Blodgett KLT-40GS Parts List
KLT-40GS
SHORT HEIGHT GAS TILTING KETTLE
PARTS AND SERVICE MANUAL
EFFECTIVE APRIL 24, 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 S00158 Rev A
TABLE OF CONTENTS
GENERAL .............................................................................3
MANIFOLD PRESSURE ................................................................3
THERMOSTAT .........................................................................3
PRESSURE SWITCH ..................................................................3
ADDING WATER (LOW WATER LIGHT COMES ON) .....................................4
RE-ESTABLISHING VACUUM ...........................................................4
TROUBLESHOOTING ..................................................................5
MATERIAL SAFETY DATA SHEET .......................................................7
APRIL 24, 2015 2 KLT-40GS
SERVICE INFORMATION
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
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 side panel of left hand console.
TOTAL INPUT
125,000 BTU/Hour DMS # 4 (.209") DMS # 20 (.161")
MANIFOLD PRESSURE
Natural Gas - 3.5 inches W.C
LP Gas - 4 inches W.C.
THERMOSTAT
The thermostat adjustment should not be changed.
Check the following before changing the thermostat.
1. With kettle cold, the pressure on the pressure gauge
should read in the green vacuum zone (25 to 30 inches Hg vacuum). If not, see ‘Re-establishing Vacuum”
section.
NATURAL PROPANE
ORIFICE SIZE
The major difculties caused by pressure switch mis-adjustment are:
1. Pressure relief valve opening, pressure rises above
45 psi.
2. Pressure in kettle is less than 30 psi and burner is
being shut down by pressure switch (not thermostat).
The pressure switch is preset for proper operation from
the factory. It is adjusted to the maximum pressure which
will prevent the pressure relief valve from opening. Dur-
ing preheat to the maximum thermostat setting (275°F),
from either a cold condition or a lower temperature setting, the temperature may overshoot the thermostat set-
ting and be shut down by the pressure switch. This is
normal, however, after the kettle has cycled 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 bot-
tom of the panel. Be sure to support the panel to
avoid excessive strain on the wiring.
2. To increase the pressure switch setting, turn the white
ribbed knob clockwise; to decrease, turn it counterclockwise. Use the centre of the black ring as an in-
dicator.
2. The pressure switch may be set too high or too low
and causing the out of adjustment condition. A voltmeter should be used by a properly trained service-
man to determine if the pressure switch or thermostat
is actually cycling the burners. If the pressure switch
is found to be cycling the burners, see “Pressure
Switch” section.
After verifying that the pressure switch is set and oper-
ating properly, To set thermostat, adjust the trim-pot on
the control inside the kettle. It is located next to terminal
2 and is not sealed. Turning pot clockwise will lower the
temperature setting, counterclockwise increases temper-
ature. At maximum setting, 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 dif-
culty. See “Thermostat” section to determine if the source
of difculty is the pressure switch or thermostat.
3. With the kettle empty and completely cold, turn kettle
on and set thermostat to maximum setting (275°F).
4. The pressure in kettle (read pressure gauge on front
panel) should reach a maximum of 30 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
45 psi; pressure switch setting is satisfactory.
6. If the safety 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 increase setting
of pressure switch, cool kettle completely by running
cold water through it and repeat steps 3 - 7.
8. Allow the kettle to cycle several times to verify the
correct pressure setting.
9. Replace the front panel when adjustment is complete.
APRIL 24, 2015 3 KLT-40GS
SERVICE INFORMATION
ADDING WATER (LOW WATER LIGHT COMES ON)
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 next to the
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 water level
at the sight glass is half way between the minimum
and maximum levels.
5. When sufcient water has been added, replace and
tighten the nut. Be sure to seal threads with a pipe
joint compound suitable for steam at 50 psi.
6. Vacuum must be re-established (See Re-establishing
Vacuum).
FOR REFERENCE:
The total amount of distilled water to be added when low
level pilot is illuminated is 372 . oz. (11 L)
RE-ESTABLISHING VACUUM
Periodically check pressure gauge when kettle is cold.
Reading should be in green vacuum zone (below 0 psi).
Otherwise air is present and proper heating will not occur. Use the following procedure to remove air and re-
establish vacuum:
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 vacuum, 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 going to the pressure switch, pressure gauge
or thermostat tting.
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.
APRIL 24, 2015 4 KLT-40GS
TROUBLESHOOTING
PROBLEM SOLUTION
Motor will not run. • No current. Check that power is being supplied to the unit.
• Defective thermostat or pressure switch.
• Defective motor.
• Motor overload out.
• Blown fuse.
Motor runs, no spark. • Defective transformer.
• Defective ignition module.
• Blown fuse on ignition module.
• Defective spark electrode (cracked insulator).
• Defective ignition cable.
• Defective centrifugal switch on motor.
Motor runs, spark present, no gas ignition. • Manual main valve off.
• Mislocated spark or ground rods.
• Defective valve.
• Defective ignition module.
• Burner rate set too high. Ensure that manifold pressure is set per
rating plate and that correct orice size installed (See table page
21.
• Burner getting too much air. Reduce air shutter opening (not be-
low 1.0).
Low water light comes on. • Add water - See previous section
Relief valve opens. • Pressure switch set too high.
• Pressure gauge is not accurate.
• Relief valve is faulty
Flame burns only about 6 seconds and shuts
off.
Short ame. • Wrong size orice.
• Flame rod or ame ground mislocated.
• Defective ame rod wire.
• Defective ignition module.
• Burner rate set too high. Ensure that manifold pressure is set per
rating plate and that correct orice size installed.
• Burner getting too much air. Reduce air shutter opening (not be-
low 1.0).
• Low gas pressure.
• Air shutter adjustment.
• Main manual valve partially closed.
APRIL 24, 2015 5 KLT-40GS
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