Steam Jacketed Kettle, Model DH, English
Contents
1. CAUTION SHIPPING STRAPS ARE UNDER TENSION AND CAN SNAP BACK WHEN CUT TAKE CARE TO AVOID PERSONAL INJURY OR DAMAGE TO THE UNIT BY STAPLES LEFT IN THE WALLS OF THE CARTON Carefully cut any polyester straps around the carton and detach the sides of the box from the skid Pull the carton up off the unit Thoroughly inspect the unit for hidden damage Report any shipping damage or incorrect shipments to the delivery agent Write down the model number serial number and installation date and retain this information for future reference Space for these entries is provided at the top of the Service Log at the back of this manual Keep this manual on file and available for operators to use CAUTION THIS UNIT WEIGHS BETWEEN 535 AND 880 POUNDS 245 TO 400 Kg DEPENDING ON SIZE INSTALLER SHOULD USE PROPER EQUIPMENT TO LIFT SAFELY When installation is to begin carefully cut any straps which hold the unit on the skid Lift the unit straight up off the skid Examine packing materials to be sure loose parts are not discarded with the materials OM DH Installation For efficient performance the DH kettle must be installed in a well ventilated area Items which might restrict or obstruct the flow of air for combustion and ventilation must be removed The area directly around the appliance must be free of combustible materials WARNING THE KETTLE MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH ELECTRICITY A2. CAUTION WARNING WARNING DANGER WARNING WARNING WARNING CAUTION WARNING WARNING CAUTION WARNING WARNING WARNING BE SURE ALL OPERATORS READ UNDERSTAND AND FOLLOW THE OPERATING INSTRUCTIONS CAUTIONS AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL THIS UNIT IS INTENDED FOR USE IN THE COMMERCIAL HEATING COOKING AND HOLDING OF WATER AND FOOD PRODUCTS PER THE INSTRUCTIONS CONTAINED IN THIS MANUAL ANY OTHER USE COULD RESULT IN SERIOUS PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT AND WILL VOID WARRANTY KETTLE MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH ELECTRICITY AND PLUMBING IMPROPER INSTALLATION CAN RESULT IN INJURY TO PERSONNEL AND OR DAMAGE TO EQUIPMENT ELECTRICALLY GROUND THE UNIT AT THE TERMINAL PROVIDED FAILURE TO GROUND UNIT COULD RESULT IN ELECTROCUTION AND DEATH DO NOT CONNECT ANY PIPING TO THE POP SAFETY VALVE THE VALVE MUST BE FREE TO VENT STEAM AS NEEDED THE ELBOW ATTACHED TO THE SAFETY VALVE SHOULD POINT TO THE FLOOR IMPROPER INSTALLATION WILL VOID WARRANTY AVOID ALL DIRECT CONTACT WITH HOT EQUIPMENT SURFACES DIRECT SKIN CONTACT COULD RESULT IN SEVERE BURNS AVOID ALL DIRECT CONTACT WITH HOT FOOD OR WATER IN THE KETTLE DIRECT CONTACT COULD RESULT IN SEVERE BURNS DO NOT OVER FILL THE KETTLE WHEN COOKING HOLDING OR CLEANING KEEP LIQUIDS A MINIMUM OF 2 3 5 8 cm BELOW THE KETTLE BODY RIM TO ALLOW CLEARANCE FOR STIRRING BOILING AND SAFE PRODUCT TR
3. As part of the daily cleaning program clean soiled external and internal surfaces Hemember to check the sides of the unit and control housing h remove burnt on foods use a brush sponge cloth plastic or rubber scraper or plastic wool with the cleaning solution To reduce effort required in washing let the detergent solution sit in the kettle and soak into the residue Do NOT use abrasive materials or metal tools that might scratch the surface Scratches make the surface harder to clean and provide places for bacteria to grow Do NOT use steel wool which may leave particles in the surface and cause eventual corrosion and pitting i The outside of the unit may be polished with a stainless steel cleaner such as Zepper from Zep Manufacturing Co j When equipment needs to be sanitized use a solution equivalent to one that supplies 15 OM DH 200 parts per million available chlorine Obtain advice on sanitizing agents from your supplier of sanitizing products j Following the supplier s instructions apply the agent after the unit has been cleaned and drained Rinse off the sanitizer thoroughly NOTICE NEVER LEAVE A CHLORINE SANITIZER IN CONTACT WITH STAINLESS STEEL SURFACES LONGER THAN 30 MINUTES LONGER CONTACT CAN CAUSE STAINING AND CORROSION It is recommended that each piece of equipment be sanitized just before use If there is difficulty removing mineral deposits or a film left by h
4. To order parts contact your Groen Certified Service Agency Supply the model designation part description part number quantity and where applicable voltage and phase TANGENT DRAW OFF TDO OPTIONAL 20 Parts List OM DH To order parts contact your Groen Certified Service Agency Supply the model designation part description part number quantity and where applicable voltage and phase Key Description Hardware Final Assembly Valve Safety amp Water Fill Assembly Chain Single Jack Link Safety Valve and Water Fill Assembly Valve Safety 50 PSI Elbow 90 degree Street 1 2 NPT Elbow 90 deg Street 1 2 NPT black Piping Water Fill Assembly Plug Pipe 1 2 NPT Brass Tee 1 2 NPT Valve Swing Check 1 2 NPT Nipple 1 2 NPT x Close black Valve Gate 1 2 NPT Plate Caution 1 3 8 x 2 1 4 Tag Water Supply Washer Plain 1 4 Screw Flat Head 8 32 x 3 8 Lg Clamp Conduit 1 2 Coupler Male Tab Clamp Conduit 3 8 OD Bracket Faucet Mounting Strap Cable Ty Wrap Nut Hex Keps 1 4 20 w washer Foot Adjustable Bullet 2 0D Nameplate Fill Jacket Tilt Mechanism Assembly Bushing Snap 3 4 x 1 Nylon Key 3 8 Square x 1 3 8 Lg Bar Square 3 8 Part No 117086 005444 003261 097008 097005 096905 004185 097007 011146 008772 004187 008877 004180 008250 084083 005472 006006 006777 007880 008224 009054 011093 012940 013275 026450 045752 000453 001474 403511 Description
