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 Hobart 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 Hobart 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 Hobart Service Technician.
The reproduction, transfer, sale or other use of this manual, without the express written
consent of Hobart, 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 Rev. D (0124)
TABLE OF CONTENTS
SERVICE UPDATES ....................................................................................... 3
SERVICE UPDATES ................................................................................... 3
GENERAL .................................................................................................. 4
INTRODUCTION ....................................................................................... 4
GENERAL .......................................................................................... 4
STATIONARY AND TILTING KETTLES ............................................................. 4
MODELS COVERED ................................................................................... 4
CONTROL PANEL ..................................................................................... 4
TOOLS ................................................................................................. 4
SPECIFICATIONS ...................................................................................... 5
OPERATION, CLEANING AND MAINTAINENCE ........................................................ 5
REMOVAL AND REPLACEMENT OF PARTS ............................................................... 6
CONTROL BOX COVER ............................................................................... 6
BOTTOM COVER ...................................................................................... 6
COMPONENT PANELS ................................................................................ 6
HEATING CONTACTORS .............................................................................. 7
TEMPERATURE CONTROLLER ........................................................................ 7
WATER LEVEL CONTROL ............................................................................. 7
MAIN TRANSFORMER ................................................................................. 8
HEATING ELEMENT ................................................................................... 8
WATER LEVEL PROBE (LLCO) ....................................................................... 10
TEMPERATURE SENSOR ............................................................................ 11
PRESSURE SWITCH ................................................................................. 11
POTENTIOMETER .................................................................................... 12
SWITCH ASSEMBLY .................................................................................. 12
GEARBOX (TILT MODELS ONLY) ..................................................................... 13
TILT BEARING ........................................................................................ 14
SERVICE PROCEDURES AND ADJUSTMENTS ........................................................... 15
TEMPERATURE CONTROLLER TEST ................................................................ 15
POTENTIOMETER TEST .............................................................................. 16
THERMOCOUPLE TEST .............................................................................. 16
VENTING ............................................................................................. 16
HEATING ELEMENT .................................................................................. 17
KETTLE TILT ADJUSTMENT (TILT MODELS ONLY) .................................................. 18
FILLING THE RESERVOIR JACKET ................................................................... 20
ELECTRICAL OPERATION ................................................................................ 24
COMPONENT FUNCTION ............................................................................ 24
COMPONENT LOCATION ............................................................................. 25
WATER LEVEL CONTROL (WLC LLCO) .............................................................. 26
SEQUENCE OF OPERATION ......................................................................... 27
SCHEMATIC DIAGRAM ............................................................................... 29
WIRING DIAGRAMS .................................................................................. 30
TROUBLESHOOTING ..................................................................................... 33
TROUBLESHOOTING ................................................................................. 33
Electric Stationary and Tilting Kettles
© VULCAN 2024
F45472 Rev. D (0124) Page 2 of 33
SERVICE UPDATES
SERVICE UPDATES
January 2024
• Updated FILLING THE RESERVOIR JACKET.
December 2023
• Updated FILLING THE RESERVOIR JACKET.
• Updated TOOLS.
December 2020
• Updated HEATING ELEMENT.
July 2018
• Updated TOOLS.
October 2017
• Updated FILLING THE RESERVOIR JACKET
Electric Stationary and Tilting Kettles - SERVICE UPDATES
Page 3 of 33 F45472 Rev. D (0124)
GENERAL
INTRODUCTION
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.
Stationary and Tilting Kettles
The electric stationary and tilting kettles are self
contained two thirds jacketed kettles. The lower two
thirds of the kettle bowl is a double wall stainless steel
construction that provides a reservoir for a solution of
heat transfer fluid and distilled water for improved
heating of the kettle contents. The kettles are used to
prepare a variety of liquid or semi-liquid food products
such as soups, stews and sauces.
MODELS COVERED
Electric Stationary and Tilting Kettles
K20EL Stationary Kettle - 20 Gallon
K40EL Stationary Kettle - 40 Gallon
K60EL Stationary Kettle - 60 Gallon
K20ELT Tilting Kettle - 20 Gallon
K40ELT Tilting Kettle - 40 Gallon
K60ELT Tilting Kettle - 60 Gallon
CONTROL PANEL
Fig. 1
TOOLS
Standard
• Standard set of hand tools.
