Service Manual

ManualsBrandsVulcan-Hart ManualsHot Beverage MakerK20EL ML-136073 Hot Beverage Maker

Electric Stationary and Tilting

Kettles

K20EL ML-136073

K40EL ML-136074

K60EL ML-136075

K20ELT ML-136077

K40ELT ML-136078

K60ELT ML-136079

- 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

F45472 (1112)

Summary of content (29 pages)

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SERVICE MANUAL Electric Stationary and Tilting Kettles K20EL K40EL K60EL K20ELT K40ELT K60ELT ML-136073 ML-136074 ML-136075 ML-136077 ML-136078 ML-136079 - 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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Electric Stationary and Tilting Kettles TABLE OF CONTENTS General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL . . . . . . . . . . . . . . . . . . . . . . . . .
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Electric Stationary and Tilting Kettles - General General INTRODUCTION CONTROL PANEL General The procedures in this manual apply to all models unless otherwise specified. The pictures and illustrations are of a model K40ELT 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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Electric Stationary and Tilting Kettles - General SPECIFICATIONS Reservoir Jacket Fluid • Water - Use only distilled water for partial re-filling of the jacket (purchase locally). • Dowfrost heat transfer fluid Part No. 558038 (5 gallon). Use during a complete re-fill of the jacket with new fluid. Refer to service procedures for volumes. ELECTRICAL SPECIFICATIONS MODEL KW K60EL/ELT 480V 208V 240V 480V --- --- 75 --- --- 3 33.3 --- 14.4 45 --- 20 1 --- 66.
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Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS REMOVAL AND REPLACEMENT OF PARTS CONTROL BOX COVER COMPONENT PANELS Disconnect the electrical power to the machine and follow lockout / tagout procedures. Disconnect the electrical power to the machine and follow lockout / tagout procedures. The following pictures show the Stationary Kettle, the Tilting Kettle and the Bottom component panels.
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Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS TEMPERATURE CONTROLLER Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1. Remove CONTROL BOX COVER. 2. Disconnect lead wires from temperature controller. 3. Remove screws securing the temperature controller to panel. 4. Reverse procedure to install and check for proper operation.
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Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS Fig. 9 MAIN TRANSFORMER Fig. 10 HEATING ELEMENT 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. Remove CONTROL BOX COVER. 2. Disconnect lead wires from the transformer. 3. Remove screws securing the transformer to panel. 4. Reverse procedure to install and check for proper operation.
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Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS Fig. 13 Fig. 11 NOTE: If liquid drained from kettle is still clean, save for reuse. 5. 8. Remove heating element from kettle. 9. Reverse procedure to install. Use a new heating element seal whenever installing heating element. Torque mounting nuts to 40 ft-lbs and tighten in an alternating pattern. Remove heater access cover. 10. Refill jacket with fluid. See FILLING THE RESERVOIR JACKET. 11.
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Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS 10. Refill jacket with fluid. See FILLING THE RESERVOIR JACKET. 11. Remove air from reservoir jacket as outlined under VENTING. 12. Check for proper operation and leaks around heating element. WATER LEVEL PROBE (LLCO) Disconnect the electrical power to the machine and follow lockout / tagout procedures. Fig. 14 1. Open pressure relief valve until reservoir jacket is completely vented. 2. Remove BOTTOM COVER. 3.
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Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS 9. Check for proper operation. PRESSURE SWITCH TEMPERATURE SENSOR 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. Open pressure relief valve until reservoir jacket is completely vented. Open pressure relief valve until reservoir jacket is completely vented. 2. Remove BOTTOM COVER. 2.
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Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS 10. Remove air from reservoir jacket as outlined under VENTING. 11. Check for proper operation. POTENTIOMETER Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1. Remove CONTROL BOX COVER. 2. Disconnect potentiometer wire from temperature control. 3. Pull temperature dial from potentiometer shaft and remove seal nut. Fig.
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Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS GEARBOX (TILT MODELS ONLY) Disconnect the electrical power to the machine and follow lockout / tagout procedures. 1. Place a pallet jack under the kettle of the unit. NOTE: Place pallet jack under kettle and not under the tubular frame. NOTE: Place 2x4 or 4x4s on the pallet jack if needed to reach the bottom of the kettle. 2. Remove CONTROL BOX COVER. 3.
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Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS Fig. 24 3. Lift kettle high enough to pull bearing assembly off of stand. 4. Slide bearing assembly off of kettle shaft. 5. Reverse procedure to install new bearing assembly.
