Cleveland KGL-100 Operator'S Manual Download Page 13 | Manualshive

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10

WRAP COVERS

TOP

LEFT SIDE

FRONT

RIGHT SIDE

BACK

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

KE01479-2

KE53483-2

KE54253-2

KE01432-2

KE02186-3

KGL-40-SH

KE01479-4

KE53483-6

KE54253-2

KE01432-2

KE02186-3

KGL-60-SH

KE01479-5

KE53483-7

KE54253-3

KE01432-3

KE02186-4

KGL-40-TSH

KE01479-4

KE53483-2

KE54253-2

KE01432-2

KE02186-3

SERVICE PARTS

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Summary of Contents for KGL-100

Page 1: ...nary KGL 40 KGL 60 KGL 80 KGL 100 Tilting KGL 40 T KGL 60 T KGL 80 T Short Series KGL 40 SH KGL 60 SH KGL 40 TSH KGL 40 KGL 40 T KGL 40SH SE95003 1 Rev 1 1333 East 179th St Cleveland Ohio U S A 44110 Phone 216 481 4900 Fax 216 481 3782 Visit our web site at www clevelandrange com Enodis ...

Page 2: ...efore cleaning or servicing unit All service must be performed by a qualified Cleveland Range Technician Do not obstruct the flow of combustion and ventilation air The installation and connection must comply with current local codes or in the absence of local codes with CAN CGA B149 1 and 2 installation code or with the national fuel gas code ANSI Z223 1 L988 Post in a prominent location instructi...

Page 3: ...14 Tangent Draw Off Valve 14 Gas Control Assembly 15 16 Gear Box Assembly 17 18 Console Controls 19 Maintenance Inspection and Maintenance Checklist 20 Kettle Safety Inspection Checklist 21 22 Lubrication Procedure 23 Hinge Adjustment Instructions 23 Operating Sequence 23 26 General 23 Kettle Won t Heat 24 Kettle Not Hot Enough 25 Kettle Gets too Hot 26 Kettle Venting Instructions 27 Vacuum Leak T...

Page 4: ...onal Building Code in Canada CLEARANCE REQUIREMENTS DRAIN LOCATIONS Note Dimensions clearance requirements and suggested drain locations are shown on the applicable SPECIFICATION DRAWING page 3 6 INSTALLATION 1 Position the unit in it s permanent location and level the unit by turning the adjustable feet 2 Once positioned and leveled permanently secure the unit s flanged feet to the floor using 5 ...

Page 5: ...kettle has been thoroughly tested before leaving the factory the installer is responsible for ensuring the proper operation of kettle once installed DO NOT ATTEMPT TO OPERATE THIS APPLIANCE DURING A POWER FAILURE KEEP APPLIANCE AND AREA FREE AND CLEAR OF COMBUSTIBLES 1 Before turning the kettle on read the vacuum pressure gauge The gauge s needle should be in the green zone If the needle is in the...

Page 6: ...0 000 100 gal DIMENSIONS GALS LITERS A B C D E F G H J K L M N O P S T I D 40 IN 35 1 8 37 32 1 4 40 1 2 9 1 4 16 71 1 2 9 9 16 17 3 4 25 15 16 10 3 8 18 5 8 26 7 8 28 1 2 4 5 8 24 1 2 26 150 mm 893 940 820 1029 235 407 1817 243 451 659 264 474 683 724 118 648 661 60 IN 38 1 4 39 34 1 4 43 1 2 8 3 4 14 1 4 75 8 15 16 19 1 8 29 5 16 10 3 8 18 5 8 27 7 8 30 1 4 5 1 4 27 29 1 2 225 mm 972 991 870 110...

Page 7: ...st be notified if unit will be operated above 2 000 ft altitude C B T U RATING 40 gal 140 000 60 gal 80 gal 190 000 100 gal H C DIMENSIONS GALS LITERS A B C D E F G H J K L M N O P Q S I D 40 IN 45 3 4 42 1 2 38 35 9 42 1 4 71 40 1 2 15 1 2 23 1 4 19 35 3 4 4 3 8 24 33 63 26 150 mm 1163 108 966 889 229 1074 1804 1029 394 591 483 909 112 610 839 1601 661 60 IN 49 3 8 46 41 1 2 37 11 3 4 47 1 4 75 4...

