Vulcan-Hart K40GL Service Manual
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Vulcan-Hart K40GL Service Manual

K series gas kettles 2/3 jacketed stationary and tilting
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K40GL Shown
This Manual is prepared for the use of trained Vulcan Service
Technicians and should not be used by those not properly
qualified.
This manual is not intended to be all encompassing. If you have
not attended a Vulcan Service School for this product, you should
read, in its entirety, the repair procedure you wish to perform to
determine if you have the necessary tools, instruments and skills
required to perform the procedure. Procedures for which you do
not have the necessary tools, instruments and skills should be
performed by a trained Vulcan Service Technician.
The reproduction, transfer, sale or other use of this Manual,
without the express written consent of Vulcan, is prohibited.
This manual has been provided to you by ITW Food Equipment
Group LLC ("ITW FEG") without charge and remains the property
of ITW FEG, and by accepting this manual you agree that you will
return it to ITW FEG promptly upon its request for such return at
any time in the future.
A product of Vulcan-Hart
SERVICE MANUAL
K Series Gas Kettles 2/3 Jacketed
Stationary and Tilting
K20GL
K40GL
K60GL
K20GLT
K40GLT
K60GLT
- NOTICE -
3600 North Point Blvd Baltimore, MD 21222
ML-136090
ML-136091
ML-136092
ML-136094
ML-136095
ML-136096
F45461 Rev. B (1117)

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  • Page 1 ITW FEG, and by accepting this manual you agree that you will return it to ITW FEG promptly upon its request for such return at any time in the future. A product of Vulcan-Hart 3600 North Point Blvd Baltimore, MD 21222 F45461 Rev. B (1117)

  • Page 2: Table Of Contents

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting TABLE OF CONTENTS SERVICE UPDATES ..................4 SERVICE UPDATES .
  • Page 3 K Series Gas Kettles 2/3 Jacketed Stationary and Tilting SEQUENCE OF OPERATION (KETTLE CONTROL CIRCUIT) ......... 38 SEQUENCE OF OPERATION (POWER TILTING OPTION) .

  • Page 4: Service Updates

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE UPDATES SERVICE UPDATES SERVICE UPDATES October 2017 • Updated FILLING THE RESERVOIR JACKET. • Updated GAS VALVE/BLOWER INLET PRESSURE CHECK (108W). • Added GAS VALVE/BLOWER INLET PRESSURE CHECK (130W). •...

  • Page 5: General

    The kettles are used to prepare a variety of liquid or semi-liquid food products such as soups, stews and sauces. MODELS COVERED All K Series kettles are mounted to the floor using legs with flanged feet for anchoring. Model Type Gallons Quarts K20GL Stationary K40GL Stationary K60GL Stationary K20GLT Tilting K40GLT Tilting K60GLT Tilting Page 5 of 48 F45461 Rev.

  • Page 6: Control Panel

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - GENERAL • Dowfrost™ heat transfer fluid Part No. 558038 (5 CONTROL PANEL gallon). Refer to FILLING THE RESERVOIR JACKET for volumes. • Distilled water only for re-filling of the jacket (purchase locally).

  • Page 7: Operation, Cleaning And Maintainence

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - GENERAL GAS SUPPLY PRESSURES GAS TYPE Manifold (in W.C.) NOMINAL (in W.C.) MIN (in W.C.) MAX (in W.C.) Low Speed * - 0.27 to 0.30 Natural High Speed - 1.91 to 1.98 Low Speed * - 0.27 to 0.30 Propane High Speed - 1.91 to 1.98...

  • Page 8: Removal And Replacement Of Parts

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS REMOVAL AND REPLACEMENT OF PARTS CONTROL BOX COVER (TILTING) Disconnect the electrical power to the machine and follow lockout / tagout procedures. NOTE: Remove screws from cover where indicated. NOTE: On kettles with manual tilt or power tilt option, the control box height is now taller (as shown) to acomodate additional tilt components.

  • Page 9: Bottom Cover

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS control area). On a stationary kettle, all the electrical BOTTOM COVER panel components are mounted in the kettle control area. CONTROL BOX (TILTING) Remove CONTROL BOX COVER (TILTING). Disconnect the electrical power to Disconnect lead wires from component being the machine and follow lockout /...

  • Page 10: Pressure Switch (1Pas)

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS Remove air from reservoir jacket as outlined under VENTING procedure. Check for proper operation. NOTE: Pressure switch setting is fixed and should not be adjusted. Kettle Control Area - K Series Tilting Kettles Fig.

  • Page 11: Blower

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS Fig. 10 Remove piping from gas valve inlet and install on Fig. 11 replacement valve. Ensure the factory tags that are wired to the piping remain installed. Remove electrical connectors (2) from blower.

  • Page 12: Burner

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS Loosen gas manifold mounting nuts and remove gas supply tube from the fittings. Fig. 13 Fig. 14 Reverse procedure to install replacement blower and check for proper operation. Remove combustion chamber cover from bottom of kettle.

