Groen Ah/1 User manual

IMPORTANT INFORMATION

IMPORTANT INFORMATIONIMPORTANT INFORMATION

IMPORTANT INFORMATION

KEEP FOR OPERATOR

KEEP FOR OPERATORKEEP FOR OPERATOR

KEEP FOR OPERATOR

IMPORTANT INFORMATION

MPORTANT INFORMATIONMPORTANT INFORMATION

MPORTANT INFORMATION

NEW Model AH/1

[Manufactured After May 1999]

OPERATOR MANUAL OM-AH

Part Number 121051 - Rev. B DOMESTIC

Model: AH/1

Steam Jacketed Kettle

[with Standard Electronic Ignition]

Self-contained

Stainless Steel

Gas Heated

Floor Mounted

Stationary

THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE. READ, UNDERSTAND

AND FOLLOW THE INSTRUCTIONS AND WARNINGS CONTAINED IN THIS MANUAL.

FOR YOUR SAFETY

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND

LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

POST IN A PROMINENT LOCATION

INSTRUCTIONS TO BE FOLLOWED IN THE EVENT USER SMELLS GAS. THIS

INFORMATION SHALL BE OBTAINED BY CONSULTING YOUR LOCAL GAS

SUPPLIER. AS A MINIMUM, TURN OFF THE GAS AND CALL YOUR GAS COMPANY

AND YOUR AUTHORIZED SERVICE AGENT. EVACUATE ALL PERSONNEL FROM

THE AREA.

WARNING

IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR

MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS THOROUGHLY

BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.

Information contained in this document is

known to be current and accurate at the time

of printing/creation. Unified Brands recom-

mends referencing our product line websites,

unifiedbrands.net, for the most updated

product information and specifications.

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IMPORTANT — READ FIRST — IMPORTANT

WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE

CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION,

OPERATING AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR

SERVICING THIS EQUIPMENT.

WARNING: THE UNIT MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH GAS AND

ELECTRICITY.

UNIT MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE CODES.

CAUTION: TO AVOID DAMAGING PARTS OF THE BURNER SYSTEM UNDERNEATH THE KETTLE, LIFT

THE UNIT ONLY BY THE RING BENEATH THE OUTER PORTION OF THE BODY.

WARNING: DO NOT ATTACH THE UNIT TO A TYPE “B” VENT. IT COULD CAUSE FIRE OR PROPERTY

DAMAGE.

WARNING: DO NOT CONNECT ANY PIPING TO THE SAFETY VALVE. IT MUST BE FREE TO VENT

STEAM AS NEEDED. TO AVOID BURNS FROM THE VENTED STEAM THE VALVE

DISCHARGE SHOULD POINT DOWN. IMPROPER INSTALLATION WILL VOID WARRANTY.

DANGER: ELECTRICALLY GROUND THE UNIT AT THE TERMINAL PROVIDED. FAILURE TO GROUND

THE UNIT COULD RESULT IN ELECTROCUTION AND DEATH.

CAUTION: BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE OPERATING

INSTRUCTIONS, CAUTIONS AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL.

CAUTION: DO NOT OVERFILL THE KETTLE WHEN COOKING, HOLDING OR CLEANING. KEEP

LIQUIDS A MINIMUM OF 2-3" (5-8 CM) BELOW THE KETTLE BODY RIM TO ALLOW

CLEARANCE FOR STIRRING, BOILING AND SAFE TRANSFER OF PRODUCT.

CAUTION: KEEP FLOORS IN FRONT OF KETTLE WORK AREA CLEAN AND DRY. IF SPILLS OCCUR,

CLEAN IMMEDIATELY TO AVOID SLIPS OR FALLS.

WARNING: KEEP WATER AND SOLUTIONS OUT OF CONTROLS AND BURNERS. NEVER SPRAY OR

HOSE DOWN THE CONTROL CONSOLE, ELECTRICAL CONNECTIONS, ETC.

CAUTION: MOST CLEANERS ARE HARMFUL TO THE SKIN, EYES, MUCOUS MEMBRANES AND

CLOTHING. TAKE PRECAUTIONS: WEAR RUBBER GLOVES, GOGGLES OR FACE

SHIELD AND PROTECTIVE CLOTHING. CAREFULLY READ WARNINGS AND FOLLOW

DIRECTIONS ON CLEANER LABELS .

NOTICE: NEVER LEAVE A SANITIZER IN CONTACT WITH STAINLESS STEEL SURFACES LONGER

THAN 10 MINUTES. LONGER CONTACT CAN CAUSE CORROSION AND PITTING.

WARNING:FAILURE TO PERIODICALLY CHECK SAFETY VALVE OPERATION COULD RESULT IN

PERSONAL INJURY AND/OR DAMAGE TO EQUIPMENT.

WARNING: WHEN TESTING, AVOID EXPOSURE TO THE STEAM BLOWING OUT OF THE SAFETY

VALVE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS.

WARNING: TO AVOID INJURY, READ AND FOLLOW ALL PRECAUTIONS STATED ON THE LABEL OF

THE WATER TREATMENT COMPOUND.

WARNING: BEFORE REPLACING ANY PARTS, DISCONNECT THE UNIT FROM THE ELECTRIC POWER

SUPPLY AND CLOSE THE MAIN GAS VALVE. ALLOW FIVE MINUTES FOR GAS TO VENT.

CAUTION: USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY GROEN OR

AUTHORIZED DISTRIBUTORS CAN CAUSE INJURY TO THE OPERATOR AND DAMAGE TO

THE EQUIPMENT AND WILL VOID ALL WARRANTIES.

WARNING: KEEP AREA AROUND KETTLE FREE AND CLEAR OF ALL COMBUSTIBLE MATERIALS.

FAILURE TO DO SO COULD RESULT IN FIRE OR PROPERTY DAMAGE.

CAUTION: HEATING AN EMPTY KETTLE MAY CAUSE THE RELEASE OF STEAM FROM THE SAFETY

VALVE.

IMPORTANT: SERVICE PERFORMED BY OTHER THAN FACTORY AUTHORIZED PERSONNEL WILL VOID

ALL WARRANTIES.

