Full Text Searchable PDF User Manual
INSTALLATION, OPERATION AND REPAIR MANUAL
GAS KETTLE
MODEL # KGL
KGL-T
CLEVELAND RANGE INC.
1333 East 179th St.
Cleveland, Ohio
U.S.A. 44110
(216)481-4900
KET-07
9102 REV:0
222-01CO
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
ONLY A QUALIFIED SERVICE TECHNICIAN SHOULD REPAIR UNIT
THE INSTALLATION AND CONNECTION MUST COMPLY WITH LOCAL CODES, OR IN
THE ABSENCE OF LOCAL CODES, WITH CAN1 B149 INSTALLATION CODE OR WITH
THE NATIONAL FUEL GAS CODE, ANSI 2223.1-1988.
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 SUPPLER.
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.
1
FOR YOUR
SAFETY
DO NOT STORE OR USE GASOLINE OR
OTHER FLAMMABLE LIQUIDS AND
VAPOURS IN THE VICINITY OF THIS OR
ANY OTHER APPLIANCE.
GENERAL INSTALLATION INSTRUCTIONS
Installation of 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.Bg, CSA, CGA, ETL,
and others. Many local codes exist, and it is
the responsibility of the owner and installer to
comply with these codes.
Observe all clearance requirements to provide
proper make-up air flow as well as sufficient
clearance for servicing. Dimensions and
clearance specifications are shown on the
specification sheet. Do not install kickplates or
otherwise obstruct the flow of combustion and
ventilation air. Check the rating plate to ensure
that the kettle has been equipped to operate
with the type of gas available at the installation.
Gas fired kettles are only to be installed under
a ventilation hood in a room which has
provisions for adequate make up air.
Electrical installation must be in accordance
with local codes and/or the National Electric
Code ANSI/NFPA 70-1987 (USA) or the
Canadian Electrical Code CSA Standard C22.1
(Canada). The kettle must be electrically
grounded by the installer. Standard supply
voltage is 115 volts A.C. However, optional
A.C. voltages can be supplied on special order.
A separate fused disconnect switch must be
supplied and installed in the high voltage
electrical supply line. The wire gauge size and
electric supply must match the power
requirements specified on the kettle's rating
plate. The conduit-enclosed permanent copper
wiring must be adequate to carry the required
current at the rated voltage. Refer to the
specification sheet for electrical specifications
and location of electrical connections.
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.
2
- -IF YOU
SMELL GAS - -
1. OPEN WINDOWS
2. DO NOT TOUCH
ELECTRICAL SWITCHES.
3. EXTINGUISH ANY OPEN FLAME.
4.
CALL YOUR GAS
SUPPLIER IMMEDIATELY.
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.
INSTALLATION
The first installation step is to refer to the
specification sheet for clearance
requirements, in order to determine the
location of the kettle. Next, carefully cut
open the shipping carton for easy removal
of the kettle.
Position the kettle in its permanent location,
and level the kettle by tuning the adjustable
feet.
Once positioned and leveled, permanently
secure the kettle's flanged feet to the floor
using 5/16 x 2 1/2 inch lag bolts and floor
anchors (supplied by the installer). Three
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 Z223.1-1984
(USA) or 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).
ELECTRICITY
Remove the two screws securing the
console cover, and remove the cover. A
wiring diagram is affixed to the inside of the
cover. Feed conduit-enclosed permanent
copper wiring through the cutout in the
bottom of the console and fasten to the
terminal block. Fasten the ground wire to the
ground lug, connected to the frame, beside
the terminal block. Replace the console
cover and secure it with the screws.
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.
3
OPERATION
1.
Before turning the kettle on, read the
vacuum/pressure gauge. The gauge's
needle should be in the green zone. I
f
the needle is in the "vent air" zone, call
your service agent to locate and repair
the source of the leak. Under normal
circumstances the kettle should
operate for years without venting.
2. Ensure that the electrical service to the
kettle is turned on.
3.
Place the kettle's power on/off switch to
the "ON" position.
4. Pre-heat the kettle by turning the
temperature control knob to the desired
temperature setting. The green light
will remain lit (indicating the gas
burners are ignited) until the
temperature setting is reached. When
the green light goes off, the burners
are off, and pre-heating is complete.
