Welbilt CLEVELAND HA-MKGL-60 User manual

Visit www.clevelandrange.com to locate a
service or sales representative in your area.
TABLE OF CONTENTS
Statement of Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Trouble Shooting & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Read the manual thoroughly.
Improper installation, operation or
maintenance can cause property
damage, injury or death.
!
For your future reference.
Model # ______________________________________
Serial # ________________________________________
Model # &
Serial #.
Mixing Kettles -
Gas, Horizontal Agitator
Installation, Operation, Maintenance, Parts & Service
This manual is updated as new information and models are released. Visit our website for the latest manual.
Model #s -
HA-MKGL-60
HA-MKGL-80
HA-MKGL-100
HA-MKGL-60-CC
HA-MKGL-80-CC
HA-MKGL-100-CC
HA-MKGL-60-T
HA-MKGL-80-T
HA-MKGL-100-T
HA-MKGL-60-CC-T
HA-MKGL-80-CC-T
HA-MKGL-100-CC-T
Part # - KE004017-2 B August 2019

1
STATEMENT OF RESPONSIBILITIES / DÉCLARATION
DES RESPONSABILITÉS /
DECLARACIÓN DE RESPONSABILIDADES
This document is for use by experienced
and trained Qualified Cleveland Range,
LLC Authorized Service Representatives
who are familiar with both the safety
procedures, and equipment they
service. Cleveland Range, LLC assumes
no liability for any death, injury,
equipment damage, or property damage
resulting from use of, improper use of,
or failure to use the information
contained in this document. Cleveland
Range, LLC has made every effort to
provide accurate information in this
document, but cannot guarantee that
this document does not contain
unintentional errors and omissions.
The information in this document may
be subject to technical and
technological changes, revisions, or
updates. Cleveland Range, LLC
assumes no liability or responsibility
regarding errata, changes, revisions, or
updates.
Qualified Cleveland Range, LLC
Authorized Service Representatives are
obligated to follow industry standard
safety procedures, including, but not
limited to, OSHA regulations, and
disconnect / lock out / tag out
procedures for all utilities including
steam, and disconnect / lock out / tag
out procedures for gas, electric, and
steam powered equipment and / or
appliances.
All utilities (gas, electric, water and
steam) should be turned OFF to the
equipment and locked out of operation
according to OSHA approved practices
during any servicing of Cleveland Range
equipment
Qualified Cleveland Range, LLC
Authorized Service Representatives are
obligated to maintain up-to-date
knowledge, skills, materials and
equipment.
Ce document est destiné à l’usage des
Représentants de Service qualifiés et
autorisés de Cleveland Range, LLC qui
possèdent l’expérience et la formation
ainsi que la bonne connaissance des
mesures de sécurité et du matériel qu’ils
entretiennent.
Cleveland Range, LLC décline toute
responsabilité pour tout cas de décès,
blessure, dommage matériel ou dommage
aux biens résultant de l'utilisation, de la
mauvaise utilisation ou du manquement
d’utilisation des renseignements contenus
dans ce document.
Cleveland Range, LLC s’est efforcé à
fournir des renseignements précis dans ce
document mais ne peut garantir que ce
document soit exempt d’erreurs et
d’omissions non intentionnelles.
Les renseignements contenus dans ce
document peuvent être assujettis à des
changements techniques et
technologiques, des révisions ou des
mises à jour.
Cleveland Range, LLC décline toute
obligation ou responsabilité concernant les
errata, modifications, révisions ou mises à
jour.
Les Représentants de Service qualifiés et
autorisés de Cleveland Range, LLC sont
tenus de se conformer aux mesures de
sécurité normalisées de l’industrie, y
compris, mais sans s'y limiter, les
réglementations de l'OSHA, les
procédures de débranchement /
verrouillage / étiquetage relatives à tous
les services publics, dont
l’approvisionnement en vapeur, et les
procédures de débranchement /
verrouillage / étiquetage relatives aux
équipements et/ou appareils fonctionnant
au gaz, à l’électricité et à la vapeur.
Au cours de tout entretien d’un appareil
Cleveland Range, tous les services publics
(gaz, électricité, eau et vapeur) doivent
être FERMÉS au niveau de l’appareil et le
dispositif de fonctionnement doit être
verrouillé suivant les pratiques approuvées
de l’OSHA.
Les Représentants de Service qualifiés et
autorisés de Cleveland Range, LLC sont
tenus d’actualiser en permanence leurs
connaissances, compétences, matériel et
équipement.
Este documento está destinado para el
uso de los Representantes de Servicio
calificados y autorizados de Cleveland
Range, LLC quienes cuentan con la
experiencia y la capacitación así como el
buen conocimiento de las medidas de
seguridad y de los equipos que
mantienen.
Cleveland Range, LLC, declina toda
responsabilidad en caso de cualquier
fallecimiento, lesiones, daños al equipo o
daños a la propiedad resultantes de la
utilización, del uso indebido o de la falta
de utilización de la información provista
en este documento.
Cleveland Range, LLC se ha esforzado
en suministrar información precisa en
este documento, pero no puede
garantizar que este documento esté
exento de errores y de omisiones no
intencionales.
La información contenida en este
documento podría estar sujeta a cambios
técnicos o tecnológicos, revisiones o
actualizaciones. Cleveland Range, LLC
declina toda obligación o responsabilidad
con respecto a erratas, modificaciones,
revisiones o actualizaciones.
Los Representantes de Servicio
calificados y autorizados de Cleveland
Range, LLC tienen la obligación de seguir
los procedimientos estándar de seguridad
de la industria; los cuales incluyen pero
no se limitan a los reglamentos de la
OSHA (La Administración de la Seguridad
y Salud Ocupacionales), los
procedimientos de desconexión, cierre y
etiquetado relativos a todos los servicios
públicos incluyendo el suministro de
vapor y los procedimientos de
desconexión, cierre y etiquetado para los
equipos y/o aparatos que funcionan a
base de gas, electricidad o vapor.
Cuando se esté dando servicio o
mantenimiento a un aparato de Cleveland
Range, todos los servicios públicos (gas,
electricidad, agua y vapor) deben estar
APAGADOS para el equipo en cuestión y
se debe seguir el procedimiento de cierre
de operaciones de acuerdo con las
prácticas aprobadas por la OSHA.
Los Representantes de Servicio
calificados y autorizados de Cleveland
Range, LLC tienen la obligación de
actualizar constantemente sus
conocimientos, destrezas, materiales y
equipamiento.

