Vulcan Materials K12ETT User's Manual
Contents
1. 0 5 0 2 19 Component Location 2 20 Water Level Control WLC LLCO 22 Sequence of 4 23 Schematic Diagram 4 24 Wiring Diagrams ya Aca ace Feet n te Gee eue tete gut Warne PLE aed REE Gee RT rE 25 TROUBEESHOOTING 4 ote ee ed ae I tae anak E LI 27 VULCAN 2009 F35496 August 2009 _ Page 2 of 28 ELECTRIC COUNTER TOP 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 K6ETT countertop tilting 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 Countertop Tilting Kettles The electric countertop 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 a2. F35496 August 2009 ELECTRIC COUNTER TOP TILTING KETTLES REMOVAL AND REPLACEMENT OF PARTS KETTLE ASSEMBIV 4 PIVOT STOP KETTLE ASSEMBLY Eos WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures Removal 1 Place kettle in full upright position 2 ids ia kettle using 2x4 blocks of wood 8 Remove outer bearing from support shaft OUTER REMOVE BOLTS 9 20 only A Remove two bolts securing kettle tilt stop to base KETTLE TILT 5 Note lead wire locations and disconnect from STOP load side of contactors Remove CONTROL BOX COVER Disconnect thermocouple lead wires from temperature control and the 4 pin wiring harness connector 6 Remove wire tie securing lead wire bundle to control box 7 Remove three set screws on pivot stop collar Access third screw thru the slot in top of control box B Remove kettle support cover F35496 August 2009 Page 8 of 28 ELECTRIC COUNTER TOP TILTING KETTLES REMOVAL AND REPLACEMENT OF PARTS KETTLE k 1 C Remove kettle support and bearing housing assembly from support shaft SUPPORT 727 7 BEARING HOUSING KETTLE SUPPORT 10 Pull kettle assembly away from control box to disengage support shaft from inner bearing and pivot stop collar Slide kettle onto the 2
3. 11 Remove 2x4 blocks from underneath kettle assembly A With kettle in full vertical position verify tilt lock operation The pivot stop pin should engage with the slot in pivot stop collar and not catch or bind when operated REMOVE BOLTS B Tilt kettle to horizontal position and verify pivot stop pin engages with the next slot in 3 OnK2OETT Only pivot stop collar A Remove bearing housing assembly from C Return kettle to full vertical position Verify kettle support the kettle pour stop pin engages properly KETTLE BEARING HOUSING to prevent backwards tilt SUPPORT ASSEMBLY D Tilt kettle and verify pour stop pin does not rub against control box housing 12 Connect lead wires to contactors and temperature control then connect 4 pin wiring harness 13 Secure lead wire bundle to control box with wire tie then install cover 14 If re installing kettle assembly verify the reservoir jacket is maintaining a vacuum as outlined under VENTING If a replacement kettle assembly was installed fill the reservoir jacket as outlined under FILLING THE RESERVOIR JACKET 15 Connect power to machine and check for proper operation 20796 4 Install replacement bearing 5 Install KETTLE ASSEMBLY Page 11 of 28 s o Qq F35496 August 2009 ELECTRIC COUNTER TOP TILTING KETTLES REMOVAL AND REPLACEMENT OF PARTS SHAFT SEAL WARNING Disconnect the electrical power to the machine and
4. 3LT amber goes out 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 LLCOLED 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 Page 23 of 28 F35496 August 2009 ELECTRIC COUNTER TOP TILTING KETTLES ELECTRICAL OPERATION SCHEMATIC DIAGRAM L2 PRIMARY TAPS OF MAIN TRANSFORMER MUST BE CONNECTED ACCORDING TO THE DATA PLATE VOLTAGE AND THE ACTUAL VOLTAGE SUPPLY MAIN TRANSFORMER 17 COM 208 240V 480V WATER LEVEL CONTROLLER 120 LIMITING CONTACTOR 1 0 TEMPERATURE CONTROLLER t IC YELLOW REGULATING CONTACTOR 2CON DERIVED FROM 857447 1 MODELS K6ETT K12ETT AND K20ETT F35496 August 2009 24 of 28 ELECTRIC COUNTER TOP TILTING KETTLES ELECTRICAL OPERATION WIRING DIAGRAM
