Operators Manual

Installation, Operation & Service

GAS MIXING KETTLES

HORIZONTAL AGITATOR

MODEL

:

HA-MKGL-60

HA-MKGL-80

HA-MKGL-100

HA-MKGL-60-T

HA-MKGL-80-T

HA-MKGL-100-T

HA-MKGL-60-CC

HA-MKGL-80-CC

HA-MKGL-60-CC-T

HA-MKGL-80-CC-T

HA-MKGL-100-CC HA-MKGL-100-CC-T

™

Cleveland

Enodis

1333 East 179th St., Cleveland, Ohio, U.S.A. 44110

Phone: (216) 481-4900 Fax: (216) 481-3782

Visit our web site at www.clevelandrange.com

SE95022 Rev.

5

FOR THE USER

IMPORTANT!

ENSURE KETTLE IS AT ROOM TEMPERATURE AND

PRESSURE GAUGE IS SHOWING ZERO OR LESS PRESSURE

PRIOR TO REMOVING ANY FITTINGS

.

FOR YOUR SAFETY

DO NOT STORE OR USE GASOLINE

OR ANY OTHER

FLAMMABLE LIQUIDS AND

VAPOURS IN THE VICINITY

OF THIS OR ANY OTHER

APPLIANCE.

WARNING

: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation and operating instructions thoroughly before installing or servicing this equipment.

.

IMPORTANT

The following points are to insure the safe installation and operation of this equipment:

• Insure all gas and electrical supplies match rating plate and electrical stickers.

• Observe all clearance requirements.

• Disconnect the electrical power supply to the appliance before cleaning or servicing unit.

• All service must be performed by a qualified Cleveland Range Technician.

• Do not obstruct the flow of combustion and ventilation air.

The installation and connection must comply with current local codes, or in the absence of local codes, with

CAN/CGA-B149.1 and .2 installation code or with the national fuel gas code, ANSI Z223.1-L988.

Post in a prominent location, instructions to be followed in the event the user smells gas. This information shall be obtained by consulting your local gas supplier.

The appliance and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig. (3.45 kpa).

The appliance must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig. (3.45 kpa).

RETAIN THIS MANUAL FOR YOUR REFERENCE.

For your safety

DANGER

Keep clear of pressure relief discharge.

Keep hands away from moving parts and pinch points.

IMPORTANT

Inspect unit daily for proper operation.

Do not fill kettle above recommended level marked on outside of kettle.

Surfaces may be extremely hot! Use protective equipment.

CAUTION

Wear protective equipment when discharging hot product.

Do not lean on or place objects on kettle lip.

Stand clear of product discharge path when discharging hot product.

SERVICING

Shut off power at main fuse disconnect prior to servicing.

0

Ensure kettle is at room temperature and pressure gauge is showing zero or less prior to removing any fittings.

GAS APPLIANCES

Do not attempt to operate this appliance during a power failure.

Keep appliance and area free and clear of combustibles.

INSTALLATION

GENERAL

Installation of the kettle must be accomplished by qualified installation personnel working to all applicable local and national codes. Improper installation of product could cause injury or damage.

This equipment is built to comply with applicable standards for manufacturers. Included among those approval agencies are: UL, A.G.A., NSF, ASME/N.Bd., CSA, CGA, ETL, and others. Many local codes exist, and it is the responsibility of the owner/installer to comply with these codes.

Observe all clearance requirements to provide proper makeup air flow as well as sufficient clearance for servicing.

Dimensions and clearance specifications are shown on the specification sheet and in the Clearance Requirements section. Do not install kick plates or otherwise obstruct the flow of combustion and ventilation air.

Check rating plate to ensure that kettle has been equipped to operate with the type of gas available at the installation.

VENTILATION

Gas fired kettles are only to be installed under a ventilation hood in a room which has provisions for adequate make up air. Further information can be obtained by referring to the U.S.A. National Fire

Protection Associations NFPA96 regulations. These standards have also been adopted by the National

Building Code in Canada.

INSPECTION

Before unpacking visually inspect the unit for evidence of damage during shipping. If damage is noticed, do not unpack the unit, follow shipping damage instructions.

SHIPPING DAMAGE

INSTRUCTIONS

If shipping damage to the unit is discovered or suspected, observe the following guidelines in preparing a shipping damage claim.

1.

Write down a description of the damage or the reason for suspecting damage as soon as it is discovered. This will help in filling out the claim forms later.

2.

As soon as damage is discovered or suspected, notify the carrier that delivered the shipment.

3.

Arrange for the carrier's representative to examine the damage.

4.

Fill out all carrier claims forms and have the examining carrier sign and date each form.

CLEARANCE REQUIREMENTS

This unit must be installed in accordance with the clearances shown on the rating label which is adhered to the unit.

FOR YOUR SAFETY

. Keep the appliance area free and clear of combustible materials.

KETTLE

1.

When removing the kettle from the platform, handle with care to prevent scratching or any other damage. It is imperative that the kettle be level before bolting to the floor. This will prevent any twist or out of roundness to the kettle and will stop deflection of the agitator. Make sure the kettle is securely bolted to the floor and follow the procedure listed below:

⇒

Raise the flange on the leg under the motor so that it sets freely (stationary kettles only).

⇒

Position the kettle in its permanent location, check clearances and level the kettle by turning the adjustable feet.

⇒

Lower the flange or flanges under the motor channel. Over adjustment, whether up or down, could cause misalignment and cause damage to the agitator drive shaft and hub (stationary kettles only).

2.

Next you must check the alignment of the drive shaft for a uniform clearance between the hub and the shaft. In order to check for clearance you must remove the seal cover plate and pull the seal back.

you can check the distance for clearance by using a wire feeler gauge.

3.

If adjustment is required for side direction, loosen the motor bolts, center the shaft and retighten.

If vertical alignment is needed, loosen the motor bolts and add a shim to raise or remove a shim to lower. Retighten bolts. When this is complete, check to see if the agitator shaft coupling slides freely for easy removal of the agitator.

4.

Once positioned and leveled, permanently secure the kettle’s flanged feet to the floor using 1/2 x 2 I/2 inch lag bolts and floor anchors (supplied by the installer). Two bolts per leg are required to secure each of the flanged feet.

GAS

It is recommended that a sediment trap (drip leg) be installed in the gas supply line. If the gas pressure exceeds 14” water column, a pressure regulator must be installed, to provide a maximum of 14” water column gas pressure to the gas control valve.

Connect the gas supply piping to the input side of the gas control valve. Location and pressure data are shown on the specification sheet.

Installation must be in accordance with local codes and/or the National Fuel Gas Code ANSI Z223.1-1988

(USA) or the Installation Codes for Gas Burning

Appliances and Equipment CANI B149.1 and B149.2

(Canada). Use a gas pipe joint compound which is resistant to L.P. gas. Test all pipe joints for leaks with soap and water solution. Ensure that the gas pressure regulator is set for the manifold pressure indicated on the gas rating plate.

The appliance and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.45 kPa). The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.45 kPa).

WATER

The sealed jacket of the gas-fired kettle is precharged with the correct amount of a water-based formula, and therefore, no water connection is required to the kettle jacket.

CLEANING

After installation the kettle must be thoroughly cleaned and sanitized prior to cooking.

WARRANTY

Our Company supports a worldwide network of

Maintenance and Repair Centres. Contact your nearest

Maintenance and Repair Centre for replacement parts, service, or information regarding the proper maintenance and repair of your cooking equipment

In order to preserve the various agency safety certification (UL, A.G.A., NSF, ASME/Ntl. Bd., etc.), only factory-supplied replacement parts should be used. The use of other than factory supplied replacement parts will void warranty.

ELECTRICAL

Electrical installation must be in accordance with local codes and/or the National Electric Code ANSI/NFPA 70-

1990 (USA) or the Canadian Electrical Code CSA

Standard C22.1 (Canada). The kettle must be electrically grounded by the installer.

A separate fused disconnect switch must be supplied and installed in the high voltage electrical supply line.

The wire gauge size and electric supply must match the power requirements specified on the kettle’s rating plate. The waterproof conduit enclosed permanent copper wiring must be adequate to carry the required current at the rated voltage. Refer to the specification sheet or rating label for electrical specifications and location of electrical connections.

Remove the screws securing the component cover

(located to the left rear side of kettle), and remove the cover. A wiring diagram is affixed to the inside of the cover. Feed conduit enclosed permanent copper wiring through the cut-out in the bottom of the console and fasten to the terminal block. Fasten the ground wire to the ground lugs connected to the frame, beside the terminal block. Replace the console cover and secure it with the screws.

SPECIFICATION DRAWING -

STATIONARY MODELS

F

ELECTRICAL

SUPPLY

VOLTS

: 208/240

PHASE

: 3

AMPS

: 15

FREQ

: 60

APPROVALS

AGA CGA NSF

GAS SUPPLY

(PIPING 3/4" NPT)

TYPE

: NAT or LP

BTU PER CU. FT

.:

1000 (NAT), 2500 (LP)

SUPPLY PRESSURE

:

4" to 14" W.C.

BTU RATINGS

:

190,000 per hour

A AIR SUPPLY (PIPING 1/2" NPT)

PRESSURE

:

90 - 100 PSI

(only required for optional 3" dia.

piston draw-off valve)

H C

HOT & COLD

WATER

CLEARANCE

1/2" NPT CONNECTION

40-60 PSI PRESSURE

RIGHT: 3", LEFT: 3"

REAR: 5"

(ALLOW 12" SPACE

MINIMUM ON LEFT

SIDE FOR SERVICE)

APPROX.

SHIPPING

WEIGHTS

60 GAL -

1010 LBS.

458 KG.

80 GAL -

1120 LBS.

508 KG.

100 GAL -

1325 LBS.

601 KG.

7 3/4"

G

WALL

H C

H

16"

RIM BAR

3 HP

ELECTRIC

MOTOR

M

12"

RECOMMENDED

FLOOR DRAIN

28"

C

A

I.D.

L

A

J

2"

5 1/2"

5/8"

Ø,

2 HOLES

ON

4"

B.C.D.

3/8"

1"

(MAX. ADJUSTMENT)

SOLID

FOOT DETAIL

SPRING ASSIST

COVER (FULLY

OPEN AT 90 )

D

E

(COVER

FULLY

OPEN)

H C

B

A

A

S

RECOMMENDED FLOOR

SLOPE 1 INCH PER 4 FEET

6" RECOMMENDED

T

13"

3" DIA. BUTTERFLY VALVE

FLOOR DRAIN

PIPE DRAIN RECOMMENDED

MINIMUM VALVE SIZE PLUS 1"

DIMENSIONS

MODEL

HA-MKGL-60-TCC

HA-MKGL-80-TCC

HA-MKGL-100-TCC

A

29 1/2"

33"

35 1/2"

B

48 1/4"

51 3/4"

54 1/4"

C

61 5/8"

65 3/8"

68 3/8"

D

46 3/4"

52"

55"

E

93"

98"

104"

F

27 3/4"

30 3/4"

32 3/4"

G

42"

45 11/16"

48 3/16"

H

30 5/8"

33 5/8"

35 5/8"

J

78"

84"

95 5/8"

L

10 3/8"

11 7/16"

11 5/8"

M

53"

57"

66"

NOTES

: CLEVELAND RANGE EQUIPMENT IS BUILT TO COMPLY WITH APPLICABLE STANDARDS FOR MANUFACTURERS. INCLUDED AMONG THOSE APPROVAL AGENCIES ARE: UL, A.G.A., NSF, ASME/N.BD., CSA, CGA, ETL, AND OTHERS.

