Blodgett G-SB Operation Manual
G-SB Series
GAS BOILER BASE STEAMER
INSTALLATION - OPERATION - MAINTENANCE
BLODGETT OVEN COMPANY
www.blodgett.com
44 Lakeside Avenue, Burlington, Vermont 05401 USA
Manufacture Service Questions: 866-518-3977
PART NUMBER 170220 REV A (04/11)
THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE. READ, UNDERSTAND
AND FOLLOW THE INSTRUCTIONS AND WARNINGS CONTAINED IN THIS MANUAL.
FOR YOUR SAFETY
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND 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.
NOTIFY CARRIER OF DAMAGE AT ONCE
IT IS THE RESPONSIBILITY OF THE CONSIGNEE TO INSPECT THE CONTAINER UPON
RECEIPT OF SAME AND TO DETERMINE THE POSSIBILITY OF ANY DAMAGE, INCLUDING
CONCEALED DAMAGE. WE SUGGEST THAT IF YOU ARE SUSPICIOUS OF DAMAGE TO
MAKE A NOTATION ON THE DELIVERY RECEIPT. IT WILL BE THE RESPONSIBILITY OF THE
CONSIGNEE TO FILE A CLAIM WITH THE CARRIER. WE RECOMMEND THAT YOU DO SO
AT ONCE.
IMPORTANT - READ FIRST - IMPORTANT
WARNING: THE UNIT MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH ELECTRICITY AND
PLUMBING. IMPROPER INSTALLATION CAN CAUSE INJURY TO PERSONNEL AND/OR DAMAGE TO
THE EQUIPMENT. INSTALLATION MUST COMPLY WITH APPLICABLE CODES.
NOTICE: DO NOT INSTALL THE UNIT IN ANY WAY WHICH WILL BLOCK THE RIGHT SIDE VENTS , OR WITHIN
12 INCHES OF A HEAT SOURCE SUCH AS A BRAISING PAN , DEEP FRYER , CHAR BROILER OR
CONVECTION OVEN .
NOTICE: LEVEL THE UNIT FRONT TO BACK , OR PITCH IT SLIGHTLY TO THE REAR , TO AVOID DRAINAGE
PROBLEMS .
WARNING: TO AVOID DAMAGE OR INJURY, FOLLOW THE WIRING DIAGRAM EXACTLY WHEN CONNECTING A
UNIT. AN ELECTRICAL GROUND IS REQUIRED.
CAUTION: DRAIN MUST BE RATED FOR BOILING WATER. DO NOT USE PLASTIC PIPE.
WARNING: DO NOT CONNECT THE DRAIN DIRECTLY TO A BUILDING DRAIN. DAMAGE TO THE EQUIPMENT MAY
RESULT.
WARNING: BLOCKING THE DRAIN MAY BE HAZARDOUS.
IMPORTANT: IMPROPER DRAIN CONNECTION WILL VOID WARRANTY .
WARNING: WHEN YOU OPEN A COMPARTMENT DOOR, STAY AWAY FROM STEAM COMING OUT OF THE UNIT.
CONTACT WITH STEAM CAN CAUSE BURNS.
WARNING: BEFORE CLEANING THE OUTSIDE OF THE STEAMER, DISCONNECT ELECTRIC POWER . KEEP
WATER AND CLEANING SOLUTIONS OUT OF CONTROLS AND ELECTRICAL COMPONENTS. NEVER
HOSE OR STEAM CLEAN ANY PART OF THE UNIT. SERIOUS INJURY COULD RESULT.
WARNING: LET COOKING CHAMBERS COOL BEFORE CLEANING. HOT SURFACES CAN CAUSE BURNS.
WARNING: CAREFULLY READ THE WARNINGS AND FOLLOW THE DIRECTIONS ON THE LABEL OF EACH
CLEANING AGENT USED. DIRECT CONTACT WITH SOME AGENTS CAN CAUSE INJURY.
WARNING: DO NOT MIX DE-LIMING AGENTS (ACID) AND DE-GREASERS (ALKALI) IN THE STEAM GENERATOR
OR ON THE COOKING CHAMBER WALLS. HARMFUL GASSES MAY RESULT.
WARNING: DO NOT PUT HANDS OR TOOLS INTO THE COOKING CHAMBER, UNTIL THE FAN HAS STOPPED
TURNING. THE ROTATING FAN CAN CAUSE INJURIES.
WARNING: DO NOT OPERATE THE UNIT UNLESS THE REMOVABLE RIGHT SIDE PANELS HAVE BEEN RETURNED
TO THEIR PROPER LOCATIONS. DAMAGE TO THE UNIT COULD OCCUR.
