Groen DH-CE Mark, DHT-CE Mark Operation Manual

OPERATOR MANUAL & SERVICE MANUAL

IMPORTANT INFORMATION, KEEP FOR OPERATOR

This manual provides information for:

MODELS DH-CE MARK

& DHT-CE MARK INTERNATIONAL

STEAM JACKETED

KETTLES

·Self-Contained

·Stainless Steel

·Gas Heated

·Floor Mounted

·Tilting

THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE. READ, UNDERSTAND AND FOLLOW THE INSTRUCTIONS AND WARNINGS CONTAINED IN THIS MANUAL (THE SERVICE MANUAL AND OPERATOR MANUAL SECTIONS).

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. Unified Brands suggests 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.

Manufacture Service/Questions 888-994-7636.

Information contained in this document is known to be current and accurate at the time of printing/creation. Unified Brands recommends referencing our product line websites, unifiedbrands.net, for the most updated product information and specifications.

PART NUMBER 128417, REV. D (6/06)

DH

DHT

1055 Mendell Davis Drive

Jackson, MS 39272 888-994-7636, fax [phone] groen.com

IMPORTANT — READ FIRST — IMPORTANT

IT IS MOST IMPORTANT THAT THESE INSTRUCTIONS AND THE OPERATOR AND SERVICE MANUALS BE CONSULTED BEFORE INSTALLING AND COMMISSIONING THE APPLIANCE. FAILURE TO COMPLY WITH SPECIFIED PROCEDURES MAY RESULT IN DAMAGE OR THE NEED FOR A SERVICE CALL.

THESE APPLIANCES HAVE BEEN CE MARKED ON THE BASIS OF COMPLIANCE WITH THE GAS APPLIANCE DIRECTIVE, EMC AND LOW VOLTAGE DIRECTIVE FOR THE COUNTRIES, GAS TYPES AND PRESSURES AS STATED ON THE DATA PLATE.

THESE APPLIANCES MUST BE INSTALLED BY A COMPETENT PERSON IN CONFORMITY WITH INSTALLATION AND SERVICING INSTRUCTIONS AND NATIONAL REGULATIONS IN FORCE AT THE TIME. PARTICULAR ATTENTION MUST BE PAID TO THE FOLLOWING:

I. E. E. REGULATIONS FOR ELECTRICAL INSTALLATIONS

ELECTRICITY AT WORK REGULATIONS

GAS SAFETY (INSTALLATION AND USE) REGULATIONS

HEALTH AND SAFETY AT WORK ACT

LOCAL AND NATIONAL BUILDING REGULATIONS

FIRE PRECAUTIONS ACT

DETAILED RECOMMENDATIONS ARE CONTAINED IN INSTITUTE OF GAS ENGINEERS PUBLISHED DOCUMENTS: IGE/UP/1, IGE/UP/2, BS6173 AND BE5440. FURTHERMORE, IF A NEED ARISES TO CONVERT THE APPLIANCE FOR USE WITH ANOTHER GAS, A COMPETENT PERSON MUST BE CONSULTED. THOSE PARTS WHICH HAVE BEEN PROTECTED BY THE MANUFACTURER MUST NOT BE ADJUSTED BY THE USER.

USERS SHOULD BE CONVERSANT WITH THE APPROPRIATE PROVISIONS OF THE FIRE PRECAUTIONS ACT AND THE REQUIREMENTS OF THE GAS SAFETY REGULATIONS. IN PARTICULAR THEY SHOULD BE AWARE OF THE NEED FOR REGULAR SERVICING BY A COMPETENT PERSON TO ENSURE THE CONTINUED SAFE AND EFFICIENT PERFORMANCE OF THE APPLIANCE.

WARNING: TO PREVENT SHOCKS, ALL APPLIANCES GAS OR ELECTRIC, MUST BE EARTHED.

UPON COMPLETION OF THE INSTALLATION, THE OWNERS MANUAL SHOULD BE HANDED TO THE USERS AND THE INSTALLER SHOULD INSTRUCT THE RESPONSIBLE PERSON(S) IN THE CORRECT OPERATION AND MAINTENANCE OF THE APPLIANCE.