• Metric set of hand tools.
• VOM with measuring micro amp current tester.
Any VOM with minimum of CAT III 600V, CE
certified. Sensitivity of at least 20,000 ohms per
volt can be used. In addition, meter leads must
also be a minimum of CAT III 600V.
• Clamp on type amp meter with minimum of
NFPA-70E CAT III 600V, UL/CSA/TUV listed.
• Field service grounding kit.
• Pipe thread sealant.
• Temperature meter (thermocouple type). Use for
checking kettle temperature.
• 6 gallon container to hold drained reservoir jacket
fluid.
Special
• Torque wrench (ft-lbs) for tightening heating
element mounting bolts.
Electric Stationary and Tilting Kettles - GENERAL
F45472 Rev. D (0124) Page 4 of 33
• Thermodyne 90395 GLYCOL, HEAT
TRANSFER FLUID, 1 GALLON, available at
Parts Town or DOWFROST™ Propylene Glycol
at ChemWorld. Refer to FILLING THE
RESERVOIR JACKET for volumes.
• Distilled water only for re-filling of the jacket
(purchase locally). Refer to FILLING THE
RESERVOIR JACKET for volumes.
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 PHASE
Amperage per Line Minimum Circuit Ampacity
208V 240V 480V 208V 240V 480V
K20EL/ELT
12
1 57.7 --- --- 75 --- ---
3 33.3 --- 14.4 45 --- 20
16
1 --- 66.7 --- --- 85 ---
3 --- 38.5 --- --- 50 ---
K40EL/ELT
K60EL/ELT
18 3 50.0 43.3 21.7 65 55 30
K40EL/ELT
K60EL/ELT
24 3 66.6 57.7 28.9 85 75 40
The 208/240V electric kettles are wired from the factory for a 208V 3-phase supply. If connecting to 240V 3-phase
supply, the primary voltage tap on the transformer must be changed to this voltage. For connecting to a single
phase supply, the wiring between terminal block and contactors must be changed as shown in the WIRING
DIAGRAMS.
OPERATION, CLEANING AND
MAINTAINENCE
Refer to F35457 Installation & Operation Manual for
specific instructions. The manual includes:
• A page from the Stainless Steel Care and
Cleaning Guide for proper care and cleaning of
stainless steel.
• Draw-Off Valve and Plug Valve dissassembly &
cleaning instructions.
Electric Stationary and Tilting Kettles - GENERAL
Page 5 of 33 F45472 Rev. D (0124)
REMOVAL AND REPLACEMENT OF PARTS
CONTROL BOX COVER
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Control Box Cover
BOTTOM COVER
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
Bottom Cover
COMPONENT PANELS
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. Use
these pictures to asist in removal and replacement of
the components in these kettles.
Stationary Kettle
Tilting Kettle
Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS
F45472 Rev. D (0124) Page 6 of 33
Bottom
HEATING CONTACTORS
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
1. Remove CONTROL BOX COVER.
2. Note location of lead wires then disconnect the
wires from contactor being replaced.
3. Remove screws securing the contactor to panel.
4. Reverse procedure to install and check for proper
operation.
Fig. 7
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.
Fig. 8
WATER LEVEL CONTROL
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
1. Remove CONTROL BOX COVER.
2. Disconnect lead wires from the water level
control.
3. Remove screws securing the water level control
to panel.
4. Reverse procedure to install and check for proper
operation.
Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS
Page 7 of 33 F45472 Rev. D (0124)
Fig. 9
MAIN TRANSFORMER
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.
Fig. 10
HEATING ELEMENT
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
TILTING KETTLE
1. Open pressure relief valve until reservoir jacket
is completely vented.
2. Remove BOTTOM COVER.
3. Remove wire from water level probe (LLCO).
4. Place a large container under the kettle. Remove
water level probe (LLCO) and open the fill valve
(40 & 60 gallon kettles) or remove pipe plug from
fill elbow (20 gallon kettles) to vent the jacket and
drain liquid from kettle.
Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS
F45472 Rev. D (0124) Page 8 of 33
Fig. 11
NOTE: If liquid drained from kettle is still clean, save
for reuse.
5. Remove heater access cover.
Fig. 12
6. Note lead wire locations and disconnect wires
from heating element.