WARNING:

CAUTION: UNIT WEIGHS 470 TO 1120 LB. (212 TO 509 KG). FOR SAFE HANDLING, INSTALLER SHOULD

OBTAIN HELP AS NEEDED, OR EMPLOY APPROPRIATE MATERIALS HANDLING EQUIPMENT

(SUCH AS A FORKLIFT, DOLLY, OR PALLET JACK) TO REMOVE THE UNIT FROM THE SKID

AND MOVE IT TO THE PLACE OF INSTALLATION.

WARNING: THIS UNIT IS DESIGNED FOR COMMERCIAL USE. NEVER USE HOME OR RESIDENTIAL

GRADE GAS CONNECTIONS. THEY DO NOT MEET COMMERCIAL GAS CODES AND COULD

BE HAZARDOUS.

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Table of Contents

INSTALLERANDOPERATORWARNINGS ......................................2

REFERENCES.............................................................3

EQUIPMENTDESCRIPTION .................................................4

INSPECTION & UNPACKING .................................................5

INSTALLATION&START-UP .................................................6

OPERATION ..............................................................8

SEQUENCEOFOPERATION ................................................10

CLEANING ...............................................................11

MAINTENANCE ...........................................................12

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

PARTSLISTS... ..........................................................16

 ................................................22

SERVICELOG ............................................................23

WARRANTY..............................................................24

References

CSA America Inc.

8501 East Pleasant Valley Road

Cleveland, Ohio 44131

ANSI Z83.11

NATIONAL SANITATION FOUNDATION

3475 Plymouth Rd.

Ann Arbor, Michigan 48106

NSF / ANSI 4

AMERICAN NAT’L STANDARDS INST., INC.

1430 Broadway

New York, New York 10018

Z223.1-1984 - National Fuel Gas Code

Z21.30 - Installation of Gas Appliances & Piping

NATIONAL FIRE PROTECTION ASSOCIATION

60 Battery March Park

Quincy, Massachusetts 02269

NFPA/54 - Installation Gas Appliances & Piping

NFPA/70 - The National Electrical Code

ELECTRICAL SCHEMATIC..

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Equipment Description

Groen AH/1E steam kettles are stainless steel, floor

mounted kettles with a self-contained steam source

heated by gas. A closed steam jacket covers the

lower bof the kettle. Heat from the gas burner boils

water in the jacket to produce steam under

pressure. To ignite the burners, Model AH/1 uses

electronic spark ignition.

The kettles are stationary (non-tilting). Liquids can

be removed through the tangent draw-off valve.

Exposed surfaces are stainless steel. Insulated

sheathing protects the kettle body, and a housing

encloses the controls. Three tubular legs support

the unit. Bullet feet adjust to level the kettle.

A one piece dome cover is hinged to the kettle on

the AH/1E-20. Covers for 40, 60, 80, and 100 gallon

kettles are supplied with counterbalancing spring

actuators to hold the covers in the fully open or

closed position.

Controls provided include the ON/OFF switch, to

control electric power for the unit, and the

thermostat, to set the cooking temperature. The

automatic controls and a brief description of each

are as follows.

a. Gas pressure regulator: Protects the unit from

high pressure in the gas supply line

b. Automatic gas valves: Allow gas into the

burners as needed

c. Pressure limit switch: Turns off the burner when

jacket pressure reaches 27 PSI. Lights the

burner when pressure drops to 22 PSI.

d. Safety valve: Lets steam out of the jacket if the

steam pressure exceeds 30 PSI.

e. Low-water cutoff: Turns off the burner if the

water level in the jacket gets too low for safe

operation

Instruments also are provided to show what is

happening inside the unit. These are:

a. Water level sight glass: Indicates whether there

is enough water in the steam jacket.

b. Pressure/vacuum gauge: Shows steam

pressure, and whether too much air has entered

the jacket.

c. Heating indicator light: Indicates that the kettle

is being heated.

d. Power on indicator light: Glows when the unit is

turned on.

e. Low water indicator light: Lights to show that

jacket water needs to be replenished.

The kettle body is welded into one piece and has a

rim reinforced by a rectangular bar. The interior and

exterior of the kettle is polished to a 180 emery grit

finish. The unit is ASME shop inspected and

registered with the National Board for working

pressures up to 30 PSI.

The standard 2 inch tangent draw-off is a 316

stainless steel, compression disc valve. A

removable strainer with ¼ inch holes keeps pieces

of product from entering the draw-off during

cooking.

The jacket is filled at the factory with water

containing rust inhibitors. The kettle can operate at

steam pressures up to 30 PSI, which provide

temperatures of 150ºF (65ºC) to approximately

270ºF (135ºC). This range allows warming,

simmering, boiling, or braising.

For AH/1 kettles, options include:

a. Larger (3 inch) draw-off

b. Solid disc strainer or strainer with cinch

perforations

c. Water fill faucets

d. Automatic, metered water filler (Gallon Master)

e. Basket Inserts (Model TRI-BC)

f. Kettle brush kit

g. Gallon etch marks

h. Flanged feet

KETTLE CHARACTERISTICS

Firing Rate, BTU/hour

Kettle Ignition Natural

Gas

Propane

Gas

AH/1E-20 Spark 85,000 85,000

AH/1E-40 Spark 100,000 85,000

AH/1E-60 Spark 145,000 145,000

AH/1E-80 Spark 145,000 145,000

AH/1E-100 Spark 145,000 145,000

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Assemble and attach the tangent draw-off valve after the kettle is unpacked.