2
WARNING: Improper
installation, operation,
adjustment, alteration, service
or maintenance can cause
property damage, injury or
death. Read the installation and
operating instructions
thoroughly before installing,
operating or servicing this
equipment.
FOR YOUR SAFETY
Do not store or use gasoline or
any other flammable liquids and
vapours in the vicinity of this or
any other appliance.
Do not spray aerosols in the vicinity
of this appliance while it is in
operation.
This appliance is not to be used by
persons with reduced physical,
sensory or mental capabilities, or
lack of experience and knowledge,
unless they have been given
supervision or instruction
concerning use of the appliance by
a person responsible for their safety.
This appliance is not for use by
children and they must be
supervised not to play with it.
Post in a prominent location,
instructions to be followed in the
event the user smells gas. This
information shall be obtained by
consulting your local gas supplier.
Do not obstruct the flow of
combustion and ventilation air.
Retain this manual for your
reference.
AVERTISSEMENT : Toute
mauvaise pratique en matière
d’installation, de
fonctionnement, de réglage, de
modification, d’entretien ou de
maintenance peut causer des
dommages matériels, des
blessures ou la mort. Lisez la
totalité des instructions
d’installation et d’utilisation
avant d’installer, d’utiliser ou
d’entretenir cet équipement.
POUR VOTRE SÉCURITÉ
Ne pas entreposer ou utiliser
d'essence ou d'autres liquides
ou vapeurs inflammables à
proximité de cet appareil ou de
tout autre appareil.
Ne pas pulvériser des aérosols
dans le voisinage de cet appareil
alors qu'il est en fonctionnement.
Cet appareil ne doit pas être utilisé
par des personnes dont les
capacités physiques, sensorielles
ou mentales sont réduites, ou des
personnes dénuées d'expérience ou
de connaissance, sauf si elles ont
pu bénéficier, par l'intermédiaire
d'une personne responsable de leur
sécurité, d'une surveillance ou
d'instructions préalables concernant
l'utilisation de l'appareil.
Cet appareil n'est pas destiné à être
utilisé par des enfants et ils doivent
être surveillés pour s'assurer qu'ils
ne jouent pas avec l'appareil.
Affichez à un endroit bien visible les
instructions à suivre dans le cas où
l'utilisateur sent une odeur de gaz.
Ces informations seront obtenues
auprès de votre fournisseur de gaz
local.
Ne pas obstruer le flux d'air de
combustion et de ventilation.
Conservez ce manuel pour votre
référence.
ADVERTENCIA: La indebida
instalación, operación, ajuste,
modificación, servicio o
mantenimiento puede ocasionar
daños a la propiedad, lesiones o
muerte. Lea detenidamente las
instrucciones de instalacion y
de operación antes de instalar,
poner a funcionar o dar servicio
a este equipo.
PARA SU SEGURIDAD
No guarde ni use gasolina o
cualesquiera otros líquidos o
vapores inflamables en las
cercanías de éste o cualquier
otro aparato.
No pulverice aerosoles en las
proximidades de este aparato
mientras está en funcionamiento.
Este aparato no debe ser utilizado
por personas con capacidades
físicas, sensoriales o mentales
reducidas, o que no tengan la
experiencia y los conocimientos
adecuados, a menos que estas
personas hayan recibido
supervisión e instrucciones en
cuanto al uso del aparato por la
persona responsable de la
seguridad de ellas.
Este aparato no debe ser usado por
los niños y ellos deben ser
supervisados para que no jueguen
con el aparato.
No obstruya el flujo del aire
combustión y de ventilación.
Guarde este manual para su
referencia.
FOR YOUR SAFETY / POUR VOTRE SÉCURITÉ /
PARA SU SEGURIDAD

3
Improper installation, operation, adjustment, alteration, service
or maintenance can cause property damage, injury or death.
Read the installation and operating instructions thoroughly
before installing, operating or servicing this equipment. /
Toute mauvaise pratique en matière d’installation, de
fonctionnement, de réglage, de modification, d’entretien ou
de maintenance peut causer des dommages matériels, des blessures ou la mort.
Lisez la totalité des instructions d’installation et d’utilisation avant d’installer,
d’utiliser ou d’entretenir cet équipement. / La indebida instalación, operación,
ajuste, modificación, servicio o mantenimiento puede ocasionar daños a la
propiedad, lesiones o muerte. Lea detenidamente las instrucciones de instalacion
y de operación antes de instalar, poner a funcionar o dar servicio a este equipo.
Surfaces and product may be hot! Wear protective
equipment. /Les surfaces et le produit peuvent être
chauds! Portez un équipement de protection. / ¡Las
superficies y el producto pueden estar calientes!
Utilice equipo protector.
Stand clear of product discharge path
when discharging hot product. /
Écartez-vous du chemin de décharge
d’un produit chaud. / Permanezca
alejado de la ruta de descarga del
producto al vaciar producto caliente.
Keep hands away from moving parts and pinch points.
/ Gardez les mains loin des pièces mobiles et des
points de pincement. / Mantenga las manos lejos de
piezas movibles y puntos de presión muy localizada.
Remove electrical power prior to servicing. / Coupez
l'alimentation électrique avant l'entretien. / Desconecte
la energía eléctrica antes de darle servicio.
Risk of electric shock. / Risque de choc électrique. /
Riesgo de choque eléctrico.
Hot product and surfaces. / Produit et
surfaces chaudes. / Producto y
superficies calientes.
Do not touch. / Ne pas toucher. / No
la toque
Do not climb, sit or stand on equipment. / Il ne faut pas
monter, s'asseoir ni se tenir debout sur l'équipement. /
No subirse, ni sentarse ni pararse sobre el equipo.
Pressurized device. / Appareil sous pression. /
Dispositivo de presión.
Keep clear of pressure relief discharge. / Restez à
l'écart de la soupape de sureté. / Permanezca alejado
de la descarga de presión.
Do not lean on or place objects on lip. / Ne vous
penchez pas sur oune placez pas des objets sur la
lèvre. / No se apoye ni coloque objetos en el labio.
Inspect unit daily for proper operation. / Inspectez
l’unité tous les jours pour son bon fonctionnement. /
Inspeccione diariamente el funcionamiento correcto de
la unidad.
WARNING / AVERTISSEMENT / ADVERTENCIA
!
Have a qualified service technician maintain your
equipment. / Demandez à un technicien en entretien
et en réparation qualifié d’effectuer l’entretien de votre
équipement. / Haga que un técnico de servicio
calificado mantenga su equipo
Floor may become slippery from product spillage. /
Déversement de produit peut causer de plancher à
être glissante. / Derrame de producto puede causar
piso a ser resbaladizo.
Do not fill kettle above recommended level marked on
outside of kettle. / Ne remplissez pas la chaudière en
excès du niveau recommandé marqué sur la
chaudière. / No llene la marmita arriba del nivel
recomendado marcado fuera de la marmita.
Unit must be anchored as per manual. / Unité doit être
ancrée selon les directives du manuel. / Unidad debe
estar fijado según el manual.
0
Ensure kettle is at room temperature and pressure
gauge is showing zero or less prior to removing any
fittings. / Assurez-vous que la chaudière est à
température ambiante et que le manomètre est à zéro
ou moins avant de retirer des accessoires. /
Asegúrese de que la marmita esté a temperatura
ambiente y el manómetro esté mostrando cero o
menos antes de retirar cualquier accesorio.
Keep appliance and area free and clear of
combustibles. / Gardez l'appareil et son entourage
libre de tous combustibles. / Mantenga el aparato y el
área libres de combustibles.
Do not attempt to operate this appliance during a
power failure. / N’essayez pas de faire fonctionner cet
appareil lors d'une panne de courant. / No intente
poner en marcha este aparato durante un fallo de
suministro eléctrico.
Shut gas supply off prior to servicing. / Fourniture de
gaz fermée au loin avant d'entretenir. / Suministro de
gas cerrado apagado antes del mantenimiento.
Unit exhaust contains carbon monoxide. Operate only
under a properly functioning hood with adequate makeup
air. / L'échappement de l'unité émet du monoxyde de
carbone. Exploiter uniquement sous une hotte
fonctionnant correctement avec une source adéquate d'air
d'appoint. / El escape de la unidad contiene monóxido de
carbono. Operar solamente bajo una campana en buen
funcionamiento con aire de relleno adecuado.
SERVICING / ENTRETIEN / SERVICIO
Heavy / Lourd / Pesado
Team or mechanical lift. / Équipe ou remontée
mécanique. / Equipo o elevador mecánico.
Do not remove guards or operate without them. / Ne
pas supprimer les gardes ou fonctionner sans eux. /
No retire los guardias ni funcionar sin ellos.