THIS EQUIPMENT IS ONLY FOR PROFESSIONAL USE, AND SHALL BE OPERATED BY QUALIFIED PERSONS. IT IS THE RESPONSIBILITY OF THE SUPERVISOR OR EQUIVALENT TO ENSURE THAT USERS WEAR SUITABLE PROTECTIVE CLOTHING AND TO DRAW ATTENTION TO THE FACT THAT SOME PARTS BY NECESSITY WILL BECOME VERY HOT, AND WILL CAUSE BURNS IF TOUCHED ACCIDENTALLY.

WARNING:	BEFORE REMOVING ANY PARTITION OR PANEL, ALWAYS TURN OFF THE
	ELECTRIC POWER AND ALLOW THE FAN TO STOP ROTATING. BEFORE
	WORKING ON ANY ELECTRICAL COMPONENT, DISCONNECT THE POWER
	SOURCE FROM THE UNIT.
NOTE:	IT IS IMPORTANT THAT THE END-USER ROUTINELY EXAMINE THE FLUE OUTLET
	ON A REGULAR BASIS. DEBRIS COVERING THE FLUE OUTLET CAN CAUSE A
	POTENTIALLY HAZARDOUS CONDITION. REMOVE ANY FOREIGN MATERIAL
	BEFORE USING THIS PIECE OF EQUIPMENT.

WARNINGS AND CAUTIONS PROVIDED IN THIS OPERATOR AND SERVICE MANUAL MUST BE COMPLIED WITH.

2 OM/SM-DH CE

Contents

		Regulations and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4
1		Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
	1.1	Model Numbers, Net Weights & Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
	1.2	Siting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
	1.3	Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
	1.4	Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
	1.5	Electrical Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
	1.6	Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6
	1.7	Total Gas Rate - Natural and Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6
	1.8	Injector Diameters-Natural and Propane Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6
	1.9	Gas Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6
	1.10	Burner Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6
2	Assembly and Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		7
	2.1	Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7
	2.2	Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7
	2.3	Electrical Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7
	2.4	Jacket Water Level/Jacket Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7
	2.5	Pre-Commissioning Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7
	2.6	Instruction to User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
3	Servicing and Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		9
	3.1	Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10
	3.2	Jacket Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10
	3.3	Jacket Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10
	3.4	Water Treatment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10
	3.5	Removal of Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
	3.6	Removal of Spark Ignition Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
	3.7	Removal of Low Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
	3.8	Removal of Tilt Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
	3.9	Removal of Gas Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
	3.10	ON/OFF Switch and Reset Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
	3.11	Removal of Neons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
	3.12	Removal of Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
	3.13	Removal of Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
	3.14	Low Water Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
	3.15	Removal of the Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
	3.16	Spark Electrode/Flame Sensing Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
	3.17	Removal of Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
	3.18	Removal of Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
	3.19	Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	17
	3.20	Filling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
	3.21	Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18

4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5 User Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.1 Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.2 Lighting and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.3 Cleaning and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

OM/SM-DH CE

3

Regulations and Safety Precautions

These Appliances have been CE marked on the basis of compliance with the Gas Appliance Directive, EMC and Low Voltage Directive for the Countries, Gas Types and Pressures as stated on the Data Plate.

These appliances MUST BE installed by a competent person in conformity with the INSTALLATION AND SERVICING INSTRUCTIONS and National Regulations in force at the time.

Particular attention MUST be paid to the following:

I.E.E. Regulations for Electrical Installations

Electricity at Work Regulations

Gas Safety (Installation & Use) Regulations

Health and Safety at Work Act

Fire Precautions Act

Local and National Building Regulations

Furthermore, if a need arises to convert the Appliance for use with another gas, a competent person must be consulted. Those parts which have been protected by the manufacturer MUST NOT be adjusted by the User.

Users should be conversant with the appropriate provisions of the Fire Precautions Act and the requirements of the Gas Safety Regulations. In particular the need for regular servicing by a competent person to ensure the continued safe and efficient performance of the Appliance.

WARNING

TO PREVENT SHOCKS, ALL APPLIANCES WHETHER GAS OR ELECTRIC, MUST BE EARTHED.

