INSTALLATION & OPERATION MANUAL - Vulcan … › sites › default › files › ...INSTALLATION &...

INSTALLATION &OPERATION MANUAL

FORM 35457 (10-09)

ELECTRICSTATIONARY ANDTILTING KETTLES

MODEL MIL

K20EL 136073K40EL 136074K60EL 136075K20ETL 136077K40ELT 136078K60ELT 136079

For additional information on Vulcan-Hart or to locate an authorized partsand service provider in your area, visit our website at www.vulcanhart.com

VULCAN-HARTDIVISION OF ITW FOOD EQUIPMENT GROUP, LLCWWW.VULCANHART.COM

3600 NORTH POINT BLVD.BALTIMORE, MD 21222

60

30

30

150

120

90

0

Hgvac psi

K40EL

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ELECTRIC STATIONARY KETTLES

IMPORTANT FOR YOUR SAFETY

THIS MANUAL HAS BEEN PREPARED FOR PERSONNEL QUALIFIED TOINSTALL ELECTRICAL EQUIPMENT, WHO SHOULD PERFORM THE INITIALFIELD START-UP AND ADJUSTMENTS OF THE EQUIPMENT COVERED BY THISMANUAL.

: Improper installation, adjustment,alteration, service or maintenance can cause propertydamage, injury or death. Read the INSTALLATION,OPERATION and MAINTENANCE instructionsthoroughly before installing or servicing this equipment.

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CONTENTSIMPORTANT FOR YOUR SAFETY ................................................................................................2

INSTALLATION, OPERATION AND MAINTENANCE OFK20EL/ELT, K40EL/ELT AND K60EL/ELT ELECTRIC KETTLES .........................................4GENERAL ...................................................................................................................................4MODEL CHART .........................................................................................................................4DATA PLATE LOCATION ..........................................................................................................4

INSTALLATION................................................................................................................................. 5UNPACKING ...............................................................................................................................5INSTALLATION CODES AND STANDARDS ...........................................................................5LOCATION..................................................................................................................................5

Stationary Kettle ................................................................................................................... 5Tilting Kettle .......................................................................................................................... 5

MINIMUM CLEARANCE REQUIREMENTS andRECOMMENDED FLOOR DRAIN LOCATIONS .....................................................................6INSTALLATION PROCEDURE .................................................................................................6

Electrical Connection ...........................................................................................................6Electrical Specifications ......................................................................................................6

OPERATION .................................................................................................................................... 8VENTING.....................................................................................................................................8RESERVOIR JACKET WATER LEVEL CHECK .....................................................................8DAILY OPERATION ................................................................................................................... 8TILTING KETTLES .....................................................................................................................8CONTROLS AND INDICATORS............................................................................................... 8

CLEANING ........................................................................................................................................ 92" & 3" COMPRESSION VALVE CLEANING INSTRUCTIONS ............................................... 9PLUG VALVE CLEAINING INSTRUCTIONS ........................................................................... 10STAINLESS STEEL EQUIPMENT CARE AND CLEANING ................................................... 11

MAINTENANCE ............................................................................................................................. 13VENTING.................................................................................................................................. 13FILLING THE RESERVOIR JACKET ..................................................................................... 13

TROUBLESHOOTING .................................................................................................................. 14

SERVICE AND PARTS INFORMATION ...................................................................................... 15

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SAVE THESE INSTRUCTIONSFOR FUTURE USE

GENERAL

Vulcan Steam Jacketed Kettles are producedwith quality workmanship and material. Properinstallation, usage and maintenance will resultin many years of satisfactory performance. Itis suggested that you thoroughly read thisentire manual and carefully follow all of theinstructions provided.

MODEL CHART

Model Gallons Quarts Liters

K20EL, K20ELT 20 80 76

K40EL, K40ELT 40 160 152

K60EL, K60ELT 60 240 227

Fig. 1 Typical Stationary Kettle

INSTALLATION, OPERATION AND MAINTENANCEOF K20EL/ELT, K40EL/ELT AND K60EL/ELT

ELECTRIC KETTLESDATA PLATE LOCATION

The data plate stating the model number,serial number and the electrical characteristicsis located on the back of Control Panel. TheNational Board Data Plate is located on thelower skirt.

