Garland CG-72 User Manual

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SERVICE MANUAL

GARLAND GAS

“PRODUCTION GRIDDLES” MODELS: CG-24,CG-36,CG-48,CG-60&CG-72

FOR YOUR SAFETY:

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN THE VICINITY OF

THIS OR ANY OTHER

APPLIANCE

WARNING:

IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY, OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS THOROUGHLY

BEFORE INSTALLING OR

SERVICING THIS EQUIPMENT

PLEASE READ ALL SECTIONS OF THIS MANUAL AND RETAIN FOR FUTURE REFERENCE.

THIS PRODUCT HAS BEEN CERTIFIED AS COMMERCIAL COOKING EQUIPMENT AND MUST BE INSTALLED BY PROFESSIONAL PERSONNEL AS SPECIFIED.

IN THE COMMONWEALTH OF MASSACHUSETTS THIS PRODUCT MUST BE INSTALLED BY A LICENSED PLUMBER OR GAS FITTER. APPROVAL NUMBER: G-1-07-05-8

For Your Safety:

Post in a prominent location, instructions to be followed in the event the user smells gas. This information shall be obtained by consulting your local gas supplier.

Users are cautioned that maintenance and repairs must be performed by a Garland authorized service agent

using genuine Garland replacement parts. Garland will have no obligation with respect to any product that has been improperly installed, adjusted, operated or not maintained in accordance with national and local codes or installation instructions provided with the product, or any product that has its serial number defaced, obliterated or removed,

or which has been modified or repaired using unauthorized parts or by unauthorized service agents.

For a list of authorized service agents, please refer to the Garland web site at http://www.garland-group.com.The information contained herein, (including design and parts specifications), may be superseded and is subject to change without notice.

GARLAND COMMERCIAL INDUSTRIES

GARLAND COMMERCIAL RANGES, LTD.

Enodis UK LTD.

185 East South Street

1177 Kamato Road, Mississauga, Ontario L W 1X

Swallowfield Way, Hayes, Middlesex UB3 1DQ ENGLAND

Freeland, Pennsylvania 18

CANADA

Telephone: 081-561-033

Phone: (570) 636-1000

Phone: 905-6-060

Fax: 081-88-001

Fax: (570) 636-3903

Fax: 905-6-5669

 

Part #GCGTRAINING06 (03/03/08)

© 006 Garland Commercial Industries, Inc.

Part #GCGTRAINING06 (03/03/08)

Page 1

IMPORTANT INFORMATION

WARNING:

This product contains chemicals known to the state of California to cause cancer and/or birth defects or other reproductive harm. Installation and servicing of this product could expose you to airborne particles of glass wool/ceramic fibers. Inhalation of airborne particles of glass wool/ceramic fibers is known to the state of California to cause cancer. Operation of this product could expose you to carbon monoxide if not adjusted properly. Inhalation of carbon monoxide is known to the state of California to cause birth defects or other reproductive harm.

Keep appliance area free and clear of combustibles.

Page

Part #GCGTRAINING06 (03/03/08))

TABLE OF CONTENTS

IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DIMENSIONS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

WHAT IS A CHAIN GRIDDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

How Does it work?.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Mechanical.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Gas Supply .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Electrical Power, Lighting & Control.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Ventilation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Start-Up.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

OPERATION & MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Have The Right Tools And Instruments.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Adjustments.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Pilot Flame Adjustment .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Burner Air .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Removing the Griddle Plate .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Thermostat.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Thermocouple.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

How To Replace A Thermocouple.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Incandescent Lamps.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Pilot Ignition Control (Control Module).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Gas Valve Regulator.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Power Switches.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Control Circuit.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

CONTROL PANEL SCHEMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SERVICE BULLETIN #95-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Part #GCGTRAINING06 (03/03/08)

Page

DIMENSIONS AND SPECIFICATIONS

INSTALLATION NOTES

SPECIFY GAS TYPE

ELECTRICAL CHARACTERISTICS

 

 

 

 

 

Combustible Wall Clearances

Operating Pressure

Specifications

 

 

 

 

 

Sides:

Back:

Natural:

Propane:

120 V, Single Phase, 60Hz, 1 amp

6" (152mm)

6" (152mm)

7" W..C.. (17.4 mbar)

11" W..C.. (24.4 mbar)

6' (1829mm) power supply cord provided..

