model: dee/4 steam jacketed kettle - parts...

IMPORTANT INFORMATION KEEP FOR OPERATOR IMPORTANT INFORMATION

OPERATOR MANUAL OM-DEE/4 Part Number 121013, Rev. B DOMESTIC

MODEL: DEE/4Steam Jacketed Kettle

Self-ContainedElectrically heatedFloor mountedTilting

THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE.READ, UNDERSTAND AND FOLLOW THE INSTRUCTIONS ANDWARNINGS CONTAINED IN THIS MANUAL.

FOR YOUR SAFETYDO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLEVAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHERAPPLIANCE.

Information contained in this document is known to be current and accurate at the time of printing/creation. Unified Brands recom-mends referencing our product line websites, unifiedbrands.net, for the most updated product information and specifications.

PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor

http://www.cvisiontech.com/

OM-DEE/4

2

IMPORTANT — READ FIRST — IMPORTANT

CAUTION: BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE OPERATINGINSTRUCTIONS, CAUTIONS, AND SAFETY INSTRUCTIONS CONTAINED IN THISMANUAL.

WARNING: THIS UNIT IS INTENDED FOR USE IN THE COMMERCIAL HEATING, COOKING ANDHOLDING OF WATER AND FOOD PRODUCTS, PER THE INSTRUCTIONSCONTAINED IN THIS MANUAL. ANY OTHER USE COULD RESULT IN SERIOUSPERSONAL INJURY OR DAMAGE TO THE EQUIPMENT AND WILL VOIDWARRANTY.

WARNING: KETTLE MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITHELECTRICITY. IMPROPER INSTALLATION CAN RESULT IN INJURY TOPERSONNEL AND/OR DAMAGE TO EQUIPMENT.

DANGER: ELECTRICALLY GROUND THE UNIT AT THE TERMINAL PROVIDED. FAILURE TOGROUND UNIT COULD RESULT IN ELECTROCUTION AND DEATH.

WARNING: AVOID ALL DIRECT CONTACT WITH HOT EQUIPMENT SURFACES. DIRECT SKINCONTACT COULD RESULT IN SEVERE BURNS.

WARNING: AVOID ALL DIRECT CONTACT WITH HOT FOOD OR WATER IN THE KETTLE.DIRECT CONTACT COULD RESULT IN SEVERE BURNS.

CAUTION: DO NOT OVER FILL THE KETTLE WHEN COOKING, HOLDING OR CLEANING.KEEP LIQUIDS A MINIMUM OF 2-3” (5-8 cm) BELOW THE KETTLE BODY RIM TOALLOW CLEARANCE FOR STIRRING, BOILING AND SAFE PRODUCT TRANSFER.

WARNING: TAKE SPECIAL CARE TO AVOID CONTACT WITH HOT KETTLE BODY OR HOTPRODUCT WHEN ADDING INGREDIENTS, STIRRING OR TRANSFERRINGPRODUCT TO ANOTHER CONTAINER.

WARNING: WHEN TILTING KETTLE FOR PRODUCT TRANSFER:1) USE CONTAINER DEEP ENOUGH TO CONTAIN AND MINIMIZE PRODUCT

SPLASHING.2) PLACE CONTAINER ON STABLE, FLAT SURFACE, AS CLOSE TO KETTLE AS

POSSIBLE.3) DO NOT OVER FILL CONTAINER. AVOID DIRECT SKIN CONTACT WITH HOT

CONTAINER AND ITS CONTENTS.

CAUTION: KEEP FLOORS IN FRONT OF KETTLE WORK AREA CLEAN AND DRY. IF SPILLSOCCUR, CLEAN IMMEDIATELY, TO AVOID SLIPS OR FALLS.

WARNING: FAILURE TO CHECK SAFETY VALVE OPERATION PERIODICALLY COULD RESULTIN PERSONAL INJURY AND/OR DAMAGE TO EQUIPMENT.

WARNING: WHEN TESTING, AVOID ANY EXPOSURE TO THE STEAM BLOWING OUT OF THESAFETY VALVE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS.

WARNING: TO AVOID INJURY, READ AND FOLLOW ALL PRECAUTIONS STATED ON THELABEL OF THE WATER TREATMENT COMPOUND.

WARNING: BEFORE REPLACING ANY PARTS, DISCONNECT THE UNIT FROM THE ELECTRICPOWER SUPPLY.

WARNING: KEEP WATER AND SOLUTIONS OUT OF CONTROLS AND ELECTRICALEQUIPMENT. NEVER SPRAY OR HOSE THE SUPPORT HOUSING OR ELECTRICALCONNECTIONS.

CAUTION: MOST CLEANERS ARE HARMFUL TO THE SKIN, EYES, MUCOUS MEMBRANESAND CLOTHING. PRECAUTIONS SHOULD BE TAKEN. WEAR RUBBER GLOVES,GOGGLES OR FACE SHIELD AND PROTECTIVE CLOTHING. CAREFULLY READ THE WARNINGS AND FOLLOW THE DIRECTIONS ON THE LABEL OF THECLEANER TO BE USED.



OM-DEE/4

3

IMPORTANT — READ FIRST — IMPORTANT

CAUTION: USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY GROENOR THEIR AUTHORIZED DISTRIBUTORS CAN CAUSE OPERATOR INJURY ANDDAMAGE TO THE EQUIPMENT, AND WILL VOID ALL WARRANTIES.

IMPORTANT: SERVICE PERFORMED BY OTHER THAN FACTORY AUTHORIZED PERSONNELWILL VOID WARRANTIES.



