Groen AH/1-100 Operation Manual

OPERATOR MANUAL

Model :AH/1,AH/1E

Steam Jacketed Kettles

Self-contained

Stainless steel

Gas heated

Floor mounted

Stationary

OM-AH

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.

OPERATOR WARNINGS

EQUIPMENT DESCRIPTION

INSPECTION & PACKING

INSTALLATION & START-UP

OPERATION

CLEANING

PREVENTIVE MAINTENANCE

TROUBLESHOOTING (OPERATOR

SEQUENCE OF OPERATION

SERVICE TROUBLESHOOTING

PARTS LISTS

DIAGRAMS & SCHEMATICS

REFERENCES

SERVICE

SERVICE LOG

WARRANTY

Table of Contents

12

13

14, 15, 16, 17

18, 19,20, 21, 22, 23, 24,25

26,27,28,29

30

31

32

33

1

2, 3,4

5

5,6

7,8

9

10, 11

IMPORTANT--READ FIRST-- IMPORTANT

WARNING: INSTALLATION OF THE UNIT MUST BE DONE BY PERSONNEL QUALIFIED TO WORK WITH

ELECTRICITY AND PLUMBING. IMPROPER INSTALLATION CAN CAUSE INJURY TO

PERSONNEL AND/OR DAMAGE TO EQUIPMENT. UNIT MUST BE INSTALLED IN

ACCORDANCE WITH ALL APPLICABLE CODES.

CAUTION: TO AVOID DAMAGING PARTS OF THE BURNER SYSTEM UNDERNEATH THE KETTLE, LIFT

THE UNIT ONLY BY THE RING BENEATH THE OUTER PORTION OF THE BODY.

WARNING: DO NOT ATTACH THE UNIT TO A TYPE "B" VENT. FAILURE COULD RESULT IN FIRE OR

PROPERTY DAMAGE.

WARNING: DO NOT CONNECT ANY PIPING TO THE POP SAFETY VALVE. THE VALVE MUST BE FREE TO

VENT STEAM AS NEEDED. ELBOW, ATTACHED TO THE SAFETY VALVE, SHOULD POINT

DOWN TOWARD THE FLOOR. IMPROPER INSTALLATION WILL VOID THE WARRANTY!

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 PRODUCT AND SAFE TRANSFER.

CAUTION: KEEP FLOORS IN FRONT OF KETTLE WORK AREA CLEAN AND DRY. IF SPILLS OCCUR,

CLEAN IMMEDIATELY TO AVOID DANGER OF SLIPS OR FALLS.

WARNING: KEEP WATER AND SOLUTIONS OUT OF CONTROLS AND BURNERS. NEVER SPRAY OR

HOSE CONTROL CONSOLE, ELECTRICAL CONNECTIONS, ETC.

CAUTION: MOST CLEANERS ARE HARMFUL TO THE SKIN, EYES, MUCOUS MEMBRANES AND

CLOTHING. PRECAUTIONS SHOULD BE TAKEN TO WEAR RUBBER GLOVES, GOGGLES OR

FACE SHIELD AND PROTECTIVE CLOTHING. CAREFULLY READ THE WARNINGS AND

FOLLOW THE DIRECTIONS ON THE LABEL OF THE CLEANER TO BE USED.

IMPORTANT: Do not mix the parts of different tangent draw-off valve assemblies during washing. The parts are not interchangeable.

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 ANY 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 COCK. 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.

IMPORTANT: Service performed by other than factory authorized personnel will void all warranties.

WARNING: KEEP AREA AROUND KETTLE FREE AND CLEAR OF ALL COMBUSTIBLE MATERIALS,

FAILURE TO DO SO, COULD RESULT IN FIRE OR PROPERTY DAMAGE.

1

Equipment Description

Groen Models AH/1 and AH/1E steam kettles are stainless steel, floor mounted kettles with a self-contained steam source heated by gas. A closed steam jacket covers the lower 2/3 of the kettle. Heat from gas flames boils water in the jacket to produce steam under pressure. To ignite the flames, Model AH/1 has a continuously burning pilot flame, called the standing pilot, and Model AH/1E has electronic spark ignition.

The kettles are of the stationary (nontilting) type. Liquids can be removed from the kettle through the tangent draw-off valve.

All exposed surfaces are stainless steel. An insulated canopy protects the kettle body, and a housing encloses all the controls.

Three tubular legs support the unit. Bullet feet on the legs can be adjusted to level the kettle.

A one piece dome cover is hinged to the kettle. Covers for 60, 80, and 100 gallon kettles are supplied with counterbalancing actuators to hold the covers in the fully open or closed position.

Controls used by the operator include the ON/OFF switch, to control electric power for the unit, and the thermostat, to set the cooking temperature.

The automatic controls and a brief description are listed below.

Gas pressure regulator: Protects the unit from high pressure in the gas supply line

Automatic gas valves:

Pressure limit switch:

Safety valve:

Low-water cutoff:

Let gas into the burners at the proper time

Closes the main automatic gas valve when steam pressure in the jacket reaches 27 PSI and opens the valve when the pressure drops to 22 PSI

Lets steam out of the jacket if the steam pressure gets too high

Turns off the burner if the water level in the jacket gets too low for safe operation

Instruments also are provided to show the operator what is happening inside the unit. These instruments are:

Water gauge glass:

Pressure/vacuum gauge:

Indicates whether there is enough water in the steam jacket

Shows the steam pressure and whether too much air has got

Heating indicator light: into the jacket

Indicates that the kettle is being heated

The kettle body is welded into one piece and furnished with a rim reinforced by a rectangular bar. The interior of the kettle is polished to a 180 emery grit finish, while the exterior is given a bright semi-deluxe finish. The unit is ASME shop inspected and registered with the National Board for working pressures up to 30 PSI.

The standard 2 inch tangent draw-off is a 316 stainless steel, compression disc valve. A removable strainer with 1/4 inch holes keeps pieces of product that are too large from going down into the drawoff.

The jacket is filled at the factory with water containing rust inhibitors. The kettle can operate at steam pressures up to 30 PSI, which provide kettle temperatures of 150 to 270°F. This temperature range allows the operator to use the kettle for warming, simmering, boiling, or braising.

For AH kettles, options include:

1.

Larger (3 inch) draw-offs

2.

Plug-type draw-off valves (not NSF approved)

3.

Solid disc strainer or strainer with 1/8 inch perforations

4.

Electronic spark ignition

5.

Fill faucet

6.

Automatic, metered water filler (Gallon Master)

7.

TRI-BC basket inserts

8.

Kettle brush kit

9.

Etch marks

10.

Flanged feet

2

Model AH/1

3

Equipment Description (cont'd)

KETTLE CHARACTERISTICS

Model

AH/1-20

AH/1-40

AH/1-60

AH/1-80

AH/1-100

AH/1E-20

AH/1E-40

AH/1E-60

AH/1E-80

AH/1E-100

Ignition

Pilot

Pilot

Pilot

Pilot

Pilot .