KETTLE CHARACTERISTICS

Model

Kettle

Capacity

Gallons

(Liters)

Jacket

Capacity

Gallons

(Liters)

Kettle

Diameter

Inches

(Millimeters)

Kettle

Depth

Inches

(Millimeters)

Overall

Width

Inches

(Millimeters)

Front-to-

Back,

Inches

(Millimeters)

Rim Height

Inches

(Millimeters)

AH/1E-20 20 (75) 4.5 (17) 20 (508) 18 (457) 36.75

(933.5) 39 (990.6) 40 (1016)

AH/1E-40 40 (150) 7 (26.5) 26 (660) 22(559) 38.25

(971.55) 45 (1143) 42 (1066.8)

AH/1E-60 60 (225) 9.5 (36) 30 (762) 25 (635) 41 (1041.4) 49 (1244.6) 49 (1244.6)

AH/1E-80 80 (300) 11.5 (43.5) 32 (813) 29 (737) 42.5

(1079.4) 51 (1295.4) 55.5

(1409.7)

AH/1E-100 100 (375) 11.5 (43.5) 32 (813) 35 (889) 42.5

(1079.4) 51 (1295.4) 61.5

(1562.1)

Inspection & Unpacking

WARNING

THIS UNIT MUST BE INSTALLED BY PERSONNEL WHO ARE QUALIFIED TO WORK WITH ELECTRICITY

AND PLUMBING. IMPROPER INSTALLATION CAN CAUSE INJURY TO PERSONNEL AND/OR DAMAGE

TO THE EQUIPMENT. THE UNIT MUST BE INSTALLED IN ACCORDANCE WITH APPLICABLE CODES.

The unit arrives completely assembled, except for the

TDO valve and flue gas converter, which are usually

packed separately and shipped inside the kettle.. The

unit is strapped on a skid in a heavy box. Inspect the

box carefully for damage. Open the container and

check the unit for hidden damage. Report shipping

damage or shipment errors to the delivery agent.

Write down the model number, serial number, and

installation date for your unit at the top of the

Maintenance and Service Log at the back of this

manual. Keep the manual with the unit.

To remove the kettle from the box, cut any straps from

around the box. Detach the box sides from the skid.

Pull the box up off the unit, taking care to avoid damage

or injury from any staples left in the box walls. When

installation is to begin, cut the straps holding the kettle

to the skid, and lift the kettle straight up off the skid.

Examine the packing materials to make sure no loose

parts are discarded with the materials.

CAUTION

SHIPPING STRAPS ARE UNDER TENSION AND

CAN SNAP BACK WHEN CUT. TAKE CARE TO

AVOID PERSONAL INJURY OR DAMAGE TO THE

UNIT BY STAPLES LEFT IN THE WALLS OF THE

CARTON.

UNIT WEIGHS FROM 468 LBS. (212 KG) TO 1120

LBS. (508 KG). FOR SAFE HANDLING,

INSTALLER SHOULD OBTAIN HELP AS NEEDED

AND USE MATERIAL HANDLING EQUIPMENT TO

REMOVE THE UNIT FROM THE SKID AND MOVE

IT TO ITS PLACE OF INSTALLATION.

Once the kettle is unpacked, the tangent draw-off

valve is easily attached, as shown below. The large

nut which attaches the valve to the kettle should be

hand tightened only.

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WARNING

THIS PRODUCT MUST BE INSTALLED BY A LICENSED PLUMBER OR GAS FITTER WHEN

INSTALLED WITHIN THE COMMON WEALTH OF MASSACHUSETTS. IMPROPER INSTALLATION CAN

CAUSE INJURY TO PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT.

THIS UNIT IS FOR COMMERCIAL USE. NEVER USE HOME OR RESIDENTIAL GRADE GAS CONNECTIONS.

THEY DO NOT MEET GAS CODES AND COULD BE HAZARDOUS.

Installation and Initial Start-Up

A. Installation

The unit should be installed in a ventilated room for

efficient performance. items which may obstruct or

restrict the flow of air for combustion and ventilation

must be removed. The area directly around the

appliance must be cleared of all combustible materials.

1. Installation requires connection with gas and

electrical services. See items 8 to 14 for details.

2. To protect the unit from damage, leave it on the

shipping pallet until the time of installation. When

installation is to begin, cut the straps holding the

kettle, and hoist the kettle straight up off the skid.

NOTICE

To avoid damaging parts of the burner system

underneath the kettle, LIFT THE UNIT ONLY BY THE

RING beneath the outer portion of the body.

3. Install the unit with a minimum clearance to

combustible and non-combustible construction of six

inches at the sides and six inches between the draft

diverter and the wall. Also leave enough room for

cleaning, maintenance, and service.

4. The draft diverter shipped with the kettle is the

correct height and shape to give maximum

performance. Install the draft diverter as shown on

Figures 1 and 2 above. Securely fasten the screw

to attach draft directly. Do not change the diverter

in any way.

WARNING

DO NOT ATTACH THE UNIT TO A TYPE “B” VENT.

FAILURE COULD RESULT IN FIRE OR PROPERTY

DAMAGE.

Install the unit under a ventilation hood, or vent the

flue directly to a masonry chimney. Put a hood at

least several inches above the upper end of the draft

diverter. Do not rest hood supports on the diverter.

Installation of a ventilating hood should comply with

local codes and/or ANSI/NFPA-96 Latest Edition.

Also, local codes may require that the kettle be

electrically interlocked to shut off the gas supply

and prevent the operation of the unit if the

exhaust fan is not operating or if the fire

suppression system is activated. Failure to

follow these instructions can cause bodily injury

and/or property damage.

5. To level the unit, adjust leg length by turning the

bullet feet

6. Make sure the water level is correct in the

jacket, by confirming that the level is between

the marks on the gauge glass. If the water level

is low, follow the instructions under “Jacket

Filling” in the “Maintenance” Section of this

manual.

CAUTION

DO NOT CONNECT ANY PIPING TO THE

PRESSURE RELIEF SAFETY VALVE. IT MUST

BE FREE TO VENT STEAM AS NEEDED.

ELBOW SHOULD POINT DOWN TOWARD

FLOOR. IMPROPER INSTALLATION

WILL VOID WARRANTY!

7. To protect personnel from steam coming out of

the safety valve, the open end of the elbow at

the outlet must be directed down. If it is not, turn

the elbow to the correct position.

DANGER ELECTRICALLY GROUND THE UNIT

AT THE TERMINAL PROVIDED. FAILURE TO

GROUND UNIT COULD RESULT IN

ELECTROCUTION AND DEATH.

