SERVICE MANUAL
Contents
1. mE ree Edad WATER LEVEL CONTROL WLC LLCO 0 III rn SEQUENGE OF OPERATION 2 bua e pisei seul era re SCHEMATIC DIAGRAM 4 i etc edu nd s eame tesi ND Er excu nd d a teda Bode WIRING DIAGRAMS ias Mte EDUC RA PARI EL t e cata TROUBLESHOOTING eet edo eee ee e e tet cer hee he eee been TROUBLESHOOTING 53 eto esi Duet eu te d ee rt n pee a Ede talea det A VULCAN 2012 F45472 1112 Page 2 of 29 Electric Stationary and Tilting Kettles General General INTRODUCTION General The procedures in this manual apply to all models unless otherwise specified The pictures and illustrations are of a model KAOELT kettle unless otherwise noted All information and specifications contained in this manual are based on the latest product information available at the time of printing Stationary and Tilting Kettles The electric stationary and tilting kettles are self contained two thirds jacketed kettles The lower two thirds of the kettle bowl is a double wall stainless steel construction that provides a reservoir for a solution of heat transfer fluid and distilled water for improved heating of the kettle contents The kettles are used to prepare a variety of liquid or semi liquid food products such as soups stews and sauces MODELS COVERED K20ELT Tilting Kettle 20 Gallon K40ELT Tilting Kettle 40 Gallon K60ELT Tilting Kettle 60 Gallon P2. TERMINAL POTENTIOMETER BLOCK MAIN SWITCH GEARBOX WATER LEVEL CONTROL 5 24271 HEATING A ELEMENT st STATIONARY AND TILTING KETTLE BOTTOM COMPONENTS level in the kettle reservoir jacket drops below the WATER LEVEL CONTROL WLC WLC LLCO probe A single low level cut off probe LLCO LLCO is connected to the control 5 The water level control has input voltage of 120VAC The water level control provides low level cut off across terminals L1 and L2 which powers the primary protection to shut off the heat source in case the fluid side of the transformer the board One side of the F45472 1112 22 of 29 Electric Stationary and Tilting Kettles ELECTRICAL OPERATION transformer secondary is powered through a series path to chassis ground The other side of the transformer secondary 12VAC is connected to the LLCO coil and the LLCO LED The grounded potential is carried through the water in the reservoir jacket to the LLCO probe When the kettle is in the full upright position and the reservoir jacket fluid is at the proper level the fluid is in constant contact with the LLCO probe and the circuit is completed When the power switch is turned ON power is supplied to the water level control With the kettle in the full upright position and the fluid level in the reservoir jacket in contact with the LLCO probe the LLCO relay coil is energized The LLCO relay conta
3. 4 positive stop traveller on the positive stop shaft threaded until it contacts the stop plate Page 19 of 29 5 Adjust position of positive stop traveller as needed to align the shoulder screw mounting hole to the threaded hole in stop plate Install shoulder screw 6 Turn crank handle to verify operation Repeat adjustment as necessary 7 Install tilt switch bracket Install control panel cover F45472 1112 Electric Stationary and Tilting Kettles ELECTRICAL OPERATION Water Level Control WLC LLCO Probe Water Level LECO sess Contactor 1CON Limiting Contactor 2CON Regulating Element Heating Fuse 1FU amp 2FU Switch 1PAS Pressure Transformer 1T Main Switch 1S Power Temperature Controller Lamp 1LT Power Lamp 2LT Low Water F45472 1112 ELECTRICAL OPERATION COMPONENT FUNCTION Low water level control Monitors condition of the WLC LLCO water level probe Protects kettle from a low water condition in the reservoir jacket and removes power from heating circuit when kettle is tilted Low Level Cut Off LLCO probe connected to WLC LLCO Controls power to heating circuit Connects one side of heating element to power Energized whenever WLC LLCO coil is energized WLC LLCO contacts closed Connects heating element to power On constantly when temperature control