Fig. 2 Data Plate Location

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INSTALLATIONLOCATION

Stationary Kettle

Position the kettle in its final location. Check thatthere are sufficient clearances for operating andservicing the kettle, and proper clearance of thecover when raised. The kettle draw-off valveshould be located near a floor drain.

Tilting Kettle

Position the kettle in its final installed location toprovide drainage directly below pour path, withsufficient rear clearance from the wall to allowthe kettle to tilt completely without obstruction.

UNPACKING

This kettle was inspected before leaving thefactory. The transportation company assumesfull responsibility for safe delivery uponacceptance of the shipment.

Immediately after unpacking, check forpossible shipping damage. If kettle damage isfound, save the packaging material andcontract the carrier within 15 days of delivery.

INSTALLATION CODESAND STANDARDS

In the United States, Vulcan kettles must beinstalled in accordance with:

1. State and local codes

2. NFPA Standard NFPA-96, Vapor Removalfrom Cooking Equipment, latest edition,available from the National Fire ProtectionAssociation, Batterymarch Park, Quincy,MA 02269

3. National Electrical Code (ANSI/NFPANo.70, latest edition) available from theNational Fire Protection Association(NFPA), Batterymarch Park, Quincy, MA02269

In Canada, Vulcan kettles must be installed inaccordance with:

1. Local codes

2. Canadian Electrical Code (CSA C22.2No.3, latest edition) available from theCanadian Standards Association, 5060Spectrum Way, Mississauga, Ontario,Canada L4W 5N6

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MINIMUM CLEARANCEREQUIREMENTS AND RECOMMENDED

FLOOR DRAIN LOCATIONS

No side and back clearance required, exceptfor operation and service requirements.

Fig 3. Floor Drain Location

INSTALLATION PROCEDURE

Level the kettle by making necessaryadjustments using the flanged feet.

1. Place a spirit level on the rim of the kettlewith the cover open. Adjust the feet to levelthe kettle left-to-right and front-to-back.

2. Mark anchoring hole locations through theflanged feet.

3. With hole location marked, drill holes toaccommodate 5/16" studs.

4. Reposition the kettle.

5. Bolt the kettle down and apply an NSFapproved silicone sealant around thebolt heads and flange making contactwith floor surface. Wipe off excesssealant immediately.

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ELECTRICAL SPECIFICATIONS

Amperage per Line Minimum MODEL kW PHASE Circuit Ampacity

208V 240V 480V 208V 240V 480V

K20EL/ELT 12 1 57.7 – – 75 – –

3 33.3 – 14.4 45 – 20

16 1 – 66.7 – – 85 –

3 – 38.5 – – 50 –

K40EL/ELT18 3 50.0 43.3 21.7 65 55 30K60EL/ELT

K40EL/ELT24 3 66.6 57.7 28.9 85 75 40K60EL/ELT

K60EL/ELT 33 3 91.6 79.4 39.7 115 100 50

ELECTRICAL CONNECTION

: Electrical and ground-ing connections must comply with appli-cable portions of the National ElectricCode and/or other local electrical codes.

Disconnectelectrical power to themachine and follow Lockout/Tagout procedures.

1. Open the control box.

2. Using the wiring diagram for reference,connect electric supply to terminal block.

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OPERATION

: The kettle and its partsare hot. Use care when operating, clean-ing or servicing the kettle.

VENTING

While the kettle is cold, check the vacuum/pressuregauge. The gauge should be in the vacuum zonemeasuring between 20 to 30 in. Hg (84 to 100kPa).If not, there is air in the jacket and it must beremoved by venting for proper heating. Performthe VENTING procedure located in theMAINTENANCE section of this manual.

RESERVOIR JACKETWATER LEVEL CHECK

During use, the reservoir water level must bemaintained high enough to submerge theheating elements. If the low water light isilluminated during use, perform the FILLINGTHE RESERVOIR JACKET procedure locatedin the MAINTENANCE section of this manual.

DAILY OPERATION

1. Press the power switch to the ON position.

2. Preheat the kettle by placing the thermostatknob at Simmer/Boil (desired setting) andwait until the temperature light cycles off.

