Comstock Castle F-3 Service Manual
INSTALLATION • OPERATION MANUAL for
COMSTOCK-CASTLE FOOD SERVICE EQUIPMENT
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, operation or
maintenance can cause property damage, injury or death. Read the
installation, operating and maintenance instructions thoroughly before
installing, operating or servicing this equipment.
NOTICE
Instructions must be posted in a prominent location that will provide the user
of this equipment with procedures, in the event he/she smells and/or detects
gas. This information must be obtained by consulting the local gas utility.
READ CAREFULLY AND KEEP FOR FUTURE REFERENCE!
NOTE: The equipment for which this Installation • Operation Manual is provided may be certified,
have certification pending or not be certified under the standards of one or more of the following
organizations: Intertek Testing Services (ETL). Please ref er to the chart on page 3 for the status
of each specific unit.
CONTENTS: PAGE NO:
Definitions and Shipping Damage ...................................................3
General Information......................................................................3-4
Installation ....................................................................................4-5
Gas Connection & Conversion Procedure....................................5-6
Lighting Instructions. ....................................................................6-7
Calibration and Adjustments ........................................................7-8
Thermostat Calibration.................................................................8-9
Manual Pilot and Thermocouple.................................................9-10
Preparation.....................................................................................10
Griddle Plate/Broiler Option .....................................................10-11
Lava or Radiant Broiler Option.......................................................11
Maintenance and Service Instructions. ..........................................11
Drawings...................................................................................12-18
Troubleshooting Chart....................................................................19
Comstock-Castle Warranty............................................................20
Comstock-Castle Stove Co. suggests that the user
read this Installation/Operation Manual in its
entirety before installing this equipment.
COMSTOCK-CASTLE STOVE COMPANY
119 WEST WASHINGTON
QUINCY IL 62301
217-223-5070 (Voice)
217-223-0007 (Fax)
www.castlestove.com
2
IN THE EVENT YOU SMELL GAS: Open Windows, Do Not
Touch Electrical Switches, Extinguish All Open Flame, and
IMMEDIATELY CALL Your Gas Utility.
DEFINITIONS
QUALIFIED AND/OR AUTHORIZED
OPERATING PERSONNEL
Qualified or authorized operating personnel are those
who have carefully read this manual and are familiar with
the functions of the equipment. Those who have had
previous experience with the functions and operations of
similar equipment should also read this manual to
acquaint themselves with the unique characteristics of
this equipment.
QUALIFIED INSTALLATION OR
SERVICE PERSONNEL
Qualified Installation and/or Service Personnel are
defined as those who, either in person or through a
representative, are engaged in and are responsible for:
The installation or replacement of gas piping from the
outlet side of the meter, (or the service regulator when a
meter is not provided), and the connection, installation,
repair, or servicing of the equipment. Qualified personnel
must be experienced in such work, be familiar with all
precautions required, and be able to comply with all
requirements of state or local authorities having
jurisdiction. Reference:
National Fuel Gas Code ANSI Z223.1-latest edition
(NFPA Code 54).
SHIPPING DAMAGE CLAIM
PROCEDURE
UNPACKING:
Inspect the crating for possible damage. Carefully
remove the gas appliance from the crate, and inspect the
unit for concealed damage. (Perform applicable steps.)
1. Remove top grates, and the range griddle plate if
applicable.
2. Open Oven door, remove rack(s), and Oven bottom.
3. All packing material and burner tie down wire, if applicable, must be removed.
4. If stainless steel, remove the protective covering.
5. Properly install the legs or casters on the range.
NOTE: For proper operation and combustion, the legs or
casters MUST be installed. STDHP counter units do not
have legs.
6. Locate the Oven door handle and associated screws.
Before mounting handle clear the insulation around
the mounting holes on the Oven door. Using the two
screws, mount handle to Oven door.
Upon receipt and during installation of your new
Comstock-Castle equipment, inspect it thoroughly for
damage that may have been incurred during shipment. If
damage is evident, contact the carrier immediately.
FOR YOUR PROTECTION, IF SHIPMENT
ARRIVES DAMAGED:
NOTE: FILE CLAIM FOR DAMAGES IMMEDIATELY,
regardless of the extent of the damage. Time limits are
in effect.
VISIBLE LOSS OR DAMAGE – Be certain this is noted
on the freight bill or express receipt, and signed by
the person making the delivery.
9 2. CONCEALED LOSS OR DAMAGE – If damage
is unnoticed until merchandise is unpacked, notify
transportation company or carrier immediately, and
file a “concealed damage” claim with them. This
should be done within 15 days of the date delivery is
made to you. Be sure to retain container for
inspection.
