Service Manual

ManualsBrandsVulcan-Hart ManualsHot Beverage MakerK80GLT Hot Beverage Maker

K40GL Shown

K Series Gas Kettles 2/3 Jacketed

Stationary and Tilting

K20GL ML-136090

K40GL ML-136091

K60GL ML-136092

K20GLT ML-136094

K40GLT ML-136095

K60GLT ML-136096

- NOTICE -

This Manual is prepared for the use of trained Vulcan Service

Technicians and should not be used by those not properly

qualified.

This manual is not intended to be all encompassing. If you have

not attended a Vulcan Service School for this product, you should

read, in its entirety, the repair procedure you wish to perform to

determine if you have the necessary tools, instruments and skills

required to perform the procedure. Procedures for which you do

not have the necessary tools, instruments and skills should be

performed by a trained Vulcan Service Technician.

The reproduction, transfer, sale or other use of this Manual,

without the express written consent of Vulcan, is prohibited.

This manual has been provided to you by ITW Food Equipment

Group LLC ("ITW FEG") without charge and remains the property

of ITW FEG, and by accepting this manual you agree that you will

return it to ITW FEG promptly upon its request for such return at

any time in the future.

SERVICE MANUAL

A product of Vulcan-Hart 3600 North Point Blvd Baltimore, MD 21222

F45461 Rev. A (0713)

Summary of content (44 pages)