CAUTION: DO NOT LOCATE THE BOILER CABINET DIRECTLY OVER A FLOOR DRAIN OR FLOOR SINK. HUMIDITY
OR WATER FROM A DRAIN WILL DAMAGE ELECTRICAL PARTS OF A UNIT.
NOTICE: DO NOT USE CLEANING OR DE -LIMING AGENTS THAT CONTAIN SULFAMIC ACID OR ANY
CHLORIDE, INCLUDING HYDROCHLORIC ACID . IF THE CHLORIDE CONTENT OF ANY PRODUCT IS
UNCLEAR, CONSULT THE MANUFACTURER . DO NOT USE CLEANING OR DE -LIMING AGENTS THAT
CONTAIN MORE THAN 30% PHOSPHORIC ACID.
WARNING: HIGH VOLTAGE EXISTS INSIDE CONTROL COMPARTMENTS. DISCONNECT POWER SOURCE
BEFORE SERVICING. FAILURE TO DO SO CAN RESULT IN SERIOUS INJURY OR DEATH.
OM-G-SB 1
IMPORTANT - READ FIRST - IMPORTANT
WARNING: DO NOT EXPOSE SKIN TO ESCAPING STEAM. SEVERE BURNS CAN RESULT.
CAUTION: MAKING ANY ELECTRICAL OR MECHANICAL CHANGE IN THE UNIT WITHOUT PRIOR WRITTEN
APPROVAL FROM ENGINEERING WILL VOID ALL WARRANTIES.
WARNING: ALL POTENTIAL USERS OF THE EQUIPMENT SHOULD BE TRAINED IN SAFE AND CORRECT
OPERATING PROCEDURES.
WARNING: DO NOT OPERATE THE UNIT UNLESS ALL REMOVABLE PANELS (RIGHT, LEFT, FRONT AND REAR)
HAVE BEEN PROPERLY INSTALLED.
NOTICE: USE NO DE -GREASER THAT CONTAINS POTASSIUM HYDROXIDE OR SODIUM HYDROXIDE OR IS
ALKALINE .
WARNING: USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY THE MANUFACTURER OR
THEIR AUTHORIZED SERVICE AGENTS VOIDS ALL WARRANTIES AND CAN CAUSE BODILY INJURY
TO THE OPERATOR AND DAMAGE THE EQUIPMENT. SERVICE PERFORMED BY OTHER THAN
FACTORY AUTHORIZED PERSONNEL WILL VOID ALL WARRANTIES.
DANGER: HIGH VOLTAGE EXISTS IN CONTROL COMPARTMENTS. DISCONNECT FROM BRANCH CIRCUIT
BEFORE SERVICING. FAILURE TO DO SO CAN RESULT IN SERIOUS INJURY OR DEATH.
2 OM-G-SB
Table of Contents
Important Operator Warnings ..................................................... page 1-2
References..................................................................................... page 3
Equipment Description.................................................................. page 4
Water Quality and Treatment ......................................................... page 5
Installation .................................................................................. page 6-8
Initial Start-Up........................................................................... page 9-10
Operation ............................................................................... page 11-13
Sequence of Operation ................................................................ page 14
Cleaning.................................................................................. page 15-17
Maintenance........................................................................... page 18-19
Troubleshooting...................................................................... page 20-21
Electrical Schematic ............................................................... page 31-32
Service Log ................................................................................. page 33
References
UNDERWRITERS LABORATORIES, INC.
333 Pngsten Road
Northbrook, Illinois 60062
KLENZADE SALES CENTER
ECOLAB, Inc.
370 Wabasha
St. Paul, Minnesota 55102
800 328-3663 or 612 293-2233
NATIONAL FIRE PROTECTION ASSOCIATION
60 Battery March Park
Quincy, Massachusetts 02269
NFPA/70 The National Electrical Code
NFPA/54 Installation of Gas Appliances & Piping
NFPA/96 Ventilating Hoods
NSF INTERNATIONAL
789 North Dixboro Road
P.O. Box 130140
Ann Arbor, Michigan 48113-0140
AMERICAN NATIONAL STANDARDS INSTITUTE
1403 Broadway, New York, New York 10018
Z21.30 Installation of Gas Appliances & Piping
Z223.1 (latest edition) National Fuel Gas Code
OM-G-SB 3
Equipment Description
WARNING
THE UNIT MUST BE INSTALLED BY
PERSONNEL WHO ARE QUALIFIED TO WORK
WITH ELECTRICITY AND/OR GAS, AND
PLUMBING. IMPROPER INSTALLATION CAN
CAUSE INJURY TO PERSONNEL AND/OR
DAMAGE TO THE EQUIPMENT. THE UNIT
MUST BE INSTALLED IN ACCORDANCE WITH
ALL APPLICABLE CODES.