4
GENERAL
Operating Conditions Acceptable Range
Ambient Air Temperature 15-40 degrees Celsius
Relative Humidity 0-80%
Altitude 0-2000 meters
Voltage 208-240,480,3ph,60Hz
Location Inside building, under ventiltation hood
Ensure gas and electrical supplies match rating plate.
Installation of the kettle must be accomplished by qualified
personnel working to all applicable local and national codes.
This equipment is built to comply with applicable standards for
manufacturers. Included among those approval agencies are:
UL, NSF, ASME/N.Bd., CSA, ETL, and others. Many local codes
exist, and it is the responsibility of the owner/installer to comply
with these codes.
Observe all clearance requirements. Do not obstruct the flow of
combustion and ventilation air.
RECEIVING INSPECTION
Before unpacking visually inspect the unit for evidence of
damage during shipping.
If damage is noticed, do not unpack the unit, follow shipping
damage instructions.
SHIPPING DAMAGE INSTRUCTIONS
If shipping damage to the unit is discovered or suspected,
observe the following guidelines in preparing a shipping
damage claim.
1. As soon as damage is discovered or suspected, notify
the carrier that delivered the shipment.
2. Write down a description of the damage or the reason for
suspecting damage as soon as it is discovered. This will
help in filling out the claim forms later.
3. Arrange for the carrier's representative to examine the
damage.
4. Fill out all carrier claims forms and have the examining
carrier sign and date each form.
UNCRATING
Caution:
Straps under tension and will snap when cut.
Carton may contain staples and Skid contains
Nails.
Use proper safety equipment andprecautions.
Unit is heavy use adequate help or lifting
equipment as needed.
1. Carefully cut any straps from container.
2. Lift off carton.
3. Inspect for hidden damage.
If found refer to “SHIPPING DAMAGE INSTRUCTIONS”.
4. Cut strap holding unit.
5. Remove lag bolts from feet.
6. Remove manual from kettle
pot. Write down the model#
and serial# of the unit onto
the front of this manual.
7. Lift kettle off skid and move
kettle to its installation
location.
8. Discard packaging material
according to local and or state
requirements.
VENTILATION
Gas fired kettles are only to be installed
under a ventilation hood in a room
which has provisions for adequate
make up air. Further information can be
obtained by referring to the U.S.A.
National Fire Protection Associations
NFPA96 regulations. These standards
have also been adopted by the National
Building Code in Canada.
POSITIONING
This unit must be installed in accordance
with the clearances shown on the rating
label which is adhered to the unit.
1. When removing the kettle from the platform, handle with
care to prevent scratching or any other damage. It is
imperative that the kettle be level before bolting to the floor.
This will prevent any twist or out of roundness to the kettle
and will stop deflection of the agitator. Make sure the kettle
is securely bolted to the floor and follow the procedure
listed below:
Þ Position the kettle in its permanent location, check
clearances and level the kettle by turning the adjustable
feet.
Þ Lower the flange or flanges under the motor channel.
Over adjustment, whether up or down, could cause
misalignment and cause damage to the agitator drive shaft
and hub (stationary kettles only).
2. Once positioned and leveled, permanently secure the
kettle’s flanged feet to the floor using 1/2 x 2 I/2 inch lag
bolts and floor anchors (supplied by the installer). Two bolts
per leg are required to secure each of the flanged feet.
COMPRESSED AIR CONNECTION
Mixer Kettles with an air activated discharge valve require a
minimum of 90 PSI to operate correctly.
If the unit is also supplying air to a Metering Filling Station then a
pressure of 100 PSI at a minimum volume of 25 CFM is required.
The air supplied to the mixer should be clean and dry. No oil
should be added to the supply air. We recommend the
compressed air system be equipped with a drier, filter, and
automatic water dump on the air compressor receiver tank. If the
distance between the tank and the unit is less than 100 feet then
a minimum line size of 3/4" is required. A distance of 100 to 300
feet requires a minimum 1" line.
INSTALLATION
Unit with
Model # Unit shipping
box
HAMKGL40T 1,010 lbs. 1,050 lbs.
HAMKGL60T 1,120 lbs. 1,160 lbs.
HAMKGL80T1,325 lbs. 1,365 lbs.
HAMKGL40 940 lbs. 980 lbs.
HAMKGL60 1,030 lbs. 1,070 lbs.
HAMKGL80 1,110 lbs. 1,150 lbs.
APPROXIMATE WEIGHTS
Model #
&
Serial #.