5. hot water from the kettle and replace it with cold This will condense steam in the kettle jacket and the pressure gauge should show a reading of 20 to 30 inches mercury Hg below zero If it does not or if the vacuum is leaking down contact a Groen authorized service agency to correct the problem Jacket Filling and Water Treatment The jacket was charged at the factory with the proper amount of treated water You may need to restore this water either because it was lost as venting steam or by draining If you are replacing water lost as steam use distilled water If you are replacing treated water that ran out of the jacket prepare more treated water as directed in Water Treatment Procedure below Allow the kettle to cool completely The procedure will be easier with the kettle under vacuum pressure gauge reading below Zero SAFETY CHECK PIPE GLOBE VALVE VALVE PLUG VALVE Test the safety valve at least twice monthly OM DH a Make sure the fill valve is closed and and maximum marks on glass Stop adding remove the square head pipe plug with water when it reaches the maximum marker open ended wrench or crescent wrench on the gauge b Position a funnel in the opening and fill it with g Record the exact amounts of water and properly treated water treatment compound needed These amounts may be used again if the same c Slowly open the fill valve to allow water to be water sources and compound are used sucke
6. Indicator Red 24 VAC Switch SPST On Off Overlay Front Panel A Stand and Housing Assembly B Gas Valve Piping amp Bottom Comps C Burner and Flame Sensor Assembly D Combustion Chamber Assembly E Flue Stack Assembly Part No 0981 71 098458 099961 117088 002845 002981 000558 008742 084208 055634 005470 074872 123804 116384 116383 006904 123802 123813 127369 123814 122093 117034 OM DH Key gt Description Stand and Housing Assembly Cabinet Side Panel otand Cladding Base Assembly Housing Weldment Assembly Parts List Part No 123813 047882 MS96694 MS96698 MS47332 Key CON Stand and Housing Assembly Description Part No Housing Cladding DH 20 123810 Housing Cladding DH 40 and 60 123811 Tray Liner 001475 Nut Hexagon 1 2 13 Heavy Duty 005705 Screw Hex Head Cap 1 2 13 x1 1 2 008679 22 Key 9 10 11 12 Description 1 2 Lock Washer Screw Truss 8 32 x 3 8 screw Truss 8 32 x 1 1 4 Lg Cabinet Cover Part No 005735 005764 071247 001465 Parts List OM DH To order parts contact your Groen Certified Service Agency Supply the model designation part description part number quantity and where applicable voltage and phase Key 0 Qn R N UJ Description Gas Valve Piping amp BottomComps Tube Copper 1 2 Elbow Female 90 Deg 1 2 NPT Thermostat electric Elbow 90 Deg 1 2 NPT Nipple 1 2 NPT x 2 1 2
7. Long Electrode Water Level Tee 1 2 x 1 2 Tube x 3 8 MPT Connector 1 4 NPT Female Part No 127369 007334 055634 009730 008747 005552 002170 074593 097074 Gas Valve Piping and Bottom Components Assembly Key 9 10 11 12 13 14 16 17 19 Description Pressure Switch 1 4 Connector 1 2 NPT Male Gas Valve Bracket Support Screw Pan Head 8 32 x 3 8 Nut Hexagon Kep 1 4 Bar Clamp Rigid Conduit Boot Probe 23 Part No 096963 049093 123815 065382 005764 012940 005440 068687 101143 Key 20 21 22 23 24 25 Description Cover Bottom Cap Bottom Cover Plate Gasket Bottom Plate Screw 10 32x3 8 Hex Elbow 1 8 NPT Male x 1 4 Tube Tube Aluminum 1 4 OD x 32 Part No 049801 049003 007937 069773 097195 006796 OM DH Parts List E hd oy ASI KE TE Y Burner and Flame Sensor Assembly Flue Stack Assembly 24 Parts List To order parts contact your Groen Certified Service Agency Supply the model designation part description part number quantity and where applicable voltage and phase Key NOOR WDM Description Burner and Flame Sensor Assly Baffle Plate Washer Lock Nut Hex Burner Bracket Support Burner Bracket Burner Assembly Pilot Burner Assembly Part No 123814 123498 005655 005601 1017010 117013 090644 123580 25 Key A nm m Desc
8. Screw Socket Head 3 8 16 x 1 1 2 Lg Washer Lock 3 8 Nut Hexagon 1 2 13 Washer Lock 1 2 Nut Hexagon 3 8 16 Screw Hexagon Head 1 2 13 x 1 1 2 Housing Bearing Assembly Screw Set Socket 3 8 16 x 1 2 Fitting Grease Straight Bearing Ball Gear Worm 3 4 Bore Washer Shim 1 3 8 ID x 1 3 4 OD Screw Set Socket w Nylon insert Pin Roll 1 4 Dia x 1 1 4 Long Ring Internal Retaining 1 3 4 Shaft Gear 3 Bore Handle Crank 3 4 Bore Shaft Handwheel 3 4 Dia x 13 1 2 Spacer 3 Sch 40 x 3 4 Shim Trunnion Shim Trunnion Shim Trunnion Nameplate Groen Bracket Support Bracket Support Assy Gas Line Clamp Conduit 1 2 Nut Hexagon Keps 1 4 20 Bracket Support 1 8 x3 4 x8 3 4 Swivel Joint 1 2 NPT Label Warning See Following Pages for Assembly Parts 21 Part No 005097 005702 005705 005735 008214 008679 009762 009763 012100 009765 012026 012039 012060 012614 013483 013609 013617 013624 013625 088246 088247 088248 055450 065382 068132 006777 012940 068133 076680 093614 Key Description Label Warning Self Contained Kettles Valve Gas Manual Shut Off Label Warning AGA Water Column Assembly Fittings Sight Glass Assembly Guard Gas Rod Gauge Label Maximum and Minimum Tube Water Level Gauge Compound Pressure w dual Elbow F 90 Deg 1 2 NPT x 1 2 tube Nut Hex Cap Bushing Reducing 1 4 x 1 8 NPT Assembly Front Panel Light Indicator Amber 24 VAC Light
