INSTALLATION &
OPERATION MANUAL
DIRECT STEAM
2/3 JACKETED
STATIONARY AND
TILTING KETTLES
MODELS
K20DL
K40DL
K60DL
K20DLT
K40DLT
K60DLT
ML-136081
ML-136082
ML-136083
ML-136086
ML-136087
ML-136088
K40DL
For additional information on Vulcan-Hart or to locate an authorized parts
VULCAN-HART
3600 NORTH POINT BLVD.
BALTIMORE, MD 21222
DIVISION OF ITW FOOD EQUIPMENT GROUP, LLC
WWW.VULCANEQUIPMENT.COM
FORM 35459 (May 2011)
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DIRECT STEAM KETTLES
CONTENTS
GENERAL ...........................................................................................................................................4
INSTALLATION ...................................................................................................................................5
Unpacking......................................................................................................................................5
Installation Codes and Standards..................................................................................................5
Location.........................................................................................................................................6
Stationary Kettle ............................................................................................................................6
Tilting Kettle...................................................................................................................................7
Installation Procedure....................................................................................................................8
Steam Supply Connection.............................................................................................................8
Initial Start-Up................................................................................................................................9
OPERATION......................................................................................................................................10
STAINLESS STEEL EQUIPMENT CARE AND CLEANING..............................................................11
CLEANING ........................................................................................................................................13
Compression Draw-Off Valve Cleaning Instructions....................................................................13
Plug Valve Cleaning Instructions.................................................................................................14
MAINTENANCE ................................................................................................................................15
Service.........................................................................................................................................15
TROUBLESHOOTING ......................................................................................................................15
— 3 —
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DIRECT STEAM KETTLES
INSTALLATION, OPERATION AND
MAINTENANCE OF KDL AND KDLT SERIES
DIRECT STEAM KETTLES
SAVE THESE INSTRUCTIONS FOR FUTURE USE
GENERAL
Vulcan direct steam 2/3 jacketed kettles are produced with quality workmanship and material. Proper
installation,usageandmaintenancewillresultinmanyyearsofsatisfactoryperformance.Itissuggested
that you thoroughly read this entire manual and carefully follow all of the instructions provided.
Model K40DL
Model K40DLT
(SHOWN WITH OPTIONAL 2" PLUG DRAW-OFF)
(SHOWN WITH OPTIONAL LID AND 2" PLUG DRAW-OFF)
MODEL CHART
Model
Gallons
20
Quarts
80
Liters
76
K20DL & K20DLT
K40DL & K40DLT
K60DL & K60DLT
40
160
152
228
60
240
— 4 —
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DIRECT STEAM KETTLES
INSTALLATION
UNPACKING
This kettle was inspected before leaving the factory. The transportation company assumes full
responsibility for safe delivery upon acceptance of the shipment.
Immediately after unpacking, check for possible shipping damage. If kettle damage is found, save the
packaging material and contact the carrier within 15 days of delivery. Freight damage is not covered
under Vulcan Warranty.
INSTALLATION CODES AND STANDARDS
In the United States, Vulcan kettles must be installed in accordance with:
1. State and local codes
2. NFPA Standard NFPA-96, Vapor Removal from Cooking Equipment, latest edition, available
from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
— 5 —
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DIRECT STEAM KETTLES
LOCATION
Plumbingconnectionsmustcomplywithapplicablesanitary,safetyandplumbing
codes.
Stationary Kettle
Position the kettle in its final location. Check that there are sufficient clearances for operating and
servicing the kettle, and proper clearance of the cover when raised. The kettle draw-off valve should
be located near a floor drain.
= FLOOR DRAIN FOR
DRAW-OFF VALVE
TRUE
MODEL
WORKING
CAPACITY
A
B
C
D
E
F
G
H
J
K
L
M
N
20 gallons
76 liters
21.6 In.
15.2 In.
31.9 In.
28.8 In.
15.7 In.
16.0 In.
14.7 In.
9.3 In.
24.5 In.
56.8 In.
14.3 In.
23.0 In.
8.3 In.
K20DL
K40DL
K60DL
549 mm 386 mm 809 mm 732 mm 399 mm 406 mm 373 mm 236 mm 622 mm 1441 mm 363 mm 586 mm 211 mm
