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
KE54420-1
AIR INTAKE WASHER (PROPANE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
FA05002-18
"O" RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
26.
CONTROL BOX - ELECTRICAL
For front panel control switches see SIDE BOX - TILT MECHANISM & SWITCHES.
CONTROL BOX - WATER METER & CHART RECORDER.
5
12 16
14
2
15
20
1
37
7
38 39
4
40
6
28 29
3
19
33
31 32
8
23
34
12
20
24
35
16
25 26
27
1
22
28
36
29
30
31
9C
9
9B
SAFETY
SWITCH
ASSEMBLY FRONT
VIEW
13 17 18
10
SAFETY
SWITCH
ASSEMBLY SIDE
VIEW
16
11 12 13
DOOR
GASKET
ITEM ON.
PART NO.
DESCRIPTION
1.
KE55287-1
KE55187-2
KE55287-3
KE55287-4
KE55284-1
KE55284-2
KE55286-1
KE55286-2
KE54860
KE55283
KE55288-1
KE55288-2
KE55298
KE50750-4
KE50750-2
KE55297-1
KE55297-2
KE55297-3
KE55285
FA40000-15
FA21007
FA32006
FA11091
FA21004
FA11146
FA40000-14
FA21006
KE55271
KE55292-1
KE55292-4
KE55292-3
KE50753-10
KE52106
KE50377
KE50376
KE50374
SK50055-1
SK50054-1
KE54761-2
SK50054-2
KE54761
KE90425-1
KE90425-2
KE90401-2
KE55232
KE54528
KE53838-2
KE52936-18
KE51139-1
KE50750-2
PANEL, REMOTE CONTROL, DUAL FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . .1
PANEL, REMOTE CONTROL, DUAL WALL . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
PANEL, REMOTE CONTROL SINGLE FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . .1
PANEL, REMOTE CONTROL, SINGLE WALL . . . . . . . . . . . . . . . . . . . . . . . . . . .1
COMPONENT MOUNTING PLATE DUAL PANEL . . . . . . . . . . . . . . . . . . . . . . . .1
COMPONENT MOUNTING PLATE SINGLE PANEL . . . . . . . . . . . . . . . . . . . . . .1
MOUNTING BRACKET, INCOMING, DUAL PANEL . . . . . . . . . . . . . . . . . . . . . .1
MOUNTING BRACKET, INCOMING, SINGLE PANEL . . . . . . . . . . . . . . . . . . . .1
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
VENT COVER PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
MOUNTING RAIL, DUAL CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . .1
MOUNTING RAIL SINGLE CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . .1
MOTOR PROTECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1
CONTACTOR, 230 VAC, 50 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
CONTACTOR, 230 VAC, 30 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SAFETY INTERLOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TOTALLY FLEXIBLE ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GD2 STANDARD ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
MOUNTING BRACKET, DOOR INTERLOCK SWITCH . . . . . . . . . . . . . . . . . . . .1
WELD STUD, #10-32 X 1/2, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
HEX NUT, #10-32, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
TOOTH LOCK WASHER, #10, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
SCREW, #8-32 X 3/8, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
NUT, #8-32, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
SCREW, #10-32 X 1/2, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11/8
WELD STUD, #10-24 X 3/4, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
HEX NUT, #10-24, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
LABEL, REMOTE CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1
LABEL TERMINAL STRIP REMOTE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
LABEL TERMINAL STRIP REMOTE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
LABEL, TERMINAL STRIP, REMOTE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . .1
RELAY, 120 V HOT COLD WATER BYPASS . . . . . . . . . . . . . . . . . . . . . . . . . . .6/3
TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4/2
TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
TERMINAL BLOCK END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TERMINAL BLOCK MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1
TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14/7
TERMINAL BLOCK END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4/2
TERMINAL BLOCK MOUNTING RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1
TERMINAL BLOCK END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4/2
TERMINAL BLOCK MOUNTING RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WIRING DIAGRAM, DUAL REMOTE CONTROL PANEL . . . . . . . . . . . . . . . . . .1
WIRING DIAGRAM, SINGLE REMOTE CONTROL PANEL . . . . . . . . . . . . . . . . .1
WIRING DIAGRAM, DUAL WATER METER OPTION . . . . . . . . . . . . . . . . . . . . .1
WIRING DIAGRAM, 3" AIR VALVE OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
AC INVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1
TRANSFORMER, 200- 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1
FUSE, 15 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6/3
FUSE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6/3
CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1
2.
3.
4.
5.
6.
7.
8.
9.
9B.
9C.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
QTY.
CONTROL BOX WATER METER & CHART RECORDER
WATER METER
START
OFF ON
EMPTY
START
CONTINUE RESET
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
BYPASS ACTIVE
EMPTY
EMPTY
EMPTY
EMPTY
ON
EMPTY
INTERRUPT
OFF
EMPTY
MAIN POWER
8
2
3
4
5
INDEX
6
Capacitor
*
Contactor Cartridges
7
5
1
INCLUDED WITH
ALL SWITCHES.