5
GAS
ENSURE THE GAS SUPPLY MATCHES THE KETTLE'S
REQUIREMENTS AS STATED ON THE RATING PLATE.
Installation must conform, with local codes or in the absence of local
codes, with the National Fuel Gas Code ANSI Z223.1/NFPA 54, or the
Natural Gas and Propane Installation Code, CSA B149.1.
The appliance must be isolated from the gas supply piping system
by closing its individual manual shut-off valve during any pressure
testing of the gas supply piping system at test pressures equal to or
less than 1/2 psi (3.45 kPa).
It is recommended that a sediment trap (drip leg) be installed in the
gas supply line. If the gas pressure exceeds 1/2 psi (3.45 kPa) water
column, a pressure regulator must be installed, to provide a
maximum of 1/2 psi (3.45 kPa) water column gas pressure to the gas
control valve.
Use a gas pipe joint compound which is resistant to L.P. gas. Test all
pipe joints for leaks.
ELECTRICAL
ENSURE THE ELECTRICAL SUPPLY MATCHES THE KETTLE'S
REQUIREMENTS AS STATED ON THE RATING LABEL.
Electrical installation must be in accordance with local codes and/or
the National Electric Code ANSI/NFPA 70-1990 (USA) or the
Canadian Electrical Code CSA Standard C22.1 (Canada). The kettle
must be electrically grounded by the installer.
A separate fused disconnect switch must be supplied and installed in
the high voltage electrical supply line.
A wiring diagram is affixed to the top of component box cover.
Remove the right side panel to access component box. Feed the
wiring through the cut-out in the bottom of the console using liquid
tight conduit.
For proper electrical connections of units with remote controls please
refer to the wiring diagram included with the unit. For tilting units
wiring package is attached under the gearbox cover. For stationary
units it is inside the Inverter housing on the left side of the kettle. For
units with Remote consoles it is inside the console box.
WATER
The sealed jacket of the gas-fired kettle is precharged with the
correct amount of a water-based formula, and therefore, no water
connection is required to the kettle jacket. The kettle can be
equipped with optional hot and cold water taps, requiring 1/2"
copper tubing as supply lines.
INSTALLATION & OPERATION CHECKS
Although the kettle has been thoroughly tested before leaving the
factory, the installer is responsible for ensuring the proper operation
of kettle once installed.
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 "VENT AIR" zone, follow Kettle Venting Instructions.
2.
Unit has been thoroughly checked for gas leaks at the factory
however the installer should check all connections for any leaks
which may have resulted from shipping or installation.
3. Supply power to the kettle by placing the fused disconnect
switch to the "ON" position.
4. Open gas shut-off valve to turn on main gas supply.
5. Turn the temperature control knob to "1" (Min.). The green LED
light should remain lit, indicating the burner is lit, until the set
temperature is reached. Then the green light will cycle on and
off, indicating the burner is cycling on and off to maintain
temperature.
6. Tilt the kettle forward. After a few seconds the red "LOW WATER"
light should be lit when the kettle is in a tilted position. This light
indicates that the burner has automatically been shut off by the
kettle's safety circuit. This is a normal condition when the kettle is
in a tilted position.
7. Raise the kettle to the upright position. The red "LOW WATER"
light should go out when the kettle is upright.
8. Turn the temperature control knob to "10" (Max.) and allow the
kettle to preheat. The green light should remain on until the set
temperature is reached. Then the green light will cycle ON and
OFF, indicating the burner is cycling ON and OFF to maintain
temperature.
9. Check carbon monoxide is less than 0.08 percent in an air-free
sample of the flue gases. See FREE AIR CALCULATION procedure
in “Maintenance Procedures & Parts Lists” manual.
10. After installation the kettle must be thoroughly cleaned and
sanitized prior to cooking.
KETTLE
VENTING
INSTRUCTIONS
1. Remove Access Panel from back of
main kettle console.
2. Turn kettle ON and set temperature
control to 10, heat the empty kettle until
unit cycles off.
3. Vent kettle by pulling Valve Ring eight to
fifteen times, holding valve open for
two seconds each time.
NOTE:If unit cycles ON, stop venting
and wait for kettle to cycle OFF before
continuing.
4. Turn kettle OFF. Add cold water to kettle
until its surface temperature is below
100°F. The pressure gauge needle
should be in the green zone, indicating
a vacuum in the kettle’s jacket.
5.
If needle is in the green zone then
venting was successful. If not repeat
procedure.
2
3
56
7
8
9
1
4
10
OFF
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
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
Pressure Relief Valve
Access
Panel
Valve
Ring
The following venting procedure should be followed when the
Vacuum/Pressure Gauge needle is in the "VENT AIR" zone:
NOTE: Check for and eliminate leaks prior to venting (see
REPAIRING LEAKS IN STEAM JACKETED KETTLE FITTINGS).

6
Temperature Sensor
Sensestemperature of product
Automatic Dump Valve
Emptieskettle of either food product or wash water
Sight Glass
For checking water level of kettle jacket
Vacuum /Pressure Gauge
Indicatessteam pressure inside steam jacket in PSI, as
well as vacuum in inchesof mercury
Gas Shut-Off Valve
Air Quick Connect
Push yellow tab down to release air pressure before
disconnecting air hose
Kettle Filler Nozzle
A
Green Heat Indicator Light - When lit, indicatesgas burner
ison; cycleson-off with solid state controls.
Red Low Water Indicator Light - When lit, in the upright
position, indicateskettle gas burner has cut out and unit
requiresmore water. Occasional pulsing of thislight isnormal.
Orange Off Indicator Light
Solid State Temperature Control Knob /
On-Off Toggle Switch - Controlselectrical power to kettle.
and allowsoperator to select kettle heat incrementsfrom
minimum, 1-10. A setting of 7 or higher will boil water.
B
Agitator Stop Button
Stopsagitator in case of emergency
Agitator Start Switch
Startsagitator. Agitator power control switch must be ON
Agitator Power Switch
Allowspower to agitator. When not in use, turn control
power OFF
Agitator Speed Control Switch
Turn clockwise until desired speed isreached
1
2
3
4
5
6
7
21 3
5
7
6
B
C
D
A
E
4
C
C
Power tilt control switch
Tiltskettle for pouring; some kettleshave manual hand tilt
Reset circuit breaker
Protectspower tilt system from overload. Push to reset
E
E
D
D
Fill Interrupt Switch
Interruptswater fill cycle
Potable Fill Water Switch
Selectshot or cold water
Fill Cycle Switch
Start/continue cycle switch
Product Discharge Valve Switch
Toggle momentary switch to desired valve opening
Water Meter Digital Counter (not shown)
Location may vary dependant on customer'sspecific
options
0123
NOTE:
Location of
switchesmay
vary dependant
on customers
specific options
OPERATING CONTROLS AND INDICATORS
OPERATING INSTRUCTIONS
WARNING
If for any reason this unit is not
functioning correctly DO NOT
OPERATE. Contact your
authorized service agent.
!
This unit has been fitted with
a cover and screen to
prevent contact with moving
mixer arms. Do not remove
or bypass these safeties.
WARNING:
!