Food products with milk or egg base shouldbe placed into a cold kettle before cooking.Avoid sudden contact of these foodproducts to a hot kettle surface becausethey stick to the surface.

3. Pour the food to be cooked into the kettle.

TILTING KETTLES

The low water indicator light (red) should notbe lit when kettle is in upright position duringoperation. This light indicates that the elementshave been automatically shut off by the kettle’ssafety circuity. It is, however, normal for thelow water light (red light) to come on when thekettle is in a tilited posistion.

60

30

30

150

120

90

0

Hgvac psi

Fig. 4 Kettle Controls

CONTROLS AND INDICATORS

CONTROL FUNCTION

Vacuum Indicates the vacuum (inPressure inches) and pressureGauge ( in PSI) inside the

kettle jacket.

Thermostat Regulates kettle temperatureKnob from warm to a rolling boil.

Low Water When lit, indicatesIndicator insufficient water in the(Red) kettle jacket and the sensing

probe has interrupted powersupply to the controls and tothe heating element.

Power ON/OFF Controls power to the kettle.Switch

Power ON When lit, indicatesIndicator machine on/powered.(Amber)

Heater When lit, indicates theLight (Amber) heating element is turned on.

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CLEANING : The kettle and its

parts are hot. Use care when operating,cleaning or servicing the kettle.

NOTICE: Never spray the exterior ofthe kettle or control box withwater under any condition.Failure to comply will voidthe warranty.

The kettle interior and exterior should bethoroughly washed after each use when adifferent food is to be cooked next or whencooking is completed for the day.

1. Add water to the kettle for cleaning and toprevent residue from drying and sticking tothe inside of the kettle.

2. Loosen stuck-on food by allowing it tosoak at a low temperature setting.

Never use harsh or corrosive cleaningchemicals.

Never scrape the inside of the kettle withabrasive cleansers, metal tools or steelscouring pads, which will scratch the surface,spoil the appearance and make it more difficultto thoroughly clean.

3. Add mild detergent and scrub the kettleinterior with a nylon brush.

4. Thoroughly rinse the interior and dry with asoft cloth.

5. Rinse the exterior and dry with a soft cloth.

2" & 3" COMPRESSION VALVECLEANING INSTRUCTIONS

Daily Before Operation

Install draw-off valve assembly:

1. Apply PetroGel lubricant to valve stemthreads, “O” ring, rubber plug face andlarge nut threads.

2. Thread the valve stem into bonnet till valvecan be pulled through bonnet.

3. Insert assembly into valve body.

4. Install large nut hand tight.

5. Install valve handle, lock washer and nutonto the valve stem.

6. Turn valve handle clockwise until closed.Do not overtighten.

Daily After Use

Remove draw-off valve stem assembly forcleaning.

1. Turn the valve handle counterclockwiseuntil it stops.

2. Pull the valve handle back until it stops.

3. Turn large bonnet retaining nutcounterclockwise until the valve stemassembly is loose.

4. Pull the assembly straight out of the valvebody.

5. Remove the stem from the bonnet.

6. Wash valve body and steam assemblywith mild soap and water.

7. Leave assembly apart to air dry.

Fig. 6 Compression Valve

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PLUG VALVE CLEAININGINSTRUCTIONS

Daily Before Operation

Install draw off valve plug:

1. Apply PetroGel lubricant to valve taperedface.

2. Holding the valve handle, slide the plugdown into the valve body.

3. Install the bottom washer, making sure toalign the key with the groove in the valveplug.

4. Install the retaining ring and hand tighten.

NOTE: If the valve is hard to open the ring hasbeen overtightened.

Daily After Use

Remove draw-off valve plug for cleaning.

1. Unscrew the retaining ring and remove itand the bottom washer.

2. Pull the valve plug straight up to removefrom valve body.

3. Wash valve body, plug, washer andretaining ring with mild soap and water.

4. Leave assembly apart to air dry.

NOTE: 1. Care should be taken not toscratch, ding or dent the valveplug to prevent valve leakage.

2. If multiple kettles are in use careshould be taken keep each plugseparate and returned to itsoriginal valve body.

Valve Plug

Valve Body

Bottom Washer

Retaining Ring

Fig. 7 Plug Valve

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STAINLESS STEEL EQUIPMENTCARE AND CLEANING

Contrary to popular belief, stainlesssteels ARE susceptible to rusting.