PART NO.
KE52074
* NOTES:
KE603208-9
KE603208-8
For units built prior to December 2006,
the complete switch assembly must be
ordered.
ITEM NO.
PART NO.
DESCRIPTION
QTY.
1.
KE53257
Digital Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.
SE50354
Pen Tip, red (pkg. of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3.
SE50354
Pen Tip, green (pkg. of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4.
KE003209-1
Switch Assembly, On/Off - Maintained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5.
KE003209-1
Switch Assembly, On/Off - Maintained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
6.
KE003209-6
Momentary Spring Return Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7.
KE003209-7
Momentary Spring Return Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .2
8.
KE53136-1
Chart Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SIDE BOX PNEUMATICS
14
9
13
21 22
9
9
19
16
8
17
5
15 18
2
(NOT SHOWN)
20
RTV ALL AROUND
1
11
12
7
6
4
3
ITEM NO.
PART NO.
DESCRIPTION
QTY.
1.
FA05166
QUICK CONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.
KE54280
SLIDE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I
3.
FA30512
SPACER WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
4.
FA32500
TOOTH LOCK WASHER 7/8" DIA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
5.
KE52697
NUT 1/2 NPS BRASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I
6.
KE52931
AIR FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
7.
F100178
TEE 1/2 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
8.
FI00351
BUSHING 1/2 MIP X 1/4 FIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9.
FI05318
HOSE BARB 90° ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
10.
FI00151
90° STREET ELBOW 1/2 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
11.
FA30090
WASHER 15/16 ID X 1 3/4 OD X 1/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12.
7100595-8
NIPPLE 1/2 NPT X 4 1/2" LONG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
13.
KE55238
FILTER-REGULATOR-LUBRICATOR BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . .1
14.
F105220-1
GEAR CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
15.
FA21006
10-24 S.S. NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
16.
KE532177
PNEUMATIC HOSE 1/4 I.D. X 31" L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
17.
KE532176
PNEUMATIC HOSE 1/4 I.D. X 12 1/2" L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
18.
FA30000
FLAT WASHER #10, ZINC PLATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
19.
KE02292
AIR SOLENOID ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
20.
KE50555-3
GROMMET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
21.
FA21008
1/4-20 NUT S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
22.
FA30002
FLAT WASHER 1/4 DIA., ZINC PLATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
22 23
SIDE BOX TILT MECHANISM
& SWITCHES
24
21
18
18
48
14
16
15
17
18
20
18
17
19
19
42
45
46
47
29
44
25 26 27 28
43
49
50
51
11 10
9 8
4
3
30
5
52
13
6
53
7
12
31
32
54
55
56
2
40
41
GAS CONNECTION
36
37
38
39
1
35
33
34
SEE PNEUMATIC
COMPONENTS DRAWING
ITEM NO.
PART NO.
DESCRIPTION
1.
KE50579-1
FA00012
KE50580
KE603208-4
KE51730
KE54531
KE54530
KE54529
KE54532
KE01889
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
"O" RING, CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WATER RESISTANT BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TILT SWITCH OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TILT SHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
AGITATOR STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
AGITATOR START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
POWER ON/OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
MICRO SWITCH TRIGGER/SEGMENT GEAR WELDMENT . . . . . . . . . . . . . . . .1
2.
3.
4.
5.*
6.*
7.*
8.
QTY.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.*
55. *
56.*
FA10772
FA20048
FA95007-4
FA95055-1
FA19201
KE54644
KE52836-2
KE50315
FA95005
KE52193-1
KE52192
KE52191
FA30088
FA95008
KE50582
FA95055-6
KE50583
KE52832-1
FA10487
FA31008
FA20026
KE50473
FO1518-1
KE02053
FI05223-1
FI05222
FI05231
FI05226-11
KE51007
FA10139
KE50498
FA32004
KE603208-7
KE603208-9
KE50581
KE54535
KE50753-10
KE54491
KE53599-8
KE53599-9
FA95062
FA95074
FA19177
FA20047
KE54606
KE003209-9
KE003209-6
KE003209-2
KE003209-3
SOCKET HD. CAP SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SQUARE KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HEX SOCKET SET SCREW 3/8-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TILT SHAFT, MANUAL TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TILT SHAFT, POWER TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
WORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TENSION PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
THRUST BEARING SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
THRUST WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ROLLER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
JAM NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
CPLG. ONTARIO BELTING #G-100 5/8 BORE . . . . . . . . . . . . . . . . . . . . . . . . . .2
SQUARE KEY 3/16 X 3/16 X 1" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
RUBBER INSERT, ONTARIO BELTING "BUNA N" . . . . . . . . . . . . . . . . . . . . . . . .1
MOTOR "BODINE" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HEX HD SCREW 1/4-20 X 1" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SPLIT LOCKWASHER 1/4" DIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
HEX NUT 1/4 - 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
GROUND LUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GAS SHUT-OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
COMBINATION GAS VALVE NATURAL GAS . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SPECIAL NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SWIVEL ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
FLUSH BUSHING 3/4M TO1/2F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
NIPPLE 1/2 X 10" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
MICRO SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MACHINE SCREW #6-32 X 1" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
MICRO SWITCH INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
TOOTH LOCK WASHER #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
CONTACT SECTION HOLDER (LATCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
CONTACT BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
BRIDGE RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
EDGE CONNECTOR (11 PIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
LID FOR GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
PAN HD. PHILLIPS SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
NYLON ANCHOR NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
HEX SOCKET SET SCREW 5/16-24 X 1" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
JAM NUT 5/16-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GAS VALVE LOCKWASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SWITCH, JOG TO OPEN AIR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SWITCH, FILL INTERRUPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SWITCH, HOT/COLD SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SWITCH, FILL CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
* SWITCHES MAY BE LOCATED ON REMOTE CONTROL PANEL.