PAGE 1
SERVICE MANUAL K Series Gas Kettles 2/3 Jacketed Stationary and Tilting K20GL K40GL K60GL K20GLT K40GLT K60GLT ML-136090 ML-136091 ML-136092 ML-136094 ML-136095 ML-136096 K40GL Shown - NOTICE This Manual is prepared for the use of trained Vulcan Service Technicians and should not be used by those not properly qualified. This manual is not intended to be all encompassing.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting TABLE OF CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODELS COVERED . . . . . . . . . . . . . . .
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 STATIONARY & TILTING - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 POWER TILTING OPTION ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - GENERAL GENERAL INTRODUCTION General The procedures in this manual apply to all models unless otherwise specified. The pictures and illustrations are of a model K40GLT floor model tilting kettle unless otherwise noted. All information and specifications contained in this manual are based on the latest product information available at the time of printing.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - GENERAL CONTROL PANEL • Dowfrost™ heat transfer fluid Part No. 558038 (5 gallon). Refer to FILLING THE RESERVOIR JACKET for volumes. • Distilled water only for re-filling of the jacket (purchase locally). Refer to FILLING THE RESERVOIR JACKET for volumes. SPECIFICATIONS Electric • 120VAC / 60HZ / 1 phase Standard • Standard set of hand tools. • Pipe thread sealant (must be resistant to the action of propane gases).
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - GENERAL GAS SUPPLY PRESSURES GAS TYPE Natural Propane Manifold (in W.C.) Low Speed * - 0.27 to 0.30 High Speed - 1.91 to 1.98 Low Speed * - 0.27 to 0.30 High Speed - 1.91 to 1.98 NOMINAL (in W.C.) MIN (in W.C.) MAX (in W.C.) 7 5 14 11 11 13 * Low Speed – Blower operates at low speed during trial for ignition (approximately 7 seconds). Ignition is successful and burner lights.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS REMOVAL AND REPLACEMENT OF PARTS CONTROL BOX COVER (TILTING) Disconnect the electrical power to the machine and follow lockout / tagout procedures. NOTE: Remove screws from cover where indicated. NOTE: On kettles with manual tilt or power tilt option, the control box height is now taller (as shown) to acomodate additional tilt components. The cover is held in place using the same number of screws.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS panel components are mounted in the kettle control area. BOTTOM COVER CONTROL BOX (TILTING) Disconnect the electrical power to the machine and follow lockout / tagout procedures. NOTE: Remove screws from cover where indicated. 1. Remove CONTROL BOX COVER (TILTING). 2. Disconnect lead wires from component being replaced. 3. Remove screws securing the component to panel.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS 5. Remove air from reservoir jacket as outlined under VENTING procedure. 6. Check for proper operation. NOTE: Pressure switch setting is fixed and should not be adjusted. Kettle Control Area - K Series Tilting Kettles Fig. 9 GAS VALVE Disconnect the electrical power to the machine and follow lockout / tagout procedures. Shut off the gas before servicing the Blower Speed Control - Switch Settings unit.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS Fig. 10 5. Remove piping from gas valve inlet and install on replacement valve. Ensure the factory tags that are wired to the piping remain installed. NOTE: Replacement gas valve contains valve plate, orifice and o-ring already assembled. The gas valve/ blower design allows natural and propane gas kettles to use the same orifice size. Labels for gas type are also included. Fig. 11 4.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS Fig. 14 Fig. 13 6. 6. Reverse procedure to install replacement blower and check for proper operation. Remove combustion chamber cover from bottom of kettle. NOTE: Install replacement blower gasket as necessary. BURNER Disconnect the electrical power to the machine and follow lockout / tagout procedures. Shut off the gas before servicing the unit.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS Fig. 16 9. Reverse procedure to install replacement burner and check for proper operation. Fig. 17 6. Ensure spark gap between ignitor electrode and ground rod is approximately 1/8". If necessary, adjust as outline under SPARK IGNITION TEST Step 8C. 7. Reverse procedure to install and check for proper operation. Apply pipe thread sealant to burner threads that is suitable for use with propane gas.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS GAS SHUT-OFF VALVE (1SOL) TILTING MODELS ONLY GEAR REDUCER - MANUAL TILTING MODELS Disconnect the electrical power to the machine and follow lockout / tagout procedures. Disconnect the electrical power to the machine and follow lockout / tagout procedures. Shut off the gas before servicing the Shut off the gas before servicing the unit. unit.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS 2. Disconnect lead wires from component being replaced. 3. Remove screws securing the component to panel. 4. Reverse procedure to install and check for proper operation. Fig. 21 8. Remove positive stop plate from gear reducer. Note that the positive stop shaft is keyed. Fig. 23 TILT SWITCH (2S) - POWER TILTING OPTION ONLY Disconnect the electrical power to the machine and follow lockout / tagout procedures.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS Fig. 24 Fig. 25 DOWN LIMIT SWITCH (3S) - POWER TILTING OPTION ONLY DC TILT MOTOR - POWER TILTING OPTION ONLY Disconnect the electrical power to the machine and follow lockout / tagout procedures. Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1. Place kettle in the fully upright position. 1. Remove CONTROL BOX COVER (TILTING). 2. Remove CONTROL BOX COVER (TILTING).