OM-DEE/4

4

Table of Contents

IMPORTANT OPERATOR WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

EQUIPMENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

INSPECTION & UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

DIAGRAMS & SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

References

NATIONAL FIRE PROTECTION ASSOCIATION60 Battery March ParkQuincy, Massachusetts 02269

NFPA/70 - The National Electrical Code

NATIONAL SANITATION FOUNDATION3475 Plymouth Rd.Ann Arbor, Michigan 48106NSF/ANSI-4

UNDERWRITERS LABORATORIES, INC.333 Pfingsten RoadNorthbrook, Illinois 60062UL / ANSI-197



OM-DEE/4

5

FRONT VIEW

Equipment Description

The Groen DEE/4 is a floor-mounted, tilting,steam jacketed kettle with a thermostaticallycontrolled, self-contained, electrically-heatedsteam supply and appropriate controls, mountedon a sturdy base. The Model DEE/4 is availablein 20, 40 or 60 gallon capacities.

The body of the DEE/4 Kettle is constructed ofstainless steel, welded into one solid piece. Thekettle is furnished with a reinforced rim and abutterfly shaped pouring lip. It has a steamjacket rated for working pressures up to 50 PSI.Kettle finish is 180 emery grit on the inside andbright semi-deluxe on the outside.

The kettle can be tilted with a hand crank to pourout its contents. Stainless steel panels enclosethe controls and the base. Four stainless steel,tubular legs support the unit. Bullet feet on eachof the legs can be adjusted to level the kettle.

A built-in steam generator, sized for the kettlecapacity and heated by electricity, delivers steaminto the jacket. “Airless” operation of the steamjacket permits uniform, efficient heating attemperatures as low as 150°F and as high as298°F. In addition to the adjustable thermostatfor operating control, the unit has a tilt cut-offswitch, low water cut-off, safety valve, and high-limit pressure switch as safety features. Aheating indicator light, pressure gauge, and sightglass are provided for monitoring kettleoperation.

A single electrical connection is required forinstallation. The unit may be ordered for use with208/240, 400 or 480 volt power. All kettles arewired for three-phase operation. Single-phaseunits are also available.

KETTLE CHARACTERISTICSDEE/4-20 DEE/4-40 DEE/4-60

BeforeJanuary 1989.

AfterJanuary 1989

BeforeJanuary 1989.

AfterJanuary 1989

Kettle Capacity 20 gal (75 l) 40 gal (150l) 40 gal (150l) 60 gal (226l) 60 gal (226l)

Kettle Diameter 20 in (51 cm) 26 in (66 cm) 26 in (66 cm) 30 in (76 cm) 30 in (76 cm)

Rim Height 39 in (99 cm) 40 in (102 cm) 40 in (102 cm) 43 in (110 cm) 44 in (112 cm)

Total Width 38 in (97 cm) 44 in (112 cm) 42 in (107 cm) 50 in (127 cm) 47 in (119 cm)

Front to Back 28 in (71 cm) 31 in (79 cm) 32 in (81 cm) 33 in (84 cm) 35 in (90 cm)

Thermostat Dial

Indicator Light

Tilting Crank



OM-DEE/4

6

REAR VIEW

Optional equipment available with DEE/4 kettles:

1. 2” or 3" diameter tangent draw-off (productvalve)

2. Lift-off or counterbalanced cover

3. Water fill faucets4. TRI-BC basket cooking system5. Powered agitators (TA/3 or INA/2)6. Kettle brush kit7. Gallon etch marks

Inspection & Unpacking

The unit will arrive in a heavy shipping cartonand will be bolted or banded to a skid.Immediately upon receipt, inspect the cartoncarefully for exterior damage.

CAUTIONSHIPPING STRAPS ARE UNDER TENSIONAND CAN SNAP BACK WHEN CUT. TAKECARE TO AVOID PERSONAL INJURY ORDAMAGE TO THE UNIT BY STAPLES LEFTIN THE WALLS OF THE CARTON.

Carefully cut any polyester straps around thecarton and detach the sides of the box from theskid. Pull the carton up off the unit.

Thoroughly inspect the unit for concealeddamage. Report any shipping damage orincorrect shipments to the delivery agent.

Write down the model number, serial number,and installation date, and retain this informationfor future reference. Space for these entries isprovided at the top of the Service Log at theback of this manual. Keep this manual on fileand available for operators to use.

CAUTIONTHIS UNIT IS VERY HEAVY. INSTALLERSHOULD OBTAIN HELP AS NEEDED TOLIFT THIS WEIGHT SAFELY.

When installation is to begin, carefully cut anystraps which hold the unit on the skid. Lift theunit straight up off the skid. Examine packingmaterials to be sure loose parts are notdiscarded with the materials.

Pressure/VacuumGauge

Water GaugeGlass

SafetyValve



OM-DEE/4

7

Installation

The Groen Kettle is provided with completeinternal wiring and is ready for immediateconnection. Wiring diagrams are provided in thismanual and on the inside of the control housingservice panel. Any mechanical or electricalchanges must be approved by Groen’s FoodService Engineering Department.

WARNINGINSTALLATION OF THE KETTLE MUST BEDONE BY PERSONNEL QUALIFIED TOWORK WITH ELECTRICITY. IMPROPERINSTALLATION CAN RESULT IN INJURYTO PERSONNEL AND/OR DAMAGE TOEQUIPMENT.

The completed unit has been operated at thefactory to test all controls and heater elements.

1. Set the kettle in place and level it by turningthe bullet feet to adjust leg length. Allowclearance around the unit for cleaning,maintenance and service.

2. Confirm that the jacket water level is abovethe mid point of sight glass (new models) orbetween the marks on the gauge glass (oldmodels). If the level is low, follow theinstructions under “Jacket Filling and WaterTreatment,” Page 13.

3. The open end of theelbow on the outlet ofthe safety valve mustface downward. If itdoes not, turn it tothe correct position.