4. A WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures 1 Open pressure relief valve until reservoir jacket is completely vented 2 Remove BOTTOM COVER 3 Disconnect lead wires from the water level probe Fig 16 4 Place a large container under kettle to catch liquid that drains from kettle NOTE If liquid drained from kettle is still clean save for reuse 5 Remove component from bottom of kettle 6 Reverse procedure to install NOTE Clean threads and apply pipe thread sealant when replacing water level probe 7T Refill jacket with fluid See FILLING THE RESERVOIR JACKET 8 Remove air from reservoir jacket as outlined under VENTING F45472 1112 Electric Stationary and Tilting Kettles REMOVAL AND REPLACEMENT OF PARTS 9 Check for proper operation TEMPERATURE SENSOR x A WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures 1 Open pressure relief valve until reservoir jacket is completely vented 2 Remove BOTTOM COVER 3 Place a large container under the kettle to catch liquid that drains from kettle NOTE If liquid drained from kettle is still clean save for reuse 4 Remove component from bottom of kettle REMOVE TEMPERATURE SENSOR Fig 17 5 Reverse procedure to install NOTE Clean threads and apply pipe thread sealant when replacing temperature sensor
5. 1112 Electric Stationary and Tilting Kettles ELECTRICAL OPERATION TO CONTROL 5 PHASE DELTA 480V TRANSFORMER 11 S9NILINI T LA 1 1 L NOL 11 1 LOVLNOO 9NILIV 10933 T OLE 1 PRIMARY TAPS CONTROL TRANSFORMER MUST BE CONNECTED ACCORDING TO THE APPLIANCE DATA PLATE VOLTAGE MARKING AND ACTUAL CONNECT SUPPLY 1CON L1 T1 2CON T2 12 X RUD Y ANS T 2CON T1 L1 N 1CON L2 T2 1CON L3 T3 ES 2 2CON T3 L3 DERIVED FROM V 00 857449 2 Models K20EL K20ELT K40EL K40ELT K60EL K60ELT 3434 Fig 41 F45472 1112 28 of 29 Electric Stationary and Tilting Kettles TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING SYMPTOM POSSIBLE CAUSES Kettle does not heat power light is lit heat light is lit low water light is not lit Kettle does not heat power light is lit low water light is lit heat light is not lit Kettle does not heat power light is lit low water light is not lit heat light is not lit Kettle does not heat power light is not lit Kettle heats up slow or will not boil product 8877209 oo p or ome Limiting contactor 1CON malfunction Regulating contactor 2CON malfunction Heating element malfunction Fluid level in reservoir jacket belo
6. 6 Refill jacket with fluid See FILLING THE RESERVOIR JACKET 7 Remove air from reservoir jacket as outlined under VENTING 8 Check for proper operation F45472 1112 PRESSURE SWITCH S A WARNING Disconnect the SS electrical power to the machine and follow lockout tagout procedures 1 Open pressure relief valve until reservoir jacket is completely vented 2 Remove BOTTOM COVER Disconnect lead wires from the pressure switch 4 Place large container under the kettle to catch liquid that drains from kettle NOTE If liquid drained from kettle is still clean save for reuse 5 Disconnect compression fitting from elbow near the pressure switch 6 Remove top nut on brass fitting to remove pressure switch from mounting bracket 7 Remove component from bottom of kettle REMOVE WIRING REMOVE TUBING Fig 18 8 Reverse procedure to install NOTE Pressure switch setting is fixed and should not be adjusted Clean threads and apply pipe thread sealant when replacing pressure switch 9 Refill jacket with fluid See FILLING THE RESERVOIR JACKET Page 10 of 29 Electric Stationary and Tilting Kettles REMOVAL AND REPLACEMENT OF PARTS 10 Remove air from reservoir jacket as outlined under VENTING 11 Check for proper operation POTENTIOMETER A WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures 1 Remove CONTROL BOX COVE
7. low water light will come on when kettle is tilted tilt models only NOTICE When filling reservoir jacket use only distilled water and heat transfer fluid The ratio is 7596 distilled water and the 25 heat transfer fluid Partial Refill 1 Place kettle in full upright position tilt kettle only 2 Turn power switch on If low water light is on continue with procedure Set temperature dial to lowest setting 4 Open pressure relief valve until reservoir jacket is completely vented 5 Remove 1 2 pipe plug from the reservoir jacket fill elbow at back of kettle Open fill valve 40 and 60 gallon kettles only 1 2 PIPE PLUG FILL VALVE K40EL K40ELT and K60EL K60ELT Page 16 of 29 Electric Stationary and Tilting Kettles SERVICE PROCEDURES AND ADJUSTMENTS 1 2 PIPE PLUG K20ELT K20ELT A Insert funnel into the opening and slowly add a mixture of water and heat transfer fluid until low water light turns off LLCO probe is satisfied B Set the thermostat and power switch to OFF position C Continue adding a mixture of water and heat transfer fluid to bring fluid to the proper operating level per the amount listed in table below Add Fluid for Proper Operating Level Qt K60EL KGOELT 3 125 Clean pipe plug threads and apply thread sealant Install pipe plug and tighten to prevent leaks Close fill valve 40 and 60 gallon kettles only 7 Turn power switch on and verify low w
