Vulcan Hart Hot Beverage Maker K20EL User Manual

INSTALLATION &  
OPERATION MANUAL  
ELECTRIC  
STATIONARYAND  
TILTINGKETTLES  
60  
30  
90  
120  
150  
30  
Hg  
vac  
psi  
MODEL  
MIL  
K20EL  
136073  
136074  
136075  
136077  
136078  
136079  
K40EL  
K60EL  
K20ETL  
K40ELT  
K60ELT  
K40EL  
For additional information on Vulcan-Hart or to locate an authorized parts  
VULCAN-HART  
3600 NORTH POINT BLVD.  
BALTIMORE, MD 21222  
DIVISION OF ITW FOOD EQUIPMENT GROUP, LLC  
WWW.VULCANHART.COM  
FORM 35457 (10-09)  
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ELECTRIC STATIONARY KETTLES  
CONTENTS  
IMPORTANT FOR YOUR SAFETY ................................................................................................2  
INSTALLATION, OPERATION AND MAINTENANCE OF  
K20EL/ELT, K40EL/ELT AND K60EL/ELT ELECTRIC KETTLES .........................................4  
GENERAL ...................................................................................................................................4  
MODEL CHART .........................................................................................................................4  
DATA PLATE LOCATION ..........................................................................................................4  
INSTALLATION.................................................................................................................................5  
UNPACKING ...............................................................................................................................5  
INSTALLATION CODES AND STANDARDS ...........................................................................5  
LOCATION..................................................................................................................................5  
Stationary Kettle ...................................................................................................................5  
Tilting Kettle ..........................................................................................................................5  
MINIMUM CLEARANCE REQUIREMENTS and  
RECOMMENDED FLOOR DRAIN LOCATIONS .....................................................................6  
INSTALLATION PROCEDURE .................................................................................................6  
Electrical Connection...........................................................................................................6  
Electrical Specifications ......................................................................................................6  
OPERATION ....................................................................................................................................8  
VENTING.....................................................................................................................................8  
RESERVOIR JACKET WATER LEVEL CHECK .....................................................................8  
DAILY OPERATION ...................................................................................................................8  
TILTING KETTLES .....................................................................................................................8  
CONTROLS AND INDICATORS...............................................................................................8  
CLEANING ........................................................................................................................................9  
2" & 3" COMPRESSION VALVE CLEANING INSTRUCTIONS ...............................................9  
PLUG VALVE CLEAINING INSTRUCTIONS ...........................................................................10  
STAINLESS STEEL EQUIPMENT CARE AND CLEANING ...................................................11  
MAINTENANCE ............................................................................................................................. 13  
VENTING.................................................................................................................................. 13  
FILLING THE RESERVOIR JACKET ..................................................................................... 13  
TROUBLESHOOTING .................................................................................................................. 14  
SERVICE AND PARTS INFORMATION ...................................................................................... 15  
— 3 —  
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ELECTRIC STATIONARY KETTLES  
INSTALLATION, OPERATION AND MAINTENANCE  
OF K20EL/ELT, K40EL/ELT AND K60EL/ELT  
ELECTRIC KETTLES  
SAVE THESE INSTRUCTIONS  
FOR FUTURE USE  
DATA PLATE LOCATION  
The data plate stating the model number,  
serialnumberandtheelectricalcharacteristics  
is located on the back of Control Panel. The  
National Board Data Plate is located on the  
lower skirt.  
GENERAL  
Vulcan Steam Jacketed Kettles are produced  
with quality workmanship and material. Proper  
installation, usage and maintenance will result  
in many years of satisfactory performance. It  
is suggested that you thoroughly read this  
entire manual and carefully follow all of the  
instructions provided.  