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Electric Stationary and Tilting Kettles - 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. B.
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Electric Stationary and Tilting Kettles - SERVICE PROCEDURES AND ADJUSTMENTS POTENTIOMETER TEST THERMOCOUPLE TEST Fig. 26 Fig. 27 1. Remove POTENTIOMETER. 2. Turn potentiometer shaft fully counterclockwise to the lowest setting. 3. Set VOM to measure resistance. 4. Connect meter leads to the white and black lead wires on potentiometer terminals. A. 5. 1. Access TEMPERATURE CONTROLLER. 2. Remove thermocouple lead wires from temperature controller. 3.
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Electric Stationary and Tilting Kettles - SERVICE PROCEDURES AND ADJUSTMENTS FILLING THE RESERVOIR JACKET NOTE: The reservoir water level must be maintained high enough to submerge the heating element. If low water light comes on during use, the level may be below water level probe (LLCO) and must be replenished before heating can continue. The low water light will come on when kettle is tilted (tilt models only). When filling reservoir jacket, use only distilled water and heat transfer fluid.
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Electric Stationary and Tilting Kettles - SERVICE PROCEDURES AND ADJUSTMENTS Complete Draining and Refill NOTE: Appearance of fluid will no longer be clear after usage in kettle. 1. Turn power switch off and set temperature dial to lowest setting. 2. Open pressure relief valve until reservoir jacket is completely vented. 3. Remove BOTTOM COVER. 4. Place a large container under kettle to catch liquid. 5. Remove WATER LEVEL PROBE (LLCO). 6.
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Electric Stationary and Tilting Kettles - SERVICE PROCEDURES AND ADJUSTMENTS NOTE: Checking current draw is the preferred method over a resistance check when an amp clamp meter is available. HEATING ELEMENT 1. Access HEATING ELEMENT. 2. Measure voltage at heating element terminals and verify it against the data plate voltage. A. 3. If voltage is incorrect, find the source of the problem. A. 4. If current draw is not correct then, replace heating element. Check for proper operation.
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Electric Stationary and Tilting Kettles - SERVICE PROCEDURES AND ADJUSTMENTS 7. 5) Adjust position of positive stop traveller as needed to align the shoulder screw mounting hole to the threaded hole in stop plate. Install shoulder screw. 6) Turn crank handle to verify operation. Repeat adjustment as necessary. 7) Install tilt switch bracket. Install control panel cover. Kettle Fully Upright - Traveller Contacts Inner Jam Nut 6. Fully tilt the kettle until crank handle stops. A.
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Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION ELECTRICAL OPERATION COMPONENT FUNCTION 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 and removes power from heating circuit when kettle is tilted. Probe, Water Level (LLCO) . . . . . . . . . . . . . . . Low Level Cut-Off (LLCO) probe connected to WLC (LLCO). Controls power to heating circuit.
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Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION COMPONENT LOCATION STATIONARY KETTLE COMPONENTS Page 21 of 29 F45472 (1112)
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Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION TILTING KETTLE COMPONENTS WATER STATIONARY AND TILTING KETTLE BOTTOM COMPONENTS level in the kettle reservoir jacket drops below the LEVEL CONTROL (WLC WLC LLCO probe. A single low level cut-off probe (LLCO) is connected to the control.
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Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION transformer secondary is powered through a series path to chassis ground. The other side of the transformer secondary (12VAC) is connected to the LLCO coil and the LLCO LED. The grounded potential is carried through the water in the reservoir jacket to the LLCO probe.
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Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION 1) WLC LLCO N.C. contacts open. Low water light (2LT) (red) remains off. C. WLC LLCO N.O. contacts close. 2) Limiting contactor (1CON) energized (power to one side of heating elements). Kettle heat cycles with the temperature controller. 7. Kettle tilted to empty contents. A. Power to temperature controller. Heat light (3LT) (amber) comes on. 2) Regulating contactor (2CON) energized and heating elements are powered. 8.
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Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION SCHEMATIC DIAGRAM Fig.
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Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION WIRING DIAGRAMS Fig.
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Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION Fig.
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Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION Fig.
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Electric Stationary and Tilting Kettles - TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING SYMPTOM POSSIBLE CAUSES 1. Kettle does not heat, power light is lit, heat light is lit, low 2. water light is not lit. 3. Kettle does not heat, power light is lit, low water light is lit, heat light is not lit. Kettle does not heat, power light is lit, low water light is not lit, heat light is not lit. Kettle does not heat, power light is not lit. Kettle heats up slow or will not boil product.