7
1. Perform daily startup inspection.
2. Preheat the kettle by turning the ON/OFF Temperature
Control to the desired temperature setting. The Heat
Indicator Light (Green) will remain lit, indicating the
burner is on, until the temperature setting is reached.
When the green light goes off, the burners are off, and
preheating is complete.
NOTE: When cooking egg and milk products, the kettle should not
be preheated, as products of this nature adhere to hot cooking
surfaces.
3. Place food product into the kettle. The green Heat
Indicator Light will cycle on and off indicating the burners
are cycling on and off to maintain the set temperature.
4. When cooking is completed turn
Temperature Control
to
the "OFF' position.
5. Pour the contents of the kettle into an appropriate
container by tilting the kettle forward or using discharge
valve.
NOTE: Cleaning should be performed immediately after cooked
foods are removed.
NOTE: A five minute complete shut-of period is required
before relighting.
Temperature Approximate
Control Product Temperature
Setting °F °C
1. 120 49
2. 135 57
3. 150 66
4. 165 74
5. 180 82
6. 195 91
7. 210 99
8. 225 107
9. 245 118
10. 265 130
NOTE: Certain combinations of ingredients will
result in temperature variations
OPERATING
THE KETTLE
Intended Use:
Processing of food and pharmaceuticals in non-residential
locations. Not for the making of dough or other heavy dough
like products.
Intended Users:
- Supervised and trained staff during production periods.
- Trained maintanance and service personnel.
Removable component weights
Lbs (kg) 60 gal 80 gal 100 gal
Primary arm with blades 51 65 70
(9.5) (10.4) (32)
Screen 7 8 9
(3.2) (3.6) (4.1)
Air valve complete 12 (5.4)
Air cylinder only 8 (3.6)
Air valve body only 4 (1.8)
Noise level
Noise level maximum 80 Decibels.
Mixing Arm Rotation speeds
Arm Speed (RPM)
Primary 0-40
Secondary 0-210
Rim (loading) heights
Rim heights are given below. It is up to owners of the equipment to ensure the
operators are performing the loading in a safe and acceptable manner.
Size Height
60 gal. 48”
80 gal. 52”
100 gal. 54”
Emergency
In the event of a fire or other emergency.
Turn off unit
Shut off power supplies including Electrical, Gas or Steam as
applicable. (If safe to do so.)
Using fire extinguishers is only recommended if you are trained
and feel safe to do so. Use only Fire extinguishers rated ABC.
This is a pressure vessel and with a properly operating safety
valve will not exceed rated pressures. Jacket contains water
and trace amounts of rust inhibitor and/or antifreeze.
WARNING
If for any reason this unit is not
functioning correctly DO NOT
OPERATE. Contact your
authorized service agent.
!

8
Heating Instructions
Manual Heating
1. Turn temperature control knob clockwise to turn on the
kettle, Green light will come on.
2. Turn temperature control knob to desired setting. (1-
10)
If Red light is on, it indicates that the water level is low in
the jacket.
With DTCI or TCR-DTCI Option
1. Turn Controller switch to “OFF” if Manual heating is
desired.
See picture #2.
2. Follow instructions for Manual Heating.
Heating with DTCI option
1. Turn Controller switch to “ON”. See pictures #2.
2. Turn temperature control knob on the kettle to “10”.
See picture #1.
3. DTCI will go through self-check sequence.
Note; ZERO flashes on left indicates no sensor
selected. Buttons only adjust flashing digits.
4. Press “*” to display set point.
5. Press and hold “*” then press to increase or press
to decrease the set point.
The Controller is operational with factory settings.
Heating with TCR-DTCI option
1. Turn Controller switch to “ON”.
See pictures #2.
2. Turn temperature control knob on the kettle to “10“.
See picture #1.
3. Push function key “ ” until “OFF” is displayed.
4. Push and hold key “ ” or “ ” until desired
temperature is set.
5. To start; push function key “ ” until “CtrL” is
displayed.
6. Push “ ” key to start operation.
7. To stop; push function key “ ” until “OFF” is
displayed.
8. Push “ ” key to stop operation.
Picture #1
Picture #2
Picture #3

9
Water Meter Option
1. Switch to “Hot” or “Cold” water.
2. Push “ ” key until the digit you want to change is
flashing in the lower display window. Then use the
“” key to change the value of the flashing digit.
3. When all digits are selected (lower display window) for
the required quantity of water press the “ENT” key.
4. Push “RST” button to start at “0”.
5. To start filling kettle, turn “START” switch to
“Continue”.
6. Delivery will start at “0” (upper display window) and
stop at the preset volume.
7. To interrupt delivery anytime, turn “INTERRUPT”
switch to right.
8. To complete delivery after interruption, again turn
“START” switch to “Continue”.
9. Turning “START” switch to “RESET” will again start
the delivery from “0”.
Mixing ("AGITATOR ")
WARNING:
• Never add product to kettle while agitator is running.
•
Do not put hands in kettle.
•
Watch for loose clothing near agitator.
1. Tur n "SPEED CONTROL" to "0".
2. Switch agitator to "ON".
3. Push agitator "START" to initiate mixing.
4. Tur n "SPEED CONTROL" to desired mixing speed.
5. To stop mixing action, push agitator stop button.
NOTE: Mixing speed depends on the product consistency.
The faster the mixing speed the more damage may be done
to fragile product.
Emptying the Kettle
1. To open automatic dump valve:
•Tur n PRODUCT DISCHARGE VALVE switch clockwise
to JOG TO OPEN. Release switch to the HOLD
position when desired valve opening is achieved.
•To close valve, turn switch counterclockwise to
CLOSED position.
2. To avoid splashing, slowly empty kettle contents into an
appropriate container by partially opening discharge
valve.
NOTE: When pumping with a Metering Filling Station the
speed of the agitator arm must be sufficient to suspend the
heavier items in the mix in order to achieve an even
distribution in your packaged items.
3.
Immediately clean kettle as outlined in CLEANING
INSTRUCTIONS on page.