8. ED ACCORDING TO THE DATA PLATE VOLTAGE AND THE ACTUAL VOLTAGE SUPPLY FUSE 2FU MAIN TRANSFORMER 1 COM 208V 240V 480V get posses gees POWER 111 LIMITING CONTACTOR 1CON TEMPERATURE CONTROLLER T4 YELLOW OUTPUT REGULAT ING CONTACTOR 2CON DERIVED FROM 857447 1 MODELS K20EL K2OELT KAOEL KAOELT KGOEL K6OELT Fig 38 Page 25 of29 F45472 1112 Electric Stationary and Tilting Kettles ELECTRICAL OPERATION WIRING DIAGRAMS TO MAIN 208 240V 5 PHASE TRANSFORMERf REGULAT ING 208 240V 1 PHASE TO MAIN TRANSFORMER LIMITING CONTACTOR DERIVED FROM 857448 1 REGULAT ING CONTACTOR 2CON MAIN TRANSFORMER PRIMARY MUST BE CONNECTED ACCORDING TO THE KETTLE DATA PLATE VOLTAGE AND THE ACTUAL VOLTAGE SUPPLY MODELS K20EL K20ELT KAOEL KAOELT K60EL K60ELT Fig 39 F45472 1112 26 of 29 Electric Stationary and Tilting Kettles ELECTRICAL OPERATION TO MAIN 480V 3 PHASE TRANSFORMER REGULAT ING CONTACTOR N 2CON MAIN TRANSFORMER PRIMARY MUST BE CONNECTED ACCORDING TO THE KETTLE DATA PLATE VOLTAGE AND THE ACTUAL VOLTAGE SUPPLY WIRING DIAGRAM 3 PH WYE Y PR LIM CON L1 CON L2 cw mu REG CON L2 CON L3 REG CON L1 LIM CON L3 857449 1 MODELS K20EL K20ELT KAOEL KAOELT KGOEL KG6OELT Fig 40 DERIVED FROM Page 27 of 29 45472
9. ND ADJUSTMENTS A WARNING 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 B If heat light does not remain on or flashes TEMPERATURE CONTROLLER momentarily as temperature setting is TEST slowly increased verify condition of potentiometer as outlined under POTENTIOMETER TEST NOTE Temperature controller will de energize internal relay and turn off the output status LED if the fees 17 T8 circuitry detects an open thermocouple LED will begin ee te O reddi to flash times pause then repeat the flash sequence J1 peep so CONNECTOR LED to indicate the open thermocouple condition nen C If heat light and heating element do not turn on JUMPER J1 INSTALLED 1 Verify condition of thermocouple as 120VAG outlined under THERMOCOUPLE T2 T3 T4 TEST 2 Verify output from terminal T8 on controller as outlined in the steps below EN 120VAC 9 Disconnect lead wire from terminal T7 on the L1 L2 controller HOT NEUTRAL A Verify 120VAC between lead wire from T7 Fig 2 8 25 and X1 on the output of main transformer If 1 Place kettle in full upright position tilt kettles correct re connect lead wire to terminal T7 only and continue wi
10. R 2 Disconnect potentiometer wire from temperature control 3 Pull temperature dial from potentiometer shaft and remove seal nut Fig 19 Remove potentiometer from control panel Reverse procedure to install and check for proper operation NOTE When installing ensure potentiometer alignment tab is seated in positioning bracket Page 11 of 29 POTENTIOMETER ALIGNMENT POSITIONING BRACKET 20777 Fig 20 SWITCH ASSEMBLY A WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures 1 Remove CONTROL BOX COVER 2 Note lead wire location and disconnect wires from switch Press down on tabs to free switch from housing 3 E 7 f PRESS TABS PRESS TABS Fig 21 4 Reverse procedure to install F45472 1112 Electric Stationary and Tilting Kettles REMOVAL AND REPLACEMENT OF PARTS GEARBOX TILT MODELS ONLY WARNING Disconnect the A electrical power to the machine and SS AS follow lockout tagout procedures 1 Place a pallet jack under the kettle of the unit NOTE Place pallet jack under kettle and not under the tubular frame NOTE Place 2x4 or 4x4s on the pallet jack if needed to reach the bottom of the kettle 2 Remove CONTROL BOX COVER 3 Note location of wiring and remove element pressure switch wires and unplug the sensor plug 1124245 Fig 22 4 Remove the four bolts holding
11. RVICE PROCEDURES AND ADJUSTMENTS PRESSURE PRESSURE GUAGE RELIEF VALVE Fig 28 1 With the kettle at room temperature verify pressure gauge is in the vacuum zone and reading 25 to 30 in Hg A If vacuum is below minimum listed air must be removed from reservoir jacket Continue with procedure to vent as necessary 2 Place kettle in full upright position 3 Turn power switch on 4 Set temperature dial to highest setting Allow kettle to heat until the heat indicator light turns off 5 Open pressure relief valve for approximately 10 seconds 6 Turn power switch off and allow kettle to cool room temperature 7 Merify pressure gauge reading is within the correct vacuum range A _ If reading is below minimum listed or will not maintain proper vacuum check all threaded fittings extending from the kettle couplings right and rear for leaks and tightness 1 Check pressure relief valve for leaks from poor valve seating or built up debris Manually operate the valve several times to reseat Repeat venting procedure 2 If pressure relief valve is malfunctioning install a replacement and check for proper operation F45472 1112 FILLING THE RESERVOIR JACKET NOTE The reservoir water level must be maintained high enough to submerge the heating element If low water light comes on during use the level may be below water level probe LLCO and must be replenished before heating can continue The