MODEL CHART  
Model  
Gallons Quarts Liters  
K20EL, K20ELT  
K40EL, K40ELT  
K60EL, K60ELT  
20  
40  
60  
80  
76  
160  
240  
152  
227  
Fig. 2 Data Plate Location  
Fig. 1 Typical Stationary Kettle  
— 4 —  
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ELECTRIC STATIONARY KETTLES  
INSTALLATION  
UNPACKING  
LOCATION  
This kettle was inspected before leaving the  
factory. The transportation company assumes  
full responsibility for safe delivery upon  
acceptance of the shipment.  
Stationary Kettle  
Positionthekettleinitsfinallocation.Checkthat  
therearesufficientclearancesforoperatingand  
servicing the kettle, and proper clearance of the  
cover when raised. The kettle draw-off valve  
should be located near a floor drain.  
Immediately after unpacking, check for  
possible shipping damage. If kettle damage is  
found, save the packaging material and  
contract the carrier within 15 days of delivery.  
Tilting Kettle  
INSTALLATION CODES  
AND STANDARDS  
Position the kettle in its final installed location to  
provide drainage directly below pour path, with  
sufficient rear clearance from the wall to allow  
the kettle to tilt completely without obstruction.  
In the United States, Vulcan kettles must be  
installed in accordance with:  
1. State and local codes  
2. NFPAStandardNFPA-96, VaporRemoval  
from Cooking Equipment, latest edition,  
available from the National FireProtection  
Association, Batterymarch Park, Quincy,  
MA02269  
3. National Electrical Code (ANSI/NFPA  
No.70, latest edition) available from the  
National Fire Protection Association  
(NFPA), Batterymarch Park, Quincy, MA  
02269  
In Canada, Vulcan kettles must be installed in  
accordance with:  
1. Local codes  
2. Canadian Electrical Code (CSA C22.2  
No.3, latest edition) available from the  
Canadian Standards Association, 5060  
Spectrum Way, Mississauga, Ontario,  
Canada L4W 5N6  
— 5 —  
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ELECTRIC STATIONARY KETTLES  
MINIMUM CLEARANCE  
INSTALLATION PROCEDURE  
REQUIREMENTS AND RECOMMENDED  
FLOOR DRAIN LOCATIONS  
Level the kettle by making necessary  
adjustments using the flanged feet.  
No side and back clearance required, except  
for operation and service requirements.  
1. Place a spirit level on the rim of the kettle  
with the cover open. Adjust the feet to level  
the kettle left-to-right and front-to-back.  
2. Mark anchoring hole locations through the  
flanged feet.  
3. With hole location marked, drill holes to  
accommodate 5/16" studs.  
4. Reposition the kettle.  
5. Bolt the kettle down and apply an NSF  
approved silicone sealant around the  
bolt heads and flange making contact  
with floor surface. Wipe off excess  
sealant immediately.  
Fig 3. Floor Drain Location  
— 6 —  
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ELECTRIC STATIONARY KETTLES  
ELECTRICAL CONNECTION  
: Electrical and ground-  
ing connections must comply with appli-  
cable portions of the National Electric  
Code and/or other local electrical codes.  
Disconnect  
electrical power to the  
machine and follow Lockout/  
Tagout procedures.  
1. Open the control box.  
2. Using the wiring diagram for reference,  
connect electric supply to terminal block.  
ELECTRICAL SPECIFICATIONS  
Amperage per Line  
Minimum  
MODEL  
kW  
PHASE  
CircuitAmpacity  
208V  
57.7  
33.3  
240V  
480V  
208V 240V  
480V  
K20EL/ELT 12  
16  
1
3
1
3
14.4  
75  
45  
20  
66.7  
38.5  
85  
50  
K40EL/ELT  
18  
3
50.0  
43.3  
21.7  
65  
55  
30  
K60EL/ELT  
K40EL/ELT  
24  
3
3
66.6  
91.6  
57.7  
79.4  
28.9  
39.7  
85  
75  
40  
50  
K60EL/ELT  
K60EL/ELT 33  
115  
100  
— 7 —  
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ELECTRIC STATIONARY KETTLES  
OPERATION  
: The kettle and its parts  
are hot. Use care when operating, clean-  
ing or servicing the kettle.  
