Blodgett Hot Beverage Maker KLT G Series User Manual

KLT-G Series  
GAS FIRED TRI-LEG TILTING KETTLE  
INSTALLATION – OPERATION MAINTENANCE  
BLODGETT OVEN COMPANY  
44 Lakeside Avenue, Burlington, Vermont 05401 USA Telephone (800) 331-5842, (802) 860-3700 Fax: (802) 864-0183  
S00052 Rev A (5/04)  
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TABLE OF CONTENTS  
DESCRIPTION  
PAGE  
Important Notes For Installation and Operation  
1.0 Service Connections  
2.0 Installation  
2
4
5
3.0 Operation  
10  
16  
20  
21  
26  
29  
4.0 Cleaning Instructions  
5.0 Maintenance  
6.0 Service  
7.0 Troubleshooting  
Appendix A, Material Safety Data Sheet  
3
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1.0 SERVICE CONNECTIONS  
Supply gas through 3/4" pipe . A gas shut-off valve must be installed in supply piping convenient and adjacent to appliance.  
Unless other wise specified, Field Wire Electrical Connection to be 120 Volts, 60 Hertz single phase with grounding wire.  
COLD WATER: 3/8"(10mm) tubing to faucet (OPTIONAL)  
HOT WATER: 3/8"(10mm) tubing to faucet (OPTIONAL)  
MODEL  
GAS SUPPLY  
SUPPLY PIPE PRESSURE (W.C.)  
BTU/HR.  
80,000  
kW/HR.  
23.4  
KLT-20G  
KLT-40G  
KLT-60G  
Propane  
11"-14" (279-356mm)  
Natural  
6"-14" (152-356mm)  
100,000  
120,000  
29.3  
35.2  
DIMENSIONS  
MODEL CAPACITY UNITS  
A
B
C
D
E
F
G
H
J
K
L
M
N
20 gallons inches  
KLT-20G  
20  
48.13  
40.63  
19  
40.13  
76.5 16.5  
24  
11  
22  
40.5  
18.38  
25.5  
76 litres  
mm  
508  
26  
1222  
55.25  
1032 483  
43.63 16.5  
1019  
43.25  
1943  
76  
419  
15.5  
610  
22.25  
279  
7.5  
559  
23  
1029  
42.5  
467  
22.13  
648  
28.5  
40 gallons inches  
152 litres mm  
60 gallons inches  
KLT-40G  
KLT-60G  
660  
1403  
1108 419  
1099  
1930 394  
565  
191 584  
1080  
562  
724  
30  
59  
45.63 17.88  
1159 454  
43.88  
1115  
82  
19.5  
495  
22.25  
565  
5.5  
23  
45.5  
24.75  
629  
30.5  
775  
227 litres  
mm  
762  
1499  
2083  
140  
584  
1156  
DIMENSIONS ARE IN INCHES [MM]  
B
(GLT-20) 6.25[159]  
(GLT-30...60) 7[178]  
10.5[267]  
FLANGED FOOT DETAIL  
2 EQUALLY SPACED  
Ø7/16" [11mm] HOLES  
ON 2.5 [63] B.C.  
3[76]  
5.875[149]  
26  
[660]  
2[51]  
35  
[889]  
C
G
A
N
MINIMUM  
4[102mm]  
F
E
36  
27.75 [705]  
8.125 [206]  
[914]  
D
H
J
6[152]  
K
L
4
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2.0 INSTALLATION  
INSTALLATION CODES AND STANDARDS  
Installation must conform with local codes, or in the absence of local codes, 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 supply  
piping system during any pressure testing of that system at pressures in excess of ½ psi  
(3.5 kPa). .  
2. The appliance must be isolated from the gas supply piping system by closing its individual  
manual shut off valve during any pressure testing of the gas supply piping system at test  
pressures equal to or less than ½ psi (3.5 kPa).  
Electrical grounding must be provided in accordance with local codes, or in the absence of local  
codes, with the National Electrical Code, ANSI/NFPA 70, or the Canadian Electrical Code, CSA  
C22.2, as applicable.  
The electrical diagram is located on the inside of side panel of left hand console.  
EXHAUST FANS AND CANOPIES: Canopies are set over ranges, ovens and kettles for  
ventilation purposes. It is recommended that a canopy extend 6 inches past appliance and be  
located 7.5 feet from the floor. Filters should be installed at an angle of 45 degrees or more with  
the horizontal. This position prevents dripping of grease and facilitates collecting the run-off  
grease in a drip pan, usually installed with the filter. A strong exhaust fan tends to create a  
vacuum in the room and may interfere with burner performance or may extinguish pilot flames.  
Makeup air openings approximately equal to the fan area will relieve such vacuum. In case of  
unsatisfactory performance on any appliance, check operation with exhaust fan in the “OFF”  
position.  
WALL EXHAUST FAN: The exhaust fan should be installed at least two feet above the vent  
opening at the top of the unit.  
CLEARANCES: Adequate clearance must be provided in aisle and at the side and back.  
Adequate clearances for air openings into the combustion chamber must be provided, as well  
as for serviceability.  
