Operators Manual Installation, Operation & Service Gas Floor Model Kettles MODELS: Stationary - KGL-40, KGL-60, KGL-80, KGL-100 Tilting - KGL-40-T, KGL-60-T, KGL-80-T Short Series - KGL-40-SH, KGL-60-SH, KGL-40-TSH KGL-40 KGL-40SH KGL-40-T 1333 East 179th St., Cleveland, Ohio, U.S.A. 44110 Enodis Phone: (216) 481-4900 Fax: (216) 481-3782 Visit our web site at www.clevelandrange.com SE95003-1 Rev.
FOR THE USER IMPORTANT! ENSURE KETTLE IS AT ROOM TEMPERATURE AND PRESSURE GAUGE IS SHOWING ZERO OR LESS PRESSURE PRIOR TO REMOVING ANY FITTINGS. FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR ANY OTHER FLAMMABLE LIQUIDS AND VAPOURS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death.
TABLE OF CONTENTS Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Shipping Damage Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION INSPECTION CLEARANCE REQUIREMENTS/ DRAIN LOCATIONS Before unpacking visually inspect the unit for evidence of damage during shipping. Note: Dimensions, clearance requirements and suggested drain locations are shown on the applicable SPECIFICATION DRAWING (page #3-6). If damage is noticed, do not unpack the unit, follow shipping damage instructions. SHIPPING DAMAGE INSTRUCTIONS INSTALLATION 1. Position the unit in it's permanent location, and level the unit by turning the adjustable feet.
ELECTRICAL INSTALLATION CHECKS ENSURE THE ELECTRICAL SUPPLY MATCHES THE KETTLE'S REQUIREMENTS AS STATED ON THE RATING LABEL. Although the kettle has been thoroughly tested before leaving the factory, the installer is responsible for ensuring the proper operation of kettle once installed. A cord and plug are supplied with the unit. Simply plug the unit into any grounded outlet rated for a minimum of 10 amps. The wiring diagram is located on the back of the console access panel.
Specification Drawing Stationary, KGL-40, KGL-60, KGL-80, KGL-100 K J A H 3 (77 mm) 4" (102 mm) M N O 120º TYP C B 4 7/8" 124 Ø mm 7/16" (11 mm) Ø 3 HOLES ON 3 1/8" (80 mm) Ø B.C.D. L 1 5/8" (42 mm) Ø 1" (25 mm) MAX. ADJUSTMENT FLANGED FOOT DETAIL FLOOR DRAIN 12" (305 mm) WIDE x 12" (305 mm) LONG VALVE OPENING P 9/16" 14 mm S 3" (77 mm) MINIMUM CLEARANCE T (I.D.
Specification Drawing Tilting, KGL-40-T, KGL-60-T, KGL-80-T 2 1/4" (57 mm) REF A 2 1/2" (64 mm) 3" (77 mm) REF M 2 1/2" (64 mm) E 7/16" (11 mm) Ø 3 HOLES ON 3 1/8" (80 mm) Ø B.C.D. L B P C F 4 7/8" 124 Ø mm 120º TYP Q 1 5/8" (42 mm) Ø 4 1/8" (105 mm) VALVE OPENING 1" (25 mm) MAX. ADJUSTMENT D 9/16" 14 mm FLANGED FOOT DETAIL O N HANDWHEEL REPLACED BY SWITCH FOR POWER TILT OPTION S I.D.
Specification Drawing - RECOMMENDED FLOOR SLOPE 4" (102 mm) RECOMMENDED Short Series, KGL-40-SH, KGL-60-SH, 1" (26 mm) per 4' (1220 mm) PIPE DRAIN RECOMMENDED min. valve size plus 1" (26 mm) 7/16" (11 mm) Ø 3 HOLES ON 3 1/8" (80 mm) Ø B.C.D. 4 7/8" 124 Ø mm 120º TYP 1 5/8" (42 mm) Ø 1" (25 mm) MAX. ADJUSTMENT 9/16" 14 mm FLANGED FOOT DETAIL DIMENSIONS MODEL NO KGL-40SH IN mm KGL-60SH IN mm A B C D E 33 41.6 43.3 37.5 69 838 1056 1099 953 1752 33.5 44 43.5 37.5 71 850 1117 1104 953 1803 F 15.