Spark

Spark

Spark

Spark

Spark

Firing rate,

BTU/hour

Natural gas

85,000

100,000

145,000

145,000

145,000

85,000

100,000

145,000

145,000

145,000

Propane gas

85,000

85,000

145,000

145,000

145,000

85,000

85,000

145,000

145,000

145,000

Dimensions

Model

AH/1-20

AH/1-40

AH/1-60

AH/1-80

AH/1-100

AH/1E-20

AH/1E-40

AH/1E-60

AH/1E-80

AH/1E-100

Kettle capacity, gallons

20

40

60

80

100

20

40

60

80

100

Jacket capacity, gallons

4-1/2

7

9-1/2

11-1/2

11-1/2

4-1/2

7

9-1/2

11-1/2

11-1/2

Kettle diameter, inches

32

20

26

30

20

26

30

32

32

32

Kettle depth, inches

35

18

22

25

18

22

25

29

29

35

Overall width, inches

36-3/4

38-1/4

41

42-1/2

42-1/2

36-3/4

38-1/4

41

42-1/2

42-1/2

Overall front-to- back, inches

51

39

45

49

39

45

49

51

51

51

Inspection & Unpacking

The unit will arrive completely assembled, wrapped in protective plastic on a heavy skid. Immediately upon receipt, remove all protective plastic wrap form the unit, and 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 file this information for future reference. Space for these entries is provided at the top of the Service Log in this manual.

CAUTION: SHIPPING STRAPS ARE UNDER TENSION AND CAN SNAP BACK WHEN CUT.

CAUTION: UNIT WEIGHS 440 TO 1100 LB. (200 TO 500 KG). FOR SAFE HANDLING, INSTALLER

SHOULD OBTAIN HELP AS NEEDED, OR EMPLOY APPROPRIATE MATERIALS

HANDLING EQUIPMENT (SUCH AS A FORKLIFT, DOLLY, OR PALLET JACK) TO REMOVE

THE UNIT FROM THE SKID ANDMOVEIT TO THE PLACE OF INSTALLATION.

When installation is to begin, cut the straps holding the unit on the skid, and lift the unit straight up off the skid.

Rim height, nches

40

42

49

55-1/2

61-1/2

40

42

49

55-1/2

61-1/2

4

Installation & Start-Up

A. Installation

The unit should be installed in a ventilated room for efficient performance. All items which may obstruct or restrict the flow of air for combustion and ventilation must be removed. The area directly around the appliance must be cleared of all combustible materials.

WARNING: INSTALLATION OF THE UNIT MUST BE DONE BY PERSONNEL QUALIFIED TO WORK WITH ELECTRICITY

AND PLUMBING. IMPROPER INSTALLATION CAN CAUSE INJURY TO PERSONNEL AND/OR DAMAGE TO

EQUIPMENT. UNIT MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE CODES.

1. Installation requires connection with gas and electrical services. See items 8 to 14 for details.

2. To protect the unit from damage, leave it on the shipping pallet until the time of installation. When installation is to begin, cut the straps holding the kettle, and hoist the kettle straight up off the skid.

NOTICE: To avoid damaging parts of the burner system underneath the kettle, LIFT THE

UNIT ONLY BY THE RING beneath the outer portion of the body.

3. Install the unit with a minimum clearance to combustible and non-combustible construction of six (6) inches at the sides and six (6) inches between the draft diverter and the wall. Also leave enough room for cleaning, maintenance, and service.

4. The draft diverter shipped with the kettle is the correct height and shape to give maximum performance. Install the draft diverter as shown on the specification sheet (drawing D-6038). Do not change the diverter in any way.

Any mechanical, electrical, or gas type change must be approved by the Groen Food Service Engineering Department.

WARNING: DO NOT ATTACH THE UNIT TO A TYPE "B" VENT. FAILURE COULD RESULT IN FIRE OR

PROPERTY DAMAGE.

Install the unit under a ventilation hood, or vent the flue directly to a masonry chimney. Put a hood at least several inches above the upper end of the draft diverter. Do not rest hood supports on the diverter. If the kettle is installed under a ventilating hood, installation of the ventilating hood should comply with local codes and/or ANSI/NFPA-96 Latest Edition. Also, local codes may require that the kettle be electrically interlocked to shut off the gas supply and prevent the operation of the unit if the exhaust fan is not operating or if the fire suppression system is activated. Failure to follow these instructions can cause bodily injury and/or property damage.

5. To level the unit, adjust leg length by turning the bullet feet.

6. Make sure the water level is correct in the jacket, by confirming that the level is between the marks on the gauge glass. If the water level is low, follow the instructions under "Jacket Filling" in the

"Maintenance" Section of this manual.

CAUTI0N: DO NOT CONNECT ANY PIPING TO THIS POP

SAFETY VALVE. IT MUST BE FREE TO VENT

STEAM AS NEEDED. ELBOW SHOULD POINT

DOWN TOWARD FLOOR. IMPROPER

INSTALLATION WILL VOID WARRANTY!

7. To protect personnel from steam coming out of the safety valve, the open end of the elbow at the outlet must be directed down. If it is not, turn the elbow to the correct position

DANGER: ELECTRICALLY GROUND THE UNIT AT THE

TERMINAL PROVIDED. FAILURE TO GROUND

UNIT COULD RESULT IN ELECTROCUTION

AND DEATH.

8. Provide 115 VAC, 60 HZ, 1 PH, 15 AMP electrical service. Use 1/2 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.

5

Installation & Start-Up (cont'd)

9.

The internal gas lines of the unit were cleaned and closed off with a gas cock, before the unit was shipped from the factory. Free all external gas lines of lint, dirt, metal chips, sealant, grease, oil, and other contaminants, before you connect the lines to the kettle.

10.

Connect the gas cock of the kettle to the gas service main with 3/4 inch IPS line or approved equivalent.

11.

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 adequately ventilated room with a provision for adequate air supply. The best ventilation will utilize a vent hood and exhaust fan with no direct connection between the vent duct and the flue. Do NOT obstruct the flue or vent duct after installation.

In Canada, the installation must conform to the CAN/CGA B149 Installation Codes for Gas

Burning Appliances and Equipment and/or local codes.

12.

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.

13.

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 employed.

14 For a unit on casters, complete connection to the gas supply with connectors that comply with the standard for connectors for moveable gas appliances, ANSI Z21.69 — latest edition. Restrain movement of the unit by attaching a cable or chain to the eyelet (provided at the back of the frame) and anchoring the cable or chain to the wall or floor. Make the length and location of the cable such that the unit cannot pull on the gas connection while the cable is connected.

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 1/2 PSIG (3.48

kPa). The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG (3.48 kPa).

16.

Check the following points to confirm that your AH kettle has been installed properly.

a. Enough room between the kettle and nearby objects for cleaning and service.

b. Minimum clearance of 6 inches from sides and 6 inches from draft diverter.

c. Unit vented to a hood or chimney.

d. Kettle level.

e. Correct amount of water in the jacket.

f. Safety valve outlet pointed down.

g. Connected with a waterproof, 115 volt, 15 amp supply of electric power in accordance with electrical codes.

h. Gas lines cleaned before connection.

i. Gas connected with 3/4 inch pipe or equivalent.

j. Gas line joints checked for leaks.

k. No obstruction to air supply or venting.

B. 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 tangent draw-off valve (TDO).

2.

Close the TDO, then put water into the kettle until the water is about 6 inches deep. Test operation of the TDO by opening it all the way, then closing it before all the water runs out.

3.

Make sure the supplies of gas and electric power are on.

4.

Following "To Start Kettle" instructions in the "Operation" section of this manual, begin heating the water at the highest thermostat setting. The heating indicator light should come on as soon as you turn up the thermostat dial, and heating should continue until the water boils.

5.