7. Remove mounting bolts securing heating
element to kettle.
Fig. 13
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.
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.
STATIONARY KETTLE
1. Open pressure relief valve until reservoir jacket
is completely vented.
2. Remove BOTTOM COVER.
3. Remove wire from Water Level Probe (LLCO).
4. Place a large container under the kettle. Remove
water level probe (LLCO) and open the fill valve
(40 & 60 gallon kettles) or remove pipe plug from
fill elbow (20 gallon kettles) to vent the jacket and
drain liquid from kettle.
Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS
Page 9 of 33 F45472 Rev. D (0124)
Fig. 14
NOTE: If liquid drained from kettle is still clean, save
for reuse.
5. Remove CONTROL BOX COVER.
6. Note lead wire locations and disconnect wires
from heating element.
7. Remove mounting nuts securing heating element
to kettle.
Fig. 15
8. Remove heating element from kettle.
9. Reverse procedure to install. Use a new heating
element seal whenever installing heating
element. Torque mounting bolts to 40 ft-lbs and
tighten in an alternating pattern.
10. Refill jacket with fluid. See FILLING THE
RESERVOIR JACKET.
11. Remove air from reservoir jacket as outlined
under VENTING.
NOTE: Step 12 is applicable for flange change on
production units starting with serial number break
46-3030197.
12. Torque all flange bolts to 38 Ft/Lbs. in 3 passes
as shown in Fig. 16.
It is recommended to heat kettle up to boil for one
hour. After kettle cools down to -20 to -30 HG and
recheck torque to verify 38 Ft/Lbs.
A. 1st pass 13 ft/lbs.
B. 2nd pass 26 ft/lbs.
C. 3rd pass 38 ft/lbs.
Fig. 16
13. 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.
1. Open pressure relief valve until reservoir jacket
is completely vented.
Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS
F45472 Rev. D (0124) Page 10 of 33
2. Remove BOTTOM COVER.
3. Disconnect lead wires from the water level
probe .
Fig. 17
4. Place a large container under kettle to catch
liquid that drains from kettle.
NOTE: If liquid drained from kettle is still clean, save
for reuse.
5. Remove component from bottom of kettle.
6. Reverse procedure to install.
NOTE: Clean threads and apply pipe thread sealant
when replacing water level probe.
7. Refill jacket with fluid. See FILLING THE
RESERVOIR JACKET.
8. Remove air from reservoir jacket as outlined
under VENTING.
9. Check for proper operation.
TEMPERATURE SENSOR
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
1. Open pressure relief valve until reservoir jacket
is completely vented.
2. Remove BOTTOM COVER.
3. Place a large container under the kettle to catch
liquid that drains from kettle.
NOTE: If liquid drained from kettle is still clean, save
for reuse.
4. Remove component from bottom of kettle.
Fig. 18
5. Reverse procedure to install.
NOTE: Clean threads and apply pipe thread sealant
when replacing temperature sensor.
6. Refill jacket with fluid. See FILLING THE
RESERVOIR JACKET.
7. Remove air from reservoir jacket as outlined
under VENTING.
8. Check for proper operation.
PRESSURE SWITCH
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
1. Open pressure relief valve until reservoir jacket
is completely vented.
2. Remove BOTTOM COVER.
3. Disconnect lead wires from the pressure switch.
4. Place a large container under the kettle to catch
liquid that drains from kettle.
Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS
Page 11 of 33 F45472 Rev. D (0124)
NOTE: If liquid drained from kettle is still clean, save
for reuse.
5. Disconnect compression fitting from elbow near
the pressure switch.
6. Remove top nut on brass fitting to remove
pressure switch from mounting bracket.
7. Remove component from bottom of kettle.
Fig. 19
8. Reverse procedure to install.
NOTE: Pressure switch setting is fixed and should not
be adjusted. Clean threads and apply pipe thread
sealant when replacing pressure switch.
9. Refill jacket with fluid. See FILLING THE
RESERVOIR JACKET.
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. 20
4. Remove potentiometer from control panel.
5. Reverse procedure to install and check for proper
operation.
NOTE: When installing, ensure potentiometer
alignment tab is seated in positioning bracket.