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS 5. Remove GAS SHUT-OFF VALVE (1SOL) TILTING MODELS ONLY. 6. Remove DC TILT MOTOR - POWER TILTING OPTION ONLY. 7. Loosen set screw securing arm to kettle pivot shaft (keyed). 8. Remove e-clip securing arm to kettle pivot shaft. Note orientation and remove arm from kettle pivot shaft. NOTE: If installed, note the number of washers in front of and behind the arm on the kettle pivot shaft for re-assembly. Fig.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - REMOVAL AND REPLACEMENT OF PARTS Fig. 31 Fig. 29 10. Lift spacer ring off gear reducer. Retain for use on replacement gear reducer. 12. Pull gear reducer away from kettle by working it off the kettle pivot shaft until free. Retain key for use on replacement gear reducer. NOTE: Control box can be moved as necessary for ease of gear reducer removal. 13. Remove reducer shaft extension from gear reducer shaft (2 roll pins).
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS SERVICE PROCEDURES AND ADJUSTMENTS Certain procedures in this section require electrical test or measurements while power is applied to the machine. Exercise extreme caution at all times. If test points are not easily accessible, disconnect power and follow lockout / tagout procedures, attach test equipment and reapply power to the test. TEMPERATURE CONTROLLER TEST A.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS A. Verify 120VAC between T8 and ground. If correct, output from controller is functioning properly. B. If incorrect, install a replacement temperature controller and check for proper operation. C. THERMOCOUPLE TEST POTENTIOMETER TEST Fig. 34 Fig. 35 1. Access control panel potentiometer by removing CORNER PANEL (TILTING) or SIDE PANEL (STATIONARY). 2.
PAGE 20
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS Fig. 36 1. With the kettle at room temperature, verify pressure gauge is in the vacuum zone and reading 25 to 30 in. Hg. A. Current Construction If vacuum is below minimum listed, air must be removed from reservoir jacket. Continue with procedure to vent as necessary. 2. Place kettle in full upright position (tilting models only). 3. Ensure water level in the jacket is visible in the sight glass.
PAGE 21
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS FILLING THE RESERVOIR JACKET NOTE: The reservoir water level must be maintained high enough to keep contact with the water level probe (LLCO). If low water light comes on during use, the visible level may be below the water level probe and must be replenished before heating can continue. The low water light will come on when kettle is tilted (tilting models only).
PAGE 22
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS 2. 3. 4. Open pressure relief valve until reservoir jacket is completely vented. Allow valve to snap shut to seal. Remove pressure relief valve from kettle to vent the jacket and facilitate draining. Retain for reuse. Remove draw-off valve or plug valve from kettle (stationary models only). 5. Place container under kettle to catch fluid and position it below the sight glass. 6.
PAGE 23
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS B. Blower high speed (15 sec. time delay) Vacuum pressure should be 1.91" W.C. to 1.98" W.C. C. If vacuum pressure reading is outside of the values stated above, check blower air inlet for debris buildup/obstructions. If found, turn power switch off. Remove debris and retest. D. If vacuum pressure results are the same after retest, replace blower. Perform GAS VALVE/BLOWER INLET PRESSURE CHECK.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS SPARK IGNITION TEST A. Inspect the ceramic insulator on spark ignitor electrode for cracks or evidence of exposure to extreme heat, which can permit leakage to ground. If either of these conditions exists, then install a replacement spark ignitor. B. Inspect the spark ignitor electrode and ground rod for contaminates, or corrosion. Clean those surfaces as necessary. C.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS IGNITION CONTROL MODULE TEST Fig. 44 3. Set VOM to micro amps scale (DC). Remove flame sense wire from ignition module and connect it to the black meter lead (-) and connect red meter lead (+) to flame sense terminal. Fig. 45 4. Turn on/off switch on and set the temperature dial to call for heat. 1. Access ignition control module in KETTLE CONTROL AREA. 5.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS NOTE: If kettle burner does not immediately light, the ignition control module continues sparking for 6 seconds, then locks out power to the gas valve (main valve remains closed). The ignition fail light comes ON. The module remains locked out until the on/off switch is cycled to reset the system and re-start the ignition trial cycle. 3. If adjustment is necessary, continue with procedure. 4.
PAGE 27
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS TILT SWITCH (2S) ADJUSTMENT POWER TILTING OPTION ONLY Kettle Fully Tilted - Traveller Contacts Stop Plate 3) 4) 5) 7. Turn crank handle clockwise to tilt the kettle. The kettle should be tilted past 90° to empty its contents. The adjustment range is 92 to 95 degrees. Turn positive stop traveller on the positive stop shaft (threaded) until it contacts the stop plate.
PAGE 28
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS DOWN LIMIT SWITCH (3S) ADJUSTMENT - POWER TILTING OPTION ONLY DC TILT MOTOR CONTROLLER TEST - POWER TILTING OPTION ONLY Fig. 50 1. Remove CONTROL BOX COVER (TILTING) to access Down Limit Switch (3S). 2. Kettle tilt operation - The switch actuator should be operated by the arm when the kettle is tilted past 90° to open the switch contacts and stop travel. The adjustment range is 92 to 95 degrees. 3.
