Blodgett KLT-G Series manual

1 IMPORTANT NOTES FOR INSTALLATION AND OPERATION KLT-G Series GAS FIRED TRI-LEG TILTING KETTLE INSTALLATION – OPERATION – MAINTENANCE BLODGETT OVEN COMPANY www.blodgett.com 44 Lakeside Avenue, Burlington, Vermont 05 401 USA Telephone (800) 33 1-5842, (802) 860 -3700 Fax: (802) 864-0183 S00052 Rev A (5/04)[...]

2 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 possible injury or death. FOR YOUR SAFETY: Do not store or use gasoline or other flammable v[...]

3 TABLE OF CONTENTS DESCRIPTION PAGE Important Notes For Installation and Operation 2 1.0 Service Connections 4 2.0 Installation 5 3.0 Operation 10 4.0 Cleaning Instructions 16 5.0 Maintenance 20 6.0 Service 21 7.0 Troubleshooting 26 Appendix A, Material Safety Data Sheet 29[...]

4 1.0 SERVICE CONNECTIONS 29 [37 3] J F L K A MINIMUM 4[102mm] 8.125 [206] 27.75 [705] 10.5[267] B 35 [889] 26 [660] G C (GL T -20) 6.25[159] (GL T -30...60) 7[178] N 5.875[149] 3[76] 2[51] H 36 [914] E M D 6[152] FLANGED FOOT DETA IL 2 7/16" [1 1mm] HOLES ON 2.5 [63] B.C. EQUALL Y SP ACED Ø DIMENSIO NS ARE IN INCHES [MM] Supply gas through 3[...]

5 2.0 INSTALLATION INSTALLATION CODES AND ST ANDARDS Installation must conform with local codes, or in the absence of local co des, with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 , or the Natural Gas and Propane Installation Code, CSA B149.1 , as applicable. 1. The appliance and its individual shut off valve must be disconnected from the gas [...]

6 INSTALLATION (Continued) All units must be installed in such a manner t hat the flow of combustion and ventilation air are not obstructed. Provisions for an adequate air supply must also be provided. Do not obstruct side of the unit, as combustion air enters through this area. Information on the construction and installation of ventilating hoods [...]

7 2.0 INSTALLATION (Continued) GAS CONNECTION The serial plate on the lower right side of the unit indicate s the type of gas your unit is equipped to burn. Do NOT connect to any other gas type. A 3/4" NPT line is provided at the rear for the connection. Each unit is equipped with an interna l pressure regulator which is set for 3.5" W.C.[...]

8 2.0 INSTALLATION (Continued) WATER CONNECTION On units equipped with an optional water fill valve connect a water line (minimum 1/4") to the valve with a 1/4" NPT female fitting. Units with dual (hot and cold) valves must have the hot water line connected to side with the hot water valve (red) and cold water line to the cold water valve[...]

9 2.0 INSTALLATION (Continued) PERFORMANCE CHECK The following items should be checked before or within the first 30 days of operation by a qualified service technician. 1. Verify correct gas type against rating plate on unit. 2. Verify correct voltage, cycle and phase against rating plate on unit. 3. Gas pressure. 4. Internal gas connections. 5. I[...]

10 3.0 OPERATION CAUTION: If you smell gas during the light ing procedure, immediately shut off the gas supply until the leak has been corre cted. WARNING: In the event of main burne r ignition failure, a 5 minute purge period must be observed prior to re-establishing ignition sourc e. WARNING: In the event you smell gas, s hut do wn equipment at t[...]

11 3.0 OPERATION (Continued) A. Lighting (Continued) If after 36 seconds the burner fails to ignite or the “ignition light goe s out, the system goes into Safety Lockout. De-energize the system by setting the thermostat to “OFF” for five minutes and try again. 1. Set the thermostat to desired temperature setting. When temperature setting has [...]

12 3.0 OPERATION (Continued) FRONT PANEL CONTROLS POWER SWITCH This switch turns the main power to the unit on and off. It must be turned on to heat the kettle. It should be turned off when the kettle will not be in use for long period s. (GREEN) IGNITION LIGHT This light is on whenever the main burner gas is on. (RED) COOKING LIGHT This light is o[...]

