Hobart GHCB40 Installation Manual

INSTALLATION &

OPERATION MANUAL

HEAVY DUTY GAS BROILERS

CERAMIC BROILERS

MODELS MLS

GHCB40C ML-52212

GHCB40 ML-52211

GHCB44 ML-52213

HCB2T ML-52203

HCB2B ML-52208

SUNGLOW BROILERS

MODELS MLS

IR2T ML-52207

IR2B ML-52201

GHIR44 ML-52210

For additional information on Vulcan-Hart or to locate an authorized parts andFor additional information on Vulcan-Hart or to locate an authorized parts and

For additional information on Vulcan-Hart or to locate an authorized parts and

For additional information on Vulcan-Hart or to locate an authorized parts andFor additional information on Vulcan-Hart or to locate an authorized parts and

service provider in your area, visit our website at www.vulcanhart.comservice provider in your area, visit our website at www.vulcanhart.com

service provider in your area, visit our website at www.vulcanhart.com

service provider in your area, visit our website at www.vulcanhart.comservice provider in your area, visit our website at www.vulcanhart.com

TECHNICAL SERVICE AND PARTS ASSISTANCE

MODEL GHCB40

1-800-814-2028

VULCAN-HART DIVISION OF ITW FOOD EQUIPMENT GROUP, LLC

WWW.VULCANHART.COM

3600 NORTH POINT BLVD.

BALTIMORE, MD 21222

FORM 32801 (Sept. 2005)

IMPORTANT FOR YOUR SAFETY

THIS MANUAL HAS BEEN PREPARED FOR PERSONNEL QUALIFIED TO INSTALL GAS EQUIPMENT, WHO SHOULD PERFORM THE INITIAL FIELD START-UP AND ADJUSTMENTS OF THE EQUIPMENT COVERED BY THIS MANUAL.

POST IN A PROMINENT LOCATION THE INSTRUCTIONS TO BE FOLLOWED IN THE EVENT THE SMELL OF GAS IS DETECTED. THIS INFORMATION CAN BE OBTAINED FROM THE LOCAL GAS SUPPLIER.

IMPORTANT

IN THE EVENT A GAS ODOR IS DETECTED, SHUT DOWN UNITS AT MAIN SHUTOFF VALVE AND CONTACT THE LOCAL GAS COMPANY OR GAS SUPPLIER FOR SERVICE.

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 OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.

IN THE EVENT OF A POWER FAILURE, DO NOT ATTEMPT TO OPERATE THIS DEVICE.

– 2 –

STOP BOLTS

IMPORTANT

STOP BOLTS MUST BE IN POSITION FOR SAFE OPERATION OF GRID.

IF DAMAGED OR MISSING, REPLACE AT ONCE.

DO NOT OPERATE GRID WITHOUT BOLTS.

– 3 –

INSTALLATION, OPERATION AND CARE OF

CERAMIC AND SUNGLOW HEAVY DUTY BROILERS

PLEASE KEEP THIS MANUAL FOR FUTURE USE

GENERAL

The manufacturer suggests that you thoroughly read this entire manual and carefully follow all of the instructions provided.

Your Vulcan Sunglow or Ceramic Broiler is produced with quality workmanship and material. Proper installation, usage and maintenance of your broiler will result in many years of satisfactory performance.

INSTALLATION

UNPACKING - ALL BROILER MODELS

This broiler was inspected before leaving the factory. The transportation company assumes full responsibility for safe delivery upon acceptance of the shipment. Immediately after unpacking, check for possible shipping damage. If the broiler is found to be damaged, save the packaging material and contact the carrier within 15 days of delivery.

Remove the small wood slats and wire used to hold burners and broiler grid in place.

Before installing, verify that the electrical service and type of gas supply (natural or propane) agree with the specifications on the rating plate.

Models Rating Plate Location

IR2 & GHIR44 Cabinet bottom, front right-hand side

GHCB44 Inside cabinet door panel

HCB2 Cabinet bottom, front left-hand side

GHCB40 Oven: behind the kick panel attached to the left side of the oven

burner box front shield, positioned behind the bell crank

Broiler: Front manifold cover

If the supply and equipment requirements do not agree, do not proceed with the installation. Contact your dealer or Vulcan-Hart immediately.

