Blodgett Hot Beverage Maker KLT DS User Manual

KLT-DS and KPT-DS Series  
DIRECT STEAM TRI-LEG TILTING KETTLE AND  
DIRECT STEAM PEDESTAL TILTING KETTLE  
INSTALLATION – OPERATION MAINTENANCE  
BLODGETT OVEN COMPANY  
44 Lakeside Avenue, Burlington, Vermont 05401 USA Telephone (800) 331-5842, (802) 860-3700 Fax: (802) 864-0183  
S00057 Rev B (6/06)  
 
TABLE OF CONTENTS  
DESCRIPTION  
PAGE  
INSTALLATION AND SERVICE CONNECTIONS – KLT-DS ............................................4  
INSTALLATION AND SERVICE CONNECTIONS – KPT-DS ............................................5  
1.0 INSTALLATION INSTRUCTIONS ..............................................................................6  
2.0 INTRODUCTION - DESCRIPTION ............................................................................7  
3.0 BASIC FUNCTIONING ..............................................................................................7  
4.0 OPERATING INSTRUCTIONS ..................................................................................8  
5.0 CLEANING INSTRUCTIONS .....................................................................................8  
6.0 TROUBLESHOOTING MAINTENANCE ..................................................................11  
3
 
SERVICE CONNECTIONS – KLT-DS  
HOT WATER: 3/8” O.D. TUBING TO FAUCET (OPTIONAL)  
COLD WATER: 3/8” O.D. TUBING TO FAUCET (OPTIONAL)  
S
STEAM SUPPLY: 3/4"IPS 5-30 PSI (34-205 kPa). OPTIONAL 5-45 PSI (34-310 KPa)  
CONDENSATE RETURN: 1/2"IPS  
DIMENSIONS  
MODEL  
CAPACITY UNITS  
A
21  
535  
24  
610  
26  
660  
29.5  
750  
33  
B
18  
460  
20  
510  
22.5  
570  
26  
660  
28  
C
D
E
28.5  
724  
F
22  
559  
G
25.63  
651  
H(2") H(3") J(2") J(3")  
K
59.5  
L
M
15.38  
391  
15.38  
391  
16.38  
416  
20 gallons  
76 litres  
inches  
mm  
37 34.75  
940 885  
37 37.75  
940 960  
37 39.75  
940 1010  
40.5 43.25  
1029 1100  
42.5 46.75  
1080 1185  
42.5 49.25  
12  
305  
13.25  
337  
17  
432  
15  
16.5  
KLT-20DS  
-
419 1512  
14.5 62.5  
368 1588  
12 64  
305 1626  
14 74  
356 1879  
12 76  
305 1930  
30 gallons  
114 litres  
40 gallons  
152 litres  
60 gallons  
227 litres  
80 gallons  
303 litres  
100 gallons  
379 litres  
inches  
mm  
inches  
mm  
inches  
mm  
inches  
mm  
31.5 20.75 27.13 12.5 14.25  
800  
33.5 20.25 28.63  
850  
37  
940  
40.5  
1030  
43  
KLT-30DS  
KLT-40DS  
KLT-60DS  
-
-
527  
689  
317  
13  
330  
362  
15.25 12.5  
387  
15.5  
394  
381  
514  
727  
318  
14.5  
368  
21.5 30.13 15.5  
546  
20  
508  
21  
533  
9.5 18.38  
241 467  
11 19.88  
279  
12.5  
318  
765  
394  
32.63 14.5 16.25 12.5  
KLT-80DS  
840  
35.5  
902  
710  
30  
762  
828  
39.25  
997  
368  
18  
413  
20.25 10.5  
514 267  
318  
505  
21.5  
546  
inches  
mm  
10  
79  
2007  
KLT-100DS  
1080 1251 1092  
457  
254  
* Pressure reducing valve is required if incoming pressure exceeds 50 PSI (345 kPa).  
DIMENSIONS ARE IN INCHES [MM]  
L
SAFETY RELIEF VALVE  
L
NOTE: 60 , 80 & 100 gallon kettles are supplied  
with 2 rear support legs  
STRAINER AND STEAM  
TRAP (OPTIONAL)  
45°  
1.63 (41)  
2" VALVE:  
CLOSED 5.13[130]  
OPENED 6.88[175]  
S
FLANGED FOOT DETAIL  
4 EQUALLY SPACED  
Ø7/16" [11mm] HOLES  
ON 3 [76] B.C.  
3” VALVE  
CLOSED 7.88[200]  
OPENED 10.13 [257]  
SPRING ASSISTED  
COVER - OPTIONAL  
FAUCET (OPTIONAL)  
M
70°  
2" or 3" TANGENT  
DRAW OFF VALVE  
(OPTIONAL)  
S
JACKET  
DRAIN VALVE  
H
E
D
G
4
 
