GROEN DH-60 (01) PDF Document

The GROEN DH-60 is a floor-mounted, tilting, steam jacketed kettle with a thermostatically or electronically controlled, self-contained, gas-heated steam source and appropriate controls, mounted on a sturdy base. The Model DH is available in 20, 40, 60 or 80 gallon capacities.

Construction:

The body of the DH Kettle is constructed of stainless steel, welded into one solid piece. The kettle is furnished with a reinforced rim and a butterfly shaped pouring lip. It has a steam jacket which is ASME shop inspected and registered with the national board for working pressures up to 50 PSI. Kettle finish is 180 emery grit on the inside and bright high buff polish on the outside.

The kettle is tilted with a hand crank to pour out its contents. Stainless steel panels enclose the controls and the base. Four stainless steel tubular legs support the unit. Bullet or flanged feet on each of the legs can be adjusted to level the kettle. Standard DHT units include a two inch tangent draw-off valve.

Heating and Controls:

The self-contained steam source is heated by propane or natural gas with electronic ignition. The kettle is charged at the factory with chemically pure water which contains rust inhibitors. The steam source provides kettle temperatures of 150° to approximately 295°F (65 to 150°C). Unit controls include a thermostat or controller, pressure gauge, safety valve, pressure limit control, low water cut-off, power switch and gas regulator valve. The gas supply shuts off automatically when the kettle is tilted.

Utilities:

The unit must be specified for use with natural or propane gas. Service connections for gas and electricity are required. Standard power supply is 115 Volt. Alternate single-phase voltages (208-240V) are available.

Options available include:

1. Two inch tangent drawoff standard on DHT models

2. Strainers, solid disk, 1/4 or 1/8 inch holes

3. No. 31 lift-off cover

4. No. 51 counterbalanced cover w/actuator*

5. Basket Inserts (Tri-BC)

6. Water fill faucets with swing spout

7. Kettle Brush Kit

It is crucial to read, understand, and follow all safety instructions before operating the GROEN DH-60.

General Warnings:

• Be sure all operators read, understand and follow the operating instructions, cautions, and safety instructions contained in this manual.

• This unit is intended for use in the commercial heating, cooking and holding of water and food products. Any other use could result in serious personal injury or damage.

• Kettle must be installed by personnel qualified to work with electricity and plumbing. Improper installation can result in injury and/or damage to equipment.

• Electrically ground the unit at the terminal provided. Failure to do so could result in electrocution and death.

• Do not connect any piping to the pop safety valve. It must be free to vent steam. The elbow attached should point to the floor.

• Avoid all direct contact with hot equipment surfaces, hot food, or water in the kettle, as it could result in severe burns.

• Do not overfill the kettle. Keep liquids a minimum of 2-3 inches below the kettle rim.

• Take special care to avoid contact with the hot kettle body or hot product when adding ingredients, stirring, or transferring product.

• Keep floors in front of the kettle work area clean and dry. Clean spills immediately.

• Periodically check the safety valve operation. Failure to do so could result in injury or damage.

• When testing the safety valve, avoid any exposure to the steam blowing out. Direct contact could result in severe burns.

• Before replacing any parts, disconnect the unit from electric power and close the main gas valve. Allow five minutes for unburned gas to vent.

• Keep water and solutions out of controls and electrical equipment. Never spray or hose the support housing or electrical connections.

• Do not heat an empty kettle, as excessive steam pressure could develop.

Tilting Warnings:

When tilting the kettle for product transfer:

1. Use a container deep enough to contain and minimize splashing.

2. Place the container on a stable, flat surface, as close to the kettle as possible.

3. Do not overfill the container. Avoid direct skin contact with the hot container and its contents.

Cleaning Precautions:

• Most cleaners are harmful to the skin, eyes, mucous membranes, and clothing. Wear rubber gloves, goggles or a face shield, and protective clothing. Carefully read the warnings and follow the directions on the label of the cleaner to be used.

CAUTION: Shipping straps are under tension and can snap back when cut. Take care to avoid personal injury or damage to the unit by staples left in the walls of the carton.