12. SERVICE MANUAL Electric Stationary and Tilting Kettles K20EL ML 136073 K40EL ML 136074 K60EL ML 136075 K20ELT ML 136077 K40ELT ML 136078 K60ELT ML 136079 K40EL NOTICE 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 3600 North Point Blvd Baltimore MD 21222 F45472 1112 Electric Stationary and Tilting Kettles TABLE OF CONTENTS General 532 9 SEI Bienen bu bete tetti TE iue a NE dte Ni INTRODUCTION M ine erectos Gila wad ed oretenus tetur e eee eats ade dene GENERAL ie
13. acts close 1 Limiting contactor 1 CON energized power to one side of heating elements 2 Power to temperature controller Set the temperature dial to call for heat warm simmer boil A 120VAC output from T8 on temperature controller 1 Heatlight 3LT amber comes on 2 Regulating contactor 2CON energized and heating elements are powered Kettle reaches set point temperature A Voltage output removed from T8 on temperature controller 1 Heatlight 3LT amber goes out Page 24 of 29 2 Regulating contactor 2CON de energized and powered is removed from heating elements Kettle heat cycles with the temperature controller Kettle tilted to empty contents A WLCLLCO probe no longer satisfied fluid in kettle reservoir jacket not in contact with probe Water level control WLC LLCO relay de energized 1 LLCO LED turns off B WLC LLCO N C contacts close and low water light 2LT red comes on C WLC LLCO N O contacts open and power is removed from heating circuit Kettle returned to upright position Water level control WLC circuit returns to normal operation and heating cycle resumes Kettle heating will continue to cycle with the temperature controller until the temperature dial is turned fully CCW or power switch is turned OFF Electric Stationary and Tilting Kettles ELECTRICAL OPERATION SCHEMATIC DIAGRAM L2 PRIMARY TAPS OF MAIN TRANSFORMER MUST BE CONNECT
14. age 3 of 29 CONTROL PANEL TEMPERATURE CONTROL DIAL LOW WATER RED LIGHT _ LOW WATER gt m POWER 7 SWITCH LIGHT E HEAT ON HEAT 20770 Fig 1 TOOLS Standard Standard set of hand tools Pipe thread sealant VOM with an AC current tester meter sensitivity should be at least 20 000 ohms per volt e Temperature meter thermocouple type Use for checking kettle temperature 6gallon container to hold drained reservoir jacket fluid Special e Torque wrench ft lbs for tightening heating element mounting bolts Dowfrost heat transfer fluid Part No 558038 5 gallon Refer to service procedures for volumes e Water Use only distilled water only for re filling of the jacket purchase locally F45472 1112 Electric Stationary and Tilting Kettles General SPECIFICATIONS Reservoir Jacket Fluid e Water Use only distilled water for partial re filling of the jacket purchase locally Dowfrost heat transfer fluid Part No 558038 5 gallon Use during a complete re fill of the jacket with new fluid Refer to service procedures for volumes ELECTRICAL SPECIFICATIONS Amperage per Line Minimum Circuit Ampacity KAOEL ELT K60EL ELT The 208 240V electric kettles are wired from the factory for a 208V 3 phase supply If connecting to 240V 3 phase supply the primary voltage tap on the transformer must be changed to this voltage For connecting to a single ph
15. ally 3 Turn inner jam nut clockwise until it stops against the positive stop traveller Tighten outer jam nut to 2 crank handle clockwise to tilt the kettle until secure the stop position it stops Kettle should be tilted past 90 to allow C Turn crank handle to verify operation contents to drain Repeat adjustment as necessary 3 If adjustment is necessary continue with procedure 4 Remove CONTROL BOX COVER Return kettle to fully upright position A inner jam nut should be in solid contact with positive stop traveller B To adjust upright position horizontal F45472 1112 18 of 29 Electric Stationary and Tilting Kettles SERVICE PROCEDURES AND ADJUSTMENTS POSITIVE STOP TRAVELLER OUTER JAM NUT T NN INNER JAM NUT 24212 Kettle Fully Upright Traveller Contacts Inner Jam Nut 6 Fully tilt the kettle until crank handle stops A Verify positive stop traveller is in solid contact with stop plate B To adjust fully tilted position 1 Remove shoulder screw from stop plate 2 Remove tilt switch bracket from stop plate POSITIVE STOP TILT SWITCH TRAVELLER BRACKET STOP PLATE POSITIVE Q 5 THREADED SHOULDER SCREW 24213 Kettle Fully Tilted Traveller Contacts Stop Plate 3 Turn crank handle clockwise to tilt the kettle and empty its contents Kettle should be tilted approximately 95 to 100