To turn off the unit, follow "To Turn Off Kettle" instructions in the "Operation" section.

If the kettle functions as described above, it is ready for use. If it does not, contact your area Groen representative.

6

Operation

CAUTION: BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE

OPERATING INSTRUCTIONS, CAUTIONS AND SAFETY INSTRUCTIONS

CONTAINED IN THIS MANUAL.

A. Controls

The operator controls for the kettle are:

1. Main gas cock, which controls the supply of gas from the main to the unit.

2. ON/OFF (toggle) switch. This switch controls the supply of electrical power to the control circuits.

3. Thermostat dial, which turns the thermostat on or off and sets the operating temperature of the kettle.

4. Reset button, used in lighting the pilot burner (on standing pilot model only).

Refer to the photograph in the "Equipment Description" section of this manual for the location of controls and other features.

B. Operating Procedure

WARNING: KEEP AREA AROUND KETTLE FREE AND

CLEAR OF ALL COMBUSTIBLE

MATERIALS.

1. To Start Kettle a. CHECK THE WATER LEVEL IN THE JACKET EVERY

DAY. The level must be between the lines on the gauge glass. If the level is low, see "Jacket Filling" in the "Preventive Maintenance" section of this manual.

b. While the kettle is cold, check the pressure gauge. If the gauge does not show 20 or more inches of vacuum

(that is, a reading of 20 to 30 below 0), see "Jacket

Vacuum" in the "Preventive Maintenance" section of this manual. c. Make sure the strainer is covering the outlet to the draw-off at the bottom of the kettle. d. Set both the toggle (ON/OFF) switch and the thermostat dial to "OFF". e. If the unit has just been turned off, allow 5 minutes for unburned gas to clear out, before you turn the kettle on again.

f. Turn the gas cock ON (handle lined up with the gas pipe), if it is not already on. g. If you are using Model AH/1 E with electronic spark ignition, or if you are using a Model AH/1 unit with the pilot burner already lit, all you must do to start heating the kettle is:

(1) Press the ON/OFF switch to "ON".

(2) Turn the thermostat dial to the desired setting. h. If you must light the pilot burner in a Model AH/1, look through the access hole in the cover of the control housing to see which kind of pilot system is in your unit. If there is a red reset button on top of the gas control, you have a Basotrol pilot system. If you see an

"ON/PILOT/OFF" knob, you have a Honeywell pilot system.

MAX niiT

7

Operation (cont'd)

i.

Light the pilot burner by the procedure that applies to your unit.

(1) With Basotrol standing pilot ignition system:

(a) Locate the red reset button on the automatic gas valve inside the control housing. You can reach the button through the hole below the pressure gauge.

(b) Hold a flame to the pilot burner and press down the reset button to start the flow of gas. Continue to hold the reset button down for 60 seconds after the pilot burner is lit.

(c) Release the button. The pilot burner should stay lit.

(2) With Honeywell pilot ignition system:

(a) To reach the "ON/PILOT/OFF" knob, remove the cover of the control housing.

(b) Set the knob to "PI LOT".

(c) Hold a flame to the pilot burner and press down the knob to start the flow of gas. Continue to hold the knob down for 60 seconds after the pilot burner is lit.

(d) Release the knob. The pilot should stay lit.

(e) Set the knob to "ON". Then replace the cover of the control housing.

(3) For all units, if pilot requires relighting:

(a) Set both the ON/OFF switch and the thermostat dial to their "OFF" positions.

(1)

(2)

(b) Wait 5 minutes.

(c) Light the pilot by the appropriate procedure above.

j.

To light the main burner and start heating the kettle, after the pilot burner is lit:

Press the ON/OFF switch to "ON".

Turn the thermostat dial to the desired setting.

CAUTION: DO NOT OVER FILL 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

PRODUCT AND SAFE TRANSFER.

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.

2.

To Turn Off Kettle.

a.

Turn the thermostat dial to "OFF".

b.

Press the ON/OFF switch to "OFF".

c.

Before the unit is serviced, or if it will be off for a week or more:

(1) Set the thermostat and ON/OFF switch at "OFF".

(2) Turn the main gas cock OFF (handle at right angles to the gas pipe).

(3) Cut off electric power for the unit at the circuit breaker or fuse box.

3.

If Electric Power Fails a.

Do not attempt to operate the unit. The main burner cannot be lit until the power comes back on.

b.

When power is restored, follow the instructions under "To Start Kettle" above.

4.

To Relight Kettle

Close the main supply gas cock, then follow the instructions under "To Start Kettle" above.

8

Cleaning

1.

2.

Suggested Tools a.

Detergent and sanitizer, or a combination cleaning-sanitizing agent like Micro-Quat from

ECOLAB.

b.

Kettle brushes.

c.

Bottle brush for cleaning the draw-off (product faucet).

Precautions

3.

Before any cleaning operation: a.

Turn off the main burner by turning the thermostat dial to "OFF".

b.

Cut off electric power to the unit at the circuit breaker or fuse box.

WARNING: KEEP WATER AND SOLUTIONS OUT OF CONTROLS AND BURNERS. NEVER

SPRAY OR HOSE THE CONTROL CONSOLE, ELECTRICAL CONNECTIONS,

ETC.

Procedure a.

Clean all food contact surfaces as soon as possible after use, preferably while the kettle is still warm. If the unit is in continuous use, thoroughly clean and sanitize both inside and outside at least once every 12 hours.

b.

Scrape and flush out large amounts of food residues. Be careful not to scratch the kettle with metal implements. After flushing the kettle, close the draw-off valve.

CAUTION: MOST CLEANERS ARE HARMFUL TO THE SKIN, EYES, MUCOUS MEMBRANES

AND CLOTHING. PRECAUTIONS SHOULD BE TAKEN TO WEAR RUBBER

GLOVES. GOGGLES OR FACE SHIELD AND PROTECTIVE CLOTHING.

CAREFULLY READ THE WARNINGS AND FOLLOW THE DIRECTIONS ON THE

LABEL OF THE CLEANER. c.

Prepare a solution of the detergent/cleaning compound as instructed by the supplier. Clean the unit thoroughly. A cloth moistened with cleaning solution can be used to clean controls, control housing, electrical conduit, etc.

d.

Drain the kettle, then take apart the tangent draw-off valve. Clean the draw-off port and each valve part with a brush.

CAUTION: DO NOT MIX THE PARTS of different draw-off assemblies during washing.

The parts are NOT INTERCHANGEABLE. e.

Rinse the kettle and draw-off valve parts thoroughly with hot water, then drain completely.

f.

When you put the draw-off valve back together, tighten the wing nut by hand only, without using a tool.

g.

Put the strainer back over the draw-off outlet in the bottom of the kettle.

h.

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.

i.

To remove materials stuck to the equipment, use a brush, sponge, cloth, plastic or rubber scraper, or plastic wool along with the detergent solution. To make washing easier, let the detergent solution sit in the kettle and soak into the residue, or warm the detergent solution briefly.

Do not use any metal material (like metal sponges) or metal implement (like a spoon, scraper, or wire brush) that might scratch the surface. Scratches make the surface hard to clean and provide places for bacteria to grow. Do not use steel wool, which may leave particles imbedded in the surface and cause eventual corrosion and pitting.

j.

The outside of the unit may be polished with a recognized stainless steel cleaner like "Zepper" from Zep Manufacturing Company.

k.