Page 8: ...5 8 2 21 6 11 5 20 8 43 5 23 mm 838 1056 1099 953 1752 394 185 170 279 711 902 208 549 292 528 1105 584 KGL 60SH IN 33 5 44 43 5 37 5 71 12 1 7 3 5 5 12 6 30 5 35 5 8 2 22 2 13 7 22 1 44 5 24 5 mm 850 1117 1104 953 1803 307 185 140 320 775 902 208 564 348 561 1130 622 GAS ELECTRIC WATER CLEARANCE NATURAL PROPANE BTU RATING 120V 1Phase 60 Hz 1 2 diameter RIGHT 0 Piping 3 4 N P T Piping 3 4 N P T 19...

Page 9: ... 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 Installation of backflow preventers vacuum breakers and other specific code requirements is the responsibility of the owner and installer Cleveland Range equipment is built to comply with applicable standards for manufacturers Included...

Page 10: ...or Light Indicates failure of heating system to ignite Amber 5 Vacuum Pressure Gauge Indicate steam pressure in PSI inside steam jacket as well as vacuum in inches of mercury 6 Pressure Relief Valve This valve is used to vent the kettle and in the unlikely event there is not shown an excess steam build up in the jacket this valve opens automatically to relieve this pressure 7 Water Level Sight Gla...

Page 11: ...ing kettle operation This light indicates that the burners have been automatically shut off by the kettle s safety circuit It is normal for the red light to come on when the kettle is in a tilted position However the kettle cannot be operated when the red light remains lit while the kettle is in the upright position This indicates a low water condition and water must be added to the reservoir Refe...

Page 12: ...ve stem is free of the valve body c In a sink wash and rinse the inside of the valve body using a nylon brush d Reassemble the draw off valve by reversing the procedure for disassembly The valve s hex nut should be hand tight only 6 Rinse kettle interior thoroughly then drain the rinse water Do not leave water sitting in unit when not in use 7 Using mild soapy water and a damp sponge wash the exte...

Page 13: ...E01432 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 KE01479 2 KE53483 2 KE54253 2 KE01432 2 KE02186 3 KGL 40 SH KE01479 4 KE53483 6 KE54253 2 KE01432 2 KE02186 3 KGL 60 SH KE01479 5 KE53483 7 KE54253 3 KE01432 3 KE02186 4 KGL 40 TSH KE01479 4 KE534...

Page 14: ...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 SAFETY VALVES 5 KE54941 5 1 2 FPT 50 PSI FOR ASME KETTLES 1 KE54941 31 1 2 FPT 50 PSI FOR CE KETTLE 1 6 KE54223 BLOW DOWN TUBE 1 7 KE54864 ACCESS PANEL 1 8 FA11518 4 THUMB SCREW 10 32 X 1 2 L 1 ...

Page 15: ...21 2 HINGE SPRING KGL 40 T 1 KE50121 1 KGL 60 T KGL 80 T KGL 100 T KGL 40 T SH KGL 60 T SH 1 4 KE50823 1 HINGE PIN KGL 40 T KGL 60 T KGL 80 T KGL 40 T SH 1 KE50823 2 KGL 100 T KGL 60 T SH 1 5 KE50824 HINGE BEARING 1 6 KE50819 1 HINGE END PIECE LHS 1 7 KE50820 HINGE INSERT 1 8 KE50819 HINGE END PIECE RHS 1 9 FA11284 SCREW SOCKET HEAD 1 4 20 X 1 2 4 10 FA11507 CUTTING SCREW 2 11 KE54907 10 PLUG BUTT...

Page 16: ...3 KE53469 IGNITION CONTROL 1 4 KE00458 KETTLE SOLID STATE CONTROL BOX 1 KE50303 BRACKET SOLID STATE CONTROL BOX 1 5 KE50753 7 RELAY 120V 1 KE50753 8 RELAY 240V 1 6 KE55069 6 SAFETY THERMOSTAT 1 7 FI05050 BRASS NUT 7 16 24 1 8 KE53436 AIR PRESSURE SWITCH 1 KE53432 AIR PRESSURE SWITCH BRACKET 1 9 KE53838 20 TRANSFORMER 120 24V 1 SIGHT GLASS ITEM ON PART NO DESCRIPTION QTY 1 KE50955 RETAINING COVER 1...