13 3.0 OPERATION (Continued) THERMOSTAT The thermostat selects the desired internal kettle operating temperature. The thermostat must be set at a desired setting in order for the burner to ignite. For Reference: DIAL SETTING E C E F 11 5 6 0 22 7 8 1 3 40 104 4 53 127 5 67 153 6 81 178 7 95 203 8 108 226 9 122 252 10 135 275 PRESSURE GAUGE The pres[...]

14 3.0 OPERATION (Continued) PRESSURE RELIEF VALVE The pressure relief valve is a safety device wh ich prevents the internal kettle pressure from exceeding 50 psi. It should never be tampered with. DAILY OPERATION Daily operation should consist of turning on the power switch and setting thermostat for th e desired temperature. It is recommended the[...]

15 3.0 OPERATION (Continued) GAS SAVING TIPS Use these reminders to help develop energy-saving procedures and habits. Using less natural or propane gas saves energy as well as money. 1. Turn off when not in use. 2. Limit preheat times. 3. Use lid when possible. 4. Maintain equipment.[...]

16 4.0 CLEANING INSTRUCTIONS WARNING: Disconnect the po wer supply to the appliance before cleaning or servicing. WARNING: Never spray water into electric control s or components! CAUTION: The equipment and its parts ar e hot. Use care when operating, cleaning and servicing. CAUTION: Do not use cleaning agents th at are corrosive. Your kettle shoul[...]

17 4.0 CLEANING INSTRUCTIONS (Continued) DRAW-OFF VALVE CLEANI NG 1. If equipped with a tangent draw-off valve, turn the large hex nut on the draw-off valve counterclockwise until it is completely dis engaged 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 surfac[...]

18 4.0 CLEANING INSTRUCTIONS (Continued) WHAT TO DO IF SURFACE RUST APPE ARS 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 [...]

19 4.0 CLEANING INSTRUCTIONS (Continued) 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 U[...]

20 5.0 MAINTENANCE WARNING: Disconnect the po wer supply to the appliance before cleaning or servicing. Daily: 1. Wash exposed cleanable areas. Monthly: 1. Blower wheel inlet and motor air vent should be cleansed if an accumulation of dust or lint is obvious. Twice a Year: (minimum) 1. Have an authorized service person clean and adjust the unit for[...]

21 6.0 SERVICE GENERAL When any difficulty arises always check that the unit has been connected to the gas supp ly 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 manufactured. Wiring diagrams for the unit are[...]

22 6.0 SERVICE (Continued) 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 rea d in the green vacuum zone (25 to 30 inches Hg vacuum). If not, see ‘Re-establishing Vacuum” section. 2. The pressure switch may be set too [...]

23 6.0 SERVICE (Continued) TO ADJUST PRESSURE SWITCH: 1. To obtain access to the pressure switch, the front panel must be removed. Remove the screws on bottom 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 r ibbed knob clockwise; to decrease, turn it cou[...]

24 6.0 SERVICE (Continued) 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. 3. Remove relief valve and attach a 3/4" NPT elbow poin[...]

25 6.0 SERVICE (Continued) RE-ESTABLISHING VACUU M 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 [...]

26 7.0 TROUBLESHOOTING PROBLEM LOOK FOR Motor will not run. S No current. Check that power is being supplied to the unit. S Defective thermostat or pressure switch. S Defective motor. S Motor overload out. S Blown fuse. Motor runs, no spark. S Defective transformer. S Defective ignition module. S Blown fuse on ignition module. S Defective spark ele[...]

27 Flame burns only about 6 seconds and shuts off. S Flame rod or flame ground mislocated. S Defective flame rod wire. S Defective ignition module. S Burner rate set too high. Ensure that manifold pressure is set per rating plate and that correct orifice size installed (See table page 21). S Burner getting too much air. Reduce air shutter opening ([...]

28 Figure 1 Shutter setting at 2.0 Figure 2[...]

29 MATERIAL SAFETY DATA SHEET PREPARATION INFORMATION: Prepared for use in Canada by: E H & S Product Regulatory Management Department DOW CHEMICAL CANADA INC. P.O. Box 1012 Sarnia, Ontario, N7T 7K7 (800) 331-6451 1. CHEMICAL PRODUCT AND COMPAN Y IDENTIFICATION IN CASE OF EMERGENCY: Fort Saskatchewan, Alberta: (780) 998-8282 Sarnia, Ontario: (5[...]

