Bakbar G592-B Installation Manual

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INSTALLATION AND OPERATION MANUAL

GAS CHARGRILL

G592
G593
G594
G596
G598

For use in GB, IE & DK

228593-24

MANUFACTURED BY

Moffat Limited

Rolleston 7675
New Zealand

INTERNATIONAL CONTACTS

AUSTRALIA

Moffat Pty Limited
Web: www.moffat.com.au
E.Mail: [e-mail]
Main Office: (tel) [phone]

(fax) [phone]

Service: (tel): 1800 622 216
Spares: (tel): 1800 337 963
Customer Service: (tel): 1800 335 315
(fax): 1800 350 281

CANADA

Serve Canada
Web: www.servecanada.com
E.Mail: [e-mail]
Sales: (tel): 800 551 8795 (Toll Free)
Service: (tel): 800 263 1455 (Toll Free)

NEW ZEALAND

Moffat Limited
Web: www.moffat.co.nz
E.Mail: [e-mail]
Main Office: (tel): 0800 663328

UNITED KINGDOM

Blue Seal
Web: www.blue-seal.co.uk
E.Mail: [e-mail]
Sales: (tel): [phone]

(fax): [phone]
Spares: (tel): [phone]
(fax): [phone]
Service: (tel): [phone]
(fax): [phone]

UNITED STATES

Moffat
Web: www.moffat.com
Sales: (tel): 800 551 8795 (Toll Free)

(tel): [phone]
(fax): [phone]
Service: (tel): 800 858 4477 (Toll Free)
(tel): [phone]
(fax): [phone]

REST OF WORLD

Moffat Limited
Web: www.moffat.co.nz
E.Mail: [e-mail]

The reproduction or copying of any part of this manual by any means whatsoever is strictly forbidden unless authorized previously in
writing by the manufacturer.

In line with policy to continually develop and im prove its products, Moffat Ltd. reserves the right to change the specifications and
design without prior notice.

© Copyright Moffat Ltd. December 2014.

Contents List

G592-B Gas Chargrill, 300mm wide - Bench Model.

G594-[2] Gas Chargrill, 450mm wide.
G594-[2] Gas Chargrill, 600mm wide.
G596-[2] Gas Chargrill, 900mm wide.
G598-[2] Gas Chargrill, 1200mm wide.

NOTE: [2]: LS - On Leg Stand.
B - Bench Models.

Introduction .............................................................................................. 2

Specification .............................................................................................. 3

Model Numbers Covered in this Specification
Gas Supply Requirements

Dimensions ................................................................................................ 5

Installation ................................................................................................ 8

Installation Requirements
Unpacking
Location
Clearances
Assembly
Fitting Leg Stand to Chargrill
Gas Connection
Commissioning

Operation ................................................................................................. 12

Operation Guide
Description of Controls
Lighting Pilot Burner
Lighting Main Burner
Griddle Plate Fitting
Chargrill Grate Reversal

Cleaning and Maintenance ...................................................................... 15

General
Daily Cleaning
Weekly Cleaning
Periodic Maintenance

Fault Finding ............................................................................................ 18

Gas Conversion and Specifications ......................................................... 19

Conversion Procedure
Gas Specifications

Replacement Parts List ........................................................................... 24

Introduction

We are confident that you will be delighted with your BLUE SEAL CHARGRILL, and it will become a most
valued appliance in your commercial kitchen.
To ensure you receive the utmost benefit from your new Blue Seal CHARGRILL, there are two important
things you can do.

Firstly:

Please read the instruction book carefully and follow the directions given. The time taken will be well
spent.

Secondly:

If you are unsure of any aspect of the installation, instructions or performance of your appliance,
contact your BLUE SEAL dealer promptly. In many cases a phone call could answer your questi on.

CE Only:

These instructions are only valid if the country code appears on appliance. If code does not appear on
appliance, refer to supplier of this appliance to obtain technical instructions for adapting appliance to
conditions for use in that country.

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 APPLIANCE.

INSTRUCTIONS
LOCATION. THIS INFORMATION SHALL BE OBTAINED BY CONSULTING THE LOCAL GAS SUPPLIER.

TO BE FOLLOWED IN THE EVENT THE USER SMELLS GAS ARE TO BE POSTED IN A PROMINENT

Warning

Warning

GREAT CARE MUST BE TAKEN BY THE OPERATOR TO USE THE EQUIPMENT SAFELY TO GUARD IT AGAINST RISK OF

FIRE.

 T
 I

 DO NOT



HE APPLIANCE MUST NOT BE LEFT ON UNATTENDED.

T IS RECOMMENDED THAT A REGULAR INSPECTION IS MADE BY A COMPETENT SERVICE PERSON TO

ENSURE CORRECT AND SAFE OPERATION OF YOUR APPLIANCE IS MAINTAINED.

STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPOURS OR LIQUIDS IN THE VICINITY OF
THIS OR ANY OTHER APPLIANCE.
DO NOT SPRAY AEROSOLS IN THE VICINITY OF THIS APPLIANCE WHILE IT IS IN OPERATION.



This appliance is for professional use and is only to be used by qualified
persons.



Only authorised service persons are to carry out installation, servicing or gas
conversion operations.



Components having adjustments protected (e.g. paint sealed) by the
manufacturer should not be adjusted by the user / operator.



DO NOT operate the appliance without the legs supplied fitted.

