Vulcan-Hart K20DL User's Manual
Contents
1. AY B 31 34 n F 7 K ace 44 y V E G SUBTRACT 1 7 H FOR 3 COMP VALVE JE MER lo oO I t TRUE MODEL WORKING 9 L CAPACITY 20 gallons 21 6 In 15 2 In 31 9 In 28 8 In 15 7 In 16 0 In 14 7 In 24 5 In 56 8 In 14 3 In 23 0 In K20DL roasts 212m orin fom rom wom sm oe om an etm wom DIRECT STEAM KETTLES Tilting Kettle Position the kettle in its final installed location to provide drainage directly below pour path with sufficient rear clearance from the wall to allow the kettle to tilt completely without obstruction 22 0 559 FOR 60 GAL ONLY FLOOL DRAIN FOR DRAW OFF VALVE AND POUR PATH E 1 ADD 2 FOR PLUG VALVE i E 52 132 KUY ADD 2 FOR OPEN POSITION a 12 0 305 SHOWN WITH OPTIONAL DRAW OFF VALVE AND SPRING ASSIST LID COVER N B DIM 132 91 335 1 230 DIM K DIM B DIM C 2 1 DL yc 1 DIM J E G h 1 A Pod H A DIM D DIM H TRUE MODEL WORKING 9 L CAPACITY 40 gallons 25 8 In 21 2 In 36 1 In 41 8 In2. v VULCAN INSTALLATION amp OPERATION MANUAL DIRECT STEAM 2 3 JACKETED STATIONARY AND TILTING KETTLES MODELS K20DL ML 136081 K40DL ML 136082 K60DL ML 136083 K20DLT ML 136086 K40DLT ML 136087 K60DLT ML 136088 For additional information on Vulcan Hart or to locate an authorized parts and service provider in your area visit our website at www vulcanequipment com VULCAN HART 3600 NORTH POINT BLVD DIVISION OF ITW FOOD EQUIPMENT GROUP LLC BALTIMORE MD 21222 WWW VULCANEQUIPMENT COM FORM 35459 May 2011 DIRECT STEAM KETTLES IMPORTANT FOR YOUR SAFETY THIS MANUAL HAS BEEN PREPARED FOR PERSONNEL QUALIFIED TO INSTALL PLUMBING AND MUST BE ABLE TO PERFORM THE INITIAL FIELD START UP AND ADJUSTMENTS OF THE EQUIPMENT COVERED BY THIS MANUAL A WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death Read the installation operating and maintenance instructions thoroughly before installing or servicing this equipment IN THE EVENT OF A POWER FAILURE DO NOT ATTEMPT TO OPERATE THIS DEVICE RETAIN THIS INSTRUCTION MANUAL FOR FUTURE REFERENCE DIRECT STEAM KETTLES CONTENTS NERA LEE 4 INS PAE TION id a ikea tlt mua MA reca STE 5 BACKING scooter eto cus Laos duse depot utbs obec aaah 5 Installation Codes and Standards sse eene nennen 5 LOCATON EET 6 Stationary Kettle
3. 24 0 In 17 7 In 12 8 In 7 5 In 18 6 In 65 8 In 12 1 In 30 3 In 12 1 In 60 gallons 29 5 In 23 9 In 38 1 In 45 7 In 26 8 In 19 7 In 15 6 In 10 9 In 19 8 In 72 3 In 14 9 In 33 0 In 13 8 In DIRECT STEAM KETTLES INSTALLATION PROCEDURE Make sure the kettle is in its final location before performing the installation procedure It may be necessary to increase the height of the kettle when leveling to clear the draw off valve on tilting kettles Use the adjustable flange feet to increase the height of the kettle 1 Place a spirit level on the rim of the kettle with the cover open Adjust the feet to level the kettle left to right and front to back Mark anchoring hole locations through the flanged feet then move the kettle out of the way With hole location marked drill holes for expansion plugs for appropriate sized lag bolts Reposition the kettle and verify that the kettle is level a A O N Bolt the kettle down and apply an NSF approved silicone sealant around the bolt heads and flange making contact with floor surface Wipe off excess sealant immediately STEAM SUPPLY CONNECTION The steam line plumbing diagram Fig 1 is a generic representation of the recommended steam supply PRESSURE REDUCING VALVE SHUT OFF STRAINER VALVE STEAM IN PRESSURE GAUGE STEAM IN TO KETTLE TO DRAIN STEAM TRAP ON DRIP LEG Fig 1 If the incoming steam pressure is greater than
4. information visit their web site at www nafem org Contrary to popular belief stainless steels ARE susceptible to rusting Corrosion on metals is everywhere It is recognized quickly on iron and steel as unsightly yellow orange rust Such metals are called active because they actively corrode in a natural environment when their atoms combine with oxygen to form rust Stainless steels are passive metals because they contain other metals like chromium nickel and manganese that stabilize the atoms 400 series stainless steels are called ferritic contain chromium and are magnetic 300 series stainless steels are called austenitic contain chromium and nickel and 200 series stainless also austenitic contains manganese nitrogen and carbon Austenitic types of stainless are not magnetic and generally provide greater resistance to corrosion than ferritic types With 12 30 percent chromium an invisible passive film covers the steel s surface acting as a shield against corrosion As long as the film is intact and not broken or contaminated the metal is passive and stain less If the passive film of stainless steel has been broken equipment starts to corrode At its end it rusts Enemies of Stainless Steel There are three basic things which can break down stainless steel s passivity layer and allow corrosion to occur 1 Mechanical abrasion 2 Deposits and water 3 Chlorides Mechanical abrasion means those things that will scratc