SIDES -  
BACK -  
FLOORS -  
0 INCHES  
4 INCHES AT FLUE BOX  
NON-COMBUSTIBLE  
5
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INSTALLATION (Continued)  
All units must be installed in such a manner that 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 may be obtained from the  
standard for “Vapor Removal from Cooking Equipment”, NFPA No. 96 (latest edition), available  
from the National Fire Protection Association, Batterymarch Park, Quincy, MA, USA, 02269.  
TO INSTALL  
1. Uncrate carefully. Report any hidden freight damage to the freight company immediately.  
2. The pressure relief valve is located at the right rear of the unit. This area should be kept  
clear and should not be in an area where operators will normally stand. The elbow on the  
relief valve should be turned toward the floor. A maximum 3 foot, 3/4" diameter pipe may be  
used to extend to the floor, but must not be piped directly to a drain. It must vent to the  
atmosphere.  
3. Set the unit in place. Be certain to maintain minimum clearances as stated above.  
4. To level the unit use a spirit level in all directions on the top of the kettle (lid up). Adjust the  
bottom foot on each leg to overcome an uneven floor.  
5. Mark hole locations on floor through anchoring holes provided in flanged adjustable feet.  
6. Remove appliance and drill holes in locations marked on floor and insert proper anchoring  
devices.  
7. Set unit back in position and re-level left to right and front to back.  
8. Bolt and anchor appliances securely to the floor.  
9. Seal bolts and flanged feet with silastic or equivalent compound.  
10. Appliance location must allow air supply to unit and obstruction free clearance for air  
opening into the combustion chamber.  
11. Make service connections as indicated.  
12. Check the pressure gauge on the front panel before operating. If the pressure gauge does  
not indicate green vacuum zone (below 0 psi), see “Re-establishing Vacuum” section under  
SERVICE, after completing installation instructions.  
6
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2.0 INSTALLATION (Continued)  
GAS CONNECTION  
The serial plate on the lower right side of the unit indicates 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 internal  
pressure regulator which is set for 3.5" W.C. manifold pressure for natural gas and 4.0" W.C. for  
propane gas. Use 1/8" pipe tap on the downstream side of the combination valve for checking  
pressure.  
An adequate gas supply is imperative. Undersized or low pressure lines will restrict the volume  
of gas required for satisfactory performance. A steady pressure, minimum 6" W.C. for natural  
gas and minimum 11" W.C. for propane gas, is recommended. With all units operating  
simultaneously, the manifold pressure on all units should not show any appreciable drop.  
Fluctuations of more than 25% on natural gas, and 10% on propane gas, will create pilot  
problems and affect burner operating characteristics. Contact your gas company for correct  
supply line sizes.  
Purge the supply line to clean out any dust, dirt, or other foreign matter before connecting the  
line to the unit. It is recommended that an individual manual shut off valve be installed in the  
gas supply line to the unit. Use pipe joint compound which is suitable for use with LP gas on all  
threaded connections. Test pipe connections thoroughly for gas leaks.  
WARNING: All connections must be checked for leaks, after the unit has been  
put in operation. Use soapy water only for testing on all gases. Never use an  
open flame to check for gas leaks.  
NOTICE: If applicable, the vent line from the gas appliance pressure regulator shall be  
installed to the outdoors in accordance with local codes or, in the absence of local codes, with  
the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation  
Code CSA B149.1, as applicable.  
NOTICE: If this equipment is being installed at over 2,000 feet altitude and was not so specified  
on order, contact service department. Failure to install with proper orifice sizing may void the  
warranty.  
7
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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 (blue). Plastic or rubber hose is not recommended, as it may melt against the hot kettle  
side.  
ELECTRICAL CONNECTION  
WARNING: Do not connect the kettle to the electrical supply until after the gas  
connection has been made.  
1. 120 VAC - 60 Hz - Single Phase  
WARNING: ELECTRICAL GROUNDING INSTRUCTIONS  
This appliance is equipped with a three-prong (grounding) plug for your protection  
against shock hazard and should be plugged directly into a properly grounded  
three-prong receptacle. Do not cut or remove the grounding prong from this plug.  
(120V units only).  
Units with this electrical rating are factory supplied with a three-wired cord and three-prong plug  
which fits any standard 120V, three-prong grounded receptacle. A separate 15 amp supply is  
needed for each unit.  
1. 208/240 VAC - 60 Hz - Single and Three Phase  
Units with this electrical rating are factory equipped with a transformer. To connect supply  
wires, remove cover from right console. Route supply wires and ground wire through the  
hole in the console with a strain relief fitting. Connect wires to the terminal block in the rear  
of the right console. Connect ground wire to lug. Replace cover. Three-phase units are  
wired as above, using only two supply wires. The third supply wire is not connected and  
must be properly terminated.  
1. 220 VAC - 50 Hz - Single Phase  
Units equipped with this voltage ratings should be wired exactly as in (2.) above.  
8
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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. Internal electrical connections.  
6. Burners - adjustment and ignition.  
7. Thermostat - cycle for operation check.  
8. Gas supply valve - check for operation.  
9. Check hinge and lid assembly.  
10. Draw-off valve - check operation.  
11. Advise user on cleaning procedure.  
9
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3.0 OPERATION  
Contact the factory, the factory representative or a local service company to perform  
maintenance and repairs should the appliance malfunction.  