Fig. 1

Fig. 2

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9. The internal gas lines of the unit were cleaned and

closed off with a gas cock before the unit was

shipped from the factory. Free all external gas lines

of lint, dirt, metal chips, sealant, grease, oil, and

other contaminants, before you connect the lines to

the kettle.

10. Connect the gas cock of the kettle to the gas service

main with 3/4 inch IPS line or approved equivalent

11. Installation must conform with local codes, or in the

absence of local codes, with the National Fuel Gas

Code, ANSI Z 223.1-1988 (or latest edition). The

unit should be installed in an adequately ventilated

room with a provision for adequate air supply. The

best ventilation will utilize a vent hood and exhaust

fan with no direct connection between the vent duct

and the flue. Do NOT obstruct the flue or vent duct

after installation.

In Canada, the installation must conform to the

CAN/CGA B149 Installation Codes for Gas Burning

Appliances and Equipment and/or local codes.

12. Adequate space for proper service and operation is

required. Do NOT block any air intake spacings to

the combustion chamber or obstruct the air flow by

piling or stacking anything near the kettle.

13. After the kettle has been connected to the gas

supply, all gas line joints must be checked for leaks.

DO NOT USE A FLAME TO CHECK FOR LEAKS.

A thick soap solution or other suitable leak detector

should be employed.

14. For a unit on casters, complete connection to the

gas supply with connectors that comply with the

standard for connectors for moveable gas

appliances, ANSI Z21.69 — latest edition. Restrain

movement of the unit by attaching a cable or chain

to the eyelet (provided at the back of the frame) and

anchoring the cable or chain to the wall or floor.

Make the length and location of the cable such that

the unit cannot pull on the gas connection while the

cable is connected.

15. The appliance and its individual shutoff valve must

be disconnected from the gas supply piping system

during any pressure testing of that system at test

pressures in excess of 1/2 PSIG (3.48 kPa). The

appliance must be isolated from the gas supply

piping system by closing its individual manual shutoff

valve during any pressure testing of the gas supply

piping system at test pressures equal to or less

than 1/2 PSIG (3.48 kPa)

16. Check the following points to confirm that your AH

kettle has been installed properly.

electrical, or gas type change must be approved

by the Groen Food Service Engineering

Department.

a. Enough room between the kettle and nearby

objects for cleaning and service.

b. Minimum clearance of 6 inches from sides

and 6 inches from draft diverter.

c. Unit vented to a hood or chimney. (Not attached

to a vent.

d. Kettle level.

e. Correct amount of water in the jacket.

f. Pressure relief safety valve outlet pointed down.

g. Connected with a waterproof, 115 volt, 15

amp supply of electric power in accordance

with electrical codes.

h. Gas lines cleaned before connection.

i. Gas connected with 3/4 inch pipe or

equivalent

j. Gas line joints checked for leaks.

k. No obstruction to air supply or venting.

B. Initial Start-Up

After the kettle has been installed, the installer

should test to ensure that it is operating correctly.

1. Remove literature and packing materials from

inside and outside of the unit.

2. Install the TDO valve.

3. Put a small amount of water into the kettle.

4. Verify that kettle water level is normal and that

kettle is holding vacuum in jacket. Correct if not.

5. Make sure the supplies of gas and electric

power are on.

6. Follow the Start Kettle Heating instructions in the

Operation section of this manual. Begin heating

the water at the highest thermostat setting. The

indicator light should come on and heating

should continue until the water boils.

7. To turn off the unit, follow “To Stop Kettle

Heating” in “Operating Instructions,” below.

If the kettle functions as described, it is ready for

use. If the unit does not operate as designed,

contact authorized Groen Service Agent.

8. Provide 115 VAC, 60 HZ, 1 PH, 15 AMP

electrical service for standard unit. Unit may be

equipped for alyternate electrical service of 208

VAC or 240 VAC, as ordered. Use 1/2 inch

waterproof conduit and waterproof connections.

Observe local codes and/or The National

Electrical Code in accordance with ANSI/NFPA

70 - latest edition. AN ELECTRICAL GROUND

IS REQUIRED. The electrical schematic is

located on the inside of the service panel.

In Canada, provide electrical service in

accordance with the Canadian Electrical Code,

CSA C22.1 Part 1 and/or local codes.

Any mechanical,

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Hinged Cover for smaller models shown.

Operation

WARNING

ANY POTENTIAL USER OF THE EQUIPMENT MUST BE TRAINED IN SAFE AND CORRECT OPERATING

PROCEDURES

A. Controls

Operator controls for the AH/1 kettle are:

1. Manual gas valve which controls the supply of gas

from the main line to the unit.

2. On-Off (toggle) switch. This switch turns the control

circuit power supply on or off.

3. Thermostat dial, which turns the thermostat on or off,

and sets the kettle operating temperature.

4. Indicator Lights to alert operator of unit conditions:

a. Power On Indicator - shows that the unit is turned

b. Heat Indicator - indicates that main gas is on to

produce steam in the kettle jacket.

c. Low Water indicator - shows that jacket water is

low

d. Unit gas pressure regulator adjustment - located

behind the access door in the kettle skirt.

B. Operating Instructions

WARNING

KEEP AREA AROUND KETTLE FREE AND CLEAR OF

ALL COMBUSTIBLE MATERIALS.

DO NOT ATTEMPT TO LIGHT ANY BURNER WITH A

FLAME.

CAUTION

HEATING AN EMPTY KETTLE MAY CAUSE THE

RELEASE OF STEAM FROM THE SAFETY VALVE.

1. To Start Kettle

a. CHECK THE WATER LEVEL IN THE JACKET

EVERY DAY. The level should be at the middle

of the sight glass. If the level is low, see Jacket

Filling in the Maintenance section of this manual

b. Check the pressure/vacuum gauge. If the gauge

does not show 20 to 30 inches of vacuum (i.e. a

reading of 20 to 30 below zero), see Jacket

Vacuum in the Maintenance section of this

manual.

c. DO NOT attempt to light any burner with a

flame.

d. Open main supply gas valve (handle in line

with the pipe).

e. Turn the toggle switch to ON. For 90

seconds, or until it succeeds, the electronic

ignition control will attempt to light the pilot.

f. Once the pilot is lit, turn the thermostat to

the desired setting.

g. If the pilot does not light, turn it off and wait

five minutes. At that time follow the

instructions for starting once again.

h. If the unit repeatedly fails to light, contact

an authorized Groen Service Agency for

assistance.

