Capkold | Steam Jacketed Kettle DH/INA/2-100 | manual | Capkold Steam Jacketed Kettle DH/INA/2-100 Manual

Capkold Steam Jacketed Kettle DH/INA/2-100 Manual
OPERATOR MANUAL
IMPORTANT INFORMATION, KEEP FOR OPERATOR
This manual provides information for:
MODEL DH/INA/2-100
STEAM JACKETED
KETTLE
· Self-Contained
· Gas Heated
· Floor Mounted
· Tilting
THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE.
READ, UNDERSTAND AND FOLLOW THE INSTRUCTIONS AND
WARNINGS CONTAINED IN THIS MANUAL.
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors
and liquids in the vicinity of this or any other appliance.
POST IN A PROMINENT LOCATION
Instructions to be followed in the event user smells gas.
This information shall be obtained by consulting your
local gas supplier. As a minimum, turn off the gas and
call your gas company and your authorized service agent.
Evacuate all personnel from the area.
WARNING
Improper installation, adjustment, alteration, service or
maintenance can cause property damage, injury or death.
Read the installation, operating and maintenance instructions
thoroughly before installing or servicing this equipment.
NOTIFY CARRIER OF DAMAGE AT ONCE
It is the responsibility of the consignee to inspect the container upon receipt of
same and to determine the possibility of any damage, including concealed damage. Unified Brands suggests that if you are suspicious of damage to make a
notation on the delivery receipt. It will be the responsibility of the consignee to file
a claim with the carrier. We recommend that you do so at once.
Manufacture Service/Questions 888-994-7636.
Information contained in this document is known to be current and accurate at the time
of printing/creation. Unified Brands recommends referencing our product line websites,
unifiedbrands.net, for the most updated product information and specifications.
PART NUMBER 176302, REV. A (01/18)
1055 Mendell Davis Drive
Jackson, MS 39272
888-994-7636, fax 888-864-7636
unifiedbrands.net
IMPORTANT - READ FIRST - IMPORTANT
2
WARNING:
FAILURE TO DISCONNECT POWER BEFORE SERVICING COULD RESULT IN ELECTROCUTION AND
DEATH.
WARNING:
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE
PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENANCE
INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.
WARNING:
DO NOT PLACE HANDS, TOOLS OR HOSES IN KETTLE WHILE AGITATOR IS MOVING. AGITATOR CAN
BE JOGGED WHILE KETTLE IS TILTED.
WARNING:
THE UNIT MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH ELECTRICITY AND
PLUMBING. UNIT MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE CODES.
WARNING:
DO NOT ATTACH THE UNIT TO A TYPE “B” VENT. IT COULD CAUSE FIRE OR PROPERTY DAMAGE.
WARNING:
DO NOT CONNECT ANY PIPING TO THE SAFETY VALVE. IT MUST BE FREE TO VENT STEAM AS
NEEDED. TO AVOID BURNS FROM THE VENTED STEAM THE VALVE DISCHARGE SHOULD POINT
DOWNWARD.
DANGER:
ELECTRICALLY GROUND THE UNIT AT THE TERMINAL PROVIDED. FAILURE TO GROUND THE UNIT
COULD RESULT IN ELECTROCUTION AND DEATH.
CAUTION:
BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE OPERATING INSTRUCTIONS,
CAUTIONS AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL.
CAUTION:
DO NOT OVERFILL THE KETTLE WHEN COOKING, HOLDING OR CLEANING. KEEP LIQUIDS A
MINIMUM OF 2-3” (5-8 CM) BELOW THE KETTLE BODY RIM TO ALLOW CLEARANCE FOR STIRRING,
BOILING AND SAFE TRANSFER OF PRODUCT.
CAUTION:
KEEP FLOORS IN FRONT OF KETTLE WORK AREA CLEAN AND DRY. IF SPILLS OCCUR, CLEAN
IMMEDIATELY TO AVOID SLIPS OR FALLS.
WARNING:
KEEP WATER AND SOLUTIONS OUT OF CONTROLS AND BURNERS. NEVER SPRAY OR HOSE DOWN
THE CONTROL CONSOLE, ELECTRICAL CONNECTIONS, ETC.
CAUTION:
MOST CLEANERS ARE HARMFUL TO THE SKIN, EYES, MUCOUS MEMBRANES AND CLOTHING. TAKE
PRECAUTIONS: WEAR RUBBER GLOVES, GOGGLES OR FACE SHIELD AND PROTECTIVE CLOTHING.
CAREFULLY READ WARNINGS AND FOLLOW DIRECTIONS ON CLEANER LABELS .
NOTICE:
NEVER LEAVE A SANITIZER IN CONTACT WITH STAINLESS STEEL SURFACES LONGER THAN 10
MINUTES. LONGER CONTACT CAN CAUSE CORROSION.
WARNING:
FAILURE TO PERIODICALLY CHECK SAFETY VALVE OPERATION COULD RESULT IN PERSONAL
INJURY AND/OR DAMAGE TO EQUIPMENT.
WARNING:
WHEN TESTING, AVOID EXPOSURE TO THE STEAM BLOWING OUT OF THE SAFETY VALVE. DIRECT
CONTACT COULD RESULT IN SEVERE BURNS.
WARNING:
TO AVOID INJURY, READ AND FOLLOW ALL PRECAUTIONS STATED ON THE LABEL OF THE WATER
TREATMENT COMPOUND.
WARNING:
BEFORE REPLACING ANY PARTS, DISCONNECT THE UNIT FROM THE ELECTRIC POWER SUPPLY
AND CLOSE THE MAIN GAS VALVE. ALLOW FIVE MINUTES FOR GAS TO VENT.
CAUTION:
USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY GROEN OR AUTHORIZED
DISTRIBUTORS CAN CAUSE INJURY TO THE OPERATOR AND DAMAGE TO THE EQUIPMENT AND
WILL VOID ALL WARRANTIES.
OM-DH/INA/2-100
IMPORTANT - READ FIRST - IMPORTANT
WARNING:
KEEP AREA AROUND KETTLE FREE AND CLEAR OF ALL COMBUSTIBLE MATERIALS. FAILURE TO DO
SO COULD RESULT IN FIRE OR PROPERTY DAMAGE.
CAUTION:
HEATING AN EMPTY KETTLE MAY CAUSE THE RELEASE OF STEAM FROM THE SAFETY VALVE.
IMPORTANT: SERVICE PERFORMED BY OTHER THAN FACTORY AUTHORIZED PERSONNEL WILL VOID ALL
WARRANTIES.
OM-DH/INA/2-100
3
Table of Contents
Important Operator Warnings ....................................................page 2-3
References.................................................................................... page 4
Equipment Description.................................................................. page 5
Inspection and Unpacking ......................................................... page 6-7
Installation .................................................................................. page 8-9
Initial Start-Up............................................................................... page 10
Operation ................................................................................ page 11-16
Cleaning........................................................................................ page 17
Maintenance............................................................................ page 18-20
Sequence of Operation ............................................................... page 21
Troubleshooting...................................................................... page 22-23
Part Lists ............................................................................ page 24-36
Wiring Diagram ............................................................................ page 37
Service Log ................................................................................. page 39
References
KLENZADE SALES CENTER
ECOLAB. Inc.
370 Wabasha
St. Paul, Minnesota 55102
800/352-5326 or 612/293-2233
NATIONAL FIRE PROTECTION ASSOCIATION
60 Battery March Park
Quincy, Massachusetts 02269
NFPA/54 Installation of Gas Appliances &
Gas Piping
NFPA/70 The National Electrical Code
NSF INTERNATIONAL
789 N. Dixboro Rd.
P.O. Box 130140
Ann Arbor, Michigan 48113
UNDERWRITERS LABORATORIES, INC.
333 Pfingsten Road
Northbrook, Illinois 60062
ZEP MANUFACTURING CO.
1310-T Seaboard Industrial Blvd.
Atlanta, Georgia 30318
4
OM-DH/INA/2-100
Equipment Description
Model
Ignition
DH-400L
Electronic
FIRING RATE,
BTU/HOUR
Natural
Gas
Propane
Gas
360,000
360,000
Capacity
100 gallons
Diameter
34” (86 cm)
Overall Width
64¼” (163 cm)
Overall
Front-to-Back
54” (137 cm)
Rim Height
54¼” (138 cm)
Groen Model DH-400L is a stainless steel, steam jacketed, floor mounted, tilting kettle
with a self-contained, gas heated steam source. The kettle body is welded into one
piece and furnished with a reinforced bar rim and welded “butterfly” pouring lip. The
interior of the kettle is polished to a 180 emery grit finish and the exterior given a
uniform Number 3 finish.