9. ceramic insulator for cracks Y That cable is not grounded out If it is correct the ground out condition or replace cable Y For proper gas pressure Y Clean pilot assembly or replace if necessary Y Tighten all mechanical and electrical connections Y If the pilot flame is weak increase pilot orifice size Y Replace ignition control module Y Main burner comes on but will not Auth Check burner ground for bad wire or connection Replace if necessary with high temperature wire Y Check for low gas supply pressure If necessary replace ignition control module Y OM DH Electrical Schematic ON OFF TOGGLE SWITCH ON OFF TOGGLE SWITCH FI FI 208 VOLT L ON GND SUPPLY TERMINAL BLOCK 240 VOLT L ON 9 END SUPPLY TERMINAL BLOCK HIGH LIMIT TILT SWITCH PRESSURE SWITCH RED RED 24 v LOW WATER CUT OFF P N 1 LOW WATER TO PILOT GAS SUPPLY i OR PILOT SPARK IGNITER P N 123580 THERMOSTAT BLK HEAT A M LN N LOW WATER RED POWER ON LOAD aa com I Sere TRANSFORMER 79 P N 106233 1 lea v COM Le NE IC Ad un gt 2 OND HINNNE RED SPARK IGNITION MODULE COMMON COMMON ON OFF TOGGLE SWITCH WHT GRN P N 085153 m FI M m rea L ON GND SUPPLY TERMINAL BLOCK P N 123581 REV 19 OM DH Parts List
10. gas heated steam source and appropriate controls mounted on a sturdy base The Model DH is available in 20 40 or 60 gallon capacities The body of the DH Kettle is constructed of stainless steel welded into one solid piece The kettle is furnished with a reinforced rim and a butterfly shaped pouring lip It has a steam jacket which is ASME shop inspected and registered with the national board for working pressures up to 50 PSI Kettle finish is 180 emery grit on the inside and bright high buff polish on the outside The kettle is tilted with a hand crank to pour out its contents Stainless steel panels enclose the controls and the base Four stainless steel tubular legs support the unit Bullet feet on each of the legs can be adjusted to level the kettle Standard DHT units include a two inch tangent draw off valve The self contained steam source is heated by propane or natural gas Ignition is electronic The kettle is charged at the factory with chemically pure water which contains rust inhibitors The steam source provides kettle temperatures of 150 to approximately 295 F 65 to 150 C Unit controls include a thermostat pressure gauge safety valve pressure limit control low water cut off power switch and gas regulator valve The gas supply shuts off automatically when the kettle is tilted The unit must be specified for use with natural or propane gas Service connections for gas and electricity are required Standar
11. 1995 27 FOODSERVICE EQUIPMENT SOLUTIONS c ANN UNIFIEDBRANDS emet 2 G GROEN 1055 Mendell Davis Drive OM DH Issued Jan 00 Jackson Mississippi 39272 Telephone 601 373 3903 Part Number 121050 Rev A FAX 601 373 9587
12. ANSFER TAKE SPECIAL CARE TO AVOID CONTACT WITH HOT KETTLE BODY OR HOT PRODUCT WHEN ADDING INGREDIENTS STIRRING OR TRANSFERRING PRODUCT TO ANOTHER CONTAINER WHEN TILTING KETTLE FOR PRODUCT TRANSFER 1 USE CONTAINER DEEP ENOUGH TO CONTAIN AND MINIMIZE SPLASHING 2 PLACE CONTAINER ON STABLE FLAT SURFACE AS CLOSE TO KETTLE AS POSSIBLE 3 DO NOT OVER FILL CONTAINER AVOID DIRECT SKIN CONTACT WITH HOT CONTAINER AND ITS CONTENTS KEEP FLOORS IN FRONT OF KETTLE WORK AREA CLEAN AND DRY IF SPILLS OCCUR CLEAN IMMEDIATELY TO AVOID SLIPS OR FALLS FAILURE TO CHECK SAFETY VALVE OPERATION PERIODICALLY COULD RESULT IN PERSONAL INJURY AND OR DAMAGE TO EQUIPMENT WHEN TESTING SAFETY VALVE AVOID ANY EXPOSURE TO THE STEAM BLOWING OUT OF THE SAFETY VALVE DIRECT CONTACT WITH STEAM COULD RESULT IN SEVERE BURNS TO AVOID INJURY READ AND FOLLOW ALL PRECAUTIONS STATED ON THE LABEL OF THE WATER TREATMENT COMPOUND 2 WARNING WARNING CAUTION CAUTION IMPORTANT OM DH BEFORE REPLACING ANY PARTS DISCONNECT THE UNIT FROM THE ELECTRIC POWER SUPPLY AND CLOSE THE MAIN GAS VALVE ALLOW FIVE MINUTES FOR UNBURNED GAS TO VENT KEEP WATER AND SOLUTIONS OUT OF CONTROLS AND ELECTRICAL EQUIPMENT NEVER SPRAY OR HOSE THE SUPPORT HOUSING OR ELECTRICAL CONNECTIONS MOST CLEANERS ARE HARMFUL TO THE SKIN EYES MUCOUS MEMBRANES AND CLOTHING PRECAUTIONS SHOULD BE TAKEN WEAR RUBBER GLOVES GOGGLES OR FACE SHIELD AND PROTECTIVE CLOTHING CAREF
13. Heat indicator light The kettle has the following safety features in addition to the 90 second ignition timer T Low water cutoff relay that will shut off gas supplies to all burners until the jacket water level is corrected High limit pressure switch set to open at about 46 PSI and to shut down the burners until jacket pressure is decreased Pop safety valve which will release steam if jacket pressure exceeds 50 PSI Tilt switch which shuts off all burners when the kettle is tilted Gas pressure regulator built into the gas control valve OM DH Maintenance NOTICE Contact Groen or an authorized Groen Service Agent when repairs are required 1 Periodic Maintenance A Maintenance amp Service Log is provided at the back of this manual with the warranty information Each time maintenance is performed on your Groen kettle enter the date on which the work was done what was done and who did it Keep this manual on file and available for operators to use Periodic inspection will minimize equipment down time and increase the efficiency of operation The following points should be checked kettle is cold If it does not see Jacket Vacuum on page 13 Also check the jacket water level every day It should be between the markers on the gauge glass If the level is low see Jacket Filing and Water Treatment on page 13 Test the safety valve at least twice each month With the kettle operating