MAINTENANCE
INSPECTION AND MAINTENANCE CHECKLIST
Cleveland Range equipment requires little preventative maintenance. We do however provide the following chart as a
guide line for inspection and maintenance to keep your unit functioning at 100%.
MONTHLY INSPECTION
Inspect all switches for damage. Replace rubber boots or switches as required.
Check that the automatic dump valve works fully and smoothly and no air leaks are evident.
Check that the 3 way regulator shuts off the incoming air and completely vacates the air from the air hose to the
metering filling station.
Tilt kettle and check for smooth operation in both directions.
Inspect gear and worm assembly in gear box for play - tighten Allen screws if required.
Inspect gasket material on covers for integrity.
Check spring assist covers for tightness to handle and insure spring is holding cover up - adjust if required. Refer to
HINGE ADJUSTMENT INSTRUCTIONS.
When kettle is cold check that pressure gauge needle is in the green zone indicating a vacuum in kettle - if
venting is required refer to KETTLE VENTING PROCEDURE.
Inspect mixer blades for cracks or other damage - replace as required. Refer to NEW SCRAPER BLADE
INSTALLATION PROCEDURE.
Check quad ring and replace if required. Refer to QUAD RING REPLACEMENT PROCEDURE.
Inspect oiler in gear box and fill with oil if required. Refer to OILER FILLING PROCEDURE.
Inspect air filter cartridge and replace if required. Refer to AIR FILTER REPLACEMENT PROCEDURE.
SIX MONTH MAINTENANCE
Grease trunnion housings in gear box and on outboard bearings.
Test pressure relief valve. Refer to PRESSURE RELIEF VALVE TESTING PROCEDURE.
OPERATING SEQUENCE - HEATING
STEP
ACTION
RESULT 1
1.
Close main circuit breaker.
120 volts is supplied by primary contactor
to kettle On/Off switch and tilt relay
contacts. Power supplied to tilt assembly.
2.
On/Off switch on kettle
switched to ON.
120/16 volt transformer supplies
power to control boxes.
3.
Control box.
A/ Requires grounded probe to
function (pin #5).
4.
12 VDC relay contacts
close.
RESULT 2
Amber LED is illuminated.
(Used prior to July 2004)
B/ More that 6 volts at pin #2. Control box
energizes 12 volt DC relay (pin #6).
a/
b/
Green LED illuminates.
12 VDC relay contacts close.
A/ Blower energizes.
a/
Air switch contacts close.
B/ 120/25 volt transformer energizes.
a/
25 volts supplied to ignition module.
C/ 120 volt supplied to ignition module.
5.
Ignition module.
Supplies 120 volts to ignition.
Within 20 seconds ignitor glows red.
6.
120 volts turned off to ignitor.
A/ Gas valve is energized.
a/
Burner ignites.
B/ Ignitor becomes sensor.
a/
If temperature drops in
chamber gas valve is deenergized within five seconds.
Ignitor will try twice more to
light before locking out.
b/
7.
Temperature reached.
A/ Less than 6 volts at pin #2.
Control box de-energizes 12 volt
DC relay (pin #6)
a/
b/
c/
d/
Green LED turns off.
12 VDC relay contacts open.
Blower turns off.
25 volt transformer de-energizes.
QUICK CHECKS: Potentiometer - Range 0 - 50K, Safety Thermostat - Normally Closed,
Thermistor - Range 0 - 100K, Water Level Probe - Must be submerged in water for burners to work
OPERATING SEQUENCE - AGITATOR
1.
On/Off switch closed.
A/ Three phase contactor closes to
a/
supply power to variable speed drive.
Indicator light is energized.
2.
Start button momentarily depressed.
A/ Power to agitator motor.
a/
Motor comes up to speed.
3.
Speed control turned up.
A/ Motor speed increases.
OPERATING SEQUENCE - POWER TILT
1.
Turn and hold tilt switch in
down position.
A/ Relay 2 is energized.
a/
Tilt motor is energized.
2.
Kettle tilts until limit switch is
depressed.
A/ Power interrupted to down side
of tilt switch.
a/
b/
Relay de-energized.
Motor stops.
Turn and hold tilt switch in up A/ Relay 1 is energized.
position.
a/
Tilt motor is energized.