The unit is ASME shop-inspected and is registered with the National Board for working
pressures up to 50 PSI. Kettle supports mount directly to the floor by use of lag bolts.
A power tilt feature is standard. Options available include: “Gallon Master” metering
system, product outlet strainer, and a power-assist cover, and a digital time-temperature
recorder.
The self-contained steam source is heated by either propane or natural gas. The
ignition system is spark or standing pilot. The kettle is charged at the factory with
chemically pure water containing corrosion inhibitors. The steam source provides kettle
temperatures of 150 to approximately 280ºF. Controls for the unit include a thermostat,
pressure gauge, water level glass, safety valve, pressure limit control, low water cutoff,
gas regulator valve, and a printed circuit board that monitors product temperature. The
gas supply shuts down automatically when the kettle is tilted. The agitator operates only
in partial rotation mode when the kettle is tilted.
The unit must be specified for use with natural or propane gas. Service connections
are required for gas, electric, air (if the air-operated valve is specified), water (if Gallon
Master metering is specified).
Left Stanchion
Kettle Body AssemblyFill Spout
Sight GlassPower-Aid Hinge
Touch Screen Control
Flue Stack, Combustion Chamber
Right Stanchionand Burner Assemblies
OM-DH/INA/2-100
5
Inspection & Unpacking
WARNING
THIS UNIT MUST BE INSTALLED BY
PERSONNEL WHO ARE QUALIFIED TO
WORK WITH ELECTRICITY AND PLUMBING.
IMPROPER INSTALLATION CAN CAUSE
INJURY TO PERSONNEL AND/OR DAMAGE
TO THE EQUIPMENT. THE UNIT MUST
BE INSTALLED IN ACCORDANCE WITH
APPLICABLE CODES.
The unit is delivered completely assembled, on a heavy skid surrounded by a wooden
crate. Immediately upon receipt, inspect the unit for damage. Report any shipping damage
or an incorrect shipment to the delivery agent.
Write down the model number, serial number, and installation date of your unit, and keep
this information for future reference. Space for these entries is provided at the top of the
Service Log provided at the rear of this manual. The unit is anchored to two metal shipping
channels (braces) which may be discarded after installation. Carefully unbolt one side of
shipping channel. Position the kettle and remove second shipping channel.
The unit is delivered crated and
bolted to a heavy skid.
WARNING
SHIPPING CHANNELS (BRACES) ARE VERY
HEAVY. USE PROPER LIFTING AND HANDLING
EQUIPMENT FOR MOVEMENT.
Two heavy shipping channels
(braces) anchor the unit for
shipment.
CAUTION
WATCH OUT FOR NAILS AND SPLINTERS
WHILE DISMANTLING THE SHIPPING CRATE.
CAUTION
UNIT HASAN APPROXIMATE SHIPPING
WEIGHT OF 1600 LBS. (727 KG.). FOR SAFE
HANDLING, INSTALLER SHOULD OBTAIN
PROFESSIONAL RIGGING HELP AS NEEDED
AND USE MATERIAL HANDLING EQUIPMENT
(SUCH AS A FORKLIFT, OVERHEAD HOIST, OR
PALLET JACKS) TO REMOVE THE UNIT FROM
THE SKID AND MOVE IT TO ITS PLACE OF
INSTALLATION.
WARNING
TO AVOID DAMAGE OR INJURY, FOLLOW THE
ELECTRICAL SCHEMATIC EXACTLY WHEN
CONNECTING THE UNIT.
6
OM-DH/INA/2-100
Shipping Channels (Braces)
When installation is to begin, unbolt the unit from the skid, and lift the unit straight up and
off the skid.
UTILITY REQUIREMENTS
1. Electrical Supply Connection-3 Phase Operation Only
a. The panel must be removed to gain access to the electrical supply connection.
Open the wiring and control panel by unscrewing the eight screws which hold it in
place. Grasp the panel by the base at the bottom edge. While lifting the panel, swing
its bottom toward you. Set the panel aside.
b. Supply Voltage: The unit must operate at the rated nameplate voltage, plus or minus
10 percent.
c. Wiring Information: Refer to the electrical schematic for wiring information. A copy
of the schematic is found inside the control panel and at the rear of this manual.
d. Terminal Block: The terminal block for incoming power is located at the back of the
control compartment. The ground terminal is located next to the terminal block. The
unit must have a separate ground wire for safe operation.
e. High Voltage safety
Inspection & Unpacking
f. Branch Circuit Protection: Each conductor must have over-current protection. Refer
to the label on the back of the unit for the proper wire type and size. Connections to
the unit must be watertight.
We strongly recommend that the Kettle have its own branch circuit protection.
Current and power demands for the different voltage units are as follows:
Maximum Voltage Three Phase Current, Per Line
208 Volts
7 AMP
240 Volts
7 AMP
480 Volts
3.5 AMP
2. Water Connection(s)
Install a check valve in the incoming cold water line, if required by local plumbing
codes. Water pressure in the line should be between 30 and 60 PSIG (210 and 420
kPa). A ¾ NPT connector is needed to attach the water supply to the water inlet valve.
The minimum recommended water feed line diameter is ½ inch (13mm). Do not allow
the connection to leak, no matter how slowly. THE INSTALLER MUST PROVIDE THE
Gas and Water Connections are on the
CHECK VALVE (ANTI-SYPHON DEVICE) IF REQUIRED BY LOCAL CODES.
back of the left stanchion.
3. Gas Connection
Connect 1 NPT gas line to the gas inlet valve on the rear of the left stanchion. Be sure
that the gas supply meets the following criteria:
Natural Gas
Propane
Minimum
7” W.C.
11” W.C.
Maximum
10” W.C.
14” W.C.
OM-DH/INA/2-100
7
Installation
WARNING
THIS UNIT IS FOR COMMERCIAL USE.
NEVER USE HOME OR RESIDENTIAL
GRADE GAS CONNECTIONS.
THEY DO NOT MEET GAS CODES AND
COULD BE HAZARDOUS.
WARNING
DO NOT ATTACH THE UNIT TO A TYPE “B”
VENT. FAILURE COULD RESULT IN FIRE OR
PROPERTY DAMAGE.
Recommended shim size.
Don’t lift here
8
OM-DH/INA/2-100
The unit should be installed in a well-ventilated room on non-combustible flooring.
Anything which might obstruct or restrict the flow of air for combustion and ventilation
must be removed. The area directly around the appliance must be free of combustible
materials.
1. Installation requires connection with air, gas, water and electric services. See items
8 to 14 for details.
2. To protect the unit from damage, leave it on the shipping pallet until installation. When
ready to start installation, disassemble the shipping crate, unbolt the stanchions,
disconnect the shipping channels (braces) and raise the unit straight up off the skid.
Do not lift the kettle at the heat exchanger. Lifting the kettle at the heat exchanger
could damage the unit.
3. Install the unit with at least 22 inches clearance from the back walls. Also leave
enough room for easy cleaning, maintenance, and service.
4. Do not alter the kettle in any way. Any mechanical, electrical, or gas change must be
approved by the Groen Food Service Engineering Department.
5. Level the unit as follows:
The stanchions are each supplied with a drip tray in which the angle frame is placed.
Steel leveling shims (not included, supplied by installer) are placed between the drip
tray and frame so that the drip tray will be flush with the floor, as shown.
Start with the right stanchion and level it as shown in the sketch. Once the right
stanchion is levelled and properly anchored front to rear, level the left stanchion front
to rear and side to side.
Level the entire unit side to side by placing a four foot carpenter’s level on the kettle
rim. Once the rim is level from side to side, rotate the level to check front to back.
Shim the left stanchion in the same manner as the right, and anchor the equipment
firmly to the floor through the shims.
6. Make sure the jacket water level is correct by confirming that it is in the middle of
the bulls-eye sight glass at the front of the kettle. If the water level is low, follow the
instructions under “Jacket Filling” in the “Maintenance” Section of this manual.
7. To protect personnel from steam coming from the safety valve, the open end of the
elbow at the outlet must be directed downward. If it is not, turn the elbow to the
correct position.
