Blodgett KLS-100G Service Manual
KLS-G SERIES
GAS STATIONARY STEAM JACKETED KETTLE
PARTS AND SERVICE MANUAL
EFFECTIVE NOVEMBER 3, 2015
The Company reserves the right to make substitution in the event that items specied are not available.
ERRORS: Descriptive and/or typographic errors are subject to correction.
44 Lakeside Avenue, Burlington, Vermont 05401 USA Telephone: (802) 658-6600 Fax: (802) 860-3732
Superseding All Previous Parts Lists.
BLODGETT OVEN COMPANY
www.blodgett.com
P/N S00161 Rev A
TABLE OF CONTENTS
GAS SYSTEM ADJUSTMENTS .........................................................3
KETTLE WATER, VACUUM & CONTROL CIRCUIT FUSES ................................5
CONVERTING BETWEEN NATURAL AND PROPANE GAS ...............................6
TROUBLESHOOTING ..................................................................7
ILLUSTRATED PARTS LIST
KETTLE PARTS .......................................................................8
BURNER ASSEMBLY ................................................................ 14
DRAW OFF VALVES ................................................................. 16
HINGED COVER ASSEMBLY ......................................................... 18
COVER ASSEMBLY .................................................................. 19
COVER ASSEMBLY .................................................................. 20
MATERIAL SAFETY DATA SHEET ..................................................... 21
DECEMBER 18, 2014 2 KLS-G SERIES STATIONARY GAS KETTLES
GAS SYSTEM ADJUSTMENTS
SAFETY VALVE MAINTENANCE AND TESTING
CAUTION
Under normal operating conditions a “try lever
test” should be performed every two months.
Under severe service conditions, or if corrosion and/or deposits are noticed within the
valve body, testing must be performed more
often. A “try lever test” should also be performed at the end of any non-service period.
CAUTION
Hot, high pressure uid may be discharged
from body drain and vent during “try lever”
test. Care must be taken to avoid any bodily
contact.
CAUTION
High sound levels may be experienced during
“try lever” test. Wear proper safety equipment and exercise extreme care! Test at, or
near, half of the operating pressure by holding
the test lever fully open for at least two sec-
onds to ush the valve seat free of sediment
and debris. Then release lever and permit the
valve to snap shut.
If lift lever does not activate, or there is no
evidence of discharge, turn off equipment immediately and contact a licensed contractor or
qualied service personnel.
Manifold Pressure
Natural Gas 4 inches W.C.
LP Gas 10 inches W.C.
PILOTS
The pilot adjustment is part of the combination control
valve located just behind the lower front access door. It
is located on the center left side of the control just below
the large slotted screw head. Remove the large slotted
screw; below this is a second slotted screw used for adjustment of the pilot burner ame.
The front burner shield should be removed to see the pi-
lot. The pilot should be adjusted as follows:
Adjust the pilot burner ame
The pilot ame should envelop 3/8 to ½ inch [10 to 13
mm] of the igniter-sensor tip. To adjust the pilot ame:
1. Remove the pilot adjustment cover screw.
GENERAL
When any difculty arises always check that the unit has
been connected to the gas supply type and voltage for
which it was supplied. This can be done by examining
the serial plate on the lower right side of the unit. It will
2. Turn the inner adjustment screw clockwise to decrease or counterclockwise to increase the pilot
ame.
3. Always replace the cover screw after adjustment and
tighten rmly to ensure proper operation.
list the gas type and voltage for which the unit was manu-
factured.
Wiring diagrams for the unit are located in a small enve-
lope afxed to the rear side of the front control panel.
UNIT TOTAL INPUT
KLS-20G 100,000 BTU/Hour 30 45
KLS-30G 100,000 BTU/Hour 30 45
KLS-40G 100,000 BTU/Hour 30 45
KLS-60G 130,000 BTU/Hour 23 39
KLS-80G 150,000 BTU/Hour 30 45
KLS-100G 150,000 BTU/Hour 30 45
ORIFICE SIZE
Natural Propane
Pilot Orice Sizes
Natural 0.018 IN
Propane 0.010 IN.