CAUTION: This unit weighs between 535 and 978 pounds (245 to 400 kg) depending on size. The installer should use proper equipment to lift safely.

The unit arrives completely assembled, except for the tilting handle on hand tilt models, which is shipped inside the kettle. The unit is strapped on a skid and in a heavy carton.

1. Inspect the carton carefully for damage. Open the container and check the unit for hidden damage. Report shipping damage or shipment errors to the delivery agent.

2. Write down the model number, serial number, and installation date for your unit in the Service Log at the end of the manual.

3. When installation is to begin, carefully cut any straps which hold the unit on the skid.

4. Lift the unit straight up off the skid.

5. Examine packing materials to be sure loose parts are not discarded with the materials.

WARNING: The unit must be installed by personnel who are qualified to work with gas, electricity, and plumbing. Improper installation can cause injury to personnel and/or damage to the equipment. The unit must be installed in accordance with applicable codes.

1. Installation can be on a combustible or noncombustible floor. Clearances should be as follows:

2. The kettle should be installed in an adequately ventilated room with provision for adequate air supply. The ventilation must employ a vent hood and exhaust fan with no direct connection between the vent duct and the kettle flue. Do not obstruct the flue or vent duct after installation.

3. Set the kettle in place and level it using a spirit level on the bar rim, by turning the bullet or flange feet to adjust leg length. Allow clearance around the unit for cleaning, maintenance and service.

4. Complete the piping to the gas service main with a 1/2″ line or approved equivalent.

5. Provide 115 vac, 60 Hz, single phase 5 AMP electrical service. The unit may also be ordered for alternate electric service of 208 VAC – 240 VAC. Observe local codes and/or The National Electrical Code.

6. For C2T models only, install the core probe storage bracket on the control console. To obtain proper adhesion, clean the bonding surface with rubbing alcohol and allow it to dry. Firmly apply pressure to the bracket to help improve bond strength.

7. Bring electrical service through the entrance at the rear of the support housing with a 1/2 inch conduit connector. Make a watertight connection with the incoming lines.

8. Electrically ground the unit at the terminal provided.

9. After the kettle has been connected to the gas supply, check all gas joints for leaks. DO NOT USE FLAME TO CHECK FOR LEAKS. A thick soap solution or other suitable leak detector should be employed.

10. Ensure the gas supply and installation conform with local codes or the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code CSA 149.1.

11. Confirm that the jacket water level is between the gauge glass markers or inside the sight glass port. If the level is low, follow instructions under Jacket Filling and Water Treatment.

12. The open end of the elbow on the outlet of the safety valve must face downward. If it does not, turn it to the correct position.

13. For units with optional tangent draw-off: Assemble the tangent draw-off by placing the large nut over the draw-off valve and inserting it into the draw-off tube. ONLY HAND-TIGHTEN THE NUT to complete installation.

After the kettle has been installed, the installer should test to ensure that it is operating correctly.

1. Remove literature and packing materials from the interior and exterior of the unit.

2. If the unit is equipped with a draw-off valve (product outlet), clean out any material which might clog or damage the draw-off.

3. Confirm that the tilting mechanism is operating properly by tilting the kettle through its full range. Then return the kettle to the upright position.

4. Turn on the electrical service to the unit.

5. Pour 1-2 gallons of water into the kettle.

6. Following “To Start Kettle” instructions in the “Operation” section, begin heating the water at the highest controller setting. The heat indicator light should come on, and heating should continue until the water boils.

If the kettle functions as described, it is ready for use. If the unit does not operate as designed, contact an authorized Service Agent.

WARNING: When tilting the kettle:

1. Wear protective oven mitt and protective apron.

2. Use a deep container to contain and minimize product splashing.

3. Place the container on a stable, flat surface, as close to the kettle as possible.

4. Stand to the right of the kettle while pouring – not directly in the pour path of hot contents.

5. Pour slowly, maintaining control of the kettle, and return the kettle body to an upright position after the container is filled or transfer is complete.