CAUTION: If you smell gas during the lighting procedure, immediately shut off the  
gas supply until the leak has been corrected.  
WARNING: In the event of main burner ignition failure, a 5 minute purge period  
must be observed prior to re-establishing ignition source.  
WARNING: In the event you smell gas, shut down equipment at the main shut off  
valve and contact the local gas company or gas supplier for service.  
GAS CONTROL INSTRUCTIONS  
The units do not require “lighting” the pilot with a match.  
A. Lighting  
NOTE: Unit is shipped with gas combination valve turned “on”.  
1. Open manual gas shut off valve.  
2. Set thermostat to OFF, and kettle in fully upright position, turn power switch ON.  
3. Set thermostat to maximum, initiating a 30 second pre-purge. Red “COOKING” pilot will  
come on, and after 30 seconds, the green “IGNITION” pilot will come on, lighting the main  
burners.  
10  
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3.0 OPERATION (Continued)  
A. Lighting (Continued)  
If after 36 seconds the burner fails to ignite or the “ignition light goes 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 been  
reached, the “IGNITION” pilot will go off, turning off the burner. The unit will then cycle on  
and off to maintain set temperature.  
NOTE: When the kettle is tilted a safety switch will automatically turn off gas supply. The kettle  
will not operate once it has been tilted.  
DAILY SHUTDOWN  
1. Turn power switch “OFF.”  
2. Turn thermostat “OFF.”  
COMPLETE SHUTDOWN  
1. Turn power switch “OFF.”  
2. Turn thermostat “OFF”.  
3. Turn power supply to unit “OFF”.  
4. Remove front access panel on left side and turn dial on combination valve to “OFF”.  
5. Close manual gas shut off valve.  
11  
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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 periods.  
(GREEN) IGNITION LIGHT  
This light is on whenever the main burner gas is on.  
(RED) COOKING LIGHT  
This light is on when the thermostat is calling for heat.  
(AMBER) LOW WATER LIGHT  
All kettles are supplied with sufficient distilled water in pressurized jacket. If at any time the  
water level falls below that required for proper operation, the kettle will not heat and this light will  
come on. See “Adding Water” in Service section.  
12  
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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  
EC  
15  
EF  
1
2
60  
27  
81  
3
40  
104  
127  
153  
178  
203  
226  
252  
275  
4
53  
5
67  
6
81  
7
95  
8
108  
122  
135  
9
10  
PRESSURE GAUGE  
The pressure gauge indicates the internal operating pressure of the kettle. When cold, the  
gauge should point to the green vacuum zone. If it does not, refer to “Re-establishing Vacuum”  
section. Under normal operation with the kettle empty (thermostat set at 10 or 275EF) the  
pressure should reach 30 psi. When loaded the pressure may be considerably less.  
SIGHT GLASS  
The sight glass indicates the minimum and maximum water level within the kettle. If water level  
falls below minimum level more distilled water should be added. See “Adding Water” in Service  
section.  
13  
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3.0 OPERATION (Continued)  
PRESSURE RELIEF VALVE  
The pressure relief valve is a safety device which 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 the  
desired temperature.  
It is recommended the kettle be preheated prior to use. Milk or egg based products should be  
placed in the kettle before heating however, to prevent sticking. The kettle is preheated when  
the cooking light goes off the first time.  
At the end of the day, or if the kettle will not be used for some time, shut the unit down by  
turning the power switch to “OFF”.  
Clean as required or on a daily basis. See “CLEANING INSTRUCTIONS” section.  
END USE TIPS  
For easier cleaning add cold water to the kettle immediately after removing contents.  
When preparing foods containing vinegar or tomatoes, or those which have a high salt content,  
clean the kettle immediately after using to prevent pitting.  
Do not use salt to clean the kettle. This will scratch the surface.  
If using salt water to cook shellfish, be sure to rinse and wash the kettle thoroughly after use.  
Bring milk and egg products slowly up to temperature in a cold kettle to prevent product from  
adhering to the sides. When preparing milk-based products do not preheat the kettle.  
When planning actual cooking capacity, allow room at top for stirring without spilling.  
When preparing puddings from a mix, place the powder in a cold kettle, add a small amount of  
liquid, and stir to form a thin paste. Turn on the kettle and add the remainder of the liquid.  
Continue as per recipe instructions.  
When browning meat, bring the kettle up to temperature before adding. This will seal the juices  
in the meat.  
14  
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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.  
15  
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4.0 CLEANING INSTRUCTIONS  
WARNING: Disconnect the power supply to the appliance before cleaning or  
servicing.  
WARNING: Never spray water into electric controls or components!  
CAUTION: The equipment and its parts are hot. Use care when operating,  
cleaning and servicing.  
CAUTION: Do not use cleaning agents that are corrosive.  
Your kettle should be cleaned immediately after each use or when cooking a different product.  
Before cleaning, check that the kettle has cooled enough to touch it.  
1. Rinse the inside of the kettle thoroughly and drain to remove any food particles.  
2. Using a nylon brush, clean the kettle with a mild detergent and water. Never use steel wool  
or scouring powder as it will scratch stainless steel. Plain steel wool can leave small pieces  
of steel which can rust.  