10
CARE AND CLEANING
Cooking equipment must be cleaned
regularly to maintain its fast, efficient
cooking performance and to ensure its
continued safe, reliable operation. The
best time to clean is shortly after each
use (allow unit to cool to a safe
temperature).
WARNINGS
Do not use
detergents or
cleansers that are
chloride based or
contain quaternary
salt.
Unit should never be
cleaned with a high
pressure spray hose.
Steel wool should
never be used for
cleaning the stainless
steel.
Do not leave water
sitting in unit when
not in use.
Do not use a metal
bristle brush or
scraper.
CLEANING INSTRUCTIONS
CLEANING INSTRUCTIONS
1. Turn power off.
2. Remove drain screen (if applicable). Thoroughly wash and rinse the screen
either in a sink or a dishwasher.
3. Prepare a warm water and mild detergent solution in the unit.
4. Remove food soil using a nylon brush.
5. Loosen food which is stuck by allowing it to soak at a low temperature setting.
6. Drain unit.
7. Rinse interior thoroughly.
8. If the unit is equipped with a Butterfly Valve, clean as follows:
a) Place valve in open position.
b) Wash using a warm water and mild detergent solution.
c) Remove food deposits using a nylon brush.
d) Rinse with fresh water.
e) Leave valve open when unit is not in use.
9. If the unit is equipped with an Air Valve, clean as follows:
a) Open product valve.
b) Disconnect air hoses.
c) Remove air cylinder.
d) Remove valve tee.
e) Remove all O-rings.
f) Clean air cylinder, do not submerge in water. Wipe clean and sanitize.
g) Clean and sanitize tee and O-rings.
h) Grease and reinstall O-rings.
i) Reinstall valve tee to kettle outlet.
j) Reinstall air cylinder to bottom of tee.
k) Reconnect air hoses.
l) Close valve and check for alignment.
10. Using mild soapy water and a damp sponge, wash the exterior, rinse, and dry.
NOTES
➩For more difficult cleaning applications one of the following can be used: alcohol,
baking soda, vinegar, or a solution of ammonia in water.
➩Leave the cover off when the kettle is not in use.
➩For more detailed instructions refer to Stainless Steel Equipment Care and
Cleaning (www.nafem.org/resources/stainlesssteelfinal.doc) on Nafem’s website
(www.nafem.org).
DISPOSAL INSTRUCTIONS
This unit is recyclable. Do not dispose in landfill.
The unit may contain rust inhibitor and or antifreeze within the
jacket. Drain unit and dispose following Federal, State and local
regulations.
The majority of the unit is composed of stainless steel. Other
alloys and electrical components make up a small percentage of
the total. Follow Federal, state and local regulations for disposal.
Chloride Cleaners
Wire Brush &
Scrapers
Steel Pads
High Pressure
Spray Hose
Stagnant
Water

11
AGITATOR
To remove and clean agitator
(two-person job):
1. Remove scraper blades.
2. Rotate agitator until pull pin is on top side.
3. Turn power OFF.
4. Pull pin out.
5. Slide coupling toward kettle wall, and carefully lift
agitator pulling back to lift out.
6. Clean in a sink, using a warm water and mild
detergent solution.
7. Rinse with fresh water.
Agitator shaft
Pin
Coupling
FLUSH PISTON VALVE
Daily - clean valve as follows:
1.
Open product valve.
2.
Disconnect air hoses.
3.
Remove air cylinder.
4.
Remove valve tee.
5.
Remove all O-rings.
6.
Clean air cylinder, do not submerge in water. Wipe
clean and sanitize.
7.
Clean and sanitize tee and O-rings.
8.
Grease and reinstall O-rings.
9.
Reinstall tee to kettle outlet.
10.
Reinstall air cylinder to bottom of tee.
11.
Reconnect air hoses.
12.
Close valve and check for alignment.
AIR HOSE
AIR
CYLINDER
AIR HOSE
OPEN
POSITION
CLOSED
POSTITION
O-RING
CLAMP
O-RING
VALVE
TEE
O-RING
CLAMP
KETTLE
OUTLET
KETTLE
AGITATOR BUSHING
With agitator out, remove bushing by:
1. Remove bushing by turning 1/4 turn and pulling away
from the kettle wall.
2. Clean, rinse and sanitize bushing and bushing
mounting area.
3. Lubricate metal surfaces with food safe grease.
4. Install bushing by locating retaining pin and sliding
bushing on.
5. Rotate to lock into position.
Slot
Bushing
Retaining
Pin
Agitator
Shaft Iddler
Pin

12
SEAL RETAINER PLATE
(Replaces QUAD RING after June 1999.)
To clean seal retainer plate:
1. Apply food safe grease to grease nipples untill you
see clean grease inside the kettle. Grease daily.
Grease Nipples
SCRAPER BLADES
To remove and clean scraper blades:
1. Remove scraper blades using the tool to release the
spring from the retaining pin and sliding the blade off
the shaft.
2. Place parts in a pan of warm water to soak.
3. Clean in a sink, using a warm water and mild detergent
solution.
4. Rinse with fresh water.
5. Allow to dry thoroughly on a flat, clean surface.
Fig. 2 Fig. 3Fig. 1
Scraper
blade
Back stop
Pin A
Pin B
Tool
Spring
To Install Scraper Blade
1. Slide scraper blade and spring onto Pin A as shown in Fig. 1.
2. Hook spring arm and pull up.
3. Using tool, engage spring arm into groove on Pin B.
Scraper blade is now in place.
To Remove Scraper Blade
1. Insert tool that is provided as shown in Fig. 2.
2. Pull up on spring arm until arm clears groove in Pin B.
3. Spring is now disengaged, gently release spring to remove
scraper blade.