Caution

2

Model Numbers Covered in this Specification

G592-B Gas Chargrill, 300mm wide - Bench Model.

G593-[2] Gas Chargrill, 450mm wide.
G594-[2] Gas Chargrill, 600mm wide.
G596-[2] Gas Chargrill, 900mm wide.
G598-[2] Gas Chargrill, 1200mm wide.

NOTE: [2]: LS - On Leg Stand.
B - Bench Models.

Gas Supply Requirements

Specifications

- Australia

Input Rating (N.H.G.C.)
Supply Pressure
Burner Operating

Pressure
Gas Connection

- New Zealand

Input Rating (N.H.G.C.)
Supply Pressure
Burner Operating

Pressure
Gas Connection

- United Kingdom

Category: II
Flue Type: A

Natural Gas LP Gas (Propane)

G592 G593 G594 G596 G598 G592 G593 G594 G596 G598

33.0 MJ/hr 48.0 MJ/hr 66.0 MJ/hr 100.0 MJ/hr 133 MJ/hr 33.0 MJ/hr 48.0 MJ/hr 66.0 MJ/hr 100.0 MJ/hr 133 MJ/hr

1.13 - 3.40 kPa 2.75 - 4.50 kPa

1.0 kPa 0.95 kPa (*) 2.5 kPa 2.6 kPa (*)

1

/2” BSP Male

3

/

” BSP Male

4

1

/2” BSP Male

3

/4” BSP Male

Natural Gas LP Gas

G592 G593 G594 G596 G598 G592 G593 G594 G596 G598

33.0 MJ/hr 48.0 MJ/hr 66.0 MJ/hr 100.0 MJ/hr 133 MJ/hr 34.5 MJ/hr 50.4 MJ/hr 69.1 MJ/hr 103.6 MJ/hr 138.2MJ/hr

1.13 - 3.40 kPa 2.75 - 4.50 kPa

1.0 kPa 0.95 kPa (*) 2.5 kPa 2.6 kPa (*)

1

/2” BSP Male

2H3P

1.

3

/

” BSP Male

4

(20, 30 / 37).

1

/2” BSP Male

3

/4” BSP Male

Heat Input

(nett)

Gas Rate

(nett)

Supply Pressure
Burner Operating

Pressure
Gas Connection

Nominal 8.8 kW 13.0 kW 18.0 kW 27.0 kW 36.0 kW 8.8 kW 13.0 kW 18.0 kW 27.0 kW 36.0 kW
Reduced 3.5 kW 4.2 kW 6.0 kW 9.0 kW 18.0 kW 3.7 kW 4.3 kW 6.4 kW 9.6 kW 12.8 kW

Nominal 0.93 m3/hr 1.38 m3/hr 1.90 m3/hr 2.86 m3/hr
Reduced 0.37 m3/hr 0.40 m3/hr 0.63 m3/hr 0.95 m3/hr

G592 G593 G594 G596 G598 G592 G593 G594 G596 G598

10.6 mbar 10 mbar (*) 25 mbar 26 mbar (*)

1

/2” BSP

Male

Natural Gas (G20) Propane (G31)

3

/

hr
hr

0.68 kg/

3

/

0.29 kg/

1

/2” BSP

1.01 kg/hr 1.40 kg/hr 2.10 kg/hr 2.80 kg/hr

hr

0.33 kg/hr 0.50 kg/hr 0.75 kg/hr 0.99 kg/hr

hr

Male

¾” BSP Male

3.81 m

1.27 m

20 mbar 30 / 37 mbar

¾” BSP Male

(*) - Measure burner operating pressure at manifold test point with one burner for G592 and

G593 Models or two burners for other models, operating at full setting. Operating
pressure is ex-factory set and is not to be adjusted, apart from when converting between
gases, if required. (Refer to ‘Gas Conversion’ section for details).

3

Specifications

- All Other Markets

Input Rating (N.H.G.C.)
Supply Pressure
Burner Operating Pressure
Gas Connection

G592 G593 G594 G596 G598 G592 G593 G594 G596 G598

33.0 MJ/hr 48.0 MJ/hr 66.0 MJ/hr 100.0 MJ/hr 133 MJ/hr 33.0 MJ/hr 48.0 MJ/hr 66.0 MJ/hr 100.0 MJ/hr 133 MJ/hr

1.0 kPa 0.95 kPa (*) 0.63kPa (**)

1

/2” BSP Male

Natural Gas Town Gas

1.13 - 3.40 kPa 0.75 - 1.50kPa

3

/

” BSP Male

4

1

/2” BSP Male

3

/

” BSP Male

4

Input Rating (N.H.G.C.)
Supply Pressure
Burner Operating Pressure
Gas Connection

G592 G593 G594 G596 G598 G592 G593 G594 G596 G598

33.0 MJ/hr 48.0 MJ/hr 66.0 MJ/hr 100.0 MJ/hr 133 MJ/hr 33.0 MJ/hr 48.0 MJ/hr 66.0 MJ/hr 100.0 MJ/hr 133 MJ/hr

2.5 kPa 2.6 kPa (*) 2.5 kPa 2.6 kPa (*)

1

/2” BSP Male

LP Gas (Propane) Butane

2.75 - 4.50 kPa 2.75 - 4.50 kPa

3

/4” BSP Male

1

/2” BSP Male

3

/4” BSP Male

NOTE:

 (*) Measure burner operating pressure at manifold test point with one burner for G592

and G593 Models or two burners for other models, operating at full setting.