60  
30  
30  
90  
120  
150  
psi  
Hg  
vac  
VENTING  
Whilethekettleiscold,checkthevacuum/pressure  
gauge. The gauge should be in the vacuum zone  
measuringbetween20to30in.Hg(84to100kPa).  
If not, there is air in the jacket and it must be  
removed by venting for proper heating. Perform  
the VENTING procedure located in the  
MAINTENANCE section of this manual.  
RESERVOIR JACKET  
WATER LEVEL CHECK  
During use, the reservoir water level must be  
maintained high enough to submerge the  
heating elements. If the low water light is  
illuminated during use, perform the FILLING  
THERESERVOIRJACKETprocedurelocated  
in the MAINTENANCE section of this manual.  
Fig. 4 Kettle Controls  
CONTROLS AND INDICATORS  
CONTROL  
FUNCTION  
DAILY OPERATION  
Vacuum  
Pressure  
Gauge  
Indicates the vacuum (in  
inches) and pressure  
( in PSI) inside the  
kettle jacket.  
1. Press the power switch to the ON position.  
2. Preheatthekettlebyplacingthethermostat  
knob at Simmer/Boil (desired setting) and  
wait until the temperature light cycles off.  
Thermostat  
Knob  
Regulates kettle temperature  
from warm to a rolling boil.  
Foodproductswithmilkoreggbaseshould  
be placed into a cold kettle before cooking.  
Avoid sudden contact of these food  
products to a hot kettle surface because  
they stick to the surface.  
Low Water  
Indicator  
(Red)  
When lit, indicates  
insufficient water in the  
kettle jacket and the sensing  
probe has interrupted power  
supply to the controls and to  
the heating element.  
3. Pour the food to be cooked into the kettle.  
Power ON/OFF Controls power to the kettle.  
Switch  
TILTING KETTLES  
The low water indicator light (red) should not  
be lit when kettle is in upright position during  
operation. Thislightindicatesthattheelements  
have been automatically shut off by the kettle’s  
safety circuity. It is, however, normal for the  
low water light (red light) to come on when the  
kettle is in a tilited posistion.  
Power ON  
Indicator  
(Amber)  
When lit, indicates  
machine on/powered.  
Heater  
When lit, indicates the  
Light (Amber) heating element is turned on.  
— 8 —  
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ELECTRIC STATIONARY KETTLES  
CLEANING  
: The kettle and its  
parts are hot. Use care when operating,  
cleaning or servicing the kettle.  
2. Thread the valve stem into bonnet till valve  
can be pulled through bonnet.  
3. Insert assembly into valve body.  
4. Install large nut hand tight.  
NOTICE: Never spray the exterior of  
the kettle or control box with  
water under any condition.  
Failure to comply will void  
the warranty.  
5. Install valve handle, lock washer and nut  
onto the valve stem.  
6. Turn valve handle clockwise until closed.  
Do not overtighten.  
The kettle interior and exterior should be  
thoroughly washed after each use when a  
different food is to be cooked next or when  
cooking is completed for the day.  
Daily After Use  
Remove draw-off valve stem assembly for  
cleaning.  
1. Add water to the kettle for cleaning and to  
prevent residue from drying and sticking to  
the inside of the kettle.  
1. Turn the valve handle counterclockwise  
until it stops.  
2. Loosen stuck-on food by allowing it to  
soak at a low temperature setting.  
2. Pull the valve handle back until it stops.  
3. Turn large bonnet retaining nut  
counterclockwise until the valve stem  
assembly is loose.  
Never use harsh or corrosive cleaning  
chemicals.  
Never scrape the inside of the kettle with  
abrasive cleansers, metal tools or steel  
scouring pads, which will scratch the surface,  
spoil the appearance and make it more difficult  
to thoroughly clean.  
4. Pull the assembly straight out of the valve  
body.  
