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INSTALLATION AND OPERATION MANUAL, DIRECT STEAM KETTLES MOUNTED ON GAS

BOILER CABINET BASE, GMT-6, GMT-10, GMT-6-6, GMT-10-6, GMT-10-10

PART NUMBER 10072R1

3

2005-09-21

TABLE OF CONTENTS

DESCRIPTION 

PAGE

1.0  Service Connections   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.0 Installation Instructions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.0 Operation Instructions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.0 Operation Instructions for CSD-1 Equipped Units   . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.0 Periodic Maintenance   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6.0 Adjustments   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7.0 Troubleshooting   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

8.0 Introduction - Direct Steam Kettles   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

9.0 Operating Procedures   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

10.0 Cleaning Procedures   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

11.0 Preventive Maintenance   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Содержание GMT-10-10

Страница 1: ...PART NUMBER 10072R1 1 2005 09 21 INSTALLATION and OPERATION MANUAL DIRECT STEAM KETTLES MOUNTED ON GAS BOILER CABINET BASE MODELS GMT 6 GMT 10 GMT 6 6 GMT 10 6 GMT 10 10 WWW SOLARISSTEAM COM ...

Страница 2: ...perator of this appliance smells gas must be posted in a prominent location This information shall be obtained by consulting the local gas supplier Do not attempt to operate this unit in the event of a power failure Keep the appliance area free and clear from combustibles Do not obstruct the flow of combustion and ventilation air Adequate clearances must be maintained for servicing and proper oper...

Страница 3: ...OF CONTENTS DESCRIPTION PAGE 1 0 Service Connections 4 2 0 Installation Instructions 10 3 0 Operation Instructions 13 4 0 Operation Instructions for CSD 1 Equipped Units 16 5 0 Periodic Maintenance 19 6 0 Adjustments 22 7 0 Troubleshooting 24 8 0 Introduction Direct Steam Kettles 26 9 0 Operating Procedures 27 10 0 Cleaning Procedures 28 11 0 Preventive Maintenance 29 ...

Страница 4: ...INSTALLATION AND OPERATION MANUAL DIRECT STEAM KETTLES MOUNTED ON GAS BOILER CABINET BASE GMT 6 GMT 10 GMT 6 6 GMT 10 6 GMT 10 10 PART NUMBER 10072R1 4 2005 09 21 ...

Страница 5: ...INSTALLATION AND OPERATION MANUAL DIRECT STEAM KETTLES MOUNTED ON GAS BOILER CABINET BASE GMT 6 GMT 10 GMT 6 6 GMT 10 6 GMT 10 10 PART NUMBER 10072R1 5 2005 09 21 ...

Страница 6: ...INSTALLATION AND OPERATION MANUAL DIRECT STEAM KETTLES MOUNTED ON GAS BOILER CABINET BASE GMT 6 GMT 10 GMT 6 6 GMT 10 6 GMT 10 10 PART NUMBER 10072R1 6 2005 09 21 ...

Страница 7: ...INSTALLATION AND OPERATION MANUAL DIRECT STEAM KETTLES MOUNTED ON GAS BOILER CABINET BASE GMT 6 GMT 10 GMT 6 6 GMT 10 6 GMT 10 10 PART NUMBER 10072R1 7 2005 09 21 ...

Страница 8: ...ossible shipping damage If the appliance is found to be damaged save the packaging material and contact the carrier within 15 days of delivery Before installing verify that the gas natural or propane the elevation from sea level and the electrical supply agree with the specification on the data plate NOTE If this appliance is being installed above 2000 feet altitude contact your authorized service...

Страница 9: ...Undersized or low pressure lines will restrict the volume of gas required for satisfactory performance A steady supply pressure between 7 W C and 14 W C for natural gas and 11 W C and 14 W C for propane gas is recommended With all units operating simultaneously the manifold pressure on all units should not show any appreciable drop Fluctuations of more than 25 on natural gas and 10 on propane gas ...