25.8 In. 21.2 In. 37.1 In. 32.9 In. 17.5 In. 17.7 In. 14.0 In. 10.5 In. 25.0 In. 66.0 In. 13.5 In. 24.8 In. 10.5 In.
656 mm 538 mm 942 mm 836 mm 445 mm 450 mm 356 mm 267 mm 635 mm 1676 mm 343 mm 632 mm 267 mm
29.5 In. 23.9 In. 39.4 In. 36.9 In. 19.3 In. 19.7 In. 13.5 In. 8.0 In. 26.5 In. 72.5 In. 13.0 In. 27.5 In. 12.2 In.
40 gallons
152 liters
60 gallons
227 liters
749 mm 607 mm 1001 mm 937 mm 490 mm 500 mm 340 mm 203 mm 673 mm 1842 mm 330 mm 700 mm 310 mm
— 6 —
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DIRECT STEAM KETTLES
Tilting Kettle
Positionthekettleinitsfinalinstalledlocationtoprovidedrainagedirectlybelowpourpath,withsufficient
rear clearance from the wall to allow the kettle to tilt completely without obstruction.
22.0 (559)
(FOR 60 GAL ONLY)
= FLOOL DRAIN FOR
DRAW-OFF VALVE
AND POUR PATH
“E”
“F”
(ADD 2” FOR
PLUG VALVE)
SHOWN WITH OPTIONAL DRAW-OFF VALVE AND
SPRING ASSIST LID COVER
“M”
5.2 (132)
(ADD 2” FOR
OPEN POSITION)
12.0 (305)
“N”
188.
DIM “A”
(476)
9.1
132.
(230)
(335)
DIM “K”
DIM “B”
DIM “H”
DIM “C”
R
DIM “J”
“L”
DIM “G”
DIM “D”
TRUE
MODEL
WORKING
CAPACITY
A
B
C
D
E
F
G
H
J
K
L
M
N
20 gallons
76 liters
21.6 In.
15.2 In.
35.7 In.
37.8 In.
21.3 In.
16.0 In.
18.4 In.
11.9 In.
20.7 In.
61.3 In.
17.7 In.
28.5 In.
9.9 In.
K20DLT
K40DLT
K60DLT
549 mm 386 mm 907 mm 960 mm 543 mm 406 mm 467 mm 302 mm 523 mm 1557 mm 451 mm 726 mm 252 mm
25.8 In. 21.2 In. 36.1 In. 41.8 In. 24.0 In. 17.7 In. 12.8 In. 7.5 In. 18.6 In. 65.8 In. 12.1 In. 30.3 In. 12.1 In.
656 mm 538 mm 917 mm 1062 mm 610 mm 451 mm 325 mm 191 mm 473 mm 1671 mm 308 mm 772 mm 308 mm
29.5 In. 23.9 In. 38.1 In. 45.7 In. 26.8 In. 19.7 In. 15.6 In. 10.9 In. 19.8 In. 72.3 In. 14.9 In. 33.0 In. 13.8 In.
40 gallons
152 liters
60 gallons
227 liters
749 mm 607 mm 968 mm 1161 mm 683 mm 500 mm 398 mm 276 mm 503 mm 1836 mm 380 mm 841 mm 352 mm
— 7 —
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DIRECT STEAM KETTLES
INSTALLATION PROCEDURE
Make sure the kettle is in its final location before performing the installation procedure.
It may be necessary to increase the height of the kettle when leveling to clear the draw-off valve on
tilting kettles. Use the adjustable flange feet to increase the height of the kettle.
1. Place a spirit level on the rim of the kettle with the cover open. Adjust the feet to level the kettle
left-to-right and front-to-back.
2. Mark anchoring hole locations through the flanged feet, then move the kettle out of the way.
3. With hole location marked, drill holes for expansion plugs for appropriate-sized lag bolts.
4. Reposition the kettle and verify that the kettle is level.
5. Bolt the kettle down and apply an NSF-approved silicone sealant around the bolt heads and
flange making contact with floor surface. Wipe off excess sealant immediately.
STEAM SUPPLY CONNECTION
The steam line plumbing diagram (Fig. 1) is a generic representation of the recommended steam
supply.
PRESSURE
REDUCING
VALVE
RELIEF VALVE
SHUT-OFF
VALVE
(50 PSI)
STRAINER
STEAM IN
PRESSURE
GAUGE
UNION
STEAM IN
(TO KETTLE )
TO DRAIN
STEAM TRAP
ON DRIP LEG
Fig. 1
If the incoming steam pressure is greater than kettle maximum operating pressure stamped on the
nameplate,installapressure-reducingvalve(notsupplied)onthelinebeforethesteaminlettothekettle.