3.
Kettle tilts until limit switch is
depressed.
a/
b/
Relay de-energized.
Motor stops.
4.
A/ Power interrupted to up side of
tilt switch.
KETTLE SAFETY INSPECTION CHECKLIST
Regular inspection and maintenance of units is essential to obtain trouble free and safe operation of
equipment. Inspections must include testing of the pressure relief valve and checks of the operating
system to insure that it has not been altered.
No safety features designed into the equipment should ever be tampered with. Tampering
with or bypassing controls is a very dangerous practice and unfortunately we have seen several cases of
this. Following is a short list of the most common and the most dangerous alterations performed on kettles.
SAFETY VALVE:
1
✘
Plug
✔
2
This illustrations show the
correct configuration of a
factory installed Safety Valves.
Any modifications are
unacceptable.
Incorrect Installations
1
3
Safety valve has plug threaded into the
discharge opening preventing any steam from
escaping.
2
Safety valve’s tube diameter has been
reduced.
3
Safety valve is sticking, frozen shut or plugged.
To test, refer to PRESSURE RELIEF VALVE
PERIODIC TESTING.
4
Safety valve is plumbed to a drain or water
line creating back pressure and reducing flow.
✘
Tube
diameter
reduced
✘
Frozen,
stuck, or
plugged
✘
4
Plumbed to
drain or
water line
SAFETY THERMOSTAT:
Incorrect
Installations
1
✔
Probe
fully
inserted
in tube
Wiring is properly
connected
2
✘
✘
Probe
removed
partially
Probe
removed
completely
3
✘
Thermostat
electrically
bypassed
1
Safety thermostat
probe is not
completely
inserted into
tubing.
2
Safety thermostat
probe is removed
from tubing.
3
Safety thermostat
electrical
connection is
bypassed.
Low Water Level Probe:
(A)
(B)
✔
Probe properly
attached
✘
Probe bypassed by
running (A) an
additional wire
Operating
Thermostat:
265º
✔
Air
Switch:
✔
260º - 270º
MAXIMUM
KETTLE
TEMPERATURE
If maximum temperature
is not in this range (on
empty kettle), refer to the
CALIBRATING
PROCEDURE.
✘
Probe bypassed by
(B) grounding the
connecting wire
Wiring is
properly
connected
Incorrect
Installation
✘
Switch
electrically
bypassed
AIR FILTER REPLACEMENT
PROCEDURE
1
Disconnect air supply and bleed system.
2.
Remove cover on console (see SIDE BOX PNEUMATICS).
3. Check for filter location.
4. Push lever down
and rotate bowl/
guard assembly
1/8 turn.
Deflector
Filter
Element
Baffle
Lever
Bowl/Guard
Assembly
5. Push down on
bowl/guard
assembly
and remove.
NEW SCRAPER BLADE
INSTALLATION PROCEDURE
Trim corners or
center to fit
Scraper
blade
Back stop
Move to
adjust
Spring
Fig. 1
Move to
adjust
Fig. 2
Fig. 3
6. Unscrew baffle
and remove filter
element, inspect
and replace filter
if required.
7. Replace filler cap
and cover.
QUAD RING REPLACEMENT
PROCEDURE
Hole cap
Retaining bolt
Retaining washer
Retaining knobs
Seal retainer plate
Quad ring
LUBRICATION PROCEDURE
Lubricate the following parts every three months to
insure smooth operation and reduce wear.
TRUNNION
HOUSING,
WORM SCREW
AND TILT GEAR
Adjusting
Screw
Retaining ring
Retaining
ring seat
1.
Remove agitator as per cleaning instructions.
2.
Remove hole cap, retaining bolt and retaining
washer.
3.
Snap retaining ring out from seating inside motor.
4.
Remove retaining knobs.
5.
Slide seal retainer plate away from kettle.
6.
Slide shaft away from kettle body to allow
clearance for removing quad ring.
7.
Remove quad ring.
8.
Slide new quad ring back into original position,
making sure it does not twist.
9.
Apply light coat of food-safe grease.
10. Slide retainer plate back toward kettle, replacing
retaining knobs -tighten with hand pressure only.
11. Reassemble.
Worm
Screw and
Tilt
Gear
Cross
Bar
These parts are
accessed through the
top cover of the
console.
Apply grease to gear
teeth. Check for
excessive play and adjust with adjusting screw located
on top of cross bar.
Trunnion Housing
Grease Nipple
KETTLE
TRUNNIONS
On the left hand side of
the kettle there are two
grease nipples on the
top back portion of the
trunnion housing. On the
right hand side of the
kettle you must remove
the console cover to
access the two grease
nipples.
PRODUCT VALVE
OIL FILLING PROCEDURE
Replacing O-Rings
1.
Disconnect air supply
and bleed system.
2.
Remove cover on
console.
3.
Check for oiler location.
4.
Inspect oil level in bowl.
CLAMP
5.
Remove filler cap.
0-RING
6.
VALVE
TEE
Add mineral oil as
required.
7.
Replace filler cap and
console cover.