4. Provide electricalpower specified onthe equipment electrical information plate.Observe local codes and/or The NationalElectrical Code in accordance withANSI/NFPA 70 - (current edition).

5. The equipment is shipped ready for threephase operation. Refer to the wiring diagramfor single phase operation.

6. Bringing the electrical service through theentrance at the rear of the support housingwith one inch conduit, making a watertightconnection with the incoming lines. Observelocal codes and/or the National ElectricalCode in compliance with ANSI/NFPA 70(latest edition). When there is a choicebetween applicable codes, Groenrecommends following the more stringentcode. (A BX connection is notrecommended.)

DANGERELECTRICALLY GROUND THE UNIT ATTHE TERMINAL PROVIDED. FAILURE TOGROUND UNIT COULD RESULT INELECTROCUTION AND DEATH.

7. Electrically ground the unit at the terminalprovided.

8. Check the following to confirm that yourDEE/4 kettle is properly installed:• Room for cleaning and servicing• The kettle is level• The correct amount of water is in the

kettle jacket• Safety valve is pointed down• Unit is connected with a waterproof

supply of the proper voltage, phase andamperage rating

ELECTRICAL SPECIFICATIONS*DEE/4-20 DEE/4-40 DEE/4-60

KW AMP KW AMP KE AMP

208 Volts 11 30 21 59 21 59

240 Volts 12 31 24 61 24 61

480 Volts 12 15 24 29 24 29

400 Volts 12 17 24 35 24 35*All three phase. Single phase is also available.



OM-DEE/4

8

Each day, confirm the jacket water level by checkingthe water gauge.

Initial Start-Up

IMPORTANT:BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE OPERATINGINSTRUCTIONS, CAUTIONS AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL.

Now that the kettle has been installed, youshould test it to ensure that the unit is operatingcorrectly.

1. Remove all literature and packing materialsfrom inside and outside of the unit.

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

3. Confirm that the tilting mechanism isoperating properly by tilting the kettlethrough its full range. Then return the kettleto the upright position.

4. Turn on the electrical service to the unit.

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

6. Following “To Start Kettle” instructions in the“Operation” section of this manual, beginheating the water at the highest thermostatsetting. The heating indicator light shouldcome on immediately, and heating shouldcontinue until the water boils.

WARNING AVOID ALL DIRECT CONTACT WITH HOTSURFACES. DIRECT SKIN CONTACTCOULD RESULT IN SEVERE BURNS.

AVOID ALL DIRECT CONTACT WITH HOTFOOD OR WATER IN THE KETTLE.DIRECT CONTACT COULD RESULT INSEVERE BURNS.

5. To shut down the unit, turn the thermostatdial to “OFF”.

If the unit functions as described above, it isready for use. If the unit does not function asdescribed, contact your local Groen CertifiedService Agency.



OM-DEE/4

9

Operation

The operator controls kettle heating with thethermostat dial. The dial turns heating elementpower on or off and sets the kettle operatingtemperature.

A. To Start Kettle

1. EVERY DAY make sure that the jacketwater level is between the marks on thegauge glass. If the level is too low, see“Jacket Filling and Water Treatment” onpage 13.

2. Check the pressure gauge. If the gaugedoes not show 20 to 30 inches ofvacuum (that is, a reading of 20 to 30below 0), see “Jacket Vacuum” on page13.

3. Turn on the electrical power to the unit.

4. Turn the thermostat dial to the desiredsetting. The heating indicator lightindicates that the kettle is heating.Cycling of the light on and off shows thatthe kettle is being held at the settemperature. Once in each cycle thecontactors in the support housing willmake a clicking sound. This isnormal.

B. To Transfer Product or Empty Kettle:

1. The kettle is tilted by means of the crankon the front of the control housing. Thekettle remains in the position to which tilted until cranked again.

2. Product may also be transfered bymeans of the optional draw-off valve ifthe kettle is so equipped.

WARNINGAVOID ALL DIRECT CONTACT WITH HOTSURFACES. DIRECT SKIN CONTACTCOULD RESULT IN SEVERE BURNS.

AVOID ALL DIRECT CONTACT WITH HOTFOOD OR WATER IN THE KETTLE. DIRECTCONTACT COULD RESULT IN SEVEREBURNS.

TAKE SPECIAL CARE TO AVOID CONTACTWITH HOT KETTLE BODY OR HOTPRODUCT, WHEN ADDING INGREDIENTS,STIRRING OR TRANSFERRING PRODUCTTO ANOTHER CONTAINER.

CAUTIONDO NOT OVERFILL THE KETTLE WHENCOOKING, HOLDING OR CLEANING. KEEPLIQUIDS AT LEAST 2-3” (5-8 cm) BELOWTHE KETTLE BODY RIM TO ALLOWCLEARANCE FOR STIRRING, BOILINGPRODUCT AND SAFE TRANSFER.

WARNING WHEN TILTING KETTLE FOR PRODUCTTRANSFER:1) WEAR PROTECTIVE OVEN MITT AND

PROTECTIVE APRON.2) USE DEEP CONTAINER TO CONTAIN

AND MINIMIZE PRODUCT SPLASHING.3) PLACE CONTAINER ON STABLE, FLAT

SURFACE, AS CLOSE TO KETTLE ASPOSSIBLE.

4) STAND TO LEFT OR RIGHT OF KETTLEWHILE POURING — NOT DIRECTLY INPOUR PATH OF HOT CONTENTS.

5) P O U R S L O W L Y , M A I N T A I N I N GCONTROL OF KETTLE AT ALL TIMES,AND RETURN KETTLE BODY TOUPRIGHT POSITION AFTER CONTAINERIS FILLED OR TRANSFER IS COMPLETE.

6) DO NOT OVERFILL CONTAINER. AVOIDDIRECT SKIN CONTACT WITH HOTCONTAINER AND ITS CONTENTS.