6. Do not overfill the container. Avoid skin contact with the hot container and its contents.

CAUTION: Do not tilt the kettle body with the cover or basket insert in place. The cover may slide off, causing injury to the operator.

a. Manual gas shut-off valve: Supplies inlet gas to the unit.

b. Lighted Power ON switch: Located on the control console. Controls main power to the unit.

c. Temperature knob: Located on the control console, used to set the kettle heat values between 1 and 10.

d. Heating indicator light: Located on the control console, lights when the controller calls to open the main gas valve and will cycle on and off once the unit reaches the set temperature. If the unit is tilted, the main gas valve will be disabled, and the light will turn off until the unit is returned to the cooking position.

e. LOW WATER indicator light: Located on the control console, illuminates when the jacket water falls below acceptable levels. When lit, the main gas valve is disabled and will not function until the jacket water is refilled.

f. Crank tilt: A handle controls the worm and gear mechanism that smoothly tilts the kettle body and holds it in the desired position.

a. Manual gas shut-off valve: Supplies inlet gas to the unit.

b. Lighted Power ON switch: Controls main power to the unit.

c. Temperature knob: Located on the control console, used to set the kettle heat values between 1.0 and 10.0. The current setting will be reflected on the display.

d. Heating indicator light: Lights when the controller sends a call to open the main gas valve. It will cycle on and off once the unit reaches the set temperature. The light turns off if the unit is tilted.

e. LOW WATER indicator light: Illuminates when the jacket water falls below acceptable levels. When lit, the main gas valve is disabled.

f. SET TnnP Mode: Allows power to the controller and gas to the pilot without the kettle heating. The kettle will heat once the LOW TEMP, MANUAL or HIGH TEMP button is selected.

g. LOW TEMP Button: Used to set operating temperature at a preset low intensity (default = 2.0). Can be pressed at any time to change to this preset, except when a TIMER is active.

h. MANUAL Mode button: Enables the user to modify the cooking temperature (between 1.0 and 10.0) using the temperature knob and display. Press the MANUAL button, set the desired temperature, then press MANUAL again or wait 5 seconds for it to be accepted. The temperature can be changed at any time using the same process.

i. HIGH TEMP button: Used to set operating temperature at a preset high intensity (default = 7.0). Can be pressed at any time to change to this preset, except when a TIMER is active.

j. TIMER button: Once a temperature is selected, a countdown timer can be set (1 minute to 10 hours). When the timer expires, the temperature automatically changes to the LOW TEMP setting, and an audible alarm will sound until the TIMER button is pressed. An active timer can be cancelled by pressing and holding the TIMER button for 5 seconds. The set temperature can be changed during an active timer by pressing the MANUAL button.

k. Crank tilt: A handle controls the tilting mechanism.

a. Lighted Power ON switch: Controls main power to the unit.

b. Heating indicator light: Lights when the controller calls for the main gas valve to open. It will turn off if the kettle is tilted.

c. Low Water indicator light: Lights when the jacket water is low. The main gas valve is disabled when this light is on.

d. Set Mode: Allows power to the controller and pilot to light, but the main burners remain off. The kettle heats once a temperature button is selected.

e. LOW TEMP Button: Sets a preset low temperature (default = 175°F). Cannot be used when a TIMER or Cook2Temp mode is active.

f. MANUAL Button: Enables user to set a unit temperature between 100°F and 287°F using the temperature knob. Press MANUAL, select temperature, and press MANUAL again or wait 5 seconds to lock it in.

g. HIGH TEMP Button: Sets a preset high temperature (default = 287°F). Cannot be used when a TIMER or Cook2Temp mode is active.

h. TIMER Button: Sets a countdown timer from 1 minute to 10 hours. When the timer expires, the unit switches to LOW TEMP setting and an alarm sounds. An active timer can be cancelled by holding the button for 5 seconds. Cannot be used if AUTO C2T or MANUAL C2T is active.

i. Ready alarm: The control sounds 3 beeps when the unit is within 20 degrees of the set point during pre-heat.