Comstock-Castle cannot assume responsibility for damage or loss incurred in transit. Comstock-Castle will,
however, be glad to assist you and furnish you with any
necessary documentation to support your claim.
GENERAL INFORMATION
TO AVOID POSSIBLE INJURY, FIRE, and/or
EXPLOSION, the following precautions must be read,
understood, and followed explicitly.
CERTIFICATION STATUS • MINIMUM CLEARANCE
Combustible Non-combustible
Model Back Side Back Side
OVENS &
RANGES
F3 Series 2” 2” 0” 0”
(ETL)
FK4 Series 6” 6” 0” 0”
(ETL)
P Series 6” 6” 0” 0”
(ET L)
B Series 6” 6” 0” 0”
(ETL)
HOT PLATES
FHP Series 5” 4” 0” 0”
(ETL)
STFHP Series 6” 6” 2” 2”
(ETL)
HPK4 Series 6” 6” 2” 2”
(ETL)
CSP Series 6” 6” 4” 0”
(ETL)
SP Series 6” 6” 4” 0”
(ETL)
GRIDDLES
FHP Series 5” 4” 0” 0”
(ETL)
10 Series 6” 6” 0” 0”
(ETL)
9 Series 6” 6” 0” 0”
(ETL)
3
BROILERS
Do not obstruct the flow of combustion gases or ventilation
FHP Series 5" 4" 0" 0"
(ETL)
9 Series 6" 6" 0" 0"
(ETL)
FRYERS
2932SF 6" 6" 6" 2"
(ETL)
J01HG 6" 6" 6" 2"
(ETL)
2616HG 6" 6" 6" 2"
(ETL)
H Series 6" 6" 6" 2"
(ETL)
All F3 and FCK4 Series Ranges of this series are suitable
for installation on combustible floors. Counter equipment is
for use on non-combustible counters.
NOTE: The Model No. HPK4 Series Hot Plates are not
AGA Certified Designs.
All FHP Series, STFHP Series and HPK4 Series Hot
Plates are for use in combustible and non-combustible
locations when installed on a non-combustible counter.
The BTU input rating on all equipment is calibrated for elevations up to 2,000 feet above sea level. All orifice drill
sizes are referenced for operation at or below this altitude.
For operation at elevations above 2,000 feet, the BTU rating must be reduced 4% for each 1,000 feet of elevation or
the orifice drill size must be changed appropriately. For
high altitude drill sizes, call your local gas company, or
Factory Authorized Service Center.
All units are equipped with fixed orifices and cannot be
adjusted. If converting the gas appliance from natural to
propane, or vice versa, all orifices and the regulator must
be changed. The correct type of gas, for which the unit is
configured, is noted on the name plate. The type of gas
specified MUST be used. For proper conversion, contact a
qualified service technician or your Factory Authorized
Service Center.
When installed with casters, adequate means of restraint
must be provided to limit the movement of the appliance
without depending on the connector and the quick disconnect device or its associated piping to limit the units
movement. The restraint should be securely fastened to
the back of the unit. If disconnection of the restraint is nec essary, the restraint must be reconnected after the appliance has been returned to its original installation position.
For a gas appliance that is equipped with casters, the
installation shall be made with a connector that complies
with the Standard for Connectors for Movable Gas
Appliances, ANSI Z21.69 - 1987, and addenda Z21.69a 1989, and a Quick Disconnect Device that complies with
the Standards for Quick Disconnect Devices for Use With
Gas Fuel, Z21.69 - latest edition, and Z21.41- latest
edition.
Provisions shall be made in the design of the kitchen, to
ensure an adequate fresh air supply for proper ventilation
and combustion.
air.
Never enclose the bottom of the unit with a raised curb
and/or any other construction that would obstruct the air
flow into the unit.
One of the most important considerations in the installation
of this unit is ventilation. A commercial gas appliance must
be installed so that the products of combustion are efficiently removed. However, the kitchen ventilation system
must not produce a draft that would interfere with the proper operation of the burners.
The area around this and any other appliance mus t always
be kept free and clear of combustibles such as: grease,
food particles, fuel, solvents, cleaning fluids, gasoline,
mops, rags, etc.
During installation, use thread compound sparingly.
Always use a compound that is impervious to chemical
reaction with propane gases. NEVER put any of the
compound on the first two outer threads. This will minimize
the possibility of the compound breaking free and clogging
the pilots, burner orifices, and controls.
When a commercial gas appliance is first installed, the gas
pressure must be checked with a manometer by a
qualified service technician. This will ensure that the
existing gas facilities will deliver the BTU's of gas required
on the rating plate. WARNING - If the appliance is
configured for LP Gas, never connect the equipment
directly to the pressure tank. Damage will result to the
appliance if the tank pressure is not properly regulated.
