Blodgett KLS-20G, KLS-40G, KLS-60G User Manual

KLS-20G, KLS-40G and KLS-60G

GAS FIRED TRI-LEG 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

S00064 Rev A (5/04)

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.

FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapours or liquids in the vicinity of this or any other appliance.

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.

PURCHASER: Instructions to be followed in the event that the operator of this appliance smells gas must be posted in a prominent location. This information shall be obtained by consulting the local gas supplier.

Do not obstruct the flow of combustion and ventilation air.

Keep the appliance area free and clear from combustibles.

Adequate clearances must be maintained for servicing and proper operation.

Do not attempt to operate this unit in the event of a power failure.

Intended for commercial use only. Not for household use.

This manual should be retained for future reference.

TABLE OF CONTENTS

DESCRIPTION PAGE

Important Notes for Installation and Operation .................................................................. 2

1.0 Service Connections ................................................................................................... 4

2.0 Installation ................................................................................................................... 5

3.0 Performance Check .................................................................................................. 10

4.0 Operation .................................................................................................................. 11

5.0 Maintenance ............................................................................................................. 17

6.0 Service ...................................................................................................................... 22

Adjustments ..................................................................................................................... 24

Troubleshooting ...............................................................................................................29

Appendix ‘A’, Material Safety Data Sheet ........................................................................ 31

1.0 SERVICE CONNECTIONS

GAS: KLS-20G

-Total 100,000 BTU. One 1" male connection (for location, see drawing below.) Natural Propane Required operating pressure: Natural Gas 4" W.C.; Propane Gas 10" W.C

- Total 100,000 BTU. One 1" male connection.

KLS-40G

(for location, see drawing below.) Natural Propane Required operating pressure: Natural Gas 4" W.C.; Propane Gas 10" W.C

- Total 130,000 BTU. One 1" male connection

GL-60E

(for location, see drawing below.) Natura Propane. Required operating pressure: Natural Gas 4" W.C.; Propane Gas 10" W.C.

MODELBACAPACITY

KLS-20G

KLS-40G

KLS-60G

20 gallons

76 litres

40 gallons

152 litres

60 gallons

227 litres



UNITS

inches

508mm

inches

660mm

inches

762mm

31.25

794

35.5

902

1016

UTILITY INFORMATION:

ELECTRIC:

STANDARD: 115/60/1 - furnished with 6 ft. cord w/3-prong



OPTIONAL: 208/60/1 or for use on 3 (190 to 219 volts) -



OPTIONAL: 240/60/1 or for use on 3 (220 to 240 volts) -

DIMENSIONS

1016

49.5

1257

813

38.5 9781118

1016

51 483

2.5 63

KLS-20G = Ø 20.75" KLS-40G = Ø 26.75" KLS-60G = Ø 30.75"

plug. Total maximum amps 2.0.

supply must be wired to unit - see drawing below. Total maximum amps 1.0.

483

21.5 546

FED

1626

215985889

610

7371829

30.5 775

889

991

6.0

152

6.0

152

8.0

203

18.25 464

559

24.62 625

6(152)

CLOSED 5.5(140) OPENED 7.5[191]

STANDARD Ø 2(51] VALVE

FRONT

ØA

120° X 3

DIMENSIONS ARE IN INCHES [MM]

2.0 INSTALLATION

INSTALLATION CODES AND STANDARDS

Installation must conform with local codes, or in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code, CSA B149.1, as applicable.

1. The appliance and its individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at pressures in excess of ½ psi (3.5 kPa).

2. The appliance must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than ½ psi (3.5 kPa).

Electrical grounding must be provided in accordance with local codes, or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70, or the Canadian Electrical Code, CSA C22.2, as applicable.

The electrical diagram is located on the inside of the console control cover.

EXHAUST FANS AND CANOPIES: Canopies are set over ranges, ovens and kettles for ventilation purposes. It is recommended that a canopy extend 6" past appliance and be located

7.5 feet from the floor. Filters should be installed at an angle of 45 degrees or more with the

horizontal. This position prevents dripping of grease and facilitates collecting the run-off grease in a drip pan, usually installed with the filter. A strong exhaust fan tends to create a vacuum in the room and may interfere with burner performance or may extinguish pilot flames. Makeup air openings approximately equal to the fan area will relieve such vacuum. In case of unsatisfactory performance on any appliance, check operation with exhaust fan in the “OFF” position.