NOTE: When cooking egg and milk products,
the kettle should
not be preheated, as products
of this nature adhere to hot cooking surfaces.
These types of food should be placed in the
kettle before heating is begun.
5. Place product into the kettle.
6.
Turn the temperature control knob to
the required temperature setting. The
green light will cycle on and off with the
solid state control, indicating the
burners are cycling on and off to
maintain the set temperature.
NOTE:
The red "low water" light should not be
lit during kettle operation. This light indicates
that the water level has reached a critically low
level,
and the gas burners have been automatically
shut off by the kettle's safety circuit. Water must
be added to the reservoir before further use.
Refer to the "Reservoir Fill Procedures" for
details.
7.
When cooking is completed, turn knob
to minimum and place the power on/off
switch to the "OFF" position.
8.
Pour the contents of the kettle into an
appropriate container by opening the
draw-off valve. Care should be taken to
pour slowly enough to avoid splashing
of the product.
NOTE
: As with cleaning food soil from any
cookware, an important part of kettle cleaning is
to prevent foods from drying on. For this
reason, cleaning should be completed
immediately after cooked foods are removed.
Refer to the "Care and Cleaning Instructions"
for detailed kettle washing procedures.
CARE AND CLEANING
Your Cleveland kettle must be cleaned
regularly to maintain its fast, efficient cooking
performance, and to ensure it
s
continued safe,
reliable operations.
1.
Prepare a warm water and mild
detergent solution in the kettle.
2.
Remove food deposits inside the kettle
using a nylon brush. Do not use a metal
bristle brush, as this may permanently
damage the kettle's stainless steel
surface.
3.
Loosen food which is stuck to the kettle
by allowing it to soak at a low
temperature setting.
4
4.
Open the draw-off valve to drain the
wash water.
5.
The draw-off valve should be
cleaned as follows:
a.
Remove the drain screen from
the bottom of the kettle.
Thoroughly wash and rinse
the screen, either in a sink or
dishwasher, then replace it
into the kettle.
b. 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.
c. In a sink, wash and rinse the
valve stem, hex nut, and
knob. Wash and rinse the
inside of the valve body using
a nylon brush.
d.
Reassemble the draw-off valve
by reversing the procedure for
disassembly. The valve's hex
nut should be hand tight only.
6.
Rinse the kettle interior thoroughly,
then drain the rinse water.
7.
Leave the cover and draw-off valve
open when the kettle is not in use.
8. Exterior Care: Allow kettle to cool
before washing. Use the same
cleaners and cleaning procedures as
for other kitchen surfaces of
stainless steel and aluminum. Mild
soapy water, with a clear water rinse,
is recommended.
Do not allow water to run into
electrical controls.
Always turn off
equipment power before using water
to wash equipment.
DO NOT HOSE DOWN THE
KETTLE.
NOTE:
For more difficult cleaning
applications, one of the following can be
used: alcohol, baking soda, vinegar, or a
solution of ammonia in water. Avoid the use
of chloride cleansers, which may damage
the kettle's stainless steel surface.
WARNING:
Steel wool should never be
used for cleaning the kettle. Particles of the
steel wool become embedded in the
surface and rust. This will weaken and
corrode the stainless steel surface.
MAINTENANCE
Cleveland kettles require very little
preventive maintenance, other than daily
cleaning
.
DRAW-OFF VALVE MAINTENANCE
To correct a leak at the draw-off valve, the
source of the leak must first be determined.
Leaks from around the valve stem are
corrected by simply replacing the "O"ring.
Faulty seating of the valve stem disc
against the valve body seat may cause
dripping from the valve even when the
valve is tightly closed. This can often be
corrected by cleaning any residue from the
disc and seat.
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.
5
In order to preserve the various agency safety
certification (UL, A.G.A., CSA. CGA, NSF,
ASME/Ntl. Bd., etc.), only factory-supplied
replacement parts should be used. The use of
other than factory-supplied replacement parts
will void the warranty.
KETTLE VENTING INSTRUCTIONS
If the vacuum/pressure gauge reading is in the
"vent air" zone, it means that air has entered
the steam/water jacket, resulting in little or no
vacuum. This reduces kettle efficiency by
slowing its heating process. To remedy this
situation, the following venting procedures
should be followed:
1.