The regulator supplied with your unit is a low pressure (1/ 2
PSI max.) appliance regulator. For proper pressure
regulation specifications, consult your local Factory
Authorized Service Agency or an LP Gas Distributor.
INSTALLATION
THIS APPLIANCE IS INTENDED FOR OTHER THAN
HOUSEHOLD USE
All Comstock-Castle commercial gas appliances are
manufactured by skilled craftsman using the finest quality
materials. PROPER installation by qualified personnel is
essential for safe, efficient, and trouble-free operation of
the unit. Any alteration and/or tampering, without proper
knowledge, tools, and test equipment, is DANGEROUS
and will void all warranties.
The installation must conform with local codes, or in the
absence of local codes, with the National Fuel Gas Code,
ANSI Z223.1-latest edition.
PRESSURE TESTING:
FAILURE TO INSTALL PRESSURE REGULATOR WILL
VOID WARRANTY. (Most units have a convertible
regulator.)
The appliance and its individual shut-off valve must be disconnected from the gas supply piping system during any
pressure testing of that system at test pressure in excess
of 1/2 psig (3.45 kPa).
4
The appliance must be isolated from the gas supply piping
system by closing its individual manual shutoff valve
during any pressure testing of the gas supply piping
system at test pressures equal to or less than 1/2 psig
(3.45 kPa).
NOTICE
The proper installation of this gas appliance is the
total responsibility of the end user.
It is the responsibility of the purchaser to determine that
the installer is qualified in installation procedures.
Conversion, connecting gas lines, calibrating thermostats,
burners, lighters, setting gas pressure with manometer,
etc., is all part of normal installation and will not be paid for
under warranty. If a warranty technician is called out and
finds the unit improperly installed, the end user may be
subject to billing.
FOR MAINTENANCE, SERVICE, REPAIRS, OR INSTALLATION - Contact your dealer or the factory, for your local
Factory Authorized Service Agency.
INSTALLING THE BACKSPLASH OR HIGH SHELF:
To install a backsplash or high shelf on a Castle Range,
proceed as follows:
1. Ensure back of unit is easily accessible.
2. If mounting low back (backsplash), slide into supports
on back of unit, and secure with #10 x 5/8 sheet metal
screws.
3. If mounting high shelf, mount shelf to high back using
#24 x 3/4" machine screws with nut and washer.
4. Slide backsplash into the side supports on back of unit,
and secure with #10 x 5/8" sheet metal screws. (Fig. 1)
GRIDDLE PLATE INSTALLATION:
Griddle Plate front trim must be placed under the plate rest
to prevent plate from moving. Rear of plate must be lifted
to allow front edge under the plate rest. If unit is equipped
with thermostat, sensing bulbs need to be installed under
the plate prior to placing front trim under plate rest.
GAS CONNECTION &
CON VERSION PROCEDURE
GAS CONNECTION:
The size of the gas line is extremely important. If the
line is too small, the gas flow in the manifold will be
low. This inadequate flow will cause slow recovery and
delayed ignition. If in doubt about the proper size of your
service line, consult your local gas utility company.
DO NOT connect appliance before testing the pressure of
the gas service supply piping system.
FOR NATURAL GAS - Fixed orifices are set at 4" W.C.
(water column). If a pressure regulator is supplied, it must
be installed when the unit is connected to the gas supply.
FOR PROPANE GAS - Fixed orifices are set at 10" W.C.
(water column). If a pressure regulator is supplied, it must
be installed when the unit is connected to the gas supply.
Pressure regulator must be tested in a full flow condition
(all valves "ON"). A condensation/particulate trap must be
provided in the supply line, with a separate shut-off valve
upstream of the regulator. These items are customer
installation responsibilities.
Your Comstock-Castle appliance is equipped with a 3/4"
NPT entrance pipe. Level the appliance under station
exhaust hood, and connect the gas line from the service
gas shut-off valve to the inlet side of the gas pressure
regulator using 3/4" pipe. DO NOT use a domestic type
gas flexible connector. If a flexible or semi-flexible
connector is used, an AGA Certified Flexible Connector
with an I.D. equal to 3/4" must be used. Always avoid
sharp bends that could restrict the gas flow to the
appliance. All piping must be installed in accordance with
local codes, or in the absence of local codes, with the
National Fuel Gas Codes: ANSI Z223.1-latest edition NFPA No. 54.