5. Remove the stem from the bonnet.  
6. Wash valve body and steam assembly  
with mild soap and water.  
3. Add mild detergent and scrub the kettle  
interior with a nylon brush.  
7. Leave assembly apart to air dry.  
4. Thoroughly rinse the interior and dry with a  
soft cloth.  
5. Rinse the exterior and dry with a soft cloth.  
2" & 3" COMPRESSION VALVE  
CLEANING INSTRUCTIONS  
Fig. 6 Compression Valve  
Daily Before Operation  
Install draw-off valve assembly:  
1. Apply PetroGel lubricant to valve stem  
threads, “O” ring, rubber plug face and  
large nut threads.  
— 9 —  
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ELECTRIC STATIONARY KETTLES  
NOTE: 1. Care should be taken not to  
scratch, ding or dent the valve  
PLUG VALVE CLEAINING  
INSTRUCTIONS  
plug to prevent valve leakage.  
2. If multiple kettles are in use care  
should be taken keep each plug  
separate and returned to its  
original valve body.  
Daily Before Operation  
Install draw off valve plug:  
1. Apply PetroGel lubricant to valve tapered  
face.  
2. Holding the valve handle, slide the plug  
down into the valve body.  
3. Install the bottom washer, making sure to  
align the key with the groove in the valve  
plug.  
4. Install the retaining ring and hand tighten.  
Valve Plug  
NOTE: If the valve is hard to open the ring has  
been overtightened.  
Daily After Use  
Valve Body  
Remove draw-off valve plug for cleaning.  
1. Unscrew the retaining ring and remove it  
and the bottom washer.  
Bottom Washer  
Retaining Ring  
2. Pull the valve plug straight up to remove  
from valve body.  
3. Wash valve body, plug, washer and  
retaining ring with mild soap and water.  
4. Leave assembly apart to air dry.  
Fig. 7 Plug Valve  
— 10 —  
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ELECTRIC STATIONARY KETTLES  
heatedleavedepositsbehindthatiflefttosit,will  
break down the passive layer and rust stainless  
steel. Other deposits from food preparation and  
service must be properly removed.  
STAINLESS STEEL EQUIPMENT  
CARE AND CLEANING  
Contrary to popular belief, stainless  
steels ARE susceptible to rusting.  
Chlorides are found nearly everywhere. They  
are in water, food and table salt. One of the  
worst chloride perpetrators can come from  
household and industrial cleaners. So what  
does all this mean? Don’t Despair!  
Corrosion on metals is everywhere. It is  
recognized quickly on iron and steel as  
unsightly yellow/orange rust. Such metals are  
called “active” because they actively corrode  
in a natural environment when their atoms  
combine with oxygen to form rust.  
Here are a few steps that can help prevent  
stainless steel rust.  
1. Use the proper tools.  
Stainless steels are passive metals because  
they contain other metals, like chromium, nickel  
and manganese that stabilize the atoms. 400  
seriesstainlesssteelsarecalledferritic,contain  
chromium, and are magnetic; 300 series  
stainless steels are called austenitic, contain  
chromium and nickel; and 200 series stainless,  
also austenitic, contains manganese, nitrogen  
andcarbon. Austenitictypesofstainlessarenot  
magnetic, and generally provide greater  
resistance to corrosion than ferritic types.  
When cleaning stainless steel products,  
use non-abrasive tools. Soft cloths and  
plastic scouring pads will not harm steel’s  
passive layer. Stainless steel pads also  
can be used but the scrubbing motion  
must be in the direction of the  
manufacturers’ polishing marks.  
2. Clean with the polish lines  
Some stainless steel comes with visible  
polishing lines or “grain.” When visible  
lines are present, always scrub in a motion  
parallel to the lines. When the grain cannot  
be seen, play it safe and use a soft cloth or  
plastic scouring pad.  
