Blodgett KLTF-40DS Installation Manual

KLTF-DS Series

BLODGETT OVEN COMPANY

FULLY JACKETED DIRECT ST EAM

TRI-LEG TILTING KETTLE

INSTALLATION – OPERATION – MAINTENANCE

44 Lakeside Avenue, Burlington, Vermont 05401 USA Telephone: [phone] Fax: [phone]

www.blodgett.com

S00155 Rev A (9/13)

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possible injury or death.

installing, operating or servicing this equipment.

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

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

Intended for commercial use only. Not for household use.

NOTICE: Contact the factory, the factory representative or local service company to

perform maintenance and repairs.

This manual should be retained for future reference.

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TABLE OF CONTENTS

DESCRIPTION PAGE

INSTALLATION AND SERVICE CONNECT IONS ............................................................. 4

1.0 INSTALLATION INSTRUCTIONS ............................................................................ 5

2.0 INTRODUCTION - DESCRIPTION ........................................................................... 6

3.0 OPERATING INSTRUCTIONS ................................................................................. 7

4.0 CLEANING INSTRUCTIONS ................................................................................... 7

5.0 MAINTENANCE ....................................................................................................... 8

6.0 TROUBLESHOOTING ............................................................................................. 8

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SERVICE CONNECTIONS

Steam Supply
Condensate Retur n
Faucet Connection

F

FLANGED FOOT DETAIL

4 EQUALLY SPACED
Ø7/16” (11) HOLES
ON 3” (76) B.C.

SAFET

Y RELIEF

V

AL

VE

STRAINERAND STEAM

TRAP

(OPTIONAL)

L

L

NOTE: 30, 40 & 60 GALLON KETTLES
ARE SUPPLIED W ITH 2 REAR SUPPORT

LEGS

2” VALVE:

CLOSED 5.13 (130)
OPENED 6.88 (175)

3” VALVE:

CLOSED 7.88 (200)
OPENED 10.13 (257)

DIMENSIONSARE IN INCHES (MM)

SPRING
ASSISTED
COVER
(OPTIONAL)

JACKE

T
DRAIN
VALVE

K

E

D

B

C

F

5.28
(134)

F

H M

J

2” OR 3” TANGENT

DRAW OFF VALVE

(OPTIONAL)

FAUCET
(OPTIONAL)

G

10.86
(276)

F

10.28
(261)

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1.0 INSTALLATION INSTRUCTIONS

1. Select a location to provide drainage for the kettle pour path when tilted and for the draw-off
valve if so equipped.

2. Mark hole locations through flanged adjustable feet. Remove the kettle.

3. On hole locations marked, drill holes and insert expansion shields to accommodate 5/16"
size lag bolts.

4. Reposition the kettle. Level the kettle by making necessary adjustment on flanged foot.

5. Bolt down kettle and seal with Silastic or other equivalent sealing compound. A sealant
must be applied not only to bolt heads but also around flanges or pedestal base making
contact with floor surface to fulfil NSF requirements.

6. Connect steam line (3/4" pipe size) to the kettle, making sure there is a steam control valve
strainer fairly convenient to the kettle.

7. Connect kettle condensate return line to a drain or to a boiler return line. Each kettle return
line must have a suitable steam trap. Boiler return lines must have a check valve.

8. The safety relief valve on the kettle must not be plugged as it is set to relieve excess
pressure in the kettle.

9. If incoming steam pressure is greater than kettle maximum operation pressure then a
pressure reducing valve must

be installed in the line.

10. If large amounts of water accumulate in the steam line, it will be necessary to install one or
more ball float traps in the line to eliminate the water.

11. A steam line pressure gauge is also recommended to determine the actual amount of
steam being supplied to the kettle.

12. Check for proper operation.

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2.0 INTRODUCTION - DESCRIPTION

All Blodgett direct connected steam jacketed kettles pertaining to this manual are direct steam
operated pressure vessels of a double-wall stainless steel construction forming a steam chamber
(jacket) enveloping the kettle bowl surface. All kettles are tilting, floor mounted in fixed positions
either on legs with adjustable flanged feet. All kettles are equipped with a drain cock, safety
relief valve and a steam control valve. Options on kettles are hinged spring assisted stainless
steel lid covering the kettle bowl opening and a sanitary stainless steel tangent draw-off valve as
an alternate method for the removal of the food product from the kettle bowl.

CAPACITIES
All model names contain either - 40 or – 60 to indicate the capacity of that kettle in U.S. gallons.

Thus a KLTF-40DS is a full jacketed direct steam kettle mounted on legs with a capacity of 40
gallons (U.S ).

FUNCTIONING MODE
Blodgett direct connected steam jacketed kettles consist of a stainless steel bowl and a stainless

steel jacket which envelopes the lower surface of the bowl thus forming a sealed pressure vessel
(chamber) into which steam is introduced by means of a manual control valve.

The kettle bowl is the container for the food product which ideally should be of a liquid or semi­liquid consistency to achieve complete contact with the bowl surface and thus fully absorb the
heat transmitted through the surface.