8. INSTALL:
Check valve in the incoming cold water line, if required by local plumbing codes, as
described in Paragraph 2, page 6.
Installation
WARNING
DO NOT CONNECT ANY PIPING TO THE POP
SAFETY VALVE. IT MUST BE FREE TO VENT
STEAM AS NEEDED. THE ELBOW SHOULD
POINT DOWN TOWARD FLOOR. IMPROPER
INSTALLATION WILL VOID WARRANTY.
DANGER
ELECTRICALLY GROUND THE UNIT AT THE
TERMINAL PROVIDED. FAILURE TO
GROUND UNIT COULD CAUSE
ELECTROCUTION AND DEATH.
9. Provide electrical service per Paragraph 1, Electrical Supply Connecton in the
Inspection and Unpacking, Requirements Section, Page 6. Use ½ inch waterproof
conduit and waterproof connections. Observe local Codes and/or The National
Electrical Code in accordance with ANSI/NFPA 70 - latest edition. AN ELECTRICAL
GROUND IS REQUIRED. The electrical schematic is located on the inside of the
service panel. In Canada, provide electrical service in accordance with the Canadian
Electrical code, CSA C22.1 Part 1 and/or local codes.
10. The internal gas lines of the unit were cleaned and closed with a gas cock before
the unit was shipped from the factory. Ensure that external gas lines are free of lint,
dirt, metal chips, sealant, grease, oil or other contaminants, before you connect the
line to the kettle.
11. Connect the kettle gas cock to the gas service main using a 1” NPT gas connection.
12. Installation must conform with local codes, or in the absence of local codes, with
the National Fuel Gas Code, ANSI Z 223.1-1988 (or latest edition). The unit should be
installed in an well-ventilated room with a provision for adequate air supply. The best
ventilation will use a vent hood and exhaust fan with no direct connection between
the vent duct and the unit flue.
Do NOT obstruct the flue or vent duct after installation. In Canada, the installation
must conform with the CAN/CGA B149 Installation Codes for Gas Burning Appliances
and Equipment and/or local codes.
13. Adequate space for proper service and operation is required. Do NOT block any
air intake spacings to the combustion chamber or obstruct the air flow by piling or
stacking anything near the kettle.
14. After the kettle has been connected to the gas supply, all gas line joints must be
checked for leaks. DO NOT USE A FLAME TO CHECK FOR LEAKS. A thick soap solution
or other suitable leak detector should be used.
15. The appliance and its individual shutoff valve must be disconnected from the gas
supply piping system during any pressure testing of that system at test pressures
in excess of ½ PSIG (3.48 kPa). The appliance must be isolated from the gas supply
piping system by closing its individual manual shutoff valve during any testing of the
gas system at pressures equal to or less than ½ PSIG (3.48 kPa).
16. Check the following to confirm that your kettle has been installed properly:
• Enough room between the kettle and nearby objects for cleaning and service.
• Minimum clearance of 24 inches from sides and 24 from back.
• Unit vented to an exhaust hood.
• Kettle level.
• Correct amount of water in the jacket.
• Safety valve outlet pointed down.
• Connected with a waterproof electric power cable in accordance with Paragraph
1 Electrical Supply Connecton (above) and local electrical codes.
• Gas lines cleaned before connection.
• Gas connected with 1 NPT or larger.
• Gas line joints checked for leaks.
• No obstruction to air supply or venting.
• Gas lines (1 NPT) connected to supply.
• Water supply connection (¾”) completed.
OM-DH/INA/2-100
9
Initial Start-Up
After the kettle has been installed, the installer should test to ensure that the unit is
operating correctly.
1. Remove all literature and packing materials from the inside and outside of the unit.
Clean out any material that might clog or damage the product outlet.
2. Add 50 gallons (180 liters) of water to the kettle to provide sufficient product for
testing.
3. Make sure the supplies of gas and electric power are on.
4. Following “Start Kettle Heating” instructions in the “Operating Instructions” section
of this manual, begin heating the water at the highest thermostat setting. The pilot
lamp should come on as soon as you pull out the emergency stop and turn on power.
Heating should continue until the water boils.
5. To turn off the unit, follow “To Stop Kettle Heating” in “Operating Instructions,” below.
If the kettle functions as described, it is ready for use. If the unit does not operate as
designed, contact an authorized Groen Service agent.
10
OM-DH/INA/2-100
Operation
WARNING
ANY POTENTIAL USER OF THE EQUIPMENT
MUST BE TRAINED IN SAFE AND CORRECT
OPERATING PROCEDURES.
CONTROLS
WARNING
KEEP AREA AROUND KETTLE FREE AND
CLEAR OF ALL COMBUSTIBLE MATERIALS.
OPERATING INSTRUCTIONS
CAUTION
HEATING AN EMPTY KETTLE MAY
CAUSE THE RELEASE OF STEAM FROM
THE SAFETY VALVE.
Refer to the drawing on the following page for identification and function of kettle
controls.
Refer to the drawing on the following page for identification and function of kettle
controls.
1. CHECK THE WATER LEVEL IN THE JACKET EVERY DAY. The level must be in the middle
of the bulls-eye sight glass. If the level is low, see “Jacket Filling” in the “Preventive
Maintenance” section of this manual.
2. With the kettle cold, check the pressure gauge. If it does not show 20 or more inches
of vacuum (a reading of 20 to 30 below 0), see “Jacket Vacuum” in the “Preventive
Maintenance” section of this manual.
3. Start Kettle Heating
a. Open main gas supply valve.
b. Pull OUT the emergency stop and turn ON the control power switch on the front
of the right stanchion.
c. The touch-screen control panel should be ON (if not, check that mains power is
connected to the unit and the mains circuit breaker is on).
OM-DH/INA/2-100
11
Operation
WARNING
DO NOT ATTEMPT TO LIGHT PILOT
MANUALLY WITH A FLAME.
4. Cooking Control
a. Touch the COOK CONTROL on the screen. The display will change to show the
main cooking control screen. This screen allows user to control kettle tilt, cooking
operation, water fill, turbo heat; and displays current product temperature in
degrees Celsius, desired cooking temperature in degrees Celsius; and lamp
status of the pilot, main gas vale, low fire burner and high fire burner.
b. Ensure kettle is tilted fully upright. If not, press TILT CONTROL on the screen.
The pop-up tilt control will appear. Press continuously on either TILT UP or TILT
DOWN until the kettle comes to a fully upright position. The tilt controls will turn
bright green when pressed and will go dark when released [Note: Press TILT
CONTROL to minimize the tilt feature on the screen.]
c. The PILOT and MAIN indicators on the screen should show green.
d. Press FAUCET FILL on the screen. The pop-up faucet fill controls will appear.
12
OM-DH/INA/2-100
Operation
CAUTION
KEEP FLOORS IN FRONT OF KETTLE WORK
AREA CLEAN AND DRY. IF SPILLS OCCUR,
CLEAN IMMEDIATELY TO AVOID THE
DANGER OF SLIPS OR FALLS.
The kettle can be filled automatically or manually by tapping on the FILL control.
i. In the AUTO mode, tap on the WATER FILL SETPOINT – a display will appear
allowing you to select a desired quantity of Liters and enter them.
Tapping once on the START FILL control will initiate water fill through the
faucet. The control will turn bright green during the fill operation and go dark
once the fill setpoint is reached. Automatic fill can be interrupted by either
setting the FILL switch to MANUAL or pushing in an EMERGENCY STOP.
ii. In the MANUAL mode, press on the START FILL control and hold until the
desired quantity of water is delivered through the faucet. The TOTAL LITERS
counter can be used to observe manual fill operation – press the RESET
COUNTER to clear the indication before starting manual fill operation.
iii. Kettle must not be allowed to heat without at least 25% of its capacity of
product/water present. The rate-of-Rise feature will shut the kettle down if
there is insufficient product present during heating.
NOTE: Press FAUCET FILL to minimize the water fill feature on the screen.
OM-DH/INA/2-100
13
Operation
e. Press COOK CONTROL on the screen. The pop-up cook controls will appear.
i. Tap on the COOK SETPOINT to bring up a key pad to select the desired
cooking temperature. Enter the numerical value in degrees Celsius and press
ENTER. The display should change to the selected value.
ii. Tap the COOK switch to turn ON or OFF the cook function. During the cook
function the burners will cycle to provide the necessary amount of heating
– during heat up to cook temperature, both the LOW FIRE and HIGH FIRE
burner indicators will indicate green – once the temperature approaches the
setpoint, the HIGH FIRE burner will shut off and the indicator will go dark.