With 12-30 percent chromium, an invisible  
passive film covers the steel’s surface acting as  
a shield against corrosion. As long as the film is  
intactandnotbrokenorcontaminated,themetal  
is passive and stain-less. If the passive film of  
stainless steel has been broken, equipment  
starts to corrode. At its end, it rusts.  
3. Use alkaline, alkaline chlorinated or  
non-chloride containing cleaners.  
While many traditional cleaners are loaded  
with chlorides, the industry is providing an  
ever-increasing choice of non-chloride  
cleaners. If you are not sure of chloride  
content in the cleaner used, contact your  
cleaner supplier. If your present cleaner  
contains chlorides, ask your supplier if they  
have an alternative. Avoid cleaners  
containingquaternarysalts;italsocanattack  
stainlesssteelandcausepittingandrusting.  
Enemies of Stainless Steel  
There are three basic things which can break  
down stainless steel’s passivity layer and  
allow corrosion to occur.  
1. Mechanical abrasion  
2. Deposits and water  
3. Chlorides  
4. Treat your water.  
Mechanical abrasion means those things  
that will scratch a steel surface. Steel pads,  
wire brushes and scrapers are prime  
examples.  
Though this is not always practical,  
softening hard water can do much to  
reduce deposits. There are certain filters  
that can be installed to remove distasteful  
and corrosive elements. To insure proper  
watertreatment, callatreatmentspecialist.  
Watercomesoutofthefaucetinvaryingdegrees  
of hardness. Depending on what part of the  
country you live in, you may have hard or soft  
water. Hard water may leave spots, and when  
— 11 —  
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ELECTRIC STATIONARY KETTLES  
5. Keep your food equipment clean.  
6. Rinse, rinse, rinse.  
Use alkaline, alkaline chlorinated or non-  
chloridecleanersatrecommendedstrength.  
Clean frequently to avoid build-up of hard,  
stubbornstains. Ifyouboilwaterinstainless  
steel equipment, remember the single most  
likely cause of damage is chlorides in the  
water.Heatingcleanersthatcontainchlorides  
have a similar effect.  
If chlorinated cleaners are used, rinse and  
wipe equipment and supplies dry immedi-  
ately. The sooner you wipe off standing  
water, especially when it contains cleaning  
agents, the better. After wiping equipment  
down, allow it to air dry; oxygen helps main-  
tain the stainless steel’s passivity film.  
7. Never use hydrochloric acid (muriatic  
acid) on stainless steel.  
8. Regularly restore/passivate stainless  
steel.  
Recommended cleaners for specific situations  
JOB  
CLEANING AGENT  
COMMENTS  
Routine cleaning  
Soap, ammonia,  
Apply with cloth or sponge  
detergent, Medallion  
Fingerprints & smears  
Arcal 20, Lac-O-Nu Ecoshine  
Provides barrier film  
Stubborn stains &  
discoloration  
Cameo, Talc, Zud,  
First Impression  
Rub in direction of polish lines  
Grease & fatty acids,  
blood, burnt-on-foods  
Easy-off, De-Grease It Oven Aid  
Excellent removal on all  
finishes  
Grease & oil  
Any good commercial detergent  
Benefit, Super Sheen  
Apply with sponge or cloth  
Restoration/Passivation  
Review  
5. Softenyourwater. Usefiltersandsofteners  
whenever possible.  
1. Stainless steels rust when passivity (film-  
shield) breaks down as a result of scrapes,  
scratches, deposits and chlorides.  
6. Wipe off cleaning agent(s) and standing  
water as soon as possible. Prolonged  
contact causes eventual problems.  
2
Stainless steel rust starts with pits and  
cracks.  
To learn more about chloride-stress corrosion  
and how to prevent it, contact the equipment  
manufacturer or cleaning materials supplier.  
3. Use the proper tools. Do not use steel  
pads, wire brushes or scrapers to clean  
stainless steel.  
Developed by Packer Engineering, Naperville, Ill., an  
independent testing laboratory.  