When the equipment needs to be sanitized, use a sanitizing solution equivalent to one that supplies

200 parts per million available chlorine. Obtain advice on the best sanitizing agent from your supplier of sanitizing products. Following the supplier's instructions, apply the sanitizing agent after the unit has been cleaned and drained. Rinse off the sanitizer thoroughly.

CAUTION: NEVER leave a sanitizer in contact with stainless steel surfaces LONGER

THAN 30 minutes. Longer contact can cause corrosion.

I.

It is recommended that the unit be sanitized just before use.

m.

If there is difficulty removing mineral deposits or a film left by hard water or food residues, clean the kettle thoroughly. Then use a deliming agent, like Lime-Away from ECOLAB, in accordance with the manufacturer's directions. Rinse and drain the unit before further use.

n.

If especially difficult cleaning problems persist, contact your cleaning product supplier for assistance. The supplier has a trained technical staff with laboratory facilities to serve you.

9

Preventive Maintenance

This section describes actions the operator must take to keep warranty coverage of the unit and to keep the unit working safely and efficiently.

1. Jacket Vacuum

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 an excess of air in the jacket. Air in the jacket slows the heating of the kettle and sometimes keeps the kettle from reaching the desired 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 5 PSI, release entrapped air and steam by lifting the lever on the safety valve for about 1 second.

Repeat this step, then let the valve lever snap back into the closed position, so the valve will seat properly and not leak.

WARNING: AVOID ANY EXPOSURE TO THE STEAM BLOWING OUT OF THE SAFETY

VALVE. A SEVERE BURN CAN RESULT ON EXPOSED SKIN.

2. Safety Valve

WARNING: FAILURE TO PERIODICALLY CHECK SAFETY VALVE OPERATION COULD RESULT

IN PERSONAL INJURY AND/OR DAMAGE TO EQUIPMENT.

WARNING: WHEN TESTING, AVOID ANY EXPOSURE TO THE STEAM BLOWING OUT OF THE

SAFETY VALVE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS.

At least twice a month, the safety valve should be tested. Test the valve with the kettle operating at 15 psi

(105 kPa), by holding the test lever for at least 5 seconds. Then release the lever and permit the valve to snap shut. If the lever does not activate, or there is no evidence of discharge, or the valve leaks, immediately discontinue use of the kettle and contact a qualified 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 for adding water 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 as directed below.

10

b.

Allow the kettle to cool completely . Remove the pipe plug from the jacket fill assembly, then open the globe valve and pour in the distilled or treated water. 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 globe valve.

d.

Air that gets into the jacket during the filling operation must be removed, because it will make heating less efficient. See "Jacket Vacuum" above.

4. Water Treatment

Color-blind persons mixing the treated water solution must use an electroanalytical instrument to measure the pH level or have a person that is not color blind read the test strip color level.

WARNING: TO AVOID INJURY, READ AND FOLLOW ALL PRECAUTIONS STATED ON

THE LABEL OF THE WATER TREATMENT COMPOUND. a.

Fill a mixing container with the approximate amount of water required (distilled water preferred). See the Table 1.

b.

Hang a strip of pH test paper on the rim of the container, with about 1 inch into the water.

c.

Stir the water continuously, while slowly adding boiler treatment compound until a color between 10.5

and 11.5 is reached as shown on the pH test kit chart.

d.

Use a measuring cup to add compound. Record the exact amount of compound used for preparing additional treated water.

TABLE 1

Kettle capacity

20 gallons

30 gallons

40 gallons

60 gallons

80 gallons

Jacket capacity

4-1/2 gallons (17 liters)

6 gallons (23 liters)

7 gallons (26 liters)



100 gallons

5. Venting System


Periodically check the draft diverter and flue or hood to make sure that nothing will block or hinder the free flow of exhaust gases.

11

Troubleshooting List for the Operator

The 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. If the actions suggested in this list do not solve the problem, call your Groen Certified Service Agency. To get the phone number of the nearest agency, call the your Area Groen representative or the Groen Parts and Service Department.

A. All Models

SYMPTOM

Pilot burner and/or burner will not light or goes out after working for a while.

WHAT TO CHECK

a. That the main gas cock is completely open (handle is in line with the gas pipe). b. That the toggle switch is ON. c. That the thermostat dial is at the correct setting. d. Lighting procedure. See the "Operation" Section of this manual. 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.

Kettle continues heating after it reaches the desired temperature.

Kettle stops heating before it reaches the desired temperature. a. That the thermostat dial is at the correct setting. a. That the thermostat dial is at the correct setting. b. That the 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.

Kettle heats slowly. a. Reading of the pressure/vacuum gauge. If it is not



Safety valve pops. a. Reading of the pressure/vacuum gauge. If it is not



B. Models with Standing Pilot Ignition

SYMPTOM WHAT TO CHECK

Pilot burner will not light. a. Lighting procedure. See the "Operation" section of this manual.

Pilot flame goes out when reset button is released. a. Lighting procedure. See the "Operation" section of this manual.

12

Sequence of Operation

The following "action-reaction" outline is provided to help service personnel understand the functioning of the unit.

A. Model AH/1 with Standing Pilot Ignition

When the operator presses down the reset button, the button overrides the automatic control and opens the pilot burner valve, admitting gas from the supply line to the pilot. Lighting and maintaining the pilot flame for 60 seconds heats the thermocouple to operating temperature, so the thermocouple begins to supply electric current at 20 to 25 mV. Current from the thermocouple powers a coil that holds the pilot burner valve open. If the pilot flame goes out and allows the thermocouple to cool, the valve closes and prevents any flow of gas into the unit.

Once the pilot burner valve is open, gas is available at the main burner valve, which is normally closed. Pushing the toggle switch to "ON" provides 120 V electric power to the thermostat. When the operator turns the thermostat dial to an operating setting, the thermostat switch closes and allows the

120 V power to energize the heating indicator light and a coil at the main burner valve. The coil opens the main burner valve. Gas flows to the main burner and is ignited by the pilot flame.

B. Model AH/1 E with Electronic Spark Ignition

When the operator presses the toggle switch to "ON", electric power at 120V is supplied to the thermostat. Turning the thermostat dial to an operating setting closes the thermostat switch, which allows the automatic gas control to be energized. Simultaneously, an electric arc is established at the spark gap, and the automatic valve for the pilot burner is opened. 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 24V power. The 24V 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 30 seconds after the spark begins, a timer shuts down the whole operation.

C. All Units

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 the jacket steam cools below the thermostat set point, the thermostat switch closes and begins another heating cycle. On-off cycling continues and maintains the kettle at the desired temperature.

The thermostat controls heating by alternately calling for flames at the full capacity of the main burner and then signaling the control to shut the burner off completely. 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.

Safety features of these units operate as explained below:

1. Pressure limit switch. If the pressure of steam in the jacket exceeds 27 PSI, the switch opens and breaks the electrical circuit to the solenoid coil at the main gas valve. The valve closes and remains closed until jacket pressure decreases to 22 PSI. The pressure limit switch then closes, energizes the gas valve coil, and permits operation to resume.

2. Low-water cutoff. As long as water in the steam jacket touches the cutoff electrode, operation of the kettle can continue. If the water level 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 30 PSI, the valve will open and relieve the excess pressure.

13

Service Troubleshooting

The 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. If an item on the list is followed by an asterisk (*), the work should be done by a factory authorized service representative.