16. and follow lockout tagout procedures 1 Remove CONTROL BOX COVER Disconnect lead wires from the transformer Fig 10 HEATING ELEMENT A WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures TILTING KETTLE Remove screws securing the transformer to panel 4 Reverse procedure to install and check for proper 2 operation 4 Page 7 of 29 1 Open pressure relief valve until reservoir jacket is completely vented Remove BOTTOM COVER Remove wire from water level probe LLCO Place a large container under the kettle Remove water level probe LLCO and open the fill valve 40 amp 60 gallon kettles or remove pipe plug from fill elbow 20 gallon kettles to vent the jacket and drain liquid from kettle F45472 1112 Electric Stationary and Tilting Kettles REMOVAL AND REPLACEMENT OF PARTS REMOVE WATER LEVEL PROBE REMOVE BOLTS 24252 Fig 13 28 8 Remove heating element from kettle Fig 11 9 9 Reverse procedure to install Use new heating NOTE If liquid drained from kettle is still clean save element seal whenever installing heating for reuse element Torque mounting nuts to 40 ft lbs and 5 Remove heater access cover tighten in an alternating pattern 10 Refill jacket with fluid See FILLING THE RESERVOIR JACKET 11 Remove air from reservoir jacket as outlined under VENTING 12 Check for proper operation and leaks
17. around heating element STATIONARY KETTLE REMOVE SCREWS 1 Open pressure relief valve until reservoir jacket is completely vented 2 Remove BOTTOM COVER Remove wire from Water Level Probe LLCO 4 Place a large container under the kettle Remove 6 Note lead wire locations and disconnect wires from heating element 7 Remove mounting bolts securing heating element to kettle F45472 1112 _ Page 8 of 29 water level probe LLCO and open the fill valve 40 amp 60 gallon kettles or remove pipe plug from fill elbow 20 gallon kettles to vent the jacket and drain liquid from kettle Electric Stationary and Tilting Kettles REMOVAL AND REPLACEMENT OF PARTS REMOVE WATER LEVEL PROBE Fig 14 NOTE If liquid drained from kettle is still clean save for reuse 5 Remove CONTROL BOX COVER 6 Note lead wire locations and disconnect wires from heating element 7 Remove mounting nuts securing heating element to kettle Fig 15 Remove heating element from kettle 9 Reverse procedure to install Use a new heating element seal whenever installing heating element Torque mounting bolts to 40 ft lbs and tighten in an alternating pattern Page 9 of 29 10 Refill jacket with fluid See FILLING THE RESERVOIR JACKET 11 Remove air from reservoir jacket as outlined under VENTING 12 Check for proper operation and leaks around heating element WATER LEVEL PROBE LLCO
18. ase supply the wiring between terminal block and contactors must be changed as shown in the WIRING DIAGRAMS OPERATION CLEANING AND MAINTAINENCE Refer to F35457 Installation amp Operation Manual for specific instructions The manual includes A page from the Stainless Steel Care and Cleaning Guide for proper care and cleaning of stainless steel Draw Off Valve and Plug Valve dissassembly amp cleaning instructions F45472 1112 4 of 29 Electric Stationary and Tilting Kettles REMOVAL AND REPLACEMENT OF PARTS REMOVAL AND REPLACEMENT OF PARTS CONTROL BOX COVER COMPONENT PANELS WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures 4t DR A WARNING Disconnect the 5 S electrical power to the machine and follow lockout tagout procedures The following pictures show the Stationary Kettle the Tilting Kettle and the Bottom component panels Use these pictures to asist in removal and replacement of the components in these kettles POTENTIOMETER 6 1T MAIN I TRANSFORMER 2 Control Cover BOTTOM COVER a i CONTROL Eo TEMPERATURE CONTROL electrical power to the machine and m follow lockout tagout procedures ELEMENTS Tilting Kettle age o Bottom Cover 5of29 F45472 1112 Electric Stationary an