Corrosion on metals is everywhere. It isrecognized quickly on iron and steel asunsightly yellow/orange rust. Such metals arecalled “active” because they actively corrodein a natural environment when their atomscombine with oxygen to form rust.

Stainless steels are passive metals becausethey contain other metals, like chromium, nickeland manganese that stabilize the atoms. 400series stainless steels are called ferritic, containchromium, and are magnetic; 300 seriesstainless steels are called austenitic, containchromium and nickel; and 200 series stainless,also austenitic, contains manganese, nitrogenand carbon. Austenitic types of stainless are notmagnetic, and generally provide greaterresistance to corrosion than ferritic types.

With 12-30 percent chromium, an invisiblepassive film covers the steel’s surface acting asa shield against corrosion. As long as the film isintact and not broken or contaminated, the metalis passive and stain-less. If the passive film ofstainless steel has been broken, equipmentstarts to corrode. At its end, it rusts.

Enemies of Stainless Steel

There are three basic things which can breakdown stainless steel’s passivity layer andallow corrosion to occur.

1. Mechanical abrasion

2. Deposits and water

3. Chlorides

Mechanical abrasion means those thingsthat will scratch a steel surface. Steel pads,wire brushes and scrapers are primeexamples.

Water comes out of the faucet in varying degreesof hardness. Depending on what part of thecountry you live in, you may have hard or softwater. Hard water may leave spots, and when

heated leave deposits behind that if left to sit, willbreak down the passive layer and rust stainlesssteel. Other deposits from food preparation andservice must be properly removed.

Chlorides are found nearly everywhere. Theyare in water, food and table salt. One of theworst chloride perpetrators can come fromhousehold and industrial cleaners. So whatdoes all this mean? Don’t Despair!

Here are a few steps that can help preventstainless steel rust.

1. Use the proper tools.

When cleaning stainless steel products,use non-abrasive tools. Soft cloths andplastic scouring pads will not harm steel’spassive layer. Stainless steel pads alsocan be used but the scrubbing motionmust be in the direct ion of themanufacturers’ polishing marks.

2. Clean with the polish linesSome stainless steel comes with visiblepolishing lines or “grain.” When visiblelines are present, always scrub in a motionparallel to the lines. When the grain cannotbe seen, play it safe and use a soft cloth orplastic scouring pad.

3. Use alkaline, alkaline chlorinated ornon-chloride containing cleaners.While many traditional cleaners are loadedwith chlorides, the industry is providing anever-increasing choice of non-chloridecleaners. If you are not sure of chloridecontent in the cleaner used, contact yourcleaner supplier. If your present cleanercontains chlorides, ask your supplier if theyhave an alternative. Avoid cleanerscontaining quaternary salts; it also can attackstainless steel and cause pitting and rusting.

4. Treat your water.Though this is not always practical,softening hard water can do much toreduce deposits. There are certain filtersthat can be installed to remove distastefuland corrosive elements. To insure properwater treatment, call a treatment specialist.

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Recommended cleaners for specific situations

JOB CLEANING AGENT COMMENTS

Routine cleaning Soap, ammonia, Apply with cloth or spongedetergent, Medallion

Fingerprints & smears Arcal 20, Lac-O-Nu Ecoshine Provides barrier film

Stubborn stains & Cameo, Talc, Zud, Rub in direction of polish linesdiscoloration First Impression

Grease & fatty acids, Easy-off, De-Grease It Oven Aid Excellent removal on allblood, burnt-on-foods finishes

Grease & oil Any good commercial detergent Apply with sponge or cloth

Restoration/Passivation Benefit, Super Sheen

Review

1. Stainless steels rust when passivity (film-shield) breaks down as a result of scrapes,scratches, deposits and chlorides.

2 Stainless steel rust starts with pits andcracks.

3. Use the proper tools. Do not use steelpads, wire brushes or scrapers to cleanstainless steel.

4. Use non-chlorinated cleaners atrecommended concentrations. Use onlychloride- free cleaners.

5. Soften your water. Use filters and softenerswhenever possible.

6. Wipe off cleaning agent(s) and standingwater as soon as possible. Prolongedcontact causes eventual problems.

To learn more about chloride-stress corrosionand how to prevent it, contact the equipmentmanufacturer or cleaning materials supplier.