  • Page 13: Spark Ignitor

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS Fig. 16 Fig. 17 Reverse procedure to install replacement burner Ensure spark gap between ignitor electrode and and check for proper operation. ground rod is approximately 1/8". If necessary, adjust as outline under SPARK IGNITION TEST Step 8C.

  • Page 14: Gas Shut-Off Valve (1Sol) - Tilting Models Only

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS GAS SHUT-OFF VALVE (1SOL) - GEAR REDUCER - MANUAL TILTING MODELS ONLY TILTING MODELS Disconnect the electrical power to Disconnect the electrical power to the machine and follow lockout / the machine and follow lockout / tagout procedures.

  • Page 15: Electrical Panel Components - Power Tilting Option Only

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS Remove reducer shaft extension from gear ELECTRICAL PANEL reducer shaft. COMPONENTS - POWER TILTING OPTION ONLY Disconnect the electrical power to the machine and follow lockout / tagout procedures.

  • Page 16: Down Limit Switch (3S) - Power Tilting Option Only

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS Remove mounting nuts and screws (2) securring tilt switch (2S) to bracket. Reverse procedure to install tilt switch (2S). Perform TILT SWITCH (2S) ADJUSTMENT - POWER TILTING OPTION ONLY.

  • Page 17: Gear Reducer - Power Tilting Option Only

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS Remove DOWN LIMIT SWITCH (3S) - POWER TILTING OPTION ONLY leaving the lead wires connected. Remove GAS SHUT-OFF VALVE (1SOL) - TILTING MODELS ONLY. Remove DC TILT MOTOR - POWER TILTING OPTION ONLY.
  • Page 18 K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS Fig. 31 Fig. 29 12. Pull gear reducer away from kettle by working it off the kettle pivot shaft until free. Retain key for 10. Lift spacer ring off gear reducer. Retain for use use on replacement gear reducer.

  • Page 19: Service Procedures And Adjustments

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS SERVICE PROCEDURES AND ADJUSTMENTS Certain procedures in this section require electrical test or measurements while power is applied to the machine. Exercise extreme caution at all times. If test points are not easily accessible, disconnect power and follow lockout / tagout procedures, attach test equipment and reapply power to the test.

  • Page 20: Potentiometer Test

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS 10. Disconnect lead wire from terminal T8 on the If the resistance value did not increase controller. smoothly but had drops or spikes over the full travel range then potentiometer is not Verify 120VAC between T8 and ground.
  • Page 21 K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS Fig. 36 With the kettle at room temperature, verify Current Construction pressure gauge is in the vacuum zone and reading 25 to 30 in. Hg. If vacuum is below minimum listed, air must be removed from reservoir jacket.

  • Page 22: Filling The Reservoir Jacket

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS Insert funnel into the fill port and slowly add FILLING THE RESERVOIR JACKET water until the level in the sight glass is 1/3 full. Low water light should be off (LLCO NOTE: The reservoir water level must be maintained probe is satisfied).

  • Page 23: Complete Draining And Refill

    Fluid (GAL) (GAL) to building water, gas, or steam supply. DO NOT K20GL, block or restrict. 2.75 K20GLT K40GL, 3.75 2.25 K40GLT Hot steam. The kettle and its parts are hot. Use care when operating, cleaning or servicing the K60GL, 9.25...

  • Page 24: Blower Inlet Pressure Check

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS BLOWER INLET PRESSURE GAS VALVE/BLOWER INLET CHECK PRESSURE CHECK (108W) Shut off the gas before servicing the unit and follow lockout / tagout procedures. NOTE: Wattage is listed on blower label. Fig.

  • Page 25: To Adjust

    Shut off the gas before servicing the unit and follow lockout / tagout procedures. NOTE: This check is for K series gas kettle models, K20GL, K20GLT, K40GL, K40GLT, K60GL, K60GLT with serial number 463023802 to present and built on 5/10/17 or after. Fig. 41 To Adjust: Remove CORNER &...

  • Page 26: Spark Ignition Test

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS Verify incoming gas supply line pressure is • Natural Gas: Turn fine adjustment screw on 7“ Water Column (natural gas) and 11” Water gas valve counterclockwise 15 turns. Column (propane).

  • Page 27: Flame Sense Current Test

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS Spark gap between the spark ignitor electrode and ground rod should be approximately 1/8". If the gap is outside of this dimension, bend the spark ignitor electrode as necessary, to make the adjustment.

  • Page 28: Ignition Control Module Test

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS IGNITION CONTROL MODULE TEST Fig. 48 Set VOM to micro amps scale (DC). Remove flame sense wire from ignition module and connect it to the black meter lead (-) and connect Fig.

  • Page 29: Tilt Switch (2S) Adjustment - Manual Tilting Models

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS NOTE: If kettle burner does not immediately light, the If adjustment is necessary, continue with ignition control module continues sparking for 6 procedure. seconds, then locks out power to the gas valve (main Remove CONTROL BOX COVER (TILTING).

  • Page 30: Tilt Switch (2S) Adjustment - Power Tilting Option Only

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS TILT SWITCH (2S) ADJUSTMENT - POWER TILTING OPTION ONLY Kettle Fully Tilted - Traveller Contacts Stop Plate Turn crank handle clockwise to tilt the kettle. The kettle should be tilted past 90°...

