Vulcan VDWS-30 Service Manual

INSTALLATION, OPERATING.

JACKETED KETTLES

SERVICE AND PARTS MANUAL

FOR DIRECT STEAM WALL

MOUNTED STATIONARY AND

WALL MOUNTED TILTING 2/3

SERIES: VDWS & VDWT

Vulcan service agencies are located throughout the United States.

For location and phone number of one near you, call your local Vulcan dealer.

VULCAN-HART CORPORATION, P.O. BOX 696, LOUISVILLE, KY 40201-

0696, TEL. [phone] TECHNICAL ASSISTANCE [phone]

FORM 30005 (2-90)

IMPORTANT

OPERATING, INSTALLING AND SERVICE PERSONNEL

The operating information on this equipment has been prepared for use by qualified and/or authorized
operating personnel.

All installation and service on this equipment is to be performed by qualified, certified, licensed and/ or
authorized installation or service personnel, with the exception of any part marked with a D in front of the
part number.
To obtain the name and location of an authorized Vulcan service agency, contact your Food Service
Equipment dealer or by calling 1 -800-626-2700.

DEFINITIONS

QUALIFIED AND/OR AUTHORIZED OPERATING PERSONNEL

Qualified or authorized operating personnel are those who have carefully read the information in this
manual and are familiar with the equipment's functions or have had previous experience with the
operation of the equipment covered in this manual.

1. For the installation of gas piping from the outlet side of the gas meter, or the service regulator when
the meter is not provided, and the connection and installation of the gas appliance, qualified
installation personnel must be experienced in such work, be familiar with all precautions required, and
have complied with all requirements of state or local authorities having jurisdiction. In the absence of
local codes, installation must comply with National Fuel Gas Code ANSI Z223.1 latest edition.

2. For the installation of electrical wiring from the electric meter, main control box or service outlet to the
electric appliance, qualified installation personnel must be experienced in such work, be familiar with
all precautions required, and have complied with all requirements of state or local authorities having
jurisdiction. In the absence of local codes, installation must comply with the National Electrical Code
ANSI NFPA No. 70 latest edition.

3. For the installation of steam piping from the source of supply to the service inlet of the appliance,
qualified installation personnel must be experienced in such work, be familiar with all precautions
required, and have complied with all requirements of state or local authorities having jurisdiction.

QUALIFIED SERVICE PERSONNEL

Qualified service personnel are those who are familiar with this equipment who have been endorsed by
our company. All authorized service personnel are required to be equipped with a complete set of service
and parts manuals and stock a minimum amount of parts for this equipment.

SHIPPING DAMAGE CLAIM PROCEDURE

For your protection, please note that equipment in this shipment was carefully inspected and packed by
skilled personnel before leaving the factory. The transportation company assumes full responsibility for
safe delivery upon acceptance of this shipment.

If shipment arrives damaged:

1. VISIBLE LOSS OR DAMAGE- Be certain this is noted on freight bill or express receipt and signed

by person making delivery.

2. FILE CLAIM FOR DAMAGES IMMEDIATELY - Regardless of extent of damage.

3. CONCEALED LOSS OR DAMAGE- If damage is unnoticed until merchandise is unpacked, notify

transportation company or carrier immediately, and file "concealed damage" claim with them. This
must be done within fifteen (15) days of the date the delivery is made to you. Be sure to retain
container for inspection.

We cannot assume responsibility for damage of loss incurred in transit. We will, however, be glad to
furnish you with necessary documents to support your claim.

PLEASE RETAIN THIS MANUAL FOR FUTURE REFERENCE

2

INDEX

DESCRIPTION

PAGE

Your Vulcan Steam Jacketed Wall Mounted Kettle is
produced with the best workmanship and material.
Proper installation, usage and maintenance will result
in many years of satisfactory performance.

The manufacturer suggests that you thoroughly read

DEFINITIONS OF PERSONNEL OPERATING, INSTALLATION
and SERVICE AND SHIPPING DAMAGE CLAIM PROCEDURES (Inside Front Cover)

INDEX 3
DESCRIPTION 4
CAPACITIES 4

INSTALLATION 4

OPERATING 5

this entire manual and carefully follow all of the instruc­tions provided. Save this manual for future reference.

A data plate with the unit model number and serial
number and direct steam supply pressure to be used
is on the unit.

CLEANING 6

SERVICE 6
MAINTNENANCE 5

AIR VENTING 6

EXTREMELY SLOW COOKING TIME 6
DRAW OFF VALVE LEAKS 6

PARTS: DRAW OFF VALVE (OPTIONAL) 7

PARTS: SPRING ASSISTED HINGED ASSEMBLY (STANDARD) 8

PARTS: TILTING MECHANISM 9-10

3

DESCRIPTION

The Vulcan VDWS and VDWT kettles are wall
mounted direct steam models. The VDWS is a modular
stationary model supplied with a tangent draw off valve
for food product removal.

