Electric Floor Model Kettles

MODELS:

• KEL-25
• KEL-25-T
• KEL-40-SH
• KEL-30
• KEL-40-T
• KEL-40-TSH
• KEL-40
• KEL-60-T
• KEL-60-SH
• KEL-60
• KEL-80-T
• KEL-60-TSH
• KEL-80
• KEL-100-T
• KEL-100

TABLE OF CONTENTS

1. Statement of Responsibilities
2. For your safety
3. Installation
4. Operating Instructions
5. Cleaning Instructions
6. Preventative Maintenance
7. Trouble Shooting & Maintenance
8. Service Parts

Important Safety Information

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.

Do not store or use gasoline or any other flammable liquids and vapors 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.

Retain this manual for your reference.

WARNING: Surfaces and product may be hot! Wear protective equipment.

Floor may become slippery from product spillage.

Unit must be anchored as per manual.

Hot product and surfaces. Product and surfaces are hot.

Do not touch.

Stand clear of product discharge path when discharging hot product.

Keep hands away from moving parts and pinch points.

Do not fill kettle above recommended level marked on outside of kettle.

Heavy / Lourd / Pesado: Team or mechanical lift.

SERVICING / ENTRETIEN / SERVICIO

Have a qualified service technician maintain your equipment.

Ensure kettle is at room temperature and pressure gauge is showing zero or less prior to removing any fittings.

ELECTRICAL

Install in accordance with local codes and/or the National Electric Code ANSI/NFPA No. 70-1990 (USA) or the Canadian Electric Code CSA Standard C22.1 (Canada). A separate fused disconnect switch must be supplied and installed. The kettle must be electrically grounded by the installer.

The electrical supply must match the power requirements specified on the kettle's rating plate. The copper wiring must be adequate to carry the required current at the rated voltage.

Note: Maximum voltage for LVD (low voltage directive for Europe) to be 440 volts for CE marked appliances.

The kettle is wired for 3-phase operation at the factory. For single phase operation, rewire the terminal block as shown in the diagram.

Note: Ensure main power is turned off before connecting wires.

Stationary Models

Remove the screws securing the dome-shaped service cover underneath the kettle and remove the cover. A wiring diagram is affixed to the inside of cover. Fasten permanent copper wiring to the three-connection terminal block. Be sure to connect ground wire to the separate ground terminal connector (ground lug). Slide the cover's slot over the wiring and secure the cover to kettle with the screws.

Tilting Models

First remove the handwheel by loosening the allen screw. Then remove the two screws at the front and rear of the console cover and remove the cover. A wiring diagram is affixed to the underside of the console cover. Feed permanent copper wiring through the cut-out in the bottom of the console, and fasten to the three-connection terminal block. Be sure to connect the ground terminal connector (ground lug). Replace the console cover and handwheel.

INSTALLATION 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.

Visual Checks

• Check Tilting (tilting kettles): Gearbox tilts kettle smoothly and freely.
• Ensure there are: Three lag bolts securely holding each foot. The bottom cover (stationary kettles) is in place and held with a nut. The console cover (tilting kettles) is in place and held with a screw.

Performance Checks

1. Supply power to the kettle by placing the fused disconnect switch to the "ON" position.
2. 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 Procedure in the Service Manual.
3. Turn the kettle's ON/OFF Switch/Solid State Temperature Control to "1" (Min.). The Heat Indicator Light (Green) should remain lit, indicating the element is on, until the set temperature is reached (130°F/54°C). Then the green light will cycle on and off, indicating the element is cycling on and off to maintain temperature.
4. Tilt the kettle forward (tilting models only). After a few moments the Low Water Indicator Light (Red) should be lit when the kettle is in a tilted position. This light indicates that the element has automatically been shut off by the kettle's safety circuit. This is a normal condition when the kettle is in a tilted position.
5. Raise the kettle to the upright position. The Low Water Indicator Light (Red) should go out when the kettle is upright.
6. Turn the ON/OFF Switch/Solid State Temperature Control to "10" (Max.) and allow the kettle to preheat. The green light should remain on until the set temperature (260°F/127°C) is reached. Then the green light will cycle ON and OFF, indicating the element is cycling ON and OFF to maintain temperature. Fill the kettle with cold water to the steam jacket's welded seam. Refer to the Temperature Range Chart for the time required to bring the water to a boil.
7. When all testing is complete, empty the kettle and turn the ON/OFF Switch/Solid State Temperature Control to the "OFF" position.

CLEANING

After installation the kettle must be thoroughly cleaned and sanitized prior to cooking.