 

 

 

 

 

• IMPORTANT: Unit must be

• Gas Input Ratings shown are for

 

installations up to 2,000 feet (610mm)

• NOTE: No cord and plug on export units..

installed on legs for proper air

above sea level.. BTU input ratings must be

Direct connection on junction box..

circulation..

 

 

derated for high altitude installations..

 

 

 

 

 

 

 

ENTRY CLEARANCE

VENTILATION

EXPORT VOLTAGES

 

 

 

 

Crated

Uncrated

• Commercial cooking equipment requires

• NOTE: Export voltages are available on

 

 

an adequate ventilation system.. For

request..

40" (1016mm)

38" (965mm)

additional information, refer to the

 

 

 

220-240volt, 50 Hz, 0.4 amps, single

• See illustration for further

National Fire Protection Association’s

phase..

specifications & size statistics

standard NFPA96..

 

 

 

 

 

 

 

 

 

 

 

 

Available in 24, 36, 48, 60 & 72 Widths 610, 914, 1219, 1524 & 1829

3" [76mm] Extended Bumper to Prevent Flue Vent Blockage

2.5

84

3.25

83

 

 

 

Grease Trough

20

 

 

 

 

 

 

 

 

 

 

Gas Connection Centered

508

 

 

 

 

 

 

 

On Unit Width [Left to Right]

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

24

 

 

 

 

 

 

 

 

 

 

 

 

38.75 610

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

984

 

 

 

 

Electric

 

 

 

 

 

 

 

 

5.5

 

 

 

 

 

 

 

 

 

 

Cord/Connection

 

 

140

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6

152

1.5

 

 

 

 

 

5

 

PLAN VIEW [Model CG-48R]

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

38

 

 

 

 

 

 

Dimensions - All Models

 

 

 

 

 

127

 

 

Grease Drawer(s)

 

2' & 3' Units - One

 

4', 5' & 6' Units - Two

Finished Floor

Optional Stand

 

 

 

 

 

DIMENSIONS:

Inches

 

 

 

 

mm

5.75

 

0.625

 

 

 

 

 

 

16

 

 

 

 

 

146

 

 

 

Cooking Surface

 

 

 

 

Electric Cord/Connection

15.75

 

10

 

400

 

 

Gas Connection

Rear

 

254

 

 

 

 

 

 

 

 

Gas Inlet

 

 

 

 

 

 

 

 

4.75

 

 

 

 

6

35

121

 

 

 

 

 

Counter

 

Counter152

 

 

 

 

889

15

 

Removable

Leg

 

 

 

 

Optional

Grease

 

 

 

 

381

Stand

Drawer 27

 

 

 

 

 

 

686

 

 

 

Finished 10 Floor

254

SIDE VIEW

INPUT CHART - Natural Or Propane Gas

Model

BTU/

 

Gas

Shipping

Kw

Weight

Number

HOUR

 

Inlet

 

 

Lbs../Kgs..

 

 

 

 

 

 

 

 

 

CG-24R

60,000

17..60

3/4"

335/152

 

 

 

 

 

CG-36R

90,000

26.4 0

3/4"

485/220

 

 

 

 

 

CG-48R

120,000

35..00

3/4"

625/284

 

 

 

 

 

CG-60R

150,000

44..00

3/4"

765/348

 

 

 

 

 

CG-72R

180,000

52..70

1"

995/411

 

 

 

 

 

FRONT VIEW [Model CG-48R]

Page

Part #GCGTRAINING06 (03/03/08))

WHAT IS A CHAIN GRIDDLE

Commercial chain restaurants impose strict food procedures on franchise owners and operators to guarantee the quality and consistency of the product.. Beef burgers, hamburgers, french fries, onion rings, fried chicken and tortillas for example, must meet rigid standards of quality involving the ingredients used, the recipes followed, storage and, not least, the cooking temperature and time of cooking..

Accuracy of temperature control and the heating stability of the cooking surface are essential in maintaining consistent quality in the product.. Control and stability are the two primary features in the new chain griddle.. As compared with previous gas griddles of the same kind, temperature control of heating zones in the chain griddle is far tighter and more precise..

Two features provide precision control.. One feature is a burner for every foot of griddle surface.. The other is that each burner is electronically monitored for temperature control.. As a result, at 30,000 BTU using natural gas, there is excellent energy management and power recovery..