14. IMPORTANT INFORMATION KEEP FOR OPERATOR IMPORTANT INFORMATION OPERATOR MANUAL OM DH Part Number 121050 Rev A DOMESTIC MODEL DH Steam Jacketed Kettle with Standard Electronic Ignition Self Contained Gas heated Floor mounted Tilting NSF Model DH 40 With Optional Counter balanced Cover THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE READ UNDERSTAND AND FOLLOW THE INSTRUCTIONS AND WARNINGS CONTAINED IN THIS MAN UAL CERTIFIED FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE POST IN A PROMINENT LOCATION INSTRUCTIONS TO BE FOLLOWED IN THE EVENT USER SMELLS GAS THIS INFORMATION SHALL BE OBTAINED BY CONSULTING YOUR LOCAL GAS SUP PLIER AS A MINIMUM TURN OFF THE GAS AND CALL YOUR GAS COMPANY AND YOUR AUTHORIZED SERVICE AGENT EVACUATE ALL PERSONNEL FROM THE AREA WARNING IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTE NANCE CAN CAUSE PROPERTY DAMAGE INJURY OR DEATH READ THE IN STALLATION OPERATING AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT Information contained in this document is known to be current and accurate at the time of printing creation Unified Brands recom p mendis referencing our product line websites MADE INUSA unifiedbrands net for the most updated product information and specifications OM DH IMPORTANT READ FIRST IMPORTANT
15. LECTRICAL CONNECTIONS WARNING ee ee WEAR EYE PROTECTION CAUTION MOST CLEANERS ARE HARMFUL TO THE SKIN EYES MUCOUS MEMBRANES AND CLOTHING PRECAUTIONS SHOULD BE TAKEN WEAR RUBBER GLOVES GOGGLES OR FACE SHIELD AND PROTECTIVE CLOTHING READ THE WARNINGS AND FOLLOW THE DIRECTIONS ON THE LABEL OF THE CLEANER CAREFULLY 3 Procedure a Clean food contact surfaces as soon as possible after use If the unit is in continuous use thoroughly clean and sanitize the interior and exterior at least once every 12 hours b Scrape and flush out food residues Be careful not to scratch the kettle with metal implements For DHT models only After flushing the kettle close the draw off valve Prepare a hot solution of the detergent cleaning compound as instructed by the supplier Clean the unit thoroughly A cloth moistened with cleaning solution can be used to clean controls housings and electrical conduits d Model DHT only Disassemble the tangent draw off valve Clean the draw off port and each valve part with a brush CAUTION DO NOT MIX PARTS OF DIFFERENT DRAW OFF VALVE ASSEMBLIES THE PARTS ARE NOT INTERCHANGEABLE e Hinse the kettle and draw off valve parts thoroughly with hot water then drain completely f When you reassemble the draw off valve When attaching the draw off valve just hand tighten the nut hand tighten the nut which holds it in place g
16. ND PLUMBING IMPROPER INSTALLATION CAN RESULT IN INJURY TO PERSONNEL AND OR DAMAGE EGUIPMENT 1 Installation on combustible floors is allowed Rear clearance of 10 inches and six inches at both sides is required for both combustible and non combustible construction 2 Installation under a vent hood is recommended Consult local codes 3 Setthe kettle in place and level it using a spirit level on the bar rim by turning the bullet feet to adjust leg length Allow clearance around the unit for cleaning maintenance and service 4 Complete the piping to the gas service main with v line or approved equivalent 5 For standard units provide 115 vac 60 Hz single phase 5 AMP electrical service The unit may also be ordered for alternate electric service of 208 VAC or 240 VAC Observe local codes and or The National Electrical Code in accordance with ANSI NFPA 70 current edition Use the wiring diagram inside the service panel and at the rear of this manual 6 Bring electrical service through the entrance at the rear of the support housing with a 1 2 inch conduit connector Make a watertight connection with the incoming lines DANGER ELECTRICALLY GROUND THE UNIT AT THE TERMINAL PROVIDED FAILURE TO GROUND UNIT COULD RESULT IN ELECTROCUTION AND DEATH 7 Electrically ground the unit at the terminal provided 8 After the kettle has been connected to the gas supply check all gas joints for leaks DO N
17. OT USE FLAME TO CHECK FOR LEAKS A thick soap solution or other suitable leak detector should be employed Confirm that the jacket water level is between the gauge glass markers If the level is low follow instructions under Jacket Filling and Water Treatment Page 13 10 The open end of the elbow on the outlet of the safety valve must face downward If it does not turn it to the correct position The open end of the pop safety valve elbow must face downward WARNING DO NOT CONNECT ANY PIPING TO THE POP SAFETY VALVE THE VALVE MUST BE FREE TO VENT STEAM AS NEEDED IMPROPER INSTALLATION WILL VOID THE WARRANTY THE ELBOW ATTACHED TO THE SAFETY VALVE MUST POINT TO THE FLOOR 11 The appliance and its individual shut off valve must be disconnected from the gas supply piping system during any testing at pressures in excess of 72 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 at or less than 12 PSI 3 45 kPa OM DH Now that the kettle has been installed you should test to ensure that it is operating correctly 1 Hemove literature and packing materials from inside and outside of the unit If the unit is equipped with a draw off valve product outlet clean out any material which might clog or damage the draw off Confirm that the tilting mechanism is operating properly by tilting
18. ULLY READ THE WARNINGS AND FOLLOW THE DIRECTIONS ON THE LABEL OF THE CLEANER TO BE USED USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY GROEN OR THEIR AUTHORIZED SERVICE AGENTS CAN CAUSE OPERATOR INJURY AND DAMAGE TO THE EQUIPMENT AND WILL VOID ALL WARRANTIES SERVICE PERFORMED BY OTHER THAN FACTORY AUTHORIZED PERSONNEL WILL VOID WARRANTIES OM DH Table of Contents IMPORTANT OPERATOR WARNINGS 2 EQUIPMENT DESCRIPTION udo chee hix chee Sex Sexe hex chee whe BEY 5 INSPECTION S UNPACKING douane t un he e 6 INSTALLATION saara 33 X ER GR XR GR CR GR oA 7 OPERATION fiue eon ts 9 SEQUENCE OF OPERATION 11 MIAINENANGE HERE nn Eo ad ee e Ro re oon en pere d 12 GEEN Cu 15 TROUBLESHOOTING oaase vasevaaesase 97 8 ver 17 PARTS au wate n Vx xen Ru ee SOR OP 19 DIAGRAMS 8 5 5 21 MAINTENANCE EO 5 5325 auus e na NU RON M CRI A tun De 22 REFERENGES Ed E RERO EORR Ope Or DEG ti ti 23 V UREN IG a acer ata ac an d de d eam ey ears cs YE 24 OM DH Equipment Description The Groen DH is a floor mounted tilting steam jacketed kettle with a thermostatically controlled self contained
