Blodgett KLT-DS User's Manual
Contents
1. Oa BLODGETT KLT DS and KPT DS Series DIRECT STEAM TRI LEG TILTING KETTLE AND DIRECT STEAM PEDESTAL TILTING KETTLE INSTALLATION OPERATION MAINTENANCE BLODGETT OVEN COMPANY www blodgett com 44 Lakeside Avenue Burlington Vermont 05401 USA Telephone 800 331 5842 802 860 3700 Fax 802 864 0183 500057 Rev 6 06 IMPORTANT NOTES FOR INSTALLATION AND OPERATION It is recommended that this manual be read thoroughly and that all instructions be followed carefully This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death WARNING Improper installation operation adjustment alteration service or maintenance can cause property damage injury or death Read the installation operating and maintenance instructions thoroughly before installing operating or servicing this equipment Intended for commercial use only Not for household use NOTICE Contact the factory the factory representative or local service company to perform maintenance and repairs This manual should be retained for future reference TABLE OF CONTENTS DESCRIPTION PAGE INSTALLATION AND SERVICE CONNECTIONS KLT DS _ 4 INSTALLATION AND SERVICE CONNECTIO2. To remove grease and food splatters or condensed vapours that have baked on the equipment apply cleanser to a damp cloth or sponge and rub cleanser on the metal in the direction of the polishing lines Rubbing cleanser as gently as possible in the direction of the polished lines will not mar the finish of the stainless steel NEVER RUB WITH A CIRCULAR MOTION Soil and burn deposits which do not respond to the above procedure can usually be removed by rubbing the surface with SCOTCH BRITE scouring pads or STAINLESS scouring pads DO NOT USE ORDINARY STEEL WOOL as any particles left on the surface will rust and further spoil the appearance of the finish NEVER USE A WIRE BRUSH STEEL SCOURING PADS EXCEPT STAINLESS SCRAPER FILE OR OTHER STEEL TOOLS Surfaces which are marred collect dirt more rapidly and become more difficult to clean Marring also increases the possibility of corrosive attack Refinishing may then be required TO REMOVE HEAT TINT Darkened areas sometimes appear on stainless steel surfaces where the area has been subjected to excessive heat These darkened areas are caused by thickening of the protective surface of the stainless steel and is not harmful Heat tint can normally be removed by the foregoing but tint which does not respond to this procedure calls for a vigorous scouring in the direction of the polish lines using SCOTCH BRITE scouring pads or a STAINLESS scouring pad in combination with a powdered cleanser Heat ti
3. 19 52 975 205 76 20 5 12 25 11 75 303 litres mm 1181 524 657 1483 1321 248 521 1930 521 311 298 SAFETY RELIEF VALVE so STEAM TRAP AND STRAINER OPTIONAL JACKET DRAIN OPTIONAL VALVE 0 4 SPRING ASSIST HINGED COVER DIMENSIONS ARE IN INCHES MM VIEW 2 or 3 TANGENT DRAW OFF VALVE OPTIONAL POUR PATH ff fi 7 38 187 4 102 gt t 4X 7 16 11 EQ SPACED ON 16 62 422 B C 20 TO 60 GALLONS ON 19 62 498 B C 80 GALLONS 4 6 25 159 FAUCET OPTIONAL 1 0 10 11 12 INSTALLATION INSTRUCTIONS Select a location to provide drainage for kettle pour path when tilted and for draw off valve if so equipped Mark hole locations through flanged adjustable feet on KLT DS models and through pedestal base on KPT DS models Remove kettle On hole locations marked drill holes and insert expansion shields to accommodate 5 16 size lag bolts Reposition kettle On KLT DS models level kettle by making necessary adjustment on flanged foot Bolt down kettle and seal with Silastic or other equivalent sealing compound Sealant must be applied not only to bolt heads but also around flanges or pedestal base making contact with floor surface to fulfil NSF requirements Connect steam line 3 4 pipe size to the kettle making sure there is a steam control valve strainer fairly convenient