INSTALLATIONS OF BACK FLOW PREVENTERS, VACUUM BREAKERS AND OTHER SPECIFIC CODE REQUIREMENTS ARE THE RESPONSIBILITY OF THE OWNER AND INSTALLER.

ALL VERTICAL DIMENSIONS SHOWN ARE MINIMUM. FEET ARE ADJUSTABLE TO +1" MAXIMUM.

MANUFACTURER MUST BE NOTIFIED IF UNIT WILL BE OPERATING ABOVE 2000' ALTITUDE.

CONSULT FACTORY FOR MANUFACTURED GAS.

S

19 1/4"

20 3/4"

22"

5" MIN

CLEARANCE

T

24 1/2"

26 3/16"

27 5/8"

Cleveland Range reserves right of design improvement or modification, as warranted.

SPECIFICATION DRAWING -

TILTING MODELS

ELECTRICAL

SUPPLY

VOLTS

: 208/240

PHASE

: 3

AMPS

: 15

FREQ

: 60

APPROVALS

AGA CGA NSF

GAS SUPPLY

(PIPING 3/4" NPT)

TYPE

: NAT or LP

BTU PER CU. FT

.:

1000 (NAT), 2500 (LP)

SUPPLY PRESSURE

:

4" to 14" W.C.

BTU RATINGS

:

190,000 per hour

A

AIR SUPPLY (PIPING 1/2" NPT)

PRESSURE

:

90 - 100 PSI

(only required for optional 3" dia.

piston draw-off valve)

H C

HOT & COLD

WATER

CLEARANCE

1/2" NPT CONNECTION

40-60 PSI PRESSURE

RIGHT: 3", LEFT: 3"

REAR: 3"

(ALLOW 12" SPACE

MINIMUM ON LEFT

SIDE FOR SERVICE)

APPROX.

SHIPPING

WEIGHTS

60 GAL -

940 LBS.

428 KG.

80 GAL -

1030 LBS.

469 KG.

100 GAL -

1110 LBS.

505 KG.

K

Q

3"

REF.

WALL

M M

L

F

10 3/8

18 3/8

G

H C

5 1/2"

5/8"

Ø,

2 HOLES

ON

4"

B.C.D.

2"

3/8"

1"

(MAX. ADJUSTMENT)

SOLID

FOOT DETAIL

N

P P

12" X 24"

RECOMMENDED

FLOOR DRAIN

C

A

I.D.

SPRING ASSIST

COVER (FULLY

OPEN AT 90 )

D

RIM BAR

3 HP

ELECTRIC

MOTOR

H

C

H C

E

(COVER

FULLY

OPEN)

B

A

RECOMMENDED FLOOR

SLOPE 1 INCH PER 4 FEET

6" RECOMMENDED

13"

8 3/4"

3" DIA. BUTTERFLY VALVE

FLOOR DRAIN

PIPE DRAIN RECOMMENDED

MINIMUM VALVE SIZE PLUS 1"

3" MIN

CLEARANCE

DIMENSIONS

MODEL

HA-MKGL-60-CC

HA-MKGL-80-CC

HA-MKGL-100-CC

A

29 1/2"

33"

35 1/2"

B

48 1/4"

51 3/4"

54 1/4"

C

50"

58"

60 1/2"

D

36 1/2"

39"

40 3/4"

E

83"

90"

96"

F

13 1/8"

14 7/8"

16 1/8"

G

34 5/8"

35 15/16"

37 1/8"

K

23 7/8"

24 5/8"

25 1/4"

L

19 1/8"

20 7/8"

22 1/8"

M

10 3/32"

11 17/32"

12 3/4"

N

24"

26"

27 1/4"

NOTES

: CLEVELAND RANGE EQUIPMENT IS BUILT TO COMPLY WITH APPLICABLE STANDARDS FOR MANUFACTURERS. INCLUDED AMONG THOSE APPROVAL AGENCIES ARE: UL, A.G.A., NSF, ASME/N.BD., CSA, CGA, ETL, AND OTHERS.

INSTALLATIONS OF BACK FLOW PREVENTERS, VACUUM BREAKERS AND OTHER SPECIFIC CODE REQUIREMENTS ARE THE RESPONSIBILITY OF THE OWNER AND INSTALLER.

ALL VERTICAL DIMENSIONS SHOWN ARE MINIMUM. FEET ARE ADJUSTABLE TO +1" MAXIMUM.

MANUFACTURER MUST BE NOTIFIED IF UNIT WILL BE OPERATING ABOVE 2000' ALTITUDE.

CONSULT FACTORY FOR MANUFACTURED GAS.

P

9 3/4"

9 3/4"

11"

Q

17 7/8"

18 5/8"

19 1/4"

Cleveland Range reserves right of design improvement or modification, as warranted.

OPERATING INSTRUCTIONS

A

B

C

D

E

NOTE:

Location of switches may vary dependant on customers specific options

A

B

1 2 3 4

Red Low Water Indicator Light

When lit, in the upright position, indicates kettle gas burner has cut out and unit requires more water.

Occasional pulsing of this light is normal.

Green Heat Indicator Light

When lit, indicates gas burner is on; cycles on-off with solid state controls.

Solid State Temperature Control Knob /

On-Off Toggle Switch

Controls electrical power to kettle. and allows operator to select kettle heat increments from minimum, 1-10.

A setting of 7 or higher will boil water

Amber Ignition Failure Indicator Light

Indicates failure of heating system to ignite

(Used prior to July 2004)

Agitator Stop Button

Stops agitator in case of emergency

Agitator Start Switch

Starts agitator. Agitator power control switch must be ON

Agitator Power Switch

Allows power to agitator. When not in use, turn control power OFF

Agitator Speed Control Switch

Turn clockwise until desired speed is reached

Power tilt control switch

Tilts kettle for pouring; some kettles have manual hand tilt

Reset circuit breaker

Protects power tilt system from overload. Push to reset

0 1 2 3

Water Meter Digital Counter

(not shown)

Location may vary dependant on customer's specific options

Fill Interrupt Switch

Interrupts water fill cycle

Potable Fill Water Switch

Selects hot or cold water

Fill Cycle Switch

Start/continue cycle switch

Product Discharge Valve Switch

Toggle momentary switch to desired valve opening

3

4

5

6

7

1

2

Temperature Sensor

Senses temperature of product

Automatic Dump Valve

Empties kettle of either food product or wash water

Sight Glass

For checking water level of kettle jacket

Vacuum /Pressure Gauge

Indicates steam pressure inside steam jacket in PSI, as well as vacuum in inches of mercury

Gas Shut-Off Valve

Air Quick Connect

Push yellow tab down to release air pressure before disconnecting air hose

Kettle Filler Nozzle

7

5

6

General

WARNING:

Do not attempt to operate this appliance during a power failure. Keep appliance and area free and clear of combustibles.

Before turning kettle on, ensure that following conditions exist:

•

If you are cooking an egg or milk product, do not pre-heat kettle.

•

The vacuum/pressure gauge needle is in green zone; if it is not and is in "vent air" zone, call your service agent to repair leak.

•

The electrical service to kettle is turned on

NOTE:

The kettle should be sanitized prior to the daily production run - see CLEANING INSTRUCTIONS .

Automatic Heating

1.

Switch "

CONTROLLER

" to "

ACTIVE

".

2.

Turn temperature control knob to "

10

".

3.

Continually push function key " displayed.

" until "

OFF

" is

4.

Push and hold key " " or " " until desired temperature is set.

5.

To Start: push function key

" " until "

CtrL

" is displayed.

6.

Push down key " ".

7.

To Stop: push function key

" " until " OFF " is displayed.

8.

Push down key " ".

9.

After closing discharge valve, place product in kettle.

Mixing

("AGITATOR ")

WARNING:

•

Never add product to kettle while agitator is running.

•

Do not put hands in kettle.

•

Watch for loose clothing near agitator.

1.

Turn "

SPEED CONTROL

" to "

0

".

2.

Switch agitator to "

ON

".

3.

Push agitator "

START

" to initiate mixing.

4.

Turn "

SPEED CONTROL

" to desired mixing speed.

5.

To stop mixing action, push agitator stop button.

NOTE:

Mixing speed depends on the product consistency. The faster the mixing speed the more damage may be done to fragile product.

Heating

(General Notes)

•

The green light cycles on and off, indicating that burners are cycling to maintain set temperature.

•

The red "low water" light should not be lit during operation. This light indicates that water level is critically low and that gas burners have automatically shut off. Before further use, refer to

RESERVOIR FILL INSTRUCTIONS for adding distilled water.

•

Occasional flashing of the red "low water" light is ok while kettle is heating.

Manual Heating

1.

Switch "POWER" to "ON".

2.

Turn temperature control knob to desired setting.

3.

Switch "

CONTROLLER

" to "

BYPASS

".

4.

After closing discharge valve, place product in kettle.

Emptying the Kettle

1.

To open automatic dump valve:

•

Turn PRODUCT DISCHARGE VALVE switch clockwise to JOG TO OPEN. Release switch to the

HOLD position when desired valve opening is achieved.

•

To close valve, turn switch counterclockwise to

CLOSED position.

2.

To avoid splashing, slowly empty kettle contents into an appropriate container by partially opening dump valve.

NOTE:

When pumping with a Metering Filling Station the speed of the agitator arm must be sufficient to suspend the heavier items in the mix in order to achieve an even distribution in your packaged items.

3.

Immediately clean kettle as outlined in CLEANING

INSTRUCTIONS on page.

Water Meter

1.

Switch "

POTABLE FILL WATER

" to "

HOT

" or "

COLD

".

2.

Set required volume by first pushing the " " key until the digit you want to change is flashing in the lower display. Then use the " " key to change the value of the selected digit.

When all digits are set, press the "

ENT

" key.

3.

Locate delivery spout over kettle.

4.

Turn switch to "

RESET

". Delivery will start at "

0

" and stop at preset volume.

5.

To stop delivery at any time, turn "

FILL INTERRUPT

" switch to "

●

".

6.

To complete delivery after interrupting, turn switch

"

FILL CYCLE" to "CONTINUE

".