WARNING: BEFORE REPLACING ANY PARTS, DISCONNECT THE UNIT FROM THE ELECTRIC

POWER SUPPLY AND CLOSE THE MAIN GAS COCK. 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.


A. All Models


Pilot burner and/or burner will not light or goes out after working for a while.

Kettle continues heating after it reaches the desired temperature.

Kettle stops heating before it reaches the desired temperature.

Kettle heats slowly. a. That the main gas cock is completely open (handle is in line with the gas pipe). b. Thermostat dial and toggle switch settings. c. Lighting procedure. See the "Operation" section of this manual. d. Jacket water level. If it is low, see "Jacket Filling" in the "Preventive Maintenance" section of this manual. e. Gas supply to the unit. f. Electric power supply to the unit. g. Thermostat operation. h. Gas pressure at the automatic valve.* a. Thermostat dial setting. b. Thermostat calibration c. Thermostat operation. d. Seat of the main automatic gas valve for dirt.* e. Solenoid plunger of the automatic valve for sticking.* a. Thermostat dial and toggle switch settings. b. For excess air in the jacket. See "Jacket Vacuum" in the "Preventive Maintenance" section of this manual. c. Thermostat calibration.* d. Thermostat operation.* e. Pressure limit switch for malfunction at low pressures.* a. For excess air in the jacket. See "Jacket Vacuum" in the "Preventive Maintenance" section of this manual. b. Gas pressure at the automatic gas valve*

Safety valve pops. a. For excess air in the jacket. See "Jacket Vacuum" in the "Preventive Maintenance" section of this manual. b. Safety valve. If the valve pops at pressures below

29 PSI, replace it* c. If high limit switch is set too high.* d. Thermostat operation.*

14

B. Models with Standing Pilot Ignition

(Refer to the electrical schematic)

SYMPTOM

Pilot burner will not light.

WHAT TO CHECK a.

Lighting procedure. See the "Operation" section of this manual.

b.

Pilot tubing and orifice for clogging.* c.

That the pilot gas supply line is purged of air.* d.

Gas pressure at the automatic valve.*

Pilot flame goes out when reset button is released.

Main burner will not light, and previously lighted pilot burner is out.

Main burner will not light, but pilot burner is lit.

a.

Lighting procedure. See the "Operation" section of this manual.

b.

That electrical connections in the controls, including ground connections, are clean and secure.* a.

Pilot tubing and orifice for clogging.* b.

That electrical connections, including ground connections, are clean and secure.* c.

Gas pressure at the automatic valve.* a.

That electrical connections, including ground connections, are clean and secure.* b.

That the pressure limit switch is closed.* c.

Low-water cutoff for continuity, and the cutoff transformer for proper input and output voltages.* d.

That the low-water cutoff electrode is clean.* e, That the pilot flame surrounds approximately 1/2 inch of the tip of the thermocouple.* If not, check for: (1)

Clogging of the pilot burner.* (2) Air currents deflecting the pilot flame.* (3) Low gas pressure at the automatic valve.* f.

That the thermocouple generates at least 17 mV at the

Basotrol valve terminal.* g.

For a defective automatic gas valve.*

15

Service Troubleshooting (cont’d)

The 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. If an item on the list is followed by an asterisk (*), the work should be done by a factory authorized service representative.

WARNING: BEFORE REPLACING ANY PARTS, DISCONNECT THE UNIT FROM

THE ELECTRIC POWER SUPPLY AND CLOSE THE MAIN GAS COCK. 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.


C. Models with Electronic Spark Ignition System

(Refer to the electrical schematic)


System does not produce a spark.

Spark is present, but the pilot will not light.

a.

Thermostat, and close the contacts, if they are open.* b.

AC voltage between terminals "2" and "GR". If it is not 24V:

(1) Check high limit switch, which should be closed.* (2)

Replace the transformer.* c.

Pilot spark gap. Regap, it is not 7/64 inch.* d, Pilot electrode ceramic for crack or break.* e.

That the high tension cable is firmly attached and in good condition. If it is cracked or brittle, replace the pilot.* f.

Replace the electronic portion of the G60 system.* a.

That the pilot valve is securely connected to terminals "1" and "GR". Some models have the pilot valve grounded internally.* b.

That gas pressure meets the control manufacturer's specifications.* c.

For gas at the pilot. If it is not flowing: (1)

Check the pilot gas line for kinks and obstructions.*

(2) Replace the pilot valve.* d.

That the pilot spark gap is 7/64 inch and located in the pilot gas stream. If not, adjust or replace the pilot* e.

Pilot orifice, and clean, if necessary.* f.

For drafts. Shield the pilot burner, if necessary.*

16

SYMPTOM

Pilot lights, but main burner will not come on, and the spark stays on.

WHAT TO CHECK

a.

Sensor cable, to make sure of secure attachments to the sensor and to terminal "4" on the G60* b.

That the cable is not grounded out. If it is, correct the ground.* c.

Cable for continuity and condition of insulation.* d.

Sensor ceramic for cracks.* 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.* If the current is less than 0.7 microamp: (1) Check the gas pressure.* (2) Clean the pilot assembly.* (3)

Tighten mechanical and electrical connections.* f.

Pilot application, and correct to increase sensor probe current, by: (1) Increasing or decreasing pilot orifice size.* (2) Shielding the pilot from drafts.*

Pilot lights, but main burner will not come on, and spark does not stay on.

a.

For 24V between terminals "3" and "GR". If voltage is not correct, replace the G60 electronics.* b.

That the gas pressure meets the control manufacturer's specifications. * 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.*

17

AH/I — 20, 30, & 40 Gallon Models

18

C-7288-2

Parts Lists

To order parts, contact your Groen Certified Service Agency. Supply the model designation, part description, part number, quantity, and, where applicable, voltage and phase or type of gas.

A. AH/1 -20, 30, and 40 Gallon Models

ITEM

NO.

23

24

29

30

31

32

25

26

27

28

33

34

35

21

22

13

14

15

16

9

10

11

12

17

18

19

20

5

6

7

8

1

2

3

4

PART

NO.

DESCRIPTION

5471 1/4--20 CAP NUT

47552 HANDLE

12691 KNOB

12733 SPACER

61012 HINGE BAR

13485 HINGE COVER

2378

2986

SPACER VENT COVER

PILOT LIGHT ASSEMBLY (115V)

99156 PRESSURE GAUGE

8453 PRESSURE LIMIT CONTROL

10390 RUBBER BOOT

74665 WARRICK ELECTRODE

12313 THERMOSTAT

12314 THERMOSTAT KNOB

6904 TOGGLE SWITCH

10412 WARRICK RELAY (115V)

576

4035

4002

4000

4001

8201

4112

4010

DRAFT DIVERTER

COMBUSTION DOOR

HINGE

PIN

SPRING

INSULATION DOOR

KNOB

SAFETY VALVE (units built before 8/1/92)

97009 SAFETY VALVE (units built after 8/1/92)

13541 WATER FILL ASSY. (units built before

8/1/92)

96007 1/2" NPT WATER FILL ASSY. (units built after 8/1/92)

10668 3/4" IPS X 90° STREET ELBOW (units built before 8/1/92

96905 1/2" NPT STREET ELBOW (units built after

8/1/92

4071

8917

8742

1/2" GAUGE GLASS CONNECTOR

ASSEMBLY

RUBBER GAUGE GLASS GASKET

WASHER (WITH ASSEMBLY #4071)

HEX NUT (WITH ASSEMBLY #4071)

WATER GAUGE GLASS

13421 1/2" CONDUIT FITTING

8902 COVER FOR ITEM 29

8904

9000

9048

1908

GASKET FOR ITEM 29

1-1/2" DRAW-OFF VALVE (COMPLETE)

9046 2" DRAW-OFF VALVE (COMPLETE)


9027 VALVE STEM (FOR 1-1/2" VALVE)

VALVE STEM (FOR 2" VALVE)

3" VALVE STEM (FOR 3" VALVE)

9024

9047

3925

9034

VALVE BONNET (FOR 1-1/2" VALVE)

VALVE BONNET (FOR 2" VALVE)


RUBBER “O" RING (FOR 1-1/2" VALVE)

9034 RUBBER "O' RING (FOR 2" VALVE)

W/1908 RUBBER "O" RING (FOR 3" VALVE)

ITEM

NO.

