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Cleveland Range KGL-80 manual

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Table of contents for the manual

  • 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-40-T KGL-40SH SE95003-1 Rev . 1 1333 East 179th St., Cle v eland, Ohio , U .S .A. 44110 Phone: (216) 481-4900 F ax: ([...]

  • Page 2

    FOR THE USER W ARNING : Improper installation, adjustment, alteration, ser vice or maintenance can cause proper ty damage, injury or death. Read the installation operating and maintenance instructions thoroughly bef ore installing or ser vicing this equipment. FOR YOUR SAFETY DO NO T ST ORE OR USE GASOLINE OR ANY O THER FLAMMABLE LIQUIDS AND V APOU[...]

  • Page 3

    T ABLE OF CONTENTS Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Shipping Damage Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 V entilation . . . . .[...]

  • Page 4

    1 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 dow[...]

  • Page 5

    2 ELECTRICAL ENSURE THE ELECTRICAL SUPPL Y MA TCHES THE KETTLE'S REQUIREMENTS AS ST A TED ON THE RA TING LABEL. A cord and plug ar e 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. W ARNING: Electrical Grounding Instruct[...]

  • Page 6

    3 Specification Drawing - Stationary , KGL-40, KGL-60, KGL-80, KGL-100 NO TES : Clev eland Range reserves right of design improvement or modification, as warranted. Many regional, state and local codes exist and it is the responsibility of the o wner and installer to comply with the codes. Installation of backflow pre venters, v acuum breakers and [...]

  • Page 7

    4 Specification Drawing - Tilting, KGL-40-T , KGL-60-T , KGL-80-T NO TES : Clev eland Range reserves right of design improvement or modification, as warranted. Many regional, state and local codes exist and it is the responsibility of the o wner and installer to comply with the codes. Installation of backflow pre venters, v acuum breakers and other[...]

  • Page 8

    5 Specification Drawing - Short Series, KGL-40-SH, KGL-60-SH, NO TES : Clev eland Range reserves right of design improvement or modification, as warranted. Many regional, state and local codes exist and it is the responsibility of the o wner and installer to comply with the codes. Installation of backflow pre venters, v acuum breakers and other spe[...]

  • Page 9

    6 Specification Drawing - Short Series, KGL-40-TSH SPECIFICA TIONS NOTES FOO T LOCA TION & FLOOR DRAIN DET AIL FLANGED FOO T DET AIL 9/16" 14 mm 120º TYP 1" (25 mm) MAX. ADJUSTMENT 1 5/8" (42 mm) Ø 7/16" (11 mm) Ø 3 HOLES ON 3 1/8" (80 mm) Ø B.C.D. 4 7/8" 124 Ø mm NO TES : Clev eland Range reserves right of de[...]

  • Page 10

    7 OPERA TING INSTRUCTIONS 3 4 5 2 1 7 5 8 10 9 6 ITEM # DESCRIPTION FUNCTION 1. Low W ater Indicator Light (Red) When lit, indicates that the kettle is low on water and will not operate in this condition (see RESERVOIR FILL PROCEDURES on page #28. 2. On-Off Switch/ T urns kettle ON/OFF and allows the operator to adjust the kettle Solid State temper[...]

  • Page 11

    8 OPERA TING THE KETTLE DO NO T A TTEMPT T O OPERA TE THIS APPLIANCE DURING A PO WER F AILURE. KEEP APPLIANCE AND AREA FREE AND CLEAR OF COMBUSTIBLES. DO NO T LEAN ON OR PLA CE OBJECTS ON KETTLE LIP . SERIOUS INJUR Y COULD RESUL T IF KETTLE TIPPED O VER, SPILLING HOT CONTENTS. IF Y OU ARE COOKING AN EGG OR MILK PRODUCT , DO NO T PRE-HEA T KETTLE. 1[...]