CARE AND CLEANING

Cooking equipment must be cleaned regularly to maintain its fast, efficient cooking performance and to ensure its continued safe, reliable operation. The best time to clean is shortly after each use (allow unit to cool to a safe temperature).

➩

➩

➩

➩

CLEANING INSTRUCTIONS

WARNINGS

➩

Do not use detergents or cleansers that are chloride based or contain quaternary salt.

Chloride Cleaners

Wire Brush &

Steel Pads

High Pressure

Spray Hose

Stagnant

Water

CAUTION

SURFACES MAY

BE EXTREMELY HOT!

Do not use a metal bristle brush or scraper.

Steel wool should never be used for cleaning the stainless steel.

Unit should never be cleaned with a high pressure spray hose.

Do not leave water sitting in unit when not in use.

CLEANING INSTRUCTIONS

1.

Turn unit off.

2.

Remove drain screen (if applicable). Thoroughly wash and rinse the screen either in a sink or a dishwasher.

3.

Prepare a warm water and mild detergent solution in the unit.

4.

Remove food soil using a nylon brush.

5.

Loosen food which is stuck by allowing it to soak at a low temperature setting.

6.

Drain unit.

7.

Rinse interior thoroughly.

8.

If the unit is equipped with a Tangent Draw-Off

Valve, clean as follows:

a)

Disassemble the draw-off valve first by turning the valve knob counter-clockwise, then turning the large hex nut counter-clockwise until the valve stem is free of the valve body.

b)

In a sink, wash and rinse the inside of the valve body using a nylon brush.

c)

Use a nylon brush to clean tangent draw-off tube.

d)

Rinse with fresh water.

e)

Reassemble the draw-off valve by reversing the procedure for disassembly. The valve's hex nut should be hand tight only.

9.

If the unit is equipped with a Butterfly Valve, clean as follows:

a)

Place valve in open position.

b)

Wash using a warm water and mild detergent solution.

c)

Remove food deposits using a nylon brush.

d)

Rinse with fresh water.

e)

Leave valve open when unit is not in use.

10.

Using mild soapy water and a damp sponge, wash the exterior, rinse, and dry.

NOTES

➩

For more difficult cleaning applications one of the following can be used: alcohol, baking soda, vinegar, or a solution of ammonia in water.

➩

Leave the cover off when the kettle is not in use.

➩

For more detailed instructions refer to the Nafem

Stainless Steel Equipment Care and Cleaning manual

(supplied with unit).

STAINLESS STEEL EQUIPMENT CARE AND CLEANING

(Suppied courtesy of Nafem. For more information visit their web site at www.nafem.org)

Contrary to popular belief, stainless steels ARE susceptible to rusting.

Corrosion on metals is everywhere. It is recognized quickly on iron and steel as unsightly yellow/orange rust. Such metals are called “active” because they actively corrode in a natural environment when their atoms combine with oxygen to form rust.

Stainless steels are passive metals because they contain other metals, like chromium, nickel and manganese that stabilize the atoms. 400 series stainless steels are called ferritic, contain chromium, and are magnetic;

300 series stainless steels are called austenitic, contain chromium and nickel; and 200 series stainless, also austenitic, contains manganese, nitrogen and carbon. Austenitic types of stainless are not magnetic, and generally provide greater resistance to corrosion than ferritic types.

With 12-30 percent chromium, an invisible passive film covers the steel’s surface acting as a shield against corrosion. As long as the film is intact and not broken or contaminated, the metal is passive and stain-less. If the passive film of stainless steel has been broken, equipment starts to corrode. At its end, it rusts.

Enemies of Stainless Steel

There are three basic things which can break down stainless steel’s passivity layer and allow corrosion to occur.

1.

Mechanical abrasion

2.

Deposits and water

3.

Chlorides

Mechanical abrasion

means those things that will scratch a steel surface.

Steel pads, wire brushes and scrapers are prime examples.

Water

comes out of the faucet in varying degrees of hardness. Depending on what part of the country you live in, you may have hard or soft water.

Hard water may leave spots, and when heated leave deposits behind that if left to sit, will break down the passive layer and rust stainless steel. Other deposits from food preparation and service must be properly removed.

Chlorides

are found nearly everywhere. They are in water, food and table salt. One of the worst chloride perpetrators can come from household and industrial cleaners. to reduce deposits. There are certain filters that can be installed to remove distasteful and corrosive elements. To insure proper water treatment, call a treatment specialist.

5.

Keep your food equipment clean.

Use alkaline, alkaline chlorinated or non-chloride cleaners at recommended strength. Clean frequently to avoid build-up of hard, stubborn stains. If you boil water in stainless steel equipment, remember the single most likely cause of damage is chlorides in the water. Heating cleaners that contain chlorides have a similar effect.

6.

Rinse, rinse, rinse.

If chlorinated cleaners are used, rinse and wipe equipment and supplies dry immediately. The sooner you wipe off standing water, especially when it contains cleaning agents, the better. After wiping equipment down, allow it to air dry; oxygen helps maintain the stainless steel’s passivity film.

7.

Never use hydrochloric acid (muriatic acid) on stainless steel.

8.

Regularly restore/passivate stainless steel.

Recommended cleaners for specific situations

Job

Routine cleaning

Fingerprints & smears

Stubborn stains & discoloration

Grease & fatty acids, blood, burnt-on-foods

Grease & oil

Restoration/Passivation

Cleaning Agent

Soap, ammonia, detergent, Medallion

Arcal 20, Lac-O-Nu

Ecoshine

Cameo, Talc, Zud,

First Impression

Easy-off, De-Grease

It Oven Aid

Any good commercial detergent

Benefit, Super Sheen

Comments

Apply with cloth or sponge

Provides barrier film

Rub in direction of polish lines

Excellent removal on all finishes

Apply with sponge or cloth

So what does all this mean? Don’t Despair!

Here are a few steps that can help prevent stainless steel rust.

1.

2.

Use the proper tools.

When cleaning stainless steel products, use non-abrasive tools. Soft cloths and plastic scouring pads will not harm steel’s passive layer.

Stainless steel pads also can be used but the scrubbing motion must be in the direction of the manufacturers’ polishing marks.

Clean with the polish lines.

Some stainless steel comes with visible polishing lines or “grain.”

When visible lines are present, always scrub in a motion parallel to the lines. When the grain cannot be seen, play it safe and use a soft cloth or plastic scouring pad.

3.

Use alkaline, alkaline chlorinated or non-chloride containing cleaners.

While many traditional cleaners are loaded with chlorides, the industry is providing an ever-increasing choice of non-chloride cleaners. If you are not sure of chloride content in the cleaner used, contact your cleaner supplier. If your present cleaner contains chlorides, ask your supplier if they have an alternative. Avoid cleaners containing quaternary salts; it also can attack stainless steel and cause pitting and rusting.

4.

Treat your water.

Though this is not always practical, softening hard water can do much

Review

1.

Stainless steels rust when passivity (film-shield) breaks down as a result of scrapes, scratches, deposits and chlorides.

2.

Stainless steel rust starts with pits and cracks.

3.

Use the proper tools. Do not use steel pads, wire brushes or scrapers to clean stainless steel.

4.

Use non-chlorinated cleaners at recommended concentrations. Use only chloride- free cleaners.

5.

Soften your water. Use filters and softeners whenever possible.

6.

Wipe off cleaning agent(s) and standing water as soon as possible.

Prolonged contact causes eventual problems.

To learn more about chloride-stress corrosion and how to prevent it, contact the equipment manufacturer or cleaning materials supplier.

Developed by Packer Engineering, Naperville, Ill., an independent testing laboratory.

PRODUCT VALVE

Daily

- clean product valve as follows:

KETTLE

KETTLE

OUTLET

CLAMP

0-RING

VALVE

TEE

0-RING

CLAMP

0-RING

CLOSED

POSTITION

OPEN

POSITION

AIR HOSE

AIR

CYLINDER

AIR HOSE

1.

Open product valve.

2.

Disconnect air hoses.

3.

Remove air cylinder.

4.

Remove valve tee.

5.

Remove all O-rings.

6.

Clean air cylinder, do not submerge in water. Wipe clean and sanitize.

7.

Clean and sanitize tee and O-rings.

8.

Grease and reinstall O-rings.

9.

Reinstall tee to kettle outlet.

10.

Reinstall air cylinder to bottom of tee.

11.

Reconnect air hoses.

12.

Close valve and check for alignment.

SCRAPER BLADES

To remove and clean scraper blades:

Scraper blade

Back stop

Pin A

Pin B

Spring

Tool

Fig. 1 Fig. 2 Fig. 3

To Remove Scraper Blade

1.

Insert tool that is provided as shown in Fig. 2.

2.

Pull up on spring arm until arm clears groove in Pin B.

3.

Spring is now disengaged, gently release spring to remove

To Install Scraper Blade

1.

Slide scraper blade and spring onto Pin A as shown in Fig. 1.

2.

Hook spring arm and pull up.

3.

Using tool, engage spring arm into groove on Pin B.

Scraper blade is now in place.

1.

Remove scraper blades using the tool to release the spring from the retaining pin and sliding the blade off the shaft.

2.

Place parts in a pan of warm water to soak.

3.

Clean in a sink, using a warm water and mild detergent solution.

4.

Rinse with fresh water.

5.

Allow to dry thoroughly on a flat, clean surface.

AGITATOR

To remove and clean agitator (two-person job):

Agitator shaft

Pin

Coupling

QUAD RING

To clean agitator quad ring:

Quad ring

Seal retainer plate

Retaining knobs

Removing Agitator

1.

Remove scraper blades.

2.

Rotate agitator until pull pin is on top side.

3.

Turn power OFF.

4.

Pull pin out.

5.

Slide coupling toward kettle wall, and carefully lift agitator pulling back to lift out.

6.

Clean in a sink, using a warm water and mild detergent solution.

7.

Rinse with fresh water.

Cleaning Quad Ring

1.

Remove retaining knobs.

2.

Slide shaft seal retainer plate and quad ring away from kettle body.

3.

Clean quad ring, shaft, and seal retainer plate with clean cloth.

4.

Rinse with fresh.

5.

Apply light coat of food safe grease to both sides of the quad ring.

6.

Slide quad ring back into original position, making sure it does not twist.

7.

Slide retainer plate back toward kettle, replacing retaining knobs.

8.

Tighten with hand pressure only.

AGITATOR BUSHING

With agitator out, remove bushing by:

Bushing

Slot

1.

Remove bushing by turning 1/4 turn and pulling away from the kettle wall.

Agitator

Shaft

Retaining pin

2.

Clean, rinse and sanitize bushing and bushing mounting area.

3.

Lubricate metal surfaces with food safe grease.

4.

Install bushing by locating retaining pin and sliding bushing on.

5.

Rotate to lock into position.

SERVICE PARTS

SCRAPER BLADES

ITEM NO.

PART NO. DESCRIPTION

1.