4. D 5 13 130 OPENED 6 88 175 FLANGED FOOT DETAIL 3 VALVE 4 EQUALLY SPACED CLOSED 7 88 200 07 16 11mm HOLES OPENED 10 13 257 ON 3 76 B C SPRING ASSISTED COVER OPTIONAL FAUCET OPTIONAL a M 2 or 3 TANGENT DRAW OFF VALVE OPTIONAL JACKET DRAIN VALVE H SERVICE CONNECTIONS KPT DS 6 CONDENSATE RETURN gt IPS 13mm lt STEAM SUPPLY 3 4 IPS 19MM 35 psi 2 4 KG CM DIMENSIONS MODEL CAPACITY UNITS B H 2 3 2005 20 91005 inches 21 18 27 34 75 1475 20 13 5 41 1525 205 59 5 175 16 25 16 25 76 litres mm 535 460 940 883 375 508 343 1041 387 521 1511 445 425 413 3005 30 gallons inches 24 20 37 37 75 16 25 215 14 1325 20 625 175 14 75 14 25 114 litres mm 959 413 546 356 1092 337 508 1587 445 375 362 KPT 40pg 40 gallons inches 39 75 17 25 25 15 5 45 1075 185 64 17 5 12 25 11 75 152 litres mm 1010 438 572 304 1143 273 470 1626 445 311 298 60 5 60 gallons inches 43 18 87 24 13 17 5 48 10 25 1925 74 17 5 14 25 13 75 227 litres mm 1092 479 613 445 1219 260 489 1879 445 362 349 8005 80 gallons inches 46 5 20 63 25 88
5. NS KPT DS 5 1 0 INSTALLATION INSTRUCTIONS 6 2 0 INTRODUCTION 5 7 3 0 BASICFUNGC TIONING nosiris anaa 7 4 0 OPERATING INSTRUCTIONS a a 8 2 0 CLEANING INSTRUCTIONS 8 6 0 TROUBLESHOOTING MAINTENANCE 11 SERVICE CONNECTIONS KLT DS lt STEAM SUPPLY 3 4 IPS 5 30 PSI 34 205 kPa OPTIONAL 5 45 PSI 34 310 KPa 10 HOT WATER 3 8 TUBING TO FAUCET OPTIONAL amp CONDENSATE RETURN 1 2 5 COLD WATER 3 8 O D TUBING TO FAUCET OPTIONAL DIMENSIONS MODEL CAPACITY _ UNITS A B D E F 2 3 2 1 59 K L KLT 20DS 20 gal ons nches 76 litres mm 30 gal inches KLT 30D8 144 litres mm 40 gal inches es 152 litres mm 6005 60 gal ons 227 litres mm 80 gallons 8005 303 litres mm 100 gallons KLT 100DS litres mm Pressure reducing valve is required if incoming pressure exceeds 50 PSI 345 kPa DIMENSIONS ARE IN INCHES MM NOTE 60 80 amp 100 gallon kettles are supplied with 2 rear support legs L SAFETY RELIEF VALVE j ys STRAINER AND STEAM TRAP OPTIONAL 1 63 41 2 VALVE CLOSE
6. angent draw off valve turn the large hex nut on the draw off valve counterclockwise until it is completely disengaged from the threads Grasp the valve knob and slowly pull out the valve stem Wash the valve stem disk and handle Insert a nylon brush wet with detergent and water into the valve body and tangent draw off tube Brush vigorously 2 Replace the valve stem assembly and turn the hex nut until snug Rinse the kettle with clean warm water 3 Leave the draw off valve open when the kettle is not in use DAIRY DRAW OFF VALVE CLEANING 1 Remove the plug by first removing the handle then turn the plug to line up with the pin and pull with both hands It is important to use both hands because the plug is heavy 2 Put the plug in a plastic pail that contains a mild soap solution A plastic pail works best as it reduces the possibility of nicking or scratching the plug If the plug gets scratched it may not seal correctly and could leak 3 Use a soft cloth or soft brush and clean all surfaces 4 Using both hands remove the valve from the soap and rinse well in another plastic pail that contains fresh water 5 Wash out the kettle as normal 6 Return the plug into the body Be sure the plug is inserted into the notch and turned Ensure the plug is tight and secure before letting go of it If you are cleaning a body and plug assembly remove the plug and follow the above procedures when finished with the plug follow the same
7. instructions for washing the body Always use both hands when handling the plugs Reassemble the plug into the body and use as normal WHAT TO DO IF SURFACE RUST APPEARS Metal utensils should never be used as they will scratch the surface of the equipment and rust may begin to form To remove surface accumulation of rust from the inadvertent use of such utensils the following procedure may be used CAUTION Improper use of this procedure may damage your appliance 1 Use undiluted white vinegar with a non abrasive scouring pad plastic or cloth on the affected area to remove the rust stain The appliance should not be heated and remain at room temperature during the entire cleaning process 2 If the stain resists removal additional exposure time with vinegar may be required to a maximum of one hour 3 Thoroughly wash all of the vinegar away with fresh clear water Dry the surface completely and allow one hour before using the appliance to cook Following daily and period maintenance procedures will prolong the life for your equipment Climatic conditions salt air may require more thorough and frequent cleaning or the life of the equipment could be adversely affected STAINLESS STEEL To remove normal dirt grease or product residue from stainless steel use ordinary soap and water with or without detergent applied with a sponge or cloth Dry thoroughly with a clean cloth Never use vinegar or any other corrosive cleaner