NOTE: The BATCH CONTROL function is used in conjunction with an
externally located multi-channel electronic chart controller. Both the kettle
and the chart recorder have to be connected to an Ethernet router to allow
communications between devices. Setup and operation of the batch control
function are described in a separate manual.
iii. The TEMPERATURE RATE OF RISE EXCEEDED!!! caution will appear on
screen and shut the unit down on both low and high fire. Add more water or
product to the kettle, press the ROR RESET to clear the lockout, and restart
the kettle cooking feature by switching the COOK switch to ON.
14
OM-DH/INA/2-100
Operation
WARNING
DO NOT STAND IN FRONT OF KETTLE
DURING TILTING. PRODUCT IS HOT AND
WILL CAUSE BURNS. EXERCISE EXTREME
CARE WHED HANDLING OR NEAR
HOT OR BOILING LIQUIDS.
f. Once the cooking setpoint is reached, the TURBO HEAT function can be used to
provide a short burst (factory preset at 30 seconds) of both high and low fire if
needed to fine tune the cooking function.
g. If mains power is interrupted during a cooking cycle, the kettle and display will
power up automatically, but the cook cycle will have to be re-started on the
COOK CONTROL pop-up display. All of the setting will have been preserved in
non-volatile memory, and will not have to be re-entered.
h. To turn off the cook process, tap the COOK switch on the COOK CONTROL
display to the OFF position. Both the LOW FIRE and HIGH FIRE indicators should
go dark.
i. To empty the kettle, first raise the cover, and then press the TILT DOWN button
on the TILT CONTROL display to slowly empty the kettle contents into suitable
capacity container(s).
5. Kettle Shut-Down
a. Clean the kettle thoroughly at the end of a cook cycle, making sure that all
surfaces are free of dirt and cooking material. Sanitize all cooking surfaces, let
dry and rinse clear.
b. Turn OFF the control power switch on the front of the right stanchion.
c. If the kettle will remain off for more than one day, turn off the mains power circuit
breaker switch.
PRESSURE GAUGE/INDICATORS/WATER LEVEL
20” to 30” of Vacuum (below 0 mark)
Top of the Window
(kettle tilted fully upright)
Check Vacuum and Water Level Daily
OM-DH/INA/2-100
15
Operation
LEFT & RIGHT STANCHION CONTROLS
Emergency Stop Switch (Left)
HMI Controller
Control Power On/Off Switch
Emergency Stop Switch (Right)
16
OM-DH/INA/2-100
OM-TD
OM-TD
Cleaning
another container,
being sure to avoid
WARNING
contact with hot product and hot basket1. Suggested Cleaning Supplies:
KEEP WATER AND SOLUTIONS OUT OF
or. . .
a. A high quality detergent and sanitizer, or a combination cleaning-
CONTROLS AND ELECTRICAL EQUIPMENT.
sanitizing agent.
DO NOT USE A HIGH PRESSURE HOSE TO
OM-TD
f) Place basket with food on stable, flat
b. Kettle brushes in good condition.
CLEAN THE CONTROL CONSOLE,
surface, setting it inside a solid steamer
ELECTRICAL
CONNECTIONS,
ETC.
another
being
sure tohot
avoid c. Groen Spray Degreaser (PN 114801) or equivalent.
or bake
pan, container,
to catch any
remaining
contact
hot
product
hot basket
water
whichwith
might
drain
from and
product.
d. Groen De-limer/De-scaler (PN 114800) or equivalent.
CAUTION
or. . .
e. A high quality stainless steel cleaner.
NEVER LEAVE A CHLORINE SANITIZER IN
f) CONTACT
Place basket
with foodSTEEL
on stable, flat
WITH STAINLESS
2. Precautions
surface, FOR
setting
it inside
SURFACES
LONGER
THANa30solid steamer
ning
Before any cleaning operation, turn off the burner system by setting the COOK
or bakeLONGER
pan, toCONTACT
catch any
remaining hot
MINUTES.
CAN
water
which
might drain from product.switch on the COOK CONTROL screen to the OFF position. Cut off electric power to
CAUSE
CORROSION.
the unit by setting the CONTROL POWER switch to the OFF position.
c. Prepare a hot solution of the detergent/
cleaning compound
CAUTIONas instructed by the3. Procedure
supplier.
MOST
CLEANERS ARE HARMFUL TO THE
a. Clean food contact surfaces as soon as possible after use, preferably while the
eaning SKIN, EYES, MUCOUS MEMBRANES AND
kettle is still warm. If the unit is in continuous use, clean and sanitize inside and
CLOTHING. PRECAUTIONS SHOULD BE
outside at least once every 12 hours.
TAKEN TO WEAR RUBBER GLOVES,
c. Prepare a hot solution of the detergent/
b. Scrape and flush out large amounts of food residues. Be careful not to scratch
GOGGLES OR FACE SHIELD AND
cleaning compound as instructed by the the kettle with metal implements.
PROTECTIVE CLOTHING. CAREFULLY
supplier.
READ THE WARNINGS AND FOLLOW
c. Prepare a solution of the detergent/cleaning compound as instructed by the supLABEL DIRECTIONS.
plier. Clean the unit thoroughly. A cloth moistened with cleaning solution can be
OM-TD
d.
e.
f.
Use brushes, sponges or cloth to clean your
kettles
Use a brush, sponge, cloth, plastic or
rubber scraper, or plastic wool to clean.
Use brushes, sponges or cloth to clean your
kettles
Don’t use metal implements
or steel wool when cleaning.
Don’t scrape with tools, steel wool or other
abrasives.
d.
g.
h.
i.
j.
k.
used to clean controls, housing, electrical conduit, etc.
Rinse the kettle thoroughly with hot water. Then drain completely.
As part of the daily cleaning program, clean all inside and outside surfaces that
may have been soiled. Remember to check such parts as the underside of the
cover, control housing, etc.
To remove burned-on foods, use a brush, sponge, cloth, plastic or rubber scraper, or plastic wool along with the cleaning solution. To reduce effort required in
washing, let the detergent solution sit in the kettle for a few minutes and soak
into the residue. Do NOT use abrasive materials or metal tools that might scratch
the surface. Scratches make the surface harder to clean and provide places for
bacteria to grow. Do not use steel wool, which will leave particles in the surface
and cause eventual corrosion and pitting.
The outside of the unit may be polished with a recognized stainless steel cleaner.
When the equipment needs to be sanitized, use a sanitizing solution equivalent
to one that supplies 100 parts per million chlorine. Obtain advice on the best
sanitizing agent from your supplier of sanitizing products. Following the suppliers instructions, apply the sanitizing agent after the unit has been cleaned and
drained. Rinse off the sanitizer thoroughly.
It is recommended that each piece of equipment be sanitized just before use.
If there is difficulty removing mineral deposits or a film left by hard water or food
residues, clean the kettle thoroughly and then use a deliming agent, like Groen
Delimer/Descaler (Part Number 114800), in accordance with the manufacturer’s
directions. Rinse and drain the unit before further use.
If cleaning problems persist, contact your cleaning product supplier for assistance. The supplier has a trained technical staff with laboratory facilities to serve
you.
Clean the unit thoroughly, inside and
outside.
Don’t
scrape
steel wool
e.
Rinse
the with
kettletools,
thoroughly
with or
hotother
OM-DH/INA/2-100
17
Maintenance
WARNING
AVOID ANY EXPOSURE TOTHE STEAM
BLOWING OUT OF THE SAFETY VALVE. SEVERE
BURNS CAN RESULT ON EXPOSED SKIN.
FAILURE TO CHECK SAFETY VALVE OPERATION
PERIODICALLY COULD RESULT IN PERSONAL
INJURY AND/OR DAMAGE TO EQUIPMENT.
WHEN TESTING, AVOID ANY EXPOSURE
TO THE STEAM BLOWING OUT OF THE
SAFETY VALVE. DIRECT CONTACT COULD
RESULT IN SEVERE BURNS.
This section describes actions the operator must take to maintain warranty coverage
and to keep the unit working safely and efficiently.