IMMEDIATELY CHECK the plumbing with a concentrated
soap solution or an approved gas detector. Coat all joints
associated with the gas distribution system. Bubbles
indicate leaks, and the appliance MUST NOT be operated
until the leak is corrected. NEVER use an open flame to
test for leaks. Be sure to check all gas connections with
the main burner "ON" and "OFF". Check and, if necessary,
adjust the manifold pressure.
HOOK-UP PROCEDURE FOR COMBINATION UNITS:
Units prefixed with a 2 may be shipped separately. For
connection, set the units side by side. Install backsplash.
Install hook-up strip in the front center of the two units.
Ensure that everything is aligned properly. Install and
tighten all screws.
GAS CONVERSION:
A qualified service technician must be used to safely
convert the appliance from natural gas to propane
gas, or vice versa. The regulator, burner orifices, pilot
orifice, and possibly the pilot lighter bar orifice, if
applicable, must be converted. The appliance must be
retested for proper alignment, calibration and gas
pressure.
Caution: Never attempt conversion when the unit is
hot!
For All Manually and Thermostatically Controlled
Equipment:
If a regulator has been shipped with the unit, it MUST be
installed properly. If not factory installed, connect
regulator with arrow pointing in the direction of gas flow.
Use thread compound sparingly. NOTE: DO NOT APPLY
thread compound to the female threads of any part.
Some larger models may have two gas inputs for the
manifold system. If this is the case, all gas inputs to the
unit MUST have a factory approved regulator.
IMPORTANT NOTICE FOR UNITS WITH
CONVERTABLE PRESSURE REGULATORS
PROPANE GAS CONVERSION INSTRUCTIONS
A griddle is equipped with fixed orifice hoods and shipped
from the factory for use on natural gas. To convert to
propane gas, install the propane burner orifice hoods
supplied as follows:
1. Remove the griddle plate by lifting with 2 people and
set it aside.
2. Slide the burners back off of the valve orifice hoods a
couple of inches and let it rest.
3. Remove the natural gas orifice hoods with a 1/2"
wrench.
4. Apply a very little bit of pipe dope on the treads of the
valve. DO NOT APPLY PIPE DOPE INTO ORIFICE
HOOD.
5. Attach the supplied propane burner orifice hoods with
a 1/2" wrench.
6. Convert the pressure regulator from Natural to
Propane gas by inverting the snap-in device beneath
the cap on the regulator. This will require a fair
amount of pressure. Do not remove the spring. When
replacing the cap make sure the snap-in insert goes
down on top of the middle of the spring.
7. Test for proper pressure; 10" W.C. (Water Column)
using a Manometer.
8. Slide burners back onto orifice hoods.
9. Apply the Propane "Notice" sticker to the front of the
unit for future reference.
LIGHTING INSTRUCTIONS
NOTE: While lighting a manual pilot system, sufficient
time must be allowed for the proper pilot flame to heat
the thermocouple that will hold the safety valve open. If
lighting for the first time, allow some time for air to be
purged from the gas distribution system.
TO LIGHT THE CHINA HAT PILOTS: (OPEN TOP
BURNERS)
1. The main gas valve should be "OFF" for at least five
minutes to allow any accumulated gas to escape the
combustion chamber.
2. Remove spider rings, open top grates, and locate the
Pilots.
3. Turn supply gas "ON", and hold match close to the
pilot head. The pilot should light.
4. Turn the manual gas control to the "ON" position. The
main burners should light.
TO TURN THE CHINA HAT PILOTS OFF:
1. Turn the supply gas control to the "OFF" position and
ensure all burners are off.
NOTE: Pilots cannot be shut off unless the main gas
supply to the appliance is shut off.
TO LIGHT THE OVEN PILOT:
Remove the lower kick panel below the oven door. Open
oven door and remove the oven rack. Remove oven
bottom.
1. The Robertshaw Grayson TS11J safety valve should
be closed for at least five minutes to allow any
accumulated gas to escape the combustion chamber.
2. Turn the thermostat to the lowest possible setting.
3. Depress and hold down the red button while lighting
the pilot. Hold the button down for about 45 seconds.
4. Release the reset button. The pilot should stay lit.
5. Set the thermostat to the desired temperature. The
main burners should light.
TO TURN OFF THE OVEN PILOT: (See Fig. 3)
1. Turn the thermostat to the lowest possible setting.
2. Blow out pilot. The safety valve will automatically shut
off the gas supply system.
TO LIGHT THE GRIDDLE:
(Thermostatically Controlled Griddles)(0ptional)
For units that are equipped with a thermostatically controlled Griddle, proceed as follows:
1. The Robertshaw Grayson TS11J safety valve should
be closed for at least five minutes to allow any
accumulated gas to escape the combustion chamber.
2. Turn the thermostat to the lowest possible setting.
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