 NAT, LPG & Butane Only - Operating pressure is ex-factory set and is not to be

adjusted, unless when converting between gases, if required.

 (**) TOWN GAS Only - Adjust burner operating pressure using adjustable gas regulator

supplied.

 Refer to ‘Gas Conversion and Specifications' section in this manual for further details.

4

Dimensions

G592-B

G593-B

NOTE: The G592 is available in Bench Model (- B) Option Only.

G594-B

G596-B

G598-B

5

Dimensions

G593-LS

G594-LS

6

G596-LS

Specifications

G598-LS

= Rating Plate Location

R

for all options.

R

7

Installation

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 occurrence of

unacceptable concentrations of health harmful substances in the room, appliance is

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.

Installations must be carried out by qualified 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 to be
adjusted by an authorised service agent. They are not to be adjusted by the installation person.

Unpacking

installed in.

Australia / New Zealand: - AS5601.1 - Gas Installations.
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.

 Remove all packaging.
 Check equipment and parts for damage. Report any damage immediately to carrier and distributor.
 Remove protective plastic coating from side panels.
 Check the following parts have been supplied with chargrill:

1 x Gas Regulator.
1 x Gas Type Conversion Kit.

 Report any deficiencies to the distributor who supplied the chargrill.
 Check available gas supply is correct to as shown on the rating plate attached to the underside of

R/H side, front hob lower trim.

Location

1. This appliance must be installed in a suitably ventilated room to prevent dangerous build up of
combustion products.

2. Installation must allow for sufficient flow of fresh air for combustion air supply. Combustion air
requirements are:-

Combustion Air Requirements

Natural Gas (G20) 9 m3/hr 18 m3/hr 27 m3/hr 36 m3/hr
LPG/Propane (G31) 9 m3/hr 18 m3/hr 26 m3/hr 35 m3/hr

G592 G594 G596 G598

G593

14 m3/hr
13 m3/hr

3. Never directly connect a ventilation system to the appliance flue outlet.

4. Position chargrill in its approximate working position.

NOTE: Do not obstruct or block the appliance flue. Never directly connect a ventilation

system to the appliance flue outlet.

8

Installation

Clearances

NOTE: Only non-combustible materials can be used in close proximity to this appliance.

Combustible Surface Non Combustible Surface

Left / Right Hand Side 200mm 0mm
Rear 150mm 0mm

Assembly

Bench Models (G592 Models Only).

1. Check all feet are securely fitted.

Bench Models (G593 / G594 / G596 / G598 Models Only)

1. Check all feet are securely fitted.

2. Adjust feet to make Chargrill steady and level.

Leg Stand Models Only

 Leg Stand Models will require assembly. Refer to 'Fitting of Adjustable Feet / Rollers

to Leg Stand Units' information on the following page for assembly instructions.

 The rear leg housings can be fitted with:-

a. Adjustable feet to assist with levelling of appliance on uneven floors.
b. Rear rollers to enable appliance to be easily moved for positioning and cleaning purposes.

Optional Accessories (Refer to Replacement Parts List)

 Plinth Kit. For installation details, refer to instructions supplied with each kit.

9

Installation

Fitting Leg Stand to Chargrill

TO

PREVENT EQUIPMENT DAMAGE AND RISK OF INJURY, REMOVE ALL CHARGRILL CASTINGS, BURNERS AND

OTHER REMOVABLE ITEMS PRIOR TO FITTING THE LEG STAND.

Warning

1. Remove grates, griddle plates and radiants from
chargrill.

2. Lower Chargrill onto it’s rear face.

3. Attach four hob legs to leg mounting positions on
underside of chargrill. Secure each leg hand tight.

4. Align four round cut out holes on base tray with four
hob legs already fitted to chargrill (Ensure base tray

Chargrill

is orientated with sloping edge of base tray facing
front of appliance.

5. Slot base tray onto four hob legs and push fully
home.

Leg Mount

Points

6. Secure base tray to front chargrill legs by screwing
adjustable feet supplied, into base of front chargrill
legs. Secure each adjustable foot, hand tight.

7. Fit rear rollers to rear leg ring plates and secure
using locating bolts supplied, tighten bolts.

8. Lift chargrill back onto its legs.

Chargrill

Legs

Sloping Edge
of Base Tray

9. Refit all grates, griddle plates and radiants to
chargrill, ensuring that they are correctly fitted.

NOTE: This appliance is fitted with adjustable

feet / rear rollers to enable appliance to be
positioned securely and level. This should
be carried out on completion of gas
connection. Refer to ‘Gas Connection’

Rear Roller

Base Tray

section.

Gas Connection

Fig 2

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 an adequate
supply pressure and volume is available. The following checks should be made before installation:-

a. Gas Type the appliance has been supplied for, is shown on a coloured sticker located above the

gas entry point and on the rating plate. Check that these are correct for the gas supply, the
appliance is being installed for. Gas conversion procedure is detailed in ‘Gas Conversion and
Specification’ section in this manual.

b. Supply Pressure required for appliance is shown in ‘Specifications’ Section of this manual.

Check gas supply to ensure that adequate supply pressure exists.

c. Input Rate of this appliance is shown on Rating Plate and in ‘Specifications’ section of this

manual. Input rate should be checked against available supply line capacity. Particular note

should be taken if 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.