5. 6 Wash valve body and stem assembly with mild soap and water and then rinse Make sure all food residue is removed from inside valve body 7 Leave assembly apart to air dry TR Install draw off valve assembly Handle Bonnet Valve Stem Body 1 Apply PetroGel lubricant to valve stem j threads O ring rubber plug face and qu g O large hex nut threads 2 Thread the valve stem into bonnet till A cee Or Ring valve stem can be pulled through bonnet 3 Insert valve stem into valve body Fig 3 4 Install large hex nut hand tight 5 Install valve handle lock washer and wing nut onto the valve stem 6 Turn valve handle clockwise until closed Do not overtighten 13 DIRECT STEAM KETTLES PLUG VALVE CLEANING INSTRUCTIONS Daily After Use Remove draw off valve plug for cleaning Fig 4 1 Unscrew the retaining ring and remove it and the bottom washer 2 Pullthevalve plug straightup to remove from valve body 3 Wash valve body plug washer and retaining ring with mild soap and water and then rinse 4 Leave assembly apart to air dry Care should be taken not to scratch ding or dent the valve plug to prevent valve leakage If multiple kettles are in use care should be taken to keep each plug separate and returned to its original valve body Install draw off valve plug 1 Apply PetroGel lubricant to valve plug face 2 Holding the valve handle slide the plug down into the v
6. OM KETTLE TO DRAIN OR BOILER CONDENSATE RETURN CHECK VALVE Fig 2 INITIAL START UP Pour a small amount of water into the kettle Open the steam inlet valve When the water begins to boil inspect all of the fittings to ensure that there are no leaks Check the safety valve by pulling the ring far enough to allow steam to escape Let the valve snap back into place to reseat the valve so it will not leak Shut down the unit by closing the steam inlet valve Open the draw off valve to ensure that it functions from fully opened to fully closed position If it functions properly then the kettle is ready for use DIRECT STEAM KETTLES OPERATION AWARNING The kettle and its parts are hot Use care when operating cleaning or servicing the kettle Food products with milk or egg base should be placed into a cold kettle before cooking Avoid sudden contact of these food products to a hot kettle surface because they stick to the surface Verify that the draw off valve is closed Fill kettle with product to the desired level Slowly turn the steam control valve to the fully open position The water should boil in 3 to 4 minutes per gallon If it does not then check incoming pressure to determine that pressure is adequate to operate the kettle Regulate the steam control valve according to the desired temperature 10 DIRECT STEAM KETTLES STAINLESS STEEL EQUIPMENT CARE AND CLEANING Supplied courtesy of NAFEM For more
7. ON UNPACKING This kettle was inspected before leaving the factory The transportation company assumes full responsibility for safe delivery upon acceptance of the shipment Immediately after unpacking check for possible shipping damage If kettle damage is found save the packaging material and contact the carrier within 15 days of delivery Freight damage is not covered under Vulcan Warranty INSTALLATION CODES AND STANDARDS In the United States Vulcan kettles must be installed in accordance with 1 State and local codes 2 NFPA Standard NFPA 96 Vapor Removal from Cooking Equipment latest edition available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 DIRECT STEAM KETTLES LOCATION WARNING Plumbing connections must comply with applicable sanitary safety and plumbing codes Stationary Kettle Position the kettle in its final location Check that there are sufficient clearances for operating and servicing the kettle and proper clearance of the cover when raised The kettle draw off valve should be located near a floor drain f ADD 2 FOR PLUG VALVE ADD 1 FOR 3 COMPRESSION VALVE FLOOR DRAIN FOR DRAW OFF VALVE on 12 Bol ADD 2 FOR OPEN POSITION 2 VALVE 8 ADD 3 OR OPEN POSITION 3 VALVE