WALL EXHAUST FAN: The exhaust fan should be installed at least 2 feet above the vent opening at the top of the unit.

CLEARANCES: Adequate clearance must be provided in aisle and at the side and back. Adequate clearances for air openings into the combustion chamber must be provided, as well as for serviceability.

SIDES - 6 INCHES

BACK - 2 INCHES AT FLUE BOX

FLOORS - 6 INCH LEGS OR 8 INCH LEGS

All units must be installed in such a manner that the flow of combustion and ventilation air are not obstructed. Provisions for an adequate air supply must also be provided. Do not obstruct the lower front or right side of the unit, as combustion air enters through these areas. The bottom of the control area must also remain unobstructed.

2.0 INSTALLATION (Continued)

TO INSTALL

1. Uncrate carefully. Report any hidden freight damage to the freight company immediately.

2. Set the unit in place. Be certain to maintain minimum clearances as stated above.

3. To level the unit use a spirit level in all directions on the top of the kettle (lid up).

A. Units with legs - adjust the bottom foot on each leg to overcome an uneven floor.

B. Units with casters - loosen the locking nuts, turn casters in or out as required and tighten

locking nuts.

4. Be certain to leave adequate clearances for cleaning, maintenance and service.

5. The pressure relief valve is located at the left rear of the unit. This area should be kept clear and should not be in an area where operators will normally stand. The elbow on the relief valve should be turned toward the floor. A maximum 3 foot, 3/4" diameter pipe may be used to extend to the floor, but must not be piped directly to a drain. It must vent to the atmosphere.

6. Check the pressure gauge on the front panel before operating. If the pressure gauge does not indicate green vacuum zone (below 0 psi), see “Re-establishing Vacuum” section under SERVICE, after completing installation instructions.

GAS CONNECTION

The serial plate on the lower right side of the unit indicates the type of gas your unit is equipped to burn. Do NOT connect to any other gas type.

A 1" NPT line is provided at the rear for the connection. Each unit is equipped with an internal pressure regulator which is set for 4" W.C. manifold pressure for natural gas and 10" W.C. for propane gas. Use 1/8" pipe tap on the burner manifold for checking pressure.

An adequate gas supply is imperative. Undersized or low pressure lines will restrict the volume of gas required for satisfactory performance. A steady pressure, minimum 6" W.C. for natural gas and minimum 11" W.C. for propane gas, is recommended. With all units operating simultaneously, the manifold pressure on all units should not show any appreciable drop. Fluctuations of more than 25% on natural gas, and 10% on propane gas, will create pilot problems and affect burner operating characteristics. Contact your gas company for correct supply line sizes.

2.0 INSTALLATION (Continued)

Purge the supply line to clean out any dust, dirt, or other foreign matter before connecting the line to the unit. It is recommended that an individual manual shut off valve be installed in the gas supply line to the unit. Use pipe joint compound which is suitable for use with LP gas on all threaded connections. Test pipe connections thoroughly for gas leaks.

WARNING: All connections must be checked for leaks, after the unit has been put in operation. Use soapy water only for testing on all gases. Never use an open flame to check for gas leaks.

NOTICE: If applicable, the vent line from the gas appliance pressure regulator shall be installed to the outdoors in accordance with local codes or, in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code CSA B149.1, as applicable.

NOTICE: If this equipment is being installed at over 2,000 feet altitude and was not so specified on order, contact service department. Failure to install with proper orifice sizing may void the warranty.

WATER CONNECTION

On units equipped with an optional water fill valve connect a water line (minimum 1/4") to the valve with a 1/4" NPT female fitting. Units with dual (hot and cold) valves must have the hot water line connected to side with the hot water valve (red) and cold water line to the cold water valve (blue). Plastic or rubber hose is not recommended, as it may melt against the hot kettle side.

2.0 INSTALLATION (Continued)

WARNING: For an appliance equipped with casters, the installation shall be made with a connector that complies with the standard for connectors for moveable gas appliances, ANSI Z21.69-CSA 6.16 and a quick-disconnect device that complies with the standard for quick-disconnect devices for use with gas fuel, ANSI Z21.41CSA 6.9; adequate means must be provided to limit the movement of the appliance without depending on the connector and the quick disconnect device or its associated piping to limit the appliance movement; the location where the restraining means may be attached to the appliance is on bottom of unit directly below relief valve.

