Vulcan-Hart GL80E Hot Beverage Maker User Manual
Contents
1. for natural gas and 10 Water Column 2 5 kPa for propane WARNING PRIOR TO LIGHTING CHECK ALL JOINTS IN THE GAS SUPPLY LINE FOR LEAKS USE SOAP AND WATER SOLUTION DO NOT USE AN OPEN FLAME After piping has been checked for leaks all piping receiving gas should be fully purged to remove air TESTING THE GAS SUPPLY SYSTEM When test pressures exceed psig 3 45 kPa the kettle and its individual shutoff valve must be disconnected from the gas supply piping system When test pressures psig 3 45 kPa or less the kettle must be isolated from the gas supply system by closing its individual manual shutoff valve FLUE DO NOT obstruct the flow of flue gases from the flue located on the rear of the kettle It is recommended that the flue gases be ventilated to the outside of the building through a ventilation system installed by qualified personnel The flue on the kettle should not be directly connected to any ventilation system From the termination of the flue to the filters of the hood venting system a minimum clearance of 18 116 cm must be maintained Information on the construction and installation of ventilating hoods may be obtained from Vapor Removal from Cooking Equipment NFPA 96 latest edition available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 FAUCET BRACKET A bracket is provided for mounting a faucet on the kettle this would allow the addition of water to the ke2. Code ANSI Z223 1 latest edition available from the American Gas Association 1515 Wilson Boulevard Arlington VA 22209 with the National Electrical Code ANSI NFPA No 70 latest edition available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 and with Vapor Removal from Cooking Equipment NFPA 96 latest edition available from NFPA In Canada the kettle must be installed in accordance with local codes with the National Fuel Gas Code CAN CGA B149 1 latest edition available from the Canadian Gas Association 178 Rexdale Boulevard Etobicoke Ontario Canada M9W 1R3 and with the Canadian Electrical Code CSA C22 2 No 3 latest edition available from the Canadian Standards Association 178 Rexdale Boulevard Etobicoke Ontario Canada M9W 1R3 GAS CONNECTION The gas supply connection and any pipe joint compound must be resistant to the action of propane gases Codes require that a gas shutoff valve be installed in the gas line ahead of the kettle Connect the gas supply line to the gas valve on the kettle Make sure the pipes are clean and free of obstructions dirt and piping compound The gas line must be capable of delivering gas to the kettle without excessive pressure drop at the rate specified on the nameplate Suggested gas supply line pressure is 7 Water Column 1 75 kPa for natural gas and 11 Water Column 2 75 kPa for propane Burner manifold pressure is 3 5 Water Column 0 875 kPa
3. VALVE Low Water Cutoff Pressure Relief Valve Pressure Limit Switch Thermostatic Air Vent Vacuum Breaker Sight Glass Assembly Fill Assembly Food Draw Off Valve FOOD DRAW OFF VALVE CONTROLS ENCLOSURE PRESSURE LIMIT SWITCH ETC PRESSURE RELIEF VALVE THERMOSTATIC AIR VENT VACUUM BREAKER FILL ASSEMBLY UPPER VALVE OPEN SIGHT GLASS WATER LEVEL LOWER VALVE OPEN Fig 4 Pilot and Main Burner won t operate if water level in jacket is low Protect the kettle against excessive pressure should the thermo stat malfunction The pressure relief valve is rated so that it will relieve generated steam faster than the burners can generate it Allows air to vent out of the jacket as steam is generated closes at approximately 180 F 82 2 C to prevent the steam from escaping Allows air to enter the jacket after cooldown preventing negative pressure Visually shows the water level in the jacket when both valves are open and pressure is equalized Tube where water can be added to the jacket A manual valve and acheck valve are provided to protect you should the manual valve be inadvertently opened while the jacket is under pressure Allows food and liquid to be drawn off from the kettle The food draw off valve is designed to allow food and liquid to be removed from the kettle in an easy and safe manner When the food draw off valve is off the valve handle is pointed to either the
