Blodgett 60G-KLT Service Manual

KLT-G Series

GAS TILTING FLOOR 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 170097 REV B (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

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

CAUTIONS, AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL.

WARNING: THIS UNIT IS INTENDED FOR USE IN THE COMMERCIAL HEATING, COOKING AND HOLDING OF

WATER AND FOOD PRODUCTS, PER THE INSTRUCTIONS CONTAINED IN THIS MANUAL. ANY OTHER USE COULD RESULT IN SERIOUS PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT AND WILL VOID WARRANTY.

WARNING: KETTLE MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH ELECTRICITY AND

PLUMBING. IMPROPER INSTALLATION CAN RESULT IN INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT.

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

COULD RESULT IN ELECTROCUTION AND DEATH.

WARNING: DO NOT CONNECT ANY PIPING TO THE POP SAFETY VALVE. THE VALVE MUST BE FREE TO VENT

STEAM AS NEEDED. THE ELBOW ATTACHED TO THE SAFETY VALVE SHOULD POINT TO THE FLOOR. IMPROPER INSTALLATION WILL VOID WARRANTY.

WARNING: AVOID ALL DIRECT CONTACT WITH HOT EQUIPMENT SURFACES. DIRECT SKIN CONTACT COULD

RESULT IN SEVERE BURNS.

WARNING: AVOID ALL DIRECT CONTACT WITH HOT FOOD OR WATER IN THE KETTLE. DIRECT CONTACT

COULD RESULT IN SEVERE BURNS.

CAUTION: DO NOT OVER FILL 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 PRODUCT TRANSFER.

WARNING: TAKE SPECIAL CARE TO AVOID CONTACT WITH HOT KETTLE BODY OR HOT PRODUCT WHEN

ADDING INGREDIENTS, STIRRING OR TRANSFERRING PRODUCT TO ANOTHER CONTAINER.

WARNING: WHEN TILTING KETTLE FOR PRODUCT TRANSFER:

1) USE CONTAINER DEEP ENOUGH TO CONTAIN AND MINIMIZE SPLASHING.

2) PLACE CONTAINER ON STABLE, FLAT SURFACE, AS CLOSE TO KETTLE AS POSSIBLE.

3) DO NOT OVER FILL CONTAINER. AVOID DIRECT SKIN CONTACT WITH HOT CONTAINER AND ITS CONTENTS.

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

IMMEDIATELY, TO AVOID SLIPS OR FALLS.

WARNING: FAILURE TO CHECK SAFETY VALVE OPERATION PERIODICALLY COULD RESULT IN PERSONAL

INJURY AND/OR DAMAGE TO EQUIPMENT.

WARNING: WHEN TESTING SAFETY VALVE, AVOID ANY EXPOSURE TO THE STEAM BLOWING OUT OF THE

SAFETY VALVE. DIRECT CONTACT WITH STEAM COULD RESULT IN SEVERE BURNS.

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 UNBURNED GAS TO VENT.

OM-KLT-G 1

IMPORTANT - READ FIRST - IMPORTANT

WARNING: KEEP WATER AND SOLUTIONS OUT OF CONTROLS AND ELECTRICAL EQUIPMENT. NEVER SPRAY

OR HOSE THE SUPPORT HOUSING OR ELECTRICAL CONNECTIONS.

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

PRECAUTIONS SHOULD BE TAKEN. WEAR RUBBER GLOVES, GOGGLES OR FACE SHIELD AND PROTECTIVE CLOTHING. CAREFULLY READ THE WARNINGS AND FOLLOW THE DIRECTIONS ON THE LABEL OF THE CLEANER TO BE USED.

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

OR AN AUTHORIZED SERVICE AGENT CAN CAUSE OPERATOR INJURY AND DAMAGE TO THE EQUIPMENT, AND WILL VOID ALL WARRANTIES.

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

WARRANTIES.

WARNING: DO NOT HEAT AN EMPTY KETTLE. EXCESSIVE STEAM PRESSURE COULD DEVELOP.

2 OM-KLT-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

Operation ................................................................................ page 8-10

Sequence of Operation ................................................................ page 11

Cleaning.................................................................................. page 12-13

Maintenance........................................................................... page 14-16

Troubleshooting...................................................................... page 17-18

Parts Lists............................................................................... page 19-27

Service Log ................................................................................. page 28

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

AMERICAN NATIONAL STANDARDS INST., Inc. 1430 Broadway New York, New York 10018

Z223.1-1984 - National Fuel Gas Code Z21.30 - Installation Gas Appliances & Piping

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-KLT-G 3

Equipment Description

The Blodgett KLT-G is a ﬂoor-mounted, tilting, steam jacketed kettle with a thermostatically controlled, self-contained, gas-heated steam source and appropriate controls, mounted on a sturdy base. The kettle is available in 20, 40, 60 or 80 gallon capacities.