Thermostat Dial

Indicator Light

Tilting Crank



OM-DEE/4

10

CAUTIONKEEP FLOORS IN FRONT OF THE KETTLEWORK AREA CLEAN AND DRY. IF SPILLSOCCUR, CLEAN AT ONCE TO AVOIDSLIPS OR FALLS.

Common Accessories

1. Lift-Off or Counterbalanced Cover

As with stock pot cooking, an optional covercan speed up the heating of water and foodproducts. A cover helps retain heat andreduces the heat and humidity released intothe kitchen. Using a cover can reduce someproduct cook times and help maintain thetemperature, color and texture of productsbeing held or simmered for longer periods.

Be sure the handle is secure on the lift-offcover before using. ALWAYS use the handleto place or remove cover from the kettle.Wear protective oven mitts and a protectiveapron.

When putting a lift-off cover on the kettle,position it on top of kettle rim, with its flatedge facing the pouring lip.

WARNINGAVOID ALL DIRECT CONTACT WITH HOTSURFACES. DIRECT SKIN CONTACTCOULD RESULT IN SEVERE BURNS.

AVOID ALL DIRECT CONTACT WITH HOTFOOD OR WATER IN THE KETTLE.DIRECT CONTACT COULD RESULT INSEVERE BURNS.

When removing the lift-off cover:

a) Firmly grasp the handle

b) Lift rear edge (farthest from operator) 1-2” (3-5 cm) to allow steam and watervapor to escape the cooking vessel.Wait 2-3 seconds.

c) Tilt cover to 45-60° angle to allow anyhot condensate or product to roll offcover back into kettle.

d) Remove cover, ensuring that anyremaining hot condensate or productdoes not drip on operator, floor or worksurfaces.

e) Place cover on safe, flat, sanitary, out-of-the-way surface, or return to kettle.

CAUTIONDO NOT TILT KETTLE WITH LIFT-OFFCOVER IN PLACE. COVER MAY SLIDEOFF, CAUSING INJURY TO OPERATOR.

2. Basket Insert

An optional kettle basket insert set canassist in cooking water-boiled productsincluding eggs, potatoes, vegetables, shellfish, pasta and rice. The nylon mesh linermust be used for products smaller than thebasket mesh size, (approximately 1/4” (6mm). This includes rice and small pastashapes.

Tips For Use.

a) Allow for displacement of the 3 basketsand product. This may mean only fillingthe kettle half way. Test baskets andproduct displacement with the kettleOFF, and with cold water in the kettle.

CAUTIONDO NOT OVERFILL THE KETTLE WHENCOOKING, HOLDING OR CLEANING.KEEP LIQUIDS AT LEAST 2-3” (5-8 cm)BELOW THE KETTLE RIM TO ALLOWCLEARANCE FOR STIRRING, BOILINGAND SAFE PRODUCT TRANSFER.



OM-DEE/4

11

WARNINGAVOID ALL DIRECT CONTACT WITH HOTFOOD OR WATER IN THE KETTLE.DIRECT CONTACT COULD RESULT INSEVERE BURNS.

b) Load baskets on a level, stable worksurface.

c) Lift loaded baskets with both hands. Gethelp from another person if the basket istoo heavy for safe handling.

d) Slowly lower product into kettle andsecurely hook the basket to the “Y”frame.

e) When removing baskets with cookedproduct, lift straight up, ensuring basketbottoms clear the kettle rim and pouringlip. Wear protective oven mitts andprotective apron.

f) Allow hot water to fully drain fromproduct, before moving basket awayfrom the kettle. Do not rest baskets onkettle rim or pouring lip. If baskets aretoo heavy for individual to lift and safelymove, get help. Remove productimmediately from basket into anothercontainer, being sure to avoid contactwith hot product and hot basket or. . .

g) Place baskets with food on a stable, flatsurface, inside a solid steamer or bakepan, to catch any remaining hot waterdraining from product.

Sequence of OperationThe following “action-reaction” outline is providedto help the user understand how the equipmentworks.

When the operator starts up the kettle by turningthe operating thermostat dial from “OFF” to adesired setting, the thermostat switch closes.This lights up the heating indicator light andcauses the contactors to close, allowing powerto flow to heating elements.

When the temperature of the steam jacketreaches the value corresponding to the dialsetting, the thermostat switch opens. This turnsoff the heating indicator light and causes thecontactors to open, stopping the power to theheaters.

As soon as the thermostat senses that the kettleis cooling below the set point, the thermostatswitch closes, the heating indicator light comeson, the contactors close, and the heaters comeon again. On-off cycling continues, keeping thekettle at the set temperature.

This is why the heating indicator light cycles onand off during normal operation. Every time thekettle is tilted, the tilt cut-off switch interrupts thepower supply to the heaters, so that the heatingelements will not operate while not submerged inthe jacket water.

If steam pressure greater than 50 PSI isgenerated in the jacket, the safety valve willopen and relieve the excess pressure.

If the jacket water level gets too low before theheating elements overheat, the high-limit controlwill open and shut off power to the elements untilthe kettle cools.

Setting the operating thermostat dial to “OFF”shuts down all control and heating circuits.



OM-DEE/4

12

The pressure gauge should show a vacuumof 20 to 30 inches when the kettle is cold.

Test the safety valve at least twicemonthly.

MaintenanceNOTICE: Contact Groen or an authorized Groen representative when repairs are required.

1. Periodic Maintenance

A Maintenance & Service Log is provided atthe back of this manual with the warrantyinformation. Each time maintenance isperformed on your Groen kettle, enter thedate on which the work was done, what wasdone, and who did it. Keep this manual onfile and available for operators to use.