With the temperature control knob set
at number 9, heat the empty kettle until
the vacuum/pressure gauge indicates
5-10 psi.
2.
Release steam and air from the
steam/water jacket by pulling out on
the pin of the safety valve for
approximately 10-15 seconds.
The kettle's steam and air from the
steam/water jacket should now be free of air.
At room temperature, the pressure gauge
needle should rest in the green zone,
indicating a vacuum in the kettle's jacket. To
check the gauge for proper vacuum after
venting, the temperature can be quickly
reduced by filling the kettle with cold water.
If the kettle will not hold vacuum, have a
qualified service technician test for leaks at the
water fill plug, sight gauge, safely valve, probe,
and vacuum/pressure gauge fittings. We
suggest mixing a 50/50 solution of liquid
detergent and water while heating the kettle to
at least 5 psi pressure. Then, shut off power to
the kettle. The soapy solution should be
applied to the suspected area while the
gauge shows at least 5 psi pressure. Any
bubbles which appear will indicate a leak.
RESERVOIR FILL PROCEDURES
The reservoir's water level must be maintained
at the proper level. Under normal operating
conditions, the sealed water reservoir should
not require the addition of water. If the red "low
water" light comes on during use, the water
level has reached a critically low level. The low
water protection control has automatically shut
off the gas burners. The following procedure
must be completed before further use:
WARNING:
Insure there is no pressure
IN
the
unit before removing filler cap.
1.
Shut off
power to the kettle.
2.
Remove water fill cap located at the
rear of the kettle.
3.
Add distilled water until the water level
is between the "HI" and "LO'' markings
on the sight gauge glass.
4.
Replace the water fill cup and carefully
tighten. Do not over-tighten.
5.
Restore power to the kettle.
6.
The kettle must now be vented. Refer
to the "Kettle Venting Instructions".
CAUTION:
It is recommended that only
distilled water be used when adding water to a
partially filled water reservoir. Local tap water
conditions may cause kettle damage which is
not covered under warranty. Add water until
the level is between the "HI" and "LO" marks
on the sight gauge.
6
PARTS LIST - ELECTRICAL COMPONENT BOX ASSEMBLY
ITEM NO.
PART NO.
DESCRIPTION
QTY.
1.
KE51141
Transformer, 120-16V.
1
2.
KE52690
Bushing
1
3.
KE53469
Ignition module
1
4.
KE00458
Solid state control
1
5.
KE50753
Relay
1
6.
KE53316
Safety thermostat
1
7.
F
I
05050
Brass nut # 7/16-24
1
8.
KE53436
Air switch
1
9.
KE51164
Transformer 120-24V.
1
10.
KE52281
Fuse bussman MDL-1/2 amp
1
11.
KE51139
Fuse holder
1
PARTS LIST - PRESSURE RELIEF ASSEMBLY
ITEM-NO.
PART NO.
DESCRIPTION
QTY.
1.
FI05215
Cap, 1/2"
1
2.
FI05225
Nipple, 1/2"
1
3.
FI00151
Street elbow, 1/2"
2
4.
KE51014
Check valve
1
5.
FI00596
Nipple
1
6.
FI05214
Cross tee
1
7.
RT00370
Tubing, 1/4" copper(per ft.)
3
8.
KE51723
Safety valve, 50 p.s.i
1
9.
FI00598
Nipple
1
10.
FI052l
6
Elbow
,
FIP
x
FIP
1
11.
FI05224
Nipple
1
12.
FI0522
1
Reducer, 1/2" pipe to 1/4" tube
1
13.
FI05050
Compression nut, 1/4"
1
PARTS LIST - GAS CONTROL ASSEMBLY ( KETTLE )
ITEM NO.
PART NO.
DESCRIPTION
QTY.
1.
KE53402
Air orifice, 140K BTU burner
1
KE53402-1
Air orifice, 170K BTU burner
2
.
KE01426
Mixing chamber
1
3
.
KE53387
Swivel
1
4.
Pipe
1
5.
KE53515
Gas control valve, N.G.
1
KE535151
Gas control valve, L.P.
6.
F01518
Shut-off valve
1
7.
Reducer
1
8.
Pipe
1
9.
Pipe
1
10.
KE53441
Blower
1
11.
Elbow
1
12.
Pipe
1
13.
Elbow
1
14.
