Cleveland KGL-100 Operator's Manual

Cleveland range inc. operators manual gas floor model kettles kgl-40, kgl-60, kgl-80, kgl-100, kgl-40-t, kgl-60-t, kgl-80-t, kgl-40-sh, kgl-60-sh, kgl-40-tsh

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Operator's manual (48 pages)

Specifications (2 pages)

Installation, operation, maintenance and parts manual (36 pages)

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Summary of Contents for Cleveland KGL-100

Page 1 Operators Manual Installation, Operation & Service Gas Floor Model Kettles 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 KGL-40SH KGL-40-T 1333 East 179th St., Cleveland, Ohio, U.S.A. 44110 Enodis Phone: (216) 481-4900 Fax: (216) 481-3782 Visit our web site at www.clevelandrange.com...
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: Table Of Contents
Installation Operating Instructions Cleaning Instructions Service Parts Maintenance Inspection ..........1 Shipping Damage Instructions.
Page 4: Installation
INSTALLATION 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.
Page 5: Electrical
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 on the back of the console access panel.
Page 6: Specification Drawings
Installation of backflow preventers, vacuum breakers and other specific code requirements is the responsibility of the owner and installer. Cleveland Range equipment is built to comply with applicable standards for manufacturers. Included among those approval agencies are U.L., A.G.A., NSF, ASME/N.Bd., CSA, CGA, ETL and others.
Page 7: Specification Drawing
Installation of backflow preventers, vacuum breakers and other specific codr requirements is the responsibility of the owner and installer. Cleveland Range equipment is built to comply with applicable standards for manufacturers. Included among those approval agencies are U.L., A.G.A., NSF, ASME/N.Bd., CSA, CGA, ETL and others.
Page 8 Installation of backflow preventers, vacuum breakers and other specific code requirements is the responsibility of the owner and installer. Cleveland Range equipment is built to comply with applicable standards for manufacturers. Included among those approval agencies are U.L., A.G.A., NSF, ASME/N.Bd., CSA, CGA, ETL and others.
Page 9: Specification Drawings
Installation of backflow preventers, vacuum breakers and other specific code requirements is the responsibility of the owner and installer. Cleveland Range equipment is built to comply with applicable standards for manufacturers. Included among those approval agencies are U.L., A.G.A., NSF, ASME/N.Bd., CSA, CGA, ETL and others.
Page 10: Operating Instructions
OPERATING INSTRUCTIONS Operating Controls & Indicators ITEM # DESCRIPTION Low Water Indicator Light (Red) On-Off Switch/ Solid State Temperature Control Heat Indicator Light (Green) Ignition Failure Indicator Light (Amber) Vacuum/Pressure Gauge Pressure Relief Valve (not shown) Water Level Sight Glass Tilt Wheel Flue Tangent Draw-Off Valve...
Page 11: Operating The Kettle
OPERATING THE KETTLE DO NOT ATTEMPT TO OPERATE THIS APPLIANCE DURING A POWER FAILURE. KEEP APPLIANCE AND AREA FREE AND CLEAR OF COMBUSTIBLES. DO NOT LEAN ON OR PLACE OBJECTS ON KETTLE LIP. SERIOUS INJURY COULD RESULT IF KETTLE TIPPED OVER, SPILLING HOT CONTENTS. IF YOU ARE COOKING AN EGG OR MILK PRODUCT, DO NOT PRE-HEAT KETTLE.
Page 12: Cleaning Instructions
CLEANING INSTRUCTIONS CARE AND CLEANING Your kettle must be cleaned regularly to maintain its fast, efficient cooking performance, and to ensure its continued safe, reliable operation. WARNING: Do not use chloride base detergents. There is a growing number of non-chloride cleaners available.
Page 13: Service Parts
SERVICE PARTS WRAP COVERS LEFT SIDE FRONT KETTLE KGL-40 KE01479-X KGL-60 KE01479-1 KGL-80 KE01479-2 KGL-100 KE01479-3 KGL-40-T KE01479-X KGL-60-T KE01479-1 KGL-80-T KE01479-2 KGL-40-SH KE01479-4 KGL-60-SH KE01479-5 KGL-40-TSH KE01479-4 BACK FRONT LEFT SIDE KE53483-4 KE54253-X KE53483-5 KE54253-1 KE53483-6 KE54253-2 KE53483-7 KE54253-3...
Page 14: Pressure Relief Assembly
PRESSURE RELIEF ASSEMBLY ITEM NO. PART NO. KE01450 KE01450-1 FA05049 FI00151 FI00178 KE54941-5 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"...
Page 15: Hinge Assembly
KGL-40/T, KGL-60/T, KGL-80/T, KGL-40-T/SH ..1 KGL-100/T, KGL-60-T/SH ......1 HINGE BEARING .
Page 16: Electrical Component Box
ELECTRICAL COMPONENT BOX ITEM ON. PART NO. DESCRIPTION KE01422 ELECTRICAL CONTROL BOX ASSEMBLY ......1 KE53439 COMPONENT BOX .
Page 17: Trunnion Assembly