53

54

55

56

48

49

50

51

52

44

45

46

47

40

41

42

43

38

39

36

37

57

58

59

64

65

66

67

60

61

62

63

68

69

70

71

72

73

PART

NO.

DESCRIPTION

8911

9354

3927

9029

SANITARY HEX NUT (FOR 1-1/2" VALVE)

SANITARY HEX NUT (FOR 2" VALVE)


VALVE HANDLE (FOR 1-1/2" VALVE)

9029 VALVE HANDLE (FOR 2" VALVE)


9028

9028

WING NUT (FOR 1-1/2" VALVE)

WING NUT (FOR 2" VALVE)

W/1908 WING NUT (FOR 3" VALVE)

2479 BULLET FOOT (STANDARD)

286

289

BURNER HEAD (PROPANE & NAT. GAS)

2-1/2" IPS STREET ELBOW

287

294

288

294

VENTURITUBE

3/8" IPS HEX LOCKNUT

AIR SHUTTER


—

—

8239

8172

280

281

279

283

9057

ORIFICE (NAT GAS)

ORIFICE (PROPANE GAS)

ORIFICE SPUD

PILOT BRACKET & ORIFICE (NAT. GAS)

284 PILOT BRACKET & ORIFICE (PROPANE)

63048 THERMOCOUPLE LEAD

9007 REMOVABLE STRAINER, 9" DIA, 1/4"

HOLES

9040 REMOVABLE STRAINER, 9" DIA, 1/8"

HOLES

REMOVABLE STRAINER, 9" DIA, NO

HOLES

8059

7439

8504

338

8239

8124

—

3/8" IPS X 90" UNION ELBOW

3/8" IPS CLOSE NIPPLE

3/8" IPS PIPE PLUG

3/4 X3/8 X 3/8" REDUCING TEE

3/4" IPS X 3" NIPPLE

3/4" IPS X 90° ELBOW

(NOT USED)

— (NOT USED)

97610 3/4" BASOTROL GAS VALVE (COMPLETE)

8347

8229

8347

5516

3/4" IPS X 90° STREET ELBOW

3/4" IPS X 4" LG NIPPLE

3/4" IPS X 90° STREET ELBOW

3/4" IPS FEMALE UNION

5561

345

3548


GAS PRESSURE REGULATOR (NAT. GAS)

GAS PRESSURE REGULATOR

(PROPANE)

(NOT USED)

(NOT USED)

NIPPLE 3/4" IPS X 3" LG

3/4" IPS GAS COCK

19

AH/I —60,80, & 100 Gallon Models

20

Parts Lists (cont'd)

To order parts, contact your Groen Certified Service Agency. Supply the model designation, part description, part number, quantity and, where applicable, voltage and phase or type of gas.

B. AH/1-60, 80, and 100 Gallon Models

33

34

35

32

30

31

18

19

20

21

22

23

24

25

26

27

28

29

12

13

14

15

8

9

10

11

16

17

ITEM

NO.

5

6

7

1

2

3

4

PART

NO. DESCRIPTION

5471 CAP NUT1/4--20 NC

47552 HANDLE

12691 KNOB

12733 SPACER

12520 COVER ACTUATOR (60 GAL.)

12521 COVER ACTUATOR (80 & 100 GAL.)

2986 PILOT LAMP(115V)

12406 BRACKET (60 GAL)

12813 BRACKET (80 & 100 GAL.)



6904 TOGGLE SWITCH

12313 EA-3 THERMOSTAT


10390 RUBBER BOOT FOR ITEM 16


4010 SAFETY VALVE (units built before 8/1/92)


4071 1/2" GAUGE GLASS CONNECTOR ASSY.

(COM.)

RUBBER GAUGE GLASS GASKET 8917

WASHER (WITH ASSY. #4071)

HEX NUT (WITH ASSY. #4071)

8742 WATER GAUGE GLASS

10412 WARRICK RELAY 115V

576

4035

DRAFT DIVERTER

COMBUSTION DOOR (COMPLETE)

4002

4000

4001

4112

HINGE

PIN

SPRING

KNOB (BLACK PLASTIC)

8201 INSULATION DOOR (COMPLETE)


8902

8904

9000

COVER FOR ITEM #28

GASKET FOR ITEM 28




9027

9048

VALVE STEM (FOR 1-1/2" VALVE)


1908 3" VALVE STEM (FOR 3" VALVE)

9024

9047



3925

9034

9034


RUBBER "O" RING (FOR 1-1/2" VALVE)

RUBBER "O' RING (FOR 2" VALVE)


8911 SANITARY HEX NUT (FOR 1-1/2" VALVE)

9354

3927



21

38

58

59

60

61

62

63

51

52

53

54

55

56

57

43

44

45

46

39

40

41

42

47

48

49

50

71

72

73

68

69

70

64

65

66

67

74

75

76

ITEM

NO.

36

37

PART

NO. DESCRIPTION

9029

9029


VALVE HANDLE (FOR 2" VALVE)


9028 WING NUT (FOR 1-1/2" VALVE)

9028 WING NUT (FOR 2" VALVE)


8246 BURNER HEAD (PROPANE & NATURAL

GAS)

289

8774

STREET ELBOW 2-1/2" IPS

REDUCER FACE BUSHING 2-1/2" TO 2"

8731 CLOSE NIPPLE 2" IPS

10542 VENTURI ASSY

—

399

403

396

397

398

(NOT USED)

NATURAL GAS ORIFICE

PROPANE GAS ORIFICE

AIR SHUTTER

LOCKNUT

END CAP

8043

8238

REDUCER FACE BUSHING 1" TO 3/4"

CLOSE NIPPLE 3/4" IPS

REDUCING TEE 575

8504

5559

8239

5493

8229

8347

—

—

PIPE PLUG 3/8" IPS

NIPPLE 3/4" IPS X 2-1/2" LG. (60 GAL)

NIPPLE 3/4" IPS X 3" LG. (80 GAL)

UNION ELBOW 3/4" IPS X 90 DEGREES

NIPPLE 3/4" IPS X 4" LG.