PAGE 29
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - SERVICE PROCEDURES AND ADJUSTMENTS 8. A. If voltage is present but pan does not raise, refer to POWER TILTING OPTION ONLY under TROUBLESHOOTING. B. If voltage is not present and the DC fuse is ok, turn the power switch off and disconnect power to the machine. Install a replacement DC tilt motor controller and check for proper operation. Page 29 of 44 F45461 Rev.
PAGE 30
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION ELECTRICAL OPERATION COMPONENT FUNCTION (STATIONARY & TILTING MODELS) Water Level Control (WLC LLCO) . . . . . . . . . Low water level control. Monitors condition of the WLC LLCO water level probe. Protects kettle from a low water condition in the reservoir jacket. Probe, Water Level (LLCO) . . . . . . . . . . . . . . . Low Level Cut-Off (LLCO) probe connected to WLC (LLCO). Controls power to heating circuit. Fuse, (1FU) .
PAGE 31
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION Light (2LT), Low Water . . .Red (RD) colored light. On when water level in the reservoir jacket drops below water level (LLCO) probe. Light (3LT), Heat . . . . . Amber (AM) colored light. On when temperature controller is calling for heat. Ignition Fail (4LT) . . . . Amber (RD) colored light. On when burner does not light. COMPONENT FUNCTION (POWER TILTING OPTION) DC Tilt Motor Controller . . . . . . . . . . . .
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION COMPONENT LOCATION (STATIONARY & TILTING MODELS) K Series Stationary Gas Kettle - Controls Side F45461 Rev.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION K Series Tilting Gas Kettle - Controls Side Page 33 of 44 F45461 Rev.
PAGE 34
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION K Series Manual Tilt Gas Kettle - Control Box Area F45461 Rev.
PAGE 35
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION K Series Gas Kettle with Power Tilt Option - Control Box Area SEQUENCE OF OPERATION (KETTLE CONTROL CIRCUIT) Refer to Schematic diagram AI3537 for stationary and manual tilting kettle models. Kettles with Power Tilt, refer to Sequence of Operation - Power Tilt Option and schematic diagram AI3538. 1. A. Kettle connected to 120VAC supply and is properly grounded. B.
PAGE 36
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION E. Tilt switch (2S) operated, N.O. contacts held closed (kettle in the full upright position tilting models only). F. Pressure switch (1PAS) N.C. contacts are closed. G. Temperature dial at lowest setting (potentiometer fully CCW). 1) H. 2. 3. Blower speed control powered at connector J5.4 for blower motor low speed operation through K4 N.C. contacts. Blower at low speed. D.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION SEQUENCE OF OPERATION (POWER TILTING OPTION) Refer to schematic diagram AI3538 for power tilting option and AI3537 for the main control circuit diagram that includes Tilt Switch (2S) and Raise-Enable relay (K3). 1. 2. Conditions. 4. A. 120VAC to kettle, polarity is correct, and is properly grounded. B. Power switch off. C. Tilt motor switch off (center position). D. Kettle in the upright position. E.
PAGE 38
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION C. The three sets of K1 N.O. contacts return to the open position. Power is removed from the DC motor controller, the DC tilt motor and kettle travel stops. F45461 Rev.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION SCHEMATIC DIAGRAM (STATIONARY & TILTING MODELS) Fig. 56 Page 39 of 44 F45461 Rev.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - ELECTRICAL OPERATION SCHEMATIC DIAGRAM (POWER TILTING OPTION) Fig. 57 F45461 Rev.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - TROUBLESHOOTING TROUBLESHOOTING STATIONARY & TILTING - GENERAL K Series Gas Kettles (Stationary & Tilting) SYMPTOM POSSIBLE CAUSE 1. Gas supply is OFF. 2. Transformer (1T) output voltage is low. 3. Tilting models only - Gas shut-off valve (1SOL) not receiving power or malfunction. Kettle does not heat, power light is lit, heat light is lit, ignition fail light is lit, low 4.
PAGE 42
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - TROUBLESHOOTING K Series Gas Kettles (Stationary & Tilting) SYMPTOM POSSIBLE CAUSE 1. Kettle unplugged; main circuit breaker off; or incoming supply line fuse F1 open. 2. Supply voltage incorrect. Kettle does not heat, power light is not 3. lit. 4. Ground fault receptacle (GFCI) is tripped. Hood system with a power interrupt is not ON. 5. Power switch off or malfunction. 6. Interconnecting wiring malfunction. 1.
PAGE 43
K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - TROUBLESHOOTING K Series Gas Kettles (Stationary & Tilting) SYMPTOM POSSIBLE CAUSE 1. Gas supply not on. 2. Tilting models only - Gas shut-off valve (1SOL) not receiving power or malfunction. 3. Ignition module not receiving power. 4. Unit not properly grounded and/or polarity of incoming power is incorrect on automatic ignition systems. Kettle not heating (burner not lighting during trial for ignition or staying lit), heat 5.
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K Series Gas Kettles 2/3 Jacketed Stationary and Tilting - TROUBLESHOOTING POWER TILTING OPTION ONLY SYMPTOM Kettle will not tilt F45461 Rev. A (0713) POSSIBLE CAUSES 1. Transformer 2T inoperative. 2. Power switch off or malfunction. 3. Tilt motor switch malfunction (momentary on - tilt). 4. Down limit switch open or malfunction. 5. K2 down relay malfunction. 6. DC tilt motor controller - Fuses open or controller malfunction. 7. DC tilt motor inoperative. 8. Gear reducer malfunction.