KPS/KLS-DS Series DIRECT STEAM STATIONARY FLOOR KETTLE INSTALLATION - OPERATION - MAINTENANCE BLODGETT OVEN COMPANY www.blodgett.
THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE. READ, UNDERSTAND AND FOLLOW THE INSTRUCTIONS AND WARNINGS CONTAINED IN THIS MANUAL. FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.
IMPORTANT - READ FIRST - IMPORTANT CAUTION: BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE OPERATING INSTRUCTIONS, CAUTIONS, AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL. WARNING: THIS UNIT IS INTENDED FOR USE IN THE COMMERCIAL HEATING, COOKING AND HOLDING OF WATER AND FOOD PRODUCTS, PER THE INSTRUCTIONS CONTAINED IN THIS MANUAL. ANY OTHER USE COULD RESULT IN SERIOUS PERSONAL INJURY OR DAMAGE TO THE EQUIPMENT AND WILL VOID WARRANTY.
Table of Contents Important Operator Warnings ....................................................... page 1 References.................................................................................... page 2 Equipment Description............................................................... page 3-4 Installation ..................................................................................... page 5 Initial Start-Up................................................................................
Equipment Description The direct steam heated kettles covered in this manual are one-piece, welded constructions of 18.8 type 304 stainless steel, which are listed by the National Sanitation Foundation. They have bar rims with a continuous seal weld on the underside. The kettles are ASME shop inspected, and registered with the national board for operation at pressures up to 25 PSI. They are finished to 180 emery grit interior, and a bright semideluxe exterior.
Equipment Description Kettle Capacity Inside Diameter Rim Height Overall Width Front-to-Back Base Style 20DS-KPS 20 Gallons 75 liters 20 inches 508 mm 36 inches 914 mm 22 inches 559 mm 26-1/4 inches Pedestal 667 mm 40DS-KPS 40 Gallons 150 liters 26 inches 660 mm 36 inches 914 mm 28 inches 711 mm 31-3/4 inches Pedestal 807 mm 60DS-KPS 60 Gallons 225 liters 30 inches 762 mm 39 inches 991 mm 32 inches 813 mm 36 inches 914 mm Pedestal 80DS-KPS 80 Gallons 300 liters 32 inches 813 mm 43
Installation WARNING THIS UNIT MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH PLUMBING. IMPROPER INSTALLATION CAN CAUSE INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT. All Models 1. Installation under a ventilation hood is recommended. 2. If the steam supply pressure is greater than the maximum working pressure stamped on the nameplate, you must install a pressure reducing valve in the steam supply line near the kettle. 3. Connect the steam supply line to the steam inlet fitting.
Initial Start-Up IMPORTANT BE SURE ALL OPERATORS READ, UNDERSTAND AND FOLLOW THE OPERATING INSTRUCTIONS, CAUTIONS, AND SAFETY INSTRUCTIONS CONTAINED IN THIS MANUAL. WARNING AVOID EXPOSURE TO ESCAPING STEAM, WHICH CAN CAUSE SEVERE BURNS. Now that the kettle has been installed, you should test it to ensure that it is operating correctly. 1. Remove all literature and packing materials from inside and outside of the unit. 2. Pour a small amount of water into the kettle. 3. Open the steam inlet valve. 4.
Operation WARNING AVOID EXPOSURE TO ESCAPING STEAM, WHICH CAN CAUSE SEVERE BURNS. WARNING AVOID ALL DIRECT CONTACT WITH HOT FOOD OR WATER IN THE KETTLE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS. TAKE SPECIAL CARE TO AVOID CONTACT WITH HOT KETTLE BODY OR HOT PRODUCT, WHEN ADDING INGREDIENTS, STIRRING OR TRANSFERRING PRODUCT TO ANOTHER CONTAINER. To heat the kettle, open the condensate return valve and the steam inlet valve. Adjusting the inlet valve allows the operator to control the heating rate.