KETTLE
KETTLE
OUTLET
Filler
Cap
Bowl
0-RING
CLAMP
0-RING
CLOSED
POSTITION
OPEN
POSITION
HINGE ADJUSTMENT
INSTRUCTIONS
AIR HOSE
3/8" Allen wrench
AIR
CYLINDER
AIR HOSE
1.
Open product valve.
2.
Disconnect air hoses.
3.
Remove air cylinder.
4.
Remove valve tee.
5.
Remove all O-rings, grease and reinstall new
O-rings as required.
1.
Insert 3/8" Allen wrench.
6.
Reinstall tee to kettle outlet.
2.
Turn clockwise to relieve tension on spring.
7.
Reinstall air cylinder to bottom of tee.
3.
8.
Reconnect air hoses.
While tension is released remove one of the two
slotted screws.
9.
Close valve and check for alignment.
4.
BUSHING REPLACEMENT
PROCEDURE
To prevent Allen wrench from springing back
abruptly while the second slotted screw is
removed, insert a pin (approximately 1/8") in the
hole where the first slotted screw was removed
from.
5.
Remove second slotted screw.
1.
Remove agitator as per cleaning instructions.
6.
While holding Allen wrench remove pin.
2.
Remove bushing by turning 1/4 turn and pulling
away from the kettle wall.
7.
3.
Lubricate metal surfaces with food safe grease.
Turn Allen wrench clockwise to tighten or
counter-clockwise to loosen tension to produce
desired effect.
4.
Install new bushing by locating retaining pin and
sliding bushing on.
8.
Re-insert pin in one of the two holes.
9.
5.
Rotate to lock into position.
Tighten one slotted screw in the other hole (it
may be necessary to turn Allen wrench slightly to
align holes).
6.
Reassemble agitator.
10.
Remove pin and repeat step number 9 for other
slotted screw.
KETTLE VENTING
INSTRUCTIONS
150
0
250
20
A. Water Level Probe.
30
10
300
40
0
50
IR
NT A
VE
VACUUM LEAK TEST
PROCEDURE
If the kettle will not hold vacuum, test for leaks at:
200
100
50
Pressure
Relief Valve
350
60
Valve
Ring
400
psi
kPa
Access
Panel
B. Pressure Relief Valve/Pressure Gauge and
connecting plumbing.
C. Boiler Drain Cap.
D. Sight Glass.
LEAK TEST PROCEDURE:
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.
1. Heat kettle until unit cycles off.
2. Shut off power to the kettle at the fused disconnect
switch.
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.
DANGER: WORKING ON MACHINES
WITH POWER COULD RESULT IN
SEVERE ELECTRICAL SHOCK.
Often, the easiest way to eliminate a leak is reseal the
suspect areas.
1. Water Level Probe
1. Remove Access Panel from
back of main kettle console.
6
5
7
4
8
3
9
2
10
1
OFF
2. Turn kettle ON and set temperature
control to 10, heat the empty kettle
until unit cycles off.
3. Vent kettle by pulling Valve Ring
eight to fifteen times, holding
valve open for two seconds
each time.
NOTE: If unit cycles ON, stop
venting and wait for kettle to cycle
OFF before continuing.
4. 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
30
10
300
40
0
IR
NT A
VE
0
250
20
50
50
60
psi
350
400
kPa
5. If needle is in the green zone then
venting was successful. If not
repeat procedure.
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
A/ Inspect face of gauge. If it contains moisture
on the inside of face replace.
B/ Check tightness of plumbing connection to
pressure Gauge.
3. Sight Glass
A/ Check tightness of sight glass.
B/ Replace "O" ring if required.
RESERVOIR FILL
PROCEDURES
150
WARNING: IMPROPER REFILLING OF
KETTLE JACKET WILL RESULT IN
IRREVERSIBLE DAMAGE TO UNIT.
30
10
300
40
0
IR
NT A
VE
0
250
20
50
1. Ensure kettle is at room
temperature and pressure
gauge showing zero or less
pressure.
200
100
50
60
psi
350
2. Shut off power to the kettle
at the fused disconnect
switch.
400
kPa
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:
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.
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.
CAUTION: Only distilled water should be used when
adding water to a partially filled water reservoir (If unit is
completely empty see KETTLE JACKET FILLING &
DRAINING PROCEDURES). Local tap water conditions
may cause kettle damage which is not covered under
warranty. Rust inhibitor is purchased locally. Read
directions and do not exceed manufacturer's
recommendation (excessive rust inhibitor can also
cause solidification).
Pressure
Relief Valve
Console
Cover
Valve
Ring
Access
Panel
3. Remove Access Panel from back of main kettle
console.
Pressure
Relief Valve
Important- Pull ring on
Pressure Relief Valve prior
to removal to insure vessel
is not pressurized.
4.
Pull Pressure Relief Valve
Ring open to insure vessel is
not pressurized.
5.
Remove main kettle Console
Cover.
6. Remove 1/4" copper tubing
and reducer bushing.
7.