Temperature sensors are embedded in the griddle plate.. Each sensor is close to the plate surface where the load is.. The effect of this arrangement is to achieve an even temperature gradient across the plate.. Thanks to the electronic monitoring feature, a much faster response to changes in surface temperature is achievable in the chain griddle than in previous units..

The smoother temperature gradient per unit surface area and accurate temperature control has made the chain griddle an instant success.. This simple explanation of the two main features of the unit is what makes it so special.. Without fast response and a smooth gradient, the chain griddle would be just another design among many..

Explaining why the unit is special is one thing and understanding how it works in another.. Service technicians need to know this to have complete confidence when servicing the unit.. We describe how it works in the next part of this section..

Figure 1 -Frontview ofcounter-topchain griddle

Burner ON amber

 

 

 

 

indicator light

 

 

Air vents

Securing

Pilot ON green

Flame

fasteners

viewport

 

 

for removable

indicator light

 

Zone

 

Removable top

top

 

thermostat

 

access panel

access panel

 

 

 

 

 

Main power

 

 

 

 

Hinged

ON

 

 

 

 

 

 

 

 

drop-down

green

 

 

 

 

 

 

 

 

bottom half

indicator

 

 

 

 

 

 

 

 

access

light

 

 

 

 

 

 

 

 

panel

 

 

 

 

 

Main power

Zone power

 

Leg of counter-top

switch

switch

 

 

Grease tray

style griddle

 

 

 

How Does it work?

When the main power switch is turned on, the power indicating lamp is illuminated and power is applied to the thermostat input of the ignition modules.. This will initiate the pilot ignition sequence.. The ignition module supplies a spark ignition at the pilot burner and will energize the pilot solenoid valve for a maximum trail period of 50 seconds..

If the pilot flame ignites and is sensed within the 50 second period, the main burner output of the ignition module will be energized.. The pilot indicating lamp will illuminate.. The main burner solenoid valves are then controlled by the thermostats.. As a thermostat calls for heat, it will energize its output and the main burner valve along with the burner indicating lamp will energize.. The main burner will cycle with the thermostat..

There is only one trial for ignition.. If the pilot flame is not sensed during the trail period, the ignition module will lock out.. All ignition module outputs will be de-energized..To reset the ignition module the main power switch must be turned off for a period of 30 seconds..

Part #GCGTRAINING06 (03/03/08)

Page

WHAT IS A CHAIN GRIDDLE continued

During normal operation, the pilot flame is continually monitored.. The flame current signal must maintain 0..15 microamps minimum.. Flame failure response time is 0..8 seconds maximum.. If at any time the ignition module does not detect a pilot flame, it will repeat the ignition process by allowing a 50 second trial of ignition..

Figure 2 illustrates this sequence of operation..

Figure 2 – Sequence of Operation

Power

 

 

 

Ignition

 

Spark

Flame

 

 

 

 

 

 

 

 

 

 

 

o/p

sensor

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pilot valve

Main valve

INSTALLATION

The instructions given for installation form part of the delivery package.. Anyone installing a chain griddle should follow a strict procedure to make sure installation and commission are safe, efficient and complies with the applicable local codes.. Here is a check list of things to do in the order we recommend..

Mechanical

Uncrate and check for shipping damage both obvious and hidden.. Write a damage report and report immediately to the carrier..

Check the serial plate behind the front panel.. To do this, remove the front panel by unscrewing the two screws in the upper right and left corners.. Next unscrew the two fasteners securing the hinged lower font panel in place.. Note the burner inputs shown on the serial number plate.. It may be necessary to refer to these later.. You also need to be certain of the type of gas to which the unit is connected.. The serial plate also specifies the type of gas required for the unit.. Also, check that the electrical connections are in good order..

NOTE : The chain griddle is certified for installation on a combustible base with minimum clearance of 6”(152mm) back and 6”(152mm) sides from combustible walls..

Every unit is fitted with a readily accessible shut-offvalve at the main manifold.. Use a minimum of 3/4” NPT pipe to connect the incoming gas supply..

CAUTION : Check the pipe capacity tables given in the installation code.. When a long supply pipe run is necessary, you may have to install a supply line lager than 3/4”

Have a qualified gas technician check the gas supply to make sure it will deliver the BTUs of gas the unit requires to operate with no more than 1/2” water pressure

drop.. Also when making this check be certain that all equipment on the gas line is turned to the ON position..

If you are installing the unit using a new gas installation, make sure the supply lines have been cleaned and purged of piping compound, chips and other debris..

