Blodgett 10G-KTC Installation Manual

KTT/KTC-G Series

GAS TABLE TOP TILTING KETTLE

INSTALLATION - OPERATION - MAINTENANCE

BLODGETT OVEN COMPANY

www.blodgett.com

44 Lakeside Avenue, Burlington, Vermont 05401 USA

Manufacture Service Questions: 866-518-3977

PART NUMBER 170081 REV A (04/11)

THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE. READ, UNDERSTAND AND FOLLOW THE INSTRUCTIONS AND WARNINGS CONTAINED IN THIS MANUAL.

FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

POST IN A PROMINENT LOCATION INSTRUCTIONS TO BE FOLLOWED IN THE EVENT USER SMELLS GAS. THIS INFORMATION SHALL BE OBTAINED BY CONSULTING YOUR LOCAL GAS SUPPLIER. AS A MINIMUM, TURN OFF THE GAS AND CALL YOUR GAS COMPANY AND YOUR AUTHORIZED SERVICE AGENT. EVACUATE ALL PERSONNEL FROM THE AREA.

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.

NOTIFY CARRIER OF DAMAGE AT ONCE IT IS THE RESPONSIBILITY OF THE CONSIGNEE TO INSPECT THE CONTAINER UPON RECEIPT OF SAME AND TO DETERMINE THE POSSIBILITY OF ANY DAMAGE, INCLUDING CONCEALED DAMAGE. WE SUGGEST THAT IF YOU ARE SUSPICIOUS OF DAMAGE TO MAKE A NOTATION ON THE DELIVERY RECEIPT. IT WILL BE THE RESPONSIBILITY OF THE CONSIGNEE TO FILE A CLAIM WITH THE CARRIER. WE RECOMMEND THAT YOU DO SO AT ONCE.

IMPORTANT - READ FIRST - IMPORTANT

WARNING: FAILURE TO DISCONNECT POWER BEFORE SERVICING COULD RESULT IN ELECTROCUTION

AND DEATH.

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.

WARNING: THE UNIT MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH GAS, ELECTRICITY

AND PLUMBING. UNIT MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE CODES.

WARNING: DO NOT ATTACH THE UNIT TO A TYPE “B” VENT. IT COULD CAUSE FIRE OR PROPERTY DAMAGE.

WARNING: DO NOT CONNECT ANY PIPING TO THE PRESSURE RELIEF VALVE. IT MUST BE FREE TO VENT

STEAM AS NEEDED. TO AVOID BURNS FROM THE VENTED STEAM THE VALVE DISCHARGE SHOULD POINT DOWNWARD.

DANGER: ELECTRICALLY GROUND THE UNIT AT THE TERMINAL PROVIDED. FAILURE TO GROUND THE

UNIT COULD RESULT IN ELECTROCUTION AND DEATH.

CAUTION: BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE OPERATING INSTRUCTIONS,

CAUTIONS AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL.

CAUTION: DO NOT OVERFILL THE KETTLE WHEN COOKING, HOLDING OR CLEANING. KEEP LIQUIDS

A MINIMUM OF 2-3” (5-8 CM) BELOW THE KETTLE BODY RIM TO ALLOW CLEARANCE FOR STIRRING, BOILING AND SAFE TRANSFER OF PRODUCT.

CAUTION: KEEP FLOORS IN FRONT OF KETTLE WORK AREA CLEAN AND DRY. IF SPILLS OCCUR, CLEAN

IMMEDIATELY TO AVOID SLIPS OR FALLS.

WARNING: KEEP WATER AND SOLUTIONS OUT OF CONTROLS AND BURNERS. NEVER USE A HIGH

PRESSURE HOSE TO CLEAN KETTLE SURFACES.

CAUTION: MOST CLEANERS ARE HARMFUL TO THE SKIN, EYES, MUCOUS MEMBRANES AND CLOTHING.