3. Rinse the inside of the kettle thoroughly with clean water. Drain the kettle by tilting or the  
tangent draw-off valve, depending on model, to allow the detergent and water solution to  
drain.  
4. Wipe the exterior of the kettle with a clean, damp cloth.  
WARNING: If you are cleaning a valve that is assembled to a kettle, be sure the  
kettle is completely empty of any product.  
16  
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4.0 CLEANING INSTRUCTIONS (Continued)  
DRAW-OFF VALVE CLEANING  
1. If equipped with a tangent draw-off valve, turn the large hex nut on the draw-off valve  
counterclockwise until it is completely disengaged 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 surfaces as it can be damaged and cause valve leakage. Wash the valve stem, disk  
and handle. Insert a nylon brush, wet with detergent and water, into the valve body and  
tangent draw-off tube. Brush vigorously.  
2. Replace the valve stem assembly and turn the hex nut until snug. Rinse the kettle with  
clean warm water.  
3. Leave the draw-off valve open when the kettle is not in use.  
DAIRY DRAW-OFF VALVE CLEANING  
1. Remove the plug by first removing the handle, then turn the plug to line up with the pin and  
pull with both hands. It is important to use both hands because the plug is heavy.  
2. Put the plug in a plastic pail that contains a mild soap solution. A plastic pail works best, as  
it reduces the possibility of nicking or scratching the plug. If the plug gets scratched it may  
not seal correctly and could leak.  
3. Use a soft cloth or soft brush and clean all surfaces.  
4. Using both hands remove the valve from the soap and rinse well in another plastic pail that  
contains fresh water.  
5. Wash out the kettle as normal.  
6. Once the kettle is washed out, return the plug into the body. Be sure the plug is inserted  
into the notch and turned. Ensure the plug is tight and secure before letting go of it.  
If you are cleaning a body and plug assembly, remove the plug and follow the above  
procedures. When finished with the plug, follow the same instructions for washing the body.  
Always use both hands when handling the plugs. Reassemble the plug into the body and use  
as normal.  
17  
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4.0 CLEANING INSTRUCTIONS (Continued)  
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.  
WHAT TO DO IF SURFACE RUST APPEARS  
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 may damage your appliance!  
1. Use undiluted white vinegar with a non-abrasive scouring pad (plastic) or cloth on the  
affected area to remove the rust stain. The appliance should not be heated and remain at  
room temperature during the entire cleaning process.  
2. If the stain resists removal, additional exposure time with vinegar may be required, to a  
maximum of one hour.  
3. Thoroughly wash all of the vinegar away with fresh clear water. Dry the surface completely  
and allow one hour before using the appliance to cook.  
Following daily and period maintenance procedures will prolong the life for your equipment.  
Climatic conditions - salt air - may require more thorough and frequent cleaning or the life of the  
equipment could be adversely affected.  
STAINLESS STEEL  
To remove normal dirt, grease or product residue from stainless steel, use ordinary soap and  
water (with or without detergent) applied with a sponge or cloth. Dry thoroughly with a clean  
cloth. Never use vinegar or any other corrosive cleaner.  
To remove grease and food splatters or condensed vapours that have baked on the equipment,  
apply cleanser to a damp cloth or sponge and rub cleanser on the metal in the direction of the  
polishing lines. Rubbing cleanser as gently as possible in the direction of the polished lines will  
not mar the finish of the stainless steel. NEVER RUB WITH A CIRCULAR MOTION.  
18  
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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 USE A WIRE BRUSH, STEEL SCOURING PADS  
(EXCEPT STAINLESS), SCRAPER, FILE OR OTHER STEEL TOOLS. Surfaces which are  
marred collect dirt more rapidly and become more difficult to clean. Marring also increases the  
possibility of corrosive attack. Refinishing may then be required.  
TO REMOVE HEAT TINT: Darkened areas sometimes appear on stainless steel surfaces  
where the area has been subjected to excessive heat. These darkened areas are caused by  
thickening of the protective surface of the stainless steel and is not harmful. Heat tint can  
normally be removed by the foregoing, but tint which does not respond to this procedure calls  
for a vigorous scouring in the direction of the polish lines using SCOTCH-BRITE™ scouring  
pads or a STAINLESS scouring pad in combination with a powdered cleanser. Heat tint action  
may be lessened by not applying or by reducing heat to equipment during slack periods.  
All food contact surfaces must be thoroughly drained and flushed prior to cooking in the kettle.  
CONTROL PANEL: The textured control panel should be cleaned with warm water and mild  
soap. Never use an abrasive cloth or steel wool. Never use cleaning solvents with a  
hydrocarbon base.  
19  
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5.0 MAINTENANCE  
Contact the factory, the factory representative or a local service company to perform  
maintenance and repairs.  
WARNING: Disconnect the power 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 maximum performance.  
2. The unit venting system should be examined and cleaned.  
3. Grease the screw jack tilt mechanism via the lubricating nipple. Use Petro-Canada type  
OG-2 or equivalent.  
Annually:  
1. Have an authorized service person inspect the screw jack assembly for wear. The screw  
must be replaced immediately if the end play has reached 0.019" [0.5mm].  