The G-SB Steamer is designed to bring you years of service. It has two stainless steel
cavities (cooking chambers) and a control compartment, which houses the electrical
components and steam valves. In each cavity, a powerful blower circulates the steam
for increased heating efficiency. Each cavity, depending on model, will hold either
three or five steam table pans (12” x 20” x 2-1/2”).
A 16 gauge stainless steel case encloses the cavities and the control compartment
that house electrical components. The door hinges are reversible (the doors may be
hung to open from the left or right).
Operator Controls are located on the front panel.
The steamer cavities are mounted on a cabinet base containing a gas-fired steam
boiler that generates low pressure steam. This model uses a spark ignition system.
The boiler is small enough to fit in a 24-1/8” wide by 34-3/16” deep by 29-3/16” tall
(maximum) cabinet. The boiler is constructed of 1/4” thick steel, which is certified by
the American Society of Mechanical Engineers (ASME) for pressure vessels. All welds
are hydrostatically tested. The boiler is also equipped with required instruments,
fittings, and controls per CSD-1 (Controls and Safety Devices for automatically fired
boilers). Heat transfer fins inside the combustion chamber add to the unit’s high
efficiency. The unit is rated as 60% efficient or better, with a firing rate of 200,000 BTU
per hour using natural or propane gas. Energy output is 120,000 BTU per hour, with an
effective boiler horsepower of 3.7.
G-SB steamers have two steam
compartments with individual controls
mounted on a gas-fired boiler base..
The drain system includes a spray condenser, which suppresses any steam escaping
from the chamber and cools condensate water going into the drain.
4 OM-G-SB
Water Quality & Treatment
REDUCE SCALE PROBLEMS BY USING
AND MAINTAINING A WATER SOFTENER
FOR YOUR STEAMER!
It is essential that the boiler be supplied with water that will not form scale at an
unacceptable rate. The boiler was engineered to minimize scale, but its formation
depends on water hardness and how much the unit is used.
In some areas of the United States the water is low enough in mineral content to avoid
scale build-up. However, most water supplies carry heavy loads of minerals. This
will form scale on the boiler, reduce its steam output, and possibly cause premature
component failure.
Your water utility or local water quality dealer can tell you about the minerals in your
water. The water going to the steam generator should have:
1. Between 1 and 30 ppm total dissolved solids (TDS)
2. A pH (acidity rating) of 7.0 - 8.0
3. Total alkalinity less than 120 ppm
4. Silica less than 13 ppm
5. Chlorides less than 30 ppm
6. Sulfates less than 40 ppm
7. Chlorine less than 10 ppm.
Please follow these simple precautions:
1. Do not rely on unproven water treatment equipment which is sold for scale
prevention or scale removal. They frequently don’t work. The best way to prevent
scale is to supply the purest possible water.
2. If your water contains scale-forming minerals, as most water does, use a wellmaintained water treatment system. Whether an exchangeable softener cartridge
or a regenerating system is chosen, a regular exchange system is essential.
3. Installing a water meter on supply line to the steamer will provide an accurate
gauge of water use, and will help determine when to exchange cartridges or
regenerate the softener. Using treated water will provide longer generator life,
higher steam capacity, and reduce maintenance requirements.
4. If you notice a slowdown in steam production, check the boiler for scale build-up.
Heavy scale reduces the unit’s ability to boil water, and can even cause heating
elements in the steam generator to overheat and burn out.
5. Pressure boilers are available with two separate water intakes:
one for the boiler (treated water)
one for the spray condenser (untreated water).
The steam generator only uses 14 to 31% of a steamer’s water. Since water
treatment systems are typically sized by total GPH (gallons per hour), the second
intake could reduce treatment requirements by up to 80%, resulting in significant
savings.
OM-G-SB 5
Installation
WARNING
MAKING ANY ELECTRICAL OR MECHANICAL
CHANGE IN THE UNIT WITHOUT PRIOR
APPROVAL WILL VOID ALL WARRANTIES.
WARNING
THE UNIT MUST BE INSTALLED BY
PERSONNEL WHO ARE QUALIFIED TO WORK
WITH GAS, ELECTRICITY AND PLUMBING.