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2. To Stop Kettle Heating

a. Turn the thermostat dial to OFF.

b. Turn the toggle switch OFF.

c. For a prolonged shut-down:

1. Follow the procedure above.

2. Turn the manual gas valve OFF (handle at

right angle to gas line).

3. Disconnect the unit’s electrical power.

3. To Relight Kettle

a Close main gas supply valve.

b. Set on-off switch to OFF.

c. Set thermostat to OFF.

d. Wait five minutes, then proceed as directed under

To Start Kettle.

4. If Electric Power Fails do not attempt to

operate the unit. When power is restored,

proceed as directed in To Start Kettle.

WARNING

AVOID ALL DIRECT CONTACT WITH HOT FOOD OR

WATER IN THE KETTLE. DIRECT CONTACT COULD

RESULT IN SEVERE BURNS.

TAKE CARE TO AVOID CONTACT WITH HOT

KETTLE BODY OR HOT PRODUCT, WHEN ADDING

INGREDIENTS, STIRRING OR TRANSFERRING

PRODUCT TO ANOTHER CONTAINER.

CAUTION

DO NOT OVERFILL THE KETTLE WHEN COOKING,

HOLDING OR CLEANING. KEEP LIQUIDS 2-3” (5-8

cm) BELOW THE KETTLE RIM TO ALLOW

CLEARANCE FOR STIRRING, BOILING PRODUCT

AND SAFE TRANSFER.

5. Basket Insert

a. An optional kettle basket insert set (Tri-BC)

will assist in cooking water-boiled products

including eggs, potatoes, vegetables, shell

fish, pasta and rice. The nylon mesh liners

must be used when cooking product

smaller than the mesh size of the basket,

which is approximately 1/4” (6 mm). This

includes rice and small pasta shapes.

b. Tips for Use

1) Allow for water displacement by the

baskets and product to be cooked. This

may mean only filling the kettle half full

of water. Test the basket and product

displacement with the kettle OFF, and

with cold water in the kettle.

2) Load baskets on a level, stable work

surface.

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3) Lift the loaded baskets with both hands. Get

help from another person, if the basket is too

heavy for safe handling.

4) Slowly lower product into the kettle.

5) When removing baskets with cooked product,

lift basket straight up, ensuring bottom of

basket clears the rim and pouring lip of the

kettle. Wear protective oven mitts and

protective apron.

6) Allow hot water to fully drain from product,

before moving basket away from the kettle.

7) If basket is too heavy for individual to

lift and safely move, get help from

another person. Remove product

immediately from basket into another

container, being sure to avoid contact

with hot product and hot basket or.

8) Place basket with food on stable, flat

surface, setting it inside a solid steamer

or bake pan, to catch any remaining

hot water draining from product.

Sequence of Operation

The following “action-reaction” outline is provided to

help understand how the AH kettle works.

1. When the power switch is turned on, it starts the

spark igniter and opens the automatic valve for the

pilot burner. The spark ignites a pilot flame, which

heats the sensor. The sensor then sends a signal

to turn off the spark. The flame thereafter acts as

a standing pilot until the power is turned off.

2. If the pilot flame is not sensed within 90 seconds

after spark begins, a timer shuts down the entire

operation. To attempt a second trial for ignition,

turn off the power switch. Check the gas supply

valves and wait five minutes before trying again by

switching power on. If you cannot establish a pilot

flame in four tries, close all valves, turn off the

power, and contact an authorized Groen Service

Agency.

3. When the operator sets a temperature on the

thermostat, it causes the automatic valve to admit

gas to the main burner, where it is ignited by the

pilot flame. When the kettle reaches the set

temperature, the thermostat switch opens. This

stops the signal to the gas control valve and shuts

off gas to the main burner. The pilot flame stays lit.

4. When the kettle cools below the set

temperature, the thermostat switch closes and

starts another cycle. On and off cycling

continues and maintains the kettle at the desired

temperature. This action is indicated by the Heat

indicator light.

The kettle has the following safety features in

addition to the 90-second ignition timer:

1. Low water cutoff relay that will shut off gas

supplies to all burners until the jacket water level

is corrected.

2. High limit pressure switch, set to open at about

26 PSI and to shut down the burners until jacket

pressure is decreased.

3. Pressure relief safety valve, which will release

steam if jacket pressure exceeds 30 PSI.

4. Gas pressure regulator built into the gas control

valve.

CAUTION DO NOT OVERFILL THE KETTLE

WHEN COOKING, HOLDING OR CLEANING.

KEEP LIQUIDS A MINIMUM OF 2-3” (5-8 cm)

BELOWTHE RIM TO ALLOW FOR STIRRING,

BOILINGAND SAFE PRODUCT TRANSFER.

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When attaching the draw-off valve, just

hand-tighten the nut.

Cleaning

1. Suggested Cleaning Supplies

a. A high quality detergent and sanitizer,

or a combination cleaning-sanitizing

agent.

b. Kettle brushes.

c. Groen Spray Degreaser (P/N 114801) or

equivalent.

e. A high quality stainless steel cleaner.

Groen Delimer-Descaler (P/N 114800) or

equivalent.

2. Precautions

Before any cleaning, shut off the kettle by turning

the thermostat dial to "OFF" and the On/Off switch

to Off .

WARNING

KEEP WATER AND SOLUTIONS OUT OF

CONTROLS AND BURNERS. NEVER SPRAY OR

HOSE THE CONTROL CONSOLE, ELECTRICAL

CONNECTIONS, ETC.