Periodic inspection will minimize equipmentdown time and increase the efficiency ofoperation. The following points should bechecked:

[BY OPERATOR]a. Check the pressure/vacuum gauge

every day. The gauge should show avacuum of 20 to 30 inches, when the kettle is cold. If it does not, see “JacketVacuum” on page 13.

b. Also check thejacket water levelevery day. Itshould bebetween themarks on thegauge glass. Ifthe level is low,see “JacketFilling and WaterTreatment” onpage 13.

c. Test the safety

valve at least twice each month. Test the valvewith the kettle operating at 15 psi (105 kPa), byholding the test lever for at least 5 seconds.Then release the lever and let the valve snapshut. If the lever does not activate, or there is noevidence of discharge, or the valve leaks, stopusing the kettle and contact a qualified Groenservice representative.

WARNINGWHEN TESTING, AVOID ANY EXPOSURETO THE STEAM BLOWING OUT OF THESAFETY VALVE. DIRECT CONTACTCOULD RESULT IN SEVERE BURNS.

[BY SERVICE TECHNICIAN]

d. Electrical wiring should be kept securelyconnected and in good condition.

e. The inside of the support housingshould be kept clean.



OM-DEE/4

13

2. Jacket Vacuum

When the kettle is cold, a positive pressure/vacuum gauge reading or a reading nearzero indicates that there is air in the jacket.Air in the jacket slows kettle heating.

To remove air:

a. Start the unit.(Be sure there is water orproduct in the kettle when heating).

b. When the pressure/vacuum gaugereaches a positive pressure reading of 5PSI, release the trapped air and steamby pulling up or out on the safety valvelever or ring for about 1 second. Repeatthis step, then let the pull ring or valvelever snap back into the closed position.

3. Jacket Filling and Water Treatment

The jacket was charged at the factory withthe proper amount of treated water. You mayneed to restore this water, either because itwas lost as steam during venting or bydraining.a. If you are replacing water lost as steam,

use distilled water. If you are replacingtreated water that ran out of the jacket,prepare more treated water as directedin step 4, “Water Treatment Procedure.”

b. Allow the kettle to cool. Turn the elbowon the safety valve counterclockwise (toavoid thread damage) until the openingof the elbow faces upward.

c. Open the safety valve and pour thewater or treated water in at the elbowuntil the water level rises to a pointbetween the marks on the gauge glass.

CAUTIONBEFORE YOU HEAT THE KETTLE AGAINFOR ANY PURPOSE, TURN THE ELBOWBACK CLOCKWISE UNTIL THE OPENINGFACES DOWNWARD.

e. Air introduced to the jacket during fillingmust be removed to obtain efficientheating. See “Jacket Vacuum” above.

4. Water Treatment Procedure

(1) Obtain water treatment compound and apH test kit from your authorized Groenparts distributor.

WARNINGTO AVOID INJURY, READ AND FOLLOWALL PRECAUTIONS STATED ON THELABEL OF THE WATER TREATMENTCOMPOUND.

(2) Fill a mixing container with themeasured amount of water required.(See table). Distilled water isrecommended.

Kettle Model Jacket Capacity

DEE/4-20 2½ Gallons

DEE/4-40 3½ Gallons

DEE/4-60 4 Gallons

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

(4) Measure the water treatment compound (One way to do this is to add thecompound from a measuring cup.)

(5) Stir the water continuously, while youslowly add water treatment compound,until the water reaches a pH between10.5 and 11.5. Judge the pH byfrequently comparing the test strip colorwith the color chart provided in the pHtest kit. If you are color blind use anelectroanalytical instrument to measurethe pH level or have a person who is notcolor blind read the test strip color level.

(6) Record the exact amounts of water andtreatment compound used. Theseamounts may be used again, if the samewater sources and compound are usedin the future. However, it is best to checkthe pH each time treated water isprepared.

WARNINGELECTRIC POWER ALWAYS SHOULDBE SHUT OFF BEFORE WORK IS DONEON INTERNAL COMPONENTS.

5. Service personnel should check the unit at leastonce a year. This periodic maintenance should include inspecting electrical wires and connect-ions, cleaning the inside of the control console.

At least twice a year, grease the two trunnion bearings and worm gear. Groen recommendsthe use of number two grade LGI lithium grease.Add grease through the zerk fittings on the gearhosing until the grease flows out of the bearingsaround the trunion shaft. Also, add grease in the gear to cover arc that is in contact with the wormgear. Clean up excess grease.

WARNINGDISCONNECT ELECTRICAL POWER FROMTHE UNIT BEFORE ATTEMPTING TO GREASE THE TRUNION BEARINGS.

(Groen Part No. 110324)



OM-DEE/4

14

Cleaning

1. Suggested Tools:a.

b.c.

d.

e.

A high quality detergent and sanitizer,or a combination cleaning-sanitizing agent.Kettle brushes.Groen Spray Degreaser (P/N 114801) orequivalent.Groen Delimer-Descaler (P/N 114800) or equivalent.A high quality stainless steel cleaner.

2. PrecautionsBefore cleaning, shut off the kettle by turningthe thermostat dial to “OFF,” and shut off allelectric power to the unit at a remote switch,such as the circuit breaker.

WARNING KEEP WATER AND SOLUTIONS AWAYFROM CONTROLS AND ELECTRICALEQUIPMENT. NEVER SPRAY THESUPPORT HOUSING OR ELECTRICALCONNECTIONS.

