Blue Seal EVOLUTION G31, Evolution Series Service Manual

Pasta Cookers
G47
Service Manual
Blue Seal Evolution Series Gas Pasta Cookers G47
Revision 1/
© Moffat Ltd, January 2007
WARNING:
ALL INSTALLATION AND SERVICE REPAIR WORK MUST BE CARRIED OUT BY
QUALIFIED PERSONS ONLY.
IMPORTANT: MAKING ALTERATIONS MAY VOID WARRANTIES AND APPROVALS.
Blue Seal Evolution Series Gas Pasta Cookers G47
Revision 1/
© Moffat Ltd, January 2007
Contents
This manual is designed to take a more in depth look at the G47 Pasta Cookers for the purpose of making
the units more understandable to service people.
There are settings explained in this manual that should never require to be adjusted, but for completeness
and those special cases where these settings are required to change, this manual gives a full explanation
as to how, and what effects will result.
Section
Page Number
1. Specifications............................................................................................1
2. Installation................................................................................................3
3. Operation...................................................................................................8
3.1 Description
of Controls
3.2
Explanation of Control System
4.
Cleaning and Maintenance......................................................................10
4.1 Cleaning
4.2
Routine Maintenance
5. Trouble-shooting Guide...........................................................................14
5.1 Trouble-shooting
5.2 Fault
Diagnosis
6. Service
Chart
Procedures..................................................................................18
6.1 Access
6.2 Replacement
6.3 Adjustment
/ Calibration
7. Accessories..............................................................................................24
8. Exploded
9. Circuit
Parts Diagrams .......................................................................25
Schematics...................................................................................28
10. Service Contacts......................................................................................29
Appendix A: Gas Type Conversion.................................................................31
Appendix B: Gas Specifications......................................................................34
Blue Seal Evolution Series Gas Pasta Cookers G47
Revision 1/
© Moffat Ltd, January 2007
Blue Seal Evolution Series Gas Pasta Cookers G47
Revision 1/
© Moffat Ltd, January 2007
Specifications
1
External dimensions: G47
Dimensions shown in millimetres
Legend
- Gas connection entry point - ¾” BSP male
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Blue Seal Evolution Series Gas pasta Cooker G47
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1
Specifications
Gas supply (Non-UK models)
Natural Gas
Input Rating
(N.H.G.C.)
Supply Pressure
Burner Operating Pressure
LP Gas (Propane)
46 MJ/hr
(44,547 Btu/hr)
47 MJ/hr
(44,547 Btu/hr)
1.13 - 3.40 kPa
2.75 - 3.40 kPa
(4.5" - 13.5" w.c.)
0.92 kPa (*)
(3.7” w.c.)
(11" - 13.5" w.c.)
2.6 kPa (*)
(10.2" w.c.)
Gas Connection
¾” BSP Male
Gas supply (UK models)
Natural Gas (G20)
Heat Input (nett)
Nominal
Reduced
Nominal
Reduced
12.0 kW
5.4 kW
12.5 kW
6.2 kW
0.97 kg/hr
0.48 kg/hr
3
Gas Rate
Propane (G31)
3
1.27 m /hr
Supply Pressure
Burner Operating Pressure
0.42 m /hr
20 mbar
37 mbar
9.5 mbar (*)
27.7 mbar (*)
3
Gas Connection
/4” BSP Male
Injector sizes
Main Burners
Pilot Burners (Non-UK models)
Pilot Burners (UK models)
Natural Gas
3.10mm
0.62mm
0.45mm
LPG / Propane
1.90mm
0.35mm
0.30mm
Tank capacity
Water capacity
40l
Useable internal dimensions of
tank (width x length)
Useable depth of water
Water supply
Water connection
Maximum water supply pressure
½” tube
550 kPa (80psi)
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Blue Seal Evolution Series Gas Pasta Cooker G47
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Installation
2
Installation Requirements
NOTE:
• It is most important that this appliance is installed correctly and that operation is
correct before use. Installation shall comply with local, gas, health and safety
requirements.
• This appliance shall be installed with sufficient ventilation to prevent the occurrence
of unacceptable concentrations of health harmful substances in the room, the
appliance is installed in.
Blue Seal pasta cookers are designed to provide years of satisfactory service and correct installation is
essential to achieve the best performance, efficiency and trouble-free operation.
This appliance must be installed in accordance with National installation codes and in addition, in
accordance with relevant National / Local codes covering gas and fire safety.
AUSTRALIA:
- AS5601
- Gas Installations.
NEW
ZEALAND:
- NZS5261
- Gas Installation.
UNITED
KINGDOM:
- Gas Safety (Installation & Use) Regulations 1998.
- BS6173
- Installation of Catering Appliances.
- BS5440
- Parts 1 & 2 Installation Flueing & Ventilation.
IRELAND:
- IS 820
- Non - Domestic Gas Installations.
Installations must be carried out by qualified service persons only. Failure to install
equipment to the relevant codes and manufacturer’s specifications shown in this section will
void the warranty.
Components having adjustments protected (e.g. paint sealed) by manufacturer, are only
allowed to be adjusted by an authorised service agent. They are not to be adjusted by the
installation person.
Unpacking
• Remove all packaging and transit protection from the appliance including all protective plastic
coating from the door outer panel and exterior stainless steel panels.
• Check equipment and parts for damage. Report any damage immediately to the carrier and
distributor.
• Report any deficiencies to the distributor who supplied the appliance.
• Check that the available gas supply is correct to that shown on the rating plate located on the inside
of the access door.
• Check that the following parts have been supplied with the appliance:
G47
Baskets 4
Basket Trays
1
Location
1.
2.
This appliance must be installed in a suitably ventilated room to prevent dangerous build up of
combustion products.
Installation must allow for a sufficient flow of fresh air for the combustion air supply.
Combustion Air Requirements
3.
Natural Gas (G20)
G47
13 m3/hr
LPG/Propane (G31)
13 m3/hr
Position the appliance in its approximate working position.
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Blue Seal Evolution Series Gas pasta Cooker G47
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Installation
4.