TAKE PRECAUTIONS: WEAR RUBBER GLOVES, GOGGLES OR FACE SHIELD AND PROTECTIVE CLOTHING. CAREFULLY READ WARNINGS AND FOLLOW DIRECTIONS ON CLEANER LABELS .

WARNING: DO NOT STAND ON OR APPLY UNNECESSARY WEIGHT OR PRESSURE ON THE KETTLE

FRONT OR POURING LIP. THIS COULD RESULT IN THE OVERLOAD AND FAILURE OF THE TILT MECHANISM, AND POSSIBLE SERIOUS INJURY AND BURNS TO THE OPERATOR AND OTHERS.

NOTICE: NEVER LEAVE A SANITIZER IN CONTACT WITH STAINLESS STEEL SURFACES LONGER THAN 30

MINUTES. LONGER CONTACT CAN CAUSE CORROSION.

WARNING: FAILURE TO PERIODICALLY CHECK PRESSURE RELIEF VALVE OPERATION COULD RESULT IN

PERSONAL INJURY AND/OR DAMAGE TO EQUIPMENT.

WARNING: WHEN TESTING, AVOID EXPOSURE TO THE STEAM BLOWING OUT OF THE PRESSURE RELIEF

VALVE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS.

OM-KTT/KTC-G 1

IMPORTANT - READ FIRST - IMPORTANT

WARNING: TO AVOID INJURY, READ AND FOLLOW ALL PRECAUTIONS STATED ON THE LABEL OF THE

WATER TREATMENT COMPOUND.

WARNING: BEFORE REPLACING ANY PARTS, DISCONNECT THE UNIT FROM THE ELECTRIC POWER SUPPLY

AND CLOSE THE MAIN GAS VALVE. ALLOW FIVE MINUTES FOR GAS TO VENT.

CAUTION: USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY THE MANUFACTURER

OR AUTHORIZED DISTRIBUTORS CAN CAUSE INJURY TO THE OPERATOR AND DAMAGE TO THE EQUIPMENT AND WILL VOID ALL WARRANTIES.

WARNING: KEEP AREA AROUND KETTLE FREE AND CLEAR OF ALL COMBUSTIBLE MATERIALS. FAILURE TO

DO SO COULD RESULT IN FIRE OR PROPERTY DAMAGE.

CAUTION: HEATING AN EMPTY KETTLE MAY CAUSE THE RELEASE OF STEAM FROM THE PRESSURE

RELIEF VALVE.

IMPORTANT: SERVICE PERFORMED BY OTHER THAN FACTORY AUTHORIZED PERSONNEL WILL VOID ALL

WARRANTIES.

2 OM-KTT/KTC-G

Table of Contents

Important Operator Warnings .....................................................page 1-2

References..................................................................................... page 3

Equipment Description.................................................................. page 4

Inspection and Unpacking ............................................................ page 5

Installation .................................................................................. page 6-7

Initial Start-Up ................................................................................ page 8

Operation ................................................................................ page 9-11

Sequence of Operation ................................................................ page 12

Cleaning.................................................................................. page 13-14

Maintenance........................................................................... page 15-20

Troubleshooting...................................................................... page 21-22

Parts Lists............................................................................... page 23-31

Wiring Diagram ........................................................................... page 32

Service Log ................................................................................. page 33

References

CSA INTERNATIONAL 8501 East Pleasant Valley Road Cleveland, Ohio 44131

NSF INTERNATIONAL 798 N. Dixboro Rd. P.O. Box 130140 Ann Arbor, Michigan 48113-0140

UNDERWRITERS LABORATORIES, INC. 333 Pﬁngsten Road Northbrook, Illinois 60062

KLENZADE SALES CENTER ECOLAB, Inc. 370 Wabasha St. Paul, Minnesota 55102

NATIONAL FIRE PROTECTION ASSOCIATION 60 Battery March Park Quincy, Massachusetts 02269

NFPA/54 -Installation Gas Appliances & Piping NFPA/70 - The National Electric Code

