Operation Manual 10/2013 (Rev. A)

Operation Manual 10/2013 (Rev. A)
OWNER’S MANUAL
Direct Steam Tilting & Stationary Kettles
Tilting Tri-Leg Models:
□ FT-20L □ FT-30L □ FT-40L □ FT-60L □ FT-80L
Tilting Pedestal Models:
□ FT-20P □ FT-30P □ FT-40P □ FT-60P □ FT-80P □ FT-100P
Stationary Tri-Leg Models:
□ F-20L □ F-30L □ F-40L □ F-60L □ F-80L □ F-100L
Stationary Pedestal Models:
□ F-20P □ F-30P □ F-40P □ F-60P □ F-80P □ F-100P
Form Number: S-6106 Rev: A
10/13
Printed in USA
35 Garvey Street, Everett, MA 02149
Telephone (617) 387-4100, (866) 698-3188, Fax (617) 387-4456, (800) 227-2659
[email protected], www.mfii.com
0
TABLE OF CONTENTS
INTRODUCTION ......................................................................................................................... 1
IMPORTANT NOTES FOR INSTALLATION AND OPERATION .............................................................. 1
SERVICE CONNECTIONS & DEMENSIONS:......................................................................................... 2
TILTING TRI-LEG MODELS................................................................................................................. 2
TILTING PEDESTAL MODELS ............................................................................................................ 3
STATIONARY PEDESTAL MODELS .................................................................................................... 4
STATIONARY TR-LEG MODELS ......................................................................................................... 5
DESCRIPTION: ................................................................................................................................... 6
BASIC FUNCTIONING ......................................................................................................................... 6
FUNCTIONING MODE ....................................................................................................................... 6
INSTALLATION ........................................................................................................................... 7
INSTALLATION INSTRUCTIONS .......................................................................................................... 7
OPERATION ............................................................................................................................... 8
OPERATING INSTRUCTIONS: ............................................................................................................. 8
Tilting Kettles .................................................................................................................................... 8
Stationary Kettles .............................................................................................................................. 8
MAINTENANCE .......................................................................................................................... 9
CLEANING INSTRUCTIONS:................................................................................................................ 9
Tilting Kettle Cleaning Instructions ................................................................................................... 9
Stationary Kettle Cleaning Instructions ............................................................................................ 9
PREVENTIVE MAINTENANCE ........................................................................................................... 10
SAFETY VALVE MAINTENANCE AND TESTING ................................................................................ 10
TROUBLE SHOOTING ................................................................................................................ 11
DRAW-OFF VALVE LEAKS ................................................................................................................ 11
EXTREMELY SLOW COOKING TIME ................................................................................................. 11
AIR VENTING ................................................................................................................................... 11
ILLUSTRATED PARTS................................................................................................................. 12
Kettles ............................................................................................................................................. 12
Kettles Parts List ............................................................................................................................. 12
Tilt Console Exploded View ............................................................................................................. 13
Tilt Console Parts List ..................................................................................................................... 14
Spring Assist Hinge Assembly.......................................................................................................... 15
Spring Assist Hinge Assembly Parts List ......................................................................................... 16
Hinge Assembly (Stationary Kettles) ............................................................................................... 17
Hinge Assembly (Stationary Kettles) Parts List .............................................................................. 17
Draw Off Valve ................................................................................................................................ 18
Draw Off Valve Parts List................................................................................................................ 18
1
INTRODUCTION
IMPORTANT NOTES FOR INSTALLATION AND OPERATION
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.
WARNING: Improper installation, operation, adjustment, alteration,
service or maintenance can cause property damage, injury or death.
Read the installation, operating and maintenance instructions
thoroughly before installing, operating or servicing this equipment.
Intended for commercial use only. Not for household use.
NOTICE: Contact the factory, the factory representative or local service
company to perform maintenance and repairs.
This manual should be retained for future reference.