Fig. 21
SWITCH ASSEMBLY
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
1. Remove CONTROL BOX COVER.
Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS
F45472 Rev. D (0124) Page 12 of 33
2. Note lead wire location and disconnect wires
from switch.
3. Press down on tabs to free switch from housing.
Fig. 22
4. Reverse procedure to install.
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. Note location of wiring and remove element,
pressure switch wires and unplug the sensor
plug.
Fig. 23
4. Remove the four bolts holding the gearbox to the
component box.
5. Lift the kettle just high enough to slide the
gearbox off of the shaft and clear the component
box lip.
NOTE: Be careful not to damage the wiring as you
remove gearbox from shaft.
6. Remove the positive stop plate assembly from
the old gearbox and install it on the new one.
Fig. 24
7. Install new gearbox in kettle.
8. Lower the gearbox until it touches component
box housing.
NOTE: Only lower the gearbox enough to align the
holes and bolt the gearbox down.
9. Lower the kettle and remove pallet jack.
10. Connect the wiring.
11. Check operation of kettle.
Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS
Page 13 of 33 F45472 Rev. D (0124)
TILT BEARING
Disconnect the electrical power to
the machine and follow lockout /
tagout procedures.
1. Place pallet jack under kettle.
NOTE: Make sure pallet jack is under kettle and not
under the tubular frame.
NOTE: Place 2x4 or 4x4s on the pallet jack if needed
to obtain the proper height.
2. Loosen set screws on bearing assembly.
Fig. 25
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.
Electric Stationary and Tilting Kettles - REMOVAL AND REPLACEMENT OF PARTS
F45472 Rev. D (0124) Page 14 of 33
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.
TEMPERATURE CONTROLLER
TEST
Fig. 26
1. Place kettle in full upright position. (tilt kettles
only)
2. Set temperature dial to lowest setting. Kettle
must be below 110°F before verifying the
potentiometer output to the controller is good
over the full range of temperature dial travel.
3. Access TEMPERATURE CONTROLLER.
4. Check all lead wires for secure connections to the
controller terminals. Wiring harness lead wires
must be connected to T1-T2 and T3-T4 for proper
input to controller.
5. Re-connect power to the machine.
6. Turn power switch on.
7. Verify temperature controller is receiving
120VAC at terminals T1-T3 and T2-T4 and
machine is properly grounded.
8. Slowly turn temperature dial to the highest setting
and monitor heat light over the full range of travel.
A. Verify heat light (amber) comes on and
heating element is energized.
B. If heat light does not remain on or flashes
momentarily as temperature setting is
slowly increased, verify condition of
potentiometer as outlined under
POTENTIOMETER TEST.
NOTE: Temperature controller will de-energize
internal relay and turn off the output status LED if the
circuitry detects an open thermocouple. LED will begin
to flash 3 times, pause, then repeat the flash sequence
to indicate the open thermocouple condition.
C. If heat light and heating element do not turn
on.
1) Verify condition of thermocouple as
outlined under THERMOCOUPLE
TEST.
2) Verify output from terminal T8 on
controller as outlined in the steps
below.
9. Disconnect lead wire from terminal T7 on the
controller.
A. Verify 120VAC between lead wire from T7
and X1 on the output of main transformer. If
correct, re-connect lead wire to terminal T7
and continue with procedure.
B. If incorrect, check pressure switch (1PS)
and water level controller (WLC LLCO).
10. Verify 120VAC between T8 and X1 on the output
of main transformer. If correct, output from
controller is functioning properly.
A. If incorrect, install a replacement
temperature controller and check for proper
operation.
Electric Stationary and Tilting Kettles - SERVICE PROCEDURES AND ADJUSTMENTS
Page 15 of 33 F45472 Rev. D (0124)
POTENTIOMETER TEST
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. Resistance should measure approximately
zero ohms.
5. Slowly turn potentiometer shaft clockwise over
the full range of travel and monitor resistance
change on the meter.
A. Resistance should measure 800 to 1200
ohms with shaft turned fully clockwise.
B. If the resistance value increased smoothly
without sudden drops or spikes and the full
travel resistance value is within tolerance
then potentiometer is functioning properly.
C. If the resistance value did not increase
smoothly but had drops or spikes over the
full travel range then potentiometer is not
functioning properly. Install a replacement
potentiometer and check for proper
operation.