WARNING : Use soap solution if you have to check the gas lines for leaks..

Place and install the unit on the legs or caters provided, and make sure there is a minimum of 4” (102mm) air space below the unit for adequate air flow to the burners..

CAUTION: Check for obstructions or objects that could restrict the air flow to the burners..

Using a spirit level variously across the front, rear and sides of the unit, level it by adjusting the leveling legs..

Gas Supply

NOTE : For efficient operation, the griddle plate must be level..

Page

Part #GCGTRAINING06 (03/03/08))

INSTALLATION continued

Each thermostat controls one zone burner though a dual solenoid-pressureregulator valve complete with a pressure test spigot.. Check the manifold gas pressure on each combination valve to make sure it is the same as

that shown on the serial plate.. The gas pressure should be 3..5”WC for natural gas and 10..0” for propane gas..

For access to the pressure test spigots, turn the main power switch and all zone power switches to the OFF position and lower the front panel on its hinge.. This is a safety precaution.. The test spigots are at the rear of the rear of the combination regulator valves..

Connect your manometer to the first valve for test and turn the manual shut-offvalve to the ON position..

NOTE : The shut off valve is under the unit.. When it is ON and in the open position, the valve position is in line with the piping.. Also, see the electrical procedure below for notes on the status indictor lights and setting the thermostats..

Turn the main power switch and the zone power switches to the ON position..

Set all the thermostat dials to 350˚F.. When all the burners are operating, check and record the manometer reading, which should be the same manifold pressure as that specified on the serial plate (3..5”WC for natural gas and 10..0” for propane gas).. Adjust the regulator to obtain the pressure rate specified..

When satisfied with the reading obtained, turn the main power switch OFF.. Remove the manometer test tube and re-capthe test spigot..

Repeat this operation on each combination regulator valve to correctly set it.. Then turn each thermostat, zone and main power switch OFF..

Electrical Power, Lighting & Control

WARNING : Do not work on ungrounded equipment.. It is dangerous..

National and local electrical codes require that all devices of this type be electrically grounded.. Check to make sure the unit is grounded..

CAUTION : Make sure the electrical connections enclosed by the panels are in good order and undamaged before closing and securing the front panels..

NOTE : This griddle is equipped with a3-prongedplug cord set to fit any 120VAC3-prong,15amp-rated,grounded receptacle..

To check the unit lighting, turn the main power switch of the unit to the ON position.. The green light of the power switch and the green indictor of the gas pilot of each section of the griddle should illuminate..

CAUTION : If after two minutes the pilot ignition fails, turn the main power switch OFF.. Wait five minutes and switch the main power ON again..

When the green indicator for each zone is illuminated, turn the zone power switch for each zone ON.. The thermostats can now be set to the desired temperature..

The amber light burner indicator cycles with the operation of the thermostat..

Ventilation

For efficient operation this unit requires a minimum ventilation air supply of 50frm.. The ideal method of ventilation is a well-designedcanopy of hood that exceeds 6” (152mm) beyond all sides of the unit.. Ideally, the bottom of the hood should be set 6’6” (1981mm) from the floor..

Gas burners and pilot devices need a sufficient air supply to operate efficiently, so do not place large objects anywhere near them to restrict or in any way limit the air flow..

In most operations, the chain griddle will be used in conjunction with other kitchen equipment.. The need for the ingress of air to the kitchen area must be sufficient to compensate for the air the ventilation system abstracts.. Unless the air flow is sufficient a subnormal, and probable negative, atmospheric pressure will result, which will adversely affect the operation of the equipment and make work in the kitchen area unpleasant..

Start-Up

When the chain griddle is used for the first time, the griddle top requires seasoning.. To season a griddle surface, follow this procedure..

1.Wash the griddle surface with a hot, mild detergent or soap solution, then rinse and dry thoroughly..

2.Set the thermostat to 175˚F for 30 minutes, then apply a film of cooking oil to the cooking surface and wipe away the excess..

3.After (5) five minutes, wipe the griddle plate clean..

Part #GCGTRAINING06 (03/03/08)

Page

INSTALLATION continued

4.Re-setthe thermostat to 275°F and apply a second film of oil.. After (5) five minutes, wipe off the excess oil..

5.Reset the thermostat to the cooking temperature and apply a final film of oil.. After (3) minutes, wipe off the excess oil.. The griddle is now seasoned and ready for use..