Specification Drawing Short Series, KGL-40-TSH 7/16" (11 mm) Ø 3 HOLES ON 3 1/8" (80 mm) Ø B.C.D. 4 7/8" 124 Ø mm 120º TYP 1 5/8" (42 mm) Ø 1" (25 mm) MAX. ADJUSTMENT 9/16" 14 mm FOOT LOCATION & FLOOR DRAIN DETAIL FLANGED FOOT DETAIL SPECIFICATIONS NOTES NOTES: Cleveland Range reserves right of design improvement or modification, as warranted. Many regional, state and local codes exist and it is the responsibility of the owner and installer to comply with the codes.
OPERATING INSTRUCTIONS 9 6 1 2 3 4 10 5 5 7 8 Operating Controls & Indicators ITEM # DESCRIPTION FUNCTION 1. Low Water Indicator Light (Red) When lit, indicates that the kettle is low on water and will not operate in this condition (see RESERVOIR FILL PROCEDURES on page #28. 2. On-Off Switch/ Solid State Temperature Control Turns kettle ON/OFF and allows the operator to adjust the kettle temperature in increments from 1 (Min.) to 10 (Max.). (see the TEMPERATURE RANGE CHART on page #8). 3.
OPERATING THE KETTLE 4. DO NOT ATTEMPT TO OPERATE THIS APPLIANCE DURING A POWER FAILURE. ! NOTE: Do not fill kettle above recommended level marked on outside of kettle. KEEP APPLIANCE AND AREA FREE AND CLEAR OF COMBUSTIBLES. DO NOT LEAN ON OR PLACE OBJECTS ON KETTLE LIP. SERIOUS INJURY COULD RESULT IF KETTLE TIPPED OVER, SPILLING HOT CONTENTS. NOTE: The red Low Water Indicator Light (1) should not be lit during kettle operation.
CLEANING INSTRUCTIONS CARE AND CLEANING c) In a sink, wash and rinse the inside of the valve body using a nylon brush. Your kettle must be cleaned regularly to maintain its fast, efficient cooking performance, and to ensure its continued safe, reliable operation. Chloride Cleaners d) Reassemble the draw-off valve by reversing the procedure for disassembly. The valve's hex nut should be hand tight only. WARNING: Do not use chloride base detergents.
SERVICE PARTS WRAP COVERS BACK TOP LEFT SIDE RIGHT SIDE FRONT KETTLE TOP FRONT LEFT SIDE RIGHT SIDE BACK KGL-40 KE01479-X KE53483-4 KE54253-X KE01432-X KE02186-1 KGL-60 KE01479-1 KE53483-5 KE54253-1 KE01432-1 KE02186-2 KGL-80 KE01479-2 KE53483-6 KE54253-2 KE01432-2 KE02186-3 KGL-100 KE01479-3 KE53483-7 KE54253-3 KE01432-3 KE02186-4 KGL-40-T KE01479-X KE53483-X KE54253-X KE01432-X KE02186-1 KGL-60-T KE01479-1 KE53483-1 KE54253-1 KE01432-1 KE02186-2 KGL-80-T KE014
PRESSURE RELIEF ASSEMBLY 4 5 2 3 6 8 7 ITEM NO. PART NO. DESCRIPTION QTY. PRESSURE RELIEF VALVE ASSEMBLIES 1. KE01450 FOR ASME KETTLES (INCLUDES #2-6) 1 KE01450-1 FOR CE KETTLES (INCLUDES #2-6) 1 2. FA05049 MALE CONNECTOR, 1/2" PIPE - 1/4" TUBE 1 3. FI00151 STREET ELBOW, 90°, 1/2", BRASS 2 4. FI00178 TEE, 1/2" FPT, BRASS 1 5. KE54941-5 1/2" FPT, 50 PSI., FOR ASME KETTLES SAFETY VALVES 1 KE54941-31 1/2" FPT, 50 PSI., FOR CE KETTLE 1 6. KE54223 BLOW DOWN TUBE 1 7.
HINGE ASSEMBLY 9 4 7 11 8 6 10 1 9 5 12 13 2 3 ITEM NO. PART NO. DESCRIPTION QTY. 1. - 11 SE00120-1 HINGE ASSEMBLY - KGL-40/T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SE00120-2 KGL-60/T, KGL-80/T, KGL-40-T/SH . . . . . . . . . . . . . . . .1 SE00120-3 KGL-100/T, KGL-60-T/SH . . . . . . . . . . . . . . . . . . . . . . . .1 1. KE50882 HINGE BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2.