All air for burner combustion is supplied from underneath the appliance. The legs must always be
fitted and no obstructions placed on the underside or around the base of the appliance, as
obstructions will cause incorrect operation and / or failure of the appliance.
5. Components
having adjustments protected (e.g. paint sealed) by manufacturer are only allowed to
be adjusted by an authorised service agent. They are not to be adjusted by the installation person.
NOTE: Do not obstruct or block the appliances flue. Never directly connect a ventilation
system to the appliance flue outlet.
Clearances
Combustible Surface
Non Combustible Surface
Left/Right hand side
50 mm
0 mm
Rear
50 mm
0 mm
NOTE:
• Only non-combustible materials can be used in close proximity to this appliance.
• In order to facilitate easy operation, drainage and servicing of the appliance, a
minimum of 600 mm clearance should be maintained at the front of the appliance.
Any gas burning appliance requires adequate clearance and ventilation for optimum and trouble-free
operation. The following minimum installation clearances are to be adhered to:
Assembly
This model is delivered completely assembled. Ensure that the adjustable feet / rollers are securely
attached.
NOTE:
• This appliance is fitted with adjustable feet / rollers to enable the appliance to be
positioned securely and level. This should be carried out on completion of the gas
connection. Refer to the “Gas Connection” section overleaf.
• The appliance rear leg housings can be fitted with:Adjustable feet to assist with levelling of the appliance on uneven floors.
Rear rollers to enable the appliance to be easily moved for positioning and cleaning
purposes.
Optional Accessories (Refer to Replacement Parts List)
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Blue Seal Evolution Series Gas Pasta Cooker G47
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Installation
Fitting of Adjustable Feet / Rear Rollers to the Pasta Cooker
This appliance rear leg mount housings can be fitted with:Adjustable feet to assist with levelling of the appliance on uneven floors.
Rear rollers to enable the appliance to be easily moved for positioning and cleaning
purposes.
Rear Adjustable Legs, fitting:1. Raise the appliance from the floor by
approximately 75 mm using suitable lifting
equipment (i.e. Palletiser / Forklift) to allow the
rear rollers to be removed.
2.
Unscrew and remove the securing bolt that
secures the rear roller to the rear leg housing.
3.
The rear rollers will drop freely from the rear
leg housings.
4.
Screw the rear adjustable feet into the rear leg
housings and tighten hand tight.
5.
Lower the appliance back to the floor and
adjust the adjustable feet to level the
appliance.
Rear Rollers, fitting:1. Raise the appliance from the floor by
approximately 75 mm using suitable lifting
equipment (i.e. Palletiser / Forklift) to allow the
rear adjustable feet to be removed.
2.
Unscrew and remove both the rear adjustable
feet from the rear leg housings.
3.
Fit the rear roller to the rear leg housing and
align the screw hole in the side of the rear leg
housing with the threaded hole in the rear
roller.
4.
Locate the rear roller to the leg support with
the bolt supplied and tighten the bolt using a
10 mm A/F spanner.
5.
Fit the second roller and tighten.
6.
Lower the appliance back to the floor and
adjust the front adjustable feet to level the
appliance.
Fig 2.1
Rear Leg
Housing
Roller
Securing Bolt
Adjustable
Foot
Rear
Roller
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Blue Seal Evolution Series Gas pasta Cooker G47
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2
Installation
Gas Connection
NOTE: ALL GAS FITTING MUST ONLY BE CARRIED OUT BY A QUALIFIED SERVICE PERSON.
1.
2.
Blue Seal Pasta Cookers do not require an electrical connection, they function totally on the gas
supply only.
It is essential that the gas supply is correct for the appliance to be installed and that adequate
supply pressure and volume are available. The following checks should therefore be made before
installation:a. The Gas Type the appliance has been supplied for is shown on
coloured stickers located above the gas entry point and next to
the rating plate. Check that this is correct for the gas supply
the appliance is being installed for. The gas conversion
procedure is detailed in this manual.
Rating Plate
Location
b. Supply Pressure required for this appliance is shown in the
“Specifications” section of this manual. Check the gas supply to
ensure that adequate supply pressure exists.
c. Input Rate of this appliance is also stated on the Rating Plate
fitted to the inside of the access door and in the
“Specifications” section of this manual. The input rate should
Fig 2.2
be checked against the available gas supply line capacity.
Particular note should be taken if the appliance is being
added to an existing installation.
NOTE: It is important that adequately sized piping runs directly to the connection joint on the
appliance, with as few tees and elbows as possible to give maximum supply volume.
3.
A suitable joining compound which resists the breakdown action of LPG must be used on every gas
line connection, unless compression fittings are used.
The connection to the appliance is 3/4” BSP male.
NOTE: A Manual Isolation Valve must be fitted to the individual appliance supply line.
4.
5.
6.
Correctly locate the appliance into its final operating position and using a spirit level, adjust the legs
so that the unit is level and at the correct height.
Connect the gas supply to the appliance.
Check gas operating pressure to as shown in the “Specifications” section. If the pressure is
incorrect, adjust the pressure by adjusting the regulator screw of the gas control valve as shown in
the ‘Gas Conversion and Specifications’ section.
WARNING:
D O NOT USE A NAKED FLAME TO CHECK FOR GAS LEAKAGES .
7.
Check all gas connections for leakages using soapy water or other gas detecting equipment.
NOTE: The operating pressure is to be measured at the Burner Operating Pressure test point
on the gas control valve, this is to be carried out with the burner operating at the 'High
Flame' setting. The operating pressure is ex-factory set, through the appliance
regulator and not to be adjusted, apart from when carrying out gas conversion, if
required. Refer to the ‘Gas Conversion and Specification’ Section for further details .
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Blue Seal Evolution Series Gas Pasta Cooker G47
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2
Installation
8.
Turn ‘OFF’ the mains gas supply and bleed the
gas out of the appliance gas lines.
9.
Turn ‘ON’ the gas supply and the appliance.
10. Verify the operating pressure remains correct
11. Check the pilot flame size. (Re-adjust if
required by changing the pilot injector. Refer
to the Gas Conversion Section).
Burner Operating
Pressure Test Point
Gas Control
Valve
Fig 2.3
Water Connection
NOTE: The water connection shall be installed in accordance with local water regulations in
force and the applicable standard/code, e.g. EN 1717 in UK / Ireland, PCA in Australia.