5. follow lockout tagout procedures All Models 1 access shaft seal between kettle and control box housing remove KETTLE ASSEMBLY 2 Remove shaft seal from control box housing T SEAL VONT 3 Clean mounting surface on control box housing then install replacement shaft seal 4 Install KETTLE ASSEMBLY K20ETT only 1 Support kettle using 2x4 blocks of wood 2 Remove kettle support cover 3 Remove kettle support and bearing housing assembly from support shaft KETTLE SUPPORT BEARING HOUSING ASSEMBLY 4 Remove shaft seal from kettle support 5 Clean mounting surface on kettle support then install replacement shaft seal F35496 August 2009 12 of 28 ELECTRIC COUNTER TOP TILTING KETTLES REMOVAL AND REPLACEMENT OF PARTS 6 Reverse procedure to complete the installation and check for proper operation KETTLE SUPPORT K20ETT WITH SHAFT SEAL INSTALLED PIVOT STOP PIN gt d Disconnect the electrical power to the machine and S S follow lockout tagout procedures 1 Remove CONTROL BOX COVER 2 Remove retaining ring from pivot stop pin RETAINING RING PIVOT STOP PIN 3 Reverse procedure to install NOTE When installing apply Lubriplate 630 AA to mating surfaces on pivot stop pin Ensure pivot stop pin fully engages with the slot in pivot stop collar and does not catch or
6. 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 F35496 August 2009 ELECTRIC COUNTER TOP TILTING KETTLES SERVICE PROCEDURES AND ADJUSTMENTS HEATING ELEMENTS 1 Access heating element as outlined in REMOVAL AND REPLACEMENT OF PARTS 2 Measure voltage at heating element terminals and verify it against the data plate voltage 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 NOTE Checking current draw is the preferred method over a resistance check when an amp clamp meter is available If current draw is not correct then replace heating element 4 Check for proper operation KW PER CURRENT PER RESISTANCE PER ELEMENT NO ELEMENT OHMS 15 6 240 25 307 1 Dual voltage elements Element lengths are staggered to fit the contour of the kettle bottom Element number 1 is the shortest 480V elements are connected in Wye configuration for 277V across each element NOTE Values in table are nominal Tolerance is 10 96 F35496 August 2009 I 16 of 28 ELECTRIC COUNTER TOP TILTING KETTLES SERVICE PROCEDURES AND ADJUSTMENTS VENTING NOTE This procedure
7. 120VAC 12 controller as outlined the steps L1 L2 below THOT _ Al2478 9 Disconnect lead wire from terminal T7 on the controller 1 Place kettle in full upright position A Verify 120VAC between lead wire from T7 2 Settemperature dial to lowest setting Kettle and X1 on the output of main transformer must be below 110 before verifying the If correct re connect lead wire to terminal potentiometer output to the controller is good T7 and continue with procedure over the full range of temperature dial travel B If incorrect check pressure switch 1PS 3 Access the temperature controller as outlined in and water level controller WLC LLCO REMOVAL AND REPLACEMENT OF PARTS 10 Verify 120VAC between T8 and X1 on the 4 Check all lead wires for secure connections to output of main transformer If correct output the controller terminals Wiring harness lead from controller is functioning properly wires must be connected to T1 T2 and T3 T4 A If incorrect install a replacement for proper input to controller temperature controller and check for Re connect power to the machine proper operation Turn power switch on Verify temperature controller is receiving 120VAC at terminals T1 T2 and T3 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 F35496 August 2009 Page 14 of 28 ELECTRI
8. 98 F35496 August 2009 n Page 22 of 28 ELECTRIC COUNTER TOP TILTING KETTLES ELECTRICAL OPERATION SEQUENCE OF OPERATION Conditions A Kettle connected to correct voltage supply and is properly grounded 1 120VAC potential across X2 and X1 on secondary of main transformer Power switch and light 1LT amber are off Low water light 2LT red is off Pressure switch 1PAS contacts closed moo 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 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 Water level control WLC energized A WLCLLCO probe satisfied fluid in kettle reservoir jacket at proper level 1 LLCOLED comes on B WLCLLCO N C contacts open Low water light 2LT red remains off C WLC LLCO N O contacts close 1 Limiting contactor 1CON 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 Heat light 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