3. Procedure

a. Clean food contact surfaces as soon as

possible after use, preferably while the kettle

is still warm. If the unit is in continuous use,

clean and sanitize inside and outside at least

once every 24 hours.

b. Scrape and flush out large amounts of food

residues. Be careful not to scratch the kettle

with metal implements.

CAUTION

NEVER LEAVE A SANITIZER IN CONTACT WITH

STAINLESS STEEL SURFACES LONGER THAN 30

MINUTES. LONGER CONTACT CAN CAUSE

CORROSION.

c. Prepare a solution of the detergent/cleaning

compound as instructed by the supplier.

Clean the unit thoroughly. A cloth moistened

with cleaning solution can be used to clean

controls, housing, electrical conduit, etc.

b. Rinse the kettle thoroughly with hot water.

Then drain completely.

c. Disassemble the tangent draw-off valve. Clean

the draw-off port and each valve part with a

brush.

d. Rinse the kettle and draw-off valve parts

thoroughly with hot water, then drain

completely.

e. When you reassemble the draw-off valve,

hand-tighten the nut which holds it in place.

CAUTION

MOST CLEANERS ARE HARMFUL TO THE SKIN,

EYES, MUCOUS MEMBRANES AND CLOTHING.

PRECAUTIONS SHOULD BE TAKEN TO WEAR

RUBBER GLOVES, GOGGLES OR FACE SHIELD

AND PROTECTIVE CLOTHING. CAREFULLY READ

THE WARNINGS AND FOLLOW LABEL

DIRECTIONS.

f. As part of the daily cleaning program, clean all

inside and outside surfaces that may have

been soiled. Remember to check such parts as

the underside of the cover, control housing, etc.

g. To remove materials stuck to the equipment,

use a brush, sponge, cloth, plastic or rubber

scraper, or plastic wool along with the

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Use sponge, cloth or plastic brush to clean the

kettle.

Scrapers or steel wool can harm the kettle surface.

detergent solution. To make washing easier,

let the detergent solution sit in the kettle and

soak into the residue, or warm the detergent

solution briefly. Do not use any metal

material (like metal sponges) or metal (like a

spoon, scraper, or wire brush) that might

scratch the surface. Scratches make the

surface hard to clean and provide places for

bacteria to grow. Do not use steel wool,

which may leave particles imbedded in the

surface and cause eventual corrosion and

pitting.

h. The outside of the unit may be polished with a

recognized stainless steel cleaner.

i. When the equipment needs to be sanitized,

use a sanitizing solution equivalent to one that

supplies 200 parts per million chlorine. Obtain

advice on the best sanitizing agent from your

supplier of sanitizing products.

j. Following the supplier’s instructions, apply the

sanitizing agent, after the unit has been

cleaned and drained. Rinse off the sanitizer

thoroughly.

k. It is recommended that the unit be sanitized

just before use.

l. If there is difficulty removing mineral deposits or

a film left by hard water or food residues, clean

the kettle thoroughly. Then use a de-liming

agent, such as Groen De-limer De-Scaler (Part

Number 114800). Rinse and drain the unit

thoroughly before further use.

m. If especially difficult cleaning problems persist,

contact your cleaning product supplier for

assistance. The supplier has a trained technical

staff with laboratory facilities to serve you.

Maintenance

NOTICE: Contact Groen or an authorized Groen Service Representative when repairs are required.

A Service Log is provided at the rear of this manual.

Each time service is performed on this Groen

equipment, enter the date on which the work was

done, and who did it. Keep this manual with the

equipment.

1. Jacket Vacuum/Removing Air from Jacket

When the kettle is cold, a positive pressure/ vacuum

gauge reading or a reading near zero indicates that

there is air in the jacket. Air in the jacket acts as an

insulator, and slows kettle heating.

To remove air:

a. Start the unit. (Be sure there is water or product

in the kettle when heating).

b. When the pressure/vacuum gauge reaches a

positive pressure reading of five PSI, release

the trapped air and steam by pulling up the

safety valve ring for about five seconds. Repeat

this step three or four times. Then let the pull

ring snap back into the closed position.

c. If there is little discharge (mostly air), and the

pressure gauge drops back to zero PSI, allow

the pressure to build back to five PSI and

repeat the procedure.

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d. Once steam has been vented from the jacket

as described in b, remove the hot water from

the kettle and replace it with cold. This will

condense steam in the kettle jacket, and the

pressure gauge should show a reading of 20

to 30 inches mercury (Hg) below zero. If it

does not, or if the vacuum is leaking down,

contact a Groen authorized service agency.

WARNING

AVOID ANY EXPOSURE TO THE STEAM BLOWING

OUT OF THE SAFETY VALVE. SEVERE BURNS

CAN RESULT ON EXPOSED SKIN.

FAILURE TO CHECK SAFETY VALVE OPERATION

PERIODICALLY COULD RESULT IN PERSONAL

INJURY AND/OR DAMAGE TO EQUIPMENT.

WHEN TESTING, AVOID ANY EXPOSURE TO THE

STEAM BLOWING OUT OF THE SAFETY VALVE.

DIRECT CONTACT COULD RESULT IN SEVERE

BURNS.

2. Test Pressure Relief Safety Valve

Test the pressure relief safety valve at least twice

each month. With the kettle operating at five psi

(105 kPa), pull the test lever and let it snap back

to its closed position. If there is little discharge

(mostly air), and the pressure gauge drops back

to zero PSI, allow the pressure to build back to five

PSI and repeat the procedure. (Tip: Using a will

screwdriver or other implement to pull the ring

help you avoid contact with the steam.)

3. Jacket Filling

Every day, before you turn on the unit, make

sure the water level is approximately in the center

of the water gauge glass. The jacket was filled at the

factory with the proper amount of treated water, and is

air-tight, but over time steam may be vented and water

lost.

From time to time, you may need to restore the

water to its proper level.to restore this water, either

because it was lost as venting steam or by draining.

If you are replacing water lost as steam, use

distilled water. If you are replacing treated water

that ran out of the jacket, prepare more treated

water as directed in “Water Treatment Procedure,”

below.