THERMOCOUPLE TEST
Fig. 28
1. Access TEMPERATURE CONTROLLER.
2. Remove thermocouple lead wires from
temperature controller.
3. Check thermocouple for a measurable
resistance (approximately 5 to 10 ohms at room
temperature). If meter reads an overload (OL)
condition (open), or zero ohms (short) replace
the thermocouple and check temperature
controller for proper operation.
VENTING
NOTE: This procedure outlines venting the reservoir
jacket to remove air for proper heat transfer to the
kettle contents.
Electric Stationary and Tilting Kettles - SERVICE PROCEDURES AND ADJUSTMENTS
F45472 Rev. D (0124) Page 16 of 33
Fig. 29
1. With the kettle at room temperature, verify
pressure gauge is in the vacuum zone and
reading 25 to 30 in. Hg.
A. If vacuum is below minimum listed, air must
be removed from reservoir jacket. Continue
with procedure to vent as necessary.
2. Place kettle in full upright position.
3. Turn power switch on.
4. Set temperature dial to highest setting. Allow
kettle to heat until the heat indicator light turns off.
5. Open pressure relief valve for approximately 10
seconds.
6. Turn power switch off and allow kettle to cool
(room temperature).
7. Verify pressure gauge reading is within the
correct vacuum range.
A. If reading is below minimum listed or will not
maintain proper vacuum, check all threaded
fittings extending from the kettle couplings
(right and rear) for leaks and tightness.
1) Check pressure relief valve for leaks
from poor valve seating or built up
debris. Manually operate the valve
several times to reseat. Repeat venting
procedure.
2) If pressure relief valve is
malfunctioning, install a replacement
and check for proper operation.
HEATING ELEMENT
1. Access HEATING ELEMENT.
2. Measure voltage at heating element terminals
and verify it against the data plate voltage.
A. If voltage is incorrect, find the source of the
problem.
3. If voltage is correct, check current draw (amps)
through the heating element lead wires. If current
draw is correct then heating element is ok. See
table below for proper values.
NOTE: Checking current draw is the preferred
method over a resistance check when an amp clamp
meter is available.
A. If current draw is not correct then, replace
heating element.
4. Check for proper operation.
MODEL VOLTAGE KW PER ELEMENT
CURRENT PER
ELEMENT
RESISTANCE PER
ELEMENT (OHMS)
K20EL/K20ELT
208 4 19.2 10.8
240 16 22.2 10.8
480 12 14.4 19.2
K40EL/K40ELT
208 6 28.8 7.2
240 6 25.0 9.6
480 6 21.7 12.8
K60EL/K60ELT
208 8 38.5 5.4
240 8 33.3 7.2
480 8 28.9 6.0
Electric Stationary and Tilting Kettles - SERVICE PROCEDURES AND ADJUSTMENTS
Page 17 of 33 F45472 Rev. D (0124)
MODEL VOLTAGE KW PER ELEMENT
CURRENT PER
ELEMENT
RESISTANCE PER
ELEMENT (OHMS)
NOTE: Values in table are nominal. Tolerance is ±10 %.
KETTLE TILT ADJUSTMENT (TILT
MODELS ONLY)
NOTE: Perform this procedure whenever the kettle is
not returning to a horizontal position when upright, or
when kettle is not tilting past 90° to empty contents.
1. With kettle fully upright, the top of kettle should
be horizontal when viewed from either side.
2. Turn crank handle clockwise to tilt the kettle until
it stops. Kettle should be tilted past 90° to allow
contents to drain.
3. If adjustment is necessary, continue with
procedure.
4. Remove CONTROL BOX COVER.
5. Return kettle to fully upright position.
A. The inner jam nut should be in solid contact
with positive stop traveller.
B. To adjust upright position (horizontal):
1) Loosen outer jam nut 2 to 3 turns
counterclockwise and turn the inner
jam nut in the same direction and
amount.
2) Turn crank handle to position the top of
kettle horizontally.
3) Turn inner jam nut clockwise until it
stops against the positive stop
traveller. Tighten outer jam nut to
secure the stop position.
C. Turn crank handle to verify operation.
Repeat adjustment as necessary.
