Vulcan Hart Hot Beverage Maker K20DL User Manual

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)  
 
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 —  
 
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 —  
 
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 —  
 
DIRECT STEAM KETTLES  
LOCATION  
Plumbingconnectionsmustcomplywithapplicablesanitary,safetyandplumbing  
codes.  
Stationary Kettle  
Position the kettle in its nal location. Check that there are sufcient 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 oor 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 —  
 
DIRECT STEAM KETTLES  
Tilting Kettle  
Positionthekettleinitsnalinstalledlocationtoprovidedrainagedirectlybelowpourpath,withsufcient  
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 —  
 
DIRECT STEAM KETTLES  
INSTALLATION PROCEDURE  
Make sure the kettle is in its nal 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 ange 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 anged 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  
ange making contact with oor 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 tting making sure there is a steam  
control valve strainer. The steam supply line must be as large as the steam inlet tting.  
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 oat type steam trap is recommended. Steam trap should  
be sized for ow-rate and differential pressure. The steam supply line must be sized to maintain  
pressure and ow (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 —  
 
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 ttings 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 —  
 
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 —  
 
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 lm covers the steel’s surface acting as a shield  
against corrosion. As long as the lm is intact and not broken or contaminated, the metal is passive  
and stain-less. If the passive lm 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 —  
 
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 lters 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’spassivitylm.  
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 lm  
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 nishes  
Grease and Oil  
Any good commercial  
detergent  
Apply with soft cloth or sponge.  
Restoration/Passivation  
Benet, Super Sheen  
Review  
1.  
Stainless steels rust when passivity (lm-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 lters 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 —  
 
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,spoiltheappearanceandmakeitmoredifculttothoroughlyclean.  
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 —  
 
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 —  
 
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.  
Parts and service are also available at www.vulcanequipment.com.  
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 —  
 
DIRECT STEAM KETTLES  
F-35459 (May 2011)  
— 16 —  
PRINTED IN U.S.A.  
 

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