CAUTIONMOST CLEANERS ARE HARMFUL TO THESKIN, EYES, MUCOUS MEMBRANES, ANDCLOTHING. PRECAUTIONS SHOULD BETAKEN. WEAR RUBBER GLOVES,GOGGLES OR FACE SHIELD, ANDPROTECTIVE CLOTHING. READ THEW A R N I N G S A N D F O L L O W T H EDIRECTIONS ON THE LABEL OF THECLEANER CAREFULLY

3. Procedurea. Clean food-contact surfaces as soon as

possible after use. If the unit is incontinuous use, thoroughly clean andsanitize the interior and exterior at leastonce every 12 hours.

b. Scrape and flush out food residues. Becareful not to scratch the kettle withmetal implements.

c. Prepare a hot solution of the detergent/cleaning compound as instructed by thesupplier. Clean the unit thoroughly. Acloth moistened with cleaning solutioncan be used to clean controls, housings,and electrical conduits.

d.

e.

f.

Rinse the kettle thoroughly with hotwater, then drain completely. Disassemble the tangent draw-off valve.Clean the draw-off port and each valvepart with a bursh.Rinse the kettle and draw-off valve partsthoroughly with hot water, then drain completely.

h. As part of the daily cleaning program,clean soiled external and internalsurfaces. Remember to check the sidesof the unit and control housing.

i. To remove stuck materials, use a brush,sponge, cloth, plastic or rubber scraper,or plastic wool with the cleaning solution.To reduce effort required in washing, letthe detergent solution sit in the kettleand soak into the residue. Do NOT useabrasive materials or metal tools thatmight scratch the surface. Scratchesmake the surface harder to clean andprovide places for bacteria to grow.

When attaching the draw-off valve, justhand-tighten the nut.

g. When you reassemble the draw-off valve, hand-tighten the nut which holds it in place.

Do NOT use steel wool, which mayleave particles in the surface and causeeventual corrosion and pitting.

Scrapers or steelwool can harm thekettle surface

Use only a sponge,cloth or plastic brush to clean kettle.



OM-DEE/4

15

When equipment needs to be sanitized,use a solution equivalent to one thatsupplies 200 parts per million availablechlorine. Obtain advice on sanitizingagents from your supplier of sanitizingproducts. Following the supplier’sinstructions, apply the agent after theunit has been cleaned and drained.Rinse off the sanitizer thoroughly.

NOTICENEVER LEAVE A CHLORINE SANITIZER INCONTACT WITH STAINLESS STEELSURFACES LONGER THAN 30 MINUTES.LONGER CONTACT CAN CAUSE STAININGAND CORROSION.

l. It is recommended that each piece ofequipment be sanitized just before use.

m. If there is difficulty removing mineraldeposits or a film left by hard water orfood residues, clean the kettlethoroughly and then use a delimingagent, like Groen Delimer/Descaler (PartNumber 114800) or Lime-Away fromEcolab, in accordance with themanufacturer’s directions. Rinse anddrain the unit before further use.

n. If cleaning problems persist, contactyour cleaning product representative forassistance. The supplier has a trainedtechnical staff with laboratory facilities toserve you.

Troubleshooting

Your Groen kettle is designed to operate smoothly and efficiently if properly maintained. However, thefollowing is a list of checks to make in the event of a problem. Wiring diagrams are furnished inside theservice panel and in this manual. If an item on the list is followed by Y , the work should be done by aqualified service representative.USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY GROEN OR THEIRAUTHORIZED DISTRIBUTORS CAN CAUSE INJURY TO THE OPERATOR AND DAMAGE TO THEEQUIPMENT AND WILL VOID ALL WARRANTIES.

SYMPTOM WHO WHAT TO CHECKY indicates items which must be performed by an authorized technician.

Kettle will not heat, and heating indicatorwill not come on.

User a. Electric power supply to the unit.b. Water level in jacket.

AuthServiceRep Only

c. Control circuit fuses. Replace a blown fuseonly with a fuse of the same AMP rating. Y

d. For loose or broken wires. Ye. Tilt cut-off switch. Yf. That pressure switch is open. Yg. Operation of variable thermostat. Yh. Low water cutoff. Y

Kettle will not heat, but heating indicatorcomes on.

User a. For air in the jacket. See “Jacket Vacuum” inthe Maintenance section of this manual.

AuthServiceRep Only

b. Contactor. Yc. Heater elements with ohmmeter for ground

short or open element. If element is defective,call Groen. Y

Kettle continues heating after it reachesthe desired temperature

User a. Thermostat dial setting.

AuthServiceRep Only

b. Thermostat circuit for short. Yc. Thermostat operation. The thermostat should

click when the dial is rotated above and belowthe setting for the temperature of the kettle. Y

d. Contactor, to determine whether it is energizedor stuck. Y

j. The outside of the unit may be polished with a recognized stainless steel cleaner. k.



OM-DEE/4SYMPTOM WHO WHAT TO CHECK

Yindicates items which must be performed by an authorized technician.

16

Kettle stops heating before it reaches thedesired temperature.

User a. Thermostat dial setting.

AuthServiceRep Only

b. Thermostat calibration. Yc. Thermostat operation. The thermostat should

click when the dial is rotated above and belowthe setting for the temperature of the kettle. Y

Kettle heats slowly User a. For air in the jacket. See “Jacket Vacuum” inthe “Maintenance” section of this manual.

AuthServiceRep Only

b. Heater elements with ohmmeter for groundshort or open element. If an element isdefective, call Groen. Y

c. Voltage of main power source. Y

Safety valve pops. User a. For air in the jacket. See “Jacket Vacuum” inthe “Maintenance” section of this manual.

b. Whether kettle was being heated empty whenvalve popped.

AuthServiceRep Only

c. Pressure switch setting. Yd. Thermostat operation. Thermostat should click

when the dial is rotated above and below thesetting for the temperature of the kettle. Y

e. Safety valve. If the valve pops at pressuresbelow 48 PSI, replace it. Y

f. Contactor, to determine whether it is de-energized. Y

Safety valve leaks a small amount ofsteam when the kettle is operating.

User a. For contamination that prevents seating ofvalve. With full pressure in the jacket, pull thelever all the way briefly to blow the valve clean,then let the lever snap back to seat the valve.