ELECTRICAL COMPONENT BOX ITEM ON. PART NO. DESCRIPTION KE01422 ELECTRICAL CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 KE53439 COMPONENT BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 KE53440 COVER, COMPONENT BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 KE53599-1 GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRUNNION ASSEMBLY 1 For the following units with covers KGL-40-T KGL-60-T KGL-80-T ITEM PART NO. NO. DESCRIPTION QTY. 1. KE00354 TRUNNION BEARING ASSEMBLY . . . . . .1 2. KE00351 TRUNNION BEARING ASSEMBLY . . . . . .1 3. KE51711 ROLLER BEARING . . . . . . . . . . . . . . . . . 2 4. KE51571-1 SPHERICAL WASHER . . . . . . . . . . . . . . . .1 5. FA95081-3 BOLT, 5/16-18 X 1/2" . . . . . . . . . . . . . . . . .1 6. KE51886 GREASE NIPPLE . . . . . . . . . . . . . . . . . . . .
GAS CONTROL ASSEMBLY Air Blower Primary Air Orifice 1 Stationary Models 21 25 22 2 23 24 3 Secondary Air Orifice 26 4 27 22 16 28 17 19 18 7 20 5 Gas Orifice 29 6 Ignitor 4 Burner Gas Valve 34 8 9 11 28 12 Shut-Off Valve 15 13 14 30 25 31 32 33 34 Tilting Models 30 29 35 15 10
GAS CONTROL ASSEMBLY ITEM ON. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. PART NO. DESCRIPTION QTY. KE53441 BLOWER, 115V, 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX ASSEMBLY 8 4 5 5 9 5 4 1 3 7 5 6 6 2 42 25 26 27 28 39 41 10 40 14 30 32 15 23 25 24 33 34 35 36 13 11 12 22 38 37 31 32 21 16 19 20 17 18 17
GEARBOX ASSEMBLY ITEM NO. PART NO. DESCRIPTION QTY. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. KE52836-2 KE50315 FA95005 KE52193 KE52192 KE52191 FA30088 FA95008 KE55057-4 FA95062 KE00508 FA19501 KE51730 FA19177 FA20047 KE53137-3 KE53184 KE53138-1 KE50580 FA00012 KE50579 KE51007 FA10139 KE50498 FA32004 KE50582 FA95014 KE50583 KE52832 FA10487 FA31008 FA20026 KE517112 KE517111 KE51712 TILT SHAFT . . . . . . . . . . . . . . . . .
CONSOLE CONTROLS 6 9 11 3 7 9 5 4 1 10 0 50 15 0 10 20 AI R 0 0 VE NT 8 9 2 20 0 30 USED PRIOR TO JANUARY 2000 25 0 40 30 0 50 35 0 ps60 i kP 40 a 0 10 ITEM NO. PART NO. DESCRIPTION 1. 2. 3. KE50504 SK50062 SE00114 KE50988-2 KE51005 KE50569-1 KE50567-1 KE50568-1 KE50567-2 FA05002-18 KE50429-2 KE5555-5-B KE95457 SWITCH, TOGGLE (USED PRIOR TO JANUARY 2000) . . . . . . . . . . . . . . . . . . .1 RUBBER BOOT (USED PRIOR TO JANUARY 2000) . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE INSPECTION AND MAINTENANCE CHECKLIST Cleveland Range equipment requires little preventative maintenance. We do however provide the following chart as a guideline for inspection and maintenance to keep your unit functioning at 100%. INSPECTION AND MAINTENANCE CHECKLIST The following checks should be completed every six months or more frequently if unit is in a high volume facility. WARNING: It is imperative that damaged seals be repaired immediately to prevent equipment failure and/or damage.
KETTLE SAFETY INSPECTION CHECKLIST Regular inspection and maintenance of units is essential to obtain trouble free and safe operation of equipment. Inspections must include testing of the pressure relief valve and checks of the operating system to insure that it has not been altered. No safety features designed into the equipment should ever be tampered with. Tampering with or bypassing controls is a very dangerous practice and unfortunately we have seen several cases of this.