10

Installation

3. Fit gas regulator supplied, into gas supply line as close to appliance as possible.

For G592, regulator connection is ½" BSP female. Connection on unit is ½" BSP male.
For G593 / G594 / G596 / G598 regulator connections are ¾" BSP female. Connection on unit is

¾" BSP male.
(Refer to ‘Specifications’ section for gas supply location dimensions).

NOTE: Gas pressure regulator provided with this appliance is convertible between Natural Gas

and LPG as shown in ‘Gas Conversion Section’ in this manual.

Ensure regulator is converted to the correct gas type that the appliance will operate

on. Regulator outlet pressure is fixed ex-factory for gas type that regulator is
converted to 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 appliance into its final operating position and using a spirit level, adjust legs so that
unit is level and at the correct height.

6. Connect gas supply to 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.

Warning

DO NOT USE A NAKED FLAME TO CHECK FOR GAS LEAKAGES.

NOTE: Measure burner operating pressure at the

manifold test point with one burner for G592
and G593 Models or two burners for other
models, operating at full setting. Operating
pressure is ex-factory set and not to be
adjusted, apart from when converting
between gases, if required. (Refer to ‘Gas

Manifold

Test Point

Conversion’ section for details).

Commissioning

Fig 3

1. Before leaving the new installation;

a. Check the following functions in accordance with operating instructions specified in ‘Operation’

section of this manual.

 Light the Pilot Burner.
 Light the Main Burner.
 Check Low Fire Burner Operation.
 Check High Fire Burner Operation.

b. Ensure operator has been instructed in the areas of correct lighting, operation, and shutdown

procedure for this appliance.

2. This manual must be kept by the owner for future reference and a record of

Date of Installation

and

Serial Number of Unit

recorded and kept with this manual. (These

Date of Purchase

,

details can be found on the rating plate attached to underside of R/H side, front hob
lower trim.

NOTE: If it is not possible to get the appliance to operate correctly, contact the suppler of

this appliance.

11

Operation

Operation Guide



This appliance is for professional use and is only to be used by qualified
persons.



Only authorised service persons are to carry out installation, servicing or gas
conversion operations.



Components having adjustments protected (e.g. paint sealed) by the
manufacturer should not be adjusted by the user / operator.

Caution

Description of Controls

Gas Control Knobs

OFF Position

PILOT Burner

HIGH Flame

Fig 4

LOW Flame

Piezo Igniter (with
burner flame viewing
ports).

12

Lighting Pilot Burner

Operation

Warning

WHEN THE SOLID GRIDDLE PLATE IS USED, IT'S SURFACE TEMPERATURE CAN REACH OVER 350°C WHEN THE

APPLIANCE IS OPERATED AT FULL HEAT SETTING.

NOTE: All chargrill models incorporate a push button piezo ignition system for each individual

pilot burner.

1. Depress gas control knob and rotate anti-clockwise to the ‘PILOT’ position.

2. With gas control knob depressed, press piezo igniter until pilot burner ignites. (Each operation of
the piezo igniter button will generate a single spark). Pilot ignition can be viewed through the
openings in the plastic surround of the piezo igniter button.

3. Hold in the gas control knob for approximately 10-15 seconds, then release. Pilot burner should
remain alight. (If not repeat Items 2 and 3 above).

Lighting Main Burner

1. Turn gas controls anti-clockwise to first stop (‘FULL’ flame position) and allow the chargrill to heat up
to operating temperature.

2. ‘LOW’ flame can be selected by depressing the gas control knob and rotating fully anti-clockwise.

3. For intermediate heat, position the gas control knob between ‘HIGH’ and ‘LOW’ positions for the

desired heat setting.

4. During idle periods, main burners can be turned down to maintain a suitable plate temperature or

gas controls can be set to ‘PILOT’ position as required.

NOTE:

 Always set the gas control knob to ‘HIGH’ position when lighting main burners.
 If pilot burner goes out during normal operation, wait 5 minutes before attempting to

re-light the pilot burner.

IMPORTANT:

Should any abnormal operation like;

- ignition problems,

- abnormal burner flame,

- burner control problems,

The appliance requires IMMEDIATE service by a qualified service person and should not be
used until such service is carried out.

13

Operation

Griddle Plate Fitting.

The following options of griddle plate (Fig 4) can be
fitted to the chargrill:-

 (A) Griddle Plate 300mm or 450mm wide (cast).
 (B) Griddle Plate 300mm or 450mm (fabricated).

NOTE: If fitting a Griddle Plate to your

chargrill, remove the required cast

Radiants (Item 2) (See Fig 5) that sit
directly beneath the griddle plate, this
will give a more intense heat onto the
griddle plate.

To fit a Griddle Plate to your Chargrill:-

1. Remove the BBQ Grates (Item 1).

2. Remove the cast Radiants (Item 2) that will sit
directly beneath the griddle plate.

3. Fit Griddle Plate (Item A) or (Item B), as
required (Fig 4).

Chargrill Grate Reversal.

B

A

Fig 4

Fig 5

The grates can be fitted to the chargrill in either of
two ways:-

They can be fitted in the FLAT position (Fig 6).
This is ideal if you require the flame grill effect as
any fat / oil will fall directly onto the Radiants (2)
and will be burnt off to give a flame grilled flavour
to the food.

They can be reversed and fitted in the RAISED
position (Fig 7) which allows the rear of the grate
to sit slightly raised, any fat released from the
product being cooked will be channelled by the
grooves in the grate, directly into the fat collection
area at the front of the chargrill.