  • Page 12

    9 CARE AND CLEANING Y our kettle must be cleaned regularly to maintain its fast, efficient cooking performance, and to ensure its continued safe, r eliable operation. W ARNING: Do not use chloride base detergents. There is a gr owing number of non-chloride cleaners available. If unsure of the cleaners chlorine content consult the supplier . Also av[...]

  • Page 13

    10 WRAP COVERS TO P LEFT SIDE FRONT RIGHT SIDE BACK KETTLE T OP FRONT LEFT SIDE RIGHT SIDE B A CK KGL-40 KE01479 -X KE53483-4 KE54253 -X KE01432 -X KE02186-1 KGL-60 KE01479-1 KE53483-5 KE54253-1 KE01432-1 KE02186-2 KGL-80 KE01479-2 KE53483-6 KE54253-2 KE01432-2 KE02186-3 KGL-100 KE01479-3 KE53483-7 KE54253-3 KE01432-3 KE02186-4 KGL-40-T KE01479 -X [...]

  • Page 14

    11 PRESSURE RELIEF ASSEMBL Y 6 5 4 2 3 8 7 ITEM NO . P ART NO . DESCRIPTION QTY . PRESSURE RELIEF V AL VE ASSEMBLIES 1. KE01450 FOR ASME KETTLES (INCLUDES #2-6) 1 KE01450-1 FOR CE KETTLES (INCLUDES #2-6) 1 2. F A05049 MALE CONNECTOR, 1/2" PIPE - 1/4" TUBE 1 3. FI00151 STREET ELBOW , 90°, 1/2", BRASS 2 4. FI00178 TEE, 1/2" FPT ,[...]

  • Page 15

    12 HINGE ASSEMBL Y 1 5 3 2 13 12 6 4 7 11 8 10 9 9 ITEM NO . P AR T NO . DESCRIPTION QTY . 1. - 11 SE00120-1 HINGE ASSEMBL Y - KGL-40/T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SE00120-2 KGL-60/T , KGL-80/T , KGL-40-T/SH . . . . . . . . . . . . . . . .1 SE00120-3 KGL-100/T , KGL-60-T/SH . . . . . . . . . . . . . . . [...]

  • Page 16

    13 ELECTRICAL COMPONENT BOX ITEM ON. P ART NO . DESCRIPTION QTY . KE01422 ELECTRICAL CONTROL BOX ASSEMBL Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 KE53439 COMPONENT BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 KE53440 COVER, COMPONENT BOX . . . . . . . . . . . . . . . . . . . [...]

  • Page 17

    14 3 4 5 6 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-40-SH KGL-60 KGL-100 KGL-60-SH 1 TRUNNION ASSEMBL Y ITEM P ART DESCRIPTION QTY . NO . NO . 1. KE00354 TRUNNION BEARING ASSEMBL Y . . . . . .1 2. KE00351 TRUN[...]

  • Page 18

    15 GAS CONTROL ASSEMBL Y 1 16 17 18 19 20 21 31 32 33 34 22 23 24 8 9 10 2 3 30 35 29 4 5 6 4 7 11 13 14 12 15 25 25 26 27 22 28 28 29 30 Stationary Models Tilting Models 34 Air Blower Primary Air Orifice Secondary Air Orifice Gas Orifice Ignitor Burner Gas Valve Shut-Off Valve[...]

  • Page 19

    16 GAS CONTROL ASSEMBL Y ITEM ON. P ART NO . DESCRIPTION QTY . 1. KE53441 BLOWER, 115V , 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 KE53441-1 BLOWER, 220V , 50 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2. KE54420 AIR INT AKE W ASHER[...]

  • Page 20

    17 GEARBOX ASSEMBL Y 40 41 25 42 26 27 28 39 4 5 6 5 7 5 6 5 4 8 25 15 14 1 10[...]

  • Page 21

    18 GEARBOX ASSEMBL Y ITEM NO . P ART NO . DESCRIPTION QTY . 1. KE52836-2 TIL T SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2. KE50315 WORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 3. F A95005 TENSION PIN . . . . . . . . . . . . . . .[...]