NOTE : We recommend reseasoning the griddle before each day’s operations begin.. Franchise operators who follow explicit operating procedures should be made aware of this recommendation..

OPERATION & MAINTENANCE

During idle periods, reduce the thermostat settings to conserve energy.. A setting of 175°F to 200˚F is enough to keep the plate warm.. Reducing the temperature also reduces the load on the thermostat..

1.At then end of the operations, turn the power and zone switches OFF.. There is no need to change the thermostat settings when the unit is not in use..

2.Don’t overheat the griddle.. Excessive heat causes grease to carbonize and makes the surfaces hard to clean..

3.Empty the grease trays often to avoid spillovers..

4.For extended shutdown or major maintenance, turn the power and zone switches OFF, close the manual shut-offgas valve, and unplug the electrical power cord..

Cleaning

1.At the end of the cooking operations, wipe and clean the unit while it is still warm.. Use a spatula to remove food residue and burnt grease..

2.When the plate is cool, wash it with a mild detergent, dry it, and wipe it with a slightly oiled cloth..

3.For a more thorough cleaning, use Garland Ranges F69 fryer and griddle cleaner.. Polish the plate to a bright finish, then wash, rinse and thoroughly dry it..

4..Follow the procedure specified (see Start-Up)to reseason the cooking surface..

5..To clean the exterior surface of a chain griddle, clean the stainless steel with a hot detergent or soap solution.. Remove baked on grease by applying the cleanser in the direction of the polishing lines of the stainless steel surface..

CAUTION : Do not rub stainless steel in a circular motion.. This destroys the finished surface of the metal and detracts from its appearance..

If it is necessary to remove hard and burnt on deposits from high quality surfaces, use SCOTCH-BRITEor STAINLESS scouring pads by running with the grain of the finished steel.. Remove heat tint the same way, using if necessary anon-abrasivepowered cleanser with theSCOTCH-BRITEor

STAINLESS pad.. On no account use ordinary steel wool, it will damage the finished surface..

Page

Part #GCGTRAINING06 (03/03/08))

SERVICING

Many factors affect the serviceability of equipment.. In the chain griddle, there are more components to service than in older models.. The new griddle is a compact design.. Access to the temperature control circuitry and ignition units is easy.. Service techniques for the thermocouple will vary depending on the model type..

They unit is available with a 6” (152mm) leg which means that under the griddle plate there is only 6” (152mm) of working room.. To replace a thermocouple it is difficult to lift the griddle plate, firmly secured to the support frame.. To replace a thermocouple requires bottom access because the plate is securely fixed (see Figure 3)..

With this introduction to serviceability, and apart from the features that make the chain griddle superior to more

conventional units, many of the servicing tasks are standard; the adjustments likewise.. The procedures that follow are

a plain guide to servicing, beginning with adjustments to various components..

Have The Right Tools And Instruments

In addition to a service technician’s normal hand tools, for servicing this chain griddle we recommend:

1.A manometer or other suitable instrument for measuring gas pressure

2.A multimeter

3.A digital read-outtemperature meter

4 A micro-ammeter

CAUTION : In this chain griddle we use aJ-typethermocouple, which requires a meter with aJ-typeconnection for checking.. Most meters haveK-typeconnections..

Adjustments

Every griddle is inspected and tested before it leaves the factory.. Adjustments to the unit during installation and servicing are the responsibility of the field operator and are not considered to be defects in material or workmanship.. For this reason, adjustments are not covered under the equipment warranty..

Pilot Flame Adjustment

A pilot adjustment valve is in the line form each pilot combination valve and access to it is behind the lower front panel..

1.To remove the upper front and lower front panels, refer to the installation procedure given earlier..

2.To reduce the volume of gas feed to the pilot, turn the small screw in the pilot adjusting valve clockwise..

3.To increase the gas feed to the pilot, turn the same screw counter-clockwise..

NOTE : Adjust the gas feed to produce a 7/16” (11mm) long flame to make sure the flame envelopes the top of the flame sensor..

Burner Air

Make sure a burner is warm before adjusting the air shutters and follow this procedure..

1.First, loosen the screw along the side of the burner near the orifice..

2.A burner flame that gets too much air appears to lift above the burner as though separated from it.. This means the shutter needs throttling back to a more closed position..

3.A yellow tip on the flame is a sign that the shutter is not passing enough air to feed the flame.. In this case, it necessary to open the shutter..