4. the pilot through the lighting hole while completely depressing the knob of the combination control valve Keep the knob depressed for about one minute after the pilot is lit Release the knob The pilot should continue burning If not repeat steps 3 and 4 5 Turn the combination control valve to the ON position 6 Replace the control box cover Replace the screw and reconnect the electric power 7 If pilot light goes out main burners will not come on Repeat starting from step 1 8 Use thermostat to regulate cooking temperatures SHUTDOWN Turn the thermostat dial to the OFF position If equipped with an On Off switch turn it off To completely shut off close the gas shutoff valve Turn combination gas control valve off 10 CLEANING After each use clean and flush the kettle liner immediately especially if the product cooked contained salt vinegar or acid in any concentration Do not use chlorine based cleaning products Do not use metalic scouring pads or brushes Daily Kettle Food Draw Off Valve CAUTION During disassembly cleaning and reassembly of the valve take special care to avoid damage to the mating surfaces of the valve plug and valve body Do not allow the valve plug to contact metal or hard surfaces during cleaning Do not use metal utensils or scouring pads to clean the valve s mating surfaces Do not drop valve plug Damage to the mating surfaces will result in a leaky valve Damaged valves are not co
5. 9 o clock position or the o clock position as you look down on the valve In this off position no liquid or food product will flow To open the valve and allow liquid or food product to flow slowly turn handle forward With the valve handle pointing to the 6 o clock position the valve is fully open Turn the valve 90 degrees right or 90 degrees left to close the valve and shut off the flow of food Stir the food product in the kettle thoroughly before opening the draw off valve this makes the food product evenly mixed before it flows into a suitable food service pan or stock pot Pans or pots may be placed on a portable dolly for ease of movement and handling Refer to Cleaning page 11 TURNING KETTLE EQUIPPED WITH ELECTRONIC IGNITION Applies to Fig 1 or Fig 2 Before lighting the pilot both the burner and pilot must have been off at least 5 minutes 1 2 3 4 Remove the control panel cover screw Remove the control box cover lift pull out at bottom lower Turn knob of the combination control valve counterclockwise until it stops at the ON position Replace the control panel cover and screw Check proper jacket water level Refer to Fig 4 page 9 and Jacket Water amp Jacket Water Treatment page 12 6a 6b 6c re 8 Make sure gas Supply is on Turn the On Off switch to the ON position On kettles built after September 2003 the pilot begins sparking and the pilot burner indicator light illumin
6. Ignition 10 Turning a Kettle Equipped With a Manual Pilot Burner 10 gd otal AIR id Anh gah Mice 10 GICANING edn eae as wats UN Ete eee Hees 11 Daily Kettle Food Draw Off Valve 11 MAINTENANCE Rare Emad Hankin EA 12 Pressure Relief Valve 12 Low Water CuO seas oe BA Ne pee eet 12 Jacket Water amp Jacket Water Treatment 12 Hood Ventiliation System 12 Service and Parts Information 12 Installation Operation and Care of GS GL amp GT SERIES FULLY STEAM JACKETED GAS KETTLES KEEP THESE INSTRUCTIONS FOR FUTURE USE GENERAL Your Vulcan steam jacketed kettle is produced with quality workmanship and material Proper installation usage and maintenance will result in many years of satisfactory performance Vulcan Hart Company suggests that you thoroughly read this entire manual and carefully follow all of the instructions provided INSTALLATION Prior to installation check the electrical service and type of gas supply natural or propane to make sure they agree with the specifications on the machine data plate located on the lower left insid
7. LECTRONIC IGNITION Prior Construction Fig 2 Thermostat Controls heat in the kettle High dial settings are for cooking low settings are for holding On Off Switch Located on the upper right hand corner of the control panel When turned to ON initiates the electronic ignition system Combination Control Valve Controls gas flow to the main burner The valve has a built in gas pressure regulator which shuts off all gas in the event of pilot outage Pressure Gauge Indicates pressure in the jacket normal operating range is 0 to 12 psig LID KETTLE JACKET ON OFF SWITCH THERMOSTAT PRESSURE GAUGE JACKET WATER LEVEL COMBINATION CONTROL VALVE Built before September 2003 Fig 2 LID KETTLE JACKET THERMOSTAT PRESSURE GAUGE JACKET WATER LEVEL COMBINATION CONTROL VALVE Built before November 2002 Fig 3 CONTROLS KETTLES WITH MANUAL PILOT BURNER Prior Construction Fig 3 Thermostat Controls heat in the kettle High dial settings are for cooking low settings are for holding Combination Control Valve Controls gas flow to the main burner The valve has a built in gas pressure regulator which shuts off all gas in the event of pilot outage Pressure Gauge 12 psig Indicates pressure in the jacket normal operating range is 0 to KETTLE FEATURES COMMON ALL CONSTRUCTIONS Fig 4 HANDLE LID FOOD DRAW OFF