Page 17: ...E51571 1 SPHERICAL WASHER 1 5 FA95081 3 BOLT 5 16 18 X 1 2 1 6 KE51886 GREASE NIPPLE 1 1 2 3 4 5 6 7 TANGENT DRAW OFF VALVE ITEM NO PART NO DESCRIPTION QTY 1 7 TD 2 DRAW OFF ASSEMBLY 1 TD 3 DRAW OFF ASSEMBLY 1 1 FA95049 WING NUT TD 2 1 FA21050 ACCORN NUT TD 2 1 FA21501 1 ACCORN NUT TD 3 1 2 KE52755 KNOB TD 2 1 SE50018 KNOB TD 3 1 3 KE52754 HEX NUT TD 2 1 SE50016 HEX NUT TD 3 1 4 KE52753 RETAINER T...

Page 18: ...20 21 31 32 33 34 22 23 24 8 9 10 2 3 30 35 29 4 5 6 4 7 11 13 14 12 15 25 25 26 27 22 28 28 29 30 Stationary Models Tilting Models 34 Air Blower Primary Air Orifice Secondary Air Orifice Gas Orifice Ignitor Burner Gas Valve Shut Off Valve ...

Page 19: ...A LEVEL UP TO 2000 40 GALLON KETTLES 1 KE53403 6 NATURAL GAS SEA LEVEL UP TO 2000 60 100 GALLON KETTLES 1 KE53403 7 PROPANE GAS SEA LEVEL UP TO 2000 60 100 GALLON KETTLES 1 KE53403 8 NATURAL GAS 2000 UP TO 4000 40 GALLON KETTLES 1 KE53403 9 PROPANE GAS 2000 UP TO 4000 40 GALLON KETTLES 1 KE53403 10 NATURAL GAS 2000 UP TO 4000 60 100 GALLON KETTLES 1 KE53403 11 PROPANE GAS 2000 TO 4000 60 100 GALLO...

Page 20: ...17 GEARBOX ASSEMBLY 40 41 25 42 26 27 28 39 4 5 6 5 7 5 6 5 4 8 25 15 14 1 10 2 3 9 11 12 13 16 17 18 19 20 21 22 32 30 32 31 24 23 24 23 36 34 33 35 37 38 ...

Page 21: ...G CIRCUIT BREAKER 1 21 KE50579 CIRCUIT BREAKER 1 22 KE51007 MICRO SWITCH 2 FA10139 MACHINE SCREW 6 32 X 1 LG 4 KE50498 MICRO SWITCH INSULATION 2 FA32004 TOOTH LOCK WASHER 6 4 23 KE50582 CPLG ONTARIO BELTING G 100 5 8 BORE 2 24 FA95014 SQUARE KEY 3 16 X 3 16 X 1 LG 1 25 KE50583 RUBBER INSERT ONTARIO BELTING BUNA N 1 26 KE52832 MOTOR BODINE NSH 54RL 1 27 FA10487 HEX HD SCREW 1 4 20 X 1 LG 4 28 FA310...

Page 22: ... POTENTIOMETER USED PRIOR TO JANUARY 2000 1 4 KE51005 RUBBER BOOT 1 5 KE50569 1 KNOB POTENTIOMETER 1 6 KE50567 1 L E D RED 1 7 KE50568 1 L E D GREEN 1 8 KE50567 2 L E D AMBER 1 9 FA05002 18 O RING 3 10 KE50429 2 PRESSURE GAUGE 1 11 KE5555 5 B LABEL 1 KE95457 LABEL USED PRIOR TO JANUARY 2000 1 50 0 100 150 200 250 300 350 400 40 50 60 0 10 20 30 psi kPa V E N T A I R 4 5 9 8 1 7 9 2 10 3 6 USED PRI...