19. ard water or food residues clean the kettle thoroughly and then use a deliming agent like Groen Delimer Descaler Part Number 114800 or Lime Away from Ecolab in accordance with the manufacturer s directions Rinse and drain the unit before further use m If cleaning problems persist contact your cleaning product representative for assistance The supplier has a trained technical staff with laboratory facilities to Serve you OM DH Troubleshooting Your Groen kettle is designed to operate smoothly and efficiently if properly maintained However the following is a list of checks to make in the event of a problem Wiring diagrams are furnished inside the service panel and in this manual If an item on the list is followed by Y the work should be done by a qualified service representative WARNING BEFORE REPLACING ANY PARTS DISCONNECT THE UNIT FROM THE ELECTRIC POWER SUPPLY AND CLOSE THE MAIN GAS VALVE ALLOW FIVE MINUTES FOR UNBURNED GAS TO VENT CAUTION USEING REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY GROEN OR THEIR AUTHORIZED DISTRIBUTOR CAN CAUSE OPERATOR INJURY AND EQUIPMENT DAMAGE AND WILL VOID ALL WARRANTIES SYMPTOM WHO WHAT TO CHECK Y indicates items which must be performed by an authorized technician Kettle is hard to tilt User fa Gears for foreign materials and lubrication Auth b Gears for alignment Y Service Worm gears or broken gears Y Rep Only Kettle continues heating after it User fa Thermo
20. at five psi 105 kPa pull the test lever and let it snap back to its closed position If there is little discharge mostly air and the pressure gauge drops back to zero PSI allow the pressure to build back to five PSI and repeat the procedure Tip Using a screwdriver or other implement to pull the ring will help you avoid contact with the steam d Ifthe valve does not activate or there is no evidence of discharge or the valve leaks stop using the kettle and contact a qualified Groen service representative WARNING gt PRESSURE CONTACT 52 WARNING WHEN TESTING AVOID ANY EXPOSURE TO THE STEAM BLOWING OUT OF THE SAFETY VALVE DIRECT CONTACT COULD RESULT IN SEVERE BURNS e Keep the primary burner gas jet air inlets free of dust and lint PROPER f The pilot flame should be blue It should WATER envelop about 1 2 inch 12 mm of the flame LEVEL sensor tip g The gear housing has fittings for lubrication of moving parts The gears do not run in oil so periodic lubrication with grease is necessary h Frequency of lubrication depends on operating conditions but it should be done at least once every six months The pressure gauge should show a vacuum of i Use a 2 grade LGI lithium grease to add 20 to 30 inches of mercury Hg and the water grease through Zerk fittings on gear housing level should be between the markers when the until it flows out of the bearings around th
21. d and in good condition If cracked or brittle replace Y d Pilot electric ceramic for crack or break Y e Pilot spark gap Regap Y afety Valve pops open OM DH SYMPTOM WHO WHAT TO CHECK Y indicates items which must be performed by an authorized technician park is present but the pilot will That the pilot valve is securely connected to terminals Y not light For 24 VAC at terminals PV PV MV If 24V is not present replace the ignition control module Y That gas pressure is at least 3 5 W C 8 7818 b Y For gas at the pilot If it is not flowing 1 Check the pilot gas line for kinks and obstructions Y 2 Clean orifice if necessary Y 3 Check magnetic operator for pilot valve on gas valve Repair or replace as necessary Y That the pilot spark gap is located in the pilot gas stream If not adjust or replace the pilot burner Y For drafts Shield the pilot burner if necessary Y For 24 V between terminals PV and PV MV If 24V is not present replace the ignition control module Y That gas pressure is at least 3 5 W C 8 7818 b Y Electrical connections of the main valve to terminals to assure that they are securely attached Check magnetic operator for pilot valve on gas valve Repair or replace as necessary Y Pilot lights but main burner will Check for bad burner ground If necessary repair with high temperature not come on the spark stays on wire Y Pilot burner
22. d into the jacket Quickly close the However it is best to check the pH each valve to prevent air from entering time treated water is prepared d Check water level in the jacket to ensure 5 Component Replacement that it is between minimum and maximum marks on glass j WARNING e Close the valve and reinstall the square BEFORE REPLACING ANY PARTS head pipe plug Reestablish the jacket vacuum as described in Paragraph 2 above if the pressure gauge does not show a negative reading of 20 to 30 inches mercury Hg 4 Water Treatment Procedure a PRECAUTIONS ON THE LABEL Obtain water treatment compound and a pH test kit from your Groen Service Agent WARNING TO AVOID INJURY READ AND FOLLOW ALL OF THE WATER TREATMENT COMPOUND b Fil a mixing container with the measured amount of water required See table Distilled water is recommended Kettle Model Approximate Jacket Capacity DISCONNECT THE UNIT FROM THE ELECTRIC POWER SUPPLY AND CLOSE THE MAIN GAS VALVE ALLOW FIVE MINUTES FOR UNBURNED GAS TO VENT When component replacement involves breaking a gas pipe connection check the new connection with soap solution or an appropriate leak detector DO NOT USE A FLAME TO TEST FOR LEAKS Internal wiring is marked as shown on the circuit schematic drawings inside control housing and in this manual Be sure that new components are wired in the same manner as old components An examination of the c