DECEMBER 18, 2014 3 KLS-G SERIES STATIONARY GAS KETTLES
GAS SYSTEM ADJUSTMENTS
GAS PRESSURE REGULATOR
The gas pressure regulator is an integral part of the com-
bination gas control located just behind the lower front
access door. The pressure regulator adjustment is on the
lower right side of the gas control. The large slotted cap
must be removed to access the adjustment screw.
To check the manifold pressure a pressure gauge (manometer) must be connected to the 1/8" NPT pressure
tap on the gas manifold. With the gas off, connect your
pressure indicating instrument to the manifold with a tting appropriate for your instrument.
1. Turn the unit on; with main burners on, read the mani-
fold pressure. The pressure should be 4 inches water column (W.C.) .2 inches W.C. for natural gas or
10 inches W.C. for propane gas. Adjust the pressure
regulator to obtain the appropriate pressure. Check
serial plate on lower right side of unit to conrm exact
gas type and manifold pressure for your unit.
When pressure has been correctly adjusted turn unit off.
Remove pressure indicating instrument and replace the
1/8" NPT plug in manifold. Replace regulator cap and
close access door.
THERMOSTAT
The thermostat adjustment should not be changed.
Check the following before changing the thermostat:
1. With kettle cool, the pressure reading on the pressure
gauge should be in the green vacuum zone (below 0
psi). If not, see “Re-establishing Vacuum” section.
2. Check that the pressure switch is not set too high or
too low and causing the out of adjustment condition.
A voltmeter should be used by a properly trained serviceman to determine if the pressure switch or thermostat is actually cycling the burners. If the pres-
sure switch is found to be the problem, see “Pressure
Switch” section.
After verifying that the pressure switch is set and operat-
ing properly, the thermostat may be adjusted using the
set screw inside the stem. The thermostat should cycle
off at a gauge pressure reading of 30 psi. Turn set screw
clockwise to decrease pressure and counterclockwise to
increase pressure.
PRESSURE SWITCH
The pressure switch should not be adjusted until it is determined to be the cause of an operating pressure de-
ciency. See “Thermostat” section to determine if the
source of difculty is the pressure switch or thermostat.
The major difculties caused by pressure switch mis-ad-
justment are:
1. Pressure relief valve opening, especially on preheat
from a cold start to 275 degrees Fahrenheit (135°C)
(pressure switch set too high).
2. Burners are being shut down by pressure switch, not
the thermostat. (Pressure switch set too low.)
The pressure switch is preset for proper operation from
the factory. It is adjusted to the maximum pressure, how-
ever not high enough to cause the pressure relief valve
to open. This setting will be slightly different on different kettles due to variations in the pressure relief valves.
During preheat to the maximum thermostat setting (275
degrees Fahrenheit) (135°C), from either a cold condi-
tion or a lower temperature setting, the temperature may
overshoot the thermostat setting and shut down the burners by the pressure switch. This is normal, however, after
the kettle cycles several times (empty) the thermostat will
begin cycling the unit.
TO ADJUST PRESSURE SWITCH:
1. To obtain access to the pressure switch, the front
panel must be removed. Remove the screws on ei-
ther side of the panel. Be sure to support the panel
to avoid excessive strain on the wiring.
2. To increase the pressure setting turn the white ribbed
knob clockwise; to decrease the pressure, turn it
counterclockwise. Use the centre of the black ring
as an indicator.
3. With the kettle empty and completely cold, bypass the
thermostat by moving the single terminal side wire to
the double terminal side connector on the thermostat.
Turn kettle on.
4. Pressure in kettle (read pressure gauge on front panel) should reach a maximum of 35 psi and pressure
relief valve should not open. Kettle pressure may rise
3 or 4 psi even after burners shut down.
5. Relief valve should not open when kettle pressure is
40 psi; pressure switch setting is satisfactory.
6. If relief valve opens, reduce setting on pressure
switch, cool kettle completely by running cold water
through it and repeat steps 3 - 6.
7. If pressure in kettle is below 30 psi when burners shut
off, increase setting of pressure switch, cool kettle
completely by running cold water through it and re-
peat steps 3 - 7.
8. When adjustment is complete, move wire from shorted terminal on the thermostat back to the appropriate
terminal and replace the front panel.