8. VULCAN INSTALLATION amp OPERATION MANUAL GS GL amp GT SERIES FULLY STEAM JACKETED GAS KETTLES MODEL GS25E GS30E GL40E GS60E GL80E GT100E GT125E GT150E ML 52633 ML 52634 ML 52635 ML 52660 ML 52637 ML 52638 ML 52639 ML 52640 GL Series Kettle VULCAN HART COMPANY P O BOX 696 LOUISVILLE KY 40201 0696 TEL 502 778 2791 FORM 30960 Rev B Oct 2003 www vulcanhart com IMPORTANT FOR YOUR SAFETY THIS MANUAL HAS BEEN PREPARED FOR PERSONNEL QUALIFIED TO INSTALL GAS EQUIPMENT WHO SHOULD PERFORM THE INITIAL FIELD START UP AND ADJUSTMENTS OF THE EQUIPMENT COVERED BY THIS MANUAL POST IN A PROMINENT LOCATION THE INSTRUCTIONS TO BE FOLLOWED IN THE EVENT THE SMELL OF GAS IS DETECTED THIS INFORMATION CAN BE OBTAINED FROM THE LOCAL GAS SUPPLIER IMPORTANT IN THE EVENT A GAS ODOR IS DETECTED SHUT DOWN UNITS AT MAIN SHUTOFF VALVE AND CONTACT THE LOCAL GAS COMPANY OR GAS SUPPLIER FOR SERVICE FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE 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 IN THE EVENT OF A POWER FAILURE DO NOT ATTEMPT TO OPERATE THIS DEVICE VULCAN HART COMPANY 2003 TABLE OF CONTENTS GENERAD oe ete
9. ant If the valve still leaks after lapping repeat the lapping procedure MAINTENANCE WARNING THE KETTLE AND ITS PARTS ARE HOT USE CARE WHEN OPERATING CLEANING AND SERVICING THE KETTLE WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURE PRESSURE RELIEF VALVE Open the pressure relief valve at least once a day to avoid lime build up If leakage occurs or if the valve opens below the rated psi it will need to be replaced by your Vulcan authorized servicer LOW WATER CUT OFF This device should be removed and inspected for lime build up at least once a year The float must move freely in its cage Clean if necessary Replace if lime or sludge cannot be removed to allow the float to move freely Contact your local Vulcan authorized servicer JACKET WATER amp JACKET WATER TREATMENT The kettle jacket is filled at the factory with chemically pure water mixed with a boiler treatment corrosion inhibitor During normal kettle operation it should not be necessary to frequently add water to the kettle jacket If the water level in the sight glass falls below half add distilled or chemically pure water to the jacket through the fill tube The water level in the sight glass should be maintained to just above the halfway position in the sight glass If the water in the sight glass appears dirty it is necessary to have a qualified service technician remove the fluid in the kettle perform a de
10. ates The pilot burner and indicator light remain on as long as the On Off switch remains on If the pilot burner goes out the kettle controls automatically attempt to relight the pilot for 90 seconds followed by a 5 minute wait this repeats until pilot lights or switch is turned off On kettles built from October 1998 to September 2003 the pilot begins sparking only when the thermostat calls for heat from the main burners The pilot burner cycles on and off with the main burners If the pilot burner goes out turn the On Off switch off for 5 minutes before attempting to restart the pilot by turning the switch back on On kettles built before October 1998 the pilot begins sparking and the pilot lights The pilot stays on as long as the On Off switch remains on If the pilot burner goes out turn the On Off switch off for 5 minutes before attempting to restart the pilot by turning the switch back on The lit pilot can be viewed through the view port at lower front of kettle Use thermostat to regulate cooking temperatures TURNING ON A KETTLE EQUIPPED WITH A MANUAL PILOT BURNER Applies to Fig 3 1 Remove the control box cover screw Remove the control box cover lift pull out at bottom then lower 2 Swing disc to open the lighting hole lower front 3 After burners have been off for at least 5 minutes open the gas shutoff valve 4 Turn the knob of the combination control valve to the PILOT position Using a taper ignite