23. d power supply is 115 Volt Alternate voltages 208V or 240V are available DH 20 DHT 20 DHA 40 DHT t 40 DH 60 DHT 60 20 gal 20 gal 40 gal 40 gal 60 gal 60 gal Capacity 75 itr 75 Itr 150 Itr 150 Itr 225 Itr 225 Itr 5 gal 5 gal 6 gal 6 gal 14 gal 14 gal 19 Itr 19 Itr 2234 Itr 2234 Itr 53 Itr 53 Itr Kettle Body 20 in 20 in 26 in 26 in 30 in 30 in Jacket Capacity Diameter 508 mm 508 mm 660 mcm 660 mm 762 mm 762 mm 35 in 35 in 47 in 47 in 47 in 47 in 889 mm 889 mm 1194 mm 1194 mm 1194 mm 1194 mm Base Front to 29 29 29 29 29 29 Back 736 mm 736 mm 736 mm 7 36 mm 736 mm 736 mm auc Rate 72 BTU 72 000 BTU 100 000 BTU 100 000 BTU 150 000 BTU 150 000 BTU Ene Imo 44 140 BTU 44 140 BTU 65 000 BTU 65 000 BTU 93 000 BTU 93 000 BTU Product per hr Options available with listed models are Base Width 1 Two inch tangent drawoff 5 Basket Inserts Tri BC 2 Strainers solid disk 1 4 or C inch holes 6 Water fill faucets with swing spout 3 No 31 lift off cover 7 Kettle Brush Kit 4 No 51 counterbalanced cover w actuator 8 Stainless steel liner Factory installed options OM DH Inspection amp Unpacking The unit will arrive in a heavy shipping carton and will be bolted or banded to a skid Immediately upon receipt inspect the carton carefully for exterior damage
24. e kettle is cold trunnion shaft a Check the pressure vacuum gauge every i Place liberal amounts of grease on the gear day The gauge should show a vacuum of to cover the arc that is in contact with the 20 to 30 inches mercury Hg when the worm gear 12 ZERK FITTINGS A Add grease through Zerk Fittings j Keep electrical wiring and connections in good condition Keep the inside of the control console clean and dry l Keep burner slots clean 2 Jacket Vacuum Removing Air from Jacket When the kettle is cold a positive pressure reading on the pressure vacuum gauge or a reading near zero indicates that there is air in the jacket Air in the jacket acts as an insulator and slows kettle heating To remove air A v f Liberally grease the wheel where it contacts the worm gear OM DH a Start the unit Be sure there is water or product in the kettle when heating b When the pressure vacuum gauge reaches a positive pressure reading of five PSI release the trapped air and steam by pulling up the safety valve ring for about five seconds Repeat this step three or four times Then let the pull ring snap back into the closed position c is little discharge mostly air and the pressure gauge drops back to zero PSI allow the pressure to build back to five PSI and repeat the procedure d Once steam has been vented from the jacket as described in b above remove the
25. ining hot water draining from product Sequence of Operation The following action reaction outline is provided to help understand how the DH kettle works 1 When the power switch is turned on it starts the spark igniter and opens the automatic valve for the pilot burner The spark ignites a pilot flame which heats the sensor The sensor then sends a signal to turn off the spark The flame thereafter acts as a standing pilot until the power is turned off If the pilot flame is not sensed within 90 seconds after spark begins a timer shuts down the entire operation To attempt a second trial for ignition turn off the power switch Check the gas supply valves and wait five minutes before trying again by switching power on If you cannot establish a pilot flame in four tries close all valves turn off the power and contact an authorized Groen service Agency When the operator sets a temperature on the thermostat it causes the automatic valve to OM DH admit gas to the main burner where it is ignited by the pilot flame When the kettle reaches the set temperature the thermostat switch opens This stops the signal to the gas control valve and shuts off gas to the main burner The pilot flame remains lit When the kettle cools below the set temperature the thermostat switch closes and starts another cycle On and off cycling continues and maintains the kettle at the desired temperature This action is indicated by the
26. ircuit schematic shows that the safety components are wired in series In most cases a faulty component may be isolated with a jumper wire to verify that the component is faulty If this determination is made contact a certified Groen Service Agency for assistance DH 20 DHT 20 212 Gallons DH 1 40 DHT 1 40 31 2 Gallons DH 60 DHT 60 4 Gallons c Hang a strip of pH test paper on the rim of the container with about 1 inch of the strip below the surface of the water d Measure the water treatment compound One way to do this is to add the compound from a measuring cup e Stir the water continuously while you slowly add treatment compound until the water has a pH between 10 5 and 11 5 Judge the pH by frequently comparing the test strip color with the color chart provided in the test kit f you add water to the jacket check water level to ensure that it is between minimum OM DH Cleaning 1 Suggested Cleaning Supplies a Cleaner such as Klenzade HC 10 or HC 32 from ECOLAB Inc b Kettle brushes in good condition c Sanitizer such as Klenzade XY 12 d Film remover such as Klenzade LC 30 2 Precautions Before cleaning shut off the kettle by turning the thermostat dial to OFF and shut off all electric power to the unit at a remote switch such as the circuit breaker WARNING KEEP WATER AND SOLUTIONS AWAY FROM CONTROLS AND ELECTRICAL EQUIPMENT NEVER SPRAY THE SUPPORT HOUSING OR E