20  
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6.0 SERVICE  
GENERAL  
When any difficulty arises always check that the unit has been connected to the gas supply 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 located in a small envelope affixed to the side panel of left hand  
console.  
Orifice Size  
Unit  
Total Input  
Natural  
Propane  
KLT-20G  
KLT-40G  
KLT-60G  
80,000 BTU/Hour  
100,000 BTU/Hour  
120,000 BTU/Hour  
DMS # 19 (.166")  
DMS # 13 (.185")  
DMS # 7 (.201")  
DMS # 30 (.125")  
DMS # 27 (.144")  
DMS # 23 (.154")  
MANIFOLD PRESSURE  
Natural Gas - 3.5 inches W.C.  
ADJUSTMENTS  
LP Gas - 4 inches W.C.  
WARNING: Adjustments and service work may be performed only by a qualified  
technician who is experienced in, and knowledgeable with, the operation of  
commercial gas cooking equipment. To assure your confidence, contact your  
authorized service agency for reliable service, dependable advice or other  
assistance, and for genuine factory parts.  
21  
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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 read 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 high or too low and causing the out of adjustment  
condition. A voltmeter should be used by a properly trained serviceman to determine if the  
pressure switch or thermostat is actually cycling the burners. If the pressure switch is found  
to be cycling the burners, see “Pressure Switch” section.  
After verifying that the pressure switch is set and operating properly, the thermostat may be  
adjusted using the set screw inside the stem. At maximum setting, the thermostat should cycle  
off at a gauge pressure reading of 30 psi. Turn set screw clockwise to decrease pressure and  
counterclockwise to increase pressure.  
PRESSURE SWITCH  
The pressure switch should not be adjusted until it is determined to be the cause of an operating  
pressure difficulty. See “Thermostat” section to determine if the source of difficulty is the  
pressure switch or thermostat.  
The major difficulties caused by pressure switch mis-adjustment are:  
1. Pressure relief valve opening, pressure rises above 45 psi.  
2. Pressure in kettle is less than 30 psi and burner is being shut down by pressure switch (not  
thermostat).  
The pressure switch is preset for proper operation from the factory. It is adjusted to the  
maximum pressure which will prevent the pressure relief valve from opening. During preheat to  
the maximum thermostat setting (275EF), from either a cold condition or a lower temperature  
setting, the temperature may overshoot the thermostat setting and be shut down by the  
pressure switch. This is normal, however, after the kettle has cycled several times (empty) the  
thermostat will begin cycling the unit.  
22  
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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 ribbed knob clockwise; to decrease,  
turn it counterclockwise. Use the centre of the black ring as an indicator.  
3. With the kettle empty and completely cold, turn kettle on and set thermostat to maximum  
setting (275EF).  
4. The pressure in kettle (read pressure gauge on front panel) should reach a maximum of 30  
psi and pressure relief valve should not open. Kettle pressure may rise 3 or 4 psi even after  
burners shut down.  
5. Relief valve should not open when kettle pressure is 45 psi; pressure switch setting is  
satisfactory.  
6. If the safety relief valve opens, reduce setting on pressure switch, cool kettle completely by  
running cold water through it and repeat steps 3 - 6.  
7. If pressure in kettle is below 30 psi increase setting of pressure switch, cool kettle  
completely by running cold water through it and repeat steps 3 - 7.  
8. Allow the kettle to cycle several times to verify the correct pressure setting.  
9. Replace the front panel when adjustment is complete.  
23  
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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 pointing upward.  
4. Using pure distilled water only, pour the water into the open end of elbow (a funnel will be  
helpful). Water will enter kettle slowly, as air must escape through the same hole. Water  
should be added until water level at the sight glass is halfway between the minimum and  
maximum levels.  
5. When sufficient water has been added, remove elbow and replace pressure relief valve. Be  
sure to seal threads with a pipe joint compound suitable for steam at 50 psi.  
6. Vacuum must be re-established (See Re-establishing Vacuum).  
FOR REFERENCE:  
The total amount of distilled water to be added when low level pilot is illuminated:  
KLT-20G  
KLT-40G  
KLT-60G  
-
-
-
169 fl. oz. (5 L)  
270 fl. oz. (8 L)  
372 fl. oz. (11 L)  
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6.0 SERVICE (Continued)  
RE-ESTABLISHING VACUUM  
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 temperature. When the pressure  
gauge reaches 20 psi, turn thermostat off, open the pressure relief valve until pressure gauge  
reads 1 psi, then sharply release it. This should remove the air and restore performance of the  
kettle.  
Should the kettle fail to maintain a vacuum after repeated attempts to establish vacuum, further  
checks should be made to see if the pressure relief valve is leaking or if there are any leaks in  
the pressure relief valve piping, copper lines going to the pressure switch, pressure gauge or  
thermostat fitting.  
25  
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7.0 TROUBLESHOOTING  
PROBLEM  
LOOK FOR  
S
No current. Check that power is being  
supplied to the unit.  
Motor will not run.  
S
Defective thermostat or pressure switch.  
Defective motor.  
Motor overload out.  
S
S
S
Blown fuse.  
S Defective transformer.  
Motor runs, no spark.  
S Defective ignition module.  
S Blown fuse on ignition module.  
