Groen NGB Installation Manual

THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE

FOR YOUR SAFETY

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE

POST IN A PROMINENT LOCATION INSTRUCTIONS TO BE FOLLOWED IN THE EVENT USER SMELLS GAS.

THIS INFORMATION SHALL BE OBTAINED BY CONSULTING YOUR LOCAL GAS SUPPLIER. AS A MINIMUM, TURN OFF THE GAS AND CALL YOUR LOCAL GAS COMPANY AND YOUR AUTHORIZED SERVICE AGENT. EVACUATE ALL PERSONNEL FROM THE AREA.

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.

IMPORTANT — READ FIRST — IMPORTANT

Congratulations on your purchase of the highly efficient Groen gas heated steam generator: This unit has been carefully designed and handcrafted in, our own machine shop, then meticulously inspected and pretested to ensure that you receive the best possible product. Given reasonable care and periodic maintenance, this generator will provide years of faithful service.

PLEASE READ THIS MANUAL CAREFULLY AND THOROUGHLY BEFORE INSTALLING OR OPERATING THE GENERATOR. Keep. it on hand for future reference.

It is recommended that you establish a timetable for periodic maintenance as outlined in this manual. Space has been provided in the Maintenance and Service Log. Keep it up to date and on file with the warranty information contained in this manual.

A warranty registration card will be attached to the unit. Fill in this card and mail it to Groen Record the model number, serial number and installation date of your unit at the top of the Maintenance and Service Log in the back of this manual. File this information for future reference.

CONDITIONS AND TERMS OF LIMITED THREE YEAR WARRANTY

The warranty on this unit does not extend to:

1. Installation and start up.

2. Simple adjustments, such as tightening fittings and electrical connections.

3. Malfunction as a result of improper maintenance.

4. Repairs made by anyone other than qualified service personnel as recommended by Groen.

5. Damage caused in shipment or damage as a result of improper use.

6. Normal maintenance as outlined in operator manual.

7. Damage as a result of excessive moisture in components. DO NOT SPRAY EQUIPMENT WITH WATER OR STEAM.

8. Damage caused by tampering with, removal of. or change of preset controls or safety device.

9. Malfunction as a result of sediment and/or lime in the valves or scale build-up in the boiler.

NOTE: MINIMUM WATER QUALITY STANDARDS MUST BE MET TO INSURE PROPER OPERATION. WATER

SOFTENING IS RECOMMENDED IF YOUR WATER QUALITY DOES NOT MEET THE FOLLOWING STANDARDS:

(1) Total dissolved solids (TDS) content should not exceed 30 parts per million. (2) Water pH should be 7.0 or higher.

CAUTION: USE OF ANY REPLACEMENT PARTS OTHER THAN THOSE SUPPLIED BY GROEN OR THEIR

If you have any questions about warranty coverage, operating procedures, or maintenance, contact your area Groen representative or an authorized Groen service agency.

AUTHORIZED DISTRIBUTOR VOIDS ALL WARRANTIES. SERVICE PERFORMED BY OTHER THAN FACTORY AUTHORIZED PERSONNEL WILL VOID ALL WARRANTIES.

Table of Contents

EQUIPMENT DESCRIPTION .............................................................................................2

INSTALLATION .......................................................................................................... 2,3, 4

INITIAL START-UP ........................................................................................................4, 5

OPERATION ..................................................................................................................5,6

SEQUENCE OF OPERATION ............................................................................................7

WATER CONDITIONING ...................................................................................................8

REFERENCES ..................................................................................................................8

MAINTENANCE & CLEANING ..................................................................................... 9, 10

TROUBLESHOOTING ....................................................................................11, 12, 13, 14

PARTS LISTS ............................................................................................5, 16, 17, 18, 19