Upon completion of the installation, the Owners Manual should be handed to the users and the installer should instruct the responsible person(s) on the correct operation and maintenance of the Appliance. This equipment is ONLY FOR PROFESSIONAL USE, and shall be operated by QUALIFIED persons. It is the responsibility of the Supervisor or equivalent to ensure that users wear SUITABLE PROTECTIVE CLOTHING and to draw attention to the fact that, some parts will, by necessity, become VERY HOT and will cause burns if touched accidentally.

IMPORTANT - READ FIRST - IMPORTANT The Groen Steam Jacketed Kettle you have just purchased has been handcrafted from the finest materials, meticulously inspected, and carefully tested to ensure that you receive the best possible product. With reasonable care and periodic maintenance, it will provide years of faithful service. It is recommended that you establish a timetable for periodic maintenance as outlined in this manual. Space is provided in the Service Log at the back of this manual.

4 OM/SM-DH CE

Section 1

Installation

UNLESS OTHERWISE STATED, PARTS WHICH HAVE BEEN PROTECTED BY THE MANUFACTURER ARE NOT TO BE ADJUSTED BY THE INSTALLER.

1.1Model Numbers, Net Weights and Dimensions

	MODEL•	DH-20	DH-40	DH-60
	WIDTH	890 (34.9)	1190 (46.8)	1190 (46.8)
	mm (inch)
	DEPTH	790 (31.0)	930 (36.5)	990 (38.9)
	mm (inch)
	HEIGHT	1040 (40.9)	1150 (45.2)	1240 (48.7)
	mm (inch)
	WEIGHT	245	295	400
	Kg
	WEIGHT	535	645	880
	lbs
	1.2 Siting

The appliance should be installed on a level floor in a well lit and draught free position.

The installation of the appliance must be executed in accordance with local and/or national regulations as listed in this manual.

1.3 Clearances

Minimum clearances of 150 mm (5.9 in) from the sides of the appliance and 250 mm (9.8 in) from the rear of the appliance are required if the appliance is installed next to combustible surfaces. A vertical clearance of 750 mm (29.6 in) minimum should be allowed between the top rim of kettle and any overlying surface.

1.4 Ventilation

The unit must be installed in an adequately ventilated room with a provision for adequate air supply to the unit. The area directly around the appliance must be cleared of all combustible material. For multiple installations, the requirements for individual appliances should be added together. Installation should be made in accordance with local and / or national regulations applying at the time. A competent installer must be employed.

WARNING

THE UNIT MUST BE INSTALLED BY PERSONNEL QUALIFIED TO WORK WITH ELECTRICITY AND GAS. IMPROPER INSTALLATION CAN CAUSE INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT. THE UNIT MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE CODES.

CAUTION

THE APPLIANCE FLUE DISCHARGES VERTICALLY FROM THE TOP OF THE UNIT AT THE REAR. IT MUST NOT BE DIRECTLY CONNECTED TO ANY FLUE, MECHANICAL EXTRACTION SYSTEM, OR DUCTING LEADING OUTSIDE THE BUILDING. THE APPLIANCE IS BEST DISCHARGED UNDER AN OPEN CANOPY WHICH CONNECTS WITH A VENTILATING SYSTEM.

Recommendations for ventilation for catering appliances are given in BS 5440:2 and are shown in the table below.

	Equipment	Ventilation Rate Required
	(Unit Type)	m³ /min	ft³ /min
	Range	17	600
	Pastry Oven	17	600
	Fryer	26	900
	Grill	17	600
	Steak Grill	26	900
	Boiling Pan	17	600
	Steamer	17	600
	Sterilizing Sink	14	500
	Bains Marie	11	400
	Tea/Coffee	8.5-14	300-500
	Machine
	1.5 Electrical Supply

This unit is designed for connection to fixed wiring. A suitably rated isolating switch with contact separation of at least 3 mm (0.12 in) on

OM/SM-DH CE

5

both poles must be fitted to the installation and the wiring executed in accordance with the regulations listed in this manual.

Cable entry is at the lower rear on the right side of the appliance. Access is gained by removing relevant panels as described in Paragraphs 3.5.1 and 3.5.2.

