Blodgett KLS-DS User's Manual
Contents
1. BLODGETT KLS DS and KPS DS Series DIRECT STEAM TRI LEG STATIONARY KETTLE AND DIRECT STEAM PEDESTAL STATIONARY 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 500055 Rev B 10 04 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 This manual should be retained for future reference TABLE OF CONTENTS DESCRIPTION 1 0 Installation and Service Connections 2 0 Installation Instructions 3 0 Introduction 4 0 Operating Instructions 5 0 Cleaning Procedures 6 0 Troubleshooting Maintenance PAGE 12 1 0 SERVICE CONNECTIONS KLS DS CS Steam supply 3 4 IPS Condensate return 1 2 IPS2. DIMENSIONS MODEL CAPACITY A B C D F 2 F 3 G2 G 3 H J K KLS 20DS 20 U S gal inches 21 18 37 2275 16 12 75 14 17 16 5 25 88 5975 17 5 76 litres mm 533 457 940 578 406 324 356 432 419 657 1518 445 KLS 30DS 30 U S gal inches 24 20 37 25 80 17 5 135 15 25 15 14 5 26 88 6288 20 5 114 litres mm 610 508 940 657 445 343 387 381 368 683 1597 521 KLS 40DS 40 U S gal inches 26 22 5 37 2788 18 5 1425 16 5 12 5 12 23 88 6488 225 152 litres mm 660 572 940 708 470 362 419 318 305 606 1648 572 KLS 60DS 60 U S gal inches 29 5 26 40 5 13138 1775 155 11725 125 12 24 69 7288 25 75 227 litres mm 749 660 1029 797 451 394 438 318 305 627 1851 654 KLS 80DS 80 U S gal inches 33 28 425 134 75 19 5 175 1925 10 5 10 23 88 7525 29 25 303 litres mm 838 711 1080 883 495 445 489 267 254 606 1911 743 KLS 100Dpg 100 U S gal inches 35 5 30 445 3725 20 75 17 19 25 12 5 12 26 60 8175 3175 379 litres mm 902 762 1130 946 527 432 489 318 305 676 2076 806 Pressure reducing valve is required if incoming pressure exceeds 50 PSI 345 kPa DIMENSIONS ARE IN INCHES MM ie WALL 120 TYP SAFETY RELIEF VALVE FLANGED FOOT DETAIL 4 EQUALLY SPACED 2 VALVE Er lt FRONT 7116 11mm HOLES CLOSED 5 13 130 ON 3 76 B C OPENED 6 88 175 3 VALVE CLOSED 7 88 200 4 OPENED 10 13
3. 2 0 INSTALLATION INSTRUCTIONS 10 11 12 13 Select a location to provide drainage directly below the tangent Draw off Valve Mark hole locations through flanged adjustable feet on KLS DS models and through pedestal base on KPS DS models Remove kettle On hole locations marked drill holes and insert expansion shields to accommodate 5 16 size lag bolts Reposition kettle On KLS 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 fulfill NSF requirements Install a steam control valve at a convenient location near kettle on the incoming steam line 3 4 size pipe Connect steam line to the kettle making sure there is a steam control valve strainer fairly convenient 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 operating 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
4. 257 3 5 89 SPRING ASSIST HINGES ON 60 80 AND 100 GALLON KETTLES i OPTIONAL FAUCET 2 4 2 ON SPRING ALLOW DIMENSION D dn ASSIST HINGES ADDITIONAL 6 152 7 ON YOKE TYPE HINGES STANDARD ON 20 40 GALLON KETTLES SERVICE CONNECTIONS KPS DS CONDENSATE RETURN 1 2 IPS CS STEAM SUPPLY 3 4 IPS 5 30 psi 34 205 kPa Optional 5 45 psi 34 310 kPa DIMENSIONS MODEL CAPACITY A 20 gallons inches 21 KPS 20DS Pri ids E 30 gallons inches 24 ie 114 litres mm 610 KPS 40DS 40 gallons inches 26 152 litres mm 660 KPS 60DS 60 gallons inches 29 5 227 litres mm 749 KPS 80DS 80 gallons inches 33 303 litres mm 838 5 10008 100 gallons inches 35 5 379 litres mm 902 Pressure reducing valve is required if incoming pressure exceeds 50 PSI 345 kPa 45 WALL 1 SAFETY RELIEF 1 CLOSED 5 5 140 OPTIONAL FAUCET ALLOW DIMENSION D ADDITIONAL 6 152 OPENED 7 5191 1 DIMENSIONS ARE IN INCHES MM PEDESTAL DETAIL c DIMENSIONS F AND ARE BASED ON 22 DRAW OFF VALVE 4 HOLES 7 16 11 FRONT OTHER VALVES VARY ACCORDINGLY EQUALLY SPACED OK SPRING ASSIST HINGES ON 60 80 AND 100 GALLON KETTLES 2 1 2 ON SPRING ASSIST HINGES 7 ON YOKE TYPE HINGES STANDARD ON 20 30 AND 40 GALLON KETTLES
5. 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 3 0 INTRODUCTION DESCRIPTION All Crown 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 stationary floor mounted in fixed positions either on legs with adjustable flanged feet KLS DS models or pedestal KPS DS models CAPACITIES All models are suffixed with either 20 30 40 60 80 or 100 to indicate the capacity of that kettle in US gallons Thus a KLS 40DS is a two thirds jacketed direct steam kettle mounted on legs with a capacity of 40 gallons US 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 that surface The temperatures required for the cooking p
6. 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 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 s
7. 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 tangent 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
8. up with the pin and pull with both hands It is important to use both hands because the plug is heavy 2 Putthe 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 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
9. g If the leak can be attributed to faulty sealing occurring between the stem disc and valve seat then this problem may be corrected by cleaning off the dried on food residue with extremely fine emery cloth If the vulcanized rubber stem piece has been damaged it 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 CAUSE PERMANENT DAMAGE EXTREMELY SLOW COOKING TIME If the cooking time is abnormally slow this 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 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 supply 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 TROUBLESHOOTING MAINTENANCE continued 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
10. poil 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 tint 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 PREVENTIVE MAINTENANCE No preventive maintenance is required other than adhering to the Cleaning Procedure instructions DRAW OFF VALVE LEAKS If a leak occurs through the valve stem replace the rin
11. rocess 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 CAUTION THE APPLIANCE AND ITS PARTS ARE HOT USE CARE WHEN OPERATING CLEANING OR SERVICING THE APPLIANCE OPERATING PROCEDURE 1 2 Ensure that draw off valve is closed Fill kettle with product to desired level Slowly turn the steam control valve ON to full open position counter clockwise The water or food should boil 3 4 minutes per gallon If it does not then incoming pressure should be checked to determine that it is adequate to operate the kettle efficiently Regulate steam control valve depending on type of food being prepared 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 WARNING Disconnect the power supply to the appliance before cleaning or servicing WARNING Never spray water into electric controls or components CAUTION The equipment and its parts are hot Use care when operating cleaning and servicing Your kettle should be cleaned immediately after each use
12. 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 or ball 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 forms a large amount of water This 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
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