STREET ELBOW 3/4" IPS X 90 DEGREES

(NOT USED)

(NOT USED)

97610 3/4" BASOTROL GAS VALVE (COMPLETE)

— (NOT USED)

—

345

3548

(NOT USED)

GAS PRESSURE REGULATOR (NAT. GAS)

GAS PRESSURE REGULATOR

(PROPANE)

8239

8172

283

9007


3/4" IPS GAS COCK

PILOT BRACKET & ORIFICE (NAT. GAS)

REMOVABLE STRAINER 9" DIA. 1/4"

9040

HOLES

REMOVABLE STRAINER 9" DIA. 1/8"

9057

HOLES

REMOVABLE STRAINER 9" DIA. NO

HOLES

69886 PILOT LIGHT SPUD (NATURAL GAS)

284 PILOT LIGHT SPUD (PROPANE GAS)

63048 THERMOCOUPLE & LEAD

13541 WATER FILL ASSY.(units built before 8/1/92)


10668 3/4" IPS X 90 DEGREE STREET ELBOW

(units built before 8/1/92


2479

8/1/92)

BULLET FOOT 1-1/2" TUBE (60 GAL.)

13275 BULLET FOOT 2" TUBE (80 & 100 GAL.)

12599 POWER AIDE BRACKET

AH/IE — 20, 30. & 40 Gallon Models

22

Parts Lists (cont'd)


C. AH/1 E--20, 30, and 40 Gallon Models

29

30

31

23

24

25

19

20

21

22

26

27

28

ITEM

NO.

1

12

13

14

15

16

17

18

6

7

8

9

2

3

4

5

10

11

32

PART

NO. DESCRIPTION

5471 1/4"-20 CAP NUT

47552 HANDLE

12691 KNOB

12733 SPACER

61012 HINGE BAR

13485 HINGE COVER

2378 SPACER VENT COVER

3332

—

PILOT LIGHT ASSEMBLY (28V)

NOT USED

— NOT USED



10390 RUBBER BOOT


12313 THERMOSTAT


576 DRAFT DIVERTER

4035

4002

4000

COMBUSTION DOOR

HINGE

PIN

4001

8201

4112

—

2479

SPRING

INSULATION DOOR

KNOB

NOT USED

BULLET FOOT

6904 TOGGLE SWITCH


9000

9046


2" DRAW-OFF VALVE (COMPLETE)


9027 VALVE STEM (FOR 1-1/2" VALVE)

9048

1908

9024

9047


3" VALVE STEM (FOR 3" VALVE)



3925

9034

9354

3927


RUBBER "0" RING (FOR 1-1/2" VALVE)

9034 RUBBER "0' RING (FOR 2" VALVE)

W/1908 RUBBER "0" RING (FOR 3" VALVE)




9029

9029

VALVE HANDLE (FOR 1-1/2' VALVE)


12209 VALVE HANDLE (FOR 3- VALVE)

9028 WING NUT (FOR 1-1/2" VALVE)

9028 WING NUT (FOR 2" VALVE)



23

50

51

52

63

64

65

66

67

59

60

61

62

57

58

59

60

53

54

55

56

68

69

70

71

72

73

74

ITEM

NO.

33

44

45

46

47

48

49

38

39

40

41

42

43

34

35

36

37

75

8239

338

8239

338

8504

7439

8059

—

—

—

4010

97009

4071

PART

NO. DESCRIPTION

8902 COVER FOR ITEM 32

3751

74839

3329

3328

9007

9040

9057

8904

286

289

287

294

288

280

281

279

3750

79801

5553

8751

8229

5493

5523

8172

8877

8917

—

—

8742

13541

96007

10668

96905

GASKET FOR ITEM 32

BURNER HEAD (PROPANE & NAT. GAS

2-1/2" IPS STREET ELBOW

VENTURITUBE


AIR SHUTTER

ORIFICE (NAT GAS)

ORIFICE (PROPANE GAS)

ORIFICE SPUD

BURNER & ELECTRODE with ORIFICE

FOR NATURAL GAS

BURNER & ELECTRODE with ORIFICE

(PROPANE)

TRANSFORMER (115V/24V)

SENSING PROBE LEAD

SENSING PROBE WITH KANTHOL

REMOVABLE STRAINER, 9" DIA, 1/4" HOLES

REMOVABLE STRAINER, 9" DIA, 1/8" HOLES

REMOVABLE STRAINER, 9" DIA, NO

HOLES

GAS CONTROL VALVE NAT. GAS


1/2" IPS X 3/4" IPS 90 DEGREE REDUCING

ELBOW


3/4" IPS X 90 DEGREE REDUCING ELBOW


3/4" IPS GAS COCK


(NOT USED)


3/4 X 3/8 X 3/8" REDUCING TEE


3/4" X 3/8" X 3/8" REDUCING TEE

3/8" IPS PIPE PLUG


3/8" IPS X 90 DEGREE UNION ELBOW

(NOT USED)

(NOT USED)

(NOT USED)

SAFETY VALVE (units built before 8/1/92)

SAFETY VALVE (units built after 8/1/92)

1/2" GAUGE GLASS CONNECTOR

ASSEMBLY


WASHER (WITH ASSEMBLY #4071)

HEX. NUT (WITH ASSEMBLY #4071)

WATER GAUGE GLASS

WATER FILL ASSY. (units built before

8/1/92)

1/2" NPT WATER FILL ASSY. (units built after 8/1/92)

3/4" IPS X 90° STREET ELBOW (units built before 8/1/92)

1/2" NPT STREET ELBOW (units built after

8/1/92)

79803 GAS CONTROL VALVE PROPANE

AH/1E —60, 80, & 100 Gallon Models

24

Parts List


D. AH/1 E-60, 80, and 100 Gallon Models

ITEM

NO.

23

24

25

18

19

20

21

22

26

27

28

29

30

31

32

34

35

33

36

9

10

11

12

5

6

7

8

13

14

15

16

17

1

2

3

4

PART

NO. DESCRIPTION

5471 CAP NUT1/4"-20 NC

47552 HANDLE

12691 KNOB

12733 SPACER

12520 COVER ACTUATOR (60 GAL.)

12521 COVER ACTUATOR (80 & 100 GAL.)

3332 PILOT LIGHT ASSEMBLY (28V)

12599 BRACKET POWER AIDE

47552 HANDLE (80 & 100 GAL.)



6904 TOGGLE SWITCH

12313 THERMOSTAT


10390 RUBBER BOOT


4010 SAFETY VALVE (units built before 8/1/92)


4071

8917

1/2- GAUGE GLASS CONNECTOR ASSY.


WASHER (WITH ASSY. #4071)

HEX NUT (WITH ASSY. #4071)

8742 WATER GAUGE GLASS


576 DRAFT DIVERTER

4035

4002

COMBUSTION DOOR

HINGE

4000

4001

4112

8201

PIN

SPRING

KNOB

INSULATION DOOR


8902 COVER FOR ITEM #28

8904

9000

COVER FOR ITEM #28




9027

9048

1908

VALVE STEM (FOR 1-1/2" VALVE)


9024

9047

3925

9034

9034





RUBBER "O" RING (FOR 1-1/2" VALVE)

RUBBER “O' RING (FOR 2" VALVE)



9354

3927



9029

9029



12209 VALVE HANDLE (FOR 3' VALVE)

25

ITEM

NO.