SERVICE CONNECTIONS – KPT-DS  
STEAM SUPPLY: 3/4" IPS (19MM) 35 psi (2.4 KG/CM2)  
S
CONDENSATE RETURN: ½" IPS (13mm)  
DIMENSIONS  
MODEL  
CAPACITY  
20 gallons  
76 litres  
UNITS  
inches  
mm  
inches  
mm  
inches  
mm  
inches  
mm  
inches  
mm  
A
21  
535  
24  
610  
26  
660  
29.5  
750  
33  
B
18  
460  
20  
510  
22.5  
570  
26  
660  
28  
C
37  
940  
37  
940  
37  
940  
40.5  
1029  
42.5  
1080  
D
E
14.75  
375  
F
G
H
J
K
L
M
N(2”) N(3”)  
16.25 16.25  
425 413  
20  
13.5  
343  
14  
356  
15.5  
394  
17.5  
445  
19  
41  
15.25 20.5  
1041 387  
59.5  
1511  
62.5  
1587  
64  
KPT-20DS  
508  
521  
20  
508  
17.5 14.75 14.25  
445 375 362  
17.5 12.25 11.75  
445 311 298  
17.5 14.25 13.75  
445 362 349  
20.5 12.25 11.75  
521 311 298  
37.75 16.25 21.5  
959 413 546  
39.75 17.25 22.5  
1010 438 572  
43 18.87  
1092 479  
46.5 20.63 25.88  
13.25  
337  
30 gallons  
114 litres  
40 gallons  
152 litres  
60 gallons  
227 litres  
80 gallons  
303 litres  
43  
1092  
45  
KPT-30DS  
KPT-40DS  
KPT-60DS  
10.75 18.5  
470  
10.25 19.25  
1143 273  
48  
1219 260  
52 9.75  
1626  
74  
1879  
76  
489  
20.5  
521  
KPT-80DS  
1181  
524  
657  
1483 1321 248  
1930  
840  
710  
DIMENSIONS ARE IN INCHES [MM]  
SAFETY RELIEF VALVE  
S
STEAM TRAP AND  
STRAINER (OPTIONAL)  
4X Ø7/16 [11] EQ. SPACED  
ON 16.62 [422] B.C. (20 TO 60 GALLONS)  
ON 19.62 [498] B.C. (80 GALLONS)  
VIEW A-A  
6.25 [159]  
SPRING ASSIST  
HINGED COVER  
(OPTIONAL)  
FAUCET (OPTIONAL)  
2"or 3" TANGENT DRAW OFF VALVE  
(OPTIONAL)  
S
POUR PATH  
A
A
JACKET DRAIN  
M
G
VALVE  
E
F
D
H
5
 
1.0 INSTALLATION INSTRUCTIONS  
1. Select a location to provide drainage for kettle pour path when tilted and for draw-off valve if  
so equipped.  
2. Mark hole locations through flanged adjustable feet on KLT-DS models and through pedestal  
base on KPT-DS models. Remove kettle.  
3. On hole locations marked, drill holes and insert expansion shields to accommodate 5/16" size  
lag bolts.  
4. Reposition kettle. On KLT-DS models level kettle by making necessary adjustment on  
flanged foot.  
5. Bolt down kettle and seal with Silastic or other equivalent sealing compound. 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. Safety relief valve on 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  
coming to the kettle.  
12. Check for proper operation.  
6
 
INTRODUCTION  
2.0 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 lower two thirds of the kettle bowl surface. All kettles are tilting, floor  
mounted in fixed positions either on legs with adjustable flanged feet (KLT-DS models) or  
pedestals (KPT-DS models). 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.  
3.0 BASIC FUNCTIONING  
3.1 CAPACITIES  
All model names contain either - 20, - 30, - 40, - 60, - 80 or - 100 to indicate the capacity of that  
kettle in U.S. gallons. Thus a KLT-40DS is a two thirds jacketed direct steam kettle mounted on  
legs with a capacity of 40 gallons (U.S ).  
3.2 FUNCTIONING MODE  
Blodgett direct connected steam jacketed kettles consist of a stainless steel bowl and a stainless  
steel jacket which envelopes two thirds of 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 semi-  
liquid 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, ie. water. 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).  
7
 
4.0 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 water or food should boil 2 to 3 gallons 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.  
5.0 CLEANING INSTRUCTIONS  
CAUTION: Do not use cleaning agents that are corrosive.  
CAUTION: The equipment and its parts are hot. Use care when  
operating, cleaning and servicing.  
Your kettle should be cleaned immediately after each use or when cooking a different product.  
Before cleaning, check that the kettle has cooled enough to touch it.  
1. Rinse the inside of the kettle thoroughly and drain to remove any food particles.  
2. Using a nylon brush, clean the kettle with a mild detergent and water. Never use steel wool  
or scouring powder as it will scratch stainless steel. Plain steel wool can leave small pieces  
of steel which can rust.  
3. Rinse the inside of the kettle thoroughly with clean water. Drain the kettle by tilting or using  
the optional tangent draw-off valve to allow the detergent and water solution to drain.  
4. Wipe the exterior of the kettle with a clean, damp cloth.  
WARNING: If your are cleaning a valve that is assembled to a kettle,  
be sure the kettle is completely empty of any product.  
8
 