8. nt action may be lessened by not applying or by reducing heat to equipment during slack periods All food contact surfaces must be thoroughly drained and flushed prior to cooking in the kettle CONTROL PANEL The textured control panel should be cleaned with warm water and mild soap Never use an abrasive cloth or steel wool Never use cleaning solvents with a hydrocarbon base 6 0 TROUBLESHOOTING MAINTENANCE 6 1 PREVENTIVE MAINTENANCE No preventive maintenance is required other than adhering to the Cleaning Procedure instructions 6 2 DRAW OFF VALVE LEAKS If a leak occurs through the valve steam replace the ring If the leak can be attributed to faulty sealing occurring between the stem disc and valve seat then quite often this problem can be corrected by cleaning off the dried on food residue with an extremely fine emery cloth or the rubber vulcanized stem piece has been damaged and must be replaced NOTICE Draw off valve has a vulcanized rubber coated stem for better sealing Do not over tighten This may cause the rubber to pull away from stem and permanently damage it 6 3 EXTREMELY SLOW COOKING TIME If the cooking time is abnormally slow then the difficulty may be due to insufficient steam pressure and or volume First determine that pressure on incoming steam line at kettle is within 5 p s i of rated kettle pressure Note that pressures approaching the rated kettle pressure are liable to set off the safety relief
9. roduct from the kettle bowl 3 0 BASIC FUNCTIONING 3 1 CAPACITIES All model names contain either 20 30 40 60 80 or 100 to indicate the capacity of that kettle in U S gallons Thus a KLT 40DS is a two thirds jacketed direct steam kettle mounted on legs with a capacity of 40 gallons 0 5 3 2 FUNCTIONING MODE Blodgett direct connected steam jacketed kettles consist of a stainless steel bowl and a stainless steel jacket which envelopes two thirds of the lower surface of the bowl thus forming a sealed pressure vessel chamber into which steam is introduced by means of a manual control valve The kettle bowl is the container for the food product which ideally should be of a liquid or semi liquid consistency to achieve complete contact with the bowl surface and thus fully absorb the heat transmitted through the surface The temperature required for the cooking process to function adequately must be greater than the boiling point of the liquid food product ie water Further the greater the steam pressure used the higher the temperature and consequently the quicker the cooking process For example steam pressurized at 30 p s i attains a temperature of 274 degrees Fahrenheit 135 degrees Celsius 4 0 OPERATING INSTRUCTIONS 1 If kettle has draw off valve close it 2 Fill kettle with product to desired level 3 Slowly turn the steam control valve ON to full open position counter clockwise 4 The water or food
10. s a large amount of water The condensate water must be removed from the kettle jacket in order for the kettle to function adequately The ball valve located at the base of the kettle jacket may be opened to remove the water It may be necessary to repeat this procedure several times depending on the number of batches being cooked as each batch will create condensate If the kettle appears to be slow in heating this would indicate that there is water in the jacket Open ball valve and drain Close valve and commence operation of kettle