1. Jacket Vacuum/Removing Air from Jacket
Every day, while the kettle is cold, read the pressure/vacuum gauge. A positive
pressure reading or a vacuum reading between zero and 20 on the pressure/ vacuum
gauge indicates excess air in the jacket. Air in the jacket slows kettle heating and
can prevent the kettle from reaching operating temperature. To remove air:
a. Start the kettle. (See the “Operation” section of this manual).
b. Make sure the elbow on the outlet of the safety valve is turned so it will direct
escaping steam down toward the floor.
c. When the pressure/vacuum gauge reaches a positive pressure reading of five
PSI, release entrapped air and steam by lifting the safety valve lever for about
one second. Repeat this step, then let the valve lever snap back into the closed
position, so the valve will seat properly and not leak.
2. Test Safety Valve
At least twice a month, test the safety valve. Test the valve with the kettle operating
at 15 psi (105 kPa), by holding the test lever for at least five seconds. Then release
the lever and permit the valve to snap shut. If the lever does not activate, there is no
discharge, or the valve leaks, stop using kettle immediately and contact a qualified
factory service representative.
3. Jacket Filling
Every day, before you turn on the unit, make sure the water level is between the
marks on the water gauge glass. The jacket was filled at the factory with the proper
amount of treated water. From time to time, you may need to restore the water to
its proper level, either because water was lost as steam during venting or because
treated water was lost by draining. The procedure follows.
a. If you are replacing water lost as steam, use distilled water. Do not use tap water.
If you are replacing treated water that was drained from the jacket, prepare more
treated water first, as directed below.
b. Allow the kettle to cool completely. Remove the pipe plug from the jacket fill
assembly. Then open the gate valve and pour in the distilled or treated water.
Using a funnel will help you in this process. Hold the safety valve open while you
pour, to let air escape from the jacket. Continue adding water until the water level
rises to a point between the marks on the gauge glass.
c. Close the gate valve.
d. Air that gets into the jacket during the filling operation must be removed because
it will make heating less efficient. Follow the procedure in “Jacket Vacuum,”
above to restore a negative pressure reading.
18
OM-DH/INA/2-100
Maintenance
WARNING
TO AVOID INJURY, READ AND FOLLOW ALL
PRECAUTIONS STATED ON THE LABEL OF
THE WATER TREATMENT COMPOUND.
4. Water Treatment
a. Fill a mixing container with the amount of water required (distilled water
preferred). The kettle requires 5½ gallons (20.4 liters).
b. Follow instructions. Apply to Groen water treatment kit part number 110324.
c. Hang a strip of pH test paper on the rim of the container, with about 1 inch of the
strip below the surface of the water.
d. Stir the water continuously, while you slowly add water treatment compound
until a color between indicating a pH of 10.5 and 11.5 is reached. (Shown on the
pH test kit chart.) Judge the pH by frequently comparing the test strip with the
color chart provided in the pH test kit.
e. Use a measuring cup to add the compound so that you may record the exact
amount used. The amount may be used again, if the same water sources and
compound are used in the future. However, it is best to check the pH each time
treated water is prepared.
5. Venting System
Periodically check the hood to make sure that nothing will block or hinder the free
flow of exhaust gases.
OM-DH/INA/2-100
19
Maintenance
WARNING
AVOID ANY EXPOSURE TO THE STEAM
BLOWING OUT OF THE SAFETY VALVE. SEVERE
BURNS CAN RESULT ON EXPOSED SKIN.
A Service Log is provided at the rear of this manual. Each time service is performed on
this Groen equipment, enter the date on which the work was done, and who did it. Keep
this manual with the equipment.
1. Periodic Service
Periodic inspection will minimize equipment down time and increase efficiency of
operation. The following points should be checked regularly.
a. Every day, when the kettle is cold, the pressure/vacuum gauge should show a
vacuum of 20 to 30 inches. If it does not, see ”Jacket Vacuum” in the “Preventive
Maintenance” section of this manual.
b. Every day, the jacket water level must be in the middle of the bulls-eye sight
glass. If it is not, see “Jacket Filling” in the “Preventive Maintenance” section of
this manual.
c. Keep the primary air shutter of the burner gas jets free of dust and lint.
d. The pilot flame should be blue and should envelop about ½ inch of the flame
sensor tip.
e. Keep electrical wiring and connections in good condition.
f. Keep the inside of the control console clean and dry.
g. Keep the burner ports clean.
h. Keep the burner shield and adjacent parts clean.
i. Twice a month, check the safety valve to make sure that it works freely. When
gauge pressure is about 5 PSI, lift the valve lever enough to vent steam, then
quickly let it snap back into place.
2. Component Replacement
When replacement involves breaking a gas pipe connection, check the new
connection with soap solution or other appropriate leak detector.
DO NOT USE A FLAME TO TEST FOR LEAKS. Internal wiring is marked as shown on
circuit schematic drawings. Be sure that new components are wired in the same
manner.
20
OM-DH/INA/2-100
Sequence of Operation
The following “action-reaction” outline is provided to help service personnel understand
how the unit functions for systematic troubleshooting and fault isolation.
When the operator turns the heat to “ON”, electric power at 120V is supplied to the
thermostat. The automatic gas control is then energized. Simultaneously, an electric
arc is established at the spark gap, and the automatic valve for the pilot burner opens.
When the electric spark ignites gas flowing from the pilot burner, a pilot flame probe
detects the flame. The probe sends a control signal that causes the spark to shut off and
a circuit to close for 24 V power.
The 24 V provides power for the heating indicator light and the main automatic valve.
Gas flowing from the main burner is ignited by the pilot flame. If a pilot flame is not
sensed within 60 seconds after the spark, a timer shuts down the whole operation.
As heat from the main burner brings the temperature of steam in the jacket up to
the thermostat setting, the thermostat switch opens. With electric power cut off, the
main burner valve closes and turns off the burner. When jacket steam cools below the
thermostat set point, the thermostat switch closes and begins another heating cycle.
On-off cycling continues to maintain the kettle at the desired temperature.
The thermostat controls heating by alternately calling for flames at the full capacity of
the main burner or signaling the control to shut the burner completely off. Because the
control works in this “all or nothing” way, the kettle will heat as fast as it can until it
reaches the set temperature, no matter what that temperature is.Turning the thermostat
dial to a higher setting will cause heating to continue longer, until the kettle reaches the
higher temperature, but it cannot make the unit heat any faster.
The unit is equipped with a Pressure Limit Switch, Low Water Cut-Off and a Safety
Valve. These safety features operate as follows:
1. Pressure limit switch: If jacket steam pressure exceeds 43 PSI, the switch opens and
breaks the electrical circuit to the main gas valve solenoid coil. The valve closes and
stays closed until jacket pressure decreases to 44 PSI. The pressure limit switch
then closes, energizes the gas valve coil, and allows operation to resume.
2. Low-water cutoff: As long as steam jacket water touches the cutoff electrode, kettle
operation can continue. If the water falls below the end of the electrode, an electrical
control circuit is broken, and the main gas valve closes. Jacket water must be
restored to a safe operating level before the kettle can be heated again.
3. Safety valve: If steam pressure in the jacket reaches 50 PSI, the valve will open and
relieve the excess pressure.
OM-DH/INA/2-100
21
Troubleshooting
Your Groen kettle is designed to operate smoothly and efficiently if properly maintained. However, the following is a list of checks to
make in the event of a problem. Wiring diagrams are furnished inside the service panel. X indicates items which must be performed
by an authorized technician.
WARNING
BEFORE REPLACING ANY PARTS, DISCONNECT THE UNIT FROM THE ELECTRIC POWER SUPPLY AND
CLOSE THE MAIN GAS VALVE. ALLOW FIVE MINUTES FOR UNBURNED GAS TO VENT.
CAUTION
USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY GROEN OR THEIR AUTHORIZED DISTRIBUTOR CAN
CAUSE INJURY TO THE OPERATOR AND DAMAGE TO THE EQUIPMENT AND WILL VOID ALL WARRANTIES.
SYMPTOM
WHO
WHAT TO CHECK
Kettle continues heating
after it reaches desired
temperature.
User
a. That the temperature controller is correct.
Kettle stops heating before
it reaches the desired
temperature.
User
a. That the temperature controller setting is correct.
b. That the Heat on/off switch is ON.
c. Reading of the pressure/vacuum gauge. If it is not 20 to 30
below zero when the kettle is cold, see “Jacket Vacuum” in the
“Preventive Maintenance” section of this manual.
Pilot burner and/or burner
will not light or goes out
after working for a while.
