Solaris DL-20 User manual

PART NUMBER 10075R2 12007-01-03
INSTALLATION AND OPERATION
MANUAL
DIRECT STEAM STATIONARY KETTLES
MODELS: DL - 20, 30, 40, 60, 80, 100 GALLON
DP - 20, 30, 40, 60, 80, 100 GALLON

INSTALLATION AND OPERATION MANUAL - DIRECT STEAM STATIONARY KETTLES,
MODELS DL-20, 30, 40, 60, 80, 100 GALLON, DP-20, 30, 40, 60, 80, 100 GALLON
PART NUMBER 10075R2 22007-01-03
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.
This manual should be retained for future reference.
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.

INSTALLATION AND OPERATION MANUAL - DIRECT STEAM STATIONARY KETTLES,
MODELS DL-20, 30, 40, 60, 80, 100 GALLON, DP-20, 30, 40, 60, 80, 100 GALLON
PART NUMBER 10075R2 32007-01-03
TABLE OF CONTENTS
DESCRIPTION PAGE
1.0 Service Connections ....................................................4
2.0 Installation Instructions ..................................................6
3.0 Introduction ..........................................................7
4.0 Operating Instructions ..................................................8
5.0 Cleaning Procedures ...................................................9
6.0 Troubleshooting Maintenance ...........................................11

INSTALLATION AND OPERATION MANUAL - DIRECT STEAM STATIONARY KETTLES,
MODELS DL-20, 30, 40, 60, 80, 100 GALLON, DP-20, 30, 40, 60, 80, 100 GALLON
PART NUMBER 10075R2 42007-01-03
1.0 SERVICE CONNECTIONS

INSTALLATION AND OPERATION MANUAL - DIRECT STEAM STATIONARY KETTLES,
MODELS DL-20, 30, 40, 60, 80, 100 GALLON, DP-20, 30, 40, 60, 80, 100 GALLON
PART NUMBER 10075R2 52007-01-03
1.0 SERVICE CONNECTIONS (Continued)

INSTALLATION AND OPERATION MANUAL - DIRECT STEAM STATIONARY KETTLES,
MODELS DL-20, 30, 40, 60, 80, 100 GALLON, DP-20, 30, 40, 60, 80, 100 GALLON
PART NUMBER 10075R2 62007-01-03
2.0 INSTALLATION INSTRUCTIONS
1. Select a location to provide drainage directly below the tangent Draw-off Valve.
2. Mark hole locations through flanged adjustable feet on DL models and through pedestal
base on DP 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 DL 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 fulfill NSF requirements.
6. Install a steam control valve at a convenient location near kettle on the incoming steam line
(3/4" size pipe).
7. Connect steam line to the kettle, making sure there is a steam control valve strainer fairly
convenient to the kettle.
8. 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.
9. Safety relief valve on kettle must not be plugged as it is set to relieve excess pressure in
the kettle.
10. If incoming steam pressure is greater than kettle maximum operating pressure then a
pressure reducing valve must be installed in the line.
11. 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.
12. A steam line pressure gauge is also recommended to determine the actual amount of
steam coming to the kettle.
13. Check for proper operation.

INSTALLATION AND OPERATION MANUAL - DIRECT STEAM STATIONARY KETTLES,
MODELS DL-20, 30, 40, 60, 80, 100 GALLON, DP-20, 30, 40, 60, 80, 100 GALLON
PART NUMBER 10075R2 72007-01-03
3.0 INTRODUCTION
DESCRIPTION
All Crown 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
stationary, floor mounted in fixed positions either on legs with adjustable flanged feet (DL
models) or pedestal (DP models).
CAPACITIES
All models are suffixed with either - 20, - 30, - 40, - 60, - 80 or -100 to indicate the capacity of
that kettle in US gallons. Thus a DL - 40 is a two thirds jacketed direct steam kettle mounted
on legs with a capacity of 40 gallons (US).
FUNCTIONING MODE
Crown 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 that surface.
The temperatures required for the cooking process to function adequately must be greater than
the boiling point of the liquid food product, viz. 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).

INSTALLATION AND OPERATION MANUAL - DIRECT STEAM STATIONARY KETTLES,
MODELS DL-20, 30, 40, 60, 80, 100 GALLON, DP-20, 30, 40, 60, 80, 100 GALLON
PART NUMBER 10075R2 82007-01-03
4.0 OPERATING INSTRUCTIONS
CAUTION: The appliance and its parts are hot. Use care when
operating, cleaning and servicing the appliance.
OPERATING PROCEDURE
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.

INSTALLATION AND OPERATION MANUAL - DIRECT STEAM STATIONARY KETTLES,
MODELS DL-20, 30, 40, 60, 80, 100 GALLON, DP-20, 30, 40, 60, 80, 100 GALLON
PART NUMBER 10075R2 92007-01-03
5.0 CLEANING PROCEDURES
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. 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.
CAUTION: Do not use cleaning agents that are corrosive.

INSTALLATION AND OPERATION MANUAL - DIRECT STEAM STATIONARY KETTLES,
MODELS DL-20, 30, 40, 60, 80, 100 GALLON, DP-20, 30, 40, 60, 80, 100 GALLON
PART NUMBER 10075R2 10 2007-01-03
5.0 CLEANING PROCEDURES (Continued)
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. Use a mild detergent, warm water and rinse
thoroughly.

INSTALLATION AND OPERATION MANUAL - DIRECT STEAM STATIONARY KETTLES,
MODELS DL-20, 30, 40, 60, 80, 100 GALLON, DP-20, 30, 40, 60, 80, 100 GALLON
PART NUMBER 10075R2 11 2007-01-03
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. This is not covered under warranty.
6.0 TROUBLESHOOTING MAINTENANCE
PREVENTIVE MAINTENANCE
No preventive maintenance is required other than adhering to the Cleaning Procedure
instructions.
DRAW-OFF VALVE LEAKS
If a leak occurs through the valve stem, replace the “O” ring.
If the leak can be attributed to faulty sealing occurring between the stem disc and valve seat,
then this problem may be corrected by cleaning off the dried-on food residue with extremely fine
emery cloth. If the vulcanized rubber stem piece has been damaged, it must be replaced.
EXTREMELY SLOW COOKING TIME
If the cooking time is abnormally slow, this 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 supply 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.

INSTALLATION AND OPERATION MANUAL - DIRECT STEAM STATIONARY KETTLES,
MODELS DL-20, 30, 40, 60, 80, 100 GALLON, DP-20, 30, 40, 60, 80, 100 GALLON
PART NUMBER 10075R2 12 2007-01-03
6.0 TROUBLESHOOTING MAINTENANCE
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).