2.

3.

KE54602

KE54608

KE01976

QTY.

SCRAPER BLADE . . . . . . . . . . . . . . .7

SPRING . . . . . . . . . . . . . . . . . . . . . . .7

SPRING REMOVAL TOOL . . . . . . . . 1

1

2 3

4.

5.

6.

7.

1.

2.

3.

AGITATOR SEAL ASSEMBLY

ITEM

NO. PART NO. DESCRIPTION QTY.

KE01911

KE54592

FA05002-8

KE54594

KE54583

KE54593

KE54590

RETAINING KNOBS . . . . . 3

SEAL RETAINER PLATE . . 1

"O" RING . . . . . . . . . . . . . . 1

PIN . . . . . . . . . . . . . . . . . . 1

COUPLING . . . . . . . . . . . . 1

IDLER PIN . . . . . . . . . . . . 1

BUSHING . . . . . . . . . . . . . 1

1 2 3 4 5 6 7

Agitator

Shaft

OPERATING CONTROLS

ITEM NO.

PART NO. DESCRIPTION

1.

2.

3.

4.

KE54531

KE54530

KE54529

KE54532

QTY.

AGITATOR STOP . . . . . . . . . . . . . . . . . . . . . . 1

AGITATOR START . . . . . . . . . . . . . . . . . . . . . 1

POWER ON/OFF SWITCH . . . . . . . . . . . . . . . 1

SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . 1

1

2

3

4

PRESSURE RELIEF ASSEMBLY

4 3

5

1

2

ITEM NO.

PART NO.

DESCRIPTION

1.

2.

3.

4.

5.

FA05049

FI00151

FI00178

KE54941-5

KE54941-31

KE54223

QTY.

MALE CONNECTOR, 1/2" PIPE - 1/4" TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

STREET ELBOW, 1/2" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

TEE, 1/2" FPT, BRASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SAFETY VALVE, 50 PSI, 1/2" (NORTH AMERICA) . . . . . . . . . . . . . . . . . . . . . . .1

SAFETY VALVE, 50 PSI, 1/2", (EUROPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

BLOW DOWN TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.

2.

3.

4.

SIGHT GLASS

ITEM ON. PART NO. DESCRIPTION QTY.

KE50955

KE52871

KE51053-1

FA05002-30

RETAINING COVER . . . . . . . . 1

WASHER . . . . . . . . . . . . . . . . 1

SIGHT GLASS . . . . . . . . . . . . 1

”O” RING . . . . . . . . . . . . . . . . 1

HI

LO

1

2

3

4

HINGE ASSEMBLY

9

6

1

5

4

7

11

8

10

9

12 13 2 3

ITEM NO.

PART NO.

DESCRIPTION

1. - 11

1.

2.

3.

8.

9.

10.

11.

4.

5.

6.

7.

12.

13.

KE50597-1

KE50597-2

KE50597-3

KE50597-4

KE50597-5

KE50822

KE51217

KE50121-2

KE50121-1

KE50823-1

KE50824

KE50819-1

KE50820

KE50819

FA11284

FA11507

SK50418

KE50151-2

QTY.

Hinge Assembly

25 - 40 Gallon, 20 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

60 - 80 Gallon, 30 - 40 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . . . . .1

100 - 150 Gallon, 60 - 100 Gallon Full Jacketed . . . . . . . . . . . . . . . . . . . . . . . .1

KDM-60, KDM-60-T, Cook Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KDL-200, KDL-250, KDL-150-F, KDL-250-F . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Hinge Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Hinge Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Hinge Spring Light

- for KE50597-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Hinge Spring Heavy

- for KE50597-1, KE50597-3, KE50597-4, KE50597-5, . .1

Hinge Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Hinge Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Hinge End Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Hinge Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Hinge End Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Screw, Socket Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Cutting Screw, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Plug Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Cover Handle (specify model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

WATER METER ASSEMBLY

12

10

2

3

2

1

4

6

7

3

2

1

ITEM ON.

PART NO.

DESCRIPTION

5.

6.

7.

8.

1.

2.

3.

4.

9.

10.

11.

12.

FI00096

F100629-2

FI00063

F100629-36

KE55228

KE54834-4

KE02290

R00179

FI00365

FI00267

FA21008

KE54336

KE54336-1

KE52002-1

QTY.

3/4 BRASS UNION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

3/4 NPT X 2 112 BRASS NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

3/4 NPT BRASS ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3/4 NPT CLOSE BRASS NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

U-BOLT, 1/4-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

MOUNTING PLATE ASSY, HOT COLD WM . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3/4 NPT BRASS FEMALE TEE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3/4 X 1 REDUCING BRASS ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

3/4 NPT BRASS COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

S.S. NUT 1/4-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

GALLON METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

QUART METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

LITER METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

9

4

8

4

FLUSH PISTON VALVE

(USED PRIOR TO 2003)

10.

11.

12.

13.

14.

15.

16.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.-13.

ITEM NO.

PART NO.

DESCRIPTION

T40430

FA05000

KE52345

KE52346

KE52347

KE52344

FA05002-22

FA05002-21

KE52315

KE52335

SE00040

KE52341

KE52340

KE52342

KE52338

KE52327

KE52328

KE52314

QTY.

Valve Assembly (includes parts 1 - 16) . . . . . . . . . . . . . . . . . . . . . . . . .1

"O" Ring, Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Piston Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Air seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Sani-Clamp Seal, 4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Sani-Clamp, 4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

"O" Ring, Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

"O" Ring, Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Compression Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Supply Hose Assembly, Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Hose Barb, 1/8” x 1/4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Supply Hose, 8” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Hose Barb, 1/4” x 1/4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Quick Connect Male End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Piston Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Piston Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Bottom Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Rev 2

FLUSH PISTON VALVE

& TEMPERATURE

SENSOR ASSEMBLIES

(USED AFTER TO 2003)

AIR VALVE

ASSEMBLY

FPVA-3

1

2

3

4

10

5

6

7

8

9

8

11

12

13

12

14

TEMPERATURE

SENSOR

15

16

ITEM ON.

PART NO.

DESCRIPTION

9.

10.

11.

12.

5.

6.

7.

8.

13.

14.

15.

16.

1.

2.

3.

4.

KE55210

FI05144-3

KE52154-4

KE02291

KE55248

KE55249

KE55250

KE55251

KE55252

KE55253

KE55254

FA05002-53

KE55256

KE54924

FA05002-46

KE52154-3

QTY.

WELD RING, KETTLE BOTTOM OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SANI CLAMP, 3” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GASKET, SANI CLAMP, 3” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

COMPLETE ACTUATOR AND DISCHARGE VALVE ASSEMBLY . . . . . . . . . . . . 1

INCLUDES PARTS 5. - 13.

BUNA-N O-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

REPLACEABLE S.S. PLUNGER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

BUNA-N O-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1/8 NPT S.S. HYDRAULIC CLOSE NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

MALE S.S. QUICK DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

AIR OPERATED CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FEMALE S.S. QUICK DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

BUNA-N O-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

FEMALE S.S. QUICK DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TEMPERATURE SENSOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

O-RING, FOOD GRADE, SIZE A0123, EPDM E 692-75 . . . . . . . . . . . . . . . . . . 1

GASKET, SANI CLAMP, 1 1/2” WHITE TEFLON . . . . . . . . . . . . . . . . . . . . . . . . . 1

GEARMOTOR - ELECTRICAL ASSEMBLY

8

1

2

3

4

5

6

7

ITEM NO.

PART NO.

DESCRIPTION

5.

6.

7.

8.

1.

2.

3.

4.

KE53838-2

KE50750-2

KE51139-1

KE52936-18

PR50003

PR50005

KE54528

KE54527-1

KE54527-2

QTY.

TRANSFORMER, 200-240V/440-480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FUSE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

15A FUSE, KLKR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

TERMINAL BLOCK

TERMINAL BLOCK BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

A.C. INVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

GEAR MOTOR, 200V/340V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

GEAR MOTOR, 230V/460V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KETTLE - ELECTRICAL COMPONENTS

5.

6.

7.

8.

ITEM ON.

PART NO.

DESCRIPTION

1.

2.

3.

4.

9.

KE53838-19

KE53444

KE54833-3

KE02372

KE53469-4

KE00458

KE50303

KE50753-7

KE55069-6

FI05050

KE02400

KE55453-1

KE53838-20

QTY.

TRANSFORMER, 120-16V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TRANSFORMER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

IGNITION MODULE, PRIOR TO SEPT. 2004 . . . . . . . . . . . . . . . . . . . . . . . . . . .1

IGNITION MODULE, SEPT. 2004 AND AFTER . . . . . . . . . . . . . . . . . . . . . . . . . .1

SOLID STATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SOLID STATE CONTROL BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SAFETY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

BRASS NUT #7/16-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

AIR SWITCH, PRIOR TO SEPT. 2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

AIR SWITCH, SEPT. 2004 AND AFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TRANSFORMER 120-24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KETTLE - GAS COMPONENTS

19

11 26

12

20 26

13

10 26

3

2

24

5

6

7

8

9

4

22

1

23

14

25

21

15

16

17

18

9.

10.

11.

12.

17.

18.

19.

20.

13.

14.

15.

16.

21.

22.

23.

24.

25.

ITEM ON.

PART NO.

DESCRIPTION

5.

6.

7.

8.

1.

2.

3.

4.

26.

QTY.

KE53617

KE53437

KE50556-2

KE00515

FI05213

FA05002-4

KE53422

GAS ORIFICE:

KE53403-6

KE53403-7

KE53403-10

KE53403-11

KE53403-10

KE53403-14

KE53403-17

KE53403-18

KE53403-17

KE53403-22

FA05002-29

KE50568-1

KE50567-1

SIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

WATER LEVEL PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

THERMISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

“O” RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

NATURAL GAS - SEA LEVEL TO 2000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

PROPANE GAS - SEA LEVEL TO 2000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

NATURAL GAS - 2000' TO 4000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

PROPANE GAS - 2000' TO 4000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

NATURAL GAS - 4000' TO 6000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

PROPANE GAS - 4000' TO 6000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

NATURAL GAS - 6000' TO 8000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

PROPANE GAS - 6000' TO 8000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

NATURAL GAS - 8000' TO 10,000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

PROPANE GAS - 8000' TO 10,000' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

“O” RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

L.E.D. GREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

L.E.D. RED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TEMPERATURE CONTROL ASSEMBLY:

KE50569-1 KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SE00114

KE51005

POTENTIOMETER WITH ON/OFF SWITCH, C/W SEAL . . . . . . . . . . . . . . . . . . .1

SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE50429-2

KE53441

KE53441-1

KE01426-1

PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

BLOWER, 110 V, 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

BLOWER, 220 V, 50 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

MIXING CHAMBER, 60 GALLON KETTLES . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

KE53402-1

FI05212

KE95087-1

KE50567-2

KE02274

KE53618

KE53619

KE53570

KE54420

KE54420-1

AIR ORIFICE, 190K BTU BURNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

OPERATING INSTRUCTION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

L.E.D. AMBER (USED PRIOR TO JULY 2004) . . . . . . . . . . . . . . . . . . . . . . . . . .1

CAPACITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SIGHT GLASS GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SIGHT GLASS RETAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

GASKET FOR IGNITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

AIR INTAKE WASHER (NATURAL GAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

AIR INTAKE WASHER (PROPANE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FA05002-18 "O" RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

33

34

35

4

19

5

14

15

1

CONTROL BOX - ELECTRICAL

For front panel control switches see -

SIDE BOX - TILT MECHANISM & SWITCHES.