A cold water supply must be connected to the water inlet connection (R 1/2" BSP), located 50 mm from the
LH side, 555 mm from rear and 135 mm from the floor.
The water inlet pressure must be as follows:Minimum water supply pressure 150 kPa (22 psi).
Maximum water supply pressure 250 kPa (36 psi).
Drainage Connection
•
The water is drained from the appliance by means of a valve located behind the front control panel.
•
A waste water tundish must be fitted below the appliance drain outlet. This should be a minimum of
127 mm (5”) major diameter.
•
If required the drain outlet can be extended in order to exit above the tundish. All drain piping must
be with materials suitable for conveying boiling water.
•
Drain connection is R1" BSP drain / overflow.
Commissioning
The following commissioning checks must be carried out before the pasta cooker is handed
over for use, to ensure that the unit operates correctly and the operator(s) understand the
correct operating procedure.
1.
2.
Before leaving the new installation;
a. Check the following functions in accordance with the operating instructions specified in the
“Operation” section of this manual.
•
Light the Pilot Burner.
•
Light the Main Burner.
b. Ensure that each operator has been instructed in the areas of correct lighting, operation, and
shutdown procedures for the appliance.
This manual must be kept by the owner for future reference and a record of
Date of
Purchase, Date of Installation and Serial Number of Unit recorded and kept with this
manual. (These details can be found on the Rating Plate attached to the inner R/H side
of the front access door panel. Refer to Figure 1 in the 'Installation' section).
NOTE: If for some reason it is not possible to get the appliance to operate correctly, shut off
the gas supply and contact the supplier of this unit.
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Blue Seal Evolution Series Gas pasta Cooker G47
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3
Operation
3.1
Description of controls
Gas Control Knob
Burner Control
OFF Position
PILOT Burner
HIGH Flame
LOW Flame
Piezo Igniter
(Behind Access Door)
Water Control Valve
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Blue Seal Evolution Series Gas Pasta Cooker G47
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Operation
3.2
holds the plunger in, allowing gas to flow through
the valve.
When the electromagnet is
de-energized, the plunger snaps to the closed
position, stopping the flow of gas.
Explanation of Control
System
Safety System
Millivolts are provided to the electromagnet by
the thermocouple (not shown) which generates
millivolts when heated. The thermocouple screws
The purpose of the safety system is to shut off
the flow of gas if the pilot flame goes out. It is
comprised of the flame itself, the thermocouple,
and the flame failure gas valve.
Thermocouple
The pilot flame is lit by holding in the gas
control knob, which in turn temporarily pushes
the plunger inside the safety valve open and
allows gas to flow through. Once the burner is
lit, the thermocouple will begin to generate
millivolts (after about 10 to 30 seconds of being
heated) and will energize the electromagnet
inside the gas valve. Once energized the
electromagnet holds the plunger inside the gas
valve in the open position. The plunger has to
have been pushed all the way in for the
electromagnet to be able to hold it in place. If
the burner flame goes out for some reason, the
thermocouple will cool after about 10 to 30
seconds and stop generating millivolts. The
electromagnet will then de-energize, and the
plunger will snap shut, cutting off the flow of gas.
Electromagnet
Shaft
Knob
Gas flow
Figure 3.2b
into a fitting at the back of the gas valve to make
an electric connection. By pressing in the gas
control knob, the plunger can be temporarily held
open while lighting. There's two reasons for this;
gas has to flow through the safety valve to make
it possible to light the pilot burner, and secondly
the plunger has to be pushed all the way in for
the electromagnet to hold it in. I.e.; the
electromagnet is strong enough to hold the
plunger in once there, but is not strong enough
to pull it in by itself. Sometimes a problem with
the flame not staying lit after releasing the button
can be attributed to not pushing the plunger all
the way in.
The thermocouple is a device that generates
electricity when heat is applied to the tip.
Interna
l Wire
Conductor
Plunger
Control Knob
Thermocouple
Nut
Plunger
Gas flow
Detail of each component in the safety system is
explained below.
Insulator
3
Tip
Figure 3.2a
The tip of the thermocouple is located in the pilot
burner flame, and the nut at the other end of the
thermocouple screws into the back of the gas
valve. Inside the copper tubing is a wire which is
joined at the tip but insulated from the rest of the
tubing. These two parts (the copper tubing and
wire) make up the "wiring" for an electrical
circuit. When these two dissimilar metals, wire
and tip, are heated an electrical voltage is
produced. This type of thermocouple generates
between 7 and 30 millivolts when heated in the
pilot flame.
This millivolt circuit is interrupted by a safety cutout thermostat. If the cut-out trips it cuts the
millivolt supply to the pilot valve magnet, thereby
shutting off the burners. The pasta cooker is then
inoperable until the cut-out has cooled below
100°C. The purpose of this is to shut off the
burners should the tank run dry.
Electromagnetic Flame Failure Gas Valve
The Troubleshooting Guide (Section 5) should be
used to identify any incorrect operation. On
correct identification of the operating fault the
Troubleshooting Guide will make reference to the
corrective action required, or refer to the Fault
Diagnosis section and/or Service section to assist
in correction of the fault.
The purpose of the safety valve is to shut off the
flow of gas if the pilot flame goes out.
Inside the body of the gas valve is an
electromagnet connected to a spring loaded
plunger. When the electromagnet is energized, it
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Blue Seal Evolution Series Gas pasta Cooker G47
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4
Cleaning / Maintenance
4.1
Cleaning
WARNING:
DO NOT USE FLAMMIBLE SOLVENTS AND CLEANING AIDS ON OR IN CLOSE PROXIMITY TO THE PASTA COOKER
WHILST THE COOKER IS STILL HOT.
CAUTION:
Always turn off the gas supply at the mains supply before cleaning.
This appliance is not water proof.
Do not use water jet spray to clean interior or exterior of this appliance.
General
Clean the pasta cooker regularly. A clean pasta cooker looks better, will last longer and will perform
better. A dirty pasta cooker will hinder the transfer of heat from the cooking surface to the food.
This will result in loss of cooking efficiency.