Add distilled water using a
funnel if necessary. Fill the
unit to the high level mark on
the Sight Glass.
8.
Apply a thread sealant (i.e.
Teflon tape) to the reducer
bushing threads and replace.
9.
Replace main kettle Console
Cover and Access Panel.
Sight
Glass
10. Restore power to unit at the fused disconnect
switch.
11. The kettle must now be vented. (Refer to the
KETTLE VENTING INSTRUCTIONS).
PRESSURE RELIEF VALVE
PERIODIC TESTING
Pressure
Relief Valve
Valve
Ring
Access
Panel
Most insurance agencies require periodic testing of
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.
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.
NOTES:
If valve appears to be sticking replace pressure relief
valve.
If foreign material is discharged then drain kettle and
replace pressure relief valve.
See service bulletin (KETTLE JACKET FILLING AND
DRAINING PROCEDURES) for full instructions on the
correct method for draining and refilling kettle jacket.
WARNING: Improper refilling of kettle jacket will result
in irreversible damage to unit.
5. Replace Access Panel.
6. Reconnect main power at fused disconnect switch..
CALIBRATING PROCEDURE
Solid State Temperature
Control Box
Adjustment
Pot
DANGER: WORKING ON MACHINES
WITH POWER COULD RESULT IN
SEVERE ELECTRICAL SHOCK.
NOTE: The following instruction is intended for use by
qualified service personnel.
1.
Insure the unit has a vacuum before you begin
calibrating procedures. If unit requires venting refer
to KETTLE VENTING INSTRUCTIONS.
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.
6
5
7
4
8
3
1. With the kettle empty, turn
unit ON and set temperature
control to 10. Allow the kettle
to heat until the unit cycles
off.
2.
5
7
1
OFF
10
3
9
2
1
10
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 Solid State
Temperature Control Box. Turn
very little. Turn clockwise to INCREASES and
counter-clockwise to DECREASE temperature.
OFF
3. Remove Access Panel at
back of main kettle console.
Pull Pressure Relief Valve
Ring 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.
3. Allow the unit to cycle twice.
8
2. Switch unit OFF and
disconnect main power at
fused disconnect switch.
4.
Turn kettle ON and set
temperature control to 10.
4
9
2
6
7.
Allow the unit to cycle twice.
8.
Check temperature of the inner kettle surface with
a digital surface thermometer.
9. Repeat steps 4. through 8. until unit is calibrated.
KETTLE JACKET FILLING &
DRAINING PROCEDURES
Under normal circumstances the kettle does not require
the draining of all fluid. If the red “low water” light is on,
follow the RESERVOIR FILL PROCEDURES in this
manual.
If unit must be drained follow the procedures described
on the following pages.
WARNING: IMPROPER REFILLING OF
DANGER: WORKING ON MACHINES
WITH POWER COULD RESULT IN
SEVERE ELECTRICAL SHOCK.
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.
KETTLE JACKET WILL RESULT IN
IRREVERSIBLE DAMAGE TO UNIT.
DANGER: EXTREMELY
HOT SURFACES.
WORK ONLY ON COLD KETTLE.
Use only a mixture of water and rust inhibitor to refill
kettle jacket (see instructions below).
Contact your local water treatment company and
purchase rust inhibitor with the specifications described
below.
Recommended Corrosion
Inhibitors for Closed Systems
Pressure
Relief Valve
Access
Panel
Valve
Ring
DESCRIPTION
Recommended for our units is a blend of SODIUM
NITRITE and BORAX for corrosion inhibition of ferrous
metals and axoles for copper and copper alloy
corrosion protection. Product should be formulated for
hot or cold closed recalculating water systems.
Source the chemicals stated above from your local
water treatment company. Mix only with water and
follow manufactures recommended mixing rate.
DISPOSAL OF INHIBITOR
Do not dispose of chemicals in any system which may
discharge into water supplies used for drinking or
washing or that could accidentally discharge into such
systems, or into stream accessible to animals.
Follow all Federal, State and local codes when
disposing of product.
Drain Plug Location
1. Remove Access Panel at back of main kettle console.
2. Pull pressure relief valve chain to ensure there is no
pressure within the kettle jacket.
3. Remove 1/4" copper tubing and reducer bushing.
4. Remove drain plug cap (located underneath the
kettle on the right rear). Allow kettle jacket to drain.
5. Replace filler plug and add water until it shows on
sight glass. Remove Drain Plug cap and allow water
to drain. Repeat until water drains clear.
Refilling Unit
(see RESERVOIR FILL
PROCEDURES).
WARNING: IMPROPER REFILLING OF
KETTLE JACKET WILL RESULT IN
IRREVERSIBLE DAMAGE TO UNIT.
DANGER: EXTREMELY
HOT SURFACES.
WORK ONLY ON COLD KETTLE.
HA DRIVE SHAFT REPLACEMENT PROCEDURE
Note: Disconnect external power supply
and shut off gas to unit prior to servicing.
1.
Remove mixer arm leaving flat surface on drive
shaft facing upwards.
2.
Remove shaft end cap.