CONTROL BOX - WATER METER & CHART RECORDER.

12 16

2

37

38 39

40

28 29

31 32

23

25 26

22

36

9C 9 9B

13 17 18 10

SAFETY

SWITCH

ASSEMBLY -

FRONT

VIEW

SAFETY

SWITCH

ASSEMBLY -

SIDE

VIEW

16 11 12 13

DOOR

GASKET

20

1

7

6

3

8

12

16

27

28

29

30

31

4.

5.

6.

7.

8.

2.

3.

18.

19.

20.

21.

14.

15.

16.

17.

22.

23.

24.

25.

26.

9.

9B.

9C.

10.

11.

12.

13.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

ITEM ON.

1.

PART NO.

KE55297-2

KE55297-3

KE55285

FA40000-15

FA21007

FA32006

FA11091

FA21004

FA11146

FA40000-14

FA21006

KE55271

KE55292-1

KE55292-4

KE55292-3

KE50753-10

KE52106

KE50377

KE50376

KE55287-1

KE55187-2

KE55287-3

KE55287-4

KE55284-1

KE55284-2

KE55286-1

KE55286-2

KE54860

KE55283

KE55288-1

KE55288-2

KE55298

KE50750-4

KE50750-2

KE55297-1

KE50374

SK50055-1

SK50054-1

KE54761-2

SK50054-2

KE54761

KE90425-1

KE90425-2

KE90401-2

KE55232

KE54528

KE53838-2

KE52936-18

KE51139-1

KE50750-2

DESCRIPTION QTY.

PANEL, REMOTE CONTROL, DUAL FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . .1

PANEL, REMOTE CONTROL, DUAL WALL . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

PANEL, REMOTE CONTROL SINGLE FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . .1

PANEL, REMOTE CONTROL, SINGLE WALL . . . . . . . . . . . . . . . . . . . . . . . . . . .1

COMPONENT MOUNTING PLATE DUAL PANEL . . . . . . . . . . . . . . . . . . . . . . . .1

COMPONENT MOUNTING PLATE SINGLE PANEL . . . . . . . . . . . . . . . . . . . . . .1

MOUNTING BRACKET, INCOMING, DUAL PANEL . . . . . . . . . . . . . . . . . . . . . .1

MOUNTING BRACKET, INCOMING, SINGLE PANEL . . . . . . . . . . . . . . . . . . . .1

FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

VENT COVER PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

MOUNTING RAIL, DUAL CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . .1

MOUNTING RAIL SINGLE CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . .1

MOTOR PROTECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1

CONTACTOR, 230 VAC, 50 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

CONTACTOR, 230 VAC, 30 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SAFETY INTERLOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TOTALLY FLEXIBLE ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

GD2 STANDARD ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

MOUNTING BRACKET, DOOR INTERLOCK SWITCH . . . . . . . . . . . . . . . . . . . .1

WELD STUD, #10-32 X 1/2, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

HEX NUT, #10-32, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

TOOTH LOCK WASHER, #10, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

SCREW, #8-32 X 3/8, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

NUT, #8-32, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

SCREW, #10-32 X 1/2, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11/8

WELD STUD, #10-24 X 3/4, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

HEX NUT, #10-24, S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

LABEL, REMOTE CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1

LABEL TERMINAL STRIP REMOTE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

LABEL TERMINAL STRIP REMOTE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

LABEL, TERMINAL STRIP, REMOTE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . .1

RELAY, 120 V HOT COLD WATER BYPASS . . . . . . . . . . . . . . . . . . . . . . . . . . .6/3

TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4/2

TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

TERMINAL BLOCK END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TERMINAL BLOCK MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1

TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14/7

TERMINAL BLOCK END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4/2

TERMINAL BLOCK MOUNTING RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1

TERMINAL BLOCK END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4/2

TERMINAL BLOCK MOUNTING RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

WIRING DIAGRAM, DUAL REMOTE CONTROL PANEL . . . . . . . . . . . . . . . . . .1

WIRING DIAGRAM, SINGLE REMOTE CONTROL PANEL . . . . . . . . . . . . . . . . .1

WIRING DIAGRAM, DUAL WATER METER OPTION . . . . . . . . . . . . . . . . . . . . .1

WIRING DIAGRAM, 3" AIR VALVE OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

AC INVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1

TRANSFORMER, 200- 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1

FUSE, 15 AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6/3

FUSE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6/3

CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2/1

CONTROL BOX -

WATER METER & CHART RECORDER

8

MAIN POWER

OFF ON BYPASS ACTIVE

INTERRUPT

WATER METER

START

CONTINUE RESET

START

OFF ON

2

3

4

5

1

6

7

5

INCLUDED WITH

ALL S WITCHE S .

Capacitor

INDEX

Contactor Cartrid g e s

*

KE52074

PART NO.

KE603208-9 KE603208-8

ITEM NO.

PART NO.

DESCRIPTION

4.

5.

6.

7.

8.

1.

2.

3.

KE53257

SE50354

SE50354

KE003209-1

KE003209-1

KE003209-6

KE003209-7

KE53136-1

*

NOTES

: For units built prior to December 2006, the complete switch assembly must be ordered.

QTY.

Digital Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Pen Tip, red (pkg. of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Pen Tip, green (pkg. of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Switch Assembly, On/Off - Maintained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Switch Assembly, On/Off - Maintained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Momentary Spring Return Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Momentary Spring Return Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Chart Recorder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SIDE BOX -

PNEUMATICS

14 9 13 21 22 9

19

15 18

(NOT SHOWN)

16 17

20

RTV ALL AROUND

1

4 3 11 12 7 6

ITEM NO.

PART NO.

DESCRIPTION

13.

14.

15.

16.

9.

10.

11.

12.

5.

6.

7.

8.

1.

2.

3.

4.

17.

18.

19.

20.

21.

22.

FA05166

KE54280

FA30512

FA32500

KE52697

KE52931

F100178

FI00351

FI05318

FI00151

FA30090

7100595-8

KE55238

F105220-1

FA21006

KE532177

KE532176

FA30000

KE02292

KE50555-3

FA21008

FA30002

QTY.

QUICK CONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SLIDE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I

SPACER WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TOOTH LOCK WASHER 7/8" DIA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

NUT 1/2 NPS BRASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I

AIR FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TEE 1/2 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

BUSHING 1/2 MIP X 1/4 FIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

HOSE BARB 90° ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

90° STREET ELBOW 1/2 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

WASHER 15/16 ID X 1 3/4 OD X 1/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

NIPPLE 1/2 NPT X 4 1/2" LONG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FILTER-REGULATOR-LUBRICATOR BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . .1

GEAR CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

10-24 S.S. NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PNEUMATIC HOSE 1/4 I.D. X 31" L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

PNEUMATIC HOSE 1/4 I.D. X 12 1/2" L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FLAT WASHER #10, ZINC PLATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

AIR SOLENOID ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

GROMMET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

1/4-20 NUT S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

FLAT WASHER 1/4 DIA., ZINC PLATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

9

8

5

2

SIDE BOX -

TILT MECHANISM

& SWITCHES

48

14

16

15

17

18

19

18

20

18

19

18

17

21

22 23

24

45

46

47

43

42

44

25 26 27 28

49

50

51

11 10

9 8

2

40

41

6

7

4

5

3

53

54

55

56

13

12

36

37

38

39

35 33

34

32

31

1

29

30

52

ITEM NO.

1.

2.

3.

4.

5.*

6.*

7.*

8.

PART NO.

KE50579-1

FA00012

KE50580

KE603208-4

KE51730

KE54531

KE54530

KE54529

KE54532

KE01889

DESCRIPTION QTY.

CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

"O" RING, CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

WATER RESISTANT BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TILT SWITCH OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TILT SHAFT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

AGITATOR STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

AGITATOR START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

POWER ON/OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

MICRO SWITCH TRIGGER/SEGMENT GEAR WELDMENT . . . . . . . . . . . . . . . .1

47.

48.

49.

50.

43.

44.

45.

46.

51.

52.

37.

38.

39.

40.

33.

34.

35.

36.

41.

42.

53.

54.*

55. *

56.*

27.

28.

29.

30.

23.

24.

25.

26.

31.

32.

19.

20.

21.

22.

15.

16.

17.

18.

9.

10.

11.

12.

13.

14.

FA95055-6

KE50583

KE52832-1

FA10487

FA31008

FA20026

KE50473

FO1518-1

KE02053

FI05223-1

FI05222

FI05231

FI05226-11

KE51007

FA10139

KE50498

FA32004

KE603208-7

KE603208-9

KE50581

FA10772

FA20048

FA95007-4

FA95055-1

FA19201

KE54644

KE52836-2

KE50315

FA95005

KE52193-1

KE52192

KE52191

FA30088

FA95008

KE50582

KE54535

KE50753-10

KE54491

KE53599-8

KE53599-9

FA95062

FA95074

FA19177

FA20047

KE54606

KE003209-9

KE003209-6

KE003209-2

KE003209-3

* SWITCHES MAY BE LOCATED ON REMOTE CONTROL PANEL.

SOCKET HD. CAP SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

JAM NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

RETAINING RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SQUARE KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

HEX SOCKET SET SCREW 3/8-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TILT SHAFT, MANUAL TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TILT SHAFT, POWER TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

WORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TENSION PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

THRUST BEARING SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

THRUST WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

ROLLER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

JAM NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

CPLG. ONTARIO BELTING #G-100 5/8 BORE . . . . . . . . . . . . . . . . . . . . . . . . . .2

SQUARE KEY 3/16 X 3/16 X 1" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

RUBBER INSERT, ONTARIO BELTING "BUNA N" . . . . . . . . . . . . . . . . . . . . . . . .1

MOTOR "BODINE" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

HEX HD SCREW 1/4-20 X 1" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

SPLIT LOCKWASHER 1/4" DIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

HEX NUT 1/4 - 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

GROUND LUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

GAS SHUT-OFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

COMBINATION GAS VALVE NATURAL GAS . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SPECIAL NIPPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SWIVEL ELBOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FLUSH BUSHING 3/4M TO1/2F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

NIPPLE 1/2 X 10" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

MICRO SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

MACHINE SCREW #6-32 X 1" LG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

MICRO SWITCH INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

TOOTH LOCK WASHER #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

CONTACT SECTION HOLDER (LATCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

CONTACT BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

BRIDGE RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

EDGE CONNECTOR (11 PIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

LID FOR GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PAN HD. PHILLIPS SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

NYLON ANCHOR NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

HEX SOCKET SET SCREW 5/16-24 X 1" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

JAM NUT 5/16-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

GAS VALVE LOCKWASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SWITCH, JOG TO OPEN AIR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SWITCH, FILL INTERRUPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SWITCH, HOT/COLD SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SWITCH, FILL CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

MAINTENANCE

INSPECTION AND MAINTENANCE CHECKLIST

Cleveland Range equipment requires little preventative maintenance. We do however provide the following chart as a guide line for inspection and maintenance to keep your unit functioning at 100%.