SAFETY THERMOSTAT: Incorrect Installations 1 ✔ 2 3 Probe fully inserted in tube Wiring is properly connected ✘ ✘ Probe removed partially Probe removed completely ✘ Thermostat electrically bypassed 1 Safety thermostat probe is not completely inserted into tubing. 2 Safety thermostat probe is removed from tubing. 3 Safety thermostat electrical connection is bypassed.
LUBRICATION PROCEDURE HINGE ADJUSTMENT INSTRUCTIONS Lubricate the following parts every three months to insure smooth operation and reduce wear. TRUNNION HOUSING, WORM SCREW AND TILT GEAR Adjusting Screw Worm Screw and Tilt Gear Cross Bar These parts are accessed through the top cover of the console. 1. 2. 3. Apply grease to gear teeth. Check for excessive play and adjust with adjusting screw located on top of cross bar. Trunnion Housing Grease Nipple 3/8" Allen wrench 4. KETTLE TRUNNIONS 5. 6.
TROUBLESHOOTING GUIDES (continued) PROBLEM: KGL Kettle Won't Heat Replace the on/off switch (toggle or rotary). Does red light come on when unit is first turned on? Yes Is 16 VAC at the secondary side of the transformer? No Yes Does red light go off shortly after unit is turned on? No Yes Is 16 VAC measured across Pins 9 and 10 on the controller? With the potentiometer set at 10, is 12 VDC at the coil of the relay? Yes No Add water to jacket of Kettle. Yes No Replace the relay.
TROUBLESHOOTING GUIDES (continued) PROBLEM: KGL Kettle Not Hot Enough See Problem: Kettle won't heat. No Does the kettle heat at all? With kettle pot empty and Yes temperature knob set at 10, is the temperature of the surface of the pot 260 degrees? Unit is operating properly Yes No Vent the kettle per instructions in the manual.
TROUBLESHOOTING GUIDES (continued) PROBLEM: KGL Kettle Gets Too Hot The kettle is working properly. Yes With the kettle empty and the temperature set at 10, is the surface temp 260-265 degrees? No Does the kettle continue to call for heat (green light stays on) when the kettle reaches 260-265 degrees? Replace the gas valve.
KETTLE VENTING INSTRUCTIONS 150 If the kettle will not hold vacuum, test for leaks at: 200 100 0 250 20 50 VACUUM LEAK TEST PROCEDURE Pressure Relief Valve A. Water Level Probe. 30 10 300 40 0 IR NT A VE 50 60 Valve Ring 400 psi B. Pressure Relief Valve/Pressure Gauge and connecting plumbing. 350 kPa C. Boiler Drain Cap. Access Panel D. Sight Glass.
RESERVOIR FILL PROCEDURES 150 200 100 30 10 WARNING: IMPROPER REFILLING OF 300 40 0 50 IR NT A VE 0 250 20 50 60 KETTLE JACKET WILL RESULT IN IRREVERSIBLE DAMAGE TO UNIT. psi 350 400 kPa 1. Ensure kettle is at room temperature and pressure gauge showing zero or less pressure. 2. Shut off power to the kettle at the fused disconnect switch. The kettle's water level must be maintained at the proper level.
PRESSURE RELIEF VALVE PERIODIC TESTING NOTES: If valve appears to be sticking replace pressure relief valve. If foreign material is discharged then drain kettle and replace pressure relief valve. Pressure Relief Valve See KETTLE JACKET FILLING AND DRAINING PROCEDURES on page #30 for full instructions on the correct method for draining and refilling kettle jacket. Valve Ring WARNING: Improper refilling of kettle jacket will result in irreversible damage to unit. Access Panel 5. Replace Access Panel.
KETTLE JACKET FILLING & DRAINING PROCEDURES 150 200 100 Under normal circumstances the kettle does not require the draining of all fluid. If the red “low water” light is on, follow the RESERVOIR FILL PROCEDURES (page #28) in this manual. 30 10 300 40 0 IR NT A VE 0 250 20 50 50 60 psi 350 400 kPa 1. Ensure kettle is at room temperature and pressure gauge showing zero or less pressure. 2. Shut off power to the kettle at the fused disconnect switch.
GAS KETTLE ORIFICE REPLACEMENT NOTE: Use thread sealant compatible with propane gas on all threaded piping connections. 1. Disconnect electrical connection. 2. Shut off main gas supply and disconnect kettle from supply line. 3. 4. Remove main kettle CONSOLE COVER. 1. Remove Console Cover Remove PLUG and SPRING. Remove Plug and 5. 2. Remove GAS ORIFICE and Spring “O” RING. 6. 7. Replace first with new “O” RING and then GAS ORIFICE. 3. Remove Orifice Replace SPRING and PLUG.