The body of the kettle is constructed of stainless steel, welded into one solid piece. The kettle is furnished with a reinforced rim and a butterﬂy shaped pouring lip. It has a steam jacket which is ASME shop inspected and registered with the national board for working pressures up to 50 PSI. Kettle ﬁnish is 180 emery grit on the inside and bright high buff polish on the outside.

The kettle is tilted with a hand crank to pour out its contents. Stainless steel panels enclose the controls and the base. Four stainless steel tubular legs support the unit. Bullet or ﬂanged feet on each of the legs can be adjusted to level the kettle. Optional feature can include a two inch tangent draw-off valve.

The self-contained steam source is heated by propane or natural gas. Ignition is electronic.

The kettle is charged at the factory with chemically pure water which contains rust inhibitors. The steam source provides kettle temperatures of 150º to approximately 295ºF (65 to 150ºC). Unit controls include a thermostat, pressure gauge, safety valve, pressure limit control, low water cut-off, power switch and gas regulator valve. The gas supply shuts off automatically when the kettle is tilted.

4 OM-KLT-G

The unit must be speciﬁed for use with natural or propane gas. Service connections for gas and electricity are required. Standard power supply is 115 Volt. Alternate voltages (208V or 240V) are available.

Model 20G-KLT 40G-KLT 60G-KLT 80G-KLT

Kettle Capacity

Jacket Capacity

Kettle Body Inside Diameter

Base - Width

Base Front to Back

Firing Rate /hr

Energy into Product /hr

20 gallons

(75 liters)

2-1/2 gallons 3-1/2 gallons 4 gallons 1-1/4 gallons

20 inches (508 mm)

35 inches (889 mm)

28 inches (736 mm)

72,000 BTU 100,000 BTU 150,000 BTU 150,000 BTU

44,140 BTU 65,000 BTU 93,000 BTU 93,000 BTU

40 gallons (150 liters)

26 inches (660 mm)

47 inches

(1194 mm)

29 inches (736 mm)

60 gallons (225 liters)

30 inches (762 mm)

47 inches

(1194 mm)

29 inches (736 mm)

80 gallons (300 liters)

34 inches (863 mm)

52 inches

(1320 mm)

37-1.2 inches

(952 mm)

Options available with listed models are:

1. Two inch tangent drawoff

2. Strainers, solid disk, 1/4 or 1/8 inch holes

3. Lift-off cover

4. Counterbalanced cover w/actuator

5. Basket Inserts

6. Water ﬁll faucets with swing spout

7. Kettle Brush Kit

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 535 AND

978 POUNDS (245 TO 400 Kg) DEPENDING

ON SIZE. INSTALLER SHOULD USE

PROPER EQUIPMENT TO LIFT SAFELY.

The unit will arrive in a heavy shipping carton and will be bolted or banded to a skid. Immediately upon receipt, inspect the carton carefully for exterior damage.

Carefully cut any polyester straps around the carton and detach the sides of the box from the skid. Pull the carton up off the unit. Thoroughly inspect the unit for hidden damage. Report any shipping damage or incorrect shipments to the delivery agent.

Write down the model number, serial number, and installation date, and retain this information for future reference. Space for these entries is provided at the top of the Service Log at the back of this manual. Keep this manual on ﬁle and available for operators to use.

When installation is to begin, carefully cut any straps which hold the unit on the skid. Lift the unit straight up off the skid. Examine packing materials to be sure loose parts are not discarded with the materials.

OM-KLT-G 5

Installation

WARNING

THE UNIT MUST BE INSTALLED BY

PERSONNEL WHO ARE QUALIFIED TO WORK

WITH GAS, ELECTRICITY AND PLUMBING.

IMPROPER INSTALLATION CAN CAUSE INJURY TO PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT. THE UNIT

MUST BE INSTALLED IN ACCORDANCE WITH

APPLICABLE CODES. THE UNIT MUST BE

INSTALLED BY A LICENSED PLUMBER

OR GAS FITTER WHEN INSTALLED WITHIN

THE COMMONWEALTH OF MASSACHUSETTS.

DANGER

ELECTRICALLY GROUND THE UNIT AT

THE TERMINAL PROVIDED. FAILURE TO GROUND UNIT COULD RESULT IN

ELECTROCUTION AND DEATH.

For efﬁcient performance the kettle must be installed in a well-ventilated area. Items which might restrict or obstruct the ﬂow of air for combustion and ventilation must be removed. The area directly around the appliance must be free of combustible materials.

1. Installation can be on a combustible or noncombustible ﬂoor. Clearances should be per table below.

Model

Left Side

Right Side

Rear

Minimum

Clearance from

Combustible walls

6 in. 0 in. 6 in.

6 in. 0 in. 10 in.

10 in. 10 in. 12 in.

Minimum

Clearance from

Non-Combustible walls

Recommended

Clearances

2. The kettle should be installed in an adequately ventilated room with provision for adequate air supply. The ventilation must 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.

3. Set the kettle in place and level it using a spirit level on the bar rim, by turning the bullet or ﬂange feet to adjust leg length. Allow clearance around the unit for cleaning, maintenance and service.