AuthServiceRep Only

b. Safety valve for defects. Replace any defectivevalve with an identical valve.Y

Kettle is hard to tilt. AuthServiceRep Only

a. Tilting gear and worm for contamination andfor proper alignment and lubrication.Y



OM-DEE/4

17

Parts List

To order parts, contact your Groen Certified Service Agency. Supply the model designation, part description, partnumber, quantity, and, where applicable, voltage and phase.

1

2 3

45

6

7

8 9 10

13

12

11

14

494826

27

15

3031

21

282223

24

25

24232221

3333

3232

34

29

4342

42

4141

4040

28 39

3837

3536

16

1718

4447

19

46

4520

A



OM-DEE/4

18

Parts List (Prior To 10/02)

Key Description Part No. Key Description Part No.1 Contactor (See Note) — 26 #10-24 Hex Cap Nut 0054702 Safety Valve, 50 PSI ¼” NPT 005587 27 Glass Gauge Rod Guard 002981

Safety Valve, 50 PSI ½”NPT 097005 28 ¼” Diameter Roll Pin 1" Long 0126143 ½” NPT Street Elbow 010668 29 Handle Crank 0136174 2” Draw-Off Valve, Complete 009000 30 Rubber Grommet 0004535 Valve Handle 009029 31 Handwheel Shaft ¾” dia 20,40 & 60 0136246 Wing Nut #10-24 009028 32 Basic Retaining Ring 0134837 Valve Stem 009027 33 Ball Bearing 009765

Valve Stem 2" 009048 34 Worm Gear 0120268 Valve Bonnet 009024 35 Warrick Relay 115 Volt 0104129 Rubber “O” Ring 009034 36 Warrick Relay 220 Volt 010410

10 Sanitary Hex Nut 008911 37 Gear 92 Teeth 3" Bore 013609Sanitary Hex Nut 2" 009354 38 Socket Set Screw 005097

11 Transformer (480 Volt 3 Phase only) 012827 39 d” x d” x 1d” Key Stock 00147412 #BAF Fuse (480 Volt 3 Phase only) 002651 40 Cylindrical Bearing 00976413 Pressure Limit Control 096963 41 Grease Fitting 01210014 Thermostat Knob 013682 42 Gauge Glass Connector (before 01120215 Electric Thermostat 009730 July 15, 1974)16 Water Level Electrode (Warrick) 002170 43 ½” 14 NPT Square Plug Head 01114617 #SC-3 Fuse 002945 (before July 15, 1974)18 Fuse Holder 002944 44 Indicator Lamp Assembly Complete 00859819 Indicator Light 250 Volt 016028 (before 1976) 115 Volt20 Pressure Gauge 001594 45 Indicator Lamp Bulb (before 1976) 00152421 Sight Glass Fitting 002845 46 Lens, Lamp Red (before 1976) 01089422 Rubber Gauge Glass Gasket 008917 47 Indicator Lamp Assembly Complete —23 Washer with Item #21 — (before 1976) 230 Volt24 Hex nut with Item #21 — 48 Control Housing 00296125 Water Gauge Glass 4¾” Long 008742 49

AFlex ConduitStand & Housing Assy.DEE/4-20DEE/4-40 & 60

044770

140842139057

Note: To order a new contactor, specify the part number on the old contactor.

Electrical Schematics

(Prior to 10/02)



OM-DEE/4

19


(Prior to 10/02)

(Prior to 10/02)



OM-DEE/4

20


(Prior to 10/02)

(Prior to 10/02)



OM-DEE/4

21


(Prior to 10/02)

(Prior to 10/02)



OM-DEE/4

22

Stand and Housing Assembly

Parts List

Key Description Part No. Key Description Part No. Key Description Part No.A Stand and Housing Assembly Base Assembly DEE/4-40 137950 9 1/2" Lock Washer 005735

DEE/4-20 140842 4 Housing Welding Assembly 138107 10 Screw Truss #8-32 x 3/8 005764DEE/4-40 & 60 139057 5 Housing Cladding 138112 11 Screw Truss #8-32 x 1-1/4 Lg. 071247

1 Cabinet Side Panel 047882 6 Tray Liner 001475 12 Cabinet Cover 1381142 Stand Cladding DEE/4-20 140425 7 Nut Hexagon 1/2-13 Heavy Duty 005705

Stand Cladding DEE/4-40 139054 8 Screw Hex Head Cap 1/2-13 x1-1/2 0086793 Base Assembly DEE/4-20 140421



OM-DEE/4

23

Parts ListAfter 10/02

To order parts, contact your Groen Certified Service Agency. Supply the model designation, part description, partnumber, quantity, and, where applicable, voltage and phase.

33 36

39 40 41

34 35

12

3

4

6

5

7

43

39 42

37 44

38 39

8

9

10

13

12

18 19 21

282523

24

30

29 15 26 16 17

20

11

31

14

27

45

Cladding

WeldmentSupport Arm

32 22



OM-DEE/4

24

Parts ListAfter 10/02

Key Description Part No. Key Description Part No.1 Wing Nut #10-24 009028 29 Gear 3 “ Bore 0136092 Valve Handle 009029 30 Crank Handle 0136173 Bonnet 009047 31 Shaft Handwheel 0136244 Rubber “O” Ring 009034 32 Spacer 3: Sch 40 0136255 Valve Stem 009048 33 Water Level Control Board 1221926 Hex Nut 009354 34 Fuse Holder Type 3AG (208/240

units)077854

7 Body Valve 009045 Fuse Holder (480 Units) 0778408 Piping Water Fill Asm. 139396 35 Fuse 3.0 Amp Type 3 AG (208/240

units)077853

9 Relief Valve With Gauge Asm. 139395 Fuse 6.0 Amp (480 units) 11982310 Thermostat 009730 36 PC Board Mounting Post 09990111 Thermostat Knob 012314 37 Screw #8-32 x 1-1/4" Rd Hd Mach. 00505612 Light Indicator Red 116383 38 Lug Ground # 14 - #6 awg 12971413 Electrical Mounting Asm. (208,