OPERATING INSTRUCTIONS

If for any reason this unit is not functioning correctly DO NOT OPERATE. Contact your authorized service agent.

NOTE: Certain combinations of ingredients will result in temperature variations

OPERATING THE KETTLE

NOTE: If you are cooking an egg or milk product, do not pre-heat kettle.

1. Perform DAILY PRE-STARTUP INSPECTION (see Maintenance).
2. Preheat the kettle by turning the dial to the desired temperature setting (see "Temperature Range Chart"). The Heat Indicator Light (Green) will remain lit, indicating the unit is heating, until the temperature setting is reached. When the green light goes off, the burners are off, and preheating is complete.
3. Place food product into the kettle. The Heat Indicator Light (Green) will cycle on and off indicating the burners are cycling on and off to maintain the set temperature.
4. NOTE: Do not fill kettle above recommended level marked on outside of kettle.
5. When cooking is completed turn dial to the "OFF" position.
6. NOTE: A five minute complete shut-of period is required before relighting.
7. Pour the contents of the kettle into an appropriate container by tilting the kettle forward. Care should be taken to pour slowly enough to avoid splashing off the product.

CLEANING INSTRUCTIONS

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).

CARE AND CLEANING

WARNINGS

• Do not use detergents or cleansers that are chloride based or contain quaternary salt.
• Do not use a metal bristle brush or scraper.
• Steel wool should never be used for cleaning the stainless steel.
• Unit should never be cleaned with a high pressure spray hose.
• Do not leave water sitting in unit when not in use.

CLEANING INSTRUCTIONS

1. Turn unit 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 Tangent Draw-Off Valve, clean as follows:
   • Disassemble the draw-off valve first by turning the valve knob counter-clockwise, then turning the large hex nut counter-clockwise until the valve stem is free of the valve body.
   • In a sink, wash and rinse the inside of the valve body using a nylon brush.
   • Use a nylon brush to clean tangent draw-off tube.
   • Rinse with fresh water.
   • Reassemble the draw-off valve by reversing the procedure for disassembly. The valve's hex nut should be hand tight only.
9. If the unit is equipped with a Butterfly Valve, clean as follows:
   • Place valve in open position.
   • Wash using a warm water and mild detergent solution.
   • Remove food deposits using a nylon brush.
   • Rinse with fresh water.
   • Leave valve open when unit is not in use.
10. If the unit is equipped with an Air Valve, clean as follows:
    • Open product valve.
    • Disconnect air hoses.
    • Remove air cylinder.
    • Remove valve tee.
    • Remove all O-rings.
    • Clean air cylinder, do not submerge in water. Wipe clean and sanitize.
    • Clean and sanitize tee and O-rings.
    • Grease and reinstall O-rings.
    • Reinstall valve tee to kettle outlet.
    • Reinstall air cylinder to bottom of tee.
    • Reconnect air hoses.
    • Close valve and check for alignment.
11. 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.

For more detailed instructions refer to Stainless Steel Equipment Care and Cleaning on Nafem's website.

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.

PREVENTATIVE MAINTENANCE

ALL SERVICE MUST BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN.

WARNING / AVERTISSEMENT / ADVERTENCIA

If for any reason this unit is not functioning correctly DO NOT OPERATE. Contact your authorized service agent.

Refer to maintenance procedures and parts list manual for detailed maintenance and testing instructions.

DAILY PRE-STARTUP INSPECTION

1. Kettle tilts smoothly, handle is tight and kettle holds in any position (tilting models only).
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).
5. Cover is held in position by spring when raised (spring assisted covers only).
6. Cover is held securely to handle, knob is on the end of the handle.

SIX MONTH SERVICE INSPECTION

1. Perform daily startup inspection.
2. Grease bearings on both trunnions.
3. Inspect worm and gear for tightness and grease.
4. Perform pressure relief valve periodic test (see Pressure Relief Valve Testing).
5. Check that both bottom cover gaskets are in place and are not cracked or split.
6. Check that unit is bolted in place.
7. Insure there are two screws firmly holding down the cover. If not replace screws.
8. Check hand wheel for tightness. If loose tighten Allen screw.
9. Check spring assist hinge screws are tight (for cover).

YEARLY SERVICE INSPECTION

1. Perform six month service inspection.
2. Check kettle maximum temperature setting (see CALIBRATING PROCEDURE).
3. Perform safety inspection using SAFETY INSPECITON CHECKLIST found in the MAINTENANCE PROCEDURES.

TROUBLESHOOTING AND MAINTENANCE PROCEDURES

The following trouble shooting guide and maintenance procedures are meant to be used by Qualified Service Technicians.