Plug
1
15.
"O" Ring
1
16.
KE53422
Spring
1
17.
KE53403
Orifice, .227, N.G., 140K BTU, 2000 ft.
1
KE53403-1
Orifice, .228, L.P., 140K BTU, 2000 ft.
KE53403-2
Orifice, .303, N.G., 170K BTU, 2000 ft.
KE53403-3
Orifice, .246, L.P., 170K BTU, 2000 ft.
18.
FA00114
"O" Ring
1
19.
Pipe
1
20.
FI00073
Union
1
GAS CONTROL ASSEMBLY ( KETTLE )
PARTS LIST - SIDE BOX ASSEMBLY (KETTLE)
ITEM NO.
PART NO.
DESCRIPTION
QTY.
1.
N/A
Sight glass
1
2.
KE53437
Igniter
1
3.
KE01432
Enclosure cover assembly
1
4.
KE00515
Thermistor
1
5.
KE517111
R.H. Trunnion bearing
1
6.
KE52833
Gear
1
7.
KE50315
Worm
1
8.
KE50245
Bearing
1
KE51738
Sleeve, bearing
1
9.
FA10623
Bolt, hex bead
1
FA20029
Nut
1
10.
FA950551
Key
1
11.
FA95008
Locknut
2
12.
FA30088
Washer
1
13.
FA95050
Retaining ring
1
14.
KE52191
Bearing
2
15.
KE52192
Thrust washer
4
16-
KE52193
Thrust washer spacer
3
17.
KE51891
Washer
1
18.
KE517112
L.H. Bearing
1
19.
KE51730
Tilt shaft bearing
1
20.
FA19186
Screw, hex socket
1
21.
KE503752
Tilt shaft
1
22.
KE50569-1
Temperature Control Assembly
1
KE50569
Knob
1
SE00074
Potentiometer
1
KE51005
Seal
1
FA32027
Star Washer
1
23.
KE50567
L.E.D., red
1
24.
KE00508
Hand wheel
1
25.
KE50429
Pressure gauge
1
26.
SK50055
Terminal block
1
27.
Switch Assembly
1
KE50504
Toggle switch
SK50062
Rubber Boot
28.
KE50568
L.E.D., green
1
29.
KE50473
Ground lug
1
30.
KE50556
Water level probe
1
31.
KE50955-1
Retaining cover
1
KE52871
Washer
1
KE51053
Sight glass
1
FA05002-30
"O"-Ring
1
32
Electrical Component Box Assy.
(See Pg. 222-09TD)
33.
FI00196
Drain cap
1
SIDE BOX ASSEMBLY ( KETTLE )
PARTS LIST - 2" TANGENT DRAW-OFF VALVE
ITEM NO.
PART NO.
DESCRIPTION
QTY.
1. to 7.
KE50972-B
Draw-off assembly
1
KE509721
Draw-off assembly, for KDM-40-T
1.
FA21008
Hex nut
1
FA95049
Wing nut
FA11134
Screw, for KDM-40-T
2.
KE527551
Knob
1
3.
KE52754
Hex nut
1
4.
KE52753
Retainer
1
5.
KE52752
Piston
1
KE53290
Piston, for KDM-40-T
6.
FA00111
''O"Ring
1
7.
KE52751
Valve body
1
KE53289
Valve body, for KDM-40-T
PARTS LIST - HINGE ASSEMBLY
ITEM NO.
PART NO.
DESCRIPTION
QTY.
1. - 9.
KE00598
Hinge assembly (40 gal. and under)
1
SK00168
Hinge assembly (60 gal. and over)
1
1.
KE51218
Body, spring assist hinge
1
2.
KE50824
Hinge bearing
1
3.
KE50823
Pin (hinge)
1
4.
KE50820
Insert, brass adjustment
1
5.
KE50819
End piece
1
6.
FA11507
Screws, adjustment
2
7.
FA11284
Bolts, end block
2
8.
KE50122
Spring (40 gal. and under)
1
KE50121
Spring (60 gal. and over)
1
9.
KE50821
Cylinder
1
10.
KE50151
Knob, ball type
1
11.
Cover handle (specify model)
1
12.
KE00095
Lid holder
1
13.
FA30500
Washer, lid holder
1
14.
FA11223
Bolt, lid holder
1
