Vulcan K40GLT - Manuals

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Manual

Manual Vulcan K40GLT

Summary

Page 2 - TABLE OF CONTENTS

TABLE OF CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 4 - GENERAL; INTRODUCTION

GENERAL INTRODUCTION General The procedures in this manual apply to all models unless otherwise specified. The pictures and illustrations are ofa model K40GLT floor model tilting kettle unless otherwise noted. All information and specifications contained inthis manual are based on the latest product...

Page 5 - SPECIFICATIONS; NOTICE

CONTROL PANEL Fig. 1 TOOLS Standard • Standard set of hand tools. • Pipe thread sealant (must be resistant to theaction of propane gases). • VOM with an AC current tester (meter sensitivityshould be at least 20,000 ohms per volt). • Temperature meter (thermocouple type) forchecking kettle temperatur...

Page 6 - OPERATION, CLEANING AND MAINTAINENCE

GAS SUPPLY PRESSURES GAS TYPE Manifold (in W.C.) NOMINAL (in W.C.) MIN (in W.C.) MAX (in W.C.) Natural Low Speed * - 0.27 to 0.30 High Speed - 1.91 to 1.98 7 5 14 Propane Low Speed * - 0.27 to 0.30 High Speed - 1.91 to 1.98 11 11 13 * Low Speed – Blower operates at low speed during trial for ignitio...

Page 7 - REMOVAL AND REPLACEMENT OF PARTS

REMOVAL AND REPLACEMENT OF PARTS CONTROL BOX COVER (TILTING) Disconnect the electrical power to the machine andfollow 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) t...

Page 8 - BOTTOM COVER; ELECTRICAL PANEL

BOTTOM COVER Disconnect the electrical power to the machine andfollow lockout / tagout procedures. NOTE: Remove screws from cover where indicated. • Tilting models - tilt kettle to empty contents andgain access to bottom components. • Stationary models - use draw off valve to emptycontents. • Raise ...

Page 9 - GAS VALVE

Kettle Control Area - K Series Tilting Kettles Blower Speed Control - Switch Settings PRESSURE SWITCH (1PAS) Disconnect the electrical power to the machine andfollow lockout / tagout procedures. 1. Open pressure relief valve until reservoir jacketis completely vented. 2. Remove CORNER PANEL (TILTING...

Page 10 - BLOWER

Fig. 10 5. Remove piping from gas valve inlet and install onreplacement valve. Ensure the factory tags thatare 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 kett...

Page 11 - BURNER

Fig. 13 6. Reverse procedure to install replacement blowerand check for proper operation. NOTE: Install replacement blower gasket as necessary. BURNER Disconnect the electrical power to the machine andfollow lockout / tagout procedures. Shut off the gas before servicing the unit. All gas joints dist...

Page 12 - SPARK IGNITOR

Fig. 16 9. Reverse procedure to install replacement burnerand check for proper operation. Apply pipe thread sealant to burner threads that is suitable for use with propane gas. NOTE: Torque mounting nuts for combustion chamber cover to 30 ft-lb. SPARK IGNITOR Disconnect the electrical power to the m...

Page 13 - TILTING MODELS ONLY; GEAR REDUCER - MANUAL

GAS SHUT-OFF VALVE (1SOL) - TILTING MODELS ONLY Disconnect the electrical power to the machine andfollow lockout / tagout procedures. Shut off the gas before servicing the unit. All gas joints disturbed during servicing must be checked for leaks. Check with asoap and water solution (bubbles). Do not...

Page 14 - TILTING OPTION ONLY

Fig. 21 8. Remove positive stop plate from gear reducer.Note that the positive stop shaft is keyed. Fig. 22 9. Reverse procedure to install replacement gearreducer. 10. Perform KETTLE TILT ADJUSTMENT - MANUAL TILTING MODELS to check for properoperation. ELECTRICAL PANEL COMPONENTS - POWER TILTING OP...

Page 15 - DC TILT MOTOR - POWER TILTING

Fig. 24 DOWN LIMIT SWITCH (3S) - POWER TILTING OPTION ONLY Disconnect the electrical power to the machine andfollow lockout / tagout procedures. 1. Place kettle in the fully upright position. 2. Remove CONTROL BOX COVER (TILTING). 3. Note lead wire locations and disconnect fromdown limit switch (3S)...

Page 18 - SERVICE PROCEDURES AND ADJUSTMENTS; TEMPERATURE CONTROLLER

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 andfollow lockout / tagout procedures, attach test eq...

Page 19 - POTENTIOMETER TEST; THERMOCOUPLE TEST

A. Verify 120VAC between T8 and ground. Ifcorrect, output from controller is functioningproperly. B. If incorrect, install a replacementtemperature controller and check for properoperation. POTENTIOMETER TEST Fig. 34 1. Access control panel potentiometer by removingCORNER PANEL (TILTING) or SIDE PAN...

Page 21 - FILLING THE RESERVOIR JACKET

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, thevisible level may be below the water level probe andmust be replenished before heating can continue. Thelow water l...

Page 26 - MANUAL TILTING MODELS

NOTE: If kettle burner does not immediately light, the ignition control module continues sparking for 6seconds, then locks out power to the gas valve (mainvalve remains closed). The ignition fail light comesON. The module remains locked out until the on/offswitch is cycled to reset the system and re...

Page 27 - POWER TILTING OPTION ONLY

Kettle Fully Tilted - Traveller Contacts Stop Plate 3) Turn crank handle clockwise to tilt thekettle. The kettle should be tilted past90° to empty its contents. Theadjustment range is 92 to 95 degrees. 4) Turn positive stop traveller on thepositive stop shaft (threaded) until itcontacts the stop pla...

Page 30 - 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. Protectskettle from a low water condition in the reservoir jacket. Probe, Water Level(LLCO) . . . ....

Page 31 - COMPONENT FUNCTION (POWER TILTING OPTION)

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 whe...

Page 35 - SEQUENCE OF 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 andmanual tilting kettle models. Kettles with Power Tilt,refer to Sequence of Operation - Power Tilt Option andschematic diagram AI3538. 1. Co...

Page 41 - TROUBLESHOOTING

TROUBLESHOOTING STATIONARY & TILTING - GENERAL K Series Gas Kettles (Stationary & Tilting) SYMPTOM POSSIBLE CAUSE Kettle does not heat, power light is lit,heat light is lit, ignition fail light is lit, lowwater light is not lit, blower motor is ON(high speed is default for blower if speedcon...