Provide 230 VAC, 50 Hz, 1 Phase, 1 AMP or 40 Watts service. The electrical schematic is in the service compartment and this manual.

WARNING

THIS APPLIANCE MUST BE EARTHED.

1.6 Gas Supply

Incoming service must be of sufficient size to supply full rate without excessive pressure drop. A gas meter is connected to the service pipe by the Gas Supplier. Any existing meter should be checked by the Gas Supplier to ensure that it has capacity to pass the required rate of gas for the kettle in addition to other installed gas equipment.

The appliance governor is incorporated in the gas control valve which is in the control cabinet. The control valve governor is suitable for both natural and propane gases without conversion.

Installation pipe work should be fitted in accordance with IEGE/UP/2. The pipe work should not be smaller than the gas inlet connection on the kettle, i.e. Rp ½ (½'' B.S.P.)

An isolating cock must be located near the appliance to allow shut down during emergency or servicing. Test for gas soundness and purged as specified in IGE/UP/1.

Water Supply-Not applicable.

1.7Total Gas Rate - Natural (G20 and G25) and Propane (G31) Gas

Model		Kw	BTU/hr
DH-20	18.6		63,500
DH-40	24.5		83,600
DH-60	39.6		135,200

Gas and Electrical Connections are made at the rear of the unit.

6 OM/SM-DH CE

1.8Injector Diameters-Natural and Propane Gas (See Note, Paragraph 1.10 at right)

	Model	DH-20	DH/1-40	DH-60
	Number of	15	20	25
	Injectors
	Natural	1.10 mm	1.25 mm	1.30 mm
	Gas G20
	Natural	1.20 mm	1.25 mm	1.40 mm
	Gas G25
	Propane	0.65 mm	0.75 mm	0.75 mm
	Gas G31

1.9 Gas Pressure Adjustment

A pressure test point is fitted on the burner manifold and on the gas control valve.

		DH-20	DH/1-40	DH-60
Natural	mBar	8.75	5.8	8.25
Gas-G20	WCI*	3.5	2.3	3.3
Natural	mBar	8.0	7.0	8.25
Gas-G25	WCI*	3.2	2.8	3.3
Propane	mBar	29	21	25
Gas-G31	WCI*	11.6	8.4	10.0

*WCI = Water Column Inches

NOTE: With reference to gas rate, pressure adjustments and conversions, this appliance is CE-approved for use with the following gases:

a)G20 natural gas may be supplied to the appliance in Austria, Belgium, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Norway, Portugal, Spain, Sweden, Switzerland and the United Kingdom.

b)G25 natural gas may be supplied to the appliance in Belgium, France and the Netherlands.

c)G31 propane gas may be supplied to the appliance in France, Germany, Ireland, the Netherlands, Portugal, Spain, Switzerland, and the United Kingdom.

Use of the appliance with non-approved gases in a listed country, or use in other countries, will void CE certification.

1.10Burner Adjustment

The burners are fixed aeration type and have no provision for adjustment of air inlet.

OM/SM-DH CE

7

Section 2

Assembly and Commissioning

2.1 Assembly

d) Unpack the appliance

b)Place on a firm, level floor. Adjust and fix the feet.

CAUTION

SHIPPING STRAPS ARE UNDER TENSION AND CAN SNAP BACK WHEN CUT. TAKE CARE TO AVOID PERSONAL INJURY OR DAMAGE FROM STAPLES LEFT IN THE WALLS OF THE CARTON.

2.2 Gas Supply

Connect the unit to the gas supply and test for gas soundness. For gas supply down stream of the gas valve, leak detection spray or soap solution may be used with the burners lit.

CAUTION

ENSURE THAT THE KETTLE CONTAINS LIQUID WHEN THE BURNERS ARE ALIGHT.

2.3 Electrical Supply

Before commissioning the appliance, ensure that the electrical installation has been carried out to the relevant regulations (Paragraph 1.5).

WARNING

THIS APPLIANCE MUST BE EARTHED.