ZEP MANUFACTURING COMPANY 1310-T Seaboard Industrial Boulevard Atlanta, Georgia 30318

OM-KTT/KTC-G 3

Equipment Description

FIRING RATE, BTU/hr

5G-KTT, 10G-KTT

5G-KTC, 10G-KTC

31,000 52,000

10G-KTT, 12G-KTT

10G-KTC, 12G-KTC

Model

KTT-G and KTC-G models are stainless steel, steam-jacketed, table top mounted kettles with a self-contained, gas heated steam source. The KTC has a crank tilt hand wheel, and the KTT has a handle that allows the operator to manually tilt the kettle. The kettle body is welded into one solid piece and furnished with a reinforced rim and weldedin “butterﬂy” shaped pouring lip. The interior of the kettle is polished to a 180 emery grit ﬁnish, and the exterior is given a bright high buff ﬁnish. The unit is A.S.M.E. shop inspected and registered with the National Board for a design pressure of 50 PSIG.

The self-contained steam source is heated by propane or natural gas and is equipped with electronic ignition. Charged at the factory with chemically pure water containing rust inhibitors, the steam source provides kettle temperatures of 150ºF to approximately 295ºF.

Controls for the KTC unit include a crank tilt handwheel, thermostat, pressure gauge, pressure relief valve, low water cut-off, On/Off switch, indicator lamp, gas regulator valve, and water level sight glass. Controls for the KTT are the same as the above, with the exception of the crank tilt hand wheel.

The gas supply shuts off automatically when the kettle is tilted.

The unit must be speciﬁed for use with natural gas or propane. For other gas types, consult factory. Service connections are required for gas and 115V electricity.

Kettle

Capacity

Jacket

Capacity

Kettle Body

Diameter

Kettle Body

Depth

Base

Width

Base Depth

5G-KTT 5G-KTC

6G-KTT 6G-KTC

10G-KTT 10G-KTC

12G-KTT 12G-KTC

5 Gal. (20 Qt.)

19 liter

6-Gal. (24 Qt.)

23 liter

10 Gal. (40

Qt.)

38 liter

12 Gal. (48

Qt.)

45 liter

6 Qt

5.7 liter

6 Qt

5.7 liter

12 Qt

11.4 liter

12 Qt

11.4 liter

14 inches

356 mm

14 inches

356 mm

16-1/2 inches

419 mm

16-1/2 inches

419 mm

11 inches

279 mm

12-1/2 inches

318 mm

14-1/2 inches

368 mm

16 inches

406 mm

28 inches

711 mm

28 inches

711 mm

28 inches

711 mm

28 inches

711 mm

Options available include:

1. One-piece, Lift-off cover

2. Holder for Lift-off Cover

3. Basket insert

4. Rice Strainer

5. Stand that supports the unit and holds a pan in position for ﬁlling

6. Water ﬁll swing faucet

7. 316 stainless steel interior (must be indicated on initial order)

24 inches

610 mm

24 inches

610 mm

26-3/4 inches

680 mm

26-3/4 inches

680 mm

4 OM-KTT/KTC-G

Inspection & Unpacking

CAUTION

SHIPPING STRAPS ARE UNDER TENSION

AND CAN SNAP BACK WHEN CUT. TAKE

CARE TO AVOID PERSONAL INJURY OR

DAMAGE TO THE UNIT BY STAPLES LEFT

IN THE WALLS OF THE CARTON.

CAUTION

THIS UNIT WEIGHS BETWEEN 214 AND

240 POUNDS (98 TO 109 Kg) DEPENDING

ON SIZE. INSTALLER SHOULD USE

PROPER EQUIPMENT TO LIFT SAFELY.

The unit arrives completely assembled, except for the tilting handle on hand tilt models which is shipped inside the kettle. The unit is strapped on a skid and in a heavy carton. Inspect the carton carefully for damage. Open the container and check the unit for hidden damage. Report shipping damage or shipment errors to the delivery agent.