Connect steam supply line (see chart) pipe size to the kettle inlet fitting making sure there is a steam
control valve strainer. The steam supply line must be as large as the steam inlet fitting.
The relief valve on the kettle must not be closed off as it is set to relieve excess pressure in the kettle.
If the steam is heavy with condensate, install a steam trap before the pressure regulator valve. To
ensure rapid heat-up of heavy loads, a ball float type steam trap is recommended. Steam trap should
be sized for flow-rate and differential pressure. The steam supply line must be sized to maintain
pressure and flow (see chart).
A steam line pressure gauge (not supplied) is recommended to determine the actual steam pressure
being supplied to the kettle.
Install the steam shut-off valve at a convenient location near the kettle on the incoming steam line.
— 8 —
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DIRECT STEAM KETTLES
Maximum Flow Rate of Dry Steam in Pounds per Hour
Supply Standard Pipe Size
1
3
11/4
"
11/2
"
2"
Pressure
/2
"
/4
"
1"
5 PSIG
20
30
40
50
60
70
80
100
40
60
70
140
220
290
360
430
500
570
760
210
320
430
530
n/a
n/a
n/a
n/a
380
600
n/a
n/a
n/a
n/a
n/a
n/a
10 PSIG
15 PSIG
20 PSIG
25 PSIG
30 PSIG
35 PSIG
50 PSIG
110
150
180
220
250
290
380
80
100
120
140
160
210
Chart values are based on 100' of clean iron pipe. Steam losses due to elbows, reductions, heat loss
or condensing steam were not considered.
Connect the kettle condensate return line (Fig. 2) to an open drain or to a boiler condensate return
line. Boiler condensate return lines must have a check valve (not supplied).
STEAM
STRAINER
TRAP
TO DRAIN OR BOILER
FROM KETTLE
CONDENSATE RETURN
CHECK
VALVE
Fig. 2
INITIAL START-UP
•
•
•
•
Pour a small amount of water into the kettle.
Open the steam inlet valve.
When the water begins to boil, inspect all of the fittings to ensure that there are no leaks.
Check the safety valve by pulling the ring far enough to allow steam to escape. Let the valve
snap back into place to reseat the valve so it will not leak.
•
•
Shut down the unit by closing the steam inlet valve.
Open the draw-off valve to ensure that it functions from fully opened to fully closed position. If
it functions properly, then the kettle is ready for use.
— 9 —
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DIRECT STEAM KETTLES
OPERATION
The kettle and its parts are hot. Use care when operating, cleaning or servicing
the kettle.
Food products with milk or egg base should be placed into a cold kettle before cooking. Avoid sudden
contact of these food products to a hot kettle surface because they stick to the surface.
•
•
•
•
Verify that the draw-off valve is closed.
Fill kettle with product to the desired level.
Slowly turn the steam control valve to the fully open position.
The water should boil in 3 to 4 minutes per gallon. If it does not, then check incoming pressure
to determine that pressure is adequate to operate the kettle.
•
Regulate the steam control valve according to the desired temperature.
— 10 —
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DIRECT STEAM KETTLES
STAINLESS STEEL EQUIPMENT CARE AND CLEANING
(Supplied courtesy of NAFEM. For more information, visit their web site at www.nafem.org)
Contrary to popular belief, stainless steels ARE susceptible to rusting.
Corrosion on metals is everywhere. It is recognized quickly on iron and steel as unsightly yellow/
orange rust. Such metals are called “active” because they actively corrode in a natural environment
when their atoms combine with oxygen to form rust.
Stainless steels are passive metals because they contain other metals, like chromium, nickel and
manganese that stabilize the atoms. 400 series stainless steels are called ferritic, contain chromium,
and are magnetic; 300 series stainless steels are called austenitic, contain chromium and nickel; and
200 series stainless, also austenitic, contains manganese, nitrogen and carbon. Austenitic types of
stainless are not magnetic, and generally provide greater resistance to corrosion than ferritic types.
With 12-30 percent chromium, an invisible passive film covers the steel’s surface acting as a shield
against corrosion. As long as the film is intact and not broken or contaminated, the metal is passive
and stain-less. If the passive film of stainless steel has been broken, equipment starts to corrode. At
its end, it rusts.