Kettle Fully Upright - Traveller Contacts Inner Jam
Nut
6. Fully tilt the kettle until crank handle stops.
A. Verify positive stop traveller is in solid
contact with stop plate.
B. To adjust fully tilted position:
1) Remove shoulder screw from stop
plate.
2) Remove tilt switch bracket from stop
plate.
Kettle Fully Tilted - Traveller Contacts Stop Plate
3) Turn crank handle clockwise to tilt the
kettle and empty its contents. Kettle
should be tilted approximately 95° to
100°.
Electric Stationary and Tilting Kettles - SERVICE PROCEDURES AND ADJUSTMENTS
F45472 Rev. D (0124) Page 18 of 33
4) Turn positive stop traveller on the
positive stop shaft (threaded) until it
contacts the stop plate.
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.
7. Install control panel cover.
Electric Stationary and Tilting Kettles - SERVICE PROCEDURES AND ADJUSTMENTS
Page 19 of 33 F45472 Rev. D (0124)
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. The ratio is 2:1, 2 parts distilled water,
1 part Heat Transfer Fluid.
Partial Refill
1. Place kettle in full upright position. (tilt kettle only)
Fig. 32
2. Turn power switch on. If low water light is on, continue with procedure.
3. Set temperature dial to lowest setting.
Pressure Relief Valve Exhaust. DO NOT connect to building water, gas, or steam supply. DO NOT block
or restrict.
Hot steam. The kettle and its parts are hot. Use care when operating, cleaning or servicing the kettle.
4. Open pressure relief valve until reservoir jacket is completely vented.
5. Remove 1/2" pipe plug from the reservoir jacket fill elbow at back of kettle. Open fill valve. (40 and 60 gallon
kettles only)
Electric Stationary and Tilting Kettles - SERVICE PROCEDURES AND ADJUSTMENTS
F45472 Rev. D (0124) Page 20 of 33
K40EL/K40ELT and K60EL/K60ELT
K20ELT, K20ELT
A. Insert funnel into the opening and slowly add a mixture of water and heat transfer fluid until low water light
turns off (LLCO probe is satisfied).
B. Set the thermostat and power switch to OFF position.
C. Continue adding a mixture of water and heat transfer fluid to bring fluid to the proper operating level per
the amount listed in the RESERVOIR JACKET VOLUME table below.
NOTE: Heat Transfer Fluid: Thermodyne 90395 GLYCOL, Heat Transfer Fluid, 1 gallon, available at
Parts Town or DOWFROST™ Propylene Glycol at ChemWorld.
6. Clean pipe plug threads and apply thread sealant. Install pipe plug and tighten to prevent leaks. Close fill valve.
(40 and 60 gallon kettles only)
7. Turn power switch on and verify low water light is off. If low water light is on, there may be a problem with the
water level control circuit. See TROUBLESHOOTING.
Electric Stationary and Tilting Kettles - SERVICE PROCEDURES AND ADJUSTMENTS
Page 21 of 33 F45472 Rev. D (0124)
8. Remove air from reservoir jacket as outlined under VENTING.
9. Check kettle for proper operation.
Model Water (Qt)
Heat Transfer
Fluid
Food Grade
Antifreeze (Qt)
Total (Qt)
Low Level
Light OFF
Light OFF
To Fill
K20EL /
K20ELT
8 4 12 9 quarts 3 quarts
K40EL /
K40ELT
12 6 18 10 quarts 8 quarts
K60EL /
K60ELT
14 7 21 12 quarts 9 quarts
Electric Stationary and Tilting Kettles - SERVICE PROCEDURES AND ADJUSTMENTS
F45472 Rev. D (0124) Page 22 of 33
Complete Draining and Refill
NOTE: Appearance of fluid will no longer be clear after usage in kettle.
Disconnect the electrical power to the machine and follow lockout / tagout procedures.
Pressure Relief Valve Exhaust. DO NOT connect to building water, gas, or steam supply. DO NOT block
or restrict.
Hot steam. The kettle and its parts are hot. Use care when operating, cleaning or servicing the kettle.
1. Disconnect power supply 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. Remove 1/2" pipe plug from reservoir jacket fill elbow (rear of kettle) to facilitate draining and provide opening
for re-fill. (Open fill valve on 40 and 60 gallon kettles)
NOTE: Clean threads and apply sealant before reinstalling pipe fittings.