Allow the kettle to cool completely. The

procedure will be easier with the kettle under

vacuum ( pressure gauge reading below zero).

a. Make sure the fill (gate) valve is closed, and

remove the square head pipe plug with open-

ended wrench or crescent wrench.

b. Position a funnel in the opening and fill it with

properly treated water.

c. Slowly open the fill valve to allow water to be

sucked into the jacket. Quickly close the valve

to prevent air from entering.

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d. Check water level in the jacket to ensure that it

is between minimum and maximum marks on

glass.

e. Close the valve and reinstall the square-head

pipe plug.

f. Reestablish the jacket vacuum as described in

Paragraph 2, above, if the pressure gauge

does not show a negative reading of 20 to 30

inches mercury (Hg).

4. Water Treatment

WARNING

TO AVOID INJURY, READ AND FOLLOW ALL

PRECAUTIONS STATED ON THE LABEL OF THE

WATER TREATMENT COMPOUND.

Fill a mixing container with the amount of

water required. Use only distilled water.

Following instructions apply to Groen Water

Treatment Kit part number 110324.

i. Hang a strip of pH test paper on the rim

of the container, with about 1 inch of the

strip below the surface of the water.

ii. Stir the water continuously, while you slowly

add water treatment compound until a color

between indicating a pH of 10.5 and 11.5 is

reached. (Shown on the pH test kit chart.)

Judge the pH by frequently comparing the test

strip with the color chart provided in the kit.

Model Kettle

Capacity

Jacket

Capacity

AH/1E-20 20 Gallons 4.5 Gallons

AH/1E-40 40 Gallons 7 Gallons

AH/1E-60 60 Gallons 9.5 Gallons

AH/1E-80 80 Gallons 11.5 Gallons

AH/1E-100 100 Gallons 11.5 Gallons

iii. Use a measuring cup to add the compound so

that you may record the exact amount used.

iv. The amount may be used again, if the same

water sources and compound are used in the

future. However, it is best to check the pH

each time treated water is prepared.

Troubleshooting

Your Groen kettle is designed to operate smoothly and efficiently if properly maintained. However, the following is a list of

checks to make in the event of a problem. Wiring diagrams are furnished inside the service panel and in this manual. If an

item on the list is followed by 



, the work should be done by a qualified service representative.

WARNING

BEFORE REPLACING ANY PARTS, DISCONNECT THE UNIT FROM THE ELECTRIC POWER SUPPLY

AND CLOSE THE MAIN GAS VALVE. ALLOW FIVE MINUTES FOR UNBURNED GAS TO VENT.

CAUTION

USEING REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY GROEN OR THEIR AUTHORIZED

DISTRIBUTOR CAN CAUSE OPERATOR INJURY AND EQUIPMENT DAMAGE AND WILL VOID ALL WARRANTIES.

SYMPTOM WHO WHAT TO CHECK





indicates items which must be performed by an authorized technician.

Kettle continues heating after it

reaches desired temperature.

User a. Thermostat dial setting.

Auth

Service

Rep Only

b. Thermostat calibration.

c. Thermostat operation. The thermostat should click when the dial is

rotated to settings above and below the temperature of the kettle.

Kettle stops heating before it

reaches the desired temperature.

User a. Thermostat dial setting.

Auth

Service

Rep Only

b. Thermostat calibration.

c. Thermostat operation. The thermostat should click when the dial is

rotated to settings above and below the temperature of the kettle.

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SYMPTOM WHO WHAT TO CHECK

;

;;

;indicates items which must be performed by an authorized technician.

Safety Valve pops open User a. For air in the jacket. See “Jacket Vacuum” in the Maintenance section.

b. Thermostat dial setting.

Auth

Service

Rep Only

c. For defective thermostat. The thermostat should click when the dial is

rotated to settings above and below the temperature of the kettle. If

defective, replace.;

d. For defective safety valve. If the valve pops at pressures below 29 PSI,

replace.;

Burners will not light. User a. That the main gas supply valve is open. (handle is in line with the gas

pipe).

b. Gas supply to the building.

Auth

Service

Rep Only

d. Thermostat operation. The thermostat should click when the dial is

rotated to settings above and below the temperature of the kettle.;

System does not produce a spark Auth

Service

Rep Only

a. AC voltage between terminals on secondary side of transformer with

unit power turned on. If it is not 24 Volt, replace the transformer ;

b. That the high tension cable is firmly attached and in good condition. If

cracked or brittle, replace.;

c. Pilot burner ceramic insulatorfor crack or break.;

d. Pilot spark gap. Regap.;

Spark is present but the pilot will

not light.

Auth

Service

Rep Only

a. That the pilot valve is securely connected to terminals.;

b. For 24 VAC at terminals PV and PV/MV. If 24V is not present, replace

the ignition control module.;

b. That gas pressure is at least 3.5" W.C.(8.7818 :b).;

c. For gas at the pilot. If it is not flowing:

(1) Check the pilot gas line for kinks and obstructions.;

(2) Clean orifice, if necessary.;

(3) Check magnetic operator for pilot valve on gas valve. Repair or

replace as necessary.;

d. That the pilot spark gap is located in the pilot gas stream. If not, adjust

or replace the pilot burner.;

e. For drafts. Shield the pilot burner, if necessary.;

Pilot lights, but main burner will

not come on and spark does not

stay on.

Auth

Service

Rep Only

a. For 24 V between terminals MV and PV/MV while pilot is burning. If

24V is not present, replace the ignition control module.;

b. That gas pressure is at least 3.5" W.C.(8.7818 :b).;

c. Electrical connections of the main valve to terminals, to assure that they

are securely attached. Check magnetic operator for main valve on gas

valve. Repair or replace as necessary.;

Pilot lights, but main burner will

not come on, the spark stays on.

Auth

Service

Rep Only

a. Check for bad burner ground. If necessary, repair with high

temperature wire.;

b. Pilot burner ceramic insulator for cracks.;

c. That cable is not grounded out. If it is, correct the ground-out condition

or replace cable.;

d. For proper gas pressure.;

e. Clean pilot assembly, or replace if necessary.;

f. Tighten all mechanical and electrical connections.;

g. If the pilot flame is weak, increase pilot orifice size.;

h. Replace ignition control module.;

Main burner comes on but will not

stay on.