240)139176 39 Screw #8-32 x 3/8" Hex Hd Cap 69789

Electrical Mounting Asm. (480) 13917714 Snap Bushing 000453 40 Screw #6-40 x 3/8"" Rd Hd Mach. 00969715 Key 3/8" Square 001474 41 Trans., 40 VA 208/240 PRI,24V

Sec137441

16 Screw Socket Head Cap 005097 Trans., 480 PRI, 24 V Sec. 13769417 Lock Washer 3/8 005618 42 Contactor, 3 Pole 65 Amp Restive 10630618 Nut Hexagon 1/2-13 005705 43 Electrical Panel Weldment 13812319 Lock Washer 005735 44 Ter. Blk 4 Pole 85 Amp #14-4 Awg 08821420 Nut Hexagon 3/8-16 008214 45 Nut #10-32 Hex Keps w/shakeproof

ws071256

21 Screw Hexagon Head Cap 1/2-13 008679 46 Probe, Water (Not shown) 13986422 Housing Assy 00976223 Ball Bearing 00976524 Worm Gear 3/4 Bore 01202625 Shim 1 3/8 x .010 Thk 01203926 Set Screw 5/16 x 3/4 Lg 01206027 Roll Pin 1/4 Dia x 1 01261428 Internal Retaining Ring 013483

Note: To order a new contactor, specify the part number on the old contactor.



OM-DEE/4

25

Electrical SchematicsAfter 10/02

208 / 240 V

COM

PRESSURE SWITCH

L2

RED

CBOARDLEVEL

NO

BRN

L1

TRANSFORMER

LLCOYEL

HIGH LIMIT

NCYELLOW

3

240 V COM

24 V

GND

F1

G LOW WATERPROBE

RED

P/N 137924 REV. A

GRN

BLUE

YEL

24 V

RED

GRN

OPERATINGTHERMOSTAT

A B

HEAT LED

B A

WHITE

GRN

ORANGE

ORANGE

GREEN

ORANGE

GREEN

208 V

LEAD TO MAIN VOLTAGE LINE

CONNECT APPROPRIATE TRANSFORMER

RED

3 PHASE SUPPLY

L2L1

BLOCK TERMINAL

CONTACTOR

208/240V

L3

YELLOW

BROWNBRN

200 C

YEL

H2

B

H1

B COIL

24VAC

HEATER ELEMENTS

RED A

TILT SWITCH

C NO

WATER

BRN

H3

RED

A

C



OM-DEE/4

26

Electrical SchematicsAfter 10/02

480 V, 3 PH



OM-DEE/4

27

Service Log

Model No. _______________________________ Purchased From _________________________

Serial No. _______________________________ Location ________________________________

Date Purchased __________________________ Date Installed ___________________________

Purchase Order No. ______________________ For Service Call __________________________

Date Service Performed Performed By



OM-DEE/4

28

Limited WarrantyTo Commercial Purchasers *

(Domestic U.S., Hawaii & Canadian Sales Only)

Groen Foodservice Equipment ("Groen Equipment") has been skillfully manufactured, carefully inspectedand packaged to meet rigid standards of excellence. Groen warrants its Equipment to be free from defectsin material and workmanship for (12) twelve months with the following conditions and subject to thefollowing limitations.

I. This parts and labor warranty is limited to Groen Equipment sold to the original commercialpurchaser/users (but not original equipment manufacturers), at its original place of installation in thecontinental United States, Hawaii and Canada.

II. Damage during shipment is to be reported to the carrier, is not covered under this warranty, and isthe sole responsibility of purchaser/user.

III. Groen, or an authorized service representative, will repair or replace, at Groen's sole election, anyGroen Equipment, including but not limited to, drawoff valves, safety valves, gas and electriccomponents, found to be defective during the warranty period. As to warranty service in the territorydescribed above, Groen will absorb labor and portal to portal transportation costs (time & mileage)for the first twelve (12) months from date of installation or fifteen (15) months from date of shipmentfrom Groen.

IV. This warranty does not cover boiler maintenance, calibration, periodic adjustments as specified inoperating instructions or manuals, and consumable parts such as scraper blades, gaskets, packing,etc., or labor costs incurred for removal of adjacent equipment or objects to gain access to GroenEquipment. This warranty does not cover defects caused by improper installation, abuse, carelessoperation, or improper maintenance of equipment. This warranty does not cover damage causedby poor water quality or improper boiler maintenance.

V. THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ALL OTHER WARRANTIES,EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITYOR FITNESS FOR A PARTICULAR PURPOSE, EACH OF WHICH IS HEREBY EXPRESSLYDISCLAIMED. THE REMEDIES DESCRIBED ABOVE ARE EXCLUSIVE AND IN NO EVENTSHALL GROEN BE LIABLE FOR SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGESFOR THE BREACH OR DELAY IN PERFORMANCE OF THIS WARRANTY.

VI. Groen Equipment is for commercial use only. If sold as a component of another (O.E.M.)manufacturer's equipment, or if used as a consumer product, such Equipment is sold AS IS andwithout any warranty.

* (Covers All Foodservice Equipment Ordered After October 1, 1995)



1055 Mendell Davis DriveJackson, Mississippi 39272Telephone 601 373-3903FAX 601 373-9587groen.com

OM-DEE/4 (Revised 02/04) Part Number 121013 Rev. B



model: dee/4 steam jacketed kettle - parts...

Documents