Страница 10: ...flow of combustion and ventilation air Clearance from combustible construction must be a minimum of 3 inches from the sides and 6 inches from the back The appliance should be installed on a noncombustible floor Provide adequate clearances for cleaning maintenance service and proper operation Sufficient air should be allowed to enter the room to compensate for the amount of air removed by any venti...

Страница 11: ...lts and flanged feet with Silastic or equivalent compound INSTALLATION CODES AND STANDARDS The boiler must be installed in accordance with Gas installation to conform to local codes or in absence of local codes with the National Fuel Gas Code ANSI Z223 1 NFPA 54 In Canada installation to be in accordance with CSA B149 1 Natural Gas and Propane Installation Code 1 The appliance and its individual s...

Страница 12: ... 6 inches past the appliance and be located 6 feet 6 inches from the floor Filters should be installed at an angle of 45 degrees or more with the horizontal This position prevents dripping of grease and facilitates collecting the run off grease in a drip pan usually installed with the filter A strong exhaust fan tends to create a vacuum in the room and may interfere with burner performance or may ...

Страница 13: ...the lighting procedure immediately shut off the gas supply until the leak has been corrected For CSD 1 equipped boilers see section 4 0 Operation Instructions for CSD 1 Equipped Boiler BOILER CONTROLS Inside Cabinet Main Power Switch ON fills the boiler tank and turns the boiler controls on You should allow 20 minutes to fill the tank and generate steam OFF shuts off the boiler controls and opens ...

Страница 14: ...egin to enter boiler and required water level will be reached in about three minutes Observe water gauge glass to verify The dial on the combination gas control valve has three positions ON PILOT OFF for manual gas control of main burners and pilot Turn DIAL to PILOT Depress dial and light pilot burner located on centre main burner of boiler Maintain dial in depressed position for about 30 seconds...

Страница 15: ...ng the boiler and gas flows to the pilot Spark will begin in 2 to 3 seconds If the pilot fails to light in 90 seconds the control will provide 100 lockout If this occurs Wait 5 minutes then turn power switch off for one minute before turning power switch back on Once the pilot is lit and the required water level has been reached the main burners will ignite Burner will cycle to meet the steam pres...

Страница 16: ... will come ON Water will begin to enter the boiler When enough water has entered the boiler the amber STAND BY pilot light will come on 5 Press the RESET switch to begin boiler operation The STAND BY pilot light will go off and the boiler will begin operation If at anytime the flame should become extinguished a five 5 minute purging is required before relighting is attempted Daily Startup Procedur...

Страница 17: ...lve is so equipped 2 Shut off all supplies of power gas and water to the appliance Normal Boiler Operating Cycle Water Fill Cycle On the initial filling of the boiler the reset switch must be activated to initialize the safety lockout circuit Once the water in the boiler has reached the proper level the level control will stop the flow of water to the boiler As water is consumed in the production ...

Страница 18: ...re safety device is installed on the boiler Should the temperature exceed the limit of this device the boiler will be shut down and be put in a state of lockout The Temperature pilot light Red and the Standby pilot amber will come on High Pressure Condition A high pressure safety switch is installed on the boiler Should the pressure exceed the limit of this device the boiler will be shut down and ...

Страница 19: ... from the chamber by blowing down the control so that the accumulation of sediment does not interfere with the movement of the float in the control Control must be flushed at least once a day CAUTION Protect yourself When flushing control hot water and steam will flow out of the drain When flushing control note water level in gauge glass allow the boiler to fill if necessary and also to come up to...

Страница 20: ... the power supply to the appliance before cleaning or servicing 1 If water in sight glass is not clear and appears murky this indicates poor water quality and may cause control failure SEE WATER QUALITY STATEMENT page 4 2 Safety valve should be tripped during operation once a week to ensure that it is functioning properly 3 Clean around burners and orifices if lint has accumulated 4 Visually ensur...