Griddle in Flat Position.

Griddle in Raised Position.

Fig 6

Fig 7

14

General

Cleaning and Maintenance

Always turn ‘Off’ the gas supply before cleaning.

This appliance is not water proof.

Do not use water jet spray to clean interior or exterior of this appliance.

Caution

Clean the chargrill regularly. A clean chargrill looks better, will last longer and will perform better.
Carbonised grease on the cooking surface or on the chargrill will hinder the transfer of heat from the
cooking surface to the food. This will result in a loss of cooking efficiency.

DO NOT use water on chargrill while this item is still hot as warping and cracking may
occur. Allow chargrill to cool down before cleaning.

NOTE:

 DO NOT use abrasive detergents, strong solvents or caustic detergents as they could

corrode or damage the chargrill.

 To prevent rust forming on the chargrill, ensure that any detergent or cleaning

material has been completely removed after each cleaning. Appliance should be
switched on briefly to ensure chargrill becomes dry. Spread a thin coat of oil or
grease over chargrill surface to form a protective greasy film.

To keep your chargrill clean and operating at peak efficiency, follow the procedures shown below:-

After Each Use

1. Clean the griddle plate with a scraper tool to remove any food debris.

2. Always ensure that scraper tool blades are changed regularly to ensure that scraper tool works

efficiently and prevents damage to griddle plate surface.

Daily Cleaning

If the Chargrill is fitted with a griddle plate, if using a scraper tool to clean the
griddle plate, always apply even pressure over whole surface of the scraper
tool, to prevent scoring of griddle plate surface.

NEVER bang the sharp edge of the scraper tool on the flat surface of the griddle
plate as this will damage the griddle plate and invalidate the warranty.

Caution

1. Crumb tray(s) should be checked and emptied frequently to prevent overflow and spillage. Remove

crumb tray(s) while still warm so that the grease is in a liquid state. Empty any grease from trays
and wash thoroughly in same manner as any cooking utensil.

2. Remove grates and radiants and thoroughly clean splash back, interior and exterior surfaces of the

chargrill with hot water, a detergent solution and a soft scrubbing brush.

3. Brush chargrill surface with a soft bristled brush. Any carbon deposits should be removed using a

scraper tool followed by wiping with a cloth to prevent accumulation of food deposits.

4. Dry the chargrill thoroughly with a dry cloth and polish with a soft dry cloth.

15

Cleaning and Maintenance

Weekly Cleaning

NOTE:

 If chargrill usage is very high, we recommend weekly cleaning is carried out more

frequently.

 Ensure protective gloves are worn during cleaning.
 DO NOT use harsh abrasive detergents, strong solvents or caustic detergents as they

will damage chargrill and burners.

 DO NOT use water on griddle plates while they are still hot as warping may occur.

Allow these items to cool and then remove for cleaning.

Grates (Cast Iron)

a. Clean grates thoroughly with a wire brush or a flexible spatula.
b. A scraper tool can be used to remove stubborn carbon and

deposits.

c. Clean with hot water, a recommended detergent solution and a

scrubbing brush. Dry all components thoroughly with a dry
cloth.

d. Switched the chargrill ‘On’ briefly to ensure grates become dry.

Spread a thin film of cooking oil over grates to form a
protective film.

Radiants (Cast Iron)

a. Clean radiants thoroughly with a wire brush or a flexible

spatula.

b. A scraper tool can be used to remove stubborn carbon and

deposits.

c. Clean with hot water, a mild detergent solution and a scrubbing

brush. Dry all radiants thoroughly with a dry cloth.

Griddle Plate (Optional Extra)

Grates

Radiants

Main Burners

Fig 8

If the Chargrill is fitted with a griddle plate, if using a scraper tool to clean the
griddle plate, always apply even pressure over whole surface of the scraper
tool, to prevent scoring of griddle plate surface.

NEVER bang the sharp edge of the scraper tool on the flat surface of the griddle
plate as this will damage the griddle plate and invalidate the warranty.

Caution

a. Remove and clean grease collection drawer frequently to prevent over spills.
b. Clean griddle surface thoroughly with a scraper tool or wire brush. If necessary use a griddle

stone or a scotch bright pad on griddle surface to remove stubborn or accumulated carbon

deposits.
c. Occasionally bleach griddle plate with vinegar when plate is cold.
d. Clean with hot water, a mild detergent solution and a scrubbing brush. Dry all components

thoroughly with a dry cloth.

NOTE: To prevent rust forming on the griddle plate, ensure all detergent and cleaning

material has been entirely removed after each cleaning process. Switch the chargrill
‘On’ briefly to ensure the griddle plate is dry. Spread oil or grease over griddle surface
to form a thin protective greasy film.

16

Main Burners

a. Clean main burners with hot water, a recommended detergent

solution and a scrubbing brush. Ensure any excess water is

removed from inside burners. Dry all burners thoroughly with

a dry cloth.
b. Ensure burners are fitted correctly over main injectors and are

located properly into recesses in chargrill.

Stainless Steel Surfaces

a. Clean exterior surfaces of chargrill with hot water, a mild

detergent solution and a soft scrubbing brush. Note that gas

control knobs are a push fit onto gas control valve spindles and

can be removed to clean 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 appliance is cold and rub in the direction of the

grain.

c. Dry grease tray thoroughly with a dry cloth.

d. Dry all components thoroughly with a dry cloth and polish with

a soft dry cloth.

