Cleveland KGL-100 Operator's Manual
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Cleveland KGL-100 Operator's Manual

Gas floor model kettles
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Operators Manual
MODELS:
Stationary - KGL-40, KGL-60, KGL-80, KGL-100
Tilting - KGL-40-T, KGL-60-T, KGL-80-T
Short Series - KGL-40-SH, KGL-60-SH,
KGL-40-TSH
KGL-40-T
™
Cleveland
Enodis
Installation, Operation & Service
Gas Floor Model Kettles
KGL-40
KGL-40SH
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
SE95003-1 Rev. 6

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  • Page 1 Short Series - KGL-40-SH, KGL-60-SH, KGL-40-TSH KGL-40-T ™ Cleveland Enodis Installation, Operation & Service Gas Floor Model Kettles KGL-40 KGL-40SH 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 SE95003-1 Rev. 6...

  • Page 2: For The User

    • 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.

  • Page 3: Gas Appliances

    For your safety Keep clear of pressure relief discharge. Inspect unit daily for proper operation. Surfaces may be extremely hot! Use protective equipment. Do not lean on or place objects on kettle lip. Shut off power at main fuse disconnect prior to servicing.

  • Page 4: 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.

  • Page 5: Installation Checks

    ELECTRICAL ENSURE THE ELECTRICAL SUPPLY MATCHES THE KETTLE'S REQUIREMENTS AS STATED ON THE RATING LABEL. A cord and plug are supplied with the unit. Simply plug the unit into any grounded outlet rated for a minimum of 10 amps. The wiring diagram is located under the cover of electrical box inside the back console.

  • Page 6: Operating Instructions

    Used for tilting the kettle on hand tilt models. In power tilt models there is a toggle switch in same location. Used for draining product or wash water from kettle. It is supplied as standard equipment on stationary kettles and is optional on tilting kettles.

  • Page 7: Operating The Kettle

    ° C APPROXIMATE BOILING TIMES The accompanying chart shows approximate times required for gas kettles of various capacities to boil water with the lid open. The ON/OFF Switch/Solid State Temperature Control (2) must be set at “10” throughout the heat-up period. Water will boil about 1/3 faster if the kettle is filled only to the outer steam jacket’s welded...

  • Page 8: Cleaning Instructions

    CLEANING INSTRUCTIONS CAUTION SURFACES MAY BE EXTREMELY HOT! 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).

  • Page 9: Stainless Steel Equipment Care And Cleaning

    STAINLESS STEEL EQUIPMENT CARE AND CLEANING (Supplied 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.

  • Page 10: Service Parts

    SERVICE PARTS CONSOLE CONTROLS ITEM NO. PART NO. KE50504 SK50062 SE00114 KE50988-2 KE51005 KE50569-1 SE003013-1 SE003013-2 SE003013-3 FA05002-18 KE50429-2 KE5555-5 KE95457 1 0 2 0 DESCRIPTION SWITCH, TOGGLE (USED PRIOR TO JANUARY 2000) ....1 RUBBER BOOT (USED PRIOR TO JANUARY 2000) .

  • Page 11: Sight Glass

    ELECTRICAL COMPONENT ITEM ON. PART NO. KE01422 KE53439 KE53440 KE53599-1 KE53838-27 KE53444 KE54833-3 KE02372 KE53469-4 KE00458 KE50303 KE50753-7 KE50753-8 KE55069-6 FI05050 KE02400 KE55453-1 KE53838-20 KE53582 Not Shown KE53523 SIGHT GLASS ITEM ON. PART NO. DESCRIPTION KE50955 KE52871 KE51053-1 FA05002-30 DESCRIPTION ELECTRICAL CONTROL BOX ASSEMBLY .