11. bricant P N 833652 is furnished with your kettle You can reorder through your local service agency or food service equipment dealer There are no substitutes for this lubricant If you fail to lubricate the valve body and plug after cleaning or use a substitute lubricant this could damage the mating surfaces which is not covered under warranty 4 lf multiple kettles in use each draw off valve body and draw off plug is stamped with a set of corresponding numbers After cleaning and lubricating make sure the body and plug numbers match before reinserting the valve plug Always examine the valve plug and valve body for nicks and heavy scratches Do not push or force the valve plug into the valve body if there are any obstructions nicks or heavy scratches in either the plug or the valve body 5 To correct a draw off valve that is leaking after lubricant has been applied examine the mating surfaces of the valve body and valve plug and carefully dress any raised places with avery fine file or emery cloth Do not cut below metal surface in removing any raised places Coat plug lightly with lapping compound insert plug into valve body and rotate back and forth several times to seat plug into valve body Use medium grade lapping compound first and finish with a fine grade Valve grinding compound from an automobile supply house is suitable for this After use of lapping compound clean surfaces thoroughly Lubricate surfaces with Petro Gel lubric
12. check the jacket water level by looking at the sight glass at the rear of the kettle with both upper and lower valves open The water level should be at the midpoint of the sight glass If water is below the recommended level or if it is murky refer to Jacket Water Level page 12 Also check the flue at the rear of the kettle for any obstructions before operating CONTROLS KETTLES WITH ELECTRONIC IGNITION Current Construction Fig 1 JACKET WATER LEVEL Thermostat Pressure Gauge On Off Switch Pilot Burner Indicator Light Main Burner Indicator Light Combination Control Valve LID KETTLE JACKET THERMOSTAT PRESSURE GAUGE ON OFF SWITCH MAIN BURNER INDICATOR LIGHT PILOT BURNER INDICATOR LIGHT COMBINATION CONTROL VALVE Kettles built after September 2003 Fig 1 Controls heat in the kettle High dial settings are for cooking low settings are for holding Indicates pressure in the jacket normal operating range is 0 to 12 psig Located below pressure gauge when turned to ON initiates electronic ignition to start the Pilot and Main Burner When lit the electronic ignition system is attempting to light the Pilot or the Pilot has been lit it remains lit when the Main Burner is on When lit the Main Burner is providing heat to the kettle Located inside box this valve controls gas flow to the Main Burner CONTROLS KETTLES WITH E
13. e front cover UNPACKING This kettle was inspected before leaving the factory The transportation company assumes full responsibility for safe delivery upon acceptance of the shipment Immediately after unpacking check for possible shipping damage If the kettle is found to be damaged save the packaging material and contact the carrier within 15 days of delivery LOCATION Position the kettle in its final location Check that there are sufficient clearances for operating and servicing the kettle and for proper clearance of the cover when raised Keep the kettle free and clear from all combustible substances Minimum clearance from combustible and non combustible construction is 2 5 0 cm at the rear and 6 15 2 cm at each side The kettle draw off valve should be located near a floor drain Do not obstruct the flow of air into and around the kettle This air flow is necessary for proper combustion of gases and for ventilation of the kettle Provisions for ventilation and incoming air supply for the equipment in the room must be in accordance with the National Fuel Gas Code ANSI 2223 1 latest edition LEVELING Place a spirit level on the rim of the kettle with the cover open Turn the feet in or out to level the kettle in both the left to right and front to rear directions INSTALLATION CODES AND STANDARDS In the United States Vulcan kettles must be installed in accordance with state and local codes with the National Fuel Gas