DIAGRAMS & SCHEMATICS...........................................................................20, 21, 22, 23

MAINTENANCE LOG ......................................................................................................24

WARRANTY INFORMATION ...........................................................................................25

Equipment Description

The Groen NGB and NGB/E steam generators are designed to generate Low pressure steam tor use in GOLDLINE cabinet mounted steamers and steam jacketed kettles. The generator is housed in a stainless steel cabinet on top of which can be mounted various combinations of steamers and kettles requiring a steam supply. It is small enough to fit in a 24 inch wide cabinet. The NGB and NGB/E feature an easily accessible control box, which may be pulled out through the cabinet door for servicing. (See Troubleshooting section of this manual.) The generator itself is constructed or 1/4 inch-boiler plate according to ASME code (all welds are hydrostatically tested) and is equipped with all required instruments, fittings, and controls. Heat transfer fins inside the combustion chamber add to the high efficiency of this unit. The NGB and NGB/E are both rated as 60% efficient or better, with a firing rate of 200,000 BTU/hr using propane or natural gas. The energy output is 120,000 BTU/hr and effective boiler horsepower is 3.6. The two models are distinguished by different ignition systems. to ignite the burners. Model NGB utilizes a standing pilot but Model NGB/E employs a Corborundum glow coil.

Installation

WARNING: INSTALLATION OF THE STEAM GENERATOR MUST BE DONE BY PERSONNEL QUALIFIED TO WORK

WITH ELECTRICITY AND PLUMBING. IMPROPER INSTALLATION CAN CAUSE INJURY TO PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT. ANY MECHANICAL, ELECTRICAL, OR GAS TYPE CHANGE MUST BE APPROVED BY THE GROEN DIVISION FOOD SERVICE ENGINEERING DEPARTMENT.

The unit should be installed in a ventilated room for efficient performance. All items which may obstruct or restrict the flow of air for combustion and ventilation must be removed. The area directly around the appliance must be cleared of all combustible materials.

1. Installation on both combustible and noncombustible floors is allowed, with a minimum clearance to combustible construction of six (6) inches at the rear and six (6) inches at each side.

2. Installation of the Gas Steam Generator under a ventilating hood is required. Installation of the ventilating hood should comply with local codes and/or ANSl/NFPA-96 Latest Edition. Also, the Gas Steam Generator should be electrically interlocked to shut off the gas supply and prevent the operation or the unit if the exhaust fan is not operating or if the fire suppression system is activated. Failure to follow these instructions can cause bodily injury and/or property damage.

3. Level the unit by adjusting the legs. and check for levelness with a spirit level on top of the cabinet.

4. Complete the piping to the gas service main using 1/2 inch NPT pipe or approved equivalent. Connection to the gas valve is at the right front corner of the generator.

5. Provide 115 VAC, 60 HZ, 1 PH, 15 AMP electrical service. Observe local codes and/or The National

Electrical Code in accordance with ANSI/NFPA 70 — latest edition. AN ELECTRICAL GROUND IS REQUIRED. The electrical schematic is located on the inside of the cabinet door.

6. Installation must conform with the American National Standard Z223.1 — latest edition and the National Fuel

Gas Code. The unit should be installed in an adequately ventilated room with a provision for adequate air supply to the unit. The best ventilation will utilize a vent hood and exhaust fan. DO NOT obstruct the flue or vent duct after installation.

7. Adequate space for proper servicing and operation is required. DO NOT block any air intake spacing to the

combustion chamber or obstruct the air flow.

8. After the steam generator has been connected to the gas supply, all gas line joints must be checked for

leaks. NO FLAME SHOULD BE USED WHEN CHECKING FOR LEAKS. A thick soap solution or other suitable leak detector should be employed.

9. The appliance and its individual shutoff valve must be disconnected from the gas supply piping system

during any pressure testing of the system at test pressures in excess of 1/2 psig (3.48 kPa). 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 (3.48 kPa).

10. Cold water must be supplied with 1/2 inch N.P.T. ,connections to the Y-strainer located at the left rear corner of the generator. It is recommended that a check valve be placed in this line before the Y-strainer to prevent back flow. Pressure of the water supply must be regulated at 20 to 30 PSI and should be maintained at 25 to 30 PSI. To prevent malfunction or damage caused by water pressures above 30 PSI, install a pressure reducing valve on the water supply line.

11. This steam generator has both an automatic drain and a manual drain at the rear of the unit. Connect the 1/2 automatic drain pipe and the 3/4 manual drain pipe to a 1 1/2 IPS (or larger) pipe header. Then extend the header to a nearby floor drain. GROEN recommends that the header have 2 or less elbows and a length of no more than 6 feet. A 2" IPS header is recommended for a drain line with more than 2 elbows or a length greater than 6 feet.