j. AUTO C2T Button: Enables the user to select a set product temperature (100°F to 230°F). The unit temperature is automatically set 100°F above the selected product temperature. The display scrolls between actual and set product temperature. An active AUTO C2T can be cancelled by holding the button for 5 seconds.

k. MANUAL C2T Button: Enables the user to select both a product temperature (100°F to 230°F) and a unit temperature. The display scrolls between actual and set product temperature. An active MANUAL C2T can be cancelled by holding the button for 5 seconds.

l. Hold Mode: Automatically enables once a set product temperature has been reached and held for 20 seconds. The display scrolls the actual product temperature and the hold timer.

a. Ensure the core probe has been properly cleaned and sanitized before each use.

b. It is important that the tip of the core probe be placed correctly into the product. Insert the probe halfway into the product, positioning the tip at the center of the food mass, avoiding any bones. For liquids, occasional stirring will ensure an accurate reading. Do not let the core probe tip touch the edges, bottom, or side of the unit.

c. If the core probe is not plugged into the receptacle when either the AUTO C2T or MANUAL C2T button is pressed, an audible alarm and error message will appear. Simply plug the core probe into the receptacle to continue.

d. If the core probe is unplugged during the cooking process or in Hold Mode, an alarm and error message will appear. Simply plug the core probe back into the receptacle to continue.

e. While the core probe is not in use, ensure the sealing cap is properly protecting the panel mount connector. Failure to properly use the sealing cap could result in damage to the unit.

1. To Start Kettle Heating:

a. EVERY DAY make sure that the jacket water level is in the middle of the sight glass. If the level is too low, see “Jacket Filling and Water Treatment”.

b. Check the pressure/vacuum gauge. If the gauge does not show 20 to 30 inches of mercury (Hg) vacuum, see “Jacket Vacuum”.

c. DO NOT attempt to light any burner with a flame.

d. Open the main supply gas valve (handle in line with the pipe).

e. Turn the switch to ON.

f. Set heat using instructions for your control model.

2. To Stop Kettle Heating:

a. Turn the switch OFF.

b. Turn the manual gas valve OFF (handle at a right angle to gas line).

c. Disconnect the unit’s electrical power.

3. To Relight Kettle:

a. Close main gas supply valve.

b. Set on-off switch to OFF.

c. Wait five minutes, then proceed as directed under To Start Kettle Heating.

4. If electric power fails, do not attempt to operate the unit. When power is restored, proceed as directed in To Start Kettle Heating.

5. To Transfer Product or Empty Kettle:

a. To tilt the body of the kettle forward, turn the hand crank on the front of the cabinet counter-clockwise. To return the kettle body to its upright position, turn the crank clockwise.

b. Product may also be transferred by means of the optional draw-off valve, if the kettle is so equipped.

1. Lift-Off or Counterbalanced Cover:

a. An optional cover can speed up heating, retain heat, and reduce humidity in the kitchen. It can also reduce some cook times and help maintain temperature, color, and texture.

b. ALWAYS use the handle to place or remove the cover from the kettle. Wear protective oven mitts and apron.

c. When putting the cover on, position it on top of the kettle rim with its flat edge facing the pouring lip.

d. When removing the cover:

1) Firmly grasp the handle.

2) Lift the rear edge 1-2 inches to allow steam to escape. Wait 2-3 seconds.

3) Tilt the cover to a 45-60° angle to allow any hot condensate to roll back into the kettle.

4) Remove the cover, ensuring no hot liquid drips on the operator, floor, or surfaces.

5) Place the cover on a safe, flat, sanitary surface.

2. Basket Insert:

a. An optional basket insert can assist in cooking water-boiled products like eggs, potatoes, vegetables, pasta, and rice. A nylon mesh liner must be used for products smaller than the basket’s mesh size (approx. 1/4″).

b. Tips For Use:

1) Allow for water displacement. You may need to only fill the kettle half full of water. Test displacement with the kettle OFF and with cold water.

2) Load the basket on a level, stable work surface.

3) Lift the loaded basket with both hands. Get help if it’s too heavy. Slowly lower it into the kettle.