8. alve body 3 Install the bottom washer making sure to align the key with the groove in the valve plug Valve Plug Valve Body gt Bottom Washer emm Retaining Ring 4 Installtheretaining ring and hand tighten Fig 4 If the valve is hard to open then the ring has been overtightened 14 DIRECT STEAM KETTLES MAINTENANCE To obtain service and parts information concerning this unit contact the Vulcan Hart Service Agency in your area refer to listing supplied with the kettle or contact the Vulcan Hart Service Department at the address or phone number shown on the front cover of this manual Parts and service are also available at www vulcanequipment com TROUBLESHOOTING Possible Causes Suggested Corrective Action Unit not Heating Noisy crackling Pressure relief valve leaking steam Verify incoming steam supply valve is open and pressure reducing valve is open Blocked plugged steam trap of strainer Contact building maintenance or authorized service company Will not harm the kettle It is an indication that there is condensate in the steam supply line and a steam trap should be installed in the supply line before the kettle Turn kettle off and open drain valve on bottom of kettle to drain water out Close valve and turn on steam control valve Incoming steam supply too high or faulty pressure reli
9. c 6 ETEA E T EET 7 Installation 8 Steam Supply Connection ts eesis ra a eieaa Aa E anae nn nene nnne nnns 8 Initial Start Up cancel a E in edie et ieee ea eet 9 OPERATION Mm 10 STAINLESS STEEL EQUIPMENT CARE AND enn 11 ois Cp M 13 Compression Draw Off Valve Cleaning 13 Plug Valve Cleaning Iristr ctloris e Rt E RERO Rd eR rx e Pas REEL bue RS 14 au giz necp 15 Ne UT 15 TROUBLESHOOTING earan Seaan 15 DIRECT STEAM KETTLES INSTALLATION OPERATION AND MAINTENANCE OF KDL AND KDLT SERIES DIRECT STEAM KETTLES SAVE THESE INSTRUCTIONS FOR FUTURE USE GENERAL Vulcan direct steam 2 3 jacketed kettles are produced with quality workmanship and material Proper installation usage and maintenance will result in many years of satisfactory performance Itis suggested that you thoroughly read this entire manual and carefully follow all of the instructions provided Model K40DL Model K40DLT SHOWN WITH OPTIONAL 2 PLUG DRAW OFF SHOWN WITH OPTIONAL LID AND 2 PLUG DRAW OFF K20DL amp K20DLT K40DL amp K40DLT K60DL amp K60DLT DIRECT STEAM KETTLES INSTALLATI
10. ef valve Contact building maintenance or authorized service company 15 DIRECT STEAM KETTLES F 35459 May 2011 16 PRINTED IN U S A
11. h a steel surface Steel pads wire brushes and scrapers are prime examples Water comes out of the faucet in varying degrees of hardness Depending on what part of the country you live in you may have hard or soft water Hard water may leave spots and when heated leave deposits behind that if left to sit will break down the passive layer and rust stainless steel Other deposits from food preparation and service must be properly removed Chlorides are found nearly everywhere They are in water food and table salt One of the worst chloride perpetrators can come from household and industrial cleaners So what does all this mean Don t Despair Here are a few steps that can help prevent stainless steel rust 1 Use the proper tools When cleaning stainless steel products use non abrasive tools Soft cloths and plastic scouring pads will not harm steel s passive layer Stainless steel pads also can be used but the scrubbing motion must be in the direction of the manufacturers polishing marks 2 Clean with the polish lines Some stainless steel comes with visible polishing lines or grain When visible lines are present always scrub in a motion parallel to the lines When the grain cannot be seen play it safe and use a soft cloth or plastic scouring pad 3 Use alkaline alkaline chlorinated or non chloride containing cleaners While many traditional cleaners are loaded with chlorides the industry is providing an ever increasing choice
12. ing Soap ammonia Apply with soft cloth or sponge detergent Medallion Fingerprints and smears Arcal 20 Lac O Nu Ecoshine Provides barrier film Stubborn stains and Cameo Talc Zud Rub in direction of polish lines discoloration First Impression Grease and fatty acids Easy off DeGrease It Oven Aid Excellent removal blood burnt on foods on all finishes Grease and Oil Any good commercial Apply with soft cloth or sponge detergent Restoration Passivation Benefit Super Sheen Review 1 Stainless steels rust when passivity film shield breaks down as a result of scrapes scratches deposits and chlorides Stainless steel rust starts with pits and cracks Use the proper tools Do not use steel pads wire brushes or scrapers to clean stainless steel 4 Use non chlorinated cleaners at recommended concentrations Use only chloridefree cleaners Soften your water Use filters and softeners whenever possible Wipe off cleaning agent s and standing water as soon as possible Prolonged contact causes eventual problems To learn more about chloride stress corrosion and how to preventit contact the equipment manufacturer or cleaning materials supplier Developed by Packer Engineering Naperville IIl an independent testing laboratory 12 DIRECT STEAM KETTLES CLEANING AWARNING The kettle and its parts are hot Use care when operating cleaning or servicing the kettle The kettle interior and exter