7. Re-install water level probe.
8. To Refill.
A. Remove pressure gauge to allow reservoir jacket to vent during fill procedure.
B. Insert funnel into the reservoir jacket fill elbow. Slowly fill the jacket according to the volumes listed in the
RESERVOIR JACKET VOLUME table below.
9. Install pipe plug and pressure gauge. Tighten to prevent leaks.
10. Reapply power and turn power switch on and verify low water light is off. If low water light is on, there may be
a problem with the water level control circuit. See troubleshooting.
11. Remove air from reservoir jacket as outlined under VENTING.
12. Install covers.
13. Check kettle for proper operation and leaks.
RESERVOIR JACKET VOLUME
Model Total Fluid Volume (Qt) Water (Qt) Heat Transfer Fluid (Qt)
K20EL/K20ELT 12.0 8.0 4.0
K40EL/K40ELT 18.0 12.0 6.0
K60EL/K60ELT 21.0 14.0 7.0
Electric Stationary and Tilting Kettles - SERVICE PROCEDURES AND ADJUSTMENTS
Page 23 of 33 F45472 Rev. D (0124)
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.
Contactor (1CON)
Limiting ...............
Connects one side of heating element to power. Energized whenever WLC (LLCO) coil
is energized (WLC LLCO contacts closed).
Contactor (2CON)
Regulating ............
Connects heating element to power. On constantly when temperature controller is calling
for heat (temperature controller contacts closed).
Element, Heating ..... Heats reservoir jacket fluid. The heat in the fluid is then transferred to kettle.
Fuse, (1FU & 2FU) .... Slow blow 3A fuse. Located on primary side of main transformer (1T). Protects control
circuitry from over-currents.
Switch (1PAS),
Pressure ..............
Pressure cut-out protection for the reservoir jacket. Range is between 38 to 42 PSI.
Removes power from control circuit if pressure in the jacket rises above switch setting.
Transformer (1T),
Main ..................
Step down transformer from line voltage to 120VAC control circuit voltage.
Switch (1S), Power ... Controls 120VAC to kettle control circuit
Temperature
Controller .............
Cycles power to regulating contactor (2CON) to maintain the set point temperature. An
external set point potentiometer is used for temperature adjustments.
Lamp (1LT), Power ... Amber (AM) colored lamp. On when power switch is on.
Lamp (2LT), Low
Water .................
Red (RD) colored lamp. On when water level in the reservoir jacket drops below water
level (LLCO) probe or when kettle is tilted (tilting models only).
Lamp (3LT), Heat ..... Amber (AM) colored lamp. On when temperature controller is calling for heat.
Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION
F45472 Rev. D (0124) Page 24 of 33
COMPONENT LOCATION
STATIONARY KETTLE COMPONENTS
Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION
Page 25 of 33 F45472 Rev. D (0124)
TILTING KETTLE COMPONENTS
STATIONARY AND TILTING KETTLE BOTTOM COMPONENTS
WATER LEVEL CONTROL (WLC
LLCO)
The water level control provides low level cut-off
protection to shut off the heat source in case the fluid
level in the kettle reservoir jacket drops below the
WLC LLCO probe. A single low level cut-off probe
(LLCO) is connected to the control.
The water level control has input voltage of 120VAC
across terminals L1 and L2 which powers the primary
side of the transformer on the board. One side of the
Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION
F45472 Rev. D (0124) Page 26 of 33
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. When the kettle is in the full upright
position and the reservoir jacket fluid is at the proper
level, the fluid is in constant contact with the LLCO
probe and the circuit is completed.
When the power switch is turned ON, power is
supplied to the water level control. With the kettle in
the full upright position and the fluid level in the
reservoir jacket in contact with the LLCO probe, the
LLCO relay coil is energized. The LLCO relay contacts
WLC LLCO-NC open, WLC LLCO-NO close and the
LLCO LED turns on. When the kettle is tilted to empty
the contents, the fluid is no longer in contact with the
LLCO probe and the circuit is open. The LLCO relay
coil is de-energized and LLCO LED turns off.
Fig. 38
Fig. 39
SEQUENCE OF OPERATION
1. Conditions.
A. Kettle connected to correct voltage supply
and is properly grounded.