If the unit is also equipped with an optional water fill valve it too must be installed with a flexible water supply tube, a quick disconnect and strain relief.

WARNING: Do not connect the appliance to the electrical supply until after the gas connection has been made.

1. 120 VAC - 60 Hz - Single Phase.

Units with this electrical rating are factory supplied with a three-wire cord and three-prong plug which fits any standard 120V, three-prong grounded receptacle. A separate 15 amp supply is needed for each unit.

2.0 INSTALLATION (Continued)

WARNING: ELECTRICAL GROUNDING INSTRUCTIONS This appliance is equipped with a three-prong (grounding) plug for your protection against shock hazard and should be plugged directly into a properly grounded three-prong receptacle. Do not cut or remove the grounding prong from this plug. (120V units only).

1. 208/240 VAC - 60 Hz - Single and Three Phase.

Units with this electrical rating are factory equipped with a transformer. To connect supply wires remove cover from transformer box at right rear of unit. Route supply wires and ground wire through the hole in the cover with a strain relief fitting. Connect wires to the primary transformer terminals as required by your power supply voltage. Connect ground wire to ground lug. Replace cover. Three-phase units are wired as above, using only two supply wires. The third supply wire is not connected and must be properly terminated.

1. 220 VAC - 50 Hz - Single Phase.

Units equipped with this voltage rating should be wired exactly as in (2) above.

3.0 PERFORMANCE CHECK

The following items should be checked before or within the first 30 days of operation by a qualified service technician.

1.0 Verify correct gas type.

2.0 Verify correct voltage, cycle and phase.

3.0 Gas pressure.

4.0 Internal gas connections.

5.0 Internal electrical connections.

6.0 Pilots - adjustment and ignition.

7.0 Burners - adjustment and ignition.

8.0 Thermostat - cycle for operation check.

9.0 Supply valve - check for operation.

10.0 Check hinge and lid assembly.

11.0 Draw-off valve - check operation.

12.0 Advise user on cleaning procedures.

4.0 OPERATION

Contact the factory, the factory representative or a local service company to perform maintenance and repairs should the appliance malfunction.

WARNING: In the event of main burner ignition failure, a 5 minute purge period must be observed prior to re-establishing ignition source.

WARNING: In the event you smell gas, shut down equipment at the main shut off valve and contact the local gas company or gas supplier for service.

CAUTION: If you smell gas during the lighting procedure, immediately shut off the gas supply until the leak has been corrected.

GAS CONTROL INSTRUCTIONS:

Appliance does not require “Lighting” the pilot with a flame.

A. STARTUP

1. Turn thermostat to “OFF” position and power switch to “OFF” position.

2. Open control panel access door located on right side at bottom.

3. Turn dial on combination control to “ON” position by rotating control knob counterclockwise. (NOTE: Any gas service valves exterior to the unit should be open.)

4. Turn “POWER” switch to “ON” position.

5. Set “COOK TEMP” to desired setting. The red “COOKING” pilot will be on until desired setting has been reached.

6. At this time the spark igniter will begin sparking at the pilot until the pilot is ignited, or for ninety seconds (an audible clicking sound will be evident).

7. When the pilot is ignited the spark igniter will automatically stop and within 15 seconds main burner gas will come on. If ignition does not occur, after a total of ninety seconds, the unit will lockout, shutting off all gas although the spark igniter will continue to spark. New installations (where there may be a considerable amount of air

in the gas line) may require the unit to be turned off and immediately back on numerous times after each lockout period until the air is purged from the gas line.

B. SHUTDOWN

STANDBY

1. Place power on switch and thermostat to “OFF” position.

COMPLETE

1. Place power on switch and thermostat to “OFF” position.

2. Turn dial on combination control from “ON” position to “OFF” position.

3. Turn any main gas service valves supplying gas to “OFF” position.

RELIGHTING

1. Turn power switch to “ON” position.

It should be noted that the pilot and electronic ignition do not cycle with the thermostat. A standing pilot is automatically established and monitored each time the power switch is turned ON. If the pilot is ever extinguished by a momentary external interruption, the spark igniter will automatically relight it without disturbing the cooking cycle, unless lockout occurs.

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