S Defective spark electrode (cracked  
insulator).  
S Defective ignition cable.  
S Defective centrifugal switch on motor.  
S Manual main valve off.  
S Mislocated spark or ground rods. See  
Figure 2 for correct position  
Motor runs, spark present, no gas ignition.  
S Defective valve.  
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 (not below 1.0).  
S Add water - See previous section  
Low water light comes on.  
Relief valve opens.  
ADJUSTMENTS.  
S Pressure switch set too high.  
S Pressure gauge is not accurate.  
S Relief valve is faulty  
26  
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S Flame rod or flame ground mislocated.  
S Defective flame rod wire.  
S Defective ignition module.  
Flame burns only about 6 seconds and shuts  
off.  
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 (not below 1.0).  
S Wrong size orifice. (See table on page  
21).  
Short flame.  
S Low gas pressure.  
S Air shutter adjustment. (See table, shutter  
setting)  
S Main manual valve partially closed.  
S
S
S
S
Wrong size orifice.  
High gas pressure.  
Dirty blower wheel or intake.  
Air shutter adjustments.  
Long hazy flame.  
S
S
Dirt on valve seat.  
Defective main valve.  
Gas fails to shut off.  
NOTE: Loose, broken or grounded wiring may cause many of the symptoms listed. Check all  
wiring and make sure it is intact.  
SHUTTER SETTINGS  
Natural  
1.5  
Propane  
2.0  
Kettle Size/Gas Type  
20 Gallon (80,000 BTU/HR)  
30/40 Gallon (100,000 BTU/HR)  
60 Gallon (120,000 BTU/HR)  
1.5  
2.0  
2.0  
3.0  
Shutter setting is on the fan intake. Adjust the shutter per the table above by loosening the  
screw on the shutter closest to the stamped numbers and turning the shuttle disc until the screw  
points to the correct setting. Tighten screw when adjustment is complete. Figure 1 below shows  
a shutter setting of 2.0. Look at the flame through the plastic window in the rear of the burner. It  
should be mostly blue with slight bits of orange flame on natural gas. On propane, flame will be  
more orange in color. Using a portable gas analyzer, shutter settings can be adjusted to yield  
between 5.0-8.0 CO2. Air free CO should read below 100ppm. Once the burner is set up and  
operating properly, secure all wires and replace all covers.  
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Figure 1 Shutter setting at 2.0  
Figure 2  
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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 COMPANY IDENTIFICATION  
IN CASE OF EMERGENCY: Fort Saskatchewan, Alberta: (780) 998-8282  
Sarnia, Ontario:  
Varennes, Quebec:  
(519) 339-3711  
(450) 652-1000  
Product::  
DOWFROST* HD HEAT TRANSFER FLUID, DYED  
Product Code:  
Effective Date:  
04632  
2/20/01  
Date Printed: 07/10/02  
MSD: 002239  
DOW CHEMICAL CANADA INC.  
P.O. Box 1012  
Sarnia, Ontario, N7T 7K7  
Prepared for use in Canada by the E H & S Product Regulatory Management Department;  
Phone: (800) 331-6451.  
2. COMPOSITION/INFORMATION ON INGREDIENTS  
Propylene Glycol  
Dipotassium PhosphateCAS# 007758-11-4  
Deionized Water CAS# 007732-18-5  
CAS# 000057-55-6  
94%  
<5%  
<5%  
* or (R) indicates a trademark of The Dow Chemical Company.  
MATERIAL SAFETY DATA SHEET  
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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  
Clear yellow liquid. Odourless. Avoid temperatures above 450EF, 232EC.  
POTENTIAL HEALTH EFFECTS (See Section 11 for toxicological data.)  
EYE: May cause slight transient (temporary) eye irritation. Corneal injury is unlikely. Mists  
may cause eye irritation.  
SKIN CONTACT: Prolonged contact is essentially nonirritating to skin. A single prolonged  
exposure is not likely to result in the material being absorbed through skin in harmful amounts.  
Repeated exposures may cause flaking and softening of skin.  
INGESTION: Single dose oral toxicity is considered to be extremely low. No hazards  
anticipated from swallowing small amounts incidental to normal handling operations.  
INHALATION: At room temperature, vapours are minimal due to physical properties. Mists  
may cause irritation of upper respiratory tract (nose and throat).  
SYSTEMIC (OTHER TARGET ORGAN) EFFECTS: Repeated excessive exposure to  
propylene glycol may cause central nervous system effects.  
CANCER INFORMATION: Did not cause cancer in laboratory animals.  
TERATOLOGY (BIRTH DEFECTS): Birth defects are unlikely. Exposures having no adverse  
effects on the mother should have no effect on the fetus.  
REPRODUCTIVE EFFECTS: In animal studies, has been shown not to interfere with  
reproduction.  
* or (R) indicates a trademark of The Dow Chemical Company.  
MATERIAL SAFETY DATA SHEET  
Product: DOWFROST* HD HEAT TRANSFER FLUID, DYED  
30  
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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 anticipated by this route of exposure incidental  
to proper industrial handling.  
INHALATION:  
Remove to fresh air if effects occur. Consult a physician.  
NOTE TO PHYSICIAN:  
No specific antidote. Supportive care. Treatment based on  
judgment of the physician in response to reactions of the patient.  