The header drain must have a gravity flow and vent freely to the atmosphere. The drain tine must not be directly connected to any building drain. Keep a vertical air gap of at least 2" between the generator drain and the building drain, unless local codes have a different requirement.

CAUTION: DO NOT LOCATE THE GENERATOR CABINET DIRECTLY OVER A FLOOR DRAIN OR FLOOR

SINK. HUMIDlTY OR WATER FROM A DRAIN WILL

DAMAGE ELECTRICAL PARTS OF THE GENERATOR. The generator drains discharge steam and hot condensate, so these hot discharges must be directed away from the generator cabinet. GROEN recommends that the floor drain be located to the rear of the cabinet. . For instructions on installation of the steam drain, see the separate steamer manual.

For units made before August 8,1991: For units made after August 7,1991:

RETROFIT KIT INSTRUCTIONS

Instructions:

1. Remove check valve and discard it.

2. Place 3/4"'tee between relief valve and existing tee.

3. Screw reducing brushing and vacuum breaker into tee.

4. Screw 1/4 elbow into reducing bushing on relief valve.

Initial Start-Up

Now that the steam generator has been installed, the unit should be tested to ensure that it is operating correctly.

For units made before August 8,1991:

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

2. If no steam connections have been made, attach a hose to the steam outlet at the top of the steam generator and pipe to a drain.

3. Open the main gas valve.

4. Before you fill the unit with water: a. For NGB: Turn the knob on the gas valve to "PILOT", then push the knob in and hold it while lighting the pilot burner. Continue to hold the knob in for 60 seconds, allowing the thermocouple to heat up (this keeps the gas valve open). b. For NGB/E: Turn the knob on the gas valve to the "ON" position. c. For NGB/2: Turn the knob on the gas valve to "PILOT", then push the knob in and hold it while lighting the pilot burner. Continue to hold the knob in for 60 seconds, allowing the thermocouple to heat up, so it will keep the gas valve open. d. For NGB/2/E: Turn the knob on the gas valve to the "ON" position.

5. For NGB or NGB/E: Push the "ON/OFF" switch on the cabinet front panel to the "ON" position. The unit will automatically fill with water. When the water level in the gauge glass reaches the full mark, wait 30 seconds, then push the "ON/OFF" switch to "RESET". The burner will then light. For NGB/2 or NGB/2/E: Push the "ON/OFF" switch on the cabinet front panel to the ON position. The red light in the switch will come on, and the unit will automatically fill with water. When the water level in the gauge glass reaches the full mark, the green "READY" light will come on. Push the "START" switch. The amber light in the switch will come on. and the burner will light.

6. If connections to a steamer or a kettle have been made, check for steam by: a. Turning on the steamer and checking for steam inside the cavity. b. Filling the kettle with water, turning it on. and making sure that the water heats up. If a hose connection (step "2" above) has been made, check for steam at the end of the hose. In all cases, steam should be detected within 20 minutes.

7. To shut down the unit push the "ON/OFF" switch to the OFF position. The generator will drain automatically after it has cooled to 170°.

For units made after August 7,1991:

Operation

1. Remove all literature and packing, materials from the interior and exterior of the unit.

2. Open the main gas valve.

3. Before you fill the unit with water: a. For NGB/2 Turn the knob on the gas valve to "PILOT", then push the knob in and hold it while lighting

the pilot burner. Continue to hold the knob in for 60 seconds, allowing the thermocouple to heat up so it will keep the gas valve open.

b. For NGB/2/E: Turn the knob on the gas valve to the "ON" position.

4. Push the "ON/OFF" switch on the cabinet front panel to the "ON" position. The red light in the switch will

come on, and the unit will automatically fill with water. When the water level in the gauge glass reaches the full mark, the green "READY" light will come on. Push the "START" switch. The amber light in the switch will come on, and the burner will light.

5. Check for steam at the drain (lower right corner as viewed from the rear). If connections to a steamer or a

kettle have been made, check for steam by: a. Turning on the steamer and checking for steam inside the cavity. b. Filling the kettle with water, turning it on, and making sure that the water heats up. In all cases, steam should be detected within 20 minutes.

6. To shut down the unit, push the "ON/OFF" switch to the OFF position. The generator wiil drain automatically after it has cooled to 170°.