Enemies of Stainless Steel
There are three basic things which can break down stainless steel’s passivity layer and allow corrosion
to occur.
1.
2.
3.
Mechanical abrasion
Deposits and water
Chlorides
Mechanical abrasion means those things that will scratch a steel surface. Steel pads, wire brushes
and scrapers are prime examples.
Water comes out of the faucet in varying degrees of hardness. Depending on what part of the country
you live in, you may have hard or soft water. Hard water may leave spots, and when heated leave
deposits behind that if left to sit, will break down the passive layer and rust stainless steel. Other
deposits from food preparation and service must be properly removed.
Chlorides are found nearly everywhere. They are in water, food and table salt. One of the worst
chloride perpetrators can come from household and industrial cleaners.
So what does all this mean? Don’t Despair!
Here are a few steps that can help prevent stainless steel rust.
1.
Use the proper tools.
When cleaning stainless steel products, use non-abrasive tools. Soft cloths and plastic scouring
pads will not harm steel’s passive layer. Stainless steel pads also can be used but the scrubbing
motion must be in the direction of the manufacturers’ polishing marks.
2.
Clean with the polish lines.
Some stainless steel comes with visible polishing lines or “grain.” When visible lines are present,
always scrub in a motion parallel to the lines. When the grain cannot be seen, play it safe and
use a soft cloth or plastic scouring pad.
3.
Use alkaline, alkaline chlorinated or non-chloride containing cleaners.
While many traditional cleaners are loaded with chlorides, the industry is providing an ever-
increasing choice of non-chloride cleaners. If you are not sure of chloride content in the cleaner
used, contact your cleaner supplier. If your present cleaner contains chlorides, ask your supplier
if they have an alternative.Avoid cleaners containing quaternary salts; it also can attack stainless
steel and cause pitting and rusting.
— 11 —
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DIRECT STEAM KETTLES
4.
Treat your water.
Though this is not always practical, softening hard water can do much to reduce deposits. There
are certain filters that can be installed to remove distasteful and corrosive elements. To insure
proper water treatment, call a treatment specialist.
5.
Keep your food equipment clean.
Use alkaline, alkaline chlorinated or non-chloride cleaners at recommended strength. Clean
frequently to avoid build-up of hard, stubborn stains. If you boil water in stainless steel equipment,
remember the single most likely cause of damage is chlorides in the water. Heating cleaners that
contain chlorides have a similar effect.
6.
Rinse, rinse, rinse.
If chlorinated cleaners are used, rinse and wipe equipment and supplies dry immediately. The
sooner you wipe off standing water, especially when it contains cleaning agents, the better. After
wipingequipmentdown,allowittoairdry;oxygenhelpsmaintainthestainlesssteel’spassivityfilm.
7.
8.
Never use hydrochloric acid (muriatic acid) on stainless steel.
Regularly restore/passivate stainless steel.
Job
Cleaning Agent
Soap, ammonia,
Comments
Routine cleaning
Apply with soft cloth or sponge.
detergent, Medallion
Fingerprints and smears
Arcal 20, Lac-O-Nu Ecoshine
Provides barrier film
Stubborn stains and
discoloration
Cameo, Talc, Zud,
First Impression
Rub in direction of polish lines.
Grease and fatty acids,
blood, burnt-on foods
Easy-off, DeGrease It Oven Aid Excellent removal
on all finishes
Grease and Oil
Any good commercial
detergent
Apply with soft cloth or sponge.
Restoration/Passivation
Benefit, Super Sheen
Review
1.
Stainless steels rust when passivity (film-shield) breaks down as a result of scrapes,
scratches, deposits and chlorides.
2.
3.
Stainless steel rust starts with pits and cracks.
Use the proper tools. Do not use steel pads, wire brushes or scrapers to clean stainless
steel.
4.
Use non-chlorinated cleaners at recommended concentrations. Use only chloridefree
cleaners.
5.
6.
Soften your water. Use filters and softeners whenever possible.
Wipe off cleaning agent(s) and standing water as soon as possible. Prolonged contact
causes eventual problems.
Tolearnmoreaboutchloride-stresscorrosionandhowtopreventit,contacttheequipmentmanufacturer
or cleaning materials supplier.
Developed by Packer Engineering, Naperville, Ill., an independent testing laboratory.