4. Use non-chlorinated cleaners at  
recommended concentrations. Use only  
chloride- free cleaners.  
Provided courtesy of NAFEM.  
— 12 —  
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ELECTRIC STATIONARY KETTLES  
MAINTENANCE  
FILLING THE RESERVOIR JACKET  
VENTING  
Before adding water to the reservoir, the water  
supply should be analyzed to ensure that  
hardness is no greater than 2.0 grains per  
gallon and the pH level is within the range of  
7.0 to 8.5. Water which fails to meet these  
standards should be treated, or use ionized  
distilled water with sodium. Equipment failure  
caused by inadequate water quality is not  
covered under warranty. To fill the reservoir  
jacket, perform the following:  
The vacuum pressure gauge measuring zone  
should be between 20 to 30 in.Hg (84 to  
100kPa). If the vacuum pressure is not within  
this range, perform the following:  
1. With the kettle empty, place the power  
switch to the ON position.  
2. Set the temperature control to the max  
heat setting. Let the kettle heat until it  
cycles off.  
1. Set the thermostat and power switch to  
OFF position.  
3. Pull the pressure relieve valve D-ring to  
relieve pressure for 10 seconds.  
4. Turn kettle off and let cool. Check for a  
correct vacuum pressure of 20 to 30 in. Hg  
(84 to 100kPa). If the reading is not correct,  
repeat steps 1 through 3.  
2. Release any pressure by the O-ring on the  
pressure relief valve. Then remove the 1/2"  
plug on the back of the kettle.  
3. Insert a funnel into the fill valve and add 3  
or 4 ounces of water.  
4. Replace and properly tighten the 1/2" plug.  
5. Turn on the kettle.  
60  
30  
30  
90  
120  
0
150  
Hg  
psi  
vac  
60  
30  
30  
90  
120  
If the low water light turns on, turn off the unit  
and repeat steps 3 and 4. If low water light is  
off, follow the venting procedure (see  
VENTING) to vent air from reservoir.  
0
150  
Hg  
psi  
vac  
TOTAL  
MODEL  
DISTILLED WATER  
REQUIREMENTS  
Fig. 5 Rear of Kettle  
K20EL / K20ELT  
K40EL / K40ELT  
K60EL / K60ELT  
1.25 gallons (4.1)  
2.0 gallons (6.5)  
2.1 gallons (7.4)  
— 13 —  
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ELECTRIC STATIONARY KETTLES  
TROUBLESHOOTING  
PROBLEM  
POSSIBLE CAUSES / SUGGESTED CORRECTIVE ACTION  
Unit not Heating  
ON/OFF switch OFF / ON/OFF switch ON.  
Thermostat not on / Turn thermostat on.  
No power / Check power supply.  
Water level too low / Add water.  
Malfunctioning power ON/OFF switch / Contact Authorized  
Vulcan-Hart Service Provider.  
Malfunctioning thermostat / Contact Authorized Vulcan-Hart  
Service Provider.  
Contactors not connecting heating element to power source / Contact  
Authorized Vulcan-Hart Service Provider.  
Unit not heating to  
Thermostat not on / Turn thermostat on.  
desired temperature  
Malfunctioning thermostat / Contact Authorized Vulcan-Hart  
Service Provider.  
Draw valve is leaking Check and clean any food residue with an extremely fine emery cloth.  
Replace the “O” ring.  
— 14 —  
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ELECTRIC STATIONARY KETTLES  
SERVICE AND PARTS INFORMATION  
To obtain service and parts information concerning this unit, contact the Vulcan-Hart Service  
Agency in your area (refer to listing supplied with the steamer), or contact the Vulcan-Hart Service  
Department at the address or phone number shown on the front cover of this manual.  
Parts and service are also available at www.vulcanhart.com.  
— 15 —  
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ELECTRIC STATIONARY KETTLES  
(10-09)  
PRINTED IN U.S.A.  
— 16 —  
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