Periodic Maintenance

Cleaning and Maintenance

Fig 9

Fig 10

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
checked and adjusted periodically by a competent serviceman. 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.

Gas Control Valve Re-Greasing

Gas control valve should be dismantled and greased every 6 months to ensure correct operation.
To carry out this operation;-

a. Remove the gas control knobs from the gas tap spindles.
b. Remove the drip tray from the appliance.
c. Remove two screws on underside of control panel, securing

control panel to the hob.
d. Remove control panel from front of appliance.
e. Remove 2 screws holding shaft plate to gas control body and

remove control shaft and plate. (See Fig 11). Note orientation

of shaft for correct re-assembly.
f. Using needle nose pliers or similar, pull out gas control

spindle, again noting its orientation.
g. Apply a suitable high temperature gas cock grease or

Two Screws

Fig 11

lubricant such as ROCOL - A.S.P (Anti scuffing paste)/

Dry Moly Paste to outside of spindle. (See Fig 12).
h. Replace spindle and re-assemble gas control in reverse

order.
i. Refit control panel to appliance and secure with 2

screws.
j. Refit knobs to gas control valve spindles.

Spindle

Fig 12

17

Fault Finding

This section provides an easy reference guide to the more common problems that may occur during
operation of your equipment. The fault finding guide in this section is intended to help you correct, or at
least accurately diagnose problems with your equipment.

Although this section covers the most common problems reported, you may encounter a problem not
covered in this section. In such instances, please contact your local authorised service agent who will
make every effort to help you identify and resolve the problem. Please note that the service agent will
require the following information:-

 Model Trade Name and Serial Number of the Appliance. (both can be found on the

Rating Plate located on the appliance.

Fault Possible Cause Remedy

Pilot won’t light. No gas supply.

Blocked pilot injector.

Pilot goes out when gas control
knob released.

Main burner will not light. Incorrect supply pressure.

NOTE: Components having adjustments protected (e.g. paint sealed) by the manufacturer,

are only to be adjusted by an authorised service agent. They are not to be adjusted
by an unauthorised service person.

Releasing knob before the
thermocouple has heated.

Pilot flame too small.

- Gas pressure too low.

- Partially blocked pilot injector.
Thermocouple faulty.

Faulty gas control.

Ensure gas isolation valve is
turned ‘On’, and bottles are not
empty.

Call service provider.
Hold knob in for at least 20

seconds following ignition of
pilot.

Call service provider.
Call service provider.
Call service provider.
Call service provider.
Call service provider.

18

Conversion Procedure

Gas Conversion and Specifications

Caution

Ensure Appliance is isolated from gas supply before commencing servicing.

NOTE:

 Gas conversions should only be carried out by qualified persons. All connections must

be checked for leaks before re-commissioning the appliance.

 Adjustment of components that have adjustments / settings sealed (e.g. paint

sealed) can only be adjusted in accordance with the following instructions and shall
be re-sealed before re-commissioning this appliance.

 For relevant gas specifications refer to ‘Gas Specifications Tables’ at rear of this

section.

Main Burners

1. Remove the following:-

 Gas control knobs.
 Control Panel.

 Chargrill castings / griddle plates and inner radiants.

 G592 Only - Remove left / right and end inner heat shield

Main Burner

panels.

 Main burners.

2. Remove main burner injectors and replace with correct size

Aeration Shutter

injectors as shown in ‘Gas Specifications Tables’ at rear of this
section.

3. Check / adjust main burner aeration shutter as shown in ‘Gas
Specifications Tables’ at the rear of this section.

4. Refit the following:-

Adjusting Screw

Aeration Gap

 Main burners.

 Inner radiants, chargrill castings / griddle plates.

Pilot Burners

G593/4/6/8 Pilots

Retaining Plate

1. Disconnect the following:-

Shell

Bracket

 Gas supply tube to pilot burner.

2. Remove pilot injectors and replace with correct size pilot injectors
as shown in ‘Gas Specifications Tables’ at rear of this section.

3. Reconnect the following:-

 Gas supply tube to pilot burner.

 G592 Only - Refit left / right and end inner heat shield

Piezo Igniter

panels, burner supports.

 Inner radiants, chargrill castings / griddle plates.

Low Fire Adjustment (All Models)

Pilot

Bracket

Clamp

1. Light main burners and check flame size on ‘Low’ setting.

 Adjust low fire adjustment screw on burner gas

Securing Screws

control valves to obtain desired flame size.

NOTE: ‘Low Fire Adjustment Screw’ should be sealed with

coloured paint on completion of low fire adjustment.

2. Refit control panel.

3. Refit gas control knobs to gas control valves.

19

Piezo HT Lead

Electrode

Pilot Bracke t

Low Fire Screw

Gas Supply Tube

G592 Pilots Only

Thermocouple

Pilot Burner

Gas

Connection

Gas Conversion and Specifications

Gas Regulators

- NAT Gas / LPG / Butane Only.

NOTE: Gas regulator supplied is

convertible between Natural
Gas and LP Gas, but it’s outlet
pressure is fixed ex-factory and
is NOT to be adjusted.

- Town Gas Only.

1) Remove slotted cap from regulator.

2) Turn ‘On’ gas supply and appliance.

3) Adjust pressure adjusting screw to achieve correct burner

operating pressure.