Write down the model number, serial number, and installation date for your unit at the top of the Service Log on Page 33. Keep this manual with the unit.

To remove the kettle from the box, cut any straps from around the box. Detach the box sides from the skid. Pull the box up off the unit, taking care to avoid damage or injury from any staples left in the box walls. When installation is to begin, cut the straps holding the kettle on the skid, and lift the kettle straight up off the skid. Examine the packing materials to make sure no loose parts are discarded with the materials. On hand tilt models, the tilting handle may be screwed into its socket. Attach handle to the kettle on left side or right side as shown below.

The kettles are shipped from

the factory strapped on a pallet.

OM-KTT/KTC-G 5

Installation

WARNING

THE KETTLE MUST BE INSTALLED BY

PERSONNEL QUALIFIED TO WORK WITH

GAS, ELECTRICITY AND PLUMBING.

IMPROPER INSTALLATION CAN CAUSE

INJURY TO PERSONNEL AND/OR DAMAGE

TO THE EQUIPMENT.

WARNING

THIS UNIT IS FOR COMMERCIAL USE. DO NOT

USE HOME OR RESIDENTIAL GRADE GAS CONNECTIONS. THEY DO NOT MEET GAS

CODES AND COULD BE HAZARDOUS.

The kettle should be installed in a ventilated room for efﬁcient performance. Items which might obstruct or restrict the ﬂow of air for combustion and ventilation must be removed. The area directly around the appliance must be cleared of any combustible material.

1. Installation on combustible ﬂoors is allowed. Minimum clearances between the unit and combustible surfaces is as follows:

Model

Left Side

Right Side

Rear

Minimum Clearance from

Combustible walls

1 in. 1 in.

0 in. 12-16 in. for servicing

1 in. 3 in. for faucet bracket

Recommended

Clearances

2. We recommends installation of the unit under a vent hood. The base must be fastened to a working surface or stand.

3. Complete the piping to the gas service main using ½ inch IPS pipe or an approved equivalent.

4. Provide 115 VAC, 60 cycle, 1 phase, 1 AMP electric service. Local codes and/ or The National Electrical Code should be observed in accordance with ANSI/ NFPA-70 latest edition. AN ELECTRICAL GROUND IS REQUIRED. The electrical schematic is located on the inside of the service panel and in this manual.

5. Electrical connection to the unit must be water resistant sealtite conduit type or equal and utilize the water resistant conduit ﬁtting provided on the unit.

6. The installation must conform with local codes or the American National Standards Z223.1 - latest edition National Fuel Gas Code. The kettle should be installed in an adequately ventilated room with provision for adequate air supply. The best ventilation will employ a vent hood and exhaust fan with no direct connection between the vent duct and the kettle ﬂue. DO NOT obstruct the ﬂue or vent duct after installation.

7. PRESSURE TEST WARNING a) Test pressure exceeding ½ PSIG (3.45 kPa). During pressure testing of the

gas supply piping system at pressures exceeding ½ PSIG, the appliance and its individual shutoff valve must be disconnected from the gas supply piping system.

b) Test pressure equal to or less than ½ PSIG (3.45 kPa). During pressure

testing of the gas supply piping system at pressures equal to or less than ½ PSIG, the kettle must be isolated from the gas supply piping system by closing its individual manual shutoff valve.

6 OM-KTT/KTC-G

Installation

8. Adequate space for proper servicing and operation is required. DO NOT block any air intake spacings to the combustion chamber or obstruct air ﬂow.

9. After the kettle has been connected to the gas supply, check all gas joints for leaks. A soap solution or other suitable gas leak detector should be used. Do not use ﬂame when checking for leaks.

10. Once the unit is anchored to a mounting surface, apply a small bead of silicone caulk around the perimeter of the kettle base and seal the joint.

11. Make sure the water level is correct in the jacket, by conﬁrming that the level is near the middle of the sight glass. If the water level is low, follow the instructions in Jacket Filling and Water Treatment in the Maintenance section of this manual.