DECEMBER 18, 2014 4 KLS-G SERIES STATIONARY GAS KETTLES
KETTLE WATER, VACUUM & CONTROL CIRCUIT FUSES
ADDING WATER
It may be necessary to replenish water in the jacket when
the low water indicator comes on. Do so as follows:
1. Unit should be completely cold and off.
2. Lift handle of pressure relief valve to release vacuum
in kettle. (Relief valve is at right rear of kettle).
3. Remove air vent nut on the tee located between kettle and relief valve.
4. Using pure distilled water only, pour the water into
the opening. (A funnel will be helpful). Water will
enter the kettle slowly, as air must escape through the
same hole. Water should be added until the water
level at the sight glass is half way between the mini-
mum and maximum levels.
5. When sufcient water has been added, replace and
tighten the nut.
6. Vacuum must be re-established. (See Re-establishing Vacuum).
For reference, the total amount of distilled water contained in each unit, and amount to be added in a low water condition is listed below:
going to the pressure switch, pressure gauge or thermostat tting.
CONTROL CIRCUIT FUSES
The control circuit is protected by a 3 amp. fuse which is
located inside control panel, top right side above transformer.
Should the unit fail to turn on, check this fuse by remov-
ing it and either replacing it or testing it with a continuity
tester. If the fuse is good, check the main power circuit
breaker, which should be external to the kettle.
AMOUNT OF
TOTAL AMOUNT
MODEL
KLS-20G 4.8 Gallons 155 . oz. (4 L)
KLS-40G 6.9 Gallons 236 . oz. (7 L)
KLS-60G 9.5 Gallons 338 . oz. (10 L)
KLS-80G & KLS100G
OF DISTILLED
WATER
16.3 Gallons 721 . oz. (10 L)
WATER TO BE
ADDED IN A
LOW WATER
CONDITION
RE-ESTABLISHING VACUUM:
With the kettle completely cold a vacuum of 25 to 30
inches mercury column (M.C.) should be maintained as
indicated in the green zone on the pressure gauge on the
front control panel. If at any time the vacuum is not in the
green zone, vacuum should be re-established.
With the kettle empty, turn the thermostat knob to the
highest temperature. When the temperature pilot light
goes off, open air vent nut one (1) full turn for 20 seconds
and then close and tighten the nut. This should remove
the air and any loss in performance should return.
Should the kettle fail to maintain a vacuum after repeated
attempts to establish it, further checks should be made
to see if the pressure relief valve is leaking or if there are
any leaks in the pressure relief valve piping, copper lines
DECEMBER 18, 2014 5 KLS-G SERIES STATIONARY GAS KETTLES
CONVERTING BETWEEN NATURAL AND PROPANE GAS
WARNING
Fire or explosion hazard can cause property
damage, severe injury, or death.
1. Do not attempt to use a gas control set for
natural gas on propane gas or gas control set
for LP gas on natural gas.
2. When making conversion, main and pilot
burner orices MUST be changed to meet appliance manufacturer’s specications.
Standard- or slow-opening gas controls may be converted from one gas to another. To convert from natural gas
to LP use the 393691 LP Conversion Kit that is included
with the VR8304M Gas Control. To convert from LP to
natural gas use the 394588 Natural Gas Conversion Kit
(order separately). Step-opening gas controls cannot be
converted.
To convert control from one gas to another:
1. Turn off main gas supply to the appliance.
2. Remove the regulator cap screw and pressure regu-
lator adjusting screw.
3. Remove the existing spring.
Gas Conversion Kit
4. Insert the replacement spring with tapered end down.
5. Install the new plastic pressure regulator adjustment
screw so that the top of the screw is ush (level) with
the top of the regulator. Turn the pressure regulator
adjustment screw clockwise six complete turns. This
provides a preliminary pressure setting of about 10
inch (254 mm) W.C. for LP regulator and 4 inch (102
mm) W.C. for natural gas regulator.
6. Check the regulator setting either with a manometer
or by clocking the gas meter.
7. Install the new cap screw.
8. Mount conversion label on control.
9. Install control and appliance according to appliance
manufacturer’s instructions.