2.4 Jacket Water Level/Jacket Pressure

a)Ensure the water level in the jacket is correct, by confirming that it is between the sight glass marks. If it is low, follow instructions in Paragraph 3.3.

b)Check the pressure gauge. If it does not show 20 or more inches of vacuum (that is, a reading of 20 to 30 below zero) see "Jacket Vacuum" (Paragraph 3.2).

Before operation, check the water level and jacket pressure.

2.5 Pre-Commissioning Check

a)Prior to operation, clean out kettle pan thoroughly using hot water and detergent. Rinse pan thoroughly.

b)Remove all literature and packing materials from the interior and exterior of the unit.

c)Ensure the open end or the elbow at the outlet of the safety valve is directed down. If not, turn the elbow to the correct position. See detailed Instructions on Page 11 for Safety Valve installation and operation.

2.5.1Lighting Sequence

From Initial Start Up:

a)Put a small amount of water in kettle pan.

b)Ensure gas and electricity mains are “on.”

c)Switch the toggle switch to the "on" position.

d)Turn thermostat dial to desired setting.

e)Verify that spark igniter lights the burners.

8 OM/SM-DH CE

f)If the unit does not light, it will lock-out. Turn it off and wait one or two minutes before attempting to switch the unit on again.

g)Press reset lock-out switch and repeat steps

(b) to (e).

h)To switch unit off, switch toggle (On/Off) switch to the "Off" position.

i)Turn gas and electricity mains off.

2.5.2Setting The Gas Pressure

a)It is necessary to check the gas pressure during commissioning. A pressure gauge must be connected to the pressure test point on the gas control valve or the gas manifold. See figure above for test points.

b)When checking pressure at test points on the gas valve, undo the screw a half turn and slip tube over nipple.

c)Turn the main gas and electricity supply on.

d)Light the burners (Paragraph 2.5.1).

e)Remove control cabinet side panel screws.

f)Remove governor cap screw from control valve. See figure for position on valve.

g)Governor is suitable for both natural and propane gas.

h)To increase pressure turn the screw inside the governor turret clockwise; anti-clockwise to reduce pressure. Check the burner pressure again after 15 minutes operation and adjust if necessary.

i)Disconnect the pressure gauge from the test point. Re-seal the pressure test point and test for gas soundness.

j)Replace governor cap screw and replace lid and panels.

2.5.3Checking Performance of Controls

a)Light the unit. Check that controls quickly and smoothly produce a healthy spark from the electrode to the earthing post.

b)Turn thermostat off and then on. Check that burners go out and reignite smoothly and quickly when switched back on. Repeat several times.

c)If the unit fails to respond as described, it should be serviced by an authorized Groen service agent.

2.6 Instruction to Installer

Important: After installing and commissioning the appliance, the user's instructions should be handed to the user or purchaser. Ensure that the instructions for lighting, turning off, correct use and cleaning are properly understood. The location of the main gas isolating valve should be emphasized and the emergency shut down procedure should be demonstrated.

OM/SM-DH CE

9

Section 3

Servicing and Conversion

IMPORTANT

BEFORE ATTEMPTING ANY SERVICING, ENSURE THAT THE ISOLATING COCK IS TURNED OFF AND CANNOT BE INADVERTENTLY TURNED ON AND THAT THE ELECTRICITY SUPPLY IS DISCONNECTED.

AFTER ANY MAINTENANCE TASK, CHECK THE APPLIANCE TO ENSURE THAT IT PERFORMS CORRECTLY AND CARRY OUT ANY NECESSARY ADJUSTMENTS AS DETAILED IN SECTION 1.

ALWAYS CHECK FOR GAS SOUNDNESS AFTER CARRYING OUT ANY SERVICING OR EXCHANGE OF GAS CARRYING COMPONENTS.

NOTE: When replacing wiring connections refer to the wiring diagram contained on the unit and within this manual.

After Servicing

a)Test for gas soundness as specified in IGE/UP1 as appropriate after any gas connection has been disturbed.

b)Check for correct operation, as appropriate (see commissioning of appliance).

Regular Servicing Procedures

The following must be serviced at regular intervals.

Burners

The burner should be cleaned periodically to maintain maximum performance. Burners are best cleaned with a wire brush and any blocked parts are best cleaned with a metal broach, taking care not to damage the burner head.