13. ior should be thoroughly washed after each use when a different food is to be cooked next or when cooking is completed for the day If the unit is used continuously through the day it should be cleaned and sanitized once every 12 hours Empty the kettle Close draw off valve and add water to the kettle for cleaning to prevent residue from drying and sticking to the inside of the kettle Never use harsh or corrosive cleaning chemicals Never scrape the inside of the kettle with abrasive cleansers metal tools or steel scouring pads which will scratch the surface spoil the appearance and make it more difficultto thoroughly clean Add mild non chlorine non chloride and non bleach detergent and scrub the kettle interior with a nylon brush Loosen stuck on food by allowing it to soak at a low temperature setting Thoroughly rinse the interior and dry with a soft cloth Rinse the exterior and dry with a soft cloth COMPRESSION DRAW OFF VALVE CLEANING INSTRUCTIONS Daily After Use Remove draw off valve stem assembly for cleaning Fig 3 1 Turn the valve handle counterclockwise until it stops 2 Pull the valve handle back until it stops 3 Turn large hex nut counterclockwise until the valve stem assembly is loose 4 Pull the assembly straight out of the valve body 5 Remove wing nut and handle Unscrew valve stem from bonnet
14. kettle maximum operating pressure stamped on the nameplate install a pressure reducing valve not supplied on the line before the steam inlet to the kettle Connect steam supply line see chart pipe size to the kettle inlet fitting making sure there is a steam control valve strainer The steam supply line must be as large as the steam inlet fitting The relief valve on the kettle must not be closed off as it is set to relieve excess pressure in the kettle If the steam is heavy with condensate install a steam trap before the pressure regulator valve To ensure rapid heat up of heavy loads a ball float type steam trap is recommended Steam trap should be sized for flow rate and differential pressure The steam supply line must be sized to maintain pressure and flow see chart A steam line pressure gauge not supplied is recommended to determine the actual steam pressure being supplied to the kettle Install the steam shut off valve at a convenient location near the kettle on the incoming steam line DIRECT STEAM KETTLES Maximum Flow Rate of Dry Steam in Pounds per Hour Standard Pipe Size Chart values are based on 100 of clean iron pipe Steam losses due to elbows reductions heat loss or condensing steam were not considered Connect the kettle condensate return line Fig 2 to an open drain or to a boiler condensate return line Boiler condensate return lines must have a check valve not supplied STEAM STRAINER TRAP FR
15. of non chloride cleaners If you are not sure of chloride content in the cleaner used contact your cleaner supplier If your present cleaner contains chlorides ask your supplier ifthey have an alternative Avoid cleaners containing quaternary salts it also can attack stainless steel and cause pitting and rusting 11 DIRECT STEAM KETTLES 4 Treat your water Though this is not always practical softening hard water can do much to reduce deposits There are certain filters that can be installed to remove distasteful and corrosive elements To insure proper water treatment call a treatment specialist 5 Keep your food equipment clean Use alkaline alkaline chlorinated or non chloride cleaners at recommended strength Clean frequently to avoid build up of hard stubborn stains If you boil water in stainless steel equipment remember the single most likely cause of damage is chlorides in the water Heating cleaners that contain chlorides have a similar effect 6 Rinse rinse rinse If chlorinated cleaners are used rinse and wipe equipment and supplies dry immediately The sooner you wipe off standing water especially when it contains cleaning agents the better After wiping equipment down allow itto air dry oxygen helps maintain the stainless steel s passivity film 7 gt Never use hydrochloric acid muriatic acid on stainless steel 8 Regularly restore passivate stainless steel Job Cleaning Agent Routine clean
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