DECEMBER 18, 2014 6 KLS-G SERIES STATIONARY GAS KETTLES
PROBLEM POSSIBLE CAUSE(S)
Unit will not come on
Unit will turn on electrically but will not heat
Excessive ame rollout on ignition, carboning
Unit slow to preheat and slow to recover
Unit continuously locks out
TROUBLESHOOTING
- Power switch is off.
- Unit not plugged in.
- Main power supply off.
- Bad electronic module.
- Bad low water control.
- Bad spark igniter.
- Bad intermittent pilot burner.
- Fuse in unit blown.
- Lockout has occurred.
- Thermostat not on.
- Gas control valve off.
- Main gas supply off.
- Low water.
- Bad thermostat.
- Bad pressure switch.
- Bad gas control valve.
- Bad spark igniter.
- Bad igniter cable.
- Bad intermittent pilot burner.
- Faulty gas control.
- Natural gas unit on propane.
- Excessive gas pressure.
- Incorrect orice size.
- Faulty regulator in gas control.
- Propane gas on natural.
- Low gas pressure.
- Incorrect orice sizes.
- Loss of vacuum.
- Faulty regulator in gas control.
- Pilot gas adjusted too low.
- Excessive draft condition.
- Excessive steam around bottom of unit during operation of cleaning.
- Faulty transformer.
- Faulty electronic module.
- Faulty ignitor cable.
- Faulty spark igniter.
- Faulty gas control.
DECEMBER 18, 2014 7 KLS-G SERIES STATIONARY GAS KETTLES
KETTLE PARTS
20 - 60 GALLON MODELS
DECEMBER 18, 2014 8 KLS-G SERIES STATIONARY GAS KETTLES
KETTLE PARTS
20 - 60 GALLON MODELS
ITEM PART NO. DESCRIPTION
1 40453 Elbow, 1/4 C x 1/4 FPT 1 1 1 1
2 40542 Level Control 1 1 1 1
3 41333 Component Mounting Bracket 1 1 1 1
4 41861 Fuse, 3 Amp., 250V 1 1 1 1
5 41863 Fuse Holder 1 1 1 1
6 40046 Thermostat 1 1 1 1
7 40033 Recess Control Panel 1 1 1 1
* ** 42548 Control Decal - English 1 1 1 1
* ** 42475 Control Decal - French 1 1 1 1
8 41889 Power Switch 1 1 1 1
9 43391 Pilot Light - 28 Volt, Red Cooking 1 1 1 1
10 42429 Pilot Light - 125 V, Amber - Low Water 1 1 1 1
11 41006 Thermostat Dial 1 1 1 1
12 40815 Pressure Gauge Bracket 1 1 1 1
13 40907 Pressure Gauge 1 1 1 1
14 40022 Support Bracket 1 1 1 1
15 42443 Pressure Switch 1 1 1 1
16 40456 Tee, 1/4 C x 1/8 MPT 1 1 1 1
17 41077 Sight Glass Assembly 1 1 1 1
* 41877 Sight Glass 1 1 1 1
* 42434 Washer 2 2 2 2
* -- Brass Washer 2 2 2 2
* -- Rods 2 2 2 2
18 42440 Tee, 3/8" - 3000 lb 1 1 1 1
19 40425 Connector 1/4 C x 3/8 MPT 1 1 1 1
20 41474 Adjustable Foot 3 3 3 3
21 40058 Door Knob 1 1 1 1
22 40038 Access Door Assembly 1
40039 Access Door Assembly 1 1
40040 Access Door Assembly 1
40049 Door Hinge 1 1 1 1
40062 Corner Front Panel 1
40063 Corner Front Panel 1
40064 Corner Front Panel 1
-- Corner Front Panel 1
40663 Cord Set, 120V 1 1 1 1
41241 Front Shield 1
41245 Front Shield 1 1 1
40035 Manifold Assembly 1 1 1 1
41813 Pipe Plug, 1/8 NPT 1 1 1 1
40709 Pilot Bracket 1 1 1
20 30 40 60
QUANTITY
DECEMBER 18, 2014 9 KLS-G SERIES STATIONARY GAS KETTLES
Loading...