CAUTION:
If cleaning detergents are allowed to enter the inner parts of the appliance,
rusting will occur on the pipe work, installation elements, heating
elements, gas fittings and electrical components, this will cause premature
failure of the appliance.
NOTE:
• DO NOT clean the appliance using high pressure water or steam jets.
• DO NOT pour water directly over the appliance.
• DO NOT use wire brushes. Clean the pan regularly after each use.
• DO NOT use combustible liquids to clean the appliance.
• DO NOT use harsh abrasive detergents, sharp scrapers, strong solvents or caustic
detergents as they will damage the appliance.
• DO NOT use any chloric or bleaching detergents to clean the appliance.
• Ensure that any detergent or cleaning material have been completely removed after
each cleaning.
• DO NOT use saline or sulfuric acid preparations for descaling the appliance.
• Ensure that protective gloves are worn during the cleaning process.
• Clean the pan regularly after each use.
Draining and Cleaning
Opening the Drain Valve
a. Lift the locking slide on valve handle (Fig 4.1a) to release the valve.
b. While holding the locking slide in the withdrawn position, rotate the handle anticlockwise (Fig
4.1b) to open the valve.
c. When the valve is closed, slide the locking slide down over the locking valve to prevent accidental
opening of the valve as shown in Fig 4.1a.
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Cleaning / Maintenance
4
Locking Slide
Locking Slide
Fig 4.1b
Fig 4.1a
After Each Use
WARNING:
HOT WATER WILL SCALD - DO NOT RUSH THIS JOB.
1.
Clean the interior of the pan regularly after each use. Do not use wire brushes on the pan. Clean
using a mild detergent and a hot water solution using soft cloth or a soft bristled brush. Dry the appliance thoroughly using a dry clean cloth.
Daily Cleaning
WARNING:
DO NOT ATTEMPT TO MOVE THE PASTA COOKER WHILST THE COOKER IS FULL OF WATER.
BEFORE ATTEMPTING TO MOVE THE PASTA COOKER, ENSURE THAT ALL THE WATER HAS
BEEN DRAINED FROM THE TANK. REFER TO THE INFORMATION ON THE PREVIOUS PAGE
ON HOW TO DRAIN THE WATER FROM THE PASTA COOKER.
1.
2.
3.
4.
5.
6.
The water should be drained and re-filled regularly. Open the drain valve slowly to minimise
splashing. Waste water will drain into the tundish fitted below the appliance drain outlet.
When the tank is empty, open the drain valve fully and check for any particles or residue lodged in
the valve. Clean out with a stiff nylon brush. Do not use wire brush or metal rods as these damage
the seating in the valve and will eventually lead to valve leakage.
If the obstruction in the valve cannot be removed with a brush, use a wooden probe to dislodge any
obstruction.
Clean the interior and exterior of the pan regularly at the end of each day. Do not use wire brushes
on the pan. Clean using a mild detergent and a hot water solution using soft cloth or a soft bristled
brush. Dry the appliance thoroughly using a dry clean cloth.
Once the daily cleaning operation is completed, ensure that the drain valve has been closed.
At the end of each day or at the end of each shift, clean the exterior of the pasta cooker using a mild
detergent and a hot water solution using soft cloth or a soft bristled brush.
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4
Cleaning / Maintenance
Weekly Cleaning
WARNING:
DO NOT ATTEMPT TO MOVE THE PASTA COOKER WHILST THE COOKER IS FULL OF WATER.
BEFORE ATTEMPTING TO MOVE THE PASTA COOKER, ENSURE THAT ALL THE WATER HAS
BEEN DRAINED FROM THE TANK. REFER TO THE INFORMATION ON THE PREVIOUS PAGE
ON HOW TO DRAIN THE WATER FROM THE PASTA COOKER.
NOTE:
• If the pasta cooker usage is very high, we recommend that the weekly cleaning
procedure is carried out on a more frequent basis.
• Ensure that protective gloves are worn during the cleaning process.
• DO NOT use harsh abrasive detergents, strong solvents, sharp scrapers or caustic
detergents as they will damage the surface of the pasta cooker.
• Ensure that the water circuit is free of ferrous particles. Any such particles deposited
in the bottom of the tank may cause it to rust.
Thoroughly clean the interior and exterior of the pasta cooker regularly. Do not use wire brushes on the
pan. Clean using a mild detergent and a hot water solution using soft cloth or a soft bristled brush. Dry
the appliance thoroughly using a dry clean cloth.
NOTE: In order to prevent the forming of rust on the steel components, ensure that the detergent or cleaning material has been entirely removed after each cleaning process.
Stainless Steel Surfaces
a. Clean the interior and exterior surfaces of the pasta cooker with hot water, a mild detergent
solution and a soft scrubbing brush. Note that the gas control knobs are a push fit onto the gas
and water control valve spindles and can be removed to allow cleaning of the front of the control
panel.
b. Baked on deposits or discolouration may require a good quality stainless steel cleaner or stainless
steel wool. Always apply cleaner when the appliance is cold and rub in the direction of the grain.
c. Dry all components thoroughly with a dry cloth and polish with a soft dry cloth.
Periodic Maintenance
NOTE: All maintenance operations should only be carried out by a qualified service person.
To achieve the best results cleaning must be regular and thorough and all controls and mechanical parts
should be checked and adjusted periodically by a qualified service person. If any small faults occur, have
them attended to promptly. Don't wait until they cause a complete breakdown. It is recommended that
the appliance is serviced every 6 months.
If the appliance is not used for long periods, close the gas shut-off valve upstream of the appliance and
clean the appliance thoroughly.
The appliance should be inspected and the gas exhaust flue cleaned by an authorized service person at
least every 6 months.
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Cleaning / Maintenance
4.2
4
Routine Maintenance
BLUE SEAL PASTA COOKERS - MAINTENANCE SCHEDULE
Business Name and Address:
Date:
Service Report No.
Phone:
Fax:
Serial No:
Clients Order No.
Serviceman:
Model: Blue Seal G47
Remarks
1
Inspect exterior condition of unit.
2
Check working gas pressure, correct to rating plate
3
Check for gas leaks
4
Check pilot flame, adjust as required
5
Check burner operation
6
Inspect thermocouple
7a
Check millivolt of thermocouple to safety cut-out
mV
7b
Check millivolt of thermocouple to valve
mV
8
Inspect is clean and free from blockages
9
Check piezo ignition of pilot
10
Check flue for build up of foreign objects
Pressure
kPa
Service Comments:
Additional work/repairs required:
Customers approval:
Name (print):
Title:
Customers signature:
Date:
Suggestion: Photocopy this form and keep on file for continued use.
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5
Trouble-shooting
WARNING:
5.1
ALL INSTALLATION AND SERVICE REPAIR WORK MUST BE CARRIED OUT BY
QUALIFIED PERSONS ONLY.
Trouble shooting chart
Fault
Piezo ignitor not sparking
Pilot won’t light
Possible Cause
Remedy
Short in high tension lead.
(Refer fault diagnosis 5.2.2)
Replace lead.
(Refer service section 6.2.11)
Piezo faulty.
(Refer fault diagnosis 5.2.2)
Replace piezo.
(Refer service section 6.3.10)
No gas supply
Ensure gas is connected and on
and bottles not empty.
Gas pressure too low.
Check gas supply pressure.
(Refer specifications section)
Knob on gas control won’t go
fully in.
Remove obstruction. Correct
control / wrapper mounting.
Replace gas control.
(Refer service section 6.3.10)
Blocked pilot spud.
Pilot goes out when knob released Releasing knob before the
thermocouple heated.
Clean or replace pilot spud.
(Refer service section 6.2.3)
Hold control in for longer (10 s),
see if pilot will stay lit.
Pilot flame too small.
Correct fault.
(Refer fault:Pilot Flame small)
Pilot flame small
Thermocouple faulty.
(Refer fault diagnosis 5.2.1)
Replace thermocouple.
(Refer service section 6.2.1)
Safety cut-out thermostat faulty.
(Refer fault diagnosis 5.2.1)
Replace safety cut-out
thermostat.
(Refer service section 6.2.5)
Gas control valve faulty
Replace gas control magnet
Gas pressure too low.
Check gas supply pressure.
(Refer specifications section)
Pilot injector restricted.
Clean pilot injector.
(Refer service section 6.2.3)
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Trouble-shooting
Fault
Pilot goes out when main burner
comes on
Pilot goes out while in use.
Main burner will not light
Possible Cause
5
Remedy
Incorrect gas pressure.
Check supply / adjust pressure.
(Refer specifications section)
Faulty gas control.
Replace gas control.
(Refer service section 6.2.8)
Gas supply - incorrect or
fluctuating pressure.
Check supply / adjust pressure.
Draught at installation (blowing
pilot out).
Shield pasta cooker from
excessive breeze
Thermocouple faulty.
(Refer fault diagnosis 5.2.1)
Replace thermocouple.
(Refer service section 6.2.1)
Safety cut-out thermostat faulty.
(Refer fault diagnosis 5.2.1)
Replace safety cut-out thermostat.
(Refer service section 6.2.5)
Main gas control valve faulty.
Replace gas control magnet.
Incorrect supply pressure.
Check supply correct pressure.
Wrong size or blocked injector.
Replace / clean injector.
(Refer service section 6.2.6)
Small pilot flame.
Correct fault.
(Refer fault:Small Pilot Flame)
Pilot flame yellow / lazy
Burner does not burn correctly
(roar / light back / incorrect
colour)
Faulty gas control.
(Refer fault diagnosis 5.2.3)
Replace gas control.
(Refer service section 6.2.8)
Gas pressure incorrect.
Check gas supply pressure.
(Refer specifications section)
Restriction in pilot spud or
aeration.
Clean or replace as required.
(Refer service section 6.2.3)
Incorrect supply pressure.
Check supply pressure.
Incorrect injector size.
Check injector size and replace if
necessary.
(Refer service section 6.2.3)
Burner faulty.
Replace burner.
(Refer section 6.2.8)
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5
Trouble-shooting
5.2
Fault Diagnosis
5.2.1
Pilot drops out
Safety cut-out tripped
The safety cut-out is set at 115
°C. If there is
water in the tank and the safety cut-out has
tripped (open circuit) then the safety cut-out is
faulty.
Pilot flame too small
If the pilot can be lit but the flame is too small to
impinge on the thermocouple, then check the gas
pressure. If ok, then remove the pilot injector
from the pilot burner and check for blockages
and/or correct size.
Safety cut-out faulty
To check if the safety cut-out is faulty hold in the
gas control button and light the pilot (leaving the
control button depressed to keep the pilot alight).
With a multimeter measure the voltage from the
gas control side of the thermocouple interrupter
block to earth. If the voltage is under 5mV (and
the thermocouple is generating at least 20mV)
then the safety cut-out is faulty—replace. If all of
the above checks out ok then check gas control
or thermocouple.
Pilot burner
Control valve
Figure 5.2.1a
Thermocouple faulty
Check the thermocouple connection is firm and
the safety cut-out lead connection to the interrupter block on the thermocouple is secure.
(Loose connections will cause resistance in
millivolt circuit and result in pilot outage.
Gas control side of interrupter block
Figure 5.2.1d
If all connections OK, then light the pilot, and
whilst holding the control knob in, measure the
voltage from the pilot side of the connecter block
to earth (e.g the body of the control valve). This
should read approximately 30mV. If this reading
is less than 20mV and there is good impingement
of the pilot flame onto the thermocouple, then
the thermocouple is faulty - replace.
5.2.2 Piezo ignitor not sparking
Short in high tension lead
If repeated sparking of the piezo shows only
intermittent sparking at the electrode, then the
lead should be traced to find area of short. This
can be visually seen as the spark arks. If the lead
is shorting the best solution is to replace it, as the
electrical insulation of the lead may have
deteriorated.
If the spark arc can be seen at the electrode insulator at the pilot burner instead of at the
electrode tip, then the insulator probably has a
fracture and should be replaced
Control valve
Pilot side of interrupter block
Figure 5.2.1b
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Trouble-shooting
5
Piezo ignitor faulty
If no spark at all can be generated, remove piezo
ignitor and hold close to cabinet body . Depress
piezo ignitor and if a spark cannot be generated
to the cabinet body the piezo ignitor is faulty and
should be replaced.
Note: If piezo ignition fails, the pilot can be
manually lit in the interim until the piezo circuit is
repaired. A standard taper torch ,lighter or
matches can be used for manual back–up
ignition.
Figure 5.2.2
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Service Procedures
Section
Page Number
6.1 Access......................................................................................................19
6.1.1 Control Panel.......................................................................................................19
6.2 Replacement............................................................................................19
6.2.1 Thermocouple .....................................................................................................19
6.2.3 Pilot
Injector........................................................................................................20
6.2.4 Pilot Burner.........................................................................................................20
6.2.5 Safety
Cut-out Thermostat ...................................................................................20
6.2.6 Main
Burner Injector............................................................................................20
6.2.7 Main Burner.........................................................................................................21
6.2.8 Gas
Control Valve ................................................................................................22
6.2.9 Piezo
Ignition Electrode .......................................................................................22
6.2.10
Piezo Ignitor........................................................................................................22
6.2.11 High
Tension Lead...............................................................................................22
6.3 Adjustment / Calibration.........................................................................23
6.3.1
6.3.2 Low
Gas Control Valve Re-greasing..............................................................................23
Fire Adjustment............................................................................................23
ALL INSTALLATION AND SERVICE REPAIR WORK MUST BE CARRIED OUT BY
QUALIFIED PERSONS ONLY.
WARNING:
ENSURE GAS SUPPLY IS SWITCHED OFF BEFORE SERVICING
ALWAYS CHECK / TEST FOR GAS LEAKS AFTER SERVICE REPAIRS ON THE GAS
SYSTEM
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6
Service Procedures
6.1 Access
6.2 Replacement
6.1.1 Control
panel
6.2.1 Thermocouple
1) Remove gas control knob by pulling knob
from valve.
1) Disconnect thermocouple from gas control.
2) Remove water valve knob by levering out
plastic cap in centre of knob and undoing
centre screw.
Thermocouple
1 screw
Figure 6.2.1a
2) Unscrew the safety cut-out thermostat wires
from the connector block on the thermocouple.
Figure 6.1.1a
Water valve
3) Unscrew thermocouple securing nut from pilot
burner.
Gas control valve
2 screws
Thermocouple
Figure 6.2.1b
Figure 6.1.1b
Note: It may be necessary to remove the piezo
ignition electrode from the pilot
assembly before removing thermocouple.
3) Remove 2 screws from underside of control
panel and lift panel off.
4) Replace thermocouple and reconnect.
When screwing thermocouple back into gas
control, once thread has tightened up tighten
another ¼ turn only. Do not over tighten.
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6
Service Procedures
6.2.3 Pilot injector
6.2.5 Safety cut-out thermostat
1) Remove ignition electrode.
1) Drain water from pasta cooker.
2) Disconnect pilot supply tube from pilot burner
by unscrewing nuts and olive.
2) Remove control panel (refer 6.2.1 )
3) Disconnect safety cut-out leads from interrupter on the thermocouple.
Pilot Burner
Safety Cut-out
Figure 6.2.3
Figure 6.2.5
3) Remove pilot injector, and clean or replace as
necessary.
4) Using 7/8” tube spanner, remove the safety
cut-out thermostat from fryer tank.
Note: Ensure correct size injector is used
(refer specifications section).
5) Replace and reassemble in reverse order,
using sealant suitable for 115 °C on threads
(locktite 567 recommended).
4) Reassemble in reverse order.
6.2.4 Pilot burner
6.2.6 Main
1) Disconnect the thermocouple and/or the piezo
electrode from the pilot burner.
injector
1) Unscrew injector out of injector mounts.
2) Remove injector, and clean or replace as
necessary. Ensure correct size of injectors are
refitted ( refer specifications section )
2) Disconnect pilot supply tube from pilot burner
by unscrewing nut and olive.
Main Injector
Thermocouple
Piezo Electrode
Figure 6.2.6
Figure 6.2.4
3) Remove screw securing the pilot burner to
front of the pasta cooker, and remove pilot
burner assembly.
4) Replace pilot burner and reassemble. Ensure
correct pilot injector is refitted (refer to the
specifications section).
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Service Procedures
6.2.7 Main
burners
6
6) Once the rear is supported the front can be
pushed up into its location. The small notch in
each side of the venturi visible externally from
the burner body is for the front to back
location and should be located up into the top
corner panels when pushing up at the burner
at front. If correctly fitted the corner support
bracket securing holes. If not, check burner
fit.
1) Unscrew 3 screws from pilot mounting
bracket.
2) Unscrew (6 screws) burner box underside
panel.
3) Unscrew and remove corner support panel
from underside of burner intake throat (2
screws)
7) Replace brackets and all connections to the
gas controls
NOTE: There may be a tie wire located at the
rear of the burner. This can be cut with a pair
of cutters, and discard.
8) Ensure underside burner box panel is refitted,
as failure to refit this panel will reduce
combustion and performance efficiency
Burner can be removed by dropping down
front of burner and pulling forward.
4) With the burner out, the tank underside
should be checked to ensure that the black
emissivity coating is still intact. There should
be no shiny stainless steel of the tank exposed, or white substance on the black surface. Clean the surface if required and remove any loose coating.
NOTE: If touch up or recoat is required, use a
spray can of matt black high temperature
enamel ( VHT1200 or equivalent ) to re-coat
the affected area.
Check the black
emissivity coating is
still intact.
5) Holding the new burner with one hand
underside and the other holding the throat,
push up the rear of the burner until it
positions on the rear support bracket within
the burner box. It is a good practice to put
your head down and have a look at this
bracket before trying too install a burner so
that you can visualise where the bracket is
when fitting the burner.
Figure 6.2.7b
Burner box screws
Figure 6.2.7a
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6
Service Procedures
6.2.8 Gas
control
6.2.10 Piezo ignitor
1) Remove control panel (refer 6.1.1).
Note: Ensure gas is isolated at main supply before any alterations are carried out on main
gas controls.
2) Remove the HT lead from the piezo ignitor by
pulling firmly away.
3) Unscrew the nut securing the piezo ignitor to
the control panel.
1) Remove control panel (refer 6.1.1).
2) Disconnect thermocouple and pilot supply
from gas control valve.
3) Undo main injector supply located at the
top of the gas control valve.
4) Undo gas supply line located on bottom of
gas control and remove valve.
Pilot supply
Main injector
supply
Figure 6.2.10
6.2.11 High tension Lead
Gas supply
1) Remove control panel (refer 6.1.1).
2) Remove H.T. lead from piezo ignitor and pilot
electrode.
Figure 6.2.8
7) Refit by reversing the above procedure.
Note: Ensure gas thread connections are resealed and electrical connections secured
when servicing.
6.2.9 Piezo
Electrode
1) Remove nut securing piezo electrode to pilot
assembly.
2) Remove piezo electrode and replace.
Figure 6.2.11
3) Replace lead and reassemble in reverse
order.
Piezo electrode nut
Figure 6.2.9
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Service Procedures
6.3
Adjustment / Calibration
6.3.1
Gas control re-greasing
6
6.3.2 Low fire adjustment
1) Light burner and turn gas tap to low position.
2) Remove gas control knob.
1) Remove control panel (refer 5.2.1).
3) Turn low fire adjustment screw, located
below and to the right of the gas control
shaft, until the desired low flame is achieved.
2) Remove 2 screws holding shaft plate to gas
control body and remove control shaft and
plate. Note orientation of shaft for correct
re-assembly.
Operating pressure test point
Low fire screw
Two Screws
Figure 6.4.2
Figure 6.4.1a
3) Using needle nose pliers or similar, pull out
gas control
spindle, again noting its
orientation.
Spindle
Figure 6.4.1b
4) Apply a suitable high temperature gas cock
grease or lubricant such as ROCOL - A.S.P
(Anti scuffing paste) / Dry Moly Paste to the
outside of the spindle.
5) Replace spindle and re-assemble gas control
in reverse order.
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7
Accessories
24
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Exploded Parts Diagrams
8
8.1 G47
8.1.1 Main Assembly
ITEM PART NO
DESCRIPTION
1
227512
SIDE PANEL LH
227511
SIDE PANEL RH
2
229804
WATER FILLER SPOUT
3
229736
SPLASHBACK BLUESEAL GAS
4
229707
BASKET DRAIN TRAY
5
227762
HOB FRONT WA BSEAL
6
229745
CONTROL PANEL BSEAL GAS
7
229695
KNOB BSEAL 10mm GAS PF
8 228846 DOOR
OUTER
9 229703 WATER
VALVE
10 228414
TOP PIVOT STUD
11 227960
BLUE SEAL BADGE
12 228308
HINGE PIVOT WA
13 228301
HINGE BUSH
14 228300
HINGE PLATE
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8
Exploded Parts Diagrams
8.1.2 Main Assembly
ITEM PART NO
DESCRIPTION
15 229837
BASKET 320 X 165
16 229682
BASKET SUPPORT FRAME
17 227856 MAGNET
CATCH
18 229823 OVERFLOW
HOSE
19 227850 LEG
150mm
20 229822
DRAIN "Y" JUNCTION
21 019390
BALL VALVE
22 229836
BASKET 165 X 165
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Exploded Parts Diagrams
8
8.1.3 Gas Assembly
ITEM PART NO
23 022575
24 229699
25 227508
26 229683
27 229814
28 229511
29 032310
032190
30 229816
31 018095
32 229702
33 018744
34 018090K
35 018743
36 019218
37 018091
018092
DESCRIPTION
BURNER KIT
GAS CONTROL
PIEZO
MANIFOLD
BURNER SUPPLY PIPE
INJECTOR ELBOW
INJECTOR 3.10 mm (NAT GAS)
INJECTOR 1.90 mm (LPG/PROPANE)
PILOT SUPPLY TUBE
HT LEAD
OVERTEMP
IGNITION ELECTRODE
PILOT BURNER KIT
THERMOCOUPLE SPACER
THERMOCOUPLE
PILOT SPUD - NAT 0.62mm
PILOT SPUD - LPG 0.35mm
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9
Circuit Schematics
G47 Pasta Cooker
SAFETY CUT-OUT
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Service Contacts
10
Australia
VICTORIA - MOFFAT PTY
HEAD OFFICE AND MAIN WAREHOUSE
740 Springvale Road
Mulgrave VIC 3170
Spare Parts Department
Tel (03) 9518 3888
Fax (03) 9518 3838
Free Call 1800 337 963
Fax (03) 9518 3895
NEW SOUTH WALES - MOFFAT PTY
Unit 3/142 James Ruse Drive
Rosehill
NSW 2142
Spare Parts
Tel (02) 8833 4111
Free Call 1800 337 963
Fax (03) 9518 3895
QUEENSLAND - MOFFAT PTY
30 Prosperity Place
Geebung QLD 4034
Spare Parts
Tel (07) 3630 8600
Free Call 1800 337 963
Fax (03) 9518 3895
WESTERN AUSTRALIA - MOFFAT PTY
67 Howe St
Osbourne Park, WA 6017
Spare Parts
Tel (08) 9202 6820
Fax (08) 9202 6836
Free Call 1800 337 963
Fax (03) 9518 3895
NATIONAL COVERAGE FOR 24 HOUR SERVICE OR MAINTENANCE DIAL
FREE CALL 1800 622 216 (AUSTRALIA ONLY)
Canada
SERVE
CANADA
22 Ashwarren Rd
Downview Fax
Ontario
M3J1Z5
Tel 416-631-0601
416-631-0315
New Zealand
CHRISTCHURCH - MOFFAT LTD
16 Osborne St
PO Box 10-001
Christchurch
Spare Parts
Tel (03) 389 1007
Fax (03) 389 1276
Free Call 0800 MOFFAT
(0800 66 33 28)
Fax (03) 381 3616
AUCKLAND - MOFFAT LTD
4 Waipuna Road
Mt Wellington
Auckland
Spare Parts
Tel (09) 574 3150
Fax (09) 574 3159
Free Call 0800 MOFFAT
(0800 66 33 28)
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10
Service Contacts
United Kingdom
Utensils Direct
0845 873 6600
www.utensilsdirect.co.uk
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A
Appendix A: Gas Type Conversion
CAUTION:
Ensure the unit is isolated from the gas supply before commencing servicing.
NOTE:
• These conversions should only be carried out by qualified service persons. All
connections must be checked for leaks before re-commissioning the appliance.
• For all relevant information and specifications refer to the table at the end of this
section.
1.
2.
3.
4.
5.
6.
Ensure that the gas supply has been turned off.
Remove the gas control knob from the gas tap spindle by
pulling the knobs away from the control panel.
Remove the water control knob by popping out the
centre of the knob and using a suitable screwdriver,
unscrew the centre screw and remove the knob.
Open the front door, unscrew and remove the two
screws on the underside of the control panel, securing
the control panel to the appliance.
Remove the control panel from the front of the appliance.
Connect a manometer to the upper test point (Line
Pressure) on the gas control valve. Turn on the gas and
ensure that the supply pressure is within the specification
shown in the ‘Gas Specifications Table’ at the end of this
section.
Burner
Operating
Pressure Test
Point
Gas Control
Valve
Fig A1
Main Burner Injectors
1.
2.
3.
Main Burner
Injector
Unscrew and remove the main burner injectors (12.7 mm
A/F) located in front of main burner venturi openings.
Determine the correct injectors for the corresponding gas
from the ‘Gas Specifications Table’ at the end of this
section.
Screw in the correct sized injectors. Refer to the ‘Gas
Specifications Table’ at the end of this section.
Pilot Burner Injectors
1.
Unscrew the pilot supply tube from the pilot burner fitted
to the mounting bracket and remove the pilot injector.
NOTE: On appliances fitted with piezo igniter electrodes, to
prevent damage to the electrode, unscrew and
remove the electrode from the mounting bracket
before unscrewing the pilot supply tube.
2. Determine the correct sized pilot injectors for the
corresponding gas from the table overleaf.
3.
Fit the correct sized injector into the pilot burner and
re-connect the gas supply tube to the pilot burner.
4.
Refit the piezo igniter electrode to the mounting bracket
and tighten hand tight.
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Fig A2
Thermocouple
Pilot Burner
Piezo
Igniter
Fig A3
© Moffat Ltd, January 2007
A
Appendix A: Gas Type Conversion
Low Fire Adjustment
a. To adjust the burner low fire adjustment, adjust the
low fire adjustment screw on the open burner gas
control valves to obtain the desired flame size.
Low Fire
Adjusting Screw
NOTE: The “Low Fire Screw” should be sealed with
coloured paint on completion of the low fire
adjustment.
On completion of the main and pilot burner adjustments, check
all gas connections for leakages and then turn off the main
burners at the gas control knob. Turn off the main gas supply.
Refit all the panels and control knobs to the appliance.
Fig A4
Gas Regulator
NOTE: The regulator supplied is convertible between Natural Gas and LPG, but it’s outlet
pressure is fixed ex-factory and is NOT to be adjusted.
NOTE, Pin rotated
for Natural Gas
NOTE, Pin
rotated for LPG
Fig A5
1.
2.
3.
4.
Ensure that the gas supply is turned ‘OFF’ at the mains.
Unscrew the hexagonal cap (23mm A/F) from the regulator.
Un-clip the plastic pin from the cap, rotate the pin and re-fit it back to
the cap the correct way for the gas type to be used. (Either ‘LP’ or
‘NAT’ should be visible on the flank of the pin once
re-fitted to the cap).
Screw the cap back into the regulator.
Gas Type Identification Label
On completion of the gas conversion, replace the gas type identification label located at:- The rear of the appliance, above the gas connection.
- Beside the rating plate.
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Appendix A: Gas Type Conversion
A
Commissioning
Before leaving the converted installation;
1.
Check all gas connections for leakages using soapy water or other gas detecting equipment.
WARNING:
DO NOT USE A NAKED FLAME TO CHECK FOR GAS LEAKAGES.
2.
Check the following functions in accordance with the operating instructions specified in the
“Operation” section of the User manual.
•
Light the Pilot Burners.
•
Light the Main Burners.
•
Check the Thermostat operation.
•
Ensure that all the controls operate correctly.
NOTE: If for some reason it is not possible to get the appliance to operate correctly, shut off the
gas supply and contact the supplier of this appliance.
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B
Appendix B: Gas Specifications
Gas Specifications
- Non - UK Only:
Natural Gas.
LP Gas (Propane)
Main Burner Injectors
Ø 3.10 mm
Ø 1.90 mm
Pilot Burner Injectors
0.62
0.35
Low Fire Screw
Ø 1.55 mm
2 turns out (c.c.w.)
Ø 1.55 mm
Fully In (c.w.)
High Fire Screw
Fully Out (c.c.w.)
Fully Out (c.c.w.)
Supply Pressure
1.13 - 3.40 kPa
2.75 - 3.40 kPa
Burner Operating Pressure
0.92 kPa (*)
2.6 kPa (*)
Natural Gas (G20)
Propane (G31)
Gas Regulator Cap Screw
- UK Only:
Appliance Classification
Category:
II2H3P.
Flue Type:
A1.
Main Burner Injectors
Ø 3.10 mm
Ø 1.90 mm
Pilot Burner Injectors
0.62
0.35
Low Fire Screw
Ø 1.55 mm
2 turns out (c.c.w.)
Ø 1.55 mm
Fully In (c.w.)
High Fire Screw
Fully Out (c.c.w.)
Fully Out (c.c.w.)
Supply Pressure
20 mbar
37 mbar
9.5 mbar (*)
27.7 mbar (*)
Burner Operating Pressure
Gas Regulator Cap Screw
NOTE: (*) The burner operating pressure is to be measured at the Burner Operating Pressure test
point on the gas control valve, this is to be carried out with the burner operating at the
'High Flame' setting. The operating pressure is ex-factory set, through the appliance
regulator and not to be adjusted, apart from when carrying out gas conversion, if
required. Refer to the ‘Gas Conversion and Specification’ Section for further details.
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