  • Page 12: Gas Control Assembly

    GAS CONTROL ASSEMBLY Stationary Models Gas Valve Shut-Off Valve 40 41 Tilting Models (for units built prior to March 2005) 23 24 Gas Orifice Ignitor Burner Air Blower Primary Air Orifice Secondary Orifice...
  • Page 13 NATURAL GAS - SEA LEVEL UP TO 2000', 60 - 100 GALLON KETTLES ......
  • Page 14 GAS CONTROL ASSEMBLY (for units built after February 2005) Tilting Models FI00040-1 FI05226 FI05231 FI05222 FI05223 KE55240R F015 KE000960 FA30505-1 FA11256 ELBOW, 1/2" ..............1 NIPPLE, 1/2"...

  • Page 15: Gearbox Assembly

    GEARBOX ASSEMBLY 16 19 20 26 27 28...
  • Page 16 GEARBOX ASSEMBLY ITEM NO. PART NO. KE52836-2 KE50315 FA95005 KE52193 KE52192 KE52191 FA30088 FA95008 KE55057-4 FA95062 KE00508 FA19501 KE51730 FA19177 FA20047 KE003209-11 KE603208-4 KE603208-7 KE603208-9 ***NOTE: for units built prior to Dec. 2006 order Complete Switch KE003209-11 KE50580 FA00012 KE50579-1 KE51007 FA10139 KE50498...
  • Page 17 PNEUMATIC BOX ASSEMBLY (FOR OPTIONAL FLUSH PISTON VALVE) (USED AFTER 2003)
  • Page 18 PNEUMATIC BOX ASSEMBLY (FOR OPTIONAL FLUSH PISTON VALVE) (USED AFTER 2003) ITEM NO. PART NO. KE003050 KE602957 KE54846-9 FA95074 KE01812-1 KE003209-9 KE601601 KE602960 KE52697 KE601602 FA32500 KE600814-1 FI00351 FI05317-2 FI05220-1 KE601603 KE02292-1 KE02369 FI05318 KE532176 KE50555-3 KE51238-1 KE50473 KE55004-3 FA21006 WC101655 FA21002 FA32004...
  • Page 19 OPTIONAL FLUSH PISTON VALVE (USED AFTER 2003) ITEM ON. PART NO. KE55210 FI05144-3 KE52154-4 KE02291 KE55248 KE55249 KE55250 KE55251 KE55252 KE55253 KE55254 KE55255 KE55256 AIR VALVE ASSEMBLY FPVA-3 DESCRIPTION WELD RING, KETTLE BOTTOM OUTLET ......1 SANI CLAMP, 3”...

  • Page 20: Trunnion Assembly

    TRUNNION ASSEMBLY ITEM PART DESCRIPTION KE00354 TRUNNION BEARING ASSEMBLY ..1 (INCLUDES PART # 3 & 6) KE00351 TRUNNION BEARING ASSEMBLY ..1 (INCLUDES PART # 3 & 6) KE51711 ROLLER BEARING ....2 KE51571-1 SPHERICAL WASHER .

  • Page 21: Pressure Relief Assembly

    KE54941-31 KE54223 KE54864 FA11518-4 DESCRIPTION PRESSURE RELIEF VALVE ASSEMBLIES FOR ASME KETTLES (INCLUDES #2-6) FOR CE KETTLES (INCLUDES #2-6) MALE CONNECTOR, 1/2" PIPE - 1/4" TUBE STREET ELBOW, 90°, 1/2", BRASS TEE, 1/2" FPT, BRASS SAFETY VALVES SAFETY VALVE, 50 PSI, 1/2" (NORTH AMERICA) SAFETY VALVE, 50 PSI, 1/2", (EUROPE)

  • Page 22: Hinge Assembly

    HINGE ASSEMBLY ITEM NO. PART NO. 1. - 11 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 DESCRIPTION Hinge Assembly 25 - 40 Gallon, 20 Gallon Full Jacketed .......1 60 - 80 Gallon, 30 - 40 Gallon Full Jacketed .