MONTHLY INSPECTION

Inspect all switches for damage. Replace rubber boots or switches as required.

Check that the automatic dump valve works fully and smoothly and no air leaks are evident.

Check that the 3 way regulator shuts off the incoming air and completely vacates the air from the air hose to the metering filling station.

Tilt kettle and check for smooth operation in both directions.

Inspect gear and worm assembly in gear box for play - tighten Allen screws if required.

Inspect gasket material on covers for integrity.

Check spring assist covers for tightness to handle and insure spring is holding cover up - adjust if required. Refer to

HINGE ADJUSTMENT INSTRUCTIONS.

When kettle is cold check that pressure gauge needle is in the green zone indicating a vacuum in kettle - if venting is required refer to KETTLE VENTING PROCEDURE.

Inspect mixer blades for cracks or other damage - replace as required. Refer to NEW SCRAPER BLADE

INSTALLATION PROCEDURE.

Check quad ring and replace if required. Refer to QUAD RING REPLACEMENT PROCEDURE.

Inspect oiler in gear box and fill with oil if required. Refer to OILER FILLING PROCEDURE.

Inspect air filter cartridge and replace if required. Refer to AIR FILTER REPLACEMENT PROCEDURE.

SIX MONTH MAINTENANCE

Grease trunnion housings in gear box and on outboard bearings.

Test pressure relief valve. Refer to PRESSURE RELIEF VALVE TESTING PROCEDURE.

OPERATING SEQUENCE - HEATING

STEP ACTION RESULT 1

1.

Close main circuit breaker.

120 volts is supplied by primary contactor to kettle On/Off switch and tilt relay contacts. Power supplied to tilt assembly.

RESULT 2

2.

3.

4.

5.

6.

On/Off switch on kettle switched to ON.

Control box.

12 VDC relay contacts close.

120/16 volt transformer supplies power to control boxes.

A/

Requires grounded probe to function (pin #5).

Amber LED is illuminated.

(Used prior to July 2004)

B/

More that 6 volts at pin #2. Control box energizes 12 volt DC relay (pin #6).

a/

Green LED illuminates.

b/

12 VDC relay contacts close.

A/

B/

Blower energizes.

120/25 volt transformer energizes.

a/

Air switch contacts close.

a/

25 volts supplied to ignition module.

Ignition module.

120 volts turned off to ignitor.

C/

120 volt supplied to ignition module.

Supplies 120 volts to ignition.

A/

Gas valve is energized.

Within 20 seconds ignitor glows red.

a/

Burner ignites.

B/

Ignitor becomes sensor.

a/

If temperature drops in chamber gas valve is deenergized within five seconds.

b/

Ignitor will try twice more to light before locking out.

7.

Temperature reached.

A/

Less than 6 volts at pin #2.

Control box de-energizes 12 volt

DC relay (pin #6)

a/

Green LED turns off.

b/

12 VDC relay contacts open.

c/

Blower turns off.

d/

25 volt transformer de-energizes.

QUICK CHECKS:

Potentiometer - Range 0 - 50K, Safety Thermostat - Normally Closed,

Thermistor - Range 0 - 100K, Water Level Probe - Must be submerged in water for burners to work

OPERATING SEQUENCE - AGITATOR

1.

On/Off switch closed.

A/

Three phase contactor closes to supply power to variable speed drive.

a/

Indicator light is energized.

a/

Motor comes up to speed.

2.

3.

Start button momentarily depressed.

A/

Power to agitator motor.

Speed control turned up.

A/

Motor speed increases.

OPERATING SEQUENCE - POWER TILT

1.

Turn and hold tilt switch in down position.

A/

Relay 2 is energized.

2.

3.

4.

Kettle tilts until limit switch is depressed.

A/

Power interrupted to down side of tilt switch.

Turn and hold tilt switch in up position.

A/

Relay 1 is energized.

Kettle tilts until limit switch is depressed.

A/

Power interrupted to up side of tilt switch.

a/

Tilt motor is energized.

a/

Relay de-energized.

b/

Motor stops.

a/

Tilt motor is energized.

a/

Relay de-energized.

b/

Motor stops.

KETTLE SAFETY INSPECTION CHECKLIST

Regular inspection and maintenance of units is essential to obtain trouble free and safe operation of equipment. Inspections must include testing of the pressure relief valve and checks of the operating system to insure that it has not been altered.

No safety features designed into the equipment should ever be tampered with

. Tampering with or bypassing controls is a very dangerous practice and unfortunately we have seen several cases of this. Following is a short list of the most common and the most dangerous alterations performed on kettles.

SAFETY VALVE:

1

✔

This illustrations show the correct configuration of a factory installed Safety Valves.

Any modifications are unacceptable.

Incorrect Installations

1

Safety valve has plug threaded into the discharge opening preventing any steam from escaping.

2

Safety valve’s tube diameter has been reduced.

3

Safety valve is sticking, frozen shut or plugged.

To test, refer to PRESSURE RELIEF VALVE

PERIODIC TESTING.

4

Safety valve is plumbed to a drain or water line creating back pressure and reducing flow.

2

3

4

✘

Plug

✘

Tube diameter reduced

✘

Frozen, stuck, or plugged

✘

Plumbed to drain or water line

SAFETY THERMOSTAT:

✔

1

Probe fully inserted in tube

Wiring is properly connected

2

✘

Probe removed partially

✘

Probe removed completely

Low Water Level Probe:

3

✘

Thermostat electrically bypassed

Incorrect

Installations

1

Safety thermostat probe is not completely inserted into tubing.

2

Safety thermostat probe is removed from tubing.

3

Safety thermostat electrical connection is bypassed.

(A)

(B)

✔

Probe properly attached

Operating

Thermostat:

265º

✔

260º - 270º

MAXIMUM

KETTLE

TEMPERATURE

If maximum temperature is not in this range (on empty kettle), refer to the

CALIBRATING

PROCEDURE.

✘

Probe bypassed by running (A) an additional wire

Air

Switch:

✘

Probe bypassed by

(B) grounding the connecting wire

✔

Wiring is properly connected

Incorrect

Installation

✘

Switch electrically bypassed

AIR FILTER REPLACEMENT

PROCEDURE

1

Disconnect air supply and bleed system.

2.

Remove cover on console (see SIDE BOX -

PNEUMATICS).

3.

Check for filter location.

Deflector

Filter

Element

4.

Push lever down and rotate bowl/ guard assembly

1/8 turn.

5.

Push down on bowl/guard assembly and remove.

Baffle

Lever

Bowl/Guard

Assembly

6.

Unscrew baffle and remove filter element, inspect and replace filter if required.

7.

Replace filler cap and cover.

NEW SCRAPER BLADE

INSTALLATION PROCEDURE

Trim corners or center to fit

Scraper blade

Back stop

Move to adjust

Spring

Fig. 1

Move to adjust

Fig. 2 Fig. 3

QUAD RING REPLACEMENT

PROCEDURE

Hole cap

Retaining bolt

Retaining washer

Retaining knobs

Seal retainer plate

Quad ring

Retaining ring

Retaining ring seat

1.

Remove agitator as per cleaning instructions.

2.

Remove hole cap, retaining bolt and retaining washer.

3.

Snap retaining ring out from seating inside motor.

4.

Remove retaining knobs.

5.

Slide seal retainer plate away from kettle.

6.

Slide shaft away from kettle body to allow clearance for removing quad ring.

7.

Remove quad ring.

8.

Slide new quad ring back into original position, making sure it does not twist.

9.

Apply light coat of food-safe grease.

10.

Slide retainer plate back toward kettle, replacing retaining knobs -tighten with hand pressure only.

11.

Reassemble.

LUBRICATION PROCEDURE

Lubricate the following parts every three months to insure smooth operation and reduce wear.

Worm

Screw and

Tilt

Gear

Adjusting

Screw

Cross

Bar

TRUNNION

HOUSING,

WORM SCREW

AND TILT GEAR

These parts are accessed through the top cover of the console.

Apply grease to gear teeth. Check for excessive play and adjust with adjusting screw located on top of cross bar.

Trunnion Housing

Grease Nipple

KETTLE

TRUNNIONS

On the left hand side of the kettle there are two grease nipples on the top back portion of the trunnion housing. On the right hand side of the kettle you must remove the console cover to access the two grease nipples.

PRODUCT VALVE

Replacing O-Rings

KETTLE

KETTLE

OUTLET

CLAMP

0-RING

VALVE

TEE

0-RING

CLAMP

0-RING

CLOSED

POSTITION

OPEN

POSITION

AIR HOSE

AIR

CYLINDER

AIR HOSE

OIL FILLING PROCEDURE

1.

Disconnect air supply and bleed system.

2.

Remove cover on console.

3.

Check for oiler location.

4.

Inspect oil level in bowl.

5.

Remove filler cap.

6.

Add mineral oil as required.

7.

Replace filler cap and console cover.

Filler

Cap

Bowl

HINGE ADJUSTMENT

INSTRUCTIONS

3 / 8 " Allen wrench

1.

Open product valve.

2.

Disconnect air hoses.

3.

Remove air cylinder.

4.

Remove valve tee.

5.

Remove all O-rings, grease and reinstall new

O-rings as required.

6.

Reinstall tee to kettle outlet.

7.

Reinstall air cylinder to bottom of tee.

8.

Reconnect air hoses.

9.

Close valve and check for alignment.

BUSHING REPLACEMENT

PROCEDURE

1.

Remove agitator as per cleaning instructions.

2.

Remove bushing by turning 1/4 turn and pulling away from the kettle wall.

3.

Lubricate metal surfaces with food safe grease.

4.

Install new bushing by locating retaining pin and sliding bushing on.

5.

Rotate to lock into position.

6.

Reassemble agitator.

1.

Insert 3/8" Allen wrench.

2.

Turn clockwise to relieve tension on spring.

3.

While tension is released remove one of the two slotted screws.

4.

To prevent Allen wrench from springing back abruptly while the second slotted screw is removed, insert a pin (approximately 1/8") in the hole where the first slotted screw was removed from.