4) When removing the basket, lift it straight up, ensuring the bottom clears the kettle rim. Wear protective oven mitts and apron.

5) Allow hot water to fully drain from the product before moving the basket away. Do not rest the basket on the kettle rim. If it’s too heavy, get help. Place the basket inside a solid pan to catch any remaining water.

Precautions:

• Before cleaning, shut off the kettle by turning the main power switch to “OFF,” and shut off all electric power to the unit at a remote switch or circuit breaker.

• Keep water and solutions away from controls and electrical equipment. Never spray the support housing or electrical connections.

• Use a brush, sponge, cloth, plastic or rubber scraper, or plastic wool to clean. Do not use metal implements or steel wool.

Suggested Cleaning Supplies:

1. Cleaner, such as Klenzade HC-10 or HC-32 or equivalent.

2. Kettle brushes in good condition.

3. Sanitizer such as Klenzade XY-12.

4. Film remover such as Klenzade LC-30.

Procedure:

1. Clean food-contact surfaces as soon as possible after use. If in continuous use, clean and sanitize at least once every 12 hours.

2. Scrape and flush out food residues. For DHT models, close the draw-off valve after flushing.

3. Prepare a hot solution of detergent/cleaning compound as instructed by the supplier and clean the unit thoroughly.

4. For Model DHT only: Disassemble the tangent draw-off valve. Clean the draw-off port and each valve part with a brush.

5. Rinse the kettle and draw-off valve parts thoroughly with hot water, then drain completely.

6. As part of the daily cleaning program, clean soiled external and internal surfaces.

7. To remove burnt-on foods, use a non-abrasive tool with cleaning solution. Soaking the residue can reduce effort.

8. The outside of the unit may be cleaned with a warm water (100°F or less) spray. Do not use a high-pressure spray.

9. The outside may be polished with a stainless steel cleaner.

10. When sanitizing is needed, use a solution that supplies 200 parts per million available chlorine. Never leave sanitizer in contact with stainless steel surfaces for longer than 30 minutes.

11. It is recommended to sanitize equipment just before use.

12. If there is difficulty removing mineral deposits, use a de-liming agent following manufacturer directions.

13. Rinse and drain the unit thoroughly before further use.

Cleaning Core Probe:

Remove all food soil from the core probe by wiping the entire probe and cable assembly with a warm detergent solution and a clean cloth. Remove detergent by wiping with clean rinse water and a cloth. Allow to air dry. Do not immerse the core probe. Hand wash only.

WARNING: Insure electrical power is removed and the gas is turned off at the shutoff valve prior to performing any maintenance on this kettle.

1. Daily: Check the pressure/vacuum gauge. When the kettle is cold, it should show a vacuum of 20 to 30 inches of mercury (Hg). If not, see “Jacket Vacuum/Removing Air From Jacket”.

2. Daily: Check the jacket water level. It should be in the middle of the sight glass. If low, see “Jacket Filling and Water Treatment”.

3. Twice Monthly: Carefully test the pressure relief valve. With the kettle operating at five psi, pull the test lever and let it snap back to its closed position. If there is little discharge (mostly air) and the pressure gauge drops to zero, allow pressure to build back to five PSI and repeat. (Tip: Use a screwdriver to pull the ring to avoid steam contact).

4. If the valve does not activate, has no discharge, or leaks, stop using the kettle and contact a qualified service representative.

5. Keep the primary burner gas jet air inlets free of dust and lint.

6. The pilot flame should be blue and envelop about 1/2 inch (12 mm) of the flame sensor tip.

7. The gear housing has fittings for lubrication of moving parts. The gears do not run in oil, so periodic lubrication with grease is necessary.

8. Every Six Months (or more frequently depending on use): Lubricate the gears. Use a #2 grade LGI lithium grease to add grease through Zerk fittings on the gear housing until it flows out of the bearings. Place liberal amounts of grease on the gear to cover the arc that is in contact with the worm gear.