19. ater light is off If low water light is on there may be a problem with the water level control circuit See troubleshooting 8 Remove air from reservoir jacket as outlined under VENTING 9 Check kettle for proper operation Page 17 of 29 Complete Draining and Refill NOTE Appearance of fluid will no longer be clear after usage in kettle 1 power switch off and set temperature dial to lowest setting 2 Open pressure relief valve until reservoir jacket is completely vented Remove BOTTOM COVER 4 Place large container under kettle to catch liquid 5 Remove WATER LEVEL PROBE LLCO 6 Remove 1 2 pipe plug from reservoir jacket fill elbow rear of kettle to facilitate draining and provide opening for re fill Open fill valve on 40 and 60 gallon kettles NOTE Clean threads and apply sealant before reinstalling pipe fittings 7 Re install water level probe 8 To Refill A Remove pressure gauge to allow reservoir jacket to vent during fill procedure B Insert funnel into the reservoir jacket fill elbow Slowly fill the jacket according to the volumes listed in the table below RESERVOIR JACKET VOLUME Total Fluid Water Heat Transfer Volume Qt Qt Fluid Qt K20EL K40EL K60EL 9 Install pipe plug and pressure gauge Tighten to prevent leaks 10 Turn power switch on and verify low water light is off If low water light is on there may be a problem with the wa
20. cts WLC LLCO NC open WLC LLCO NO close and the LLCO LED turns on When the kettle is tilted to empty the contents the fluid is no longer in contact with the LLCO probe and the circuit is open The LLCO relay coil is de energized and LLCO LED turns off WATER LEVEL CONTROL WLC LLCO LLCO LOW LEVEL CUT OFF PROBE LLCO LED WLC LLCO NC WLC LLCO NC 20798 Fig 36 A Page 23 of 29 BAL WARRICK CONTROLS 26B1D0H Fig 37 SEQUENCE OF OPERATION 1 Conditions A Kettle connected to correct voltage supply and is properly grounded 1 120VAC potential across X2 and X1 on secondary of main transformer B Power switch and light 1L T amber are off C Low water light 2LT red is off Pressure switch 1PAS contacts closed E Temperature dial at lowest setting potentiometer fully CCW 1 Internal relay contacts N O are open F Kettle at room temperature and in the full upright position 2 Power switch turned ON A Power light 1LT amber comes on B Power from secondary of main transformer to control circuit thru pressure switch 1PAS N C contacts 3 Water level control WLC energized WLC LLCO probe satisfied fluid in kettle reservoir jacket at proper level F45472 1112 F45472 1112 Electric Stationary and Tilting Kettles ELECTRICAL OPERATION 1 LLCO LED comes on B WLCLLCO N C contacts open Low water light 2LT red remains off C WLC LLCO N O cont
21. d Tilting Kettles REMOVAL AND REPLACEMENT OF PARTS WATER LEVELS TEMPERATURE CONTROLLER A WARNING Disconnect the JN electrical power to the machine and SS JA follow lockout tagout procedures 1 Remove CONTROL BOX COVER 2 Disconnect lead wires from temperature controller 3 Remove screws securing the temperature controller to panel 4 Reverse procedure to install and check for proper operation Bottom HEATING CONTACTORS WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures 1 Remove CONTROL BOX COVER 2 Note location of lead wires then disconnect the wires from contactor being replaced Remove screws securing the contactor to panel 4 Reverse procedure to install and check for proper Fig 8 operation WATER LEVEL CONTROL WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures 1 Remove CONTROL BOX COVER 2 Disconnect lead wires from the water level control 3 Remove screws securing the water level control to panel 4 Reverse procedure to install and check for proper Fig 7 operation F45472 1112 Page 6 of 29 Electric Stationary and Tilting Kettles REMOVAL AND REPLACEMENT OF PARTS onn _ qm 4 Des oye 696 Se WARNING Disconnect the electrical power to the machine
22. ente eem uer eee br Een iu unu eet dione nere dus STATIONARY AND TILTING KETTLES ccc eee eee hn MODELS COVERED 2 2 2 25 prb op I bir hes cedo vul etre dot tanh dte dd adds CONTROL PANELB 7 5252 tn trate otc ere eo tar eed at au Dd evi A doit s e heen tte ua TOOLS vr SPEGIPIGATIONS crier heo dues eate Vend poesie deer V dures adus OPERATION CLEANING AND MAINTAINENCE s sene cece eee eee eee rares REMOVAL AND REPLACEMENT OF PARTS s eme e eren CONTROL BOX COVER 1 esame medie dad ue a edo ue a ret deel deny uta BOTTOM COVER eset p retro dealt bs e dace i prn od ue inh oda ee obs ados ate e mis dade gis bee a oda COMPONENT PANELS bein ta rtt pi ree re Reign PRA Sedet do tpa eerte mee perte HEATING CONTAQGT ORS niit tert te ie ede dese eer dae ela da da be a TEMPERATURE CONTROLLER 0 e e e e e e e ren WATER EEVELE CONTROL rtr retta t tci t ee te ae dr ka te hat MAIN TRANSFORMER eden edet ded da eder sedan PAPA TE a at HEATING EEEMENT ti nre oe nete bhi ete edel T de et ated FEDT Re wing edge DP ie traded dhe WATER EEVEL PROBE ELCO rire eere het eerte Re itia ede Ret tee wate ea ede teca ier TEMPERATURE SENSOR cri eae pazei b dtr nbi nar bd eet ater tese de