The kettles in this manual are direct steam operated
pressure vessels with a double wall stainless steel
construction forming a steam chamber (jacket) around
the lower two thirds of the kettle. These kettles are
equipped with a drain valve, a pressure relief valve and
a steam

CAPACITIES

All models end with 20,30,40,60 and 80 to indicate the
capacity of that kettle in gallons. For example, model
VDWT40 indicates a two thirds jacketed wall mounted
tilting steam kettle, with a capacity of 40 gallons. A
VDWS40 is a stationary wall mounted kettle, 40 gallon
capacity.

control valve. Stationary kettles (VDWS) have a hinged
stainless steel cover and a stainless steel tangent draw
off valve. A stainless steel cover and a tangent draw
off valve are optional extras on the tilting kettle (Model
VDWT).
The kettle bowl is the container for the food product
which should be a liquid or semi-liquid for complete
contact with the bowl surface to fully absorb the heat
transmitted through the surface from the steam in the
kettle jacket.

INSTALLATION

WARNING: PLUMBING CONNECTIONS MUST

COMPLY WITH APPLICABLE HEALTH, SAFETY
AND PLUMBING CODES.

A. Mount the kettle on the wall carrier and secure it

in place. Use the Vulcan supplied in-the-wall
carrier.

B. Install a separately purchased steam control valve

at a convenient location near the kettle on the
incoming steam line (3/4" size pipe).

C. Connect the steam line (3/4" pipe) line to the

kettle, making sure there is a steam control valve
strainer (not supplied) fairly convenient to the
kettle.

D. Connect the kettle condensate return line to a

drain or to a boiler return line. Each kettle return
line must have a suitable steam trap (not sup­plied). Boiler return lines must have a check valve
(not supplied).

E. The relief valve on the kettle must not be adjusted

or closed off as it is set to relieve excess pressure
in the kettle.

F. If the incoming steam pressure is greater than the

kettle maximum operating pressure, then a pres­sure reducing valve (not supplied) must be in­stalled in the line.

G. If large amounts of water accumulate in the steam

line, it will be necessary to install one or more ball
float traps (not supplied) in the line to eliminate the
water.

H. A steam line pressure gauge (not supplied) is also

recommended to determine the actual amount of
steam coming to the kettle.

I. Check for proper operation.

4

OPERATING

WARNING: THE KETTLE IS HOT. USE CARE

WHEN OPERATING AND SERVICING THE KETTLE.
A. If a draw off valve is provided, check that it is

closed.

B. Fill the kettle with product to the desired level.

NOTE: Food products with milk or egg base should be

placed into a cold kettle and then the cooking
operation begun. Avoid sudden contact of these food
products with a hot kettle surface because the food will
stick to the surface.

C. Slowly turn the steam control valve ON to the full

open position (counter clockwise). The kettle will
begin to heat. It is important that the condensate
return valve located on the bottom of the kettle be
opened daily before starting the unit up. This will
allow any accumulation of water to be emptied.
Not doing this reduces the efficiency of the kettle.

D. Slowly open the relief valve to allow all air to

escape. WARNING: STAY CLEAR OF THE
VALVE OUTLET DURING THIS OPERATION TO
AVOID VERY HOT STEAM.

E. The food or liquid should boil 3 to 4 minutes per

gallon. If it does not, then the incoming pressure
should be checked to determine that it is adequate
to operate the kettle efficiently.

F. Regulate the steam control valve depending on

the type of food being prepared.

G. When the food is cooked, turn off the steam,

remove the food through the draw off valve or by
tilting. Clean the kettle immediately to prevent
residue from drying on the kettle bowl.

H. To tilt the VDWT, turn the hand wheel to raise

and lower the kettle.

CLEANING

The kettle interior and exterior should be thoroughly
washed after each use when a different food is to be
cooked next or when cooking is completed for the day.
Before cleaning check that the kettle has cooled
enough to touch it.

A. Check that the steam supply is turned "OFF".
B. Rinse the inside of the kettle thoroughly and drain

to remove any food particles.

C. Using a nylon brush, clean the kettle with a mild

detergent and water rinse. Never use steel wool
or scouring powder as it will scratch stainless
steel. Also, plain steel wool can leave small
pieces of steel wool which can rust.

D. Tilt the kettle to its highest position or open the

tangent draw off valve, if one is provided, to allow
the detergent and water solution to drain. Rinse
thoroughly with clean water.

E. On a kettle equipped with a draw off valve, by

hand, turn the large hex nut on the draw off valve
counter clockwise until it is completely disengaged
from the threads. Grasp the valve knob and slowly
pull out the valve stem and disk. Do not allow the
disk to come in contact with hard surfaces as it
can be damaged and cause valve leakage. Wash
the valve stem, disk and handle. insert a nylon
brush wet with detergent and water into the valve
body and the tangent draw off tube. Brush
vigorously.