  • Page 22

    19 CONSOLE CONTROLS ITEM NO . P ART NO . DESCRIPTION QTY . 1. KE50504 SWITCH, TOGGLE (USED PRIOR TO JANUARY 2000) . . . . . . . . . . . . . . . . . . .1 2. SK50062 RUBBER BOOT (USED PRIOR TO JANUARY 2000) . . . . . . . . . . . . . . . . . . . . .1 3. SE00114 POTENTIOMETER WITH ON/OFF SWITCH, C/W ITEM #4 . . . . . . . . . . . . . . . . .1 KE50988-2 [...]

  • Page 23

    20 MAINTENANCE INSPECTION AND MAINTENANCE CHECKLIST Cleveland Range equipment requir es little preventative maintenance. W e do however pr ovide the following chart as a guideline for inspection and maintenance to keep your unit functioning at 100%. INSPECTION AND MAINTENANCE CHECKLIST The following check s should be completed eve r y six months or[...]

  • Page 24

    21 KETTLE SAFETY INSPECTION CHECKLIST Regular inspection and maintenance of units is essential to obtain trouble fr ee and safe operation of equipment. Inspections must include testing of the pressur e relief valve and checks of the operating system to insure that it has not been alter ed. No safety features designed into the equipment should ever [...]

  • Page 25

    22 SAFETY THERMOST A T : ✘ Probe removed partially ✘ Probe removed completely[...]

  • Page 26

    23 GENERAL 1. T o tur n the unit on, turn the switch to the on position. ■ Power is sent to primary side of the 120vac/16vac transformer . ■ Power is sent to the normally closed high limit. ■ From the high limit power is sent to the normally open contacts of the 12VDC relay and the L1 and L2 terminals of the ignition module. 2. From the secon[...]

  • Page 27

    24 TROUBLESHOOTING GUIDES (continued) PROBLEM: KGL Kettle Won't Heat Does red light come on when unit is first turned on? Does red light go off shortly after unit is turned on? Yes Add water to jacket of Kettle. With the potentiometer set at 10, is 12 VDC at the coil of the relay? No Yes Is 16 VAC measured across Pins 9 and 10 on the controlle[...]

  • Page 28

    25 TROUBLESHOOTING GUIDES (continued) PROBLEM: KGL Kettle Not Hot Enough With kettle pot empty and temperature knob set at 10, is the temperature of the surface of the pot 260 degrees? Unit is operating properly Yes When unit is cold (room temp) is the pressure gauge in the green? No Vent the kettle per instructions in the manual. No When the unit [...]

  • Page 29

    26 TROUBLESHOOTING GUIDES (continued) PROBLEM: KGL Kettle Gets Too Hot With the kettle empty and the temperature set at 10, is the surface temp 260-265 degrees? The kettle is working properly. Yes Does the kettle continue to call for heat (green light stays on) when the kettle reaches 260-265 degrees? No Is there supply voltage to the coil of the g[...]

  • Page 30

    KETTLE VENTING INSTRUCTIONS 1. Remove Access Panel from back of main kettle console. 2. T urn kettle ON and set temperature control to 10 , heat the empty kettle until unit cycles off. 3. V ent kettle by pulling V alve Ring eight to fifteen times, holding valve open for two seconds each time. NOTE : If unit cycles ON, stop venting and wait for kett[...]

  • Page 31

    RESERVOIR FILL PROCEDURES The kettle's water level must be maintained at the proper level. Under normal operating conditions, the sealed water reservoir should never r equire 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 [...]

  • Page 32

    29 PRESSURE RELIEF V AL VE PERIODIC TESTING Most insurance agencies requir e periodic testing of pressur e relief valves used on pr essure vessels. This procedur e will allow you to safely and quickly test your kettle's pressur e relief valve. W e recommend this test be perfor med twice a year . NOTE: The following instruction is intended for [...]