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.

For periodic maintenance recommendations see “Operators Manual".

Extreme caution must be taken if unit is electrically energized for testing. Remove power from the unit while servicing.

DIAGNOSTIC GUIDE

This section contains servicing information intended for use by Authorized Service Personnel.

NOTE 1: If Fault Isolation Procedure is required, be sure to start at step #1.

NOTE 2: On table type kettles the entire control mounting panel may be removed from kettle control housing for easier troubleshooting and parts replacement.

A/ Problem: Kettle is not heating at all. (Kettle must be on and temperature control set.)

Possible Causes

• No incoming power.
• Kettle is tilted.
• Low water condition.
• Defective ON/OFF switch.
• Defective 12 VDC relay.
• Defective safety thermostat.
• Defective contactor/s.
• Defective potentiometer.
• Defective low water level probe.
• Defective thermistor.
• Defective 240/16 VAC transformer.
• Defective control box.
• Defective elements.

Fault Isolation Procedure

B/ Problem: Kettle heats too slowly or not hot enough. (Note: normal max. operating pressure with an empty kettle is 30-35 psi.)

Possible Causes

• Air in jacket requires venting.
• Defective safety thermostat.
• Defective potentiometer.
• Defective thermistor.
• Defective contactor/s.
• Defective control box.
• Defective elements/s.

Fault Isolation Procedure

C/ Problem: Kettle is overheating.

Possible Causes

• Defective thermistor
• Defective potentiometer.
• Defective 12 VDC relay.
• Defective control box.

Fault Isolation Procedure

D/ Problem: Red LED remains illuminated even though water has been added.

Possible Causes

• Defective low water level probe
• Defective control box.

Fault Isolation Procedure

SAFETY INSPECTION CHECKLIST

NOTE: The following instructions are intended for use by qualified service personnel. The following steps should be completed IN SEQUENCE.

A/ KETTLE PREPARATION

1. Disconnect main power at fused disconnect switch.
2. Kettle should be cold. If necessary add water to kettle pot to cool unit.
3. The pressure gauge should now show a vacuum and have no indication of leakage. If gauge looks damaged replace gauge.
4. Gauge must be showing a vacuum prior to proceeding. If not check for leaks, and repair kettle prior to proceeding. Refer to REFERENCE SECTION (KETTLE VENTING INSTRUCTIONS).

B/ MECHANICAL CHECKS

1. Inspect controls, replace damaged seals, switches, LED's etc..
2. Remove the console cover and check that the seal is not cracked or split. Replace seal, screws, missing or worn nylon anchor nuts. Leave cover off.
3. Remove the kettle bottom cover and check that the seal is not cracked or split. Leave cover off.
4. For units with tilt handle-
   • Check handle for tightness. If loose apply lock tight and reinstall. Check handle knob is on end of handle and firmly tightened. If missing replace, if loose apply lock tight and reinstall.
   • Check that kettle tilts smoothly and there is no excessive wear in the trunnion bearings. Add grease to nipples as required.
5. For units with tilt crank-
   • Check that the kettle tilts smoothly. If there is excess play adjust the worm to gear clearance with Locking Nuts or Adjusting Screw as required.
   • Check that there is no excessive wear in the trunnion bearings.
   • Apply grease to gear teeth and bearings.

C/ CONTACTOR TEST

1. Remove power to unit.
2. Remove nut holding component mounting plate to console.
3. Pull plate out and place on top of console. (Depending on how the installer wired the kettle you may have to remove the supply wire and reconnect).
4. Physically push in on contacts of each contactor to check for free movement. Replace contactor(s) if required.

D/ LOW WATER LEVEL PROBE:

Installation Check:

• Probe properly attached
• Probe bypassed by turning (A) an additional wire
• Probe bypassed by (B) grounding the connecting wire

Functional Test:

1. Turn main power on at fused disconnect switch.
2. Turn kettle on and set temperature to maximum.
3. Green light will come on and contactors close.
4. Tilt kettle over. After approximately a five-second delay the red light will come on, green light go off and the contactors will disengage.
5. Turn kettle upright. Green light will come back on and contactors reengage.
6. Turn kettle off
7. If unit does not function as above, make required repairs.
8. Disconnect main power at fused disconnect switch.

E/ SAFETY THERMOSTAT

Installation Check:

• Correct Installation: Probe fully inserted in tube. Wiring is properly connected.
• Incorrect Installations:
  • Safety thermostat probe is not completely inserted into tubing (except KET-3-T that has a small loop).
  • Safety thermostat probe is removed from tubing.
  • Safety thermostat electrical connection is bypassed.