Page 23: ...smoothly Grease as described in LUBRICATION PROCEDURE page 23 ON OFF SWITCH Check for damage Replace if necessary TEMPERATURE CONTROL PRESSURE GAUGE Check that the gauge does not have moisture on its inside face Replace if moisture is present Check that the gauge shows a vacuum needle is well into the Green zone when cold and shows between 25 40 psi when unit is hot If not follow VACUUM LEAK TEST ...

Page 24: ... is a short list of the most common and the most dangerous alterations performed on kettles Plug Tube diameter reduced Frozen stuck or plugged Plumbed to drain or water line 1 2 3 4 Incorrect Installations 1 Safety valve has plug threaded into the discharge opening preventing any steam from escaping 2 Safety valve s tube diameter has been reduced 3 Safety valve is sticking frozen shut or plugged T...

Page 25: ...is removed from tubing 3 Safety thermostat electrical connection is bypassed Low Water Level Probe Probe bypassed by running A an additional wire Probe properly attached 260º 270º MAXIMUM KETTLE TEMPERATURE 265º If maximum temperature is not in this range on empty kettle refer to the CALIBRATING PROCEDURE on page 29 Operating Thermostat Probe bypassed by B grounding the connecting wire A B Switch ...

Page 26: ...gniter and ignite The kettle will build pressure until the controller is satisfied by the thermistor at the setting of the potentiometer The controller will then turn off the heat circuit until the temperature of the kettle is below the setting TROUBLESHOOTING GUIDES LUBRICATION PROCEDURE Lubricate the following parts every three months to insure smooth operation and reduce wear TRUNNION HOUSING W...

Page 27: ...o the kettle No Does the relay pull in Yes Replace the relay No Is there power to the blower Yes With the high limit temporarily bypassed is power at the blower No Replace the high limit Yes Replace the wire to the blower No Is there power to the ignition transformer Is there 24 VAC at the secondary of the ignition transformer Is there 24 VAC to the igniton module Yes Does the blower turn Replace ...

Page 28: ...hermister No Is the potentiometer resistance 50 000 ohms at low and 0 ohms at high Yes Replace controller Yes Replace the potentiometer No Does the kettle heat at all Yes See Problem Kettle won t heat No Is the blower turning Replace the high limit Is there voltage to the blower No Yes No Replace the blower No Replace the air switch Yes PROBLEM KGL Kettle Has Delayed Ignition Delayed Igniton Is th...

Page 29: ... Yes No Is the resistance of the thermister 100 000 ohms 10 at room temperature Yes Replace the thermister No Is the resistance of the potentiometer 50 000 ohms at the low setting and 0 ohms at high Yes Replace the controller Replace the potentiometer No Yes PROBLEM Red Add Water LED Stays On Does Red LED stay on after adding the proper amount of distilled water and rust inhibitor Add the proper a...

Page 30: ... STEAM CONTACT WITH SKIN COULD RESULT IN SERIOUS BURNS KEEP FACE HANDS AND BODY CLEAR OF DISCHARGE DANGER WORKING ON MACHINES WITH POWER COULD RESULT IN SEVERE ELECTRICAL SHOCK VACUUM LEAK TEST PROCEDURE If the kettle will not hold vacuum test for leaks at A Water Level Probe B Pressure Relief Valve Pressure Gauge and connecting plumbing C Boiler Drain Cap D Sight Glass LEAK TEST PROCEDURE 1 Heat ...

Page 31: ...rust inhibitor can also cause solidification 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 3 Remove Console Cover and Access Panel 4 Pull Pressure Relief Valve Ring open to insure vessel is not pressurized 5 Remove 1 4 copper tubing and reducer bushing 6 Add distilled water using a funnel if nec...

Page 32: ...page 30 for full instructions on the correct method for draining and refilling kettle jacket WARNING Improper refilling of kettle jacket will result in irreversible damage to unit 5 Replace Access Panel 6 Reconnect main power at fused disconnect switch CALIBRATING PROCEDURE 1 Insure the unit has a vacuum before you begin calibrating procedures If unit requires venting refer to KETTLE VENTING INSTR...

Page 33: ...osed Systems DESCRIPTION Recommended for our units is a blend of SODIUM NITRITE and BORAX for corrosion inhibition of ferrous metals and axoles for copper and copper alloy corrosion protection Product should be formulated for hot or cold closed recalculating water systems Source the chemicals stated above from your local water treatment company Mix only with water and follow manufactures recommend...