9. C COUNTER TOP TILTING KETTLES SERVICE PROCEDURES AND ADJUSTMENTS POTENTIOMETER TEST POTENTIOMETER 1 0 POSITIONING TAB FULL RANGE TOLERANCE 800 1200 OHMS Remove potentiometer from control panel as outlined in REMOVAL AND REPLACEMENT OF PARTS Turn potentiometer shaft fully counterclockwise to the lowest setting Set VOM to 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 If the 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 Page 15 of 28 THERMOCOUPLE TEST fal OUTPUT STATUS LED por 31 THERMOCOUPLE TYPE K 12479 Access the temperature controller outlined REMOVAL AND REPLACEMENT OF PARTS Remove thermocouple lead wires from temperature controller Check the thermocouple for a measurable resistance approximately 5 to
10. CTOR E Page 5 of 28 _ F496 August 2009 ELECTRIC COUNTER TOP TILTING KETTLES REMOVAL AND REPLACEMENT OF PARTS BOTTOM COMPONENTS WATER LEVEL PROBE LLCO TEMPERATURE SENSOR AND PRESSURE SWITCH 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 Remove BOTTOM COVER Disconnect lead wires from component being replaced 4 If removing pressure switch A Disconnect compression fitting from elbow near the pressure switch B Remove top nut on brass fitting to remove pressure switch from mounting bracket Remove component from bottom of kettle Reverse procedure to install Remove air from reservoir jacket as outlined under VENTING procedure 8 Check for proper operation NOTE Pressure switch setting is fixed and should not be adjusted Clean threads and apply pipe thread sealant when replacing pressure switch water level probe or temperature sensor WATER LEVEL PROBE LLCO TEMPERATURE SENSOR PRESSURE SWITCH F35496 August 2009 POTENTIOMETER WARNING Disconnect the amp electrical power to the machine and follow lockout tagout procedures Q S gout p 1 Remove CONTROL BOX COVER 2 Disconnect potentiometer wire from temperature control 3 Pull temperature dial from potentiometer shaft and r
11. ICAL OPERATION ELECTRICAL OPERATION COMPONENT FUNCTION Water Level Control WLC LLCO Probe Water Level LLCO Contactor 1CON Limiting Contactor 2CON Regulating Element Heating Fuse IFU amp 2FU Switch 1PAS Pressure Transformer 1T Main Switch 1S Power Temperature Controller Lamp 1LT Power Lamp 2LT Low Water Lamp 3LT Heat 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 Connects heating element to power On constantly when temperature controller is calling for heat 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
12. O The water level control provides low level cut off protection to shut off the heat source in case the fluid level in the kettle reservoir jacket drops below the WLC LLCO probe A single low level cut off probe LLCO is connected to the control The water level control has input voltage of 120VAC across terminals L1 and L2 which powers the primary side of the transformer on the board One side of the transformer secondary is powered through a series path to chassis ground The other side of the transformer secondary 12VAC is connected to the LLCO probe that supplies power to the LLCO relay coil on the board 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 contacts 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 WARRICK CONTROLS LLCO LOW LEVEL CUT OFF PROBE LLCO LED WLC LLCO NC WLC LLCO NC 207