5. FIRE FIGHTING MEASURES  
FLAMMABLE PROPERTIES  
FLASH POINT:  
214EF, 107EC (based on a similar material)  
PMCC  
METHOD USED:  
AUTOIGNITION TEMPERATURE: NOT DETERMINED  
FLAMMABILITY LIMITS  
LFL: Not determined  
UFL: Not determined  
* or (R) indicates a trademark of The Dow Chemical Company.  
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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 include and are not limited to carbon monoxide and carbon dioxide.  
OTHER FLAMMABILITY INFORMATION: Violent steam generation or eruption may occur  
upon application of direct water stream to hot liquids. Flammable concentrations of vapour can  
accumulate at temperatures above 214EF. Liquid mist of this product can burn. Spills of these  
organic liquids on hot fibrous insulations may lead to lowering of the autoignition temperatures  
possibly resulting in spontaneous combustion. Container may rupture from gas generation in a  
fire situation.  
EXTINGUISHING MEDIA: Water fog or fine spray, carbon dioxide, dry chemical, foam. Alcohol  
resistant foams (ATC type) are preferred if available. General purpose synthetic foams  
(including AFFF) or protein foams may function, but much less effectively. Do not use direct  
water stream. May spread fire.  
MEDIA TO BE AVOIDED: Do not use direct water stream.  
FIRE FIGHTING INSTRUCTIONS: Keep people away. Isolate fire area and deny unnecessary  
entry. Burning liquids may be moved by flushing with water to protect personnel and minimize  
property damage. Burning liquids may be extinguished by dilution with water. Do not use direct  
water stream. May spread fire. Fight fire from protected location or safe distance. Consider  
use of unmanned hose holder or monitor nozzles. Use water spray to cool fire exposed  
containers and fire affected zone until fire is out and danger of re-ignition has passed.  
Immediately withdraw all personnel from area in case of rising sound from venting safety device  
or discolouration of the container. Move container from fire area if this is possible without  
hazard.  
PROTECTIVE EQUIPMENT FOR FIRE FIGHTERS: Wear positive-pressure self-contained  
breathing apparatus (SCBA) and protective fire fighting clothing (includes fire fighting helmet,  
coat, pants, boots and gloves). If protective equipment is not available or not used, fight fire  
from a protected location or safe distance.  
* or (R) indicates a trademark of The Dow Chemical Company.  
32  
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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 MEASURES (See Section 15 for Regulatory Information)  
PROTECT PEOPLE: Use appropriate safety equipment. For additional information, refer to  
Section 8, Exposure Controls/ Personal Protection.  
PROTECT THE ENVIRONMENT: Avoid contamination of all waterways.  
CLEAN-UP: See Section 13, Disposal Consideration.  
7. HANDLING AND STORAGE  
SPECIAL PRECAUTIONS TO BE TAKEN IN HANDLING AND STORAGE: No special handling  
requirements data available.  
HANDLING: See Section 8, Exposure Controls/Personal Protection.  
STORAGE: See Section 10, Stability and Reactivity.  
8. EXPOSURE CONTROLS/PERSONAL PROTECTION  
ENGINEERING CONTROLS: Provide general and/or local exhaust ventilation to control  
airborne levels below the exposure guidelines.  
PERSONAL PROTECTIVE EQUIPMENT  
EYE/FACE PROTECTION: Use safety glasses. Safety glasses should be sufficient for most  
operations; however, for misty operations wear chemical goggles.  
SKIN PROTECTION: Use gloves impervious to this material.  
RESPIRATORY PROTECTION: Atmospheric levels should be maintained below the exposure  
guideline. When respiratory protection is required for certain operations, use an approved air-  
purifying respirator. In misty atmospheres, use an approved mist respirator.  
* or (R) indicates a trademark of The Dow Chemical Company.  
33  
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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:  
ODOUR:  
Clear yellow liquid.  
Odourless  
VAPOUR PRESSURE:  
VAPOUR DENSITY:  
0.22 mmHg @ 20EC  
2.6  
BOILING POINT:  
SOLUBILITY IN WATER/MISCIBILITY:  
SPECIFIC GRAVITY OR DENSITY:  
320EF, 160EC  
Complete  
1.058 @ 25/25EC  
10. STABILITY AND REACTIVITY  
CHEMICAL STABILITY: Thermally stable at typical use temperatures.  
CONDITIONS TO AVOID: Avoid use temperatures above 450EF, 232EC. Product can degrade  
at elevated temperatures. Generation of gas during decomposition can cause pressure in  
closed systems.  
INCOMPATIBILITY WITH OTHER MATERIALS: Avoid contact with oxidizing materials. Avoid  
contact with strong acids  
HAZARDOUS DECOMPOSITION PRODUCTS: Hazardous decomposition products depend  
upon temperature, air supply and the presence of other materials.  
HAZARDOUS POLYMERIZATION: Will not occur.  
11. TOXICOLOGICAL INFORMATION (See Section 3 for Potential Health Effects. For  
detailed toxicological data, write or call the address or non-emergency number shown in Section  
1).  
SKIN: The LD50 for skin absorption in rabbits is >10,000 mg/kg.  