Developed by Packer Engineering, Naperville, Ill., anindependent testing laboratory.Provided courtesy of NAFEM.

5. Keep your food equipment clean.Use alkaline, alkaline chlorinated or non-chloride cleaners at recommended strength.Clean frequently to avoid build-up of hard,stubborn stains. If you boil water in stainlesssteel equipment, remember the single mostlikely cause of damage is chlorides in thewater. Heating cleaners that contain chlorideshave a similar effect.

6. Rinse, rinse, rinse.If chlorinated cleaners are used, rinse andwipe equipment and supplies dry immedi-ately. The sooner you wipe off standingwater, especially when it contains cleaningagents, the better. After wiping equipmentdown, allow it to air dry; oxygen helps main-tain the stainless steel’s passivity film.

7. Never use hydrochloric acid (muriaticacid) on stainless steel.

8. Regularly restore/passivate stainlesssteel.

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MAINTENANCE

VENTING

The vacuum pressure gauge measuring zoneshould be between 20 to 30 in.Hg (84 to100kPa). If the vacuum pressure is not withinthis range, perform the following:

1. With the kettle empty, place the powerswitch to the ON position.

2. Set the temperature control to the maxheat setting. Let the kettle heat until itcycles off.

3. Pull the pressure relieve valve D-ring torelieve pressure for 10 seconds.

4. Turn kettle off and let cool. Check for acorrect vacuum pressure of 20 to 30 in. Hg(84 to 100kPa). If the reading is not correct,repeat steps 1 through 3.

60

30 150120

90

0Hgvac

psi

30

60

30 150120

90

0Hgvac

psi

30

Fig. 5 Rear of Kettle

FILLING THE RESERVOIR JACKET

Before adding water to the reservoir, the watersupply should be analyzed to ensure thathardness is no greater than 2.0 grains pergallon and the pH level is within the range of7.0 to 8.5. Water which fails to meet thesestandards should be treated, or use ionizeddistilled water with sodium. Equipment failurecaused by inadequate water quality is notcovered under warranty. To fill the reservoirjacket, perform the following:

1. Set the thermostat and power switch toOFF position.

2. Release any pressure by the O-ring on thepressure relief valve. Then remove the 1/2"plug on the back of the kettle.

3. Insert a funnel into the fill valve and add 3or 4 ounces of water.

4. Replace and properly tighten the 1/2" plug.

5. Turn on the kettle.

If the low water light turns on, turn off the unitand repeat steps 3 and 4. If low water light isoff, follow the venting procedure (seeVENTING) to vent air from reservoir.

TOTALMODEL DISTILLED WATER

REQUIREMENTS

K20EL / K20ELT 1.25 gallons (4.1)



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TROUBLESHOOTING

PROBLEM

Unit not Heating

Unit not heating todesired temperature

Draw valve is leaking

POSSIBLE CAUSES / SUGGESTED CORRECTIVE ACTION

ON/OFF switch OFF / ON/OFF switch ON.

Thermostat not on / Turn thermostat on.

No power / Check power supply.

Water level too low / Add water.

Malfunctioning power ON/OFF switch / Contact AuthorizedVulcan-Hart Service Provider.

Malfunctioning thermostat / Contact Authorized Vulcan-HartService Provider.

Contactors not connecting heating element to power source / ContactAuthorized Vulcan-Hart Service Provider.

Thermostat not on / Turn thermostat on.

Malfunctioning thermostat / Contact Authorized Vulcan-HartService Provider.

Check and clean any food residue with an extremely fine emery cloth.Replace the “O” ring.

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To obtain service and parts information concerning this unit, contact the Vulcan-Hart ServiceAgency in your area (refer to listing supplied with the steamer), or contact the Vulcan-Hart ServiceDepartment at the address or phone number shown on the front cover of this manual.

Parts and service are also available at www.vulcanhart.com.

SERVICE AND PARTS INFORMATION

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(10-09) PRINTED IN U.S.A.

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