  • Page 31: Down Limit Switch (3S) Adjustment - Power Tilting Option Only

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS DOWN LIMIT SWITCH (3S) DC TILT MOTOR CONTROLLER ADJUSTMENT - POWER TILTING TEST - POWER TILTING OPTION OPTION ONLY ONLY Fig. 54 Remove CONTROL BOX COVER (TILTING) to access Down Limit Switch (3S).
  • Page 32 K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS If voltage is present but pan does not raise, refer to POWER TILTING OPTION ONLY under TROUBLESHOOTING. If voltage is not present and the DC fuse is ok, turn the power switch off and disconnect power to the machine.

  • Page 33: Electrical Operation

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION ELECTRICAL OPERATION COMPONENT FUNCTION (STATIONARY & TILTING MODELS) Water Level Control Low water level control. Monitors condition of the WLC LLCO water level probe. Protects (WLC LLCO) ..kettle from a low water condition in the reservoir jacket.

  • Page 34: Component Function (Power Tilting Option)

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION Light (2LT), Low Red (RD) colored light. On when water level in the reservoir jacket drops below water Water ....level (LLCO) probe.

  • Page 35: Component Location (Stationary & Tilting Models)

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION COMPONENT LOCATION (STATIONARY & TILTING MODELS) K Series Stationary Gas Kettle - Controls Side Page 35 of 48 F45461 Rev. B (1117)
  • Page 36 K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION K Series Tilting Gas Kettle - Controls Side F45461 Rev. B (1117) Page 36 of 48...
  • Page 37 K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION K Series Manual Tilt Gas Kettle - Control Box Area Page 37 of 48 F45461 Rev. B (1117)

  • Page 38: Sequence Of Operation (Kettle Control Circuit)

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION K Series Gas Kettle with Power Tilt Option - Control Box Area Kettle connected to 120VAC supply and is SEQUENCE OF OPERATION properly grounded. (KETTLE CONTROL CIRCUIT) Kettle connected to correct gas supply and the supply is on.
  • Page 39 K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION Tilt switch (2S) operated, N.O. contacts held NOTE: Relay K4 contacts provide the 24VAC input closed (kettle in the full upright position - voltage signal to the blower speed control to select tilting models only).

  • Page 40: Sequence Of Operation (Power Tilting Option)

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION With 2S N.O. contacts open - power is SEQUENCE OF OPERATION removed from control circuit and (POWER TILTING OPTION) heating stops. With 2S N.C. contacts closed - Raise Refer to schematic diagram AI3538 for power tilting enable-relay coil (K3) is energized and option and AI3537 for the main control circuit diagram...
  • Page 41 K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION The three sets of K1 N.O. contacts return to the open position. Power is removed from the DC motor controller, the DC tilt motor and kettle travel stops. Page 41 of 48 F45461 Rev.

  • Page 42: Schematic Diagram (Stationary & Tilting Models)

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION SCHEMATIC DIAGRAM (STATIONARY & TILTING MODELS) Fig. 60 F45461 Rev. B (1117) Page 42 of 48...
  • Page 43 K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION Fig. 61 Page 43 of 48 F45461 Rev. B (1117)

  • Page 44: Schematic Diagram (Power Tilting Option)

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION SCHEMATIC DIAGRAM (POWER TILTING OPTION) Fig. 62 F45461 Rev. B (1117) Page 44 of 48...

  • Page 45: Troubleshooting

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - TROUBLESHOOTING TROUBLESHOOTING STATIONARY & TILTING - GENERAL K Series Gas Kettles (Stationary & Tilting) SYMPTOM POSSIBLE CAUSE Gas supply is OFF. Transformer (1T) output voltage is low. Tilting models only - Gas shut-off valve (1SOL) not receiving power or malfunction.
  • Page 46 K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - TROUBLESHOOTING K Series Gas Kettles (Stationary & Tilting) SYMPTOM POSSIBLE CAUSE Kettle unplugged; main circuit breaker off; or incoming supply line fuse F1 open. Supply voltage incorrect. Kettle does not heat, power light is not Ground fault receptacle (GFCI) is tripped.

  • Page 47: Power Tilting Option Only

    K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - TROUBLESHOOTING K Series Gas Kettles (Stationary & Tilting) SYMPTOM POSSIBLE CAUSE Gas supply not on. Tilting models only - Gas shut-off valve (1SOL) not receiving power or malfunction. Ignition module not receiving power. Unit not properly grounded and/or polarity of incoming power is incorrect on automatic ignition systems.
  • Page 48 K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - TROUBLESHOOTING POWER TILTING OPTION ONLY SYMPTOM POSSIBLE CAUSES Transformer 2T inoperative. Power switch off or malfunction. Tilt motor switch malfunction (momentary on - tilt). Down limit switch open or malfunction. Kettle will not tilt K2 down relay malfunction.

This manual is also suitable for:

K20glK60glK20gltK40gltK60glt

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