NOTE: Measure burner operating pressure at manifold test

point and with two burners operating at ‘High
Flame’ setting. (With exception of G592 and G593
models which have one burner only).

4) Verify operating pressure remains correct (Re-adjust regulator if required).

5) Screw cap nut back onto regulator.

Gas Type Labels

NOTE, Pin rotated
for Natural Gas

NOTE, Pin rotated
for LPG

Cap Nut

Pressure Adjusting

Screw

On completion of the gas conversion, replace gas type labels located at:-

- The rear of the unit, above the gas connection.

- Beside the rating plate.

Commissioning

Before leaving the converted installation;

1) Check all gas connections for leakages using soapy water or other gas detecting equipment.

2) Check the following functions in accordance with the operating instructions specified in the ‘Operation’

Warning

DO NOT USE A NAKED FLAME TO CHECK FOR GAS LEAKAGES.

section of this manual.

 Light the Pilot Burners.
 Light the Main Burners.
 Check the Low Fire burner operation.
 Check the High Fire burner operation.
 Ensure that all the controls operate correctly.
 Ensure that the operating pressure remains correct.

NOTE: If it is not possible to get the unit to operate correctly, shut ‘Off’ the gas supply and

contact the supplier of this unit.

20

Gas Specifications

- Australia

Gas Conversion and Specifications

Main Burner Injectors
Pilot Burner Injectors

Low Fire Adjustment

Burner Operating Pressure
Main Burner Aeration Shutter

G592 G593

2.70mm 3.50mm 2.70mm 1.65mm 1.90mm 1.65mm

0.35 0.45 0.25 0.30

11/4 turns out

(ccw)

1.0 kPa (*) 0.95 kPa (*) 2.5 kPa (*) 2.6 kPa (*)

Natural Gas LP Gas (Propane)

G594
G596
G598

17/8 turns out

(ccw)

Fully Open Fully Open

11/4 turns out

(ccw)

G592 G593

½ turn out

(ccw)

11/4 turns
out (ccw)

½ turn out

G594
G596
G598

(ccw)

Gas Regulator Cap Screw

- New Zealand

Main Burner Injectors
Pilot Burner Injectors

Low Fire Adjustment

Burner Operating Pressure
Main Burner Aeration Shutter

G592 G593

2.70mm 3.50mm 2.70mm 1.65mm 1.90mm 1.65mm

0.35 0.45 0.25 0.30

11/4 turns out

(ccw)

1.0 kPa (*) 0.95 kPa (*) 2.5 kPa (*) 2.6 kPa (*)

Natural Gas LP Gas

G594
G596
G598

17/8 turns out

(ccw)

Fully Open Fully Open

11/4 turns out

(ccw)

G592 G593

½ turn out

(ccw)

½ turn out

(ccw)

G594
G596
G598

½ turn out

(ccw)

Gas Regulator Cap Screw

NOTE:
* - Measure burner operating pressure at manifold test point with one burner for G592 and

G593 Models or two burners for other models, operating at full setting. Operating
pressure is ex-factory set and is not to be adjusted, apart from when converting between
gases, if required. (Refer to ‘Gas Conversion’ section for details).

21

Gas Conversion and Specifications

- United Kingdom

Category: II
Flue Type: A

Main Burner Injectors
Pilot Burner Injectors

Low Fire Adjustment
Burner Operating Pressure

Main Burner Aeration Shutter

(20, 30 / 37).

2H3P

1.

Natural Gas (G20) Propane (G31)

G594

G592 G593

2.70mm 3.50mm 2.70mm 1.65mm 1.90mm 1.65mm

0.35 0.45 0.25 0.30

11/4 turns out

(ccw)

1.0 kPa (*) 0.95 kPa (*) 2.5 kPa (*) 2.6 kPa (*)

17/8 turns out

(ccw)

Fully Open Fully Open

G596
G598

11/4 turns out

(ccw)

G592 G593

½ turn out

(ccw)

11/4 turns out

(ccw)

G594
G596
G598

½ turn out

(ccw)

Gas Regulator Cap Screw

NOTE:
* - Measure burner operating pressure at manifold test point with one burner for G592 and

G593 Models or two burners for other models, operating at full setting. Operating
pressure is ex-factory set and is not to be adjusted, apart from when converting between
gases, if required. (Refer to ‘Gas Conversion’ section for details).

22

Gas Conversion and Specifications

- All Other Markets

Main Burner Injectors
Pilot Burner Injectors

Low Fire Adjustment

Burner Operating Pressure
Main Burner Aeration Shutter

Natural Gas Town Gas (**)

G594

G592 G593

2.70mm 3.50mm 2.70mm Ø 4.50mm T.B.A. Ø 4.50mm

0.35 0.45 0.60m 0.75mm

11/4 turns out

(ccw)

1.0 kPa (*) 0.95 kPa (*) 0.63 kPa (*)

17/8 turns out

(ccw)

Fully Open Fully Open

G596
G598

11/4 turns out

(ccw)

Gas Regulator Cap Screw

Main Burner Injectors
Pilot Burner Injectors

Low Fire Adjustment
Burner Operating Pressure

Main Burner Aeration Shutter

LP Gas (Propane) Butane

G594

G592 G593

1.65mm 1.90mm 1.65mm 1.55mm 1.80mm 1.55mm

0.25 0.30 0.25 0.30

½ turn out

(ccw)

2.5 kPa (*) 2.6 kPa (*) 2.5 kPa (*)

11/4 turns out

(ccw)

Fully Open Fully Open

G596
G598

½ turn out

(ccw)

G592 G593

½ turn out

G594

G592 G593

2 turns out (ccw)

Adjustable Regulator (Adjust to Burner

Operating Pressure specified).