If the generator functions as described above, the unit is ready for use. If it does not. contact your Groen Authorized Service Agent.

A. Controls

The operating controls for NGB and NGB/E are:

1. The "ON/OFF" switch on the cabinet front panel. This control is used to call for electrical power to the unit by pushing the switch to the "ON"; to light the unit by turning it to "RESET":to restart the unit in the event that a low water condtion cuts off power to the gas valve (by turning to "RESET" again): and, finally, to turn the unit off by turning the switch to "OFF".

2. The control knob on the gas valve. This control on the NGB is used in the "PILOT" position. when you are lighting the pilot burner. Turning the knob to the "ON" position allows gas to flow through the valve to the burner, and turning the knob to "OFF" cuts off the gas flow.

The operating control for NGB/2 and NGB/2/E are:

1. The "ON/OFF" switch on the cabinet front panel. This control is used to call for electrical power to the unit, by pushing the switch to the ON position, and to shut down the unit, by pushing the switch to the OFF position.

2. The "START" switch beside the "ON/OFF" switch. This control is used by briefly pushing the switch to the "START" position. Using this switch lights the burner and also restarts the unit, if an electric power failure or low water condition has cut off power to the gas valve.

3. The control knob on the gas valve. This control is used in the "PILOT" position (NGB/2 only), when you are lighting the pilot burner. For either the NGB/2 or the NGB/2/E, turning the knob to the "ON" position allows gas to flow through the valve to the burner. Turning the knob to "OFF" shuts off the gas flow.

Operation (cont'd)

B. Operating Procedure

1. For Model NGB with standing pilot: a. To light the pilot, turn the knob on the gas valve to "PILOT" and push it in. Hold the knob in

while lighting the pilot and for 50 seconds after the pilot is lit. Then turn the knob to "ON" and the unit is ready to light. Do not attempt to light the main burners directly with a flame.

b. Push the "ON/OFF" switch to the "ON" position. The unit will automatically fill with water.

Wait 30 seconds after the water level reaches the full mark on the gauge glass. then push the

"ON/OFF" switch to "RESET". The unit will light. c. If the pilot requires relighting, first turn the unit off and wait 5 minutes. Then follow the instructions in step "a." above.

2. For Model NGB/E with Carborundum ignition coil: a. The manual control knob on the gas valve must be in the "ON" position. b. Push the "ON/OFF" switch to the "ON" position. The unit will automatically fill with water.

Wait 30 seconds after the water level reaches the full mark on the gauge glass, then push the "ON/OFF" switch to "RESET". The unit will light.

3. For Model NGB/2 with standing pilot: a. To light the pilot, turn the knob on the gas valve to "PILOT", then push the knob in and hold

it while lighting the pilot burner. Continue to hold the knob in for 60 seconds after the pilot is lit. Then turn the knob to "ON". Do not try to light the main burners directly with a flame.

b. Push the "ON/OFF" switch on the cabinet front panel to the ON position. The red light in the

switch will come on, and the unit will automatically fill with water. When the water level in the gauge glass reaches the full mark. the green "READY" light will come on. Push the "START"

switch. The amber light in the switch will come on. and the burner will light. c. If the pilot goes out, first turn the unit off and wait 5 minutes, before you try to relight the pilot. Then follow the operating instructions, beginning with step "a" above.

4. For Model NGB/2/E with electronic ignition: a. Turn the knob on the gas valve to "ON". b. Push the "ON/OFF" switch on the cabinet front panel to the ON position. The red light in the

switch will come on, and the unit will automatically fill with water. When the water level in the gauge glass reaches the full mark, the green "READY" light will come on. Push the "START" switch. The amber light in the switch will come on, and the burner will light.

5. To shut down any model: a. Push the "ON/OFF" switch to the OFF position. When the generator has partially cooled, the unit will drain automatically. b. To shut down the unit completely, also turn the knob on the gas valve to the "OFF" position.

6. For any model:

a. If electric power failure or low water condition has stopped operation, wait at least 5 minutes, then follow the operating procedure for your unit to restart it. b. If generator pressure rises too far (over 14 PSI), the safety pressure switch will shut off power to the controls. In this case, after waiting at least 5 minutes, restart the unit by following the operating procedure for your unit, beginning with step "a".

If the pressure rises too high more than once, call your Groen Authorized Service Agency

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