1
INTRODUCTION
SERVICE CONNECTIONS & DEMENSIONS:
TILTING TRI-LEG MODELS
2
INTRODUCTION
SERVICE CONNECTIONS & DEMENSIONS:
TILTING PEDESTAL MODELS
3
INTRODUCTION
SERVICE CONNECTIONS & DEMENSIONS:
STATIONARY PEDESTAL MODELS
4
INTRODUCTION
SERVICE CONNECTIONS & DEMENSIONS:
STATIONARY TR-LEG MODELS
5
INTRODUCTION
DESCRIPTION:
All 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. Kettles included are tilting and stationary, floor mounted in
fixed positions either on legs with adjustable flanged feet or pedestals. All kettles are equipped with a
drain cock, safety relief valve and a steam control valve. Options on kettles include hinged spring
assisted stainless steel lid covering the kettle bowl opening and a sanitary stainless steel tangent drawoff valve as an alternate method for the removal of the food product from the kettle bowl.
BASIC FUNCTIONING
FUNCTIONING MODE
Market Forge 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. Further, the greater the steam pressure used, the higher the
temperature and consequently the quicker the cooking process. For example, steam pressurized at 30
PSI attains a temperature of 274oF (135oC).
6
INSTALLATION
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 tri-leg models and through pedestal
base on pedestal models. Remove kettle.
3. On hole locations marked, drill holes and insert expansion shields to accommodate
lag bolts.
5/16" size
4. Reposition kettle. On tri-leg 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
being supplied to the kettle.
12. Check for proper operation.
7
OPERATION
OPERATING INSTRUCTIONS:
Tilting Kettles
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 (counterclockwise).
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.
Stationary Kettles
1. Ensure that draw-off valve is closed.
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 - 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.
CAUTION: The equipment and its parts are hot. Use care when operating, cleaning and servicing.
8
MAINTENANCE
CLEANING INSTRUCTIONS:
CAUTION: The equipment and its parts are hot. Use care when operating, cleaning and servicing.
CAUTION: Do not use cleaning agents that are corrosive.
Use of cleaning agents that contain chloride, acids or salts are corrosive and may cause pitting and
corrosion when used over a period of time; this will reduce the life of the appliance.
Should pitting or corrosion occur, this is not covered by warranty.
Follow the recommended cleaning instructions.
thoroughly.
Use a mild detergent, warm water and rinse
Tilting Kettle Cleaning Instructions
Your kettle should be cleaned immediately after each use.
1. Ensure that steam supply is OFF.
2. Pre-rinse inside of kettle thoroughly and drain to remove any food particles.
3. Using a nylon brush, clean kettle with a mild detergent and warm water rinse. Never use steel
wool or scouring powder as it will scratch stainless steel.
4. Tilt kettle fully or open the tangent draw-off valve if one is provided to allow soap and water
solution to drain. Rinse with clean water.
5. On kettles equipped with a draw-off valve, turn the large hex nut counterclockwise by hand until
it is completely disengaged from the thread. Grasp knob to valve and slowly pull out valve stem
and disc. Do not allow disc to come in contact with hard surfaces since damage to disc may
occur and result in valve leakage. Wash the valve stem, disc and handle. Insert nylon brush
with detergent into interior of valve body and tangent draw-off tube and brush vigorously.
Replace valve stem assembly and engage hex nut fully by hand. Flush kettle with clean warm
water. Leave valve open when kettle is not in use.
Stationary Kettle Cleaning Instructions
Your kettle should be cleaned immediately after each use.
1. Ensure that steam supply is OFF.
2. Pre-rinse inside of kettle thoroughly and drain to remove any food particles.
3. Using a nylon brush, clean kettle with a mild detergent and warm water rinse. Never use steel
wool or scouring powder as it will scratch stainless steel.
9
MAINTENANCE
4. Open the tangent draw-off valve to allow soap and water solution to drain. Rinse with clean
water.
WARNING: If you are cleaning a valve that is assembled to a kettle be sure the
kettle is completely empty of any product.
5. By hand, turn the large hex nut counterclockwise on draw off valve until it is completely
disengaged from thread. Grasp knob to valve and slowly pull out valve stem and disc. Do not
allow disc to come in contact with hard surfaces since damage to disc may occur and result in
valve leakage. Wash the valve stem, disc and handle. Insert nylon brush with detergent into
interior of valve body and tangent draw-off tube and brush vigorously.
6. Replace valve stem assembly and engage hex nut fully by hand. Flush kettle with clean warm
water.
7. Leave valve open when kettle is not in use.
PREVENTIVE MAINTENANCE
No preventive maintenance is required other than adhering to the Cleaning Procedure instructions.