11. should boil 2 to 3 gallons per minute If it does not then incoming pressure and piping should be checked to determine that it is adequate to operate the kettle efficiently 5 Regulate steam control valve depending on type of food being prepared 6 When food is cooked turn off steam remove food and clean kettle immediately to prevent residue from drying on kettle bowl surface 5 0 CLEANING INSTRUCTIONS CAUTION Do not use cleaning agents that are corrosive CAUTION The equipment and its parts are hot Use care when operating cleaning and servicing Your kettle should be cleaned immediately after each use or when cooking a different product Before cleaning check that the kettle has cooled enough to touch it 1 Rinse the inside of the kettle thoroughly and drain to remove any food particles 2 Using a nylon brush clean the kettle with a mild detergent and water Never use steel wool or scouring powder as it will scratch stainless steel Plain steel wool can leave small pieces of steel which can rust 3 Rinse the inside of the kettle thoroughly with clean water Drain the kettle by tilting or using the optional tangent draw off valve to allow the detergent and water solution to drain 4 Wipe the exterior of the kettle with a clean damp cloth WARNING If your are cleaning a valve that is assembled to a kettle be sure the kettle is completely empty of any product DRAW OFF VALVE CLEANING 1 If equipped with a t
12. to the kettle Connect kettle condensate return line to a drain or to a boiler return line Each kettle return line must have a suitable steam trap Boiler return lines must have a check valve Safety relief valve on kettle must not be plugged as it is set to relieve excess pressure in the kettle If incoming steam pressure is greater than kettle maximum operation pressure then a pressure reducing valve must be installed in the line If large amounts of water accumulate in the steam line it will be necessary to install one or more ball float traps in the line to eliminate the water A steam line pressure gauge is also recommended to determine the actual amount of steam coming to the kettle Check for proper operation INTRODUCTION 2 0 DESCRIPTION All Blodgett direct connected steam jacketed kettles pertaining to this manual are direct steam operated pressure vessels of a double wall stainless steel construction forming a steam chamber jacket enveloping the lower two thirds of the kettle bowl surface All kettles are tilting floor mounted in fixed positions either on legs with adjustable flanged feet KLT DS models or pedestals KPT DS models All kettles are equipped with a drain cock safety relief valve and steam control valve Options on kettles are hinged spring assisted stainless steel lid covering the kettle bowl opening and a sanitary stainless steel tangent draw off valve as an alternate method for the removal of the food p
13. valve If required pressure is available to kettle then possibly volume of steam is not sufficient Minimum 3 4 pipe size is required to the kettle but if the steam generating source is at a great distance from the kettle larger pipe will be required Finally the core of the steam supply pipe may have debris or scalants that impede steam flow and will require disassembly and inspection 6 4 AIR VENTING It is recommended that the optional steam trap assembly be installed This should be plumbed to the exit end of the kettle The thermostatic trap is a mechanical device that closes on high temperature and opens when the temperature drops allowing the water which formed from condensate to exhaust but retain the steam under pressure The temperatures required for the cooking process to function adequately must be greater than the boiling point of the liquid food product that is water The greater the steam pressure used the higher the temperature and the quicker the cooking process For example steam pressurized at 30 p s i reaches a temperature of 274 degrees Fahrenheit 135 degrees Celsius Since air is an unsuitable media through which heat may be transferred the air should be exhausted from the jacket by opening the pressure relief valve until the air has been completely replaced by pressurized steam In the initial stages of the cooking process when the steam comes in contact with the cold kettle bowl surface it condenses and form
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