..........2 For the following units with covers KGL-40-T KGL-60-T KGL-80-T For the following units with or with-out covers KGL-40-TSH For the following units with-out covers KGL-40 KGL-80 KGL-60 KGL-100 KGL-40-SH KGL-60-SH QTY.
Page 18: Gas Control Assembly
GAS CONTROL ASSEMBLY Stationary Models Gas Valve Shut-Off Valve Tilting Models 23 24 Gas Orifice Ignitor Burner Air Blower Primary Air Orifice Secondary Orifice...
Page 19 GAS CONTROL ASSEMBLY ITEM ON. PART NO. KE53441 KE53441-1 KE54420 KE54420-1 KE54239 KE01426-4 KE01426-1 KE01426-2 KE01426-3 KE53523 KE53402 KE53402-1 KE53402-2 KE53402-3 KE01449 KE53618 KE53617 KE53619 KE00515 KE50556-2 KE53437 KE53570 FI05257 FI05213 KE53422 FA05002-4 GAS ORIFICES: KE53403-4 KE53403-5 KE53403-6 KE53403-7 KE53403-8 KE53403-9 KE53403-10 KE53403-11...
Page 20: Gearbox Assembly
GEARBOX ASSEMBLY 19 20 26 27 28...
Page 21 GEARBOX ASSEMBLY ITEM NO. PART NO. KE52836-2 KE50315 FA95005 KE52193 KE52192 KE52191 FA30088 FA95008 KE55057-4 FA95062 KE00508 FA19501 KE51730 FA19177 FA20047 KE53137-3 KE53184 KE53138-1 KE50580 FA00012 KE50579 KE51007 FA10139 KE50498 FA32004 KE50582 FA95014 KE50583 KE52832 FA10487 FA31008 FA20026 KE517112 KE517111 KE51712 KE01889 FA10772...
Page 22: Console Controls
CONSOLE CONTROLS ITEM NO. PART NO. KE50504 SK50062 SE00114 KE50988-2 KE51005 KE50569-1 KE50567-1 KE50568-1 KE50567-2 FA05002-18 KE50429-2 KE5555-5-B KE95457 1 0 2 0 DESCRIPTION SWITCH, TOGGLE (USED PRIOR TO JANUARY 2000) ....1 RUBBER BOOT (USED PRIOR TO JANUARY 2000) .
Page 23: Maintenance
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 24: Kettle Safety Inspection Checklist
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.
Page 25: 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 on page #29.
Page 26: 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 27: Kettle Won't Heat
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 28: Kettle Not Hot Enough
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 29: Kettle Gets Too Hot
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 30: 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 on page #27). DANGER: PRESSURE RELIEF VALVE WILL EXHAUST HIGH...
Page 31: Reservoir Fill Procedures
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.
Page 32: 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 33: Kettle Jacket Filling & Draining Procedures
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 (page #28) in this manual. If unit must be drained follow the procedures described on the following pages.
Page 34: Gas Kettle Orifice Replacement
GAS KETTLE ORIFICE REPLACEMENT NOTE: Use thread sealant compatible with propane gas on all threaded piping connections. Disconnect electrical connection. Shut off main gas supply and disconnect kettle from supply line. Remove main kettle CONSOLE COVER. 1. Remove Console Cover Remove PLUG and SPRING.
Page 35: Field Conversion Instructions
FIELD CONVERSION INSTRUCTIONS Natural Gas to Propane Gas Kettles BTU's per Hour Type KGL-40, 140000 Natural Gas KGL-40-T, 140000 Propane KGL-60 to 100, KGL-60-T to 80-T, 190000 Natural Gas KGL-40-TSH, 190000 Propane KGL-40-F to 60-F, KGL-40-SH to 60-SH, NOTE: Use thread sealant compatible with propane gas on all threaded piping connections.
Page 36: Wiring Diagram
Diagram #1: Floor Gas Kettle (except KGL-25/T) 110-120 Volts, 60Hz WIRING DIAGRAMS KE90407-E...
Page 37 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 KE00458 DESCRIPTION SAFETY THERMOSTAT ..........1 AIR PRESSURE SWITCH .
Page 38 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 39 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 40: Symbols Legend
Symbol Legend (page 1 of 2) English French Spanish Italian RISK OF ELECTRICAL SHOCK DANGER DE SECOUSSE ÉLECTRIQUE PELIGRO DE ELECTROCHOQUE PERICOLO DI SCOSSA STROMSCHLAG-GEFAHR SPLASHPROOF ANTIÉCLABOUSSURES A PRUEBA DE SALPICADURAS PROTETTO CONTRO GLI SPRUZZI SPRITZWASSERDICHT DISCONNECT ELECTRICAL SUPPLY BEFORE WORKING ON KETTLE COUPER LE COURANT AVANT D'INTERVENIR SUR L'ÉQUIPEMENT DESCONECTAR LA ALIMENTACION ELECTRICA ANTES DE REALIZAR TRABAJOS EN EL EQUIPO DISINSERIRE LA CORRENTE PRIMA DI LAVORARE SULLA MACCHINA...
Page 41: Symbols Legend
Symbol Legend (page 2 of 2) English French Spanish Italian AUTOMATIC TEMPERATURE CONTROL COMMANDE AUTOMATIQUE DE LA TEMPÉRATURE AJUSTE AUTOMATICO DE TEMPERATURA CONTROLLO AUTOMATICO TEMPERATURA AUTOMATISCHE TEMPERATURREGELUNG BURNER AND/OR ELEMENT ENERGIZED BRÛLEUR ET/OU ÉLÉMENT ALLUMÉ QUEMADOR O ELEMENTO ENCENDIDO FIAMMA E/O ELEMENTO ATTIVATI BRENNER ODER ELEMENT EINGESCHALTET HEATING ÉBULLITION...
Page 42: Spare Parts List
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 KE00458...

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