13
PREVENTATIVE MAINTENANCE
FOR MAINTENANCE AND REPAIRS CONTACT YOUR AUTHORIZED MANITOWOC SERVICE AGENCY
AND HAVE A QUALIFIED SERVICE TECHNICIAN MAINTAIN YOUR EQUIPMENT.
0
WARNING
If for any reason this unit is not functioning correctly DO
NOT OPERATE. Contact your authorized service agent.
!
INSPECTION AND MAINTENANCE CHECKLIST
Cleveland Range equipment requires little preventative maintenance. We do however provide the
following chart as a guide line for inspection and maintenance to keep your unit functioning at 100%.
DAILY PRE-STARTUP INSPECTION
1. Flue is not obstructed.
2. Pressure Gauge is in the green when unit is cold.
3. Green Light comes on when unit is energized.
4. Red Light comes on when unit is tilted (tilting models only).
MONTHLY INSPECTION
1. Inspect all switches for damage. Replace rubber boots or switches as required.
2. Check that product discharge valve works fully and smoothly.
3. Check that the 3 way regulator shuts off the incoming air and completely vacates the air from the air hose to the
metering filling station.
4. Tilt kettle and check for smooth operation in both directions (tilting models).
5. Inspect mixer blades for cracks or other damage - replace as required. Refer to NEW SCRAPER BLADE
INSTALLATION PROCEDURE.
SIX MONTH MAINTENANCE
1. Check spring assist covers for tightness to handle and ensure spring is holding cover up - adjust if required. Refer to
HINGE ADJUSTMENT INSTRUCTIONS.
2. Check quad ring and replace if required. Refer to QUAD RING REPLACEMENT PROCEDURE.
3. Inspect oiler in gear box and fill with oil if required. Refer to OILER FILLING PROCEDURE.
4. Inspect air filter cartridge and replace if required. Refer to AIR FILTER REPLACEMENT PROCEDURE.
SIX MONTH SERVICE INSPECTION
1. Perform daily startup inspection.
2. Gasket around top cover is in good condition.
3. Tilt hand wheel is tight.
4. Grease bearings on both trunnions.
5. Check for play in gears (adjust if required).
6. Fasteners securing panels are in place and tight.
7. Perform pressure relief valve periodic test (see Pressure Relief Valve Testing).
8. Adequate exhaust and makeup air is supplied to working area.
9. Check spring assist covers for tightness to handle and ensure spring is holding cover up - adjust if required. Refer to
HINGE ADJUSTMENT INSTRUCTIONS.
10. Check quad ring and replace if required. Refer to QUAD RING REPLACEMENT PROCEDURE.
11. Inspect oiler in gear box and fill with oil if required. Refer to OILER FILLING PROCEDURE.
12. Inspect air filter cartridge and replace if required. Refer to AIR FILTER REPLACEMENT PROCEDURE.
YEARLY SERVICE INSPECTION
1. Perform six month service inspection.
2. Check kettle maximum temperature setting (see Calibrating Procedure).
3. Inspect safety thermostat for proper connections (see Safety Thermostat).
4. Inspect Low water probe for proper connections (see Low Water Level Probe).
5. Inspect safety valve installation (see SAFETY VALVE INSTALLATION).
6. Clean blower.
7. Perform free air calculation (see FREE AIR CALCULATION).

14
TROUBLESHOOTING & MAINTENANCE
PROCEDURES / DÉPANNAGE ET PROCÉDURES DE
MAINTENANCE / PROCEDIMIENTOS DE SOLUCIÓN
DE PROBLEMAS Y MANTENIMIENTO
All trouble shooting guides and maintenance procedures are meant to be used by
Qualified Service Technician /
Tous les guides de dépannage et les procédures d'entretien sont destinés à être
utilisés par un technicien qualifié /
Todas las guías de solución de problemas y los procedimientos de mantenimiento
están diseñados para ser utilizados por un técnico calificado.
Any repairs to the pressure vessel must be done by a certified pressure vessel repair
shop and all repair methods and materials must be approved by the manufacturer.
Toute réparation du Navire à pression doit être effectuée par un atelier de réparation
agréé et toutes les méthodes et matériaux de réparation doivent être approuvés par le
fabricant.
Cualquier reparación del recipiente a presión debe ser efectuada por un taller de
reparación certificado y todos los métodos y materiales de reparación deben ser
aprobados por el fabricante.
0
GENERAL
1. When the unit is turned on.
■ Power is sent to primary side of the 115vac/16vac
transformer.
■ Power is sent to the normally closed high limit.
■ From the high limit power is sent to the normally open
contacts of the 12VDC relay and the L1 and L2
terminals of the ignition module.
2. From the secondary of the transformer 16VAC is sent to
the controller.
■ Power is sent to the red LED (low water indicator
light) from terminal 4 of the controller.
■ If the water probe is grounded through water the LED
will go off.
■ If the water probe is not grounded the LED will
remain on and the unit will not heat.
■ If the resistance of the thermistor is higher than the
setting of the potentiometer( the unit is calling for heat)
then 16VDC is sent to the coil of the relay and the
green LED (heat indicator light)
■ The 12VDC relay will close until the unit reaches
temperature
3. With the contacts of the relay closed, 115VAC is sent to
the blower and primary coil of the 115VAC/24VAC
transformer.
■ From the secondary of the 24VAC transformer power
is sent to the normally open contacts of the air switch.
■ When the air from the blower closes the air switch,
24VAC is sent to the Th terminal of the ignition module.
4. With both 115VAC (at L1 and L2) and 24VAC (at Gnd
and Th) to the ignition module then 115VAC will be sent
to the surface igniter.
5. After the ignition module has been energized for 24
seconds the module will send 24VAC to the gas valve.
■ The gas will touch the hot igniter 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

15
OPERATING SEQUENCE - HEATING
QUICK CHECKS: Potentiometer - Range 0 - 50K, Safety Thermostat - Normally Closed,
Thermistor - Range 0 - 100K, Water Level Probe - Must be submerged in water for burners to work
RESULT 2
Amber LED is illuminated.
(Used prior to July 2004)
a/ Green LED illuminates.
b/ 16 VDC relay contacts close.
a/ Air switch contacts close.
a/
25 volts supplied to ignition module.
Within 20 seconds ignitor glows red.
a/ Burner ignites.
a/ If temperature drops in
chamber gas valve is de-
energized within five seconds.
b/ Ignitor will try twice more to
light before locking out.
a/ Green LED turns off.
b/ 16 VDC relay contacts open.
c/ Blower turns off.
d/ 25 volt transformer de-energizes.
ACTION
Close main circuit breaker.
On/Off switch on kettle
switched to ON.
Control box.
16 VDC relay contacts
close.
Ignition module.
115 volts turned off to ignitor.
Temperature reached.
STEP
1.
2.
3.
4.
5.
6.
7.
RESULT 1
115 volts is supplied by primary contactor
to kettle On/Off switch and tilt relay
contacts. Power supplied to tilt assembly.
115/16 volt transformer supplies
power to control boxes.
A/ Requires grounded probe to
function (pin #5).
B/ More than 6 volts at pin #2. Control box
energizes 16 volt DC relay (pin #6).
A/ Blower energizes.
B/ 115/25 volt transformer energizes.
C/ 115 volt supplied to ignition module.
Supplies 115 volts to ignition.
A/ Gas valve is energized.
B/ Ignitor becomes sensor.
A/ Less than 6 volts at pin #2.
Control box de-energizes 16 volt
DC relay (pin #6)
OPERATING SEQUENCE - AGITATOR
A/
Three phase contactor closes to
supply power to variable speed drive.
A/ Power to agitator motor.
A/ Motor speed increases.
a/ Indicator light is energized.
a/ Motor comes up to speed.
On/Off switch closed.
Start button momentarily depressed.
Speed control turned up.
1.
2.
3.
OPERATING SEQUENCE - POWER TILT
A/ Relay 2 is energized.
A/ Power interrupted to down side
of tilt switch.
A/ Relay 1 is energized.
A/ Power interrupted to up side of
tilt switch.
a/ Tilt motor is energized.
a/ Relay de-energized.
b/ Motor stops.
a/ Tilt motor is energized.
a/ Relay de-energized.
b/ Motor stops.
Turn and hold tilt switch in
down position.
Kettle tilts until limit switch is
depressed.
Turn and hold tilt switch in up
position.
Kettle tilts until limit switch is
depressed.
1.
2.
3.
4.