4. Complete the piping to the gas service main with ½” line or approved equivalent.

5. For standard units, provide 115 vac, 60 Hz, single phase 5 AMP electrical service. The unit may also be ordered for alternate electric service of 208 VAC or 240 VAC. Observe local codes and/or The National Electrical Code in accordance with ANSI/NFPA 70 (current edition), or the Canadian Electrical Code, CSA C22.2 (current edition), as applicable. Use the wiring diagram inside the service panel and at the rear of this manual

6. Bring electrical service through the entrance at the rear of the support housing with a ½ inch conduit connector. Make a watertight connection with the incoming lines.

7. Electrically ground the unit at the terminal provided.

8. After the kettle has been connected to the gas supply, check all gas joints for leaks. DO NOT USE FLAME TO CHECK FOR LEAKS. A thick soap solution or other suitable leak detector should be employed.

6 OM-KLT-G

Installation

WARNING

DO NOT CONNECT ANY PIPING TO

THE PRESSURE RELIEF VALVE. THE VALVE

MUST BE FREE TO VENT STEAM AS NEEDED. IMPROPER INSTALLATION

WILL VOID THE WARRANTY! THE ELBOW

ATTACHED TO THE PRESSURE RELIEF

VALVE MUST POINT TO THE FLOOR.

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.

The open end of the pressure relief

valve elbow must face downward.

9. The gas supply and unit’s installation must conform with local codes or in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 (current edition), or the Natural Gas and Propane Installation Code CSA

149.1(current edition), as applicable. Additionally following must be complied with: THE AREA DIRECTLY AROUND THE APPLIANCE MUST BE CLEARED OF ALL COMBUSTIBLE MATERIAL. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE BODILY INJURY AND /OR PROPERTY DAMAGE. The appliance and its individual shut-off valve must be disconnected from the gas supply piping system during any testing at pressures in excess of ½ PSI (3.45 kPa). The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing at or less than ½ PSI (3.45 kPa).

10. Conﬁrm that the jacket water level is between the gauge glass markers or inside the sight glass port. If the level is low, follow instructions under “Jacket Filling and Water Treatment,” Page 16.

11. The open end of the elbow on the outlet of the safety valve must face downward. If it does not, turn it to the correct position.

12. For units with optional tangent draw-off, assemble the tangent draw-off by placing the large nut over the draw-off valve and inserting it into the draw-off tube. ONLY HAND-TIGHTEN THE NUT to complete installation.

13. Now that the kettle has been installed, you should test to ensure that it is operating correctly. a. Remove literature and packing materials from inside and outside of the

unit.

b. If the unit is equipped with a draw-off valve (product outlet), clean out any

material which might clog or damage the draw-off.

When attaching the draw-off

valve hand tighten the nut.

Each day conﬁrm the jacket water

level by checking the water gauge.

c. Conﬁrm that the tilting mechanism is operating properly by tilting the kettle

through its full range. Then return the kettle to the upright position.

e. Turn on the electrical service to the unit.

f. Pour 1-2 quarts of water into the kettle.

g. Following “To Start Kettle” instructions in the “Operation” section (Page

9), begin heating the water at the highest thermostat setting. The heat indicator light should come on, and heating should continue until the boils.

14. If the unit functions as described it is ready for use. If it does not function as described, contact your local Authorized Service Agency.

OM-KLT-G 7

Operation

A. Controls

Operator controls for the kettle are:

1. Manual gas valve (on gas line behind the unit), which controls the supply of gas from the main to the unit.

2. On-Off (Toggle) Switch. This controls the supply of electric power to the control circuits.

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

4. Tilting crank, used to tilt the kettle body.

5. Indicator Lights to alert operator of unit conditions: a. Power On Indicator - shows that the unit is turned on

b. Heat Indicator - indicates that main gas is on to produce steam in

the kettle jacket.

c. Low Water indicator - shows that jacket water is low

6. Unit gas pressure regulator adjustment - located behind the access door in the kettle skirt.

B. Operating Procedure

1. To Start Kettle: a. EVERY DAY make sure that the jacket water level is between the

markers on the gauge glass or inside the sight glass port. If the level is too low, see “Jacket Filling and Water Treatment” on page 16.

b. Check the pressure gauge. If the gauge does not show 20 to 30

inches of mercury (Hg) vacuum (that is a reading of 20 to 30 below 0 atmospheric pressure), see “Jacket Vacuum” on page 16.

c. Do not attempt to light any burner with a ﬂame. Turn the manual

gas valve ON (align handle with gas line).

1) Turn toggle (on-off) switch ON. The electronic ignition will attempt to light the pilot for 90 seconds, or until it is lit. Once lit, proceed to step two.

2) Turn thermostat to desired setting. The main gas burner will ignite, and will cycle to maintain the set temperature. The

3) If the unit does not light, turn it off and wait ﬁve minutes. Then follow the instructions again.

2. To Empty Kettle: 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.

8 OM-KLT-G

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

valve, if the kettle is so equipped.

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