12. Check to be sure that the open end of the elbow on the outlet of the pressure relief valve is directed downward. Be sure to read and follow the instructions on the attached pressure relief valve tag.

OM-KTT/KTC-G 7

Initial Start-Up

IMPORTANT

BE SURE ALL OPERATORS READ,

UNDERSTAND AND FOLLOW THE OPERATING

INSTRUCTIONS, CAUTIONS, AND SAFETY

INSTRUCTIONS CONTAINED IN THIS MANUAL.

WARNING

DO NOT STAND ON OR APPLY UNNECESSARY

WEIGHT OR PRESSURE ON THE KETTLE FRONT

OR POURING LIP. THIS COULD RESULT IN

THE OVERLOAD AND FAILURE OF THE TILT

MECHANISM, AND POSSIBLE SERIOUS INJURY

AND BURNS TO THE OPERATOR AND OTHERS.

Make sure that the open end of the elbow on

the pressure relief valve is directed downward.

After the kettle has been installed, the installer should test to ensure that it is operating correctly.

1. Remove literature and packing materials from inside and outside of the unit.

2. Add water to the kettle to a depth of at least one inch.

3. Make sure the supplies of gas and electric power are on.

4. Follow the “To Start Kettle Heating” instructions in the Operation section of this manual. Begin heating the water at the highest thermostat setting. The indicator light should come on and heating should continue until the water boils.

5. To turn off the unit, follow “To Stop Kettle Heating” in the Operation Section of this manual.

If the kettle functions as described, it is ready for use. If the unit does not operate as designed, contact an authorized Service Agent.

8 OM-KTT/KTC-G

Correct water level

Operation

CAUTION ANY POTENTIAL USER OF THE EQUIPMENT MUST BE TRAINED IN SAFE AND CORRECT

OPERATING PROCEDURES.

WARNING

KEEP AREA AROUND KETTLE FREE AND

CLEAR OF ALL COMBUSTIBLE MATERIALS.

DO NOT ATTEMPT TO LIGHT ANY BURNER

WITH A FLAME.

CAUTION

HEATING AN EMPTY KETTLE MAY CAUSE

THE RELEASE OF STEAM FROM THE

PRESSURE RELIEF VALVE.

A. Controls

Operator controls for the kettle are:

1. Manual gas valve which controls the supply of gas from the main to the unit.

2. On-Off (toggle) switch. This switch turns the control circuit power supply on or off.

3. Thermostat dial, which turns the thermostat on or off, and sets the kettle operating temperature.

4. Crank tilt handwheel which controls kettle movement.

B. Operating Procedure

1. To Start Kettle: a. CHECK THE WATER LEVEL IN THE JACKET EVERY DAY. The level

should be in the middle of the sight glass. If the water level is low, see Jacket Filling in the Maintenance section of this manual.

b. Check the pressure/vacuum gauge. If the gauge does not show

20 to 30 inches of vacuum (i.e., a reading of 20 to 30 below zero), see Jacket Vacuum in the Maintenance section of this manual.

c. DO NOT attempt to light any burner with a ﬂame.

Crank tilt model shown on optional stand.

d. Open the main supply gas valve (handle in line with the pipe).

e. Turn the toggle switch to ON.

f. Turn the thermostat to the desired heat setting.

2. To Stop Kettle Heating: a. To tilt the body of the kettle forward, turn the hand crank on the

front of the cabinet counter-clockwise. The body will stay in the position it holds when you stop cranking. To return the kettle body to its upright position, turn the crank clockwise.

b. Product may also be transferred by means of the optional draw-off

valve, if the kettle is so equipped.

3. To Relight Kettle a. Close main gas supply valve.

b. Set on-off switch to OFF.

c. Set thermostat to OFF.

d. Wait ﬁve minutes, then proceed as directed under To Start Kettle

Heating.

4. If electric power fails, do not attempt to operate the unit. When power is restored, proceed as directed in To Start Kettle Heating.

OM-KTT/KTC-G 9

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