4.When the shutter adjustment is complete, tighten the screw to lock the shutter setting in the adjusted position..

5.Re-closethe upper and lower front panels and replace the fasteners..

Removing the Griddle Plate

If it is necessary to remove the griddle top, follow this procedure:

1.Disconnect the power supply..

2.Remove the upper control panel..

3.Open the lower control panel..

4.Disconnect all thermocouple sensors and shield bayonet adapters.. (To reassemble, see the Thermocouple section..)

5.Remove the griddle top retaining bolts (both left and right)..

6.Remove the back flue..

7.The griddle top is now easily removed..

Part #GCGTRAINING06 (03/03/08)

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SERVICING continued

Thermostat

Make sure the thermostat knob is correctly aligned with the dial indicator.. To align the knob with the graduated dial correctly, follow this procedure..

1.Turn the knob and shaft fully counter-clockwise..Loosen the set screw in the knob and align the pointer with the first line of the scale at the lower left position..

NOTE : When the knob is fully rotated clockwise, the pointer should align with the last line of the scale..

2.Set the dial to 350˚F.. Wait at least three cycles before monitoring the temperature..

3.Use a surface temperature probe disc positioned on the center line with the thermostat knob and centered front to back on the griddle plate..

The thermostat will overshoot and undershoot as caused by the lag time in the thermal response of the heat source- to-plateandplate-to-sensor..The calibration temperature will be themid-pointbetween the minimum and maximum readings.. Other than the alignment of the knob pointer, there is no means to calibrate the thermostat.. It has been precisely calibrated by the manufacturer..

Thermocouple

If the temperature is incorrect check the thermocouple.. The thermocouple in this unit is a Type J, which requires the use of a J-typetemperature meter for checking.. For a complete understanding of the thermocouple used in the chain griddle see the GCR Service Bulletin#95-5entitled “Thermocouples”..

A thermocouple is an accurate temperature measuring device that consists of two dissimilar conductors joined together at their ends.. It works on a simple principle, which is that the thermoelectric voltage between the two junctions is proportional to the temperature difference between them.. This principle is applied to measure the temperature at one of the junctions when the other is held at a fixed known temperature.. The technology is not new, but its use in GCR griddles is recent..

The thermocouple probe is embedded in the griddle plate and accurately registers the surface temperature.. It is a reliable device, but can cause problems when it fails for any reason.. In addition to deterioration from aging, it can fail in two ways: one from an open-circuit(that is, a break in one of its wired); the other when itshort-circuits..

If a thermocouple open circuits, the thermostat will shut off and prevent the gas valve from opening, which means the burner will not function..

If a unit short circuits somewhere behind the junction, it creates a new junction and because the circuit cannot detect the existence of a short circuit fault, there is a dramatic increase in temperature.. The thermocouple detects changes in temperature, but because of the short circuit it may fail to register the set temperature at the thermostat.. This means the burner may not shut off.. At the other extreme, the short circuit may occur in a place not shielded from the flue gases, which means the burner may shut off prematurely.. These are the two conditions to look for in a shorted thermocouple..

Deterioration from aging and from welding dissimilar metals together to for a junction introduces a contaminant that causes mechanical stress.. Over time, five to ten years, metal fatigue from aging is certain.. As a result, the temperature curve will vary..

How To Replace A Thermocouple

A heat shield protects the thermocouple from the burner flames and flue gases.. Without the shield, the thermocouple would register flame heat to the thermostat instead of sensing the temperature of the griddle plate..

To replace a thermocouple (refer to Figure 3), following this procedure:

1.Open the front panel to get access to the terminal board..

2.To withdraw the thermocouple, first remove the heat shield.. It is held in place by two combination Philip and Robinson-heatsize number 10 sheet metal screws.. Remove the heat shield by sliding it down the wire..

3.A bayonet connector secures the thermocouple in place.. Reach inside the hole and push and twist the bayonet connector a quarter turn..

4.Remove the connection to the terminal board and feed these wires through the heat shield.. The thermocouple is now removed..

5.Connect the wires of the replacement thermocouple, but make sure the polarity is correct.. Connect the negative red wires to terminal 7 on the thermostat and the positive white wire to terminal 8.. (See schematic diagram)..

6.Thread the thermocouple through the heat shield and into the plate cavity..

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Part #GCGTRAINING06 (03/03/08))