* or (R) indicates a trademark of The Dow Chemical Company.  
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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.  
The oral LD50 for rats is 20,000 - 34,000 mg/kg.  
INGESTION:  
MUTAGENICITY:  
In vitro mutagenicity studies were negative. Animal mutagenicity  
studies were negative.  
12. ECOLOGICAL INFORMATION (For detailed Ecological data, write or call the address or  
non-emergency number shown in Section 1.)  
ENVIRONMENTAL FATE  
MOVEMENT & PARTITIONING: Based largely or completely on data for major component(s).  
Bioconcentration potential is low (BCF less than 100 or Log Pow less than 3). Potential for  
mobility in soil is very high (Koc between 0 and 50).  
DEGRADATION AND PERSISTENCE: Based largely or completely on data for major  
component(s). Material is readily biodegradable. Passes OECD test(s) for ready  
biodegradability. Degradation is expected in the atmospheric environment within minutes to  
hours.  
ECOTOXICITY: Based largely or completely on data for major component(s). Material is  
practically non-toxic to aquatic organisms on an acute basis (LC50/EC50 >100 mg/L in most  
sensitive species).  
13. DISPOSAL CONSIDERATIONS (See Section 15 for Regulatory Information)  
DISPOSAL: DO NOT DUMP INTO ANY SEWERS, ON THE GROUND OR INTO ANY BODY  
OF WATER. All disposal methods must be in compliance with all Federal, State/Provincial and  
local laws and regulations. Regulations may vary in different locations. Waste  
characterizations and compliance with applicable laws are the responsibility solely of the waste  
generator. THE DOW CHEMICAL COMPANY HAS NO CONTROL OVER THE  
MANAGEMENT PRACTICES OR MANUFACTURING PROCESSES OF PARTIES HANDLING  
OR USING THIS MATERIAL. THE INFORMATION PRESENTED HERE PERTAINS ONLY TO  
THE PRODUCT AS SHIPPED IN ITS INTENDED CONDITION AS DESCRIBED IN MSDS  
SECTION 2 (Composition/Information On Ingredients).  
* or (R) indicates a trademark of The Dow Chemical Company.  
35  
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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 & UNCONTAMINATED PRODUCT, the preferred options include  
sending to a licensed, permitted: recycler, reclaimer, incinerator or other thermal  
destruction device.  
As a service to its customers, Dow can provide names of information resources to help  
identify waste management companies and other facilities which recycle, reprocess or  
manage chemicals or plastics, and that manage used drums. Telephone Dow’s  
Customer Information Center at 800-258-2436 or 989-832-1556 for further details.  
14. TRANSPORT INFORMATION  
DEPARTMENT OF TRANSPORTATION (D.O.T.): For D.O.T. regulatory information, if  
required, consult transportation regulations, product shipping papers, or contact your  
Dow representative.  
CANADIAN TDG INFORMATION: For TDG regulatory information, if required, consult  
transportation regulations, product shipping papers, or your Dow representative.  
15. REGULATORY INFORMATION (Not meant to be all-inclusive – selected  
regulations represented).  
NOTICE: The information herein is presented in good faith and believed to be accurate  
as of the effective date shown above. However, no warranty, express or implied is  
given. Regulatory requirements are subject to change and may differ from one location  
to another; it is the buyer’s responsibility to ensure that its activities comply with federal,  
state or provincial, and local laws. The following specific information is made for the  
purpose of complying with numerous federal, state or provincial, and local laws and  
regulations. See other sections for health and safety information.  
* or (R) indicates a trademark of The Dow Chemical Company.  
36  
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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 CATEGORY: This product has been reviewed according to the EPA  
“Hazard Categories” promulgated under Sections 311 and 312 of the Superfund  
Amendment and  
Reauthorization Act of 1986 (SARA Title III) and is considered, under applicable  
definitions, to meet the following categories:  
Not to have met any hazard category.  
TOXIC SUBSTANCES CONTROL ACT (TSCA):  
All ingredients are on the TSCA inventory or are not required to be listed on the TSCA  
inventory.  
STATE RIGHT-TO-KNOW: The following product components are cited on certain state  
lists as mentioned. Non-listed components may be shown in the composition section of  
the MSDS.  
CHEMICAL NAME  
1, 2-Propanediol  
CAS NUMBER  
000057-55-6  
LIST  
PA1  
PA1= Pennsylvania Hazardous Substance (present at greater than or equal to 1.0%).  
OSHA HAZARD COMMUNICATION STANDARD:  
This product is not a “Hazardous Chemical” as defined by the OSHA Hazard  
Communication Standard, 29 CFR 1910.1200.  
* or (R) indicates a trademark of The Dow Chemical Company.  
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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” under WHMIS.  
CANADIAN ENVIRONMENTAL PROTECTION ACT (CEPA)  
This product contains one or more substances which are not listed on the Canadian  
Domestic Substances List (DSL). Contact your Dow representative for more  
information.  
16. OTHER INFORMATION  
MSDS STATUS: Revised to 16 section format.  
* or (R) indicates a trademark of The Dow Chemical Company.  
The information herein is given in good faith, but no warranty, express or implied, is  
made. Consult The Dow Chemical Company for further information.  
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