27. mm This includes rice and small pasta shapes a Allow for displacement of the three baskets and product This may mean only half filling the kettle Test baskets and product displacement with the kettle OFF and with cold water in the kettle CAUTION DO NOT OVERFILL THE KETTLE WHEN COOKING HOLDING OR CLEANING KEEP LIQUIDS AT LEAST 2 3 5 8 cm BELOW THE KETTLE RIM TO ALLOW CLEARANCE FOR STIRRING BOILING AND SAFE PRODUCT TRANSFER WARNING AVOID ALL DIRECT CONTACT WITH HOT FOOD OR WATER IN THE KETTLE DIRECT CONTACT COULD RESULT IN SEVERE BURNS b Load baskets on a level stable work surface c Lift loaded baskets with both hands Get help from another person if the basket is too heavy for safe handling d Slowly lower product into kettle and securely hook basket to the Y frame e When removing baskets with cooked product lift straight up ensuring basket bottoms clear the kettle rim and pouring lip Wear protective oven mitts and protective apron f Allow hot water to fully drain from product before moving basket away from the kettle Do not rest baskets on kettle rim or pouring lip If baskets are too heavy for individual to lift and safely move get help Remove product immediately from basket into another container being sure to avoid contact with hot product and hot basket or g Place baskets with food on a stable flat surface inside a solid steamer or bake pan to catch any rema
28. n you stop cranking To return the kettle body to its upright position turn the crank clockwise b Product may also be transferred by means of the optional draw off valve if the kettle is so equipped To Shut Down Kettle a Turn thermostat dial to OFF b Turn toggle switch to OFF For a prolonged shut down a Follow the procedure above b Turn the manual gas valve off handle at right angles to gas line c Disconnect electric power from the unit WARNING WHEN TILTING KETTLE 1 2 3 4 5 3 WEAR PROTECTIVE OVEN MITT AND PROTECTIVE APRON USE DEEP CONTAINER TO CONTAIN AND MINIMIZE PRODUCT SPLASHING PLACE CONTAINER ON STABLE FLAT SURFACE AS CLOSE TO KETTLE AS POSSIBLE STAND TO RIGHT OF KETTLE WHILE POURING NOT DIRECTLY IN POUR PATH OF HOT CONTENTS POUR SLOWLY MAINTAINING CONTROL OF KETTLE AND RETURN KETTLE BODY TO UPRIGHT POSITION AFTER CONTAINER 15 FILLED OR TRANSFER IS COMPLETE DO NOT OVERFILL CONTAINER AVOID SKIN CONTACT WITH HOT CONTAINER AND ITS CONTENTS If power fails Do not attempt to operate the unit until electric power is restored b When power comes back on follow directions To Start Kettle above C Use of Common Accessories 1 Lift Off or Counterbalanced Cover As with stock pot cooking an optional cover can speed up the heating of water and food products It helps retain heat and reduces the heat and humidity in the kitchen A cove
29. od As to warranty service in the territory described above Groen will absorb labor and portal to portal transportation costs time amp mileage for the first twelve 12 months from date of installation or fifteen 15 months from date of shipment from Groen This warranty does not cover boiler maintenance calibration periodic adjustments as specified in operating instructions or manuals and consumable parts such as scraper blades gaskets packing etc or labor costs incurred for removal of adjacent equipment or objects to gain access to Groen Equipment This warranty does not cover defects caused by improper installation abuse careless operation or improper maintenance of equipment This warranty does not cover damage caused by poor water quality or improper boiler maintenance THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE EACH OF WHICH IS HEREBY EXPRESSLY DISCLAIMED THE REMEDIES DESCRIBED ABOVE ARE EXCLUSIVE AND IN NO EVENT SHALL GROEN BE LIABLE FOR SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGES FOR THE BREACH OR DELAY IN PERFORMANCE OF THIS WARRANTY Groen Equipment is for commercial use only If sold as a component of another O E M manufacturer s equipment or if used as a consumer product such Equipment is sold AS IS and without any warranty Covers All Foodservice Equipment Ordered After October 1
30. ows that the unit is turned on b Heat Indicator indicates that main gas is on to produce steam in the kettle jacket c Low Water indicator shows that jacket water is low Unit gas pressure regulator adjustment located behind the access door in the kettle skirt Operating Procedure To Start Kettle a EVERY DAY make sure that the jacket water level is between the markers on the gauge glass If the level is too low see Jacket Filling and Water Treatment on page 13 b Check the pressure gauge If the gauge does not show 20 to 30 inches of mercury Hg vacuum that is a reading of 20 to 30 below 0 atmospheric pressure see Jacket Vacuum on page 13 c Do notattempt to light any burner with a flame Turn the manual gas valve ON align handle with gas line 1 Turn toggle on off switch ON The electronic ignition will attempt to light the pilot for 90 seconds or until it is lit Once lit proceed to step two 2 Turn thermostat to desired setting The main gas burner will ignite and will cycle LOW WATER INDICATOR LIGHT 7 ON OFF TOGGLE SWITCH to maintain the set temperature The heat indicator light will come on 3 Ifthe unit does not light turn it off and wait five minutes Then follow the instructions again To Empty Kettle a Totilt the body of the kettle forward turn the hand crank on the front of the cabinet counter clockwise The body will stay in the position it holds whe