F/ SAFETY VALVE

Installation Check:

• Correct Installation: 4" maximum length.
• Incorrect Installation: Plug, Tube diameter reduced, Plumbed to drain or water line.

Physical Checks

1. Check that the PSI rating on the valve matches MAWP (maximum allowable working pressure) on the plate welded to the kettle.
2. Check that the Safety Valve has a "UV" stamp.
3. Check that the valve is not damaged in any way. If any of the above criteria is not met, replace valve.

Pressure Relief Valve Periodic Testing Procedure

1. With the kettle empty, set On-Off Switch/Temperature Control to "10" (Max.). Allow the kettle to heat until the unit cycles off.
2. Switch On-Off Switch/Temperature Control to "0" (Off) and disconnect main power at fused disconnect switch.
3. Stand to the side of the pressure relief valve discharge tube and pull valve open for a maximum of one second. Repeat test three to four times. Each time the mechanism should move freely and be accompanied by a rapid escape of steam.

If valve appears to be sticking replace pressure relief valve.

If foreign material is discharged then drain kettle and replace pressure relief valve.

G/ CALIBRATING PROCEDURE

1. Kettle must be empty when this procedure is executed.
2. Insure the unit has a vacuum before you begin calibrating procedures. If unit requires venting see REFERENCE SECTION (KETTLE VENTING INSTRUCTIONS).
3. Turn kettle ON and set temperature dial to 10 (Max.).
4. Allow the unit to cycle twice (the green light must go on and off).
5. Check temperature of the inner kettle surface with a digital surface thermometer. For accurate readings move probe around bottom of kettle to locate the hottest location.
6. Temperature should be between 260° F and 265° F. Pressure gauge should read between 20 - 28 PSI.
7. Using a screwdriver adjust temperature by turning the potentiometer on the black box. Turn very little. Turn clockwise to INCREASES and counter-clockwise to DECREASE temperature.
8. Allow the unit to cycle twice.
9. Re-check temperature.
10. Repeat steps 7 - 9 until unit is calibrated.

REPAIRING LEAKS IN STEAM JACKETED KETTLE FITTINGS

If unit will not hold a vacuum the most likely cause is a leak at one of the fittings. Often, the easiest way to eliminate a leak is reseal the suspect areas.

1. Water Level Probe: Remove, clean threads, apply teflon thread sealant and reinstall.
2. Pressure Relief Valve: Inspect for signs of leaks. Replace if required.
3. Pressure Gauge: Remove, clean threads, apply teflon thread sealant and reinstall.

THERMISTOR REPLACEMENT

1. Disconnect main power at fused disconnect switch.
2. Remove bottom cover.
3. Locate the thermistor.
4. Cut pigtail connection off.
5. Remove wire from ground lug.
6. Remove thermistor from tube.
7. Add new “eye” connector to one of the thermistor leads and fasten to ground lug.
8. Connect orange wire to the other thermistor lead and fasten with pigtail connector.
9. Insert thermistor as far as possible into tube and hold in place. While holding add silicon to secure thermistor into tube. Insure silicon completely surrounds tube and thermistor.
10. Replace covers, reconnect power and test operation.

KETTLE CLEANOUT AND PASSIVATION PROCEDURES

The following procedure should be preformed at least once every three years to prevent possible corrosion and ensure the optimum life of the kettle.

DANGER:

Rust inhibitor can be dangerous. read label and follow safety instructions.

WARNING:

Improper refilling of kettle jacket will result in irreversible damage to unit.

RUST INHIBITOR

Use a "radiator rust inhibitor" that can be purchased at your local automotive centre. It should not contain any anti-freeze and preferably no lubricant.

To ensure satisfactory mixing follow the manufacturer's instructions.

DISPOSAL - Follow all Federal, State and local codes when disposing of product.

KETTLE VENTING INSTRUCTIONS

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).

1. Set On-Off Switch/Temperature Control to "10" (Max.). Heat the empty kettle until unit cycles off.
2. Vent kettle by pulling safety valve ring 8-10 times in short 2-3 second blasts with a 5 second interval between pulls.
3. 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.

LUBRICATION PROCEDURE

Lubricate the following parts every three months to insure smooth operation and reduce wear.

KETTLE TRUNNIONS

On the left hand side of the kettle there are two grease nipples on the top back portion of the trunnion housing. On the right hand side of the kettle you must remove the console cover to access the two grease nipples.