13. O and must be replenished before heating can continue The low water light will come on when kettle is tilted NOTICE When filling reservoir jacket use only distilled water Partial Refill 1 Place kettle in full upright position 2 Turn power switch on If low water light is on continue with procedure Set temperature dial to lowest setting 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 A Insert funnel into the opening and slowly add water until low water light turns off LLCO probe is satisfied B Turn power switch off C Continue adding water to bring fluid to the proper operating level per the amount listed in table below Add Water for Proper Mogel Operating Level Qt 6 Clean pipe plug threads and apply thread sealant Install pipe plug and tighten to prevent leaks 7 Turn power switch on and verify low water 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 F35496 August 2009 ELECTRIC COUNTER TOP TILTING KETTLES SERVICE PROCEDURES AND ADJUSTMENTS Complete Draining and Refill NOTE Appearance of fluid will no longer be clear after usage in kettle 1 Turn power switch off and set temperature dial
14. S Heating Element Wiring TO MAIN 208 240V 3 PHASE TRANSFORMER REGULATING CONTACTOR 208 240V 1 PHASE LIMITING CONTACTOR L DERIVED FROM 857448 1 21 22 TO MAIN TRANSFORMER 4 2 REGULATING mi Ni 42 O sors EB E EE n 26 MAIN TRANSFORMER PRIMARY MUST BE CONNECTED ACCORDING TO THE KETTLE DATA PLATE VOLTAGE AND THE ACTUAL VOLTAGE SUPPLY MODELS K6ETT 12 AND 20 Page 25 of 28 F35496 August 2009 ELECTRIC COUNTER TOP TILTING KETTLES ELECTRICAL OPERATION TO MAIN 3 PHASE 480V TRANSFORMER REGULATING CONTACTOR MAIN TRANSFORMER PRIMARY MUST BE CONNECTED ACCORDING TO THE KETTLE DATA PLATE VOLTAGE AND THE ACTUAL VOLTAGE SUPPLY WIRING DIAGRAM 3 PH WYE X 1 hada o LIM CON 11 Ny aie CON L2 ON L2 4277 yt CON L3 REG CON L1 LIM CON L3 Z 857449 1 MODELS K6ETT K12ETT AND K20ETT 12476 DERIVED FROM F35496 August 2009 P T Page 26 of 28 ELECTRIC COUNTER TOP TILTING KETTLES TROUBLESHOOTING TROUBLESHOOTING SYMPTOM POSSIBLE CAUSES Kettle does not heat power light is lit heat Limiting contactor 1CON malfunction light is lit low water light is not lit Regulating contactor 2CON malfunction Heating element malfunction Kettle does not heat power light is lit low Fluid level in reservoir jacket below water level probe LLCO water light is lit hea
15. SERVICE MANUAL ELECTRIC COUNTER TOP TILTING KETTLES K6ETT ML 136067 K12ETT ML 136068 K20ETT ML 136069 20769 K12ETT ON STAND 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 Reproduction or other use of this Manual without the express written consent of Vulcan is prohibited For additional information on Vulcan Hart or to locate an authorized parts and service provider in your area visit our website at www vulcanhart com A product of VULCAN HART LOUISVILLE KY 40201 0696 F35496 August 2009 ELECTRIC COUNTER TOP TILTING KETTLES TABLE OF CONTENTS GENERAL atr LIII cath LEM LEA Met Ah aaa AM MM Ata A 3 225722 Z dee Ob RE vetet e ie Ce dete oe det db 3 MOOS a ec tui reet Sects ee Seles Bay ene E TORRE baht UE Pans Sule Bay eee Sele amit Sed 3 Slor te eua 4 REMOVAL AND REPLACEMENT OF PARTS 1 5 Govers a
16. 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 Amber AM colored lamp On when temperature controller is calling for heat Page 19 of 28 s F35496 August 2009 ELECTRIC COUNTER TOP TILTING KETTLES ELECTRICAL OPERATION COMPONENT LOCATION Mais POTENTIOMETER 4 i i WATER LEVEL Lid nmm CONTROL WLC ii SWITCH MAIN TRANSFORMER an TEMPERATURE REGULATING CONTACTOR D CONTROLLER l 2CON REGULATING CONTACTOR 2CON SWITCH LIMITING CONTACTOR 1CON WATER LEVEL CONTROL WLC K20ETT CONTROL BOX F35496 August 2009 CV Page 20 of 28 TERMINAL GROUND TERMINAL BLOCK FUSES MAIN TRANSFORMER 17 TEMPERATURE CONTROLLER ELECTRIC COUNTER TOP TILTING KETTLES ELECTRICAL OPERATION HEATING ELEMENT TEMPERATURE SENSOR PRESSURE SWITCH WATER LEVEL PROBE LLCO K6ETT FRONT VIEW SHOWN Page 21 of 28 F35496 August 2009 ELECTRIC COUNTER TOP TILTING KETTLES ELECTRICAL OPERATION WATER LEVEL CONTROL WLC LLC