31. r can reduce some product cook times and help maintain the temperature color and texture of products held or simmered for longer periods Be sure the handle is secure on the lift off cover before using ALWAYS use the handle to place or remove cover from the kettle Wear protective oven mitts and apron When putting a lift off cover on the kettle position it on top of kettle rim with its flat edge facing the pouring lip WARNING AVOID ALL DIRECT CONTACT WITH HOT SURFACES AND HOT FOOD OR WATER IN THE KETTLE DIRECT CONTACT COULD RESULT IN SEVERE BURNS When removing a lift off cover a Firmly grasp the handle and lift the rear edge farthest from operator 1 2 3 5 cm to allow steam and water vapor to escape Wait 2 3 seconds b Tilt cover to 45 60 angle to allow any hot condensate or product to roll off cover back into kettle c Remove cover ensuring that remaining hot condensate or product does not drip on operator floor or work surfaces d Place cover on safe flat sanitary out of the way surface or return to kettle CAUTION DO NOT TILT KETTLE WITH LIFT OFF COVER IN PLACE COVER MAY SLIDE OFF CAUSING INJURY TO OPERATOR 2 Basket Insert An optional kettle basket insert set Tri BC will assist in cooking water boiled products including eggs potatoes vegetables shell fish pasta and rice The nylon mesh liner must be used for products smaller than the basket mesh size approx 4 6
32. ription Flue Stack Assembly Flue Top Section of Top Plate Flue Bottom Section of Top Plate Flue Front Section Flue Main Body Screw Truss Head OM DH Part No 117034 117029 117033 117032 117031 072189 OM DH Service Log Model No Purchased From Serial No Location Date Purchased Date Installed Purchase Order No For Service Call Service Performed Performed By 26 Limited Warranty To Commercial Purchasers Domestic U S Hawaii amp Canadian Sales Only Groen Foodservice Equipment Groen Equipment has been skillfully manufactured carefully inspected and packaged to meet rigid standards of excellence Groen warrants its Equipment to be free from defects in material and workmanship for 12 twelve months with the following conditions and subject to the following limitations VI This parts and labor warranty is limited to Groen Equipment sold to the original commercial purchaser users but not original equipment manufacturers at its original place of installation in the continental United States Hawaii and Canada Damage during shipment is to be reported to the carrier is not covered under this warranty and is the sole responsibility of purchaser user Groen or an authorized service representative will repair or replace at Groen s sole election any Groen Equipment including but not limited to drawoff valves safety valves gas and electric components found to be defective during the warranty peri
33. stat dial setting reaches desired temperature b Thermostat calibration Y c Thermostat operation The thermostat should click when the dial is rotated to settings above and below the temperature of the kettle Y Kettle stops heating before it User fa Thermostat dial setting reaches the desired temperature Auth b Thermostat calibration Y Service Thermostat operation The thermostat should click when the dial is Hep Only rotated to settings above and below the temperature of the kettle Y a For air in the jacket See Jacket Vacuum in the Maintenance section b Thermostat dial setting c For defective thermostat The thermostat should click when the dial is rotated to settings above and below the temperature of the kettle If defective replace Y d For defective safety valve If the valve pops at pressures below 49 PSI replace Y Burners will not light a hat the main gas supply valve is open handle is in line with gas pipe b Gas supply to the building c hat the kettle body is not tilted d Thermostat operation The thermostat should click when the dial is rotated to settings above and below the temperature of the kettle Y That tilt limit switch is closed when body is not tilted Y a Thermostat and close the contacts if they are open Y b AC voltage between terminals on secondary side of transformer If it is not 24 Volt replace the transformer Y c That the high tension cable is firmly attache
34. the kettle through its full range Then return the kettle to the upright position Turn on the electrical service to the unit Pour 1 2 quarts of water into the kettle Following To Start Kettle instructions in the Operation section Page 9 begin heating the water at the highest thermostat setting The heat indicator light should come on and heating should continue until the water boils If the unit functions as described it is ready for use If it does not function as described contact your local Groen Certified Service Agency For units with optional tangent draw off Assemble the tangent draw off by placing the large nut over the draw off valve and inserting it into the draw off tube ONLY HAND TIGHTEN THE NUT to complete installation When attaching the draw off valve hand tighten the nut Each day confirm the jacket water level by checking the water gauge OM DH Operation A Controls HEAT POWER ON Operator controls for the DH kettle are INDICATOR INDICATOR LIGHT LIGHT 1 Manual gas valve on gas line behind the unit which controls the supply of gas from the main to the unit On Off Toggle Switch This controls the supply of electric power to the control circuits Thermostat dial which turns the thermostat on or off and sets the kettle temperature Tilting crank used to tilt the kettle body Indicator Lights to alert operator of unit conditions a Power On Indicator sh
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