The injector orifice should be cleaned with a wooden splinter. Metal reamers may distort or increase the orifice size and should be avoided.

Gears

The gear housing has fitting for proper lubrication of moving parts. The gears do not run in oil, periodic lubrication with grease is necessary. Frequency of lubrication will depend on operating conditions, but it should be performed at least once every 6 months. It is recommended that a #2 grade LGI lithium grease be used. Add grease through the Zerk fittings on the gear housing until grease flows out of bearings around the trunnion shaft. Place a

liberal amount of grease on the gear to cover the arc that is in contact with the worm gear.

Safety Valve

At least twice a month the safety valve requires checking to make sure it works correctly. When the gauge pressure is about five PSI, lift the valve lever enough to vent steam, then quickly let it snap back into place.

WARNING

AVOID ANY EXPOSURE TO THE STEAM BLOWING OUT OF THE SAFETY VALVE.

This procedure should be explained to the user, since it is to be carried out at least twice a month. Safety procedures and requirements should also be explained to the user when carrying out the procedure.

Safety Valve Operating Instructions

If adding water to a boiler, DO NOT ALLOW water to flow through safety valve as sediment or debris may be deposited on seating surface.

To achieve topmost performance and maximum service life, it is necessary to maintain a proper pressure margin between set pressure of the safety valve and equipment operating pressure.

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The minimum required pressure margin for this type of valve is 10% of the safety relief valve set pressure, but not less than five PSI. UNDER NO

CIRCUMSTANCES SHOULD THIS MARGIN BE LESS THAN 5 PSI. Failure to maintain this operating margin may result in water leakage past the seat and accumulation of deposits on the seating surface. Excessive deposits may prevent the valve from operating properly, and a dangerous pressure build-up and equipment rupture may result.

Maintenance and Testing

Test the operation of the safety valve on a regular basis.

CAUTION

BEFORE TESTING, MAKE CERTAIN DISCHARGE PIPE IS PROPERLY CONNECTED TO VALVE OUTLET AND ARRANGED TO CONTAIN AND SAFELY DISPOSE OF BOILER DISCHARGE (SEE “INSTALLATION INSTRUCTIONS”).

Under normal operating conditions a “try lever test” must be performed every two months. Under severe service conditions, or if corrosion and/or deposits are noticed within the valve body, testing must be performed more often. A “try lever test” must also be performed at the end of any non-service period.

Test at or near maximum operating pressure by holding the test lever fully open for at least 5 seconds to flush the valve seat free of sediment and debris. Then release lever and permit the valve to snap shut.

If lift lever does not activate, or there is no evidence of discharge, discontinue use of equipment immediately and contact a licensed contractor or qualified service personnel.

Neither Conbraco Industries, Inc. nor its agents assume any liability for valves improperly installed or maintained.

This quality Conbraco safety relief valve, along with proper installation, use, and maintenance, will provide many years of reliable service and protection against excessive pressure build-up of water/steam. Use of this valve for any other purpose or media places all responsibility upon the user. Before installing valve or operating equipment to which it is installed, read instructions carefully. Always wear proper safety equipment.

INSTALLATION OF SAFETY VALVE

a)Installation must be performed by qualified service personnel only.

b)The BTU/hr or lb/hr rating of this valve must equal or exceed that of the equipment to which it is attached.

c)DO NOT use this valve on a coal or wood boiler having an uncontrolled heat input.

d)Ensure that all connections, including the valve inlet, are clean and free from any foreign material.

e)Use pipe compound sparingly, or tape, on external threads only.

f)DO NOT USE A PIPE WRENCH! Use proper type and size wrench on wrench pads only.

g)This valve must be mounted in a vertical, upright position directly to a clean, tapped opening in the top of the boiler or equipment. Under no circumstances should there be a flow restriction or valve of any type between the safety relief valve and the pressure vessel

h)WARNING! During operation, this valve may discharge large amounts of steam and/or hot water. To reduce the potential for bodily injury and property damage, a discharge line MUST be installed that:

OM/SM-DH CE

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