  • Page 33

    3. Remove Console Cover and Access Panel. 4. Pull Pressur e Relief V alve Ring open to insur e vessel is not pressurized. 5. Remove 1/4" copper tubing and reducer bushing. 6. Remove Drain Plug cap and allow water to drain. 7. Replace Drain Plug cap and add water until it shows on sight glass. 8. Repeat steps 6 & 7 until water drains clear [...]

  • Page 34

    31 GAS KETTLE ORIFICE REPLACEMENT Gas Orifice Console Cover "O" Ring Spring Plug 1. Remove Console Cover 2. Remove Plug and Spring 3. Remove Orifice 4. Replace with new Orifice and "O" ring 5. Replace Spring and Plug 6. Replace Console Cover Kettles BTU's per Gas W ater # of Hour T ype Column Orifices KGL-40, 140000 Natural[...]

  • Page 35

    32 NOTE: Use thread sealant compatible with pr opane gas on all threaded piping connections. 1. Disconnect electrical connection. 2. Shut off main gas supply and disconnect kettle fr om supply line. 3. Remove main kettle CONSOLE CO VER . 4. Remove PLUG and SPRING . 5. Remove GAS ORIFICE and “O” RING . 6. Replace first with new “O” RING and [...]

  • Page 36

    33 WIRING DIAGRAMS Diagram #1 : Floor Gas K ettle (except KGL-25/T) 110-120 V olts, 60Hz 1 2 3 4 5 7 13 14 15 17 18 19 20 16 6 9 11 10 8[...]

  • Page 37

    34 Diagram #1 (continued): Floor Gas K ettle (except KGL-25/T) 110-120 V olts, 60Hz ITEM NO . P ART NO . DESCRIPTION QTY . 1 KE55069-6 SAFETY THERMOST A T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2 KE53436 AIR PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 38

    35 Diagram #2 (see Diagram #1 f or common par ts): Floor Gas K ettle (except KGL-25/T) 200-240 V olts, 60Hz ITEM NO . P ART NO . DESCRIPTION QTY . 21 KE53838-2 TRANSFORMER 120-24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 22 KE53441 BLOWER, 115V , 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 39

    36 Diagram #3 (see Diagram #1 f or common par ts): Floor Gas K ettle (except KGL-25/T) 200-240 V olts, 50Hz ITEM NO . P ART NO . DESCRIPTION QTY . 23 KE53441-1 BLOWER, 220V , 50 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 24 KE53838-2 TRANSFORMER 120-24V . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 40

    37 ON MARCHE ENCENDIDO ACCESO AN P AUSE, INTERRUPTION P AUSE, INTERRUPTION P AUSA, INTERRUPCION P AUSA, INTERRUZIONE P AUSE, UNTERBRECHUNG RESET RÉENCLENCHER RECONECT AR RESET NULLSTELLEN STOP OF ACTION ARRÊT DE L'ACTION P ARAR FUNCIONAMIENTO ARRESTO OPERAZIONE FUNKTION STOPPEN F AST STOP , EMERGENCY ARRÊT RAPIDE D'URGENCE P ARADA RAPI[...]

  • Page 41

    38 LOW W A TER NIVEAU BAS DE L'EAU NIVEL DE AGUA BAJO LIVELLO BASSO W ASSERST AND NIEDRIG IGNITION F AILURE P ANNE D'ALLUMAGE F ALLO DE ENCENDIDO MANCA T A ACCENSIONE ZÜNDUNGSFEHLER COOLING REFROIDISSEMENT REFRIGERACION RAFFREDDAMENTO KÜHLUNG MIXER BRIDGE PONT DU MÉLANGEUR PUENTE DE MEZCLADORA MENSOLA MESCOLA TORE MISCHER-BRÜCKE RIGHT[...]

  • Page 42

    SP ARE P ARTS LIST The following is a spare parts listing of parts that wear during nor mal us or are apt to be misplaced during normal operation. These par ts should be kept on hand to prevent loss time due to a minor problem. P ART NUMBER DESCRIPTION QUANTITY KE00458 KETTLE SOLID ST A TE CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . .[...]