SAFETY VALVE MAINTENANCE AND TESTING
CAUTION! Under normal operating conditions a “try lever test” should be
performed every two months. Under severe service conditions, or if
corrosion and/or deposits are noticed within the valve body, testing must
be performed more often. A “try lever test” should also be performed at
the end of any non-service period.
CAUTION! Hot, high pressure fluid may be discharged from body drain
and vent during “try lever” test. Care must be taken to avoid any bodily
contact.
CAUTION! High sound levels may be experienced during “try lever” test. Wear proper
safety equipment and exercise extreme care! Test at, or near, half of the operating
pressure by holding the test lever fully open for at least two seconds to flush the valve
seat free of sediment and debris. Then release lever and permit the valve to snap
shut.
If lift lever does not activate, or there is no evidence of discharge, turn off equipment
immediately and contact a licensed contractor or qualified service personnel.
10
TROUBLE SHOOTING
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.
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 PSI 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.
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 that there is water in the jacket. Open ball
valve and drain. Close valve and commence operation of kettle.
11
ILLUSTRATED PARTS
Kettles
ILLUSTRATED PARTS
ITEM
PART
NO.
NO.
1
97-5156
2
97-6491
3
97-6492
4
97-5032
5
97-6739
*6
97-5592/5045
**6
97-5009
*7
97-6368
* NOT SHOWN.
** SELECT AS REQUIRED.
Kettles Parts List
QTY
DESCRIPTION
BALL VALVE
TILT CONSOLE
CONSOLE COVER
ASJUSTABLE FLANGED FOOT
SCREW, 10-32 x 1/2”
RELIEF VALVE, 35 PSI
RELIEF VALVE, 50 PSI (OPTIONAL)
DOWN TUBE FOR RELIEF VALVE
12
1
1
1
3
1
1
1
1
ILLUSTRATED PARTS
Tilt Console Exploded View
13
ILLUSTRATED PARTS
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
*13
14
15
16
PART
NO.
97-5090/5713
97-5091
97-5092
97-5096
97-5909
97-5882
97-5416
97-5093
97-7248
97-7247
97-7246
97-6493
97-6405
97-5099
97-5584
97-5583
Tilt Console Parts List
QTY
DESCRIPTION
HANDWHEEL
SET SCREW, 3/8 – 16 x 1/2”
TILT SHAFT
JAM NUT, 3/4 - 16 UNF
THRUST BEARING
SEGMENT GEAR & WORM GEAR KIT (7 THRU 12)
SET SCREW, 1/4 – 20 x 1/2”
TENSION PIN, 3/16” OD x 1-1/4” L
NUT, 1/2 – 13 UNC
LOCK WASHER, 1/2”
BOLT, 1/2 – 13 UNC x 2”
KEY, 1/4”
“O” RING LUBRICATION
SPACER
NUT, 3/8 – 16 UNC
SET SCREW, 3/8 – 16 UNC x 1 – 3/4”
OUTBORE BEARING COMPLETE w/EXTENTION
*** 17
97-5179
(USED ON SPRING ASSIST COVER ONLY)
18
97-5368
STAINLESS STEEL WASHER
19
97-5883
BOLT
20
97-5177
OUTBORE BEARING
21
97-5366
“O” RING
22
97-5367
BRASS FITTING
23
97-7324
BOILT, 3/8 – 16 UNC x 1”
24
97-7325
LOCK WASHER, 3/8”
25
97-5171
BLOCK BEARING
26
97-5877
90o ELBOW, 3/4”
27
97-5878
NIPPLE, 3/4 x 2-1/2” L
28
97-5879
COUPLING, 3/4 x 2-1/2” L
29
97-6495
PIPE-STEAM SUPPLY, 3/4” x 12-1/2” L
30
97-5030/5362 CONTROL VALVE, 3/4”
31
97-5306
CONTROL VALVE KNOB
32
97-6494
DECAL – TILT
33
97-5820
WASHER, 3/4” ID x 1-1/4” OD
34
97-7214
COTTER PIN, STAINLESS STEEL, 3/16” x 1” L
35
97-5110
“O” RING
36
97-5546
RETAINING RING
* NOT SHOWN.
*** SPECIFY MODEL.
14
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
1
1
1
1
1
1
1
1
1
1
4
1
ILLUSTRATED PARTS
Spring Assist Hinge Assembly
15
ILLUSTRATED PARTS
ITEM
NO.