The temperature required for the cooking process to function adequately must be greater than
the boiling point of the liquid food product. Further, the greater the steam pressure used, the
higher the temperature and consequently the quicker the cooking process. For example, steam
pressurized at 30 p.s.i. attains a temperature of 274 degrees Fahrenheit (135 degrees Celsius).

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3.0 OPERATING INSTRUCTIONS

1. If kettle has draw-off valve, close it.

2. Fill kettle with product to desired level.

3. Slowly turn the steam control valve ON to full open position (counter clockwise).

4. The kettle should boil 2-3 gallons of water per minute. If it does not then incoming pressure

and piping should be checked to determine that it is adequate to operate the kettle efficiently.

5. Regulate steam control valve depending on type of food being prepared.

6. When food is cooked, turn off steam, remove food and clean kettle immediately to prevent

residue from drying on kettle bowl surface.

4.0 CLEANING INSTRUCTIONS

Your kettle should be cleaned immediately after each use.

1. Ensure that steam supply is OFF.

2. Pre-rinse inside of the kettle thoroughly and drain to remove any food particles.

3. Using a nylon brush, clean the kettle with a mild detergent and warm water rinse. Never use

steel wool or scouring powder as it will scratch stainless steel.

4. Tilt the kettle fully or open the tangent draw-off valve if one is provided to allow soap and

water solution to drain. Rinse with clean water.

5. On kettles equipped with a draw-off valve, turn the large hex nut counterclockwise by hand

until it is completely disengaged from the thread. Grasp the knob to valve and slowly pull out
valve stem and disc. Do not allow the disc to come in contact with hard surfaces since
damage may occur and result in valve leakage. Wash the valve stem, disc and handle.
Insert nylon brush with detergent into interior of valve body and tangent draw-off tube and
brush vigorously. Replace valve stem assembly and engage the hex nut fully by hand. Flush
the kettle with clean warm water. Leave the valve open when the kettle is not in use

CAUTION: Do not use cleaning agents that are corrosive.

Use of cleaning agents that contain chloride, acids or salts are corrosive and may cause pitting
and corrosion when used over a period of time; this will reduce the life of the appliance.

Pitting or corrosion is not covered by warranty.
Follow the recommended cleaning instructions. Use a mild detergent, warm water and rinse

thoroughly.

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should also be performed at the end of any non-service period.

any bodily contact.

test. Wear proper safety equipment and exercise extreme care! Test

qualified service personnel.

5.0 MAINTENANCE

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”

CAUTION! Hot, high pressure fluid may be discharged from body
drain and vent during “try lever” test. Care must be taken to avoid

CAUTION! High sound levels may be experienced during “try lever”
at, or near, half of the operating pressure by holding the test lever

fully open for at least two seconds to flush 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

6.0 TROUBLESHOOTING

DRAW-OFF V ALVE LEAKS

If a leak occurs through the valve steam, replace the “O” ring. If the leak can be attributed to
faulty sealing occurring between the stem disc and valve seat, then quite often this problem can
be corrected by cleaning off the dried on food residue with an extremely fine emery cloth or the
rubber vulcanized stem piece has been damaged and must be replaced.

NOTICE: Draw-off valve has a vulcanized rubber coated stem for better sealing. Do n o t o ver
tighten. This may cause the rubber to pull away from stem and permanently damage it.

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EXTREMELY SLOW COOKING TIME
If the cooking time is abnormally slow then the difficulty may be due to insufficient steam

pressure and/or volume. First determine that pressure on incoming steam line at kettle is within
5 p.s.i. of rated kettle pressure. Note that pressures approaching the rated kettle pressure are
liable to set off the safety relief valve. If required pressure is available to kettle, then possibly
volume of steam is not sufficient. Minimum 3/4" pipe size is required to the kettle but if the steam
generating source is at a great distance from the kettle, larger pipe will be required. Finally, the
core of the steam supply pipe may have debris or scalants that impede steam flow and will
require disassembly and inspection.

AIR VENTING
It is recommended that the “optional” steam trap assembly be installed. This should be plumbed

to the exit end of the kettle. The thermostatic trap is a mechanical device that closes on high
temperature and opens when the temperature drops, allowing the water which formed from
condensate to exhaust but retain the steam under pressure.

The temperatures required for the cooking process to function adequately must be greater than
the boiling point of the liquid food product, that is, water. The greater the steam pressure used,
the higher the temperature and the quicker the cooking process. For example, steam
pressurized at 30 p.s.i. reaches a temperature of 274 degrees Fahrenheit (135 degrees Celsius).
Since air is an unsuitable media through which heat may be transferred, the air should be
exhausted from the jacket by opening the pressure relief valve until the air has been completely
replaced by pressurized steam.

In the initial stages of the cooking process when the steam comes in contact with the cold kettle
bowl surface, it condenses and forms a large amount of water. The condensate water must be
removed from the kettle jacket in order for the kettle to function adequately. The ball valve
located at the base of the kettle jacket may be opened to remove the water. It may be necessary
to repeat this procedure several times depending on the number of batches being cooked as
each batch will create condensate. If the kettle appears to be slow in heating, this would indicate
that there is water in the jacket. Open ball valve and drain. Close valve and commence
operation of kettle.

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