User
a. That the main gas valve is open (handle is in line with the gas
pipe)
b. That the Heat on/off switch is ON.
c. That the temperature controller is at the correct setting.
d. Use the “Start Kettle Procedure.” See the manual’s “Operation”
Section.
e. Jacket water level. If it is low, see “Jacket Filling” in the
“Preventive Maintenance” section of this manual.
f. That electric power is turned on at the circuit breaker or fuse
box, and that power is being supplied to your building.
g. Gas supply to your building.
h. Is steam trap working?
Kettle heats slowly.
User
a. Reading of the pressure/vacuum gauge. If not 20 to 30 below
zero when the kettle is cold, see “Jacket Vacuum” in the
“Preventive Maintenance” section of this manual.
Authorized
b. Check operation of pressure limit switch. X
Service Rep Only
Safety valve pops.
22
OM-DH/INA/2-100
User
a. Reading of the pressure/vacuum gauge. If it is not 20 to 30
below zero when the kettle is cold, see “Jacket Vacuum” in the
“Preventive Maintenance” section of this manual.
Troubleshooting
System does not produce a
spark.
Authorized
a. Thermostat, and close the contacts if they are open. X
Service Rep Only b. AC voltage between terminals “2” and “GR”. If it is not 24 Volt:
(1) Check high limit switch, which should be closed. X
(2) Replace the transformer. X
c. Pilot spark gap. Regap, if it is not 7/64 inch. X
d. Pilot electric ceramic for crack or break. X
e. That the high tension cable is firmly attached and in good
condition. If cracked or brittle, replace the pilot. X
f. Replace the electronic portion of the G60 electronic system. X
Spark is present but the
pilot will not light.
Authorized
a. That the pilot valve is securely connected to terminals “1” and
“GR”. Some models have the pilot valve grounded internally. X
Service Rep Only
b. That gas pressure meets the control manufacturer’s
specifications. X
c. For gas at the pilot. If it is not flowing:
(1) Check the pilot gas line for kinks and obstructions. X
(2) Replace the pilot valve. X
d. That the pilot spark gap is 7/64 inch and located in the pilot gas
stream. If not, adjust or replace the pilot. X
e. Pilot orifice, and clean, if necessary. X
f. For drafts. Shield the pilot burner, if necessary. X
Pilot lights, but main burner
will not come on, and
spark does not stay on.
Authorized
a. For 24 V between terminals “3” and “GR”. If voltage is not
Service Rep Only
correct, replace the G60 electronics. X
b. That the gas pressure meets the control manufacturer’s
specifications. X
c. Electrical connections to the main valve to terminals “3” and
“GR”, to assure that they are securely attached. If they are,
replace the main valve.”
Pilot lights, but main burner
will not come on, the spark
stays on.
Authorized
a. Sensor cable, to make sure of secure and attachments to the
sensor and to terminal “4” the G60. X
Service Rep Only
b. That the cable is not grounded. If it is, correct the ground fault. X
c. Cable for continuity and insulation condition. X
d. Sensor ceramic for cracks. X
e. That sensor probe current is less than 0.7 microamp, by
disconnecting the sensor cable from terminal “4” and
connecting a DC microammeter between the sensor cable
terminal and terminal “4”. If the current is equal to or greater
than 0.7 microamp, replace the G60 electronics. X
If the current is less than 0.7 microamp:
(1) Check the gas pressure. X
(2) Clean the pilot assembly. X
(3) Tighten mechanical and electrical connections. X
f. Pilot application and correct to increase sensor probe current,
by:
(1) Increasing or decreasing pilot orifice size. X
(2) Shielding the pilot from drafts. X
OM-DH/INA/2-100
23
172194
KETTLE BODY ASSEMBLY
Location
Ref
Function or Connection
A
LEFT TRUNNION
B
RIGHT TRUNNION
C
POUR LIP
D
WELL AND COUPLING FOR RTD
E
WATER LEVEL SIGHT GLASS
F
HEAT EXCHANGE FIN-TUBES
G
COUPLING FOR WATER LEVEL PROBE
H
COUPLING FOR TEMPERATURE PROBE
I
ASME DATA PLATE
Description
Part #
-
LABEL, DISTILLED WATER
Z026450
-
PROBE, TEMPERATURE, 6” LONG
115369
-
VALVE, SAFETY, 50 PSI, ¾ NPT
Z005587
-
ASSEMBLY, WATER FILL
115372
-
ELBOW, 90 DEGREE, ¾ NPT
Z010668
-
ASSEMBLY, PLATE & CHAIN
Z8832
-
24
Parts List
ASSEMBLY, FAUCET BRACKET&
SPOUT
FLUE STACK/COMBUSTION
CHAMBER ASSEMBLY
OM-DH/INA/2-100
115247
149665
172278
LEFT STANCHION ASSEMBLY
Ref
Description
Parts List
Part #
1
NIPPLE, 1 NPT, 7" LONG
Z002490
2
NIPPLE, 1 NPT, 21" LONG
Z014018
3
ELBOW, 90 DEGREE, 1" NPT
Z010006
4
ELBOW, 90 DEGREE, 3/4 NPT, SS
Z009802
5
NIPPLE, 3/4 NPT, 6-1/2" LONG, SS
Z006230
6
HOSE, WATER FILLER
172466
7
ADAPTER, SWIVEL, 3/4 NPT, SS
115284
8
ADAPTER, 3/4 NPT, SS
115283
9
ASSEMBLY, WATER PIPING
172474
10
NIPPLE, 1 NPT, 15-1/2" LONG
Z014019
11
JOINT, SWIVEL, 1 NPT, (GAS)
115275
12
COUPLING, FULL, 1 NPT
Z010230
13
BLOCK, PILLOW
115225
14
BEARING, BRONZE
115268
16
NUT, HEX, KEPS, 1/4-20
Z012940
17
SCREW, HEX HEAD, 1/2-13, 2" LONG
Z083944
18
NUT, HEX, 1/2-13
Z003565
19
SCREW, SET, CUP POINT, 3/8-16, 5/8" LONG
Z012060
20
SET COLLAR, 3" TRUNNION
115239
21
FITTING, GREASE, STRAIGHT, 1/4 NPT
Z009547
22
NIPPLE, 3/4 NPT, 12" LONG
133409
23
COUPLING, FULL, 1 NPT
Z010230
24
SCREW, TRUSS HEAD, 10-32, 1/2" LONG
Z072189
25
COVER, STANCHION, LEFT SIDE
172383
26
ASSEMBLY, INNER CLADDING, STANCHION,