Sequence of Operation The following “action-reaction” outline is provided to help you understand how the equipment functions. When the steam inlet valve is opened, steam flows into the jacket at a pressure determined by the boiler system, or by the pressure reducing valve which serves the kettle. In the jacket steam releases its heat to the kettle as it condenses into water. The steam trap allows condensate (water) to leave the kettle while holding the steam in.
Maintenance WARNING WHEN TESTING, AVOID ANY EXPOSURE TO THE STEAM BLOWING OUT OF THE SAFETY VALVE. DIRECT CONTACT COULD RESULT IN SEVERE BURNS. NOTICE: Contact an authorized representative when repairs are required. Periodic Maintenance A Service Log is provided at the back of this manual with the warranty information. Each time maintenance is performed on your kettle, enter the date on which the work was done, what was done, and who did it. Keep this manual on file and available for operators to use.
Cleaning WARNING AVOID ANY DIRECT CONTACT WITH HOT SURFACES. DIRECT SKIN CONTACT COULD RESULT IN SEVERE BURNS. CAUTION MOST CLEANERS ARE HARMFUL TO THE SKIN, EYES, MUCOUS MEMBRANES, AND CLOTHING. PRECAUTIONS SHOULD BE TAKEN. WEAR RUBBER GLOVES, GOGGLES OR FACE SHIELD, AND PROTECTIVE CLOTHING. READ THE WARNINGS AND FOLLOW THE DIRECTIONS ON THE LABEL OF THE CLEANER CAREFULLY. CAUTION DO NOT MIX DIFFERENT KETTLE DRAWOFF ASSEMBLY PARTS WHEN WASHING.
Cleaning 12. When equipment needs to be sanitized, use a solution equivalent to one that supplies 200 parts per million available chlorine. Obtain advice on sanitizing agents from your supplier of sanitizing products. Following the supplier’s instructions, apply the agent after the unit has been cleaned and drained. Drain and thoroughly rinse off the sanitizer. 13. It is recommended that each piece of equipment be sanitized just before use. 14.
Troubleshooting Your kettle will operate smoothly and efficiently if properly maintained. However, the following is a list of checks to make in the event of a problem. If the actions suggested do not solve the problem, call your qualified Service Representative. If an item on the list is followed by * , the work should be done by a qualified service representative.
Parts List Key Description Part # 1 2 3 3 3 3 4 5 6 7 8 9 ¼”-20 N.C. CAP NUT SPACER HANDLE (COVERS W/ACTUATOR) COVER ACTUATOR COVER HANDLE U-HANDLE KNOB (FRICTION) SPRING (28” & 30” COVERS) SPRING (32” & 36” COVERS) SPRING (38” & 42” COVERS) SPRING (44” & 48” COVERS) SPRING (50” COVERS) ½”-20 N.F. X 1” LG HEX HD CAPSCR. ½” BRASS WASHER ½”-20 N.F. JAM NUT ¾” I.P.S.
Piping Diagram* Bucket Type Steam Trap Assembly *All of the fittings illustrated are required for proper and safer installation and operation, and are NOT PROVIDED as standard with the unit. Steam trap assemblies can be purchased in two versions. 1. COMPLETELY PIPED — Complete, preassembled, with nipples and fittings, as shown in the diagram. 2. LOOSE — Unassembled, without nipples and fittings, but includes steam trap, check valve, globe valve and gate valve.
Piping Diagram* Thermostatic Type Steam Trap Assembly *All of the fittings illustrated are required for proper and safer installation and operation, and are NOT PROVIDED as standard with the unit. Steam trap assemblies can be purchased in two versions. 1. COMPLETELY PIPED — Complete, preassembled, with nipples and fittings, as shown in the diagram. 2. LOOSE — Unassembled, without nipples and fittings, but includes steam trap, check valve, globe valve and gate valve.
Service Log Model No: Purchased From: Serial No: Location: Date Purchased: Date Installed: Purchase Order No: For Service Call: Date 16 OM-KPS/KLS-DS Service Performed Performed By
Service Log Model No: Purchased From: Serial No: Location: Date Purchased: Date Installed: Purchase Order No: For Service Call: Date Service Performed Performed By OM-KPS/KLS-DS 17
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