(ccw)

½ turn out

(ccw)

2.6 kPa (*)

G596
G598

G594
G596
G598

½ turn out

(ccw)

Gas Regulator Cap Screw

NOTE:

 * Measure burner operating pressure at manifold test point with one burner for G592

and G593 Models or two burners for other models, operating at full setting.

 NAT, LPG & Butane Only - Operating pressure is ex-factory set and is not to be

adjusted, unless when converting between gases, if required.

 (**) TOWN GAS Only - Adjust burner operating pressure using adjustable gas regulator

supplied.

 Refer to ‘Gas Conversion and Specifications' section in this manual for further details.

23

Replacement Parts List

Replacement Parts List

IMPORTANT:

Only genuine authorized replacement parts should be used for servicing and repair of this
appliance. Instructions supplied with parts should be followed when replacing
components.

For further information and servicing instructions, contact your nearest authorized
service branch (contact details are as shown on reverse of front cover of this manual).

When ordering replacement parts, please quote the part number and description as listed below. If the
part required is not listed below, request part by description and quote the model and serial number which
is shown on rating plate.

CHARGRILL - PARTS LIST

Part No. Description G592 G593 G594 G596 G598

227286 BURNER.
237107 BURNER.
227286 BURNER.
229719 PILOT ASSY 3 WAY.

019464K PILOT BURNER KIT - BBQ.

227508 PIEZO - SIT.
228010 PIEZO HOUSING.
019428 THERMOCOUPLE 320mm, M9 x 1.
019218 THERMOCOUPLE 450mm.
227404 GAS VALVE 21S.
231540 SPARK ELECTRODE.
019624 ELECTRODE.
229731 HT LEAD 250mm RING TERMINAL..
228047 HT LEAD 250mm.

227985 PILOT INJECTOR - 0.35mm - NAT GAS.
018972 PILOT INJECTOR - 0.45mm - NAT GAS.
227984 PILOT INJECTOR - 0.25mm - LPG / PROPANE / BUTANE.
018971 PILOT INJECTOR - 0.30mm - LPG / PROPANE / BUTANE.
232309 PILOT INJECTOR - 0.60mm - TOWNS.

026393 PILOT INJECTOR - 0.75mm - TOWNS.

037270 MAIN INJECTOR - 2.70mm - NAT GAS.
037350 MAIN INJECTOR - 3.50mm - NAT GAS.
037165 MAIN INJECTOR - 1.65mm - LPG (PROPANE).
037190 MAIN INJECTOR - 1.90mm - LPG (PROPANE).
037155 MAIN INJECTOR - 1.55mm - BUTANE.
037180 MAIN INJECTOR - 1.80mm - BUTANE.
037450 MAIN INJECTOR - 4.50mm - TOWNS.

227378 KNOB B-SEAL 8mm GAS PF
229531 DRIP TRAY.
236655 CRUMB TRAY.
228488 CRUMB TRAY.
228487 CRUMB TRAY.
228489 CRUMB TRAY.

013908 SPACER FOOT ASSY.
227851 LEG 150mm (EXTEND. STUD).
227850 LEG 150mm (FLUSH STUD).
229674 REAR ROLLER ASSY.
227854 LEG EXTENSION 430mm.
227855 LEG 80mm (FOR BENCH MOUNT).

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T.B.A

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24

Gas Regulators

Replacement Parts List

Gas Type

Nat. Gas
LPG (Propane)
Butane

Gas Conversion Kits

Model

G592 231947 231946 231948 231949
G593 237004 237003 237005 237006
G594 231951 231950 231952 231953

Model

Gas Regulators

Part No. Description

G592 228533 ½” BSP F/F Convertible.
G593
G594

228531 ¾” BSP F/F Convertible.

G596
G598

Gas Type to Convert to

Nat. Gas LPG (Propane) Butane Town Gas

G596 231955 231954 231956 231957
G598 231959 231958 231960 231961

Optional Accessories

Casting Scraper Tool. 228787
Smooth Plate Scraper Blades (Pack of 5 blades). 228567
Chargrill Scraper Assembly. 228787
Dr o p - On G r i d d l e P l a te - 3 0 0 m m ( C as t , n o s i d e s ) - ( r e f e r Op e r a t i o n S e c ti o n ) . 227002
Dr o p - On G r i d d l e P l a te - 4 5 0 m m ( C as t , n o s i d e s ) - ( r e f e r Op e r a t i o n S e c ti o n ) . 227003
Dr o p - O n G rid d l e P l a t e - 3 0 0 m m ( S t eel , w i t h s i d es) - ( r e f e r Op e r a t i o n Sec t i o n ) . 230707
Dr o p - O n G rid d l e P l a t e - 4 5 0 m m ( S t eel , w i t h s i d es) - ( r e f e r Op e r a t i o n Sec t i o n ) . 230710
BBQ Grate Casting Straight 233965
450mm Plinth Kit 234792
600mm Plinth Kit. 228795
900mm Plinth Kit. 228799
1200mm Plinth Kit. 228803

Description

Part No

25