PART
NO.
97-5464
1
97-5352
2
97-5343
3
98-5354
98-6074/
4
97-5355
5
97-5160
**6
97-5585
97-5586
97-6388
97-5059
97-5587
97-5588
7
97-6391/5355
8
97-5356
9
97-5349
10
97-5008
11
97-7271
**12
97-5471
97-5723
97-5053
97-5054
97-5594
97-5595
** SELECT AS REQUIRED.
Spring Assist Hinge Assembly Parts List
QTY
DESCRIPTION
HINGE ASSEMBLY
LOCK PIN
END LOCK PLATE
STATIONARY DISC
1
1
1
1
CORE
1
SPRING
HANDLE ASSEMBLY, 20 GALLON KETTLE
HANDLE ASSEMBLY, 30 GALLON KETTLE
HANDLE ASSEMBLY, 40 GALLON KETTLE
HANDLE ASSEMBLY, 60 GALLON KETTLE
HANDLE ASSEMBLY, 80 GALLON KETTLE
HANDLE ASSEMBLY, 100 GALLON KETTLE
ROTARY DISC
END STOP PLATE
CAP SCREWS, 1/4-20 x 3/4
KNOB
MOUNTING PLATE – TILTING KETTLES ONLY
COVERS, 20 GALLON KETTLES
COVERS, 30 GALLON KETTLES
COVERS, 40 GALLON KETTLES
COVERS, 60 GALLON KETTLES
COVERS, 80 GALLON KETTLES
COVERS, 100 GALLON KETTLES
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
1
1
16
ILLUSTRATED PARTS
Hinge Assembly (Stationary Kettles)
ILLUSTRATED PARTS
ITEM
NO.
1
**2
PART
NO.
97-5008
97-5596
97-5597/5722
97-5598
3
97-5200
4
97-7326
5
97-5601
6
97-7200
7
97-5471
97-5723
97-5053
** SELECT AS REQUIRED.
Hinge Assembly (Stationary Kettles) Parts List
QTY
DESCRIPTION
KNOB
HANDLE ASSEMBLY, 20 GALLON KETTLE
HANDLE ASSEMBLY, 30 GALLON KETTLE
HANDLE ASSEMBLY, 40 GALLON KETTLE
HEX BOLT, 1/2 – 20 UNF x 1” STAINLESS STEEL
FIBRE WASHER
HEX NUT, 1/2 – 20 UNF, STAINLESS STEEL
SPLIT LOCK WASHER, 1/2” STAINLESS STEEL
COVER, 20 GALLON KETTLE
COVER, 30 GALLON KETTLE
COVER, 40 GALLON KETTLE
17
1
1
1
1
2
4
2
2
1
1
1
ILLUSTRATED PARTS
Draw Off Valve
ITEM
NO.
1
2
3
4
5
6
7
1
2
3
4
5
6
7
PART
NO.
97-5062
98-6155
97-5566
97-5068
97-5071
97-5077
97-5074
97-6496
97-5063
98-6155
97-5566
97-5069
97-5072
97-5078
97-5075A
98-6156
Draw Off Valve Parts List
QTY
DESCRIPTION
1-/2” DRAW OFF VALVE ASSEMBLY
ACORN NUT 10-24 UNC
HANDLE, STAINLESS STEEL
GLAND NUT
BONNET
“O” RING
STEM ASSEMBLY
VALVE BODY
2” DRAW OFF VALVE ASSEMBLY
ACORN NUT 10-24 UNC
HANDLE, STAINLESS STEEL
GLAND NUT
BONNET
“O” RING
STEM ASSEMBLY
VALVE BODY
18
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
ILLUSTRATED PARTS
ITEM
NO.
1
2
3
4
5
6
7
PART
NO
97-5605
97-5066
97-5067
97-5068
97-5073
97-5079
97-5076
97-6497
Draw Off Valve Parts List
QTY
DESCRIPTION
3” DRAW OFF VALVE ASSEMBLY
ACORN NUT 10-24 UNC
HANDLE, STAINLESS STEEL
GLAND NUT
BONNET
“O” RING
STEM ASSEMBLY
VALVE BODY
19
1
1
1
1
1
1
1
1
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement