Blue Seal Evolution G592 User manual

Revision 1/ © Moffat Ltd, January 2007
Blue Seal Evolution Series Gas Chargrills
Gas Chargrills
G592 / G594 / G596 / G598
Service Manual

Revision 1/ © Moffat Ltd, January 2007
Blue Seal Evolution Series Gas Chargrills
ALL INSTALLATION AND SERVICE REPAIR WORK MUST BE CARRIED OUT BY
QUALIFIED PERSONS ONLY.
WARNING:
MAKING ALTERATIONS MAY VOID WARRANTIES AND APPROVALS.
IMPORTANT:

Revision 1/ © Moffat Ltd, January 2007
Blue Seal Evolution Series Gas Chargrills
This manual is designed to take a more in depth look at the G59 Chargrills 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 ................................................................................................4
3. Operation...................................................................................................8
3.1 Description of Controls
3.2 Explanation of Control System
4. Cleaning / Maintenance ..........................................................................10
5. Trouble-shooting Guide...........................................................................12
5.1 Trouble shooting chart
5.2 Fault diagnosis
6. Service Procedures ..................................................................................14
6.1 Access
6.2 Replacement
6.3 Adjustment / Calibration
7. Accessories ..............................................................................................20
8. Exploded Parts Diagrams ........................................................................21
8.1 G592 300mm Chargrill
8.2 G594 600mm Chargrill
8.3 G596 900mm Chargrill
8.4 G598 1200mm Chargrill
9. Service Contacts......................................................................................32
Appendix A: Gas Type Conversion .................................................................34
Contents

Revision 1/ © Moffat Ltd, January 2007
Blue Seal Evolution Series Gas Chargrills

1
1
Specifications
Revision 1/ © Moffat Ltd, January 2007
Blue Seal Evolution Series Gas Chargrills
Model Numbers covered in this Specification
G592 300mm wide 1 burner gas Chargrill
G594 600mm wide 2 burner gas Chargrill
G596 900mm wide 3 burner gas Chargrill
G598 1200mm wide 4 burner gas Chargrill
Gas Supply (non-UK units)
G594 TBD
G596 TBD
G598 TBD
G592 TBD
Unit Weights (Net)
Natural Gas LP Gas (Propane)
G592 G594 G596 G598 G592 G594 G596 G598
Input Rating
(N.H.G.C.) 33 Mj/hr 66 MJ/hr 100 Mj/hr 133 Mj/hr 33 Mj/hr 66 MJ/hr 100 Mj/hr 133 Mj/hr
31,270 Btu/hr 62,500 Btu/hr 94,700 Btu/hr 126,000 Btu/hr 31,270 Btu/hr 62,500 Btu/hr 94,700 Btu/hr 126,000 Btu/hr
Supply Pressure 1.13 - 3.40 kPa
(4.5” - 13.5 w.c.) 2.75 - 3.40 kPa (11” - 13.5” w.c.)
Burner Operating
Pressure 1.0 kPa 0.95 kPa (*) 2.5 kPa 2.6 kPa (*)
(4” w.g.) (3.8” w.g.) (9.8” w.g.)
Gas Connection 1/2” BSP
Male 3/4” BSP Male 1/2” BSP Male 3/4” BSP Male
(10” w.g.)
Natural Gas (G20) Propane (G31)
G592 G594 G596 G598 G592 G594 G596 G598
Heat Input
(nett) Nominal 8.8 kW 18.0 kW 27.0 kW 36.0 kW 8.8 kW 18.0 kW 27.0 kW 36.0 kW
Reduced 3.5 kW 6.0 kW 9.0 kW 18.0 kW 3.7 kW 6.4 kW 9.6 kW 12.8 kW
Gas Rate
(nett) Nominal 0.93 m3/hr 1.90 m3/hr 2.86 m3/hr 3.81 m3/hr 0.68 kg/hr 1.40 kg/hr 2.10 kg/hr 2.80 kg/hr
Reduced 0.37 m3/hr 0.63 m3/hr 0.95 m3/hr 1.27 m3/hr 0.29 kg/hr 0.50 kg/hr 0.75 kg/hr 0.99 kg/hr
Supply Pressure 20 mbar 37 mbar
Burner Operating
Pressure 10.6 mbar 10 mbar (*) 25 mbar
Gas Connection 1/2” BSP
Male 3/4” BSP Male 1/2” BSP Male 3/4” BSP Male
26 mbar (*)
Gas Supply (UK units)
Natural Gas (G20) LP Gas (Propane) (G31)
G592 G594
G596
G598 G592 G594
G596
G598
Main Burner Injectors 2.70 mm 1.65 mm
Pilot Burner Injectors 0.35 0.41 0.25 0.25
Injector Sizes

2
1
Specifications
Revision 1/ © Moffat Ltd, January 2007
Blue Seal Evolution Series Gas Chargrills
External Dimensions
G592-B
NOTE: G592 are only available in Bench Model (- B) Option.
G594-LS
Front Side Plan

3
1
Specifications
Revision 1/ © Moffat Ltd, January 2007
Blue Seal Evolution Series Gas Chargrills
G596-LS
G598-LS

4
2
Installation
Revision 1/ © Moffat Ltd, January 2007
Blue Seal Evolution Series Gas Chargrills
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 electrical, 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 chargrills 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 - 1 & 2 Installation Flueing & Ventilation.
Ireland: - IS 820 - Non - Domestic Gas Installations.
Installations must be carried out by authorised 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.
• Check equipment and parts for damage. Report any damage immediately to the carrier and
distributor.
• Remove protective plastic coating from the side panels.
• Check that the following parts have been supplied with the chargrill:
1 x Gas Regulator.
1 x Gas Type Conversion Kit.
• Report any deficiencies to the distributor who supplied the chargrill.
• Check that the available gas supply is correct to that shown on the rating plate attached to the underside
of the R/H side, front hob lower trim.
Location
1. Installation must allow for a sufficient flow of fresh air for the combustion air supply.
2. Installation must include adequate ventilation to prevent dangerous build up of combustion products.
3. Never directly connect a ventilation system to the appliance flue outlet.
4. Position the chargrill in its approximate working position.
5. 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.
NOTE: Do not obstruct or block the appliances flue. Never directly connect a ventilation system to
the appliance flue outlet.
G592 G594 G596 G598
Natural Gas (G20) 9m3/hr 18m3/hr 27m3/hr 36m3/hr
LPG/Propane (G31) 9m3/hr 18m3/hr 26m3/hr 35m3/hr
Combustion Air Requirements

5
2
Installation
Revision 1/ © Moffat Ltd, January 2007
Blue Seal Evolution Series Gas Chargrills
Clearances
NOTE: Only non-combustible materials can be used in close proximity to this appliance.
Assembly
NOTE:
• All Models will require assembly. Refer to the 'Fitting of Adjustable Feet / Rollers to Leg
Stand Units' information below for assembly instructions.
• This appliance is fitted with adjustable feet 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'.
Optional Accessories (Refer to Replacement Parts List)
• Plinth Kit. For installation details, refer to the instructions supplied with each kit.
Bench Models
1. Check that all the feet (or castors) are securely fitted.
2. Adjust the feet to make the Chargrill steady and level.
Fitting Leg Stand to Chargrill
1. Remove the grates, griddle plates and
radiants from the chargrill.
2. Lower the Chargrill onto it’s rear face.
3. Attach the four hob legs to the leg mounting
positions on the underside of the chargrill. Se-
cure each leg hand tight.
4. Align the four round cut out holes on the base
tray with the four hob legs already fitted to the
chargrill (Ensure that the base tray is orientated
with the sloping edge of the base tray facing the
front of the appliance.
5. Slot the base tray onto the four hob legs and
push fully home.
6. Secure the base tray to the front chargrill legs by
screwing the adjustable feet supplied, into the
base of the front chargrill legs. Secure each
adjustable foot, hand tight.
7. Fit the rear rollers to the rear leg ring plates and
secure using the locating bolts supplied and
tighten bolts using a 10mm spanner.
8. Lift the chargrill back onto its legs.
9. Refit all the grates, griddle plates and radians to
the chargrill, ensuring that they are correctly
fitted.
NOTE: This appliance is fitted with adjustable feet / rear 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.
Combustible Surface Non Combustible Surface
Left / Right hand side 200 mm 0 mm
Rear 100 mm 0 mm
Fig 1
Sloping Edge
of Base Tray
Rear Roller
Base Tray
Chargrill
Legs
Leg Mount
Points
Chargrill

6
2
Installation
Revision 1/ © Moffat Ltd, January 2007
Blue Seal Evolution Series Gas Chargrills
Gas Connection
NOTE: ALL GAS FITTING MUST ONLY BE CARRIED OUT BY AN AUTHORISED PERSON.
1. Blue Seal Chargrills do not require an electrical connection, as they function on the gas supply only.
2. It is essential that the gas supply is correct for the Chargrill to be installed and that adequate
supply pressure and volume is 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 these are correct for the gas supply the
appliance is being installed for. The gas conversion procedure is detailed in the ‘Gas Conversion and
Specification’ section of this manual.
b. The 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. The Input Rate of this appliance is shown on the Rating Plate and in the “Specifications”
section of this manual. The input rate should be checked against the available supply line
capacity. Particular note should be taken if the Chargrill 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. Fit the gas regulator supplied, into the gas supply line as close to the appliance as possible.
The regulator connections are ¾" BSP female.
The connection is ¾" BSP male.
(Refer to the ‘Specifications’ section for the gas supply location dimensions).
NOTE: The gas pressure regulator provided with this appliance is convertible between Natural Gas
and LPG and is already converted ex-factory to the gas type labelled beside the gas
connection point. The regulator outlet pressure is fixed ex-factory and it is NOT to be
adjusted.
4. A suitable joining compound which resists the breakdown action of LPG must be used on every gas line
connection, unless compression fittings are used.
NOTE: A manual isolation valve must be fitted to the individual appliance supply line.
5. 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.
6. Connect the gas supply to the appliance.
7. Check gas operating pressure is as shown in “Specifications” section.
8. Check all gas connections for leakages using soapy water or
other gas detecting equipment.
NOTE: The operating pressure to be measured at the
manifold test point and with two burners operating
at the ‘High Flame’ setting. (With the exception of
the G592 model which has one burner only).
9. Turn off the mains gas supply and bleed the gas out of the
appliance gas lines.
10. Turn ‘ON” the gas supply and the appliance.
11. Verify the operating pressure remains correct.
WARNING:
CHECK CONNECTIONS FOR LEAKS WITH SOAPY WATER. DO NOT USE A NAKED FLAME.
Fig 2
Manifold
Test Point