LEFT SIDE
172267
27
LABEL, NATURAL GAS
Z087993
27
LABEL, PROPANE GAS
Z087992
28
ASSEMBLY, OUTER CLADDING,
STANCHION, LEFT SIDE
172265
29
GASKET, 1/16 X 1, NEOPRENE, CLOSED
CELL, 7' LONG
115336
30
ASSEMBLY, FRAME, LEFT STANCHION
172360
31
LABEL, WATER IN
Z040232
32
ASSEMBLY, FRAME, POWER COVER
172366
33
GASKET, NEOPRENE, 9-1/2 X 9-1/2,
FRAME TOP
172365
35
NIPPLE, CLOSE, 1 NPT
Z005517
36
ASSEMBLY, FRAME, LEFT SIDE
172360
-
BOLT, HEX, 3/8-16, 1-1/4" LONG
FA BLT0101
-
NUT, HEX, 3/8-16
FA NUT0341
-
WASHER, FLAT, 3/8
Z005830
SWITCH, EMERGENCY STOP
N87527
WASHER, LEVELING
172280
BRACKET, KETTLE SHROUD
115310
NUT, ACORN, 1/4-20
Z090567
OVERLAY, EMERGENCY STOP
115317A
40
42
44
OM-DH/INA/2-100
25
172474
WATER PIPING ASSEMBLY
Ref
Part #
1
ELBOW, STREET, 90 DEGREE, 3/4
NPT, SS
172471
2
ELBOW, 90 DEGREE, 3/4 NPT, SS
172473
3
NIPPLE, 3/4 NPT, 2" LONG, SS
172472
4
NIPPLE, 3/4 NPT, 4" LONG, SS
172470
5
METER, WATER, {MEASURES IN
GALLONS)
METER, WATER, [MEASURES IN
LITERS]
Z055211
VALVE, SOLENOID, WATER, 24VDC
172475
5
6
26
Description
Parts List
OM-DH/INA/2-100
Z098369
172378
GAS VALVE PIPING, PRESSURE GAUGE
AND BOX ASSEMBLY
Ref
Description
Part #
1
GASKET, CLOSED CELL, NEOPRENE
115336
2
CAP, PROBE, WATER LEVEL
115319B
3
FITTING, PROBE, WATER LEVEL
146992
4
ASSEMBLY, PIPING, GAS
149650
6
COVER, ENCLOSURE, GAS VALVE
115294
7
SCREW, TRUSS HEAD, 10-32 X 1/2"
LONG
Z072189
8
NUX, HEX, 8-32
Z011030
9
SCREW, CAP, HEX HEAD, 1/4-20 X
1/2" LONG
Z005608
10
NUT, HEX, 1/4-20
Z005601
11
COVER, ENCLOSURE, WATER LEVEL
115290
13
ENCLOSURE, WATER LEVEL
172377
14
ASSEMBLY, PIPING, PRESSURE
SWITCH & GAUGE
172376
15
UNION, 3/8 NPT
Z027421
16
GROMMET, 11/16 ID
Z007245
17
GROMMET, 9/16 ID
Z074974
18
GROMMET, 7/8 ID
Z007400
19
GROMMET, 1/4 ID
Z001518
20
GROMMET, STRAIN RELIEF
Z088239
22
LIGHT, INDICATOR, RED, 24VAC
116383
23
OVERLAY, OPERATING PRESSURE
115317D
25
GRIP, CORD, 1/2 NPT
Z009196
26
117801
27
FITTING, COMPRESSION, STRAIGHT,
3/8 NPT - 3/8 TUBE
FITTING, COMPRESSION, 90 DEGREE,
3/8 NPT - 3/8 TUBE
28
TUBING, COPPER, 3/8 OD, 12" LONG
Z007332
29
CONNECTOR, 90 DEGREES, 1/2 NPT
Z001668
30
PROBE, WATER LEVEL
Z076526
31
MODULE, IGNITION, INTERMITTENT
PILOT
Z085153
32
CONDUIT, GAS PIPING
115234
33
GASKET, CONDUIT
115299
34
RIVNUT, OPEN END, 10-32
113235
-
CONDUIT, SEALTITE, 1/2"
Z001697
Z006796
38
TUBING, ALUMINUM, 1/4 OD, 36"
LONG
CABLE, HIGH VOLTAGE, IGNITION, 36"
LONG
Z096728
39
WIRE HARNESS, MAIN
115335
40
NUT, CONDUIT, 1/2 NPT
Z008808
41
37
117802
ENCLOSURE, GAS VALVE
115292
-
GROMMET, SILICONE, 11/16 ID
128863
-
TEE, 1/2 NPT
Z013650
-
NIPPLE, CLOSE, 1/2 NPT
Z004306
COUPLING, 1/2 RECESSED, 1/4 NPT
Z004158
48
Parts List
OM-DH/INA/2-100
27
172376
PRESSURE SWITCH AND GAUGE
PIPING ASSEMBLY
Ref
28
Description
Part #
1
PRESSURE SWITCH, SET AT 43 PSI
Z096963
2
TEE, 1/4 NPT
Z008539
3
PRESSURE SWITCH, SET AT 43 PSI
Z096963
4
ELBOW, 90 DEGREE, 1/4 NPT
Z005682
5
NIPPLE, 1/4 NPT, 1" LONG
Z005683
6
NIPPLE, 1/4 NPT, 6-1/2" LONG
Z003674
7
UNION, STRAIGHT, 1/4 NPT
Z005126
8
NIPPLE, 1/4 NPT, 2"LONG
Z005675
9
BUSHING, REDUCING, 3/8 NPT - 1/4
NPT
Z059907
10
TEE, 3/8 NPT
Z012794
11
NIPPLE, 3/8 NPT, 10" LONG
Z012794
12
ELBOW, STREET, 90 DEGREE, 3/8 NPT
Z009853
13
NIPPLE, 3/8 NPT, 6" LOG
Z005752
17
ELBOW, 90 DEGREE, 3/8 NPT
Z055335
18
GAUGE, PRESSURE
115293
19
FITING, STRAIGHT, COMPRESSION,
1/4 NPT - 1/4 TUBE
Z064565
20
NIPPLE, 3/8 NPT, 1-1/2" LONG
Z005678
21
NIPPLE, 3/8 NPT, 1" LONG
Z007439
22
TUBING, COPPER, 1/4, 24" LONG
116002
NIPPLE, 3/8 NPT, 4" LONG
Z005720
OM-DH/INA/2-100
Parts List
149650
GAS VALVE PIPING ASSEMBLY
Ref
Description
Parts List
Part #
1
UNION, STRAIGHT, 1 NPT
Z005534
2
NIPPLE, CLOSE, 1 NPT
Z005517
3
ELBOW, REDUCING, 1 NPT X 3/4 NPT
Z003610
4
VALVE, GAS, MAIN
115298
5
NIPPLE, CLOSE, 3/4 NPT
Z008238
6
VALVE, GAS, SOLENOID, 3/4 NPT
108963
7
TEE, REDUCING, 3/4 NPT X 3/4 NPT
X 1/2 NPT
Z005484
8
NIPPLE, 3/4 NPT, 4" LONG
Z005554
9
ELBOW, 3/4 NPT
Z008124
10
ELBOW, REDUCING, 3/4 NPT X 1/2
NPT
Z008751
11
NIPPLE, 1/2 NPT, 4" LONG
Z005554
12
UNION, STRAIGHT, 1/2 NPT
Z004186
13
NIPPLE, 1/2 NPT, 2" LONG
Z005551
14
BUSHING, REDUCING, 1/2 NPT X 1/4
NPT
Z008739
15
NIPPLE, 1/4 NPT, 2" LONG
Z005675
16
UNION, STRAIGHT, 1/4 NPT
Z005126
17
NIPPLE, 1/4 NPT, 3-1/2" LONG
Z041509
18
ELBOW, 90 DEGREE, 1/2 NPT
Z008747
19
NIPPLE, 1/2 NPT, 1-1/2" LONG
Z004184
OM-DH/INA/2-100
29
172361
RIGHT STANCHION ASSEMBLY
Ref
Description
Part #
Ref
Part #
Ref
1
COVER, STANCHION, RIGHT SIDE
172384
16
Z009547
31
17
FITTING, GREASE, STRAIGHT,
1/4 NPT
CASTING, TRUNNION GEAR
CARRIER
2
172293
6
ASSEMBLY, FRAME, RIGHT
STANCHION
ASSEMBLY, OUTER CLADDING,
STANCHION, RIGHT SIDE
ASSEMBLY, INSIDE CLADDING,
STANCHION, RIGHT SIDE
SUBASSEMBLY, ELECTRICAL
COMPONENTS
ASSEMBLY, ENCLOSURE,
CONTROL PANEL
7
Description
Z012222
32
172265
18
COLLAR, SET, 1" ID
Z012012
172294
19
SCREW, SET, CUP POINT, 3/8-16,
5/8" LONG
172393
20
172390
MOTOR, DRIVE, 1/2 HP
8
Description
Part #
Z012192
33
WASHER, SHIM, 1-3/4 OD,
0.001" THICK
WASHER, SHIM, 1-3/4 OD,
0.003" THICK
WASHER, SHIM, 1-3/4 OD,
0.005" THICK
Z012060
34
WASHER, FLAT, 3/8, SS
Z005830
SHAFT, DRIVE
115242
35
WASHER, LOCK, SPLIT, 3/8
Z005618
21
KEY, 1/4" SQUARE, 3-1/4" LONG
Z012468
36
NUT, HEX, 5/16-18
Z005602
128973
22
BEARING, ROLLER, 1"
Z012036
37
BLOCK, STOP, MECHANICAL
115213