1) 120VAC potential across X2 and X1 on
secondary of main transformer.
B. Power switch and light (1LT) (amber) are
off.
C. Low water light (2LT) (red) is off.
D. Pressure switch (1PAS) contacts closed.
E. Temperature dial at lowest setting
(potentiometer fully CCW).
1) Internal relay contacts N.O. are open.
F. Kettle at room temperature and in the full
upright position.
2. Power switch turned ON.
A. Power light (1LT) (amber) comes on.
B. Power from secondary of main transformer
to control circuit thru pressure switch
(1PAS) N.C. contacts.
3. Water level control (WLC) energized.
A. WLC LLCO probe satisfied (fluid in kettle
reservoir jacket at proper level).
Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION
Page 27 of 33 F45472 Rev. D (0124)
1) LLCO LED comes on.
B. WLC LLCO N.C. contacts open. Low water
light (2LT) (red) remains off.
C. WLC LLCO N.O. contacts close.
1) Limiting contactor (1CON) energized
(power to one side of heating
elements).
2) Power to temperature controller.
4. Set the temperature dial to call for heat (warm/
simmer/boil).
A. 120VAC output from T8 on temperature
controller.
1) Heat light (3LT) (amber) comes on.
2) Regulating contactor (2CON)
energized and heating elements are
powered.
5. Kettle reaches set point temperature.
A. Voltage output removed from T8 on
temperature controller.
1) Heat light (3LT) (amber) goes out.
2) Regulating contactor (2CON) de-
energized and powered is removed
from heating elements.
6. Kettle heat cycles with the temperature
controller.
7. Kettle tilted to empty contents.
A. WLC LLCO probe no longer satisfied (fluid
in kettle reservoir jacket not in contact with
probe). Water level control (WLC) LLCO
relay de-energized.
1) LLCO LED turns off.
B. WLC (LLCO) N.C. contacts close and low
water light (2LT) (red) comes on.
C. WLC (LLCO) N.O. contacts open and power
is removed from heating circuit.
8. Kettle returned to upright position. Water level
control (WLC) circuit returns to normal operation
and heating cycle resumes. Kettle heating will
continue to cycle with the temperature controller
until the temperature dial is turned fully CCW or
power switch is turned OFF.
Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION
F45472 Rev. D (0124) Page 28 of 33
SCHEMATIC DIAGRAM
Fig. 40
Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION
Page 29 of 33 F45472 Rev. D (0124)
WIRING DIAGRAMS
Fig. 41
Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION
F45472 Rev. D (0124) Page 30 of 33
Fig. 42
Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION
Page 31 of 33 F45472 Rev. D (0124)
Fig. 43
Electric Stationary and Tilting Kettles - ELECTRICAL OPERATION
F45472 Rev. D (0124) Page 32 of 33
TROUBLESHOOTING
TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSES
Kettle does not heat, power light is lit, heat light is lit, low
water light is not lit.
1. Limiting contactor (1CON) malfunction.
2. Regulating contactor (2CON) malfunction.
3. Heating element malfunction.
Kettle does not heat, power light is lit, low water light is
lit, heat light is not lit.
1. Fluid level in reservoir jacket below water level
probe (LLCO).
2. Water level probe (LLCO) wiring connection
malfunction; or probe coated (not sensing fluid); or
probe malfunction.
3. Water level control malfunction.
Kettle does not heat, power light is lit, low water light is
not lit, heat light is not lit.
1. Pressure switch (1PAS) malfunction.
2. Temperature sensor malfunction; potentiometer
malfunction or temperature controller malfunction.
3. Interconnecting wiring malfunction.
Kettle does not heat, power light is not lit.
1. Main circuit breaker off; or control circuit fuse F1 or
F2 open.
2. Supply voltage incorrect.
3. Main transformer (1T) malfunction.
4. Power switch off or malfunction.
5. Interconnecting wiring malfunction.
Kettle heats up slow or will not boil product.
1. No vacuum in reservoir jacket when kettle is cold.
2. Supply voltage incorrect.
3. Heating element malfunction.
4. Temperature sensor malfunction; or potentiometer
malfunction; or temperature controller malfunction.
Electric Stationary and Tilting Kettles - TROUBLESHOOTING
Page 33 of 33 F45472 Rev. D (0124)