17. bind when tilt lock is operated The picture below is shown with outer bearing removed for clarity Page 13 of 28 9998 PIVOT STOP COLLAR F35496 August 2009 ELECTRIC COUNTER TOP TILTING KETTLES SERVICE PROCEDURES AND ADJUSTMENTS SERVICE PROCEDURES AND ADJUSTMENTS 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 test TEMPERATURE CONTROLLER A Verify heat light amber comes on and TEST heating element is energized B If heat light does not remain on or flashes momentarily as temperature setting is slowly increased verify condition of JUMPER J1 INSTALLED potentiometer as outlined under POTENTIOMETER TEST NOTE Temperature controller will de energize 5 2 OUTPUT i internal relay and turn off the output status LED if the Por 3 circuitry detects an open thermocouple LED will CONNECTOR OUTPUT begin to flash 3 times pause then repeat the flash crydorn sequence to indicate the open thermocouple TEMPERATURE CONTROLLER condition 240VAC 70 7 C If heat light and heating element do not a turn on 1 T2 T3 T4 1 Verify condition of thermocouple as outlined under THERMOCOUPLE TEST K See eee 2 Verify output from terminal T8 on e
18. d Part No 558038 5 gallon Use during a complete re fill of the jacket with new fluid Refer to service procedures for volumes Electric The kettle models listed in this manual with exception of 480V steamers are shipped pre wired for 208 60 3 operation Kettle heating element wiring change is required if connecting to 208 60 1 240 60 1 or 240 60 3 electrical service ELECTRICAL SPECIFICATIONS K6ETT K12ETT K20ETT K6ETT only Heating elements on 208 240VAC three phase machines are not wired as a balanced load F35496 August 2009 n 4 of 28 ELECTRIC COUNTER TOP TILTING KETTLES REMOVAL AND REPLACEMENT OF PARTS REMOVAL AND REPLACEMENT OF PARTS COVERS AND PANELS A Ww x Disconnect the electrical power to the machine and amp amp follow lockout tagout procedures Control Box Cover Bottom Cover ELECTRICAL PANEL COMPONENTS WATER LEVEL CONTROL TRANSFORMER CONTACTORS AND TEMPERATURE CONTROL ome Disconnect the Se lt electrical power to the machine and CUP follow lockout tagout procedures Remove CONTROL BOX COVER 2 Disconnect lead wires from component being replaced 3 Remove screws securing the component to panel 4 Reverse procedure to install and check for proper operation WATER LEVEL CONTROL WLC TILT KETTLE TO ACCESS A _ TEMPERATURE x 2 CONTROL eae REGULATING 4 CONTA
19. emove seal nut 4 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 POTENTIOMETER ALIGNMENT TAB POSITIONING BRACKET Page 6 of 28 ELECTRIC COUNTER TOP TILTING KETTLES REMOVAL AND REPLACEMENT OF PARTS HEATING ELEMENT WARNING Disconnect the electrical power to the machine and follow lockout tagout procedures 1 Open pressure relief valve until reservoir jacket is completely vented Tilt kettle to expose the heater access cover Remove three screws where indicated Loosen remaining screw and allow cover to rotate out of way REMOVE SCREWS HHT 4 Note lead wire locations and disconnect wires from heating element 5 Remove mounting bolts securing heating element to kettle MOUNTING BOLTS 4 Page 7 of 28 6 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 7 Remove air from reservoir jacket as outlined under VENTING 8 Check for proper operation and leaks around heating element NOTE On K6ETT only element lengths are staggered to fit the contour of the kettle bottom Install with the shortest element toward the bottom of kettle SHORTEST ELEMENT TOWARD BOTTOM OF KETTLE
20. ight When the kettle is tilted the pin engages with the slot near the top to lock the kettle in position PIVOT STOP COLLAR Insert lead wire bundle thru the outer bearing Slide bearing onto support shaft and position it against pivot stop collar Install bolts and tighten to secure the bearing 0795 Apply Lubriplate 630 AA to mating surfaces on pivot stop pin Ensure pivot stop pin fully engages with the slot in pivot stop collar and does not catch or bind when tilt lock is operated Clean threads screw amp hole with cleaner amp degreaser Apply Loctite 7471 Primer N and Threadlocker 242 to set screws and threaded holes on pivot stop collar ELECTRIC COUNTER TOP TILTING KETTLES REMOVAL AND REPLACEMENT OF PARTS NOTE Allow cleaner to fully evaporate before BEARINGS applying primer Spay primer on the threads and allow to dry for 60 seconds Shake Loctite 242 bottle 1 Remove KETTLE ASSEMBLY procedure thoroughly to mix then apply several drops of the threadlocker to threads Do not allow the tip of bottle to touch a primed surface as it will activate the 2 Remove inner bearing from control box housing Loctite 242 in the bottle 9 Install set screws on pivot stop collar Hold the collar against inner bearing and tighten set Screws to secure 10 On K20ETT only A Install kettle support to shaft and base includes outer bearing removal B Install kettle support cover and tilt stop to base