Auth

Service

Rep Only

a. Check burner ground for bad wire or connection. Replace if necessary

with high temperature wire.;

b. Check for low gas supply pressure. If necessary, replace ignition

control module.;

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Parts List, AH/1E

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Parts List — AH/1E

To order parts, contact your Groen Certified Service Agency. Supply the model designation, part description,

and number, quantity, and where applicable, voltage and phase.

Key Description Part No. Key Description Part No.

A. Hardware ASM AH/1E-40 Spark Ignition 117095 Safety Valve and Water Fill Assy 097010

Bracket, Gas Manifold 1/8 x 1 x 15-3/4" lg 002006 Safety Valve 30 PSI 1/2" NPT 097009

Nameplate Class II 1" x 4-1/2" long 003479 Elbow 90 Deg Street 1/2" NPT Black 096905

Hinge, Spring Loaded 18 Ga x 1 x 1-1/4" 004114 Plug Pipe 1/2" NPT 011146

Clamp Bar Pipe 1/4" x 1 x 4-1/2" lg w/stud 004568 Elbow 90 Deg Street 1/2" NPT 004185

Door Insulated Pilot Light Assy 008201 Tee, 1/2" NPT 008772

Plate, Caution 1-3/8 x 2-1/4" 008350 Valve Swing Check 1/2" NPT 004187

Chain Single, Jack Link #16 600" long 009009 Nipple, 1/2" NPT x Close 008877

Screw, Sheet Metal pan hd #12 x 1/2" lg 008769 Valve, Gate 1/2" NPT 004180

Bracket, faucet Mounting 16 Ga x 4-3/4" 009054 Label, Warning 098171

Diverter, Draft 6" AH/1E-20 -40 012474 Wiring Diagram Label 123863

Diverter, Draft 7" AH/1E-60 -80 -100 000576 Harness Wiring 123864

Nut hex Keps 1/4"-20 w/shakeproof washer 012940 Nut Hex 3/8"-16 005619

Nameplate, Groen - Large 055450 Washer, Lock #10 005619

Label, warranties void... 059201 Washer, Lock 3/8"

Water Treatment Kit

005618

110324

Label Warning 093614

B Cover Power Aid Assembly 047693 E Shell Outer/Inner Assembly 127445

C Pot Inner Assembly F Burner and Sensor Assembly

D TDO Kit G Gas Valve, Pipe & Elec Assembly 127335

Nut, Wing #10-24 for 1-1/2" & 2" 009028 Ignition Module Box Assembly 127334

Handle, 3" Dia Sanitary & TDO Valve 127452 Electrical Panel Assembly 123823

Strainer Assembly 9" Dia, 1/4" holes for 2" 009044

Handle, Sanitary DO-150 127452

See Following Pages for Assembly Parts

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Parts List — AH/1E-40

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Parts List — AH-40

To order parts, contact your Groen Certified Service Agency. Supply the model designation, part description, and number, quantity, and where applicable, voltage

and phase.

Key Description Part No. Key Description Part No.

F. Burner Assembly, AH/1E-20 & -40 127331 F. Burner Assembly, AH/1E-60 -80 & -100 127349

1 Burner Head 000286 1 Burner Head 008246

2 90º Elbow, 2-1/2" NPT 000289 2 90º Elbow, 2-1/2" NPT 000289

3 Venturi 000287 3 Reducing Bushing, 2-1/2" x 2" NPT 08774

4 Air Shutter 000288 4 Nipple, Close 2" NPT 008731

5 Spud Orifice 000279 5 Venturi 010542

6 Retaining Ring, E type 000460 6 Mixer Head 000395

7 Lock Nut, 3/8" NPT 000294 7 Air Shutter 000396

8 Orifice, N.G., AH/1E-20, 0'-1500' elev 000489 8 Lock Nut, 3/4" NPT 000397

Orifice, Prop, AH/1E-20 Higher Elev 000281 9 End Cap 000398

Orifice, N.G., AH/1E-40, 0'-1500' elev 000280 10 Orifice, N.G., 0'-1500' elev 000399

Orifice, Prop, AH/1E-40 Higher Elev 000281 Orifice, Prop, Higher Elev 000403

9 Bracket, Pilot Burner Mounting 123824 11 Bracket, Pilot Burner Mounting 123824

10 Screw #10-24 x 3/8" lg. Round Head 006009 12 Screw #10-24 x 3/8" lg. Round Head 006009

11 Pilot Burner Assy AH/1E-20, 0'-1500' el 096705 13 Pilot Burner Assy, 0'-1500' elev 096705

Pilot Burner Assy AH/1E-20, Higher el 096706 Pilot Burner Assy, Higher elev 096705

Pilot Burner Assy AH/1E-40, 0'-1500' el 096705 14 Screw #10-32 x 1/4 Fillister Head 090797

Pilot Burner Assy AH/1E-40, Higher el 096706 15 Plug, pipe, square head 1" NPT 008507

12 Screw #10-32 x 1/4 Fillister Head 090797 16 Pilot Tubing, 1/4" OD aluminum 006796

13 Pilot Orifice Spud AH/1E-40, 0-1500' el 098647 17 90º male elbow 1/8" NPT x 1/4" tubing 097195

Pilot Orifice Spud AH/1E-40, Higher el 098647 18 Hi Volt Spark Ignition Cable 36" long 096728

14 Pilot Tubing, 1/4" OD aluminum 006796 19 Pilot Orifice Spud 098647

15 90º male elbow 1/8" NPT x 1/4" tubing 097195 20 Nipple, 3/8" x 2-1/2" lg 005676

16 Hi Volt Spark Ignition Cable 36" long 096728

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Ignition Module Box Assembly

Gas Valve, Piping & Electrical Control Panel Assembly

Electrical Panel Assembly

Front Panel Components Assembly

Parts List

To order parts, contact your Groen Certified Service Agency. Supply the model designation, part description, and number, quantity, and where applicable, voltage

and phase.