— 12 —
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DIRECT STEAM KETTLES
CLEANING
The kettle and its parts are hot. Use care when operating, cleaning or servicing
the kettle.
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. If the unit is used continuously through
the day, it should be cleaned and sanitized once every 12 hours.
Empty the kettle. Close draw-off valve and add water to the kettle for cleaning to prevent residue from
drying and sticking to the inside of the kettle.
•
•
Never use harsh or corrosive cleaning chemicals.
Never scrape the inside of the kettle with abrasive cleansers, metal tools or steel scouring pads,
whichwillscratchthesurface,spoiltheappearanceandmakeitmoredifficulttothoroughlyclean.
•
Add mild, non-chlorine, non-chloride, and non-bleach detergent and scrub the kettle interior
with a nylon brush.
•
•
•
Loosen stuck-on food by allowing it to soak at a low temperature setting.
Thoroughly rinse the interior and dry with a soft cloth.
Rinse the exterior and dry with a soft cloth.
COMPRESSION DRAW-OFF VALVE CLEANING INSTRUCTIONS
Daily After Use
Remove draw-off valve stem assembly for cleaning (Fig. 3).
1.
2.
3.
4.
5.
6.
Turn the valve handle counterclockwise until it stops.
Pull the valve handle back until it stops.
Turn large hex nut counterclockwise until the valve stem assembly is loose.
Pull the assembly straight out of the valve body.
Remove wing nut and handle. Unscrew valve stem from bonnet.
Wash valve body and stem assembly with mild soap and water, and then rinse. Make sure
all food residue is removed from inside valve body.
7.
Leave assembly apart to air dry.
Valve Stem
Install draw-off valve assembly:
1.
2.
Apply PetroGel lubricant to valve stem
threads, “O” ring, rubber plug face and
large hex nut threads.
Thread the valve stem into bonnet till
valvestemcanbepulledthroughbonnet.
Fig. 3
3.
4.
5.
6.
Insert valve stem into valve body.
Install large hex nut hand tight.
Install valve handle, lock washer and wing nut onto the valve stem.
Turn valve handle clockwise until closed. Do not overtighten.
— 13 —
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DIRECT STEAM KETTLES
PLUG VALVE CLEANING INSTRUCTIONS
Daily After Use
Remove draw-off valve plug for cleaning (Fig. 4).
1.
2.
3.
Unscrew the retaining ring and remove
it and the bottom washer.
Pull the valve plug straight up to remove
from valve body.
Wash valve body, plug, washer and
retaining ring with mild soap and water,
and then rinse.
4.
Leave assembly apart to air dry.
Valve Plug
Care should be taken not to scratch, ding or dent
the valve plug to prevent valve leakage.
If multiple kettles are in use, care should be taken
to keep each plug separate and returned to its
original valve body.
Valve Body
Install draw-off valve plug.
1.
2.
3.
Apply PetroGel lubricant to valve plug
face.
Bottom Washer
Retaining Ring
Holding the valve handle, slide the plug
down into the valve body.
Install the bottom washer, making sure
to align the key with the groove in the
valve plug.
4.
Installtheretainingringandhandtighten.
Fig. 4
If the valve is hard to open, then the ring has been overtightened.
— 14 —
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DIRECT STEAM KETTLES
MAINTENANCE
SERVICE
To obtain service and parts information concerning this unit, contact the Vulcan-Hart Service Agency
in your area (refer to listing supplied with the kettle), or contact the Vulcan-Hart Service Department
at the address or phone number shown on the front cover of this manual.
TROUBLESHOOTING
Problem
Unit not Heating
Possible Causes / Suggested Corrective Action
Verify incoming steam supply valve is open and pressure-
reducing valve is open.
Blocked/plugged steam trap of strainer. Contact building
maintenance or authorized service company.
Noisy (crackling)
Will not harm the kettle. It is an indication that there is
condensate in the steam supply line and a steam trap
should be installed in the supply line before the kettle. Turn
kettle off and open drain valve on bottom of kettle to drain
water out. Close valve and turn on steam control valve.
Pressure relief valve leaking
steam
Incoming steam supply too high or faulty pressure relief
valve. Contact building maintenance or authorized service
company.
— 15 —
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DIRECT STEAM KETTLES
F-35459 (May 2011)
— 16 —
PRINTED IN U.S.A.
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