21. nd Panels urteri wa ce tusu pt us eu Ee aes Oe he eed bug ee ree eed 5 Electrical Panel Components Water Level Control Transformer Contactors and Temperature Control 5 Bottom Components Water Level Probe LLCO Temperature Sensor and Pressure Switch 6 uou Dx 6 Heating Element eia tue Bese ees Dee SQ Lire De ee INQUE NE S IBS DAR Sates eae 7 Kettle Assembly 8 Bearings me rb obe ER b ee CR ede ege ORC IER Ae DR M EUR as 11 Shaft Seal 12 xem bebe CS EO deat 13 SERVICE PROCEDURES AND ADJUSTMENTS 14 Temperature Controller Test 14 Potentiometer est is nei abies METERS Cel eee be ee NUR heed ME RR de 15 Thermocouple Test u os eal ce era l a eon qe e ne nee eem aoe 15 Heating Elements 2 LER le ke ERR ERE b D dE eg 16 Vong es chs eet eee dev ee Leddy eee eei eee e ee ee 17 Filling the Reservoir Jacket 4 1 2 lt 17 ELEGTRIGAL OPERATION V u 12252 dates ied eec Het deed UC e ts o e 19 Component Function
22. outlines venting the reservoir jacket to remove air for proper heat transfer to the kettle contents PRESSURE GAUGE 5 55 RELIEF 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 Place kettle in full upright position Turn power switch on 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 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 Page 17 of 28 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 LLC
23. t light is not lit Water level probe LLCO wiring connection malfunction or probe coated not sensing fluid or probe malfunction Water level control malfunction Kettle does not heat power light is lit low Pressure switch 1PAS malfunction water light is not lit heat light is not lit Temperature sensor malfunction potentiometer malfunction or temperature controller malfunction Interconnecting wiring malfunction Kettle does not heat power light is not lit 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 Kettle heats up slow or will not boil No vacuum in reservoir jacket when kettle is cold product Supply voltage incorrect Heating element malfunction Temperature sensor malfunction or potentiometer malfunction or temperature controller malfunction Page 27 of 28 F35496 August 2009 ELECTRIC COUNTER TOP TILTING KETTLES F35496 August 2009 Printed in U S A
24. to lowest setting 2 Open pressure relief valve until reservoir jacket is completely vented 3 Remove bottom cover as outlined under COVERS AND PANELS 4 Remove water level probe LLCO from kettle as outlined in REMOVAL AND REPLACEMENT OF PARTS 5 Place kettle in full upright position and allow fluid to drain into container Remove 1 2 pipe plug from reservoir jacket fill eloow rear of kettle to facilitate draining and provide opening for re fill NOTE Clean threads and apply sealant before re installing pipe fittings 6 Tilt kettle and re install water level probe 7 Refill A Place kettle in full upright position B Remove pressure gauge to allow reservoir jacket to vent during fill procedure C 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 2 K20ETT 8 Install pipe plug and pressure gauge Tighten to prevent leaks 9 Turn power switch on and verify low water light is off If low water light is on there may be a problem with the water level control circuit See troubleshooting 10 Remove air from reservoir jacket as outlined under VENTING 11 Check kettle for proper operation and leaks 12 Install covers F35496 August 2009 T Page 18 of 28 ELECTRIC COUNTER TOP TILTING KETTLES ELECTR