23. ge wl reete e unte PRESSURE SWITCH onec donet b er c iot wd Na dug ete POTENTIOMETER caer e Pest eet et de e etu kate ee Eod Des ur ae zd are SWITCH ASSEMBLY Fazit rtr ere ettet ire ede er v at lr etd ATIS ede E sake nat dren GEARBOX TILT MODELS ONLY I em en TET BEARING irris yaad etre sae eet tese eerte ere dn oth i ee eee e dota te Sid x Rete e dec pee and SERVICE PROCEDURES AND ADJUSTMENTS see ene TEMPERATURE CONTROLLER TEST a mme POTENTIOMETER TEST ree a oL A ert da epe deese tete sie aat THERMOGOUPEE TEST oio srt meii eive PIU Rr PSY e pire p biduo Mzgcq ce FILLING THE RESERVOIR JACKET ss e e eee ne PARTIAL REFIL Pipe rper Ped eher oce deca denotat COMPLETE DRAINING AND REFILL III HEATING ELEMENT acts agai robe seta A eese E tede ada pital KETTLE TILT ADJUSTMENT TILT MODELS III ELECTRICAL OPERATION reete bseeI eR deem eene dae rei COMPONENT FUNCTION rone ere Rer aree ES S Eee dd oe ia COMPONENT LOCATION Wiel eh bra aden
24. ler is calling for heat temperature controller contacts closed Heats reservoir jacket fluid The heat in the fluid is then transferred to kettle Slow blow 3A fuse Located on primary side of main transformer 1T Protects control circuitry from over currents Pressure cut out protection for the reservoir jacket Range is between 38 to 42 PSI Removes power from control circuit if pressure in the jacket rises above switch setting Step down transformer from line voltage to 120VAC control circuit voltage Controls 120VAC to kettle control circuit Cycles power to regulating contactor 2CON to maintain the set point temperature An external set point potentiometer is used for temperature adjustments Amber AM colored lamp On when power switch is on Red RD colored lamp On when water level in the reservoir jacket drops below water level LLCO probe or when kettle is tilted tilting models only Amber AM colored lamp On when temperature controller is calling for heat Page 20 of 29 Electric Stationary and Tilting Kettles ELECTRICAL OPERATION COMPONENT LOCATION CONTACTORS TERMINAL BLOCK FUSES POTENTIOMETER TRANSFORMER MAIN SWITCH TEMPERATURE CONTROL WATER LEVEL CONTROL HEATING ELEMENT 24270 STATIONARY KETTLE COMPONENTS Page 21 of 29 T F45472 1112 Electric Stationary and Tilting Kettles ELECTRICAL OPERATION FUSES TEMPERATURE CONTACTORS TRANSFORMER P e
25. measure resistance Connect meter leads to the white and black lead wires on potentiometer terminals A Resistance should measure approximately zero ohms Slowly turn potentiometer shaft clockwise over the full range of travel and monitor resistance change on the meter A Resistance should measure 800 to 1200 ohms with shaft turned fully clockwise B Ifthe resistance value increased smoothly without sudden drops or spikes and the full travel resistance value is within tolerance then potentiometer is functioning properly C Ifthe resistance value did not increase smoothly but had drops or spikes over the full travel range then potentiometer is not functioning properly Install a replacement potentiometer and check for proper operation THERMOCOUPLE TEST 240VAC 4 T3 T4 120VAC dd YELLOW THERMOCOUPLE TYPE K Fig 27 Access TEMPERATURE CONTROLLER 2 Remove thermocouple lead wires from temperature controller 3 Check thermocouple for a measurable resistance approximately 5 to 10 ohms at room temperature If meter reads an overload OL condition open or zero ohms short replace the thermocouple and check temperature controller for proper operation VENTING NOTE This procedure outlines venting the reservoir jacket to remove air for proper heat transfer to the kettle contents 15 of29 F45472 1112 Electric Stationary and Tilting Kettles SE