Страница 21: ...every 90 to 120 days for scale build up Regular maintenance should be carried out at this time If the boiler is descaled a new Anode should be installed in the boiler to help extend its life 1 With boiler empty close manual blowdown valve If appliance is equipped with automatic blowdown turn water supply OFF to appliance Turn power switch ON This will energize and close blowdown valve 2 Remove 3 4...

Страница 22: ...turn OFF power switch and open low water control valve This will allow complete drainage Once drained close water level control valve 8 Turn appliance switch ON When boiler is completely filled turn power switch OFF This will rinse and drain boiler Appliance with manual blowdown valve must be opened to drain 9 Complete Step 8 twice to assure boiler is completely rinsed 10 Appliance is now ready fo...

Страница 23: ...uts off This should occur at 15 psi Set the high signal to switch at 14 5 psi on the gauge and the low signal to 13 0 psi 2 OVERRIDE PRESSURE SWITCHES Allow pressure to increase to 13 psi Set the high signal to switch at 13 psi on the gauge and the low signal to 11 psi 3 OPERATING PRESSURE SWITCHES Set the high signal to switch at 11 psi on the gauge and the low signal to 9 psi 4 Release pressure ...

Страница 24: ...orrect pressure at supply PILOT DOES NOT LIGHT OR GOES OUT 1 Gas not on 2 Power supply is off 3 Gas control knob is off 4 Low incoming gas pressure 5 Check thermocouple millivolts 6 Dirty or loose wire connection to ignition module Clean and or tighten 7 Pilot outage due to draft excess steam from drain or unit not level Improper venting can direct the flame away from the thermocouple or flame sen...

Страница 25: ...ply to unit is OFF 2 Manual shut off valve is OFF 3 Power supply is OFF 4 Faulty valve or ignition module 5 Pilot out 6 Pilot may require flame adjustment 7 Water level has not been reached in boiler Check water supply is on check water level control 8 If water at proper level check relay which energizes pressure switch and gas control 9 Pressure switch may need to be replaced if relay is operatin...

Страница 26: ...0 10 PART NUMBER 10072R1 26 2005 09 21 WATER NOT BEING SUPPLIED TO BOILER 1 Water supply is OFF 2 Defective water fill Solenoid Valve 3 Water level control clogged or defective unable to operate fill valve 4 Check that drain valve is closed 5 Supply water pressure too low BOILER SLOW TO HEAT UP 1 Lime build up contact service ...

Страница 27: ...d thus fully absorb the heat transmitted through that surface The temperatures required for the cooking process to function adequately must be greater than the boiling point of the liquid food product Further the greater the steam pressure used the higher the temperature and consequently the quicker the cooking process For example steam pressurized at 30 psi attains a temperature of 274 degrees Fa...

Страница 28: ... IN OPERATION MODE 1 Fill kettle with product to desired level 2 Slowly turn the steam control valve ON to full open position 3 The water or food should boil 3 4 minutes per gallon If it does not then incoming pressure should be checked to determine that it is adequate to operate the kettle efficiently 4 Regulate steam control valve depending on type of food being prepared 5 When food is cooked tu...

Страница 29: ...ve any food particles 3 Using a nylon brush clean kettle with a mild detergent and warm water rinse Never use steel wool or scouring powder as it will scratch stainless steel 4 Tilt kettle and rinse thoroughly draining out detergent solution Use of cleaning agents that contain chloride acids or salts are corrosive and may cause pitting and corrosion when used over a period of time this will reduce...

Страница 30: ...uted white vinegar with a non abrasive scouring pad plastic or cloth on the affected area to remove the rust stain The appliance should not be heated and remain at room temperature during the entire cleaning process 2 If the stain resists removal additional exposure time with vinegar may be required to a maximum of one hour 3 Thoroughly wash all of the vinegar away with fresh clear water Dry the s...

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