9. Keep electrical wiring and connections in good condition.

10. Keep the inside of the control console clean and dry.

11. Keep burner slots clean.

When the kettle is cold, a positive pressure reading on the gauge or a reading near zero indicates air is in the jacket. Air acts as an insulator and slows heating.

To remove air:

1. Start the unit. (Be sure there is water or product in the kettle when heating).

2. When the pressure/vacuum gauge reaches a positive pressure reading of five PSI, release the trapped air and steam by pulling up the safety valve ring for about five seconds. Repeat this step three or four times. Then let the pull ring snap back into the closed position.

3. If there is little discharge (mostly air), and the pressure gauge drops back to zero PSI, allow the pressure to build back to five PSI and repeat the procedure.

4. Once steam has been vented, remove the hot water from the kettle and replace it with cold. This will condense the steam in the jacket, and the pressure gauge should show a reading of 20 to 30 inches mercury (Hg) below zero. If it does not, or if the vacuum is leaking down, contact a Groen authorized service agency.

Jacket Filling and Water Treatment:

The jacket was charged at the factory with treated water. If you need to restore this water, follow these steps.

1. Allow the kettle to cool completely. The procedure is easier with the kettle under vacuum (pressure gauge reading below zero).

2. Make sure the fill valve is closed, and remove the square head pipe plug with an open-ended wrench.

3. Position a funnel in the opening and fill it with properly treated water (see procedure below).

4. Slowly open the fill valve to allow water to be sucked into the jacket. Quickly close the valve to prevent air from entering.

5. Check the water level in the jacket to ensure it is between the minimum and maximum marks on the glass or at the top of the sight glass port for DH/DHT-80 models.

6. Close the valve and reinstall the squarehead pipe plug.

7. Reestablish the jacket vacuum as described previously if the pressure gauge does not show a negative reading of 20 to 30 inches mercury (Hg).

Water Treatment Procedure:

1. Obtain water treatment compound and a pH test kit from your Groen Service Agent.

2. Fill a mixing container with the measured amount of required distilled water:

• DH-20, DHT-20: 1-3/4 gallons
• DH/1-40, DHT/1-40: 1-1/2 gallons
• DH-60, DHT-60: 3 gallons
• DH-80, DHT-80: 3 gallons

3. Hang a strip of pH test paper on the rim of the container, with about 1 inch of the strip below the surface of the water.

4. Measure the water treatment compound.

5. Stir the water continuously while slowly adding treatment compound, until the water has a pH between 10.5 and 11.5. Judge the pH by comparing the test strip color with the color chart. Caution: Do not add excess amount of treatment compound.

6. As you add water to the jacket, check the water level. Stop adding water when it reaches the maximum marker on the gauge.

7. Record the exact amounts of water and treatment compound needed for future use.

1. When the power switch is turned on, it starts the spark igniter and opens the automatic valve for the pilot burner. The spark ignites a pilot flame, which heats the sensor. The sensor then sends a signal to turn off the spark. The flame thereafter acts as a standing pilot until the power is turned off.

2. If the pilot flame is not sensed within 90 seconds after the spark begins, a timer shuts down the entire operation. To retry, turn off the power switch, check gas supply valves, and wait five minutes before trying again.

3. When the operator sets a temperature on the controller, it causes the automatic valve to admit gas to the main burner, where it is ignited by the pilot flame. When the kettle reaches the set temperature, the relay switch opens, stopping the signal to the gas control valve and shutting off gas to the main burner. The pilot flame remains lit. When the kettle cools, the relay switch closes and starts another cycle. This action is indicated by the Heat indicator light.

The kettle also has the following safety features:

• Low water cutoff relay: Shuts off gas supplies to all burners until the jacket water level is corrected.

• High limit pressure switch: Opens at about 43 PSI to shut down the burners until jacket pressure is decreased.

• Pop safety valve: Releases steam if jacket pressure exceeds 50 PSI.

• Tilt switch: Shuts off all burners when the kettle is tilted.

• Gas pressure regulator: Built into the gas control valve.

The following is a list of checks to make in the event of a problem. Items marked with (X) should be performed by an Authorized Service Technician.