37

38

51

52

53

54

47

48

49

50

43

44

45

46

39

40

41

42

55

56

57

71

72

73

67

68

69

70

62

63

64

65

58

59

60

61

66

74

75

76

77

78

PART

NO. DESCRIPTION

9028

9028

WING NUT (FOR 1-1/2" VALVE)

WING NUT (FOR 2" VALVE)


8246

289

8774

BURNER HEAD (PROPANE & NATURAL

GAS)

STREET ELBOW 2-1/2" IPS

REDUCER FACE BUSHING 2-1/2" TO 2"

8731 CLOSE NIPPLE 2" IPS

10542 VENTURIASSY

395

399

403

396

397

398

8043

—

MIXER TUBE

NATURAL GAS ORIFICE

PROPANE GAS ORIFICE

AIR SHUTTER

LOCKNUT

END CAP

REDUCER FACE BUSHING 1" TO 3/4"

(NOT USED)

575

8504

5559

8239

5493

8229

8751

REDUCING TEE

PIPE PLUG 3/8" IPS

NIPPLE 3/4" IPS X 2-1/2" LG. (60 GAL)

NIPPLE 3/4" IPS X 3" LG. (80 GAL)

UNION ELBOW 3/4" IPS X 90 DEGREE


REDUCING ELBOW 3/4" X 1/2" X 90

DEGREE

8877 CLOSE NIPPLE 1/2" IPS

79802 SPRING KIT, PROPANE GAS

79801 CONTROL VALVE (NAT. GAS)

5553 NIPPLE 1/2" IPS X 3" LG.

8286

—

—

8172

3750

3751


(NOT USED)

(NOT USED)

3/4" IPS GAS COCK

BURNER & ELECTRODE WITH ORIFICE

(NAT.GAS)

BURNER & ELECTRODE WITH ORIFICE

(PROPANE)

9007

9040

9057

3328

REMOVABLE STRAINER 9" DIA. 1/4" HOLES

REMOVABLE STRAINER 9" DIA 1/8" HOLES

REMOVABLE STRAINER 9" DIA NO HOLES

SENSING PROBE WITH KANTHOL

3329 SENSING PROBE LEAD

74839 TRANSFORMER (115V/24V)

13541 WATER FILL ASSEMBLY (units built before

8/1/92)


10668 3/4" IPS X 90 DEGREE STREET ELBOW

(units built before 8/1/92


8/1/92)

2479 BULLET FOOT 1-1/2" TUBE (60 GAL.)

13275 BULLET FOOT 2" TUBE (80 & 100 GAL.)

12406 BRACKET HINGE ASSY (60 GAL.)

12813 BRACKET HINGE ASSY (80 & 100 GAL.)

79803 GAS CONTROL VALVE PROPANE

26

AH/1 E Electrical Spark Ignition — Natural Gas

For units built between March, 1984 and June, 1989

AH/1 E Electrical Spark Ignition — Propane Gas

For units built between March, 1984 and June, 1989

Wiring Diagrams (cont'd)

AH/IE Electrical Spark Ignition

For units built between June, 1989 and June 1996

28

References

AMERICAN GAS ASSOCIATION LABORATORIES

8501 East Pleasant Valley Rd.

Cleveland, Ohio 44131

NATIONAL FIRE PROTECTION ASSOCIATION

60 Battery March Park

Quincy, Massachusetts 02269

AMERICAN NATIONAL STANDARDS

INSTITUTE, INC.

1430 Broadway

New York, New York 10018

Z223.1 -1984 National Fuel Gas Code

NFPA/54 Installation Gas Appliances &

Gas Piping

NFPA/70 The National Electrical Code

NATIONAL SANITATION FOUNDATION

3475 Plymouth Rd.

Ann Arbor, Michigan 48106

CANADIAN GAS ASSOCIATION

55 Scarsdale Rd.

Don Mills, Ontario

Canada, M3B 2R3

UNDERWRITERS LABORATORIES, INC.

333 Pfingsten Rd.

Northbrook, Illinois 60062

CAN 1-B149 Installation Codes for Gas ZEP MANUFACTURING CO.

Burning Appliances & Equipment 1310-T Seaboard Industrial Blvd.

Atlanta, Georgia 30318

KLENZADE SALES CENTER

ECOLAB, Inc.

370 Wabasha

St. Paul, Minnesota 55102

800/352-5326 or 612/293-2233

30

Service

A Service Log is provided with the warranty information. Each time service is performed on this Groen equipment, enter the date on which the work was done, what was done, and who did it. The owner should file the log with the warranty.

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.


1. Periodic Service

Periodic inspection can minimize equipment down time and increase the efficiency of operation. The following points should be checked at least once a year or more often as indicated. 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 between the marks on the gauge glass. If it is not, see

"Jacket Filling" in the "Preventive Maintenance" section. 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 1/2 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.

WARNING: FAILURE TO PERIODICALLY CHECK SAFETY VALVE OPERATION COULD

RESULT IN PERSONAL INJURY AND/OR DAMAGE TO EQUIPMENT.

WARNING: WHEN TESTING, AVOID ANY EXPOSURE TO THE STEAM BLOWING OUT

OF THE SAFETY VALVE. DIRECT CONTACT COULD RESULT IN SEVERE

BURNS. 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

WARNING: BEFORE REPLACING ANY PARTS, TURN OFF THE ELECTRIC POWER

SUPPLY TO THE UNIT AND CLOSE THE MAIN GAS COCK. ALLOW FIVE

MINUTES FOR UNBURNED GAS TO VENT.

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.

All internal wiring is marked as shown on the circuit schematic drawings. Be sure that new components are wired in the same manner as the old components.

31

Limited Warranty To Commercial

Purchasers *

(Domestic U.S., Hawaii &

Canadian Sales Only)

Groen Foodservice Equipment ("Groen Equipment") has been skillfully manufactured, carefully inspected and packaged to meet rigid standards of excellence. Groen warrants its Equipment to be free from defects in material and workmanship for (12) twelve months with the following conditions and subject to the following limitations.

I. This parts and labor warranty is limited to Groen Equipment sold to the original commercial purchaser/users (but not original equipment manufacturers), at its original place of installation in the continental United States, Hawaii and Canada.

II. Damage during shipment is to be reported to the carrier, is not covered under this warranty, and is the sole responsibility of purchaser/user.

III. Groen, or an authorized service representative, will repair or replace, at Groen's sole election, any

Groen Equipment, including but not limited to, draw off valves, safety valves, gas and electric components, found to be defective during the warranty period. As to warranty service in the territory described above, Groen will absorb labor and portal to portal transportation costs (time & mileage) for the first twelve (12) months from date of installation or fifteen (15) months from date of shipment from Groen.

IV. This warranty does not cover boiler maintenance, calibration, periodic adjustments as specified in operating instructions or manuals, and consumable parts such as scraper blades, gaskets, packing, etc., or labor costs incurred for removal of adjacent equipment or objects to gain access to Groen

Equipment. This warranty does not cover defects caused by improper installation, abuse, careless operation, or improper maintenance of equipment. This warranty does not cover damage caused by poor water quality or improper boiler maintenance.

V. THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR

IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE, EACH OF WHICH IS HEREBY EXPRESSLY DISCLAIMED. THE REMEDIES

DESCRIBED ABOVE ARE EXCLUSIVE AND IN NO EVENT SHALL GROEN BE LIABLE FOR SPECIAL,

CONSEQUENTIAL OR INCIDENTAL DAMAGES FOR THE BREACH OR DELAY IN PERFORMANCE OF

THIS WARRANTY.

VI. Groen Equipment is for commercial use only. If sold as a component of another (O.E.M.) manufacturer's equipment, or if used as a consumer product, such Equipment is sold AS IS and without any warranty.

* (Covers All Foodservice Equipment Ordered After October 1,1995)

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