  • Page 23: Wrap Covers

    WRAP COVERS LEFT SIDE FRONT KETTLE FRONT KGL-40 KE01479-X KE53483-4 KGL-60 KE01479-1 KE53483-5 KGL-80 KE01479-2 KE53483-6 KGL-100 KE01479-3 KE53483-7 KGL-40-T KE01479-X KE53483-X KGL-60-T KE01479-1 KE53483-1 KGL-80-T KE01479-2 KE53483-2 KGL-40-SH KE01479-4 KE53483-6 KGL-60-SH KE01479-5 KE53483-7 KGL-40-TSH KE01479-4 KE53483-2 BACK LEFT RIGHT...

  • Page 24: Inspection And Maintenance Checklist

    MAINTENANCE INSPECTION AND MAINTENANCE CHECKLIST Cleveland Range equipment requires little preventative maintenance. We do however provide the following chart as a guideline for inspection and maintenance to keep your unit functioning at 100%. INSPECTION AND MAINTENANCE CHECKLIST The following checks should be completed every six months or more frequently if unit is in a high volume facility.

  • Page 25: Safety Valve

    In most cases these accidents are caused by poor maintenance and/or incorrect installation. We at Cleveland would like to restate that 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.

  • Page 26: Safety Thermostat

    SAFETY THERMOSTAT: ✔ Probe fully inserted in tube Wiring is properly connected Low Water Level Probe: ✔ Probe properly attached Operating Thermostat: 260º - 270º ✔ 265º MAXIMUM KETTLE TEMPERATURE If maximum temperature is not in this range (on empty kettle), refer to the “Calibrating Procedure”...

  • Page 27: Lubrication Procedure

    LUBRICATION PROCEDURE Lubricate the following parts every three months to insure smooth operation and reduce wear. TRUNNION Adjusting HOUSING, Screw WORM SCREW AND TILT GEAR Worm Screw and These parts are Tilt Gear accessed through the Cross top cover of the console.
  • Page 28 TROUBLESHOOTING GUIDES (continued) PROBLEM: Kettle Won't Heat Replace Is 16 VAC at the the on/off secondary side of switch (toggle the transformer? or rotary). Is there Power to Replace the the primary of the transformer. transformer? Supply power to the kettle. Replace the ignition transformer...
  • Page 29 TROUBLESHOOTING GUIDES (continued) PROBLEM: See Problem: Kettle won't Kettle Not heat. Hot Enough PROBLEM: KGL Kettle Has Delayed Ignition Is the gas Delayed Igniton pressure to the burner 3.5" W.C.? Adjust or replace the gas Valve. With kettle pot empty and Does the kettle temperature knob heat at all?
  • Page 30 TROUBLESHOOTING GUIDES (continued) PROBLEM: KGL Kettle Gets Too kettle is working properly. Replace the gas valve. Replace the Relay PROBLEM: Red Add Water LED Stays On Add the proper amount of distilled water and rust inhibitor. Clean or replace water probe.

  • Page 31: Kettle Venting Instructions

    KETTLE VENTING INSTRUCTIONS 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.

  • Page 32: Reservoir Fill Procedures

    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.

  • Page 33: Pressure Relief Valve Periodic Testing

    PRESSURE RELIEF VALVE PERIODIC TESTING 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.
  • Page 34 KETTLE JACKET CLEANOUT AND PASSIVATION PROCEDURES The following procedure should be preformed at least once every three years to prevent possible corrosion and ensure the optimum life of the kettle. WARNING: IMPROPER REFILLING OF KETTLE JACKET WILL RESULT IN IRREVERSIBLE DAMAGE TO UNIT DANGER: MOLYFILM 315 IS CORROSIVE, AVOID CONTACT WITH SKIN AND EYES.

  • Page 35: Gas Kettle Orifice Replacement

    Replace main kettle CONSOLE COVER. 5. Replace Spring and Plug Reconnect electrical supply. 6. Replace Console Cover Console Cover "O" Ring Gas Orifice Spring Plug Kettles KGL-40, KGL-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, BTU's per...