3.
Remove shaft retaining bolt.
4.
Remove shaft retaining ring.
5.
6.
8.
Insert new shaft.
9.
Push new shaft past retraining ring groove and
install retaining ring.
Gently hammer out shaft and remove.
Clean seal.
10. Tap shaft back to seat up against retaining ring.
7.
Grease seal with food grade grease.
11. Complete reassembly by reinstalling bolt and
end cap.
FIELD CONVERSION
INSTRUCTIONS Natural Gas to Propane Gas
Power Burner Gas Kettles
KGL-40,
KGL-40-T,
MKGL-40-T,
KGL-60 to 100,
KGL-60-T to 80-T,
KGL-40-TSH,
KGL-40-F to 60-F,
KGL-40-SH to 60-SH,
HA-MKGL-60 to 100,
HA-MKGL-60 to 100-T
BTU's per
Hour
Gas
Type
Water
Column
# of
Orifices
140000
140000
NAT
LP
3.5
3.5
1
1
“O” RING
GAS ORIFICE
190000
190000
NAT
LP
3.5
3.5
1
1
SPRING
PLUG
TOP COVER
NOTE: Use thread sealant compatible with propane gas
on all threaded piping connections.
1.
Disconnect electrical connection.
2.
Shut off main gas supply and disconnect kettle from
supply line.
Conversion Parts Required
KGL-40
Part No.
Description
Quantity
KE95549
Conversion Label
1
3.
Remove TOP COVER.
KE54420-1
Air Intake Washer
1
4.
Remove PLUG and SPRING.
KE53403-5
Gas Orifice
1
FA05002-29
“O” Ring
1
5.
Remove GAS ORIFICE and “O” RING.
6.
Replace with new GAS ORIFICE and “O” RING.
7.
Replace SPRING and PLUG.
KGL-60 to 100
Part No.
Description
Quantity
KE95549
Conversion Label
1
8.
Replace TOP COVER.
KE54420-1
Air Intake Washer
1
9.
Place gas conversion label next to rating label.
KE53403-7
Gas Orifice
1
FA05002-29
“O” Ring
1
10. Reconnect electrical supply.
SPARE PARTS LIST
The following is a spare parts listing of parts that wear during normal us or are apt to be misplaced during
normal operation. These parts should be kept on hand to prevent loss time due to a minor problem.
PART NUMBER
DESCRIPTION
QUANTITY
KE54602
SCRAPER BLADE
1
KE54608
SPRING
3
KE01911
RETAINING KNOBS
1
FA05002-8
"O" RING
3
KE54594
PIN
1
KE54834-4
SOLENOID VALVE
1
KE55248
BUNA-N O-RING
5
KE55255
BUNA-N O-RING
5
FA05002-46
O-RING, FOOD GRADE, SIZE A0123, EPDM E 692-75
5
KE52154-3
GASKET, SANI CLAMP, 1 1/2” WHITE TEFLON
5
KE55297-3
GD2 STANDARD ACTUATOR
1
KE52936-2
FUSE, 15 AMP
6
SE50354
PEN TIP, RED (PKG. OF 5)
1
SE50354
PEN TIP, GREEN (PKG. OF 5)
1
The following is a recommended list of space parts that may be required if the service agency is of some
distance away or if down time must be kept to a minimum and spare parts are required for the service
agent on site.
PART NUMBER
DESCRIPTION
QUANTITY
KE54834-4
SOLENOID VALVE
1
KE55253
AIR OPERATED CYLINDER
1
KE53469-4
IGNITION MODULE
1
KE00458
SOLID STATE CONTROL
1
KE50753-7
RELAY
1
KE00515
THERMISTOR
1
KE50753-10
RELAY, 120 V HOT COLD WATER BYPASS
1
KE02274
CAPACITOR ASSEMBLY
3
KE603208-9
CONTACTOR CARTRIDGE, NORMALLY OPEN
2
KE603208-8
CONTACTOR CARTRIDGE, NORMALLY CLOSED
2
KE50753-10
RELAY
1
AC INVERTER PROGRAMMING INSTRUCTIONS
The WFC Series AC Inverters come wired for external use and must be installed for use in a side panel control (See
WIRING DIAGRAMS). Refer to owners manual for complete instructions and explanations. Manual used for the
following was FORM 1094.
After installation is complete the inverter must be reprogrammed to Cleveland's modifications of the factory settings. All
modifications are achieved in Access Level 2.
1. Turn agitator power on. The top four LED indicators will illuminate momentarily - wait for the three green LED's to go
out before proceeding.
2. Press the PROGram and SHIFT keys simultaneously to reach Access Level 2. The display display will now read:
3. Use the UP/DOWN arrow keys to select the program parameter for change.
4. Press the SHIFT key. The program number will blink indicating that that the data value may be changed.
5. Use the UP/DOWN arrow keys to select the new data code.
6. Press the ENTER key. The display will indicate **STORED** for one second, then revert to the normal parameter
display.
7. Press the PROGram key to exit the programming mode or the UP/DOWN keys to select an new parameter for
change.