30 Product: DOWFROST* HD HEAT TRANSFER FLUID, DYED Product Code: 04632 Effective Date: 02/20/01, Date Printed: 07/10/02, MSD: 002239 3. HAZARDS IDENTIFICATION EMERGENCY OVERVIEW POTENTIAL HEALTH EFFECTS (See Section 11 for toxicological data.) EYE: May cause slight transient (temporary) eye i rritation. Corneal injury is unlikely. Mists may cause e[...]

31 Product Code: 04632 Effective Date: 02/20/01, Date Printed: 07/10/02, MSD: 002239 4. FIRST AID EYES: Flush eyes with plenty of water. SKIN: Wash off in flowing water or shower. INGESTION: No adverse effects anticipat ed by this route of exposure incidental to proper industrial handling. INHALATION: Remove to fresh air if effects occur. Consult a[...]

32 MATERIAL SAFETY DATA SHEET Product: DOWFROST* HD HEAT TRANSFER FLUID, DYED Product Code: 04632 Effective Date: 02/20/01, Date Printed: 07/10/02, MSD: 002239 HAZARDOUS COMBUSTION PRODUCTS : During a fire, smoke may contain the original material in addition to unidentified toxic and/or irritating compounds. Hazardous combustion products may includ[...]

33 MATERIAL SAFETY DATA SHEET Product: DOWFROST* HD HEAT TRANSFER FLUID, DYED Product Code: 04632 Effective Date: 02/20/01, Date Printed: 07/10/02, MSD: 002239 6. ACCIDENTAL RELEASE MEA SURES (See Section 15 for Regulatory Information) PROTECT PEOPLE: Use appropriate safety equipment. For additional information, refer to Section 8, Exposure Control[...]

34 MATERIAL SAFETY DATA SHEET Product: DOWFROST* HD HEAT TRANSFER FLUID, DYED Product Code: 04632 Effective Date: 02/20/01, Date Printed: 07/10/02, MSD: 002239 EXPOSURE GUIDELINES: Propylene glycol: AIHA WEEL is 50 ppm total, 10 mg/m3 aerosol only. 9. PHYSICAL AND CHEMICAL PROPERTIES APPEARANCE/PHYSICAL STATE: Clear yellow liquid. ODOUR: Odourless [...]

35 MATERIAL SAFETY DATA SHEET Product: DOWFROST* HD HEAT TRANSFER FLUID, DYED Product Code: 04632 Effective Date: 02/20/01, Date Printed: 07/10/02, MSD: 002239 SKIN: The LD50 for skin absorption in rabbits is >10,000 mg/kg. INGESTION: The oral LD50 for rats is 20,000 - 34,000 mg/kg. MUTAGENICITY: In vitro mutagenicity studi es were negative. Ani[...]

36 MATERIAL SAFETY DATA SHEET Product: DOWFROST* HD HEAT TRANSFER FLUID, DYED Product Code: 04632 Effective Date: 02/20/01, Date Printed: 07/10/02, MSD: 002239 FOR UNUSED & UNCONT AMINATED PROD UCT , the preferred options include sending to a licensed, permitted: recycler, reclaimer, incinerator or other thermal destruction device. As a service[...]

37 MATERIAL SAFETY DATA SHEET Product: DOWFROST* HD HEAT TRANSFER FLUID, DYED Product Code: 04632 Effective Date: 02/20/01, Date Printed: 07/10/02, MSD: 002239 U.S. REGULATIONS SARA 313 INFORMATION: To the best of our knowledge, this product contains no chemical subject to SARA Title III Section 313 supplier notification requirements. SARA HAZARD C[...]

38 MATERIAL SAFETY DATA SHEET Product: DOWFROST* HD HEAT TRANSFER FLUID, DYED Product Code: 04632 Effective Date: 02/20/01, Date Printed: 07/10/02, MSD: 002239 CANADIAN REGULATIONS WHMIS INFORMATION: The Canadian Workplace Hazardous Materials Information System (WHMIS) Classification for this product is: This product is not a “Controlled Product?[...]