IMPROPER INSTALLATION CAN CAUSE
INJURY TO PERSONNEL AND/OR DAMAGE
TO THE EQUIPMENT. THE UNIT MUST
BE INSTALLED IN ACCORDANCE WITH
APPLICABLE CODES. THE UNIT MUST BE
INSTALLED BY A LICENSED PLUMBER OR
GAS FITTER WHEN INSTALLED WITHIN THE
COMMONWEALTH OF MASSACHUSETTS.
WHEN THE UNIT IS RECEIVED, IMMEDIATELY INSPECT IT FOR EXTERNAL OR INTERNAL
DAMAGE. REPORT ANY DAMAGE TO THE FREIGHT CARRIER. After inspection, keep the
unit in its shipping container until it is installed. It can be installed on combustible and
non-combustible floors. Minimum clearances are:
Right Side 2 inches
Left Side 4 inches
Rear 6 inches
In order to service the unit properly, access with at least 24 inches clearance is
needed on the right side.
Install the unit in a well-vented room so that there is an adequate air supply. Since
products of combustion come out of its flue, the appliance must be located under a
ventilation hood. Do not directly vent the flue.
Level the unit front to rear and left to right by adjusting its legs. Levelness may be
checked by using a spirit level on top of the cabinet.
A free flow of air around the boiler promotes efficient operation. Items which might
restrict air flow must be removed. After installation, do not obstruct the flue, or any
front, side, rear or top vents. Similarly, keep the area directly around the appliance
clear of combustible material.
Installation must conform with local codes, or in the absence of local codes, with the
National Fuel Gas Code, ANSI Z223.1 (latest edition, including the following paragraph:
“The unit and its individual shut-off valve must be disconnected from the gas supply
piping system during any pressure testing of that system at test pressures in excess
of 1⁄2 PSI (3.45 kPA). The unit must be isolated from the gas piping system by closing
its individual manual shut-off valve during any pressure testing of the gas supply
piping system at test pressures equal to or less than 1⁄2 PSI (3.45 kPA).”
1. Gas Supply Connection
a. Connection to the gas supply can be completed with 1/2” NPT pipe
or approved equivalent. Although this is the diameter for immediate
connection to the unit, gas supply piping must be large enough to
provide volumes and pressure sufficient for 200,000 BTU per hour.
Supply pressure must be at least 5.0” W.C. (14.0” W.C. maximum) for
natural gas or 11.0 W.C. (14.0” W.C. maximum) for propane.
b. In Canada, the installation must conform to the Canada Gas Code, CAN
1-B149 (Installation Codes for Gas Burning Appliances and Equipment),
and/or local codes.
c. After the unit has been connected to the gas supply, check piping joints for
leaks. Do NOT use flame to check for leaks. A thick soap solution or other
suitable leak detector should be used.
6 OM-G-SB
Installation
WARNING
THE UNIT MUST BE INSTALLED BY
PERSONNEL WHO ARE QUALIFIED TO
WORK WITH ELECTRICITY AND PLUMBING.
IMPROPER INSTALLATION CAN CAUSE
INJURY TO PERSONNEL AND/OR DAMAGE TO
THE EQUIPMENT. THE UNIT MUST BE
INSTALLED IN ACCORDANCE WITH ALL
APPLICABLE CODES.
CAUTION
SHIPPING STRAPS ARE UNDER TENSION.
THEY CAN SNAP BACK VIOLENTLY AND
CAUSE INJURY WHEN CUT.
CAUTION
MAKING ELECTRICAL OR MECHANICAL
CHANGES TO THE UNIT WITHOUT APPROVAL
FROM THE FOOD SERVICE ENGINEERING
DEPARTMENT WILL VOID WARRANTIES.
IMPORTANT
IMPROPER DRAIN CONNECTION
WILL VOID WARRANTY.
CAUTION
DO NOT LOCATE THE BOILER CABINET
DIRECTLY OVER A FLOOR DRAIN OR
FLOOR SINK. HUMIDITY OR WATER
WILL DAMAGE ELECTRICAL.
2. Electrical Supply Connection
a. Power is supplied to cavity controls and blower from the boiler base, and
no other electrical connections are required.
b. The maximum electrical load is 4 AMP. You must provide 115 Volt
Alternating Current, 60 Hz, 1PH, 15 AMP service. Local codes and/or the
National Electrical Code should be followed (ANSI/NFPA-70-1987 - or latest
edition). AN ELECTRICAL GROUND IS REQUIRED.
c. The electrical schematic is located in the electrical enclosure and in
this manual. In Canada provide electrical service in accordance with the
Canadian Electrical Code, CSA C22.1, Part 1 and/or local codes.