5.

Remove second slotted screw.

6.

While holding Allen wrench remove pin.

7.

Turn Allen wrench clockwise to tighten or counter-clockwise to loosen tension to produce desired effect.

8.

Re-insert pin in one of the two holes.

9.

Tighten one slotted screw in the other hole (it may be necessary to turn Allen wrench slightly to align holes).

10.

Remove pin and repeat step number 9 for other slotted screw.

KETTLE VENTING

INSTRUCTIONS

0

50

100

10

150

200

20

30

40

250

300

0

V

50

350 psi

60 kPa

400

Access

Panel

Pressure

Relief Valve

The following venting procedure should be followed when the

Vacuum/Pressure Gauge needle is in the "VENT AIR" zone:

NOTE

: Check for and eliminate leaks prior to venting

(See REPAIRING LEAKS IN STEAM JACKETED KETTLE

FITTINGS).

DANGER:

PRESSURE RELIEF

VALVE WILL EXHAUST HIGH

TEMPERATURE STEAM. CONTACT

WITH SKIN COULD RESULT IN

SERIOUS BURNS. KEEP FACE,

HANDS AND BODY CLEAR OF DISCHARGE

.

DANGER:

WORKING ON MACHINES

WITH POWER COULD RESULT IN

SEVERE ELECTRICAL SHOCK.

Valve

Ring

3

4

2

OFF

5

1

6

7

10

9

8

1.

Remove Access Panel from back of main kettle console.

2.

Turn kettle ON and set temperature control to

10

, heat the empty kettle until unit cycles off.

3.

Vent kettle by pulling Valve Ring eight to fifteen times, holding valve open for two seconds each time.

NOTE

: If unit cycles ON, stop venting and wait for kettle to cycle

OFF before continuing.

4.

Turn kettle OFF. Add cold water to kettle until its surface temperature is below 100°F. The pressure gauge needle should be in the green zone, indicating a vacuum in the kettle’s jacket.

VACUUM LEAK TEST

PROCEDURE

If the kettle will not hold vacuum, test for leaks at:

A.

Water Level Probe.

B.

Pressure Relief Valve/Pressure Gauge and connecting plumbing.

C.

Boiler Drain Cap.

D.

Sight Glass.

LEAK TEST PROCEDURE:

1.

Heat kettle until unit cycles off.

2.

Shut off power to the kettle at the fused disconnect switch.

3.

Spread Bubble Type Leak Detector over suspected areas and watch closely for bubbles.

4.

Repair areas as required.

REPAIRING LEAKS IN STEAM

JACKETED KETTLE FITTINGS

If unit will not hold a vacuum the most likely cause is a leak at one of the fittings.

Often, the easiest way to eliminate a leak is reseal the suspect areas.

1.

Water Level Probe

Remove,clean threads, apply teflon thread sealant and reinstall.

2.

Pressure Relief Valve

A

/ Inspect for signs of leaks. Replace if required.

B

/ Remove, clean threads, apply teflon thread sealant and reinstall.

3.

Pressure Gauge

A

/ Inspect face of gauge. If it contains moisture on the inside of face replace.

B

/ Check tightness of plumbing connection to pressure Gauge.

3.

Sight Glass

A

/ Check tightness of sight glass.

B

/ Replace "O" ring if required.

0

50

100

10

150

200

20

30

40

250

300

0

V

50

350 psi

60 kPa

400

5.

If needle is in the green zone then venting was successful. If not repeat procedure.

RESERVOIR FILL

PROCEDURES

WARNING:

IMPROPER REFILLING OF

KETTLE JACKET WILL RESULT IN

IRREVERSIBLE DAMAGE TO UNIT.

The kettle's water level must be maintained at the proper level. Under normal operating conditions, the sealed water reservoir should never require the addition of water.

If the red "low water" light comes on during use (while the kettle is in an upright position), the water level has reached a critically low level. The low water protection control has automatically shut off the gas burner. The following procedure must be completed before further use:

DANGER:

PRESSURE RELIEF

VALVE WILL EXHAUST HIGH

TEMPERATURE STEAM. CONTACT

WITH SKIN COULD RESULT IN

SERIOUS BURNS. KEEP FACE,

HANDS AND BODY CLEAR OF DISCHARGE

.

DANGER:

WORKING ON MACHINES

WITH POWER COULD RESULT IN

SEVERE ELECTRICAL SHOCK.

NOTE:

Have a qualified service technician repair the leakage problem and add water to the unit. Ensure that the red "low water" light is on when the kettle is upright.

On tilting kettles, it is normal for the red light to come on when the kettle is in a tilted position.

CAUTION:

Only distilled water should be used when adding water to a partially filled water reservoir (If unit is completely empty see KETTLE JACKET FILLING &

DRAINING PROCEDURES). Local tap water conditions may cause kettle damage which is not covered under warranty. Rust inhibitor is purchased locally. Read directions and do not exceed manufacturer's recommendation (excessive rust inhibitor can also cause solidification).

0

50

100

10

150

200

20

30

40

250

300

0

V

50

350 psi

60 kPa

400

1.

Ensure kettle is at room temperature and pressure gauge showing zero or less pressure.

2.

Shut off power to the kettle at the fused disconnect switch.

Pressure

Relief Valve

Console

Cover

Access

Panel

Valve

Ring

3.

Remove Access Panel from back of main kettle console.

4.

Pull Pressure Relief Valve

Ring open to insure vessel is not pressurized.

Pressure

Relief Valve

Important

- Pull ring on

Pressure Relief Valve prior to removal to insure vessel is not pressurized.

5.

Remove main kettle Console

Cover.

6.

Remove 1/4" copper tubing and reducer bushing.

7.

Add distilled water using a funnel if necessary. Fill the unit to the high level mark on the Sight Glass.

8.

Apply a thread sealant (i.e.

Teflon tape) to the reducer bushing threads and replace.

Sight

Glass

9.

Replace main kettle Console

Cover and Access Panel.

10.

Restore power to unit at the fused disconnect switch.

11.

The kettle must now be vented. (Refer to the

KETTLE VENTING INSTRUCTIONS).

PRESSURE RELIEF VALVE

PERIODIC TESTING

Pressure

Relief Valve

Valve

Ring

Access

Panel

Most insurance agencies require periodic testing of pressure relief valves used on pressure vessels. This procedure will allow you to safely and quickly test your kettle's pressure relief valve. We recommend this test be performed twice a year.

DANGER:

PRESSURE RELIEF

VALVE WILL EXHAUST HIGH

TEMPERATURE STEAM. CONTACT

WITH SKIN COULD RESULT IN

SERIOUS BURNS. KEEP FACE,

HANDS AND BODY CLEAR OF DISCHARGE

.

NOTES:

If valve appears to be sticking replace pressure relief valve.

If foreign material is discharged then drain kettle and replace pressure relief valve.

See service bulletin (KETTLE JACKET FILLING AND

DRAINING PROCEDURES) for full instructions on the correct method for draining and refilling kettle jacket.

WARNING:

Improper refilling of kettle jacket will result in irreversible damage to unit.

5.

Replace Access Panel.

6.

Reconnect main power at fused disconnect switch..

CALIBRATING PROCEDURE

Solid State Temperature

Control Box

Adjustment

Pot

DANGER:

WORKING ON MACHINES

WITH POWER COULD RESULT IN

SEVERE ELECTRICAL SHOCK.

NOTE:

The following instruction is intended for use by qualified service personnel.

WARNING:

Kettle surface will be hot and steam will be released during testing. Take necessary precautions including the use of gloves and eye protection to prevent personal injury.

3

4

5

6

7

8

1.

With the kettle empty, turn unit ON and set temperature control to

10

. Allow the kettle to heat until the unit cycles off.

9

2

1

10

2.

Switch unit OFF and disconnect main power at fused disconnect switch.

OFF

3.

Remove Access Panel at back of main kettle console.

4.

Pull Pressure Relief Valve

Ring open for a maximum of one second. Repeat test three to four times. Each time the mechanism should move freely and be accompanied by a rapid escape of steam

.

1.

Insure the unit has a vacuum before you begin calibrating procedures. If unit requires venting refer to KETTLE VENTING INSTRUCTIONS.

3

6

2.

Turn kettle ON and set temperature control to

10

.

5

7 3.

Allow the unit to cycle twice.

4

8

4.

Check temperature of the inner kettle surface with a digital surface thermometer.

9

2

10

5.

Temperature should be between 260°F and 265°F.

1

OFF

6.

Using a screw driver adjust temperature by turning the potentiometer on the Solid State

Temperature Control Box. Turn very little. Turn clockwise to INCREASES and counter-clockwise to DECREASE temperature.

7.

Allow the unit to cycle twice.

8.

Check temperature of the inner kettle surface with a digital surface thermometer.

9.

Repeat steps

4.

through

8.

until unit is calibrated.

KETTLE JACKET FILLING &

DRAINING PROCEDURES

Under normal circumstances the kettle does not require the draining of all fluid. If the red “low water” light is on, follow the RESERVOIR FILL PROCEDURES in this manual.

If unit must be drained follow the procedures described on the following pages.

WARNING:

IMPROPER REFILLING OF

KETTLE JACKET WILL RESULT IN

IRREVERSIBLE DAMAGE TO UNIT.

Use only a mixture of water and rust inhibitor to refill kettle jacket (see instructions below).

Contact your local water treatment company and purchase rust inhibitor with the specifications described below.

Recommended Corrosion

Inhibitors for Closed Systems

DESCRIPTION

Recommended for our units is a blend of SODIUM

NITRITE and BORAX for corrosion inhibition of ferrous metals and axoles for copper and copper alloy corrosion protection. Product should be formulated for hot or cold closed recalculating water systems.

Source the chemicals stated above from your local water treatment company. Mix only with water and follow manufactures recommended mixing rate.

DISPOSAL OF INHIBITOR

Do not dispose of chemicals in any system which may discharge into water supplies used for drinking or washing or that could accidentally discharge into such systems, or into stream accessible to animals.

Follow all Federal, State and local codes when disposing of product.

DANGER:

WORKING ON MACHINES

WITH POWER COULD RESULT IN

SEVERE ELECTRICAL SHOCK.

DANGER:

PRESSURE RELIEF

VALVE WILL EXHAUST HIGH

TEMPERATURE STEAM. CONTACT

WITH SKIN COULD RESULT IN

SERIOUS BURNS. KEEP FACE,

HANDS AND BODY CLEAR OF DISCHARGE

.

DANGER:

EXTREMELY

HOT SURFACES.

WORK ONLY ON COLD KETTLE.

Pressure

Relief Valve

Access

Panel

Valve

Ring

Drain Plug Location

1.

Remove Access Panel at back of main kettle console.

2.

Pull pressure relief valve chain to ensure there is no pressure within the kettle jacket.

3.

Remove 1/4" copper tubing and reducer bushing.