26. ter level control circuit See troubleshooting 11 Remove air from reservoir jacket as outlined under VENTING 12 Check kettle for proper operation and leaks 13 Install covers F45472 1112 Electric Stationary and Tilting Kettles SERVICE PROCEDURES AND ADJUSTMENTS HEATING ELEMENT NOTE Checking current draw is the preferred method over a resistance check when an amp clamp meter is available 1 Access HEATING ELEMENT If current draw is not correct then replace 2 Measure voltage at heating element terminals heating element and verify it against the data plate voltage 4 Check for proper operation A If voltage is incorrect find the source of the problem 3 If voltage is correct check current draw amps through the heating element lead wires If current draw is correct then heating element is ok See table below for proper values K40EL K40ELT K60EL K60ELT NOTE Values in table are nominal Tolerance is 10 1 Loosen outer jam nut 2 to 3 turns KETTLE TILT ADJUSTMENT TILT counterclockwise and turn the inner MODELS ONLY jam nut in the same direction and amount NOTE Perform this procedure whenever the kettle is 2 Turncrank handle to position the top of not returning to a horizontal position when upright or when kettle is not tilting past 90 to empty contents 1 With kettle fully upright the top of kettle should be horizontal when viewed from either side kettle horizont
27. th procedure 2 Set temperature dial to lowest setting Kettle B If incorrect check pressure switch 1 5 must be below 110 F before verifying the and water level controller WLC LLCO potentiometer output to the controller is good over the full range of temperature dial travel 10 Verify 120VAC between T8 and X1 on the output of main transformer If correct output from Access TEMPERATURE CONTROLLER controller is functioning properly 4 Checkalllead wires for secure connections to the A If incorrect install a replacement controller terminals Wiring harness lead wires temperature controller and check for proper must be connected to T1 T2 and T3 T4 for proper operation input to controller 5 Re connect power to the machine 6 Turn power switch on 7 Verify temperature controller is receiving 120VAC at terminals T1 T3 and T2 T4 and machine is properly grounded 8 Slowly turn temperature dial to the highest setting and monitor heat light over the full range of travel A Verify heat light amber comes on and heating element is energized F45472 1112 14 of 29 Electric Stationary and Tilting Kettles SERVICE PROCEDURES AND ADJUSTMENTS POTENTIOMETER TEST POTENTIOMETER 1 0 B BLACK POSITIONING TAB FULL RANGE TOLERANCE 800 TO 1200 OHMS Fig 26 Remove POTENTIOMETER Turn potentiometer shaft fully counterclockwise to the lowest setting Set VOM to
28. the gearbox to the component box 5 the kettle just high enough to slide the gearbox off of the shaft and clear the component box lip NOTE Be careful not to damage the wiring as you remove gearbox from shaft 6 Remove the positive stop plate assembly from the old gearbox and install it on the new one F45472 1112 REMOVE POSITIVE Fig 23 7 Install new gearbox in kettle 8 Lower the gearbox until it touches component box housing NOTE Only lower the gearbox enough to align the holes and bolt the gearbox down 9 Lower the kettle and remove pallet jack 10 Connect the wiring 11 Check operation of kettle TILT BEARING A WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures 1 Place pallet jack under kettle NOTE Make sure pallet jack is under kettle and not under the tubular frame NOTE Place 2x4 or 4x4s on the pallet jack if needed to obtain the proper height 2 Loosen set screws on bearing assembly Page 12 of 29 Electric Stationary and Tilting Kettles REMOVAL AND REPLACEMENT OF PARTS LOOSEN SET SCREWS 3 Lift kettle high enough to pull bearing assembly off of stand Slide bearing assembly off of kettle shaft Reverse procedure to install new bearing assembly 130f20 F45472 1112 Electric Stationary and Tilting Kettles SERVICE PROCEDURES AND ADJUSTMENTS SERVICE PROCEDURES A
29. w water level probe LLCO Water level probe LLCO wiring connection malfunction or probe coated not sensing fluid or probe malfunction Water level control malfunction Pressure switch 1PAS malfunction Temperature sensor malfunction potentiometer malfunction or temperature controller malfunction Interconnecting wiring malfunction Main circuit breaker off or control circuit fuse F1 or F2 open Supply voltage incorrect Main transformer 1T malfunction Power switch off or malfunction Interconnecting wiring malfunction No vacuum in reservoir jacket when kettle is cold Supply voltage incorrect Heating element malfunction Temperature sensor malfunction or potentiometer malfunction or temperature controller malfunction Page 29 of29 F45472 1112
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