DRAW-OFF VALVE CLEANING  
1. If equipped with a tangent draw-off valve, turn the large hex nut on the draw-off valve  
counterclockwise until it is completely disengaged from the threads. Grasp the valve knob  
and slowly pull out the valve stem. Wash the valve stem, disk and handle. Insert a nylon  
brush, wet with detergent and water, into the valve body and tangent draw-off tube. Brush  
vigorously.  
2. Replace the valve stem assembly and turn the hex nut until snug. Rinse the kettle with clean  
warm water.  
3. Leave the draw-off valve open when the kettle is not in use.  
DAIRY DRAW-OFF VALVE CLEANING  
1. Remove the plug by first removing the handle, then turn the plug to line up with the pin and  
pull with both hands. It is important to use both hands because the plug is heavy.  
2. Put the plug in a plastic pail that contains a mild soap solution. A plastic pail works best, as it  
reduces the possibility of nicking or scratching the plug. If the plug gets scratched it may not  
seal correctly and could leak.  
3. Use a soft cloth or soft brush and clean all surfaces.  
4. Using both hands remove the valve from the soap and rinse well in another plastic pail that  
contains fresh water.  
5. Wash out the kettle as normal.  
6. Return the plug into the body. Be sure the plug is inserted into the notch and turned. Ensure  
the plug is tight and secure before letting go of it.  
If you are cleaning a body and plug assembly, remove the plug and follow the above procedures.  
when finished with the plug, follow the same instructions for washing the body. Always use both  
hands when handling the plugs. Reassemble the plug into the body and use as normal.  
WHAT TO DO IF SURFACE RUST APPEARS  
Metal utensils should never be used as they will scratch the surface of the equipment and rust  
may begin to form. To remove surface accumulation of rust from the inadvertent use of such  
utensils, the following procedure may be used.  
CAUTION: Improper use of this procedure may damage your  
appliance!  
1. Use undiluted white vinegar with a non-abrasive scouring pad (plastic) or cloth on the  
affected area to remove the rust stain. The appliance should not be heated and remain at  
room temperature during the entire cleaning process.  
9
 
2. If the stain resists removal, additional exposure time with vinegar may be required, to a  
maximum of one hour.  
3. Thoroughly wash all of the vinegar away with fresh clear water. Dry the surface completely  
and allow one hour before using the appliance to cook.  
Following daily and period maintenance procedures will prolong the life for your equipment.  
Climatic conditions - salt air - may require more thorough and frequent cleaning or the life of the  
equipment could be adversely affected.  
STAINLESS STEEL  
To remove normal dirt, grease or product residue from stainless steel, use ordinary soap and  
water (with or without detergent) applied with a sponge or cloth. Dry thoroughly with a clean  
cloth. Never use vinegar or any other corrosive cleaner.  
To remove grease and food splatters or condensed vapours that have baked on the equipment,  
apply cleanser to a damp cloth or sponge and rub cleanser on the metal in the direction of the  
polishing lines. Rubbing cleanser as gently as possible in the direction of the polished lines will  
not mar the finish of the stainless steel. NEVER RUB WITH A CIRCULAR MOTION.  
Soil and burn deposits which do not respond to the above procedure can usually be removed by  
rubbing the surface with SCOTCH-BRITE™ scouring pads or STAINLESS scouring pads. DO  
NOT USE ORDINARY STEEL WOOL as any particles left on the surface will rust and further  
spoil the appearance of the finish. NEVER USE A WIRE BRUSH, STEEL SCOURING PADS  
(EXCEPT STAINLESS), SCRAPER, FILE OR OTHER STEEL TOOLS. Surfaces which are  
marred collect dirt more rapidly and become more difficult to clean. Marring also increases the  
possibility of corrosive attack. Refinishing may then be required.  
TO REMOVE HEAT TINT: Darkened areas sometimes appear on stainless steel surfaces  
where the area has been subjected to excessive heat. These darkened areas are caused by  
thickening of the protective surface of the stainless steel and is not harmful. Heat tint can  
normally be removed by the foregoing, but tint which does not respond to this procedure calls for  
a vigorous scouring in the direction of the polish lines using SCOTCH-BRITE™ scouring pads or  
a STAINLESS scouring pad in combination with a powdered cleanser. Heat tint action may be  
lessened by not applying or by reducing heat to equipment during slack periods.  
All food contact surfaces must be thoroughly drained and flushed prior to cooking in the kettle.  
CONTROL PANEL: The textured control panel should be cleaned with warm water and mild  
soap. Never use an abrasive cloth or steel wool. Never use cleaning solvents with a  
hydrocarbon base  
10  
 
6.0 TROUBLESHOOTING MAINTENANCE  
6.1 PREVENTIVE MAINTENANCE  
No preventive maintenance is required other than adhering to the Cleaning Procedure  
instructions.  
6.2 DRAW-OFF VALVE 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 not over  
tighten. This may cause the rubber to pull away from stem and permanently damage it.  
6.3 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.  
6.4 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  
11  
 
that there is water in the jacket. Open ball valve and drain. Close valve and commence  
operation of kettle.  
12  
 

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