25. u shaft seal and inner bearing SUPPORT 2 Push kettle assembly support shaft thru shaft seal and inner bearing F35496 August 2009 ELECTRIC COUNTER TOP TILTING KETTLES REMOVAL AND REPLACEMENT OF PARTS 3 Square the kettle assembly to control box housing Maintain squareness during adjustments 4 and K12ETT only A Ensure the pour stop pin on kettle assembly engages with tilt stop on control box housing Approximately 3 16 spacing should be maintained between the pour stop pin and control box housing Adjust kettle assembly position as necessary NOTE The kettle assembly may drop slightly after 2x4 blocks are removed and when fully loaded The spacing of pour stop pin will prevent it from rubbing the control box during tilt CONTROL BOX KETTLE HOUSING ASSEMBLY POUR STOP PIN APPROX 3 16 A SPACING REAR VIEW SHOWN 5 Insert lead wire bundle thru pivot stop collar Position pivot stop collar as shown in the picture below Set screws should remain out of collar F35496 August 2009 Page 10 of 28 A Slide pivot stop collar onto support shaft Operate tilt lock then slide collar against inner bearing Hold the collar in position and release tilt lock Verify pivot stop pin fully engages with the slot in pivot stop collar for the tilt lock as shown Adjust kettle assembly position as necessary NOTE The pin location shown will lock the kettle fully upr
26. variety of liquid or semi liquid food products such as soups stews and sauces MODELS COVERED The 6 and 12 gallon kettles can be mounted to a counter top or optional stand The 20 gallon kettle is a floor model mounted to its own stand Electric Countertop Tilting Kettles K6ETT 6 gallon K12ETT 12 gallon K20ETT 20 gallon Page 3 of 28 CONTROL PANEL TEMPERATURE CONTROL DIAL LOW WATER RED LIGHT LOW WATER gt SWITCH AMBER LIGHT 1 HEAT ON HEAT 20770 TOOLS Standard Standard set of hand tools Pipe thread sealant e with an AC current tester meter sensitivity should be at least 20 000 ohms per volt Temperature meter thermocouple type Use for checking kettle temperature 2gallon container to hold drained reservoir jacket fluid Special Torque wrench ft Ibs for tightening heating element mounting bolts Lubriplate 630 AA Part No 501687 for lubrication of tilt lock pivot stop pin Loctite amp ODC Free Cleaner amp Degreaser McMaster Carr Part No 66415A21 or equivalent fast drying no residue cleaner Loctite amp 7471 Primer Part No 544434 2 Loctite amp 242 Part No 520228 F35496 August 2009 ELECTRIC COUNTER TOP TILTING KETTLES GENERAL SPECIFICATIONS Reservoir Jacket Fluid Water Use only distilled water for partial re filling of the jacket purchase locally Dowfrost heat transfer flui
27. x4 blocks A Pull lead wire bundle thru inner bearing and pivot stop collar during removal NOTE If support shaft of kettle assembly does not easily disengage apply force between control box housing and kettle assembly to release pivot stop collar The support shaft should slide out of inner bearing easily Page 9 of 28 11 If re installing kettle assembly proceed to Installation in this section If installing a replacement kettle assembly remove components as outlined below from old kettle assembly for re use A Open pressure relief valve until reservoir jacket is completely vented B Place kettle on floor with the pressure relief valve and reservoir jacket fill elbow facing up C Remove BOTTOM COVER Remove WATER LEVEL PROBE E Position kettle assembly to drain fluid into container Remove 1 2 pipe plug from the reservoir jacket fill elbow to facilitate draining F Remove TEMPERATURE SENSOR AND PRESSURE SWITCH including condensate coil G Remove pressure relief valve assembly plumbing and reservoir jacket fill elbow H Remove HEATING ELEMENT I Install all removed components onto replacement kettle Clean threads and apply sealant before re installing pipe fittings Installation NOTE Bearings and shaft seal are self aligning for easy installation Bearings do not require lubrication 1 Place kettle assembly on 2x4 blocks and align support shaft to shaft seal Pull lead wire bundle thr
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