PROGRAM CODE SUMMARY:
#
01
02
03
05
06
07
08
09
12
13
14
15
16
17
18
19
21
24
27
31
32
33
34
35
36
37
38
39
41
42
Name
MODEL
RVLVL
IRAT
SERNO
REP
FLT3
FLT2
FLT1
FOUT
VOUT
IOUT
LOAD
TORQ
TEMP
TIME1
TIME2
MODE
FSEL
TLSEL
FMIN
FMAX
F2
F3
F4
F5
F6
F7
FTL
RSEL
ACC1
Description
Model Number
Software Revision
Rated Current
Serial Number
Repair Date
Last Fault
2nd Fault
1st Fault
Output Frequency
Output Voltage
Output Current
Drive Load
Load Torque
Inverter Temp
Total Run Time
Power On Hours
Input Mode
Reference Select
Torque Limit Select
Min. Frequency
Max. Frequency
Preset Speed #2 - Jog
Preset Speed #3
Preset Speed #4
Preset Speed #5
Preset Speed #6
Preset Speed #7
Min. Frequency in Torque Limit
Ramp Selector
Acceleration Time #1
Data Range
0-65000
0-640
2-200
0-65000
0-65000
------0-400
0-100
0-650
0-200
0-200
2-105
0-65000
0-65000
0-36
0-18
0-6
0.00-400
20.00-400
0.00-400
0.00-400
0.00-400
0.00-400
0.00-400
0.00-400
0.00-400
0-7
0.10-600
Factory Setting
Note 1
Note 1
Note 1
--------------------------0
0
0
0
60
5
20
40
60
0
0
10
0
3
Units
----A
----------Hz
%
A
%
%
C
h
h
------Hz
Hz
Hz
Hz
Hz
Hz
Hz
Hz
Hz
--s
Access Level
1
2
2
2
2
1
2
2
1
1
1
1
1
1
2
2
1
2
2
1
1
1
2
2
2
2
2
2
2
1
Customer Setting
4
14
70
9
43
44
45
46
47
48
51
52
53
54
55
56
57
58
59
61
62
DEC1
ACC2
DEC2
DECTL
DCBRK
DCVLT
VSEL
BOOST
FKNEE
SKBND
SK1
SK2
SK3
SK4
MVOLT
LTLF
LTLR
Deceleration Time #1
0.10-600
Acceleration Time #2
0.10-600
Deceleration Time #2
0.10-600
Torq. Limit Response Time
0.10-30
DC Brake Time
0-5
DC Brake voltage
0-15
V/Hz Characteristic Selector
0-5
Torque Boost
0-25
V/Hz Knee Frequency
26-640
Skip Fresq. Hysteresis Band
0.20-20
Skip Frequency #1
0.00-400
Skip Frequency #2
0.00-400
Skip Frequency #3
0.00-400
Skip Frequency #4
0.00-400
Rated Motor Voltage
185-480
Load Torq. Limit Forward
5-150
Load Torq. Limit Reverse
5-150
3
1
1
1
0.2
Note1
0
Note 1
60
1
0
0
0
0
Note 1
150
150
s
s
s
s
s
%
--%
Hz
Hz
Hz
Hz
Hz
Hz
V
%
%
1
2
2
2
2
2
2
1
2
2
2
2
2
2
2
2
2
63
64
65
66
67
68
69
6C
71
72
73
74
75
81
82
83
84
85
86
87
A2
B1
Cx
Ex
RTLF
RTLR
SLIP
STAB
TOL
NRST
DRST
TOLC
METER
ST1
ST2
ST3
STR
PRGNO
START
PWM
DISP
UNITS
LANG
ACODE
RATIO
OPTNO
CNTLx
ECNTx
Regenerative Torq. Limit FWD
5-110
Regenerative Torq. Limit REV
5-110
Slip Compensation
0-10*
Current Stability
0-5
Timed Overload Trip Point
0-100
Restart Number
0-8
Restart Delay
0-60*
Timed Overload Characteristic
0-7
Analog Meter Output
0-7
Auxiliary Output #1
0-11
Auxiliary Output #2
0-11
Auxiliary Output #3
0-11
Auxiliary Relay (Fault)
0-11
Special Program Number
0-65000
Inverter Start Options
0-7
Carrier Frequency Selector
0-1
Display Option Full Setting
0-65000
Display Units
ALPHA
Display Language
0-3
Security Access Code
0-999
Master Slave Speed Ratio (Note 2) 50-2000
Option Board Number
0-6
Event Control (1-9)
BINARY (8)
Event Counts (1-9)
0-65535
80
80
0
2
0
0
0
0
1
6
3
7
2
0
0
0
0
RPM_1
0
0
100
0
0
0
%
%
%
--%
--s
--------------------------%
-------
2
2
1
2
2
2
2
2
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
Bolded areas indicate Cleveland modifications of factory settings.
1
2
8
75
100
3
2
1
WIRING DIAGRAM - DUAL REMOTE
43
WIRING DIAGRAM SINGLE REMOTE