  • Page 36: Field Conversion Instructions

    FIELD CONVERSION INSTRUCTIONS - Natural Gas to Propane Gas Power Burner Gas Kettles BTU's per Hour Type KGL-40, 140000 KGL-40-T, 140000 MKGL-40-T, KGL-60 to 100, KGL-60-T to 80-T, KGL-40-TSH, 190000 KGL-40-F to 60-F, 190000 KGL-40-SH to 60-SH, HA-MKGL-60 to 100,...
  • Page 37 WIRING DIAGRAMS (after Sept. 2004) Diagram #1 Floor Gas Kettle (except KGL-25/T) 110-120 Volts, 60Hz (NORTH AMERICA)
  • Page 38 WIRING DIAGRAMS (after Sept. 2004) Diagram #1 (continued) Floor Gas Kettle (except KGL-25/T) 110-120 Volts, 60Hz (NORTH AMERICA) ITEM NO. PART NO. KE55069-6 KE53436 KE53441 KE53838-20 KE53437 KE53515 SE003013-1 SE003013-2 SE00114 KE50753-7 KE53838-20 KE50753-10 FA20047 KE53137-3 KE53184 KE50581 KE51007 KE50579 KE52832 KE00458 KE53469-4...
  • Page 39 WIRING DIAGRAMS (after Sept. 2004) Diagram #2 (see diagram #1 for common parts): Floor Gas Kettle (except KGL-25/T) 200-240 Volts, 60Hz (NORTH AMERICA) ITEM NO. PART NO. KE53838-2 KE53441 DESCRIPTION TRANSFORMER 120-24V ......... .1 BLOWER, 115V, 60 HZ .
  • Page 40 WIRING DIAGRAMS (after Sept. 2004) Diagram #3 Floor Gas Kettle (except KGL-25/T) 200-240 Volts, 50Hz (CE FRANCE)
  • Page 41 WIRING DIAGRAMS (after Sept. 2004) Diagram #4 Floor Gas Kettle (except KGL-25/T) 100-120 Volts, 50Hz (CE, JAPAN)
  • Page 42 WIRING DIAGRAMS (after Sept. 2004) Diagram #5 Floor Gas Kettle (except KGL-25/T) 200-240 Volts, 60Hz (CE ENGLAND)
  • Page 43 WIRING DIAGRAMS (prior to Sept. 2004) Diagram #1 Floor Gas Kettle (except KGL-25/T) 110-120 Volts, 60Hz...
  • Page 44 WIRING DIAGRAMS (prior to Sept. 2004) Diagram #1 (continued) Floor Gas Kettle (except KGL-25/T) 110-120 Volts, 60Hz ITEM NO. PART NO. KE55069-6 KE53436 KE53441 KE53838-20 KE53437 KE53515 KE50567-2 KE50567-1 KE50568-1 SE00114 KE50753-7 KE53838-20 KE50753-10 FA20047 KE53137-3 KE53184 KE50581 KE51007 KE50579 KE52832 KE00458 KE53469-4...
  • Page 45 WIRING DIAGRAMS (prior to Sept. 2004) Diagram #2 (see diagram #1 for common parts) Floor Gas Kettle (except KGL-25/T) 200-240 Volts, 60Hz ITEM NO. PART NO. KE53838-2 KE53441 DESCRIPTION TRANSFORMER 120-24V ......... .1 BLOWER, 115V, 60 HZ .
  • Page 46 WIRING DIAGRAMS (prior to Sept. 2004) Diagram #3 (see diagram #1 for common parts) Floor Gas Kettle (except KGL-25/T) 200-240 Volts, 50Hz ITEM NO. PART NO. KE53441-1 KE53838-2 KE50753-8 DESCRIPTION BLOWER, 220V, 50 HZ ..........1 TRANSFORMER 120-24V .

  • Page 47: Spare Parts List

    1/2" FPT, 50 PSI., FOR ASME KETTLES ........

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