NUT, HEX, KEPS, 1/4-20
NT1101
23
GEAR, WORM
Z012054
38
SCREW, SAP, HEX HEAD, 5/1618, 1-1/2" LONG
Z006017
9
GEAR, 72 TOOTH
115269
24
172292
39
WASHER, FLAT, 5/16
Z012093
10
ASSEMBLY, MECHANICAL STOP
115240
25
115282
40
WASHER, LOCK, 5/16
Z005658
11
SCREW, CAP, SOCKET, 5/16-18,
2" LONG
115302
26
Z005764
41
SCREW, CAP, HEX HEAD, 1/2-13,
2-1/2" LONG
Z005629
12
COUPLING, SHAFT
115276
27
HMI, TOUCH SCREEN
CONTROLLER
ASSEMBLY, TILT SWITCH &
HARNESS
SCREW, TRUSS HEAD, 8-32,
3/8" LONG
BAR, 1/2" SQUARE, SS, 3-1/2"
LONG
303208
42
PLATE, SHIP, TILT MOTOR
172272
13
NUT, HEX 1/2-13
Z003565
28
KEY, 1/4" SQUARE, 2" LONG
Z009258
43
ASSEMBLY, SWITCH, 2 POSITION
115337A
14
RIVNUT, OPEN END, 10-32
113235
29
Z005615
44
SWITCH, EMERGENCY STOP
N87527
15
SCREW, TRUSS HEAD, 10-32,
1/2" LONG
Z072189
30
SCREW, CAP, HEX, 3/8-16,
1-1/2" LONG
GASKET, NEOPRENE, CLOSED
CELL, 90-INCHES
115336
45
OVERLAY, POWER AND
EMERGENCY STOP
172398
3
4
5
30
Parts List
OM-DH/INA/2-100
Z012193
Z012079
172476
ELECTRICAL SUBPANEL ASSEMBLY
Ref
Description
Part #
1
PLC, 1763-L16DWD
172520
2
ANALOG OUTPUT, 1762-IR4
172521
3
ETHERNET SWITCH, EKI-2525 AE 5
PORT
172522
4
24 VDC POWER SUPPLY, MDR-120-24
172523
5
3A CIRCUIT BREAKER, FAZ-C3/2-NA
UL 489 3A
1A CIRCUIT BREAKER, FAZ-C1/1SP UL
1077 1A
2A CIRCUIT BREAKER, FAZ-C2/1SP UL
1077 2A
172524
8
5A CIRCUIT BREAKER, FAZ-C5/1SP UL
1077 5A
172527
9
75 VA TRANSFORMER, PH75MLI 75VA
172528
10
1.5A FUSE, ATDR1.5
172529
11
10A FUSE, ATMR10
172530
12
FUSE HOLDER, US3J31
172531
13
CONTACTOR, MC-9B-DC24-11S
172532
14
CONTACTOR, MC-9B/R-DC24-22S
172533
15
ON / OFF CONTROL WITH LOCKOUT,
MMS-32H-2.5 BRK/OL
172534
16
RELAY, AB 700-HLT12U24
172535
19
172536
20
TERMINAL, 1492-J3-W 600VOLT 25
AMP
TERMINAL, 1492-JG3-IEC 600VOLT
GND
21
LOW WATER CUTOFF, PN 26B3B
172538
-
PANEL, ELECTRICAL MOUNT
172296
-
NUT, HEX, 1/4-20
Z005601
6
7
Parts List
172525
172526
172537
OM-DH/INA/2-100
31
115282
TILT SWITCH ASSEMBLY
Ref
32
Description
Parts List
Part #
1
SWITCH, OVERTRAVEL,
PLUNGER TYPE
115261
2
BRACKET, TILT SWITCH
115221
3
HARNESS, TILT SWITCH
115281
OM-DH/INA/2-100
Parts List
HIGH FIRE BURNER ASSEMBLY
Ref
Description
Part #
1
MANIFOLD, BURNER, 40-PORT
146985
2
NIPPLE, 1/2 NPT, 3-1/2" LONG
Z008227
3
Z088290
4
BUSHING, REDUCING, 1/2 NPT TO
1/8 NPT
BURNER JET, BRASS, 7/16-24 NS,
#654
5
PLUG, PIPE, RECESSED HEX, 1/8 NPT
Z010286
Ref
BURNER JETS, BRASS, 7/16-24 NS
Elevation - Jet Orifice Size
Part #
SEE
ELEVATION
TABLE
NATURAL GAS
ELEVATION -- 1.15MM
N02 0-2000'
(0.0453)
ELEVATION -- 1.05MM
N24 2001-4000'
(0.0413)
ELEVATION -- 1.05MM
N46 4001-6000'
(0.0394)
ELEVATION -- 0.95MM
N68 6001-8000'
(0.0374)
ELEVATION -- 0.89MM
N810 8001-10000'
(0.0350)
LP GAS
0-2000'
ELEVATION
-- 0.79MM
L02 (0.0310)
ELEVATION -- 0.71MM
L24 2001-4000'
(0.0280)
ELEVATION -- 0.70MM
L46 4001-6000'
(0.0276)
ELEVATION -- 0.65MM
L68 6001-8000'
(0.0256)
ELEVATION -- 0.61MM
L810 8001-10000'
(0.0240)
127554
106159
127560
174293
127361
102944
127563
174292
154178
104291
OM-DH/INA/2-100
33
Parts List
LOW FIRE BURNER ASSEMBLY
Ref
Description
Part #
1
MANIFOLD, BURNER, 20-PORT
146986
2
NIPPLE, 1/2 NPT, 3-1/2" LONG
Z008227
3
BUSHING, REDUCING, 1/2 NPT TO
1/8 NPT
Z088290
4
NIPPLE, 1/2 NPT, 1-1/2" LONG
5
BURNER JET, BRASS, 7/16-24 NS,
#654
SEE
ELEVATION
TABLE
6
PLUG, PIPE, RECESSED HEX, 1/8 NPT
Z010286
Ref
BURNER JETS, BRASS, 7/16-24 NS
Elevation - Jet Orifice Size
Part #
Z004184
NATURAL GAS
ELEVATION -- 1.15MM
N02 0-2000'
(0.0453)
ELEVATION -- 1.05MM
N24 2001-4000'
(0.0413)
ELEVATION -- 1.05MM
N46 4001-6000'
(0.0394)
ELEVATION -- 0.95MM
N68 6001-8000'
(0.0374)
ELEVATION -- 0.89MM
N810 8001-10000'
(0.0350)
LP GAS
0-2000'
ELEVATION
-- 0.79MM
L02 (0.0310)
ELEVATION -- 0.71MM
L24 2001-4000'
(0.0280)
ELEVATION -- 0.70MM
L46 4001-6000'
(0.0276)
ELEVATION -- 0.65MM
L68 6001-8000'
(0.0256)
L810 8001-10000' ELEVATION -- 0.61MM
(0.0240)
34
OM-DH/INA/2-100
127554
106159
127560
174293
127361
102944
127563
174292
154178
104291
Parts List
AGITATOR ASSEMBLY
Ref
Description
Part #
1
DISC, 1e DIAMETER X 10 GA (2)
019058
2
COUPLING, QUICK DISCONNECT
012719
3
BLADE, SCRAPER (6)
005098
4
HOLDER SCRAPER BLADE (6)
005099
-
SCRAPER LOCKING PIN (NOT SHOWN)
003655
5
LOCKING HAIRPIN CLIP (6)
003652
7
YOKE, BLADE CARRIER (6)
004923
OM-DH/INA/2-100
35
Parts List
LOW FIRE BURNER ASSEMBLY
Ref
Part #
1
REGULATOR, AIR
050119
2
NIPPLE, 1/4” X CLOSE BRASS
003923
3
TEE, 1/4” BRASS
014360
4
COUPLING, FULL 3/8”
012740
5
FITTING COMPRESSION
091940
6
CONNECTION HOSE 3/8” X 65” (NOT
SHOWN)
155102
7
ELBOW, 90 STREET 3/8”
055336
8
DISCONNECT, QUICK 3/8”
N71392
9
ELBOW, 90 STREET 1/4”
010232
10
FILTER, AIR, IN LINE PARKET #
4M-F4L-10-BN-B
FITTING COMP, 3/8” T X 1/4” P 90
DEG FEMALE ELBOW
CONNECTOR MALE 3/8” MPT X 3/8”
TUBE
069038
11
13
36
Description
OM-DH/INA/2-100
057218
050879
Wiring Diagram
OM-DH/INA/2-100
37
Wiring Diagram
38
OM-DH/INA/2-100
Service Log
Model No:
Purchased From:
Serial No:
Location:
Date Purchased:
Date Installed:
Purchase Order No:
For Service Call:
Date
Maintenance Performed
Performed By
OM-DH/INA/2-100
39
1055 Mendell Davis Drive • Jackson MS 39272
888-994-7636 • 601-372-3903 • Fax 888-864-7636
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PART NUMBER 176302, REV. A (01/18)
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