F. Replace the valve stem assembly and turn the

hex nut until snug. Rinse the kettle with clean
warm water.

G. Leave the draw off valve open when the kettle is

not in use.

H. Wipe the exterior of the kettle with a clean, damp

cloth.

5

SERVICE

MAINTENANCE

DRAW OFF VALVE LEAKS

No general maintenance is required other than follow­ing the cleaning procedures.

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 the pressure on the
incoming steam line at the kettle is within 5 p.s.i. of the
rated kettle pressure. Note that a pressure approaching
the rated kettle pressure is liable to set off the relief
valve. If the required pressure is available at the kettle,
then possibly the 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
inside of the steam supply pipe may have debris or
scalants that impede the steam flow and the pipe will
require disassembly and inspection.

AIR VENTING

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 F. (135 deg. C.). 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.

If a leak occurs through the valve stem, replace the "O"
ring.

If the leak is due to faulty sealing between the stem
disc and valve seat, this problem can usually be
corrected by cleaning off the dried on food residue with
an extremely fine emery cloth.

If the disk or valve seat are found to be excessively
damaged, either or both must be replaced.

However, if only slight damage to either the disk or
seat has occurred, then the following lapping
procedure should correct it:

A. Follow cleaning procedures.
B. Remove the knob handle from the end of the

stem. Unscrew and remove the bonnet from the
stem. Put the knob back on the stem.

C. Apply a fine grade lapping compound around the

sealing edge of the disk and insert it into the valve,
making light contact against the seat.

D. By hand, rotate the stem disk against the valve

seat, allowing the stem to wobble slightly in the
space previously occupied by the bonnet.

E. Repeat steps C and D several times.
F. Reassemble, close the valve and test it for leaks.

G. If leakage persists, then repeat this lapping

procedure.

6

PARTS: DRAW OFF VALVE (OPTIONAL)

ITEM NO.

1 836939 '836939 836940 Nut 1
2 836967 836967 836942 Handle 1
3 836943 836944 836945 Hex. Assembly Nut 1
4 836946 836947 836948 Bonnet 1
5 836965 836950 836951 Disc & Stem Assembly 1
6 836966 836953 836954 "0" Ring 1
7 836955 836956 836957 Valve Body 1

1" Valve 2" Valve 3" Valve

PART NO.

DESCRIPTION QUANTITY

7

PARTS: SPRING ASSISTED HINGE ASSEMBLY (STANDARD)

ITEM NO. PART NO. DESCRIPTION (20 to 40 Gal. Kettles) QUANTITY

1 836977 Lock Pin 1
2 836978 End Lock Plate 1
3 836979 Stationary Disc 1
4 836980 Cores 2
5 836981 Spring 1
6 836982-X Handle Assembly (Specify Model No.) 1
7 836983 Rotary Disc 1
8 836932 End Stop Plate 1
9 SC-041-50 Cap Screws 4

10 836964 Knob (Also 60 to 100 Gal. Kettles) 1

ITEM NO. PART NO. DESCRIPTION (60 to 100 Gal. Kettles) QUANTITY

1 836986 Lock Pin 1
2 836987 End Lock Plate 1
3 839988 Stationary Disc 1
4 836989 Cores 2
5 836990 Spring 1
6 836991-X Handle Assembly (Specify Model No.) 1
7 836992 Rotary Disc 1
8 836993 End Stop Plate 1
9 SC-041-01 Cap Screws 4

836994 -X Cover (Not Shown - Specify Model No.) 1

8

PARTS: TILTING MECHANISM

9

PARTS: TILTING MECHANISM

1 881962

Handwheel

1

ITEM NO. PART NO. DESCRIPTION QUANTITY

2 SC-047-42 Set Screw 1
3 836936 Tilting Shaft 1
4 836952 Tension Pin 1
5 881965 Worm Gear 1
6 881963 Thrust Bearing 2
7 NS-013-50 Jam Nut 2
8 881984 Steam Control Valve 1
9

10 836971 Spacer Collar 1
11 SC-090-12 Fastening Bolt 4
12 WL-004-06 Lock Washer 4
13 SC-047-42 Set Screw 1

14 836970 Outbore Bearing 1

881964 "Large Segment Gear 1

836949 Key (Not Visible) 1
881967 "O" Ring (Not Visible) 4

*Small Segment Gear or 1

NOTE: Item No. 14, Outbore Bearing as shown, is standard for all kettles without Hinged

Covers. If the optional Hinged Cover has been ordered, specify the part number as well as
Model and Capacity of Kettle.

* Small Segment Gear is used on 20, 30 and 40 Gallon Kettles
* Large Segment Gear is used on 60, 80 and 100 Gallon Kettles

10