3. Water Supply Connection
a. This Model features two separate water inlets – one for the steam boiler
(treated water), the other for the spray condenser (untreated water). The
second intake will reduce treatment requirements resulting in significant
savings.
b. Cold water should be supplied to a 3/8” NPT pipe connection for untreated
water at the rear of the unit. A back siphonage device (check valve) must
be installed, complying with local plumbing codes. The water pressure
should be between 30 and 60 PSI (210 to 410 kPa). A pressure regulator is
required above 60 PSI (410 kPa). A strainer screen at the connection is also
recommended, to trap debris before it can enter the system.
c. The condenser spray uses 0.70 to 0.95 gallons of water per minute (2.6 to
3.6 liters per minute) at 30 to 60 PSI (210 and 410 kPa). The spray will only
operate when a steamer cavity (cooking chamber) is in operation.
Leave an air gap between the hose and the build-
ing drain, and don’t allow water traps in the line.
d. Water supply lines should be sized to provide for maximum water use (the
total of the boiler and condenser spray) as shown in the following table:
Maximum Water Consumption-gal/hr (L/hr)
Gas boiler only 12.9 (48.8)
Steamer condenser spray only
AT 40 PSI (280 kPa) 47.4 (180)
AT 60 PSI (410 kPa) 57.0 (215)
4. Drain Connection
a. The drain connection is made at the rear of the unit, using a 1-1/4” NPT
pipe. Do NOT use plastic pipe — the piping must be able to withstand
steam and hot water. Extend the drain piping to a nearby floor drain. Piping
of 1 - 1/4” NPT (or 1 - 1/2” NPT) is acceptable for distances of six feet or
less. If the distance to the drain is further than six feet, use 2” NPT piping.
b. Install the drain line with a constant downward pitch. Do not allow any
water traps in the line. A trap can cause pressure to build up inside the
cavity during steaming, which will make the door gasket leak. A vertical
air gap must be maintained between the drain line and the building drain,
unless otherwise specified by local plumbing codes.
OM-G-SB 7
Installation
5. Utility Connections
a. Hot water (for faucet on 36” and wider units with kettles).
b. Steam outlet (for power take-off).
c. Cold water (treated).
d. Cold water (untreated).
e. Gas, natural or propane.
f. Drain (for boiler, steamers and condenser spray). Also for kettle
condensate and sink where used.
g. Electrical (conduit through underside, terminals at the right on the
inside).
8 OM-G-SB
Operating Controls are located on the
front of the cabinet base unit.
Initial Start-Up
After the unit has been installed, test it to ensure that it is operating properly.
1. Remove literature and packing material from the interior and exterior of the unit.
2. Make certain the water supply is turned on.
3. Turn on electrical power to the unit.
4. Make sure the gas supply line is open, and turn on the gas valve.
Turn the knob on the gas valve to the “ON” position.
NOTE: The “trial for ignition” period is approximately 90 seconds after the on/off
switch is turned to the “ON” position. (Refer to the Control Panel illustration in
the Operation Section).
During initial start-up several trials may be necessary to remove air from the gas
piping. Subsequent start-ups should only need about five seconds for the pilot to
light. If the pilot burner does not light within the trial period, the ignition system
will automatically stop gas flow to the pilot burner, and terminate the ignition
trial. If this happens, turn the switch to “OFF” and then “ON” again, to repeat the
trial for ignition.
5. Turn the on/off switch on the cabinet front panel to the “ON” position:
• The amber light in the switch will come on
• The boiler drain valve will close
• The unit will ll with water
When the water level reaches the “mid” probe, the red RESET light will come on.
Push the start switch.
• The green light in the switch will come on
• The RESET light will go out
• The main burner will light
When the water level reaches the “hi” probe, the water supply to the boiler will
shut off.
6. After about 15 minutes, the pressure on the gauge will rise. When the pressure
reaches 9- 1/2 PSI, the main burner will turn off. Thereafter, as pressure
decreases, the burner will automatically re-light to maintain the 9-1/2 PSI level.
The pilot burner should stay lit, even though the main burner cycles on and off.
7. To shut the unit down, turn the on/off switch to OFF. When it has cooled to
approximately 170ºF, the boiler will automatically drain.
The pilot is off when the on/off switch is OFF.
If the boiler functions as described above, it is ready for use. If it does not, contact
your authorized Service Agent.
OM-G-SB 9
Loading...