14. lime or cleaning operation and refill the kettle with distilled chemically pure water with a boiler treatment additive Do not fill kettle jacket with chlorinated tap water Appliance failure caused by water quality is not covered under warranty HOOD VENTILATION SYSTEM Annually when cool check the ventilation system and clear any obstructions SERVICE AND PARTS INFORMATION To obtain service and parts information concerning the kettle contact the Vulcan Hart Service Agency in your area refer to listing supplied with the kettle or Vulcan Hart Company Service Department at the address or phone number shown on the front cover of this manual FORM 30960 Rev B Oct 2003 SASE PRINTED IN U S A
15. out Bi ree AA a ance tiene tient ap tone eran tee eee as 4 INSTAELATION eei Aaa Gin ae LARS eatin Moto aks ates 4 UNPACKING lt 2 82526 thie eb vow a Gees bd 4 Bok toe ota 4 4 Installation Codes and Standards 5 Gas CONNC CON sekarone ea aa eee ek ew es EE Ea 5 Testing the Gas Supply System 24 00 e78ccen 81 ee bead bh 5 Flue Soya da Sete 5 Faucet Bracket bade E A A 6 oe wae Bs 6 Before FIRST WSO esis sae Maca ba ee ee 6 OPERA BL Nae ele ae gee eS ae Ee SR a le dre Ole A ee eT Pee 7 Controls Kettles With Electronic Ignition Current Construction 7 Controls Kettles With Electronic Ignition Prior Construction 8 Controls Kettles With Manual Pilot Light Prior Construction 8 Kettle Features Common All 5 lt 9 Food Draw Oll wid wheats tow Rae 9 Turning On a Kettle Equipped With Electronic
16. ttle for the convenience of the food preparer A faucet is available as an accessory NOTE Do notuse tap water from faucet to fill kettle jacket Refer to Jacket Water amp Jacket Water Treatment on page 12 ELECTRICAL CONNECTION WARNING ELECTRICAL AND GROUNDING CONNECTIONS MUST COMPLY WITH THE APPLICABLE PORTIONS OF THE NATIONAL ELECTRICAL CODE AND OR OTHER LOCAL ELECTRICAL CODES WARNING DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT TAGOUT PROCEDURE All kettles are connected to 120 volt 60 Hz supply through the pigtail leads in the supply junction box located inside the control panel Remove the control box cover Connect electrical supply to the terminal block per the wiring diagram located inside the control box cover Use copper wire suitable for at least 75 C Connect a ground wire to the ground lug in the junction box NOTE Earth ground is required for proper operation of electonic ignition Replace the control box cover BEFORE FIRST USE Use a non corrosive grease dissolving commercial cleaner to clean the protective metal oils from all surface parts and the interior of the kettle Follow the cleaner manufacturer s directions Rinse thoroughly with warm water to remove all traces of the cleaner Drain the kettle s interior cooking area Wipe dry with a clean cloth OPERATION WARNING THE KETTLE AND ITS PARTS ARE HOT USE CARE WHEN OPERATING CLEANING AND SERVICING THE KETTLE Before operating
17. vered under warranty 1 Disassemble and clean valve daily With kettle empty turn valve handle to the removable position Lift valve plug from valve body A pin locks the valve plug into the valve body the valve plug can only be removed or replaced when the valve handle is at the removable position Do not attempt to slide the valve plug into the valve body when the valve handle is in any other than the removable position This would damage the pin cause the plug not to seat properly and cause leakage between the valve plug and the valve body removable position for valves manufactured after June 2003 is with the handle positioned at 7 o clock The removable position for valves manufactured from March 1992 through June 2003 is with the handle positioned at 4 o clock The removable position for valves manufactured prior to March 1992 is with the handle positioned at 6 o clock 2 Using a solution of warm water and detergent wash the entire valve body the opening that goes into the kettle interior Also wash the interior and exterior of the valve plug 3 After cleaning the valve lubricate the valve body and valve plug with Petro Gel lubricant supplied with kettle Make sure all interior mating surfaces are covered with this lubricant before sliding the valve plug into the valve body Make sure the valve plug handle is in the removable position when the plug is slipped carefully into the valve body A 4 oz tube of Petro Gel lu
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