Page 34: ...1 KGL 60 to 100 KGL 60 T to 80 T 190000 Natural Gas 3 5 1 KGL 40 TSH 190000 Propane 3 5 1 KGL 40 F to 60 F KGL 40 SH to 60 SH 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 Remove main kettle CONSOLE COVER 4 Remove PLUG and SPRING 5 Remove GAS ORIFICE and O...

Page 35: ...s Orifice 1 FA05002 29 O Ring 1 KGL 60 to 100 Part No Description Quantity KE95591 Conversion Label 1 KE54420 1 Air Intake Washer 1 KE53403 7 Gas Orifice 1 FA05002 29 O Ring 1 FIELD CONVERSION INSTRUCTIONS Natural Gas to Propane Gas CONSOLE COVER NOTE Changing the gas type requires a new Rating Label be affixed to the unit When ordering conversion parts it is essential to provide both the Model an...

Page 36: ...33 WIRING DIAGRAMS Diagram 1 Floor Gas Kettle except KGL 25 T 110 120 Volts 60Hz 1 2 3 4 5 7 13 14 15 17 18 19 20 16 6 9 11 10 8 KE90407 E ...

Page 37: ...BER 1 8 KE50567 1 L E D RED 1 9 KE50568 1 L E D GREEN 1 10 SE00114 POTENTIOMETER WITH ON OFF SWITCH 1 11 KE50753 7 RELAY 120V 1 12 KE53838 20 TRANSFORMER 120 24V 1 13 KE50753 10 RELAY 2 14 FA20047 JAM NUT 5 16 24 1 KE53137 3 MOMENTARY SWITCH ACTIVATOR 1 KE53184 CONTACT SECTION HOLDER LATCH 1 15 KE50581 BRIDGE RECTIFIER 1 16 KE51007 MICRO SWITCH 2 17 KE50579 CIRCUIT BREAKER 1 18 KE52832 MOTOR BODIN...

Page 38: ...iagram 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 1 KE90407 1F 21 22 ...

Page 39: ...gram 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 1 KE90407 2E 23 25 24 ...

Page 40: ... CONTRO GLI SPRUZZI SPRITZWASSERDICHT DISCONNECT ELECTRICAL SUPPLY BEFORE WORKING ON KETTLE COUPER LE COURANT AVANT D INTERVENIR SUR L ÉQUIPEMENT DESCONECTAR LA ALIMENTACION ELECTRICA ANTES DE REALIZAR TRABAJOS EN EL EQUIPO DISINSERIRE LA CORRENTE PRIMA DI LAVORARE SULLA MACCHINA STROMVERSORGUNG AUSSCHALTEN BEVOR AM GERÄT GEARBEITET WIRD MAIN POWER ALIMENTATION ÉLECTRIQUE ALIMENTACION PRINCIPAL AL...

Page 41: ...OMMANDE AUTOMATIQUE DE LA TEMPÉRATURE AJUSTE AUTOMATICO DE TEMPERATURA CONTROLLO AUTOMATICO TEMPERATURA AUTOMATISCHE TEMPERATURREGELUNG BURNER AND OR ELEMENT ENERGIZED BRÛLEUR ET OU ÉLÉMENT ALLUMÉ QUEMADOR O ELEMENTO ENCENDIDO FIAMMA E O ELEMENTO ATTIVATI BRENNER ODER ELEMENT EINGESCHALTET HEATING ÉBULLITION CALEFACCION RISCALDAMENTO HEIZUNG HEAT ADJUSTMENT RÉGLAGE DE LA CHALEUR REGULACION DE CALO...

Page 42: ...s a recommended list of space parts that may be required if the service agency is of some distance away or if down time must be kept to a minimum and spare parts are required for the service agent on site PART NUMBER DESCRIPTION QUANTITY KE54941 5 1 2 FPT 50 PSI FOR ASME KETTLES 1 KE54941 31 1 2 FPT 50 PSI FOR CE KETTLE 1 KE53838 27 TRANSFORMER 120 14V 1 KE53469 IGNITION CONTROL 1 KE00458 KETTLE S...

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