Blodgett SB-G Series User Manual

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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 B (04/12)

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

Improperinstallation,adjustment,alteration,serviceormaintenancecan 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 bloc k 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.

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Table of Contents

ImportantOperatorWarnings

.....................................................page1-2

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

SequenceofOperation................................................................

page14

Cleaning..................................................................................

page15-17

Maintenance...........................................................................

page 18-19

Troubleshooting......................................................................

page 20-21

ElectricalSchematic...............................................................

page31-32

Service Log .................................................................................

page 33

References

UNDERWRITERS LABORATORIES, INC.

333 Pfingsten 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

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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.

G-SB steamers have two steam compartments with individual controls mounted on a gas-fired boiler base.

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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.

The drain system includes a spray condenser, which suppresses any steam escaping from the chamber and cools condensate water going into the drain.

REDUCE SCALE PROBLEMS BY USING AND MAINTAINING A WATER SOFTENER FOR YOUR STEAMER!

Water Quality & Treatment

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 well maintained 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

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.

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Installation

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.

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.

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-gal/hr (L/hr)

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.

Leave an air gap between the hose and the building

b.

Install the drain line with a constant downward pitch. Do not allow any

 

drain, and don’t allow water traps in the line.

 

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

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Installation

5.Utility Connections

1.Cold water (untreated).

2.Cold water (treated).

3.Hot water (for faucet on 36” and wider units with kettles).

4.Steam outlet (for power take-off).

5.Gas, natural or propane.

6.Drain (for boiler, steamers and condenser spray). Also for kettle condensate and sink where used.

7.Electrical (conduit through underside, terminals at the right on the inside).

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Initial Start-Up

Operating Controls are located on the front of the cabinet base unit.

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 fill 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 130ºF, 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.

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