HINGE ADJUSTMENT INSTRUCTIONS

1. Insert 3/8" Allen wrench.
2. Turn clockwise to relieve tension on spring.
3. While tension is released remove one of the two slotted screws.
4. To prevent Allen wrench from springing back abruptly while the second slotted screw is removed, insert a pin (approximately 1/8") in the hole where the first slotted screw was removed from.
5. Remove second slotted screw.
6. While holding Allen wrench remove pin.
7. Turn Allen wrench clockwise to tighten or counter-clockwise to loosen tension to produce desired effect.
8. Re-insert pin in one of the two holes.
9. Tighten one slotted screw in the other hole (it may be necessary to turn Allen wrench slightly to align holes).
10. Remove pin and repeat step number 9 for other slotted screw.

SSK SOLID STATE CONTROL TEST INSTRUCTIONS

DIAGNOSTIC

POTENTIOMETER

HEATER OUTPUT

1. If required remove board from holding bracket for better access.
2. Turn unit on and set to 10 (maximum).
3. Push and hold the SWITCH button for approximately 5 seconds until the CPU starts to flash 1 flash/second. You are now in TEST #1. Output to 12v relay is disabled. With kettle upright the DIAGNOSTIC LED should be green, with kettle tilted it should be red.
4. Push SWITCH button. The CPU starts to flash 2 flash/second. You are now in TEST #2. Check the DIAGNOSTIC LED for indication of the temperature probe status.
5. Push SWITCH button. The CPU starts to flash 3 flash/second. You are now in TEST #3. The HEATER OUTPUT LED should light for 20 seconds and power to the relay should energize the 12v relay for the heat source. After 20 seconds test mode is exited and unit reverts to normal operation.

RESERVOIR FILL PROCEDURES

The kettle's water level must be maintained at the proper level to submerge the heater elements. Under normal operating conditions, the sealed water reservoir should never require the addition of water.

SPRING WATER REQUIREMENTS

If the red "low water" light comes on during use (while the kettle is in an upright position), the water level has reached a critically low level. The low water protection control has automatically shut off the heater elements. The following procedure must be completed before further use:

NOTE: Have a qualified service technician repair the leakage problem and add water to the unit. Ensure that the red "low water" light is on when the kettle is upright. On tilting kettles, it is normal for the red light to come on when the kettle is in a tilted position, as the elements are not submerged in water at this point.

CAUTION: Only a mixture of distilled water and rust inhibitor should be used when adding water to a partially filled water reservoir. Local tap water conditions may cause kettle damage which is not covered under warranty. Rust inhibitor is purchased locally. Read directions and do not exceed manufacturer's recommendation (excessive rust inhibitor can also cause solidification).

DRAINING PROCEDURE

WARNING: THE FUSED DISCONNECT SWITCH MUST BE OFF BEFORE REMOVING THE KETTLES BOTTOM COVER.

Draining procedure

1. Pull pressure relief valve to insure there is no pressure within the kettle jacket.
2. Remove bottom covers.
3. Remove low water level probe and allow water to drain.
4. To rinse kettle jacket:
   • On tilting kettles fill jacket from low water probe fitting.
   • On stationary kettles:
     • Replace low water probe.
     • Remove pressure relief valve and replace with street elbow.
     • Using a small funnel (one made of paper works great) slowly pour water into the kettle.
5. Allow kettle to drain again.
6. Repeat until water drains clear.

REFILLING UNIT

1. Apply a thread sealant (i.e. Teflon tape) to the water level probe threads and replace.
2. See RESERVOIR FILL PROCEDURE

WIRING DIAGRAM

200-240v

WIRING DIAGRAM

480-600v

SERVICE PARTS

WARRANTY

Our Company supports a worldwide network of Maintenance and Repair Centers. Contact your nearest Maintenance and Repair Centre for replacement parts, service, or information regarding the proper maintenance and repair of your cooking equipment.

In order to preserve the various agency safety certification (UL, NSF, ASME/Ntl. Bd., etc.), only factory-supplied replacement parts should be used. The use of other than factory supplied replacement parts will void warranty.

HINGE ASSEMBLY

TRUNNION HOUSING - TILTING KETTLES

TANGENT DRAW-OFF VALVES

1.5" & 3" TANGENT DRAW-OFF VALVE

2" TANGENT DRAW-OFF VALVE

KETTLE BOTTOM & SIDE

CONTROL CONSOLE COMPONENTS - HAND TILT

CONTROL CONSOLE COMPONENTS - POWER TILT

SPARE PARTS LIST

Refer to Kettle Bottom & Side for parts drawing

Refer to Faucet Assembly for drawing