4.

Remove drain plug cap (located underneath the kettle on the right rear). Allow kettle jacket to drain.

5.

Replace filler plug and add water until it shows on sight glass. Remove Drain Plug cap and allow water to drain. Repeat until water drains clear.

Refilling Unit

(see RESERVOIR FILL

PROCEDURES).

WARNING:

IMPROPER REFILLING OF

KETTLE JACKET WILL RESULT IN

IRREVERSIBLE DAMAGE TO UNIT.

DANGER:

EXTREMELY

HOT SURFACES.

WORK ONLY ON COLD KETTLE.

HA DRIVE SHAFT REPLACEMENT PROCEDURE

Note:

Disconnect external power supply and shut off gas to unit prior to servicing.

1.

Remove mixer arm leaving flat surface on drive shaft facing upwards.

3.

Remove shaft retaining bolt.

2.

Remove shaft end cap.

4.

Remove shaft retaining ring.

5.

Gently hammer out shaft and remove.

8.

Insert new shaft.

9.

Push new shaft past retraining ring groove and install retaining ring.

6.

Clean seal.

7.

Grease seal with food grade grease.

10.

Tap shaft back to seat up against retaining ring.

11.

Complete reassembly by reinstalling bolt and end cap.

FIELD CONVERSION

INSTRUCTIONS -

Natural Gas to Propane Gas

Power Burner Gas Kettles

BTU's per Gas Water

Hour Type Column

# of

Orifices

KGL-40,

KGL-40-T,

MKGL-40-T,

KGL-60 to 100,

KGL-60-T to 80-T,

KGL-40-TSH,

KGL-40-F to 60-F,

KGL-40-SH to 60-SH,

HA-MKGL-60 to 100,

HA-MKGL-60 to 100-T

140000

140000

190000

190000

NAT

LP

NAT

LP

3.5

3.5

3.5

3.5

1

1

1

1

“O” RING

GAS ORIFICE

SPRING

PLUG

TOP COVER

NOTE:

Use thread sealant compatible with propane gas on all threaded piping connections.

1.

Disconnect electrical connection.

2.

Shut off main gas supply and disconnect kettle from supply line.

3.

Remove

TOP COVER

.

4.

Remove

PLUG

and

SPRING

.

5.

Remove

GAS ORIFICE

and

“O” RING

.

6.

Replace with new

GAS ORIFICE

and

“O” RING

.

7.

Replace

SPRING

and

PLUG

.

8.

Replace

TOP COVER

.

9.

Place gas conversion label next to rating label.

10.

Reconnect electrical supply.

Conversion Parts Required

KGL-40

Part No.

Description Quantity

KE95549 Conversion Label 1

KE54420-1

KE53403-5

FA05002-29

Air Intake Washer

Gas Orifice

“O” Ring

1

1

1

KGL-60 to 100

Part No.

Description

KE95549 Conversion Label

KE54420-1

KE53403-7

FA05002-29

Air Intake Washer

Gas Orifice

“O” Ring

1

1

Quantity

1

1

SPARE PARTS LIST

The following is a spare parts listing of parts that wear during normal us or are apt to be misplaced during normal operation. These parts should be kept on hand to prevent loss time due to a minor problem.

PART NUMBER DESCRIPTION QUANTITY

KE54602

KE54608

KE01911

FA05002-8

KE54594

KE54834-4

KE55248

KE55255

FA05002-46

KE52154-3

KE55297-3

KE52936-2

SE50354

SE50354

SCRAPER BLADE

SPRING

RETAINING KNOBS

"O" RING

PIN

SOLENOID VALVE

BUNA-N O-RING

BUNA-N O-RING

O-RING, FOOD GRADE, SIZE A0123, EPDM E 692-75

GASKET, SANI CLAMP, 1 1/2” WHITE TEFLON

GD2 STANDARD ACTUATOR

FUSE, 15 AMP

PEN TIP, RED (PKG. OF 5)

PEN TIP, GREEN (PKG. OF 5)

6

1

1

5

1

5

5

1

5

3

1

1

3

1

The following is a recommended list of space parts that may be required if the service agency is of some distance away or if down time must be kept to a minimum and spare parts are required for the service agent on site.

PART NUMBER DESCRIPTION QUANTITY

KE54834-4

KE55253

KE53469-4

KE00458

KE50753-7

KE00515

KE50753-10

KE02274

KE603208-9

KE603208-8

KE50753-10

SOLENOID VALVE

AIR OPERATED CYLINDER

IGNITION MODULE

SOLID STATE CONTROL

RELAY

THERMISTOR

RELAY, 120 V HOT COLD WATER BYPASS

CAPACITOR ASSEMBLY

CONTACTOR CARTRIDGE, NORMALLY OPEN

CONTACTOR CARTRIDGE, NORMALLY CLOSED

RELAY

1

1

1

1

1

1

1

2

1

3

2

AC INVERTER PROGRAMMING INSTRUCTIONS

The WFC Series AC Inverters come wired for external use and must be installed for use in a side panel control (See

WIRING DIAGRAMS). Refer to owners manual for complete instructions and explanations. Manual used for the following was FORM 1094.

After installation is complete the inverter must be reprogrammed to Cleveland's modifications of the factory settings. All modifications are achieved in Access Level 2.

1.

Turn agitator power on. The top four LED indicators will illuminate momentarily - wait for the three green LED's to go out before proceeding.

2.

Press the PROGram and SHIFT keys simultaneously to reach Access Level 2. The display display will now read:

3.

Use the UP/DOWN arrow keys to select the program parameter for change.

4.

Press the SHIFT key. The program number will blink indicating that that the data value may be changed.

5.

Use the UP/DOWN arrow keys to select the new data code.

6.

Press the ENTER key. The display will indicate **STORED** for one second, then revert to the normal parameter display.

7.

Press the PROGram key to exit the programming mode or the UP/DOWN keys to select an new parameter for change.

#

PROGRAM CODE SUMMARY:

Name Description Data Range

16

17

18

19

12

13

14

15

06

07

08

09

01 MODEL Model Number

02 RVLVL Software Revision

03 IRAT Rated Current

05 SERNO Serial Number

REP

FLT3

FLT2

FLT1

Repair Date

Last Fault

2nd Fault

1st Fault

FOUT

VOUT

IOUT

LOAD

TORQ

TEMP

TIME1

TIME2

Output Frequency

Output Voltage

Output Current

Drive Load

Load Torque

Inverter Temp

Total Run Time

Power On Hours

21 MODE Input Mode

24 FSEL Reference Select

27 TLSEL

31 FMIN

Torque Limit Select

Min. Frequency

32 FMAX

33 F2

34

35

F3

F4

Max. Frequency

Preset Speed #2 - Jog

Preset Speed #3

Preset Speed #4

36

37

38

39

F5

F6

F7

FTL

41 RSEL

42 ACC1

Preset Speed #5

Preset Speed #6

Preset Speed #7

Min. Frequency in Torque Limit

Ramp Selector

Acceleration Time #1

0-36

0-18

0-6

0.00-400

20.00-400

0.00-400

0.00-400

0.00-400

0.00-400

0.00-400

0.00-400

0.00-400

0-7

0.10-600

0-400

0-100

0-650

0-200

0-200

2-105

0-65000

0-65000

0-65000

0-640

2-200

0-65000

0-65000

---

---

---

60

0

0

10

60

5

20

40

0

3

0

0

0

0

---

---

---

---

Factory Setting Units

Note 1

Note 1

Note 1

---

---

---

A

---

---

---

---

---

---

---

---

---

Hz

%

A

%

---

---

---

---

Hz

Hz

Hz

Hz

Hz

Hz

Hz

Hz

---

s

---

---

---

Hz

h h

%

C

2

2

2

2

2

1

2

2

1

1

2

1

1

2

2

2

1

1

Access Level

2

2

1

2

1

1

1

1

2

2

2

1

Customer Setting

4

14

70

9

43 DEC1 Deceleration Time #1

44

45

ACC2

DEC2

Acceleration Time #2

Deceleration Time #2

46 DECTL Torq. Limit Response Time

47 DCBRK DC Brake Time

48 DCVLT

51 VSEL

DC Brake voltage

V/Hz Characteristic Selector

52 BOOST Torque Boost

53 FKNEE V/Hz Knee Frequency

54 SKBND Skip Fresq. Hysteresis Band

55 SK1 Skip Frequency #1

56

57

SK2

SK3

Skip Frequency #2

Skip Frequency #3

63

64

65

66

58 SK4

59 MVOLT

61

62

LTLF

LTLR

RTLF

RTLR

SLIP

STAB

Skip Frequency #4

Rated Motor Voltage

Load Torq. Limit Forward

Load Torq. Limit Reverse

Regenerative Torq. Limit FWD

Regenerative Torq. Limit REV

Slip Compensation

Current Stability

67

68

69

6C

TOL

NRST

DRST

TOLC

Timed Overload Trip Point

Restart Number

Restart Delay

Timed Overload Characteristic

71 METER Analog Meter Output

72 ST1 Auxiliary Output #1

73

74

ST2

ST3

Auxiliary Output #2

Auxiliary Output #3

75 STR Auxiliary Relay (Fault)

81 PRGNO Special Program Number

82

83

START

PWM

Inverter Start Options

Carrier Frequency Selector

84

85

DISP

UNITS

Display Option Full Setting

Display Units

86 LANG Display Language

87 ACODE Security Access Code

0-11

0-65000

0-7

0-1

0-65000

ALPHA

0-3

0-999

A2 RATIO Master Slave Speed Ratio (Note 2) 50-2000

B1 OPTNO Option Board Number 0-6

Cx CNTLx

Ex ECNTx

Event Control (1-9)

Event Counts (1-9)

BINARY (8)

0-65535

0-100

0-8

0-60*

0-7

0-7

0-11

0-11

0-11

0.00-400

185-480

5-150

5-150

5-110

5-110

0-10*

0-5

0.10-600

0.10-600

0.10-600

0.10-30

0-5

0-15

0-5

0-25

26-640

0.20-20

0.00-400

0.00-400

0.00-400

Bolded

areas indicate Cleveland modifications of factory settings.

3

7

1

6

0

0

0

0

0

Note 1

150

150

0

2

80

80

3

1

1

1

0.2

Note1

0

Note 1

60

0

0

1

0

0

0

2

0

0

RPM_1

0

0

100

0

0

0

---

---

---

---

%

--s

---

%

%

%

---

Hz

V

%

%

Hz

Hz

Hz

Hz

%

---

%

Hz s

s s s s

---

---

---

---

---

---

---

---

%

---

---

---

2

2

1

2

2

2

2

2

1

2

2

2

2

2

2

2

2

2

2

2

1

2

2

2

1

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

1

2

8

75

100

3

2

1

WIRING DIAGRAM - DUAL REMOTE

43

WIRING DIAGRAM -

SINGLE REMOTE