16
TROUBLESHOOTING GUIDES (Legend)
KE95555-10A
10
9
8
7
6
5
4
3
2
1
OFF
Thermistor
Thermistor
1. Green Light
12. Flame Sight Glass
17. Ignition Module
13. 14V
Transformer
11. Ignitor
2. Red Light
3. ON/OFF Switch
c/w Potentiometer
6. Pressure
Gauge
5. Kettle Jacket Water Sight Glass
7. Gas Valve
(showing hose for
pressure tap)
8. Blower
14. 24V
Igniton
Transformer
9. Water
Level Probe
16. High
Limit Tube
10.Thermistor
15. SSK Controller
18. Relay
16. High
Limit
19. Air Switch
10 9 8 7 6 5 4 123
1. Green Light
2. Red Light
3. ON/OFF Switch
5. Kettle Jacket
Water Sight Glass
6. Pressure Gauge
7. Gas Valve
8. Blower
9. Water Level Probe
10. Thermistor
11. Ignitor
12. Sight Glass
13. 14V Transformer
14. 24V Iginiton
Transformer
15. SSK Controller
16. High Limit
17. Ignition Module
18. Relay
19. Air Switch
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

17
TROUBLESHOOTING GUIDES (continued)
PROBLEM:
Kettle Won't
Heat
Does red light (2)
come on when unit
is first turned on?
Does red light (2)
go off shortly after
unit is turned on?
Yes
Add water
to jacket of
Kettle.
No
Yes
Is 16 VAC (13)
measured across
Pins 9 and 10 on
the controller (15)?
No
Yes
Is 16 VAC
(13)at the
secondary side of
the transformer
No
Replace
the on/off (3)
switch (toggle
or rotary).
Yes
Is there Power to
the primary of the
transformer
(13)?
No
Replace the
transformer
(13).
Yes
Supply power
to the kettle.
No
Does the relay pull
in (18)?
Yes
Replace the
relay (18).No
Is there power to
the blower (8)?
Yes
With the high limit
(16) temporarily
bypassed, is
power at the
blower (8)?
No
Replace the
high limit
(16).
Yes
Replace
the wire to
the blower
(8).
No
Is there power to
the ignition
Is there 24 VAC at
the secondary of
the ignition
transformer (14)?transformer (14)?
Is there 24 VAC to
the igniton
module (17)?
Yes
Does the blower
(8) turn?
Replace
blower (8).No
Yes
Yes
Replace the
DC relay
(18).
Replace the
ignition
transformer
(14).
Replace the air
switch (19).
No
Is there 120 VAC
to the
igniter (11)?
Yes
Replace
ignition module
(17).
No
Does the ignitor
glow (11)?
Yes
Replace the
ignitor (11).
No
No
Does the gas
valve (7)get 24 VAC
20 sec. after the
ignitor (11)is
energized?
Yes
No
Does the gas
valve (7)open?
Yes Replace gas
valve (7).
No
Yes No
With the
potentiometer (4)
set at 10,
is 12 VDC at
the
coil of the relay
(18) ?

18
PROBLEM:
Kettle Not
Hot Enough
With kettle pot
empty and
temperature knob
set at 10, is the
temperature of the
surface of the pot
260 degrees?
Unit is
operating
properly
Yes
When unit is cold
(room temp) is the
pressure gauge in
the green (6)?
No
Vent
the kettle per
instructions in
the manual.
No
When the unit is
calling for heat
(the green light
(1)is on),
is there flame
at the burner?
Yes
Is the resistance of
the thermister (10)
100,000 ohms
+10% at room
temperature?
Yes
Replace the
thermister
(10).
No
Is the
potentiometer (4)
resistance 50,000
ohms at low and 0
ohms at high?
Yes
Replace
controller
(15).
Yes
Replace the
potentiometer
(4).
No
Does the kettle
heat at all? Yes
See Problem:
Kettle won't
heat.
No
Is the blower
turning (8)?
Replace the
high limit
(16)?
Is there voltage to
the blower (8)?
No Yes
No
Replace the
blower
(8).
No
Replace the air
switch
(19).
Yes
PROBLEM: Kettle Has Delayed Ignition
Delayed Igniton
Is the gas
pressure to the
burner 3.5" W.C.?
Adjust or
replace the gas
valve (7).
Does the ignitor
(11) glow evenly,
check through
sight glass (12).
Replace ignitor
(11).
No
Yes
No
Does the gas
valve (7)
get 24 VAC
20 seconds after
ignior (11)is
energized?
Replace the
ignition module
(17).
Is the blower (8)
turning?
Replace
blower (8)
and air switch
(19).
Replace burner
Yes
No
Yes
No
Yes
TROUBLESHOOTING GUIDES (continued)
Gas Valve
(showing hose for
pressure tap)

19
PROBLEM:
Kettle
Gets Too
Hot
With the kettle
empty and the
temperature set at
10, is the surface
temp 260-265
degrees?
The
kettle is working
properly.
Yes
Does the kettle
continue to call for
heat (green light (1)
stays on) when
the kettle reaches
260-265 degrees?
No
Is there supply
voltage to the coil
of the gas valve
(7).
No
Replace the
gas valve
(7).
No
Is there any DC
voltage to the coil
of the relay
(18)?
Replace the
Relay
(18).
Yes
Replace the
controller
(15).
Yes
No
Is the resistance of
the thermister (10).
100,000 ohms +
10% at room
temperature?
Yes Replace the
thermister
(10).
No
Is the resistance of
the potentiometer (4)
50,000 ohms at
the low setting and
0 ohms at high?
Yes
Replace the
controller
Replace the
potentiometer
(4).
No
Yes
PROBLEM: Red LED Stays On
Does red LED (2)
stay on
after adding the proper
amount of distilled
water and rust inhibitor?
Add the proper
amount of distilled
water and rust
inhibitor.
No
No
No
Is the red
LED (2)
on with probe
grounded?
Yes
Clean or
replace water
probe (9).
jumper between
pins 5 and 7 on
Yes
Replace the
wire harness in
the trunion.
Replace the
Yes
(15).
Does red LED (2)
stay on with a
controller
(15).
the controller (15).
TROUBLESHOOTING GUIDES (continued)