FIELD CONVERSION INSTRUCTIONS Natural Gas to Propane Gas Kettles KGL-40, KGL-40-T, KGL-60 to 100, KGL-60-T to 80-T, KGL-40-TSH, KGL-40-F to 60-F, KGL-40-SH to 60-SH, BTU's per Hour 140000 140000 Gas Type Natural Gas Propane Water Column 3.5 3.5 # of Orifices 1 1 “O” RING GAS ORIFICE SPRING 190000 190000 Natural Gas Propane 3.5 3.5 PLUG 1 1 CONSOLE COVER Conversion Parts Required KGL-40 NOTE: Use thread sealant compatible with propane gas on all threaded piping connections. Part No.
WIRING DIAGRAMS Diagram #1: Floor Gas Kettle (except KGL-25/T) 110-120 Volts, 60Hz 3 1 4 2 5 6 20 7 8 10 9 11 19 16 18 13 17 15 14 KE90407-E 33
Diagram #1 (continued): Floor Gas Kettle (except KGL-25/T) 110-120 Volts, 60Hz ITEM NO. PART NO. DESCRIPTION QTY. 1 KE55069-6 SAFETY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 2 KE53436 AIR PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 3 KE53441 BLOWER, 115V, 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram #2 (see Diagram #1 for common parts): Floor Gas Kettle (except KGL-25/T) 200-240 Volts, 60Hz ITEM NO. PART NO. DESCRIPTION QTY. 21 KE53838-2 TRANSFORMER 120-24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 22 KE53441 BLOWER, 115V, 60 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram #3 (see Diagram #1 for common parts): Floor Gas Kettle (except KGL-25/T) 200-240 Volts, 50Hz ITEM NO. PART NO. DESCRIPTION QTY. 23 KE53441-1 BLOWER, 220V, 50 HZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 24 KE53838-2 TRANSFORMER 120-24V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 25 KE50753-8 RELAY, 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
✔ Symbol Legend (page 1 of 2) ❐ English ❐ French ❐ Spanish ❐ Italian ❐ German ❐ Chinese-Simplified ❐ Chinese-Traditional ✔ ✔ ✔ RISK OF ELECTRICAL SHOCK DANGER DE SECOUSSE ÉLECTRIQUE PELIGRO DE ELECTROCHOQUE PERICOLO DI SCOSSA STROMSCHLAG-GEFAHR ✔ ✔ ✔ ✔ SPLASHPROOF ANTIÉCLABOUSSURES A PRUEBA DE SALPICADURAS PROTETTO CONTRO GLI SPRUZZI SPRITZWASSERDICHT ✔ ✔ ✔ ✔ DISCONNECT ELECTRICAL SUPPLY BEFORE WORKING ON KETTLE COUPER LE COURANT AVANT D'INTERVENIR SUR L'ÉQUIPEMENT DESCONECTAR LA ALIMENTACION EL
Symbol Legend (page 2 of 2) ❐ English ❐ French ❐ Spanish ❐ Italian ❐ German ❐ Chinese-Simplified ❐ Chinese-Traditional ✔ AUTOMATIC TEMPERATURE CONTROL COMMANDE AUTOMATIQUE DE LA TEMPÉRATURE AJUSTE AUTOMATICO DE TEMPERATURA CONTROLLO AUTOMATICO TEMPERATURA AUTOMATISCHE TEMPERATURREGELUNG LOW WATER NIVEAU BAS DE L'EAU NIVEL DE AGUA BAJO LIVELLO BASSO WASSERSTAND NIEDRIG ✔ ✔ ✔ BURNER AND/OR ELEMENT ENERGIZED BRÛLEUR ET/OU ÉLÉMENT ALLUMÉ QUEMADOR O ELEMENTO ENCENDIDO FIAMMA E/O ELEMENTO ATTIVATI BRENNER OD
SPARE PARTS LIST The following is a spare parts listing of parts that wear during normal us or are apt to be misplaced during normal operation. These parts should be kept on hand to prevent loss time due to a minor problem. PART NUMBER DESCRIPTION QUANTITY KE00458 KETTLE SOLID STATE CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 KE50753-7 RELAY, 120V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .