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CUSTOM
™
PASTA
SYSTEM
GAS
SERVICE
MANUAL
KEEP THIS MANUAL FOR TRAINING NEW PERSONNEL
1-800-KEATING
www.keatingofchicago.com
Gas Pasta 0107 9/07
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NOTICE This operating, installation, and service manual should be given to the user. The operator of the Pasta System should be familiar with the functions and operation of the cooker. This manual must be kept in a prominent, easily reachable location near the Pasta System. POST THIS LABEL IN A PROMINENT LOCATION ON YOUR UNIT IMPORTANT IN THE EVENT A GAS ODOR IS DETECTED, SHUT DOWN UNITS AT MAIN SHUT OFF VALVE AND CONTACT THE LOCAL GAS COMPANY OR GAS SUPPLIER FOR SERVICE. WARNING FOR YOUR SAFET
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TABLE OF CONTENTS SECTION I INTRODUCTION SECTION IV MAINTENANCE General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Warranty Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . .1 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . .9 Model Variations . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
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MODEL VARIATIONS I INTRODUCTION Basket-Lift Model: Basket-Lift Model Pasta Systems come with all the same features as the standard models. The Basket-Lift mechanism lowers the baskets of food into the water when the timer button is pressed GENERAL and raises the baskets when the cooking cycle is Keating Pasta Gas Systems are designed to give complete. Split baskets are required for these models. maximum production efficiency, delivering high quality food products. The following design feature
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You must maintain this appliance free and clear Installed in accordance with all local codes, or in from combustibles. the absence of local codes, with the current National Fuel Gas Code A223.1/NFPA54, Natural You must maintain the following minimum Gas Installation CAN/CGA-B149.1 or Propane clearances from combustible and noncombustible Installation Code CAN/CGA-B149.2. construction: Installed under a properly designed operating CLEARANCES exhaust hood. Combustible Non-Combustible Const
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WARNING INSTALLATION Installation must conform with local codes or, in IF NOT INSTALLED, OPERATED AND MAINTAINED absence of local codes, with the current National Fuel IN ACCORDANCE WITH THE MANUFACTURER’S Gas Code Z223.1/NFPA 54, Natural Gas Installation INSTRUCTIONS, THIS PRODUCT COULD EXPOSE CAN/CGA - B149.1 or Propane Installation Code YOU TO SUBSTANCES IN FUEL OR IN FUEL CAN/CGA-B149.2. COMBUSTION WHICH CAN CAUSE DEATH OR SERIOUS ILLNESS AND WHICH ARE KNOWN TO POSITIONING THE STATE OF CALI
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Figure 2-1 NOTE: Roughly half of all service calls result from inadequate gas supply. Do not use pipe sizes smaller than recommended in the table above. GAS CONNECTION WARNING HAVE YOUR PLUMBER OR GAS COMPANY CHECK FOR LEAKS. PIPE JOINT COMPOUNDS RESISTANT TO PROPANE GASES MUST BE USED. BEFORE OPERATING THIS PASTA SYSTEM, CHECK PIPE JOINTS FOR LEAKS BY USING A Caster SOAP AND WATER SOLUTION OR SNIFFER ONLY. DO NOT USE AN OPEN FLAME! RESTRAINING Figure 2-3 DEVICES Main Gas and Water S
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3 A /4" IPS manual gas valve is shipped with each single NOTE: It is estimated that half of all service calls Pasta System for field installation. Batteries have a made on Keating Pasta Gas Systems result from an factory installed manual gas valve for each Pasta inadequate gas supply. During installation, have a gas System. The required gas pressure for proper operation company representative make certain that the Pasta of each Pasta System is 4" water column (WC) for natural System is receivi
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Constructional changes to the area where the Pasta DEPARTMENT TO DETERMINE IF THIS IS System is installed shall not affect the air supply to the NECESSARY IN YOUR SPECIFIC AREA. Pasta System. The installation, start-up and changes required when changing from one gas type to another can be performed only by a certified professional. III OPERATING The Pasta System is intended only for commercial use and is to be operated only by professionals. It is required that the Pasta System is regularly insp
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2. Turn “On” main power On/Off switch (located SPLASHING HOT WATER FROM PASTA between the amber and green indicating lights). SYSTEM VESSEL. 3. Light the constant pilot (located next to left burner as NEVER LIFT BASKETS DIRECTLY OUT OF THE you face it). If your Pasta System has an optional PASTA SYSTEM VESSEL WITHOUT DRAINING spark ignitor, omit this step. AS SEVERE INJURY MAY RESULT. 4. Activate pilot light momentary switch (let top corner) NOTE: For counter model Pasta Systems, always and
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1. Turn off Pasta System and open the door. 6. Once boil has been reached, turn Pasta System off. Figure 3-3 7. Dissolve 3 cups of vinegar for every five gallons of water and let soak for one hour. If there is a large Drain, drain valve and overflow tubing build-up of scale, allow Pasta System to soak Over flow overnight. tubing 8. While soaking, a natural fiber brush may be used to scrub the tubes and inside walls of Pasta System vessel. 9. Drain the water and vinegar. 10. Spread Keating Klenz
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B. How to program the “Keating” Electronic Timer ELECTRONIC TIMER OPERATING INSTRUCTIONS PART # 056921 DIGITAL TIMERS The electronic timers, standard on pasta cookers, provide a clearly visible and accurate display and are very easy to use. PROGRAMMING The Keating Electronic Timer is programmable to To program the timers, the unit must be in the idle mode. four different timer ranges with two different alarm Press and hold the set button for approximately two modes for each time range. secon
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(at 1-800-KEATING) before calling a local service company 1. Set thermostat to 212°F(190°C). 2. Allow Pasta System to cycle three times. PREVENTIVE 3. Place an accurate thermometer in the water. MAINTENANCE Preventive maintenance should be done in daily, Figure 4-1: Thermometer in water weekly, monthly and yearly intervals as necessary. Following preventive maintenance procedures will help keep your Pasta System working efficiently. Proper care and servicing will lead to years of quality perfor
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auto-fill system. The water level is controlled by two circuit boards and two sensors. The sensors are located in the tube on the right side of the overflow deck. The upper sensor controls the water level and the lower sensor controls the low water safety shut-off system. Once the water On/Off switch is turned on, the blue light will come on and start to fill until the water level reaches the upper sensor. The burners will not come on until the water level reaches the lower sensor, preventing th
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PROBLEM PROBABLE CAUSE SOLUTION Constant pilot won’t a.Gas isn't turned on. a.Turn manual gas valve on. If using light. flexible connector with quick disconnect, make sure quick disconnect is completely engaged. b.Clogged constant pilot tubing. b.Turn Custom Pasta System and manual gas valve off. Clean tubing. c.Constant pilot valve isn't turned on. c.Turn constant pilot valve on and adjust pilot flame height. Runner pilot tube a.Gas isn't turned on. a.Turn manual gas valve on. If using won't li
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PROBLEM PROBABLE CAUSE SOLUTION Flames come out a.Burners misaligned. a.Adjust position of burners. front. b.Exhaust problems. b.Install deflector to block down draft. Install or adjust flue restrictors. If problem persists, contact your HVAC representative. c.Radiants have slipped forward. c.Reposition radiants. d.Flue blockage. d.Turn Custom Pasta System and manual gas valve off. Let flue cool and remove foreign objects. Custom Pasta a.Baskets overfilled. a.Don’t overfill baskets. System has p
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PROBLEM SOLUTIONS (Follow Sequentially) Water always filling. a.Clean sensors thoroughly with brush and vinegar. b.Adjust the sensitivity of the B Board (for the top sensor) fully clockwise. c.If filling persists, ground out the top sensor (if filling stops, replace sensor – Part #010212). d.If filling persists after grounding out the sensor, replace the B Board (Part #001166) Water never fills. a.Turn water switch (far right) ‘ON.’ b.Clean sensors thoroughly with brush and vinegar. c.Adjust the
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REPLACEMENT OF A AND B BOARDS 1. Locate the wiring diagram. it will help later with connecting wires to the board. 2. Disconnect wires from the board. 3. Unscrew mounting screws. There are three of them per board. 4. Replace the board. 5. Reconnect the wires. 6. Adjust sensitivity. 7. Close the box. 8. Seal the box using silicone and filling all openings and gaps if the box is made out of aluminized material. Rubber sealed box does not need to be sealed. 15
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V SERVICE DIAGNOSIS The burners when on will produce clear blue flames directed at the inside walls of the heat transfer tubes. The radiant’s fins, located towards the rear of each transfer tube, will glow bright red, helping to ensure optimum heat distribution into the Pasta System vessel. All radiants should be pushed to the rear and then pulled gently forward (until their retaining clips engage the rear of the tubes) for optimum heat distribution. 3 1 On constant pilot models, the pilot l
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™ MANUAL FILL CUSTOM PASTA SYSTEM CONTROL PANEL WITH DIGITAL TIMERS ITEM DESCRIPTION QUANTITY PART NUMBER 1 TOGGLE SWITCH - PILOT ON 1 004507 2 INDICATING LIGHT, AMBER - PILOT ON 1 031624 3 TOGGLE SWITCH – MAIN ON-OFF 1 004501 4 INDICATING LIGHT, GREEN - SECONDARY BURNER ON 1 009375 5 UNUSED 3 ------ 6 DIGITAL TIMER(S) 2 056921 7 THERMOSTAT 2 031466 8 DIAL PLATE 2 034975 9 THERMOSTAT KNOB 2 004163 10 FLAME SWITCH (NOT SHOWN) 1 037406 11 LOW WATER SAFETY CONTROL “A” BOARD (NOT SHOWN) 1 001167 12