– 4 –

LOCATION

The equipment area must be kept free and clear of combustible substances.

This broiler is design certified for installation with the following minimum clearances from combustible and noncombustible adjacent wall construction:

COMBUSTIBLE NONCOMBUSTIBLE

MODELS CONSTRUCTION CONSTRUCTION

GHCB40 Back 6" (152 mm) 0" GHCB40C Right Side 6" (152 mm) 0" GHCB44 Left Side 6" (152 mm) 0"

Floor 6" (152 mm) 0"

COMBUSTIBLE NONCOMBUSTIBLE

MODEL CONSTRUCTION CONSTRUCTION

GHIR44 Back 4" (102 mm) 0"

Right Side 0" 0" Left Side 0" 0" Floor 6" (152 mm) 0"

COMBUSTIBLE NONCOMBUSTIBLE

MODEL CONSTRUCTION CONSTRUCTION

HCB2 Back 4" (102 mm) 0"

Right Side 4" (102 mm) 0" Left Side 4" (102 mm) 0" Floor 6" (152 mm) 0"

COMBUSTIBLE NONCOMBUSTIBLE

MODEL CONSTRUCTION CONSTRUCTION

IR2 Back 4" (102 mm) 0"

Right Side 0" 0" Left Side 0" 0" Floor 6" (152 mm) 0"

The installation location must allow adequate clearances for servicing and proper operation. A minimum front clearance of 35" (889 mm) is required.

Do not obstruct the flow of combustion and ventilation air. Adequate clearance for air openings into the combustion chamber must be provided. Make sure there is an adequate supply of air in the room to replace air taken by ventilating systems and allow for combustion gas at the broiler burners.

– 5 –

INSTALLATION CODES AND STANDARDS - ALL BROILER MODELS

Your broiler must be installed in accordance with:

In the United States

1. State and local codes.

2. National Fuel Gas Code, ANSI/Z223.1 (latest edition). Copies may be obtained from The American Gas Association, Inc., 1515 Wilson Blvd., Arlington, VA 22209.

3. National Electrical Code, ANSI/NFPA-70 (latest edition). Copies may be obtained from The National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

In Canada

1. Local codes.

2. CSA B149.1 Natural Gas and Propane Installation Code.

3. CSA C22.1 Canadian Electric Code (latest edition).

The above are available from the Canadian Standard Association, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6.

BROILERS MOUNTED ON CASTERS

Broilers mounted on casters must use a flexible connector (not supplied by Vulcan) that complies with the Standard for Connectors for Movable Gas Appliances, ANSI Z21.69 • CSA 6.16 and a quickdisconnect device that complies with the Standard for Quick-Disconnect Devices for Use With Gas Fuel, ANSI-Z21.41 • CSA 6.9. In addition, adequate means must be provided to limit movement of the appliance without depending on the connector and the quick-disconnect device or its associated piping to limit appliance movement. Attach the restraining device at the rear of the broiler.

If disconnection of the restraint is necessary, turn off the gas supply before disconnection. Reconnect this restraint prior to turning the gas supply on and returning the broiler to its installation position.

Separate instructions for installing casters to the broiler are included with the casters.

Note: If the broiler is installed on casters and is moved for any reason, it is recommended that the broiler be releveled front to back and side to side.

UNSTACKING AND STACKING - MODEL GHCB2

Read all instructions carefully before unstacking or stacking broilers.

The height of Models HCB2 and IR2 sometimes prohibits entry through the kitchen facility doorway. For this reason, two 3

/4 x 11/2 x 3/64" (95 mm x 38 mm x 1.2 mm), aluminized stacking straps are shipped

with each broiler for ease of top section disassembly.

Broilers Shipped Pre-stacked

1. Remove top section finishing back.

2. From oval slots inside finishing back of the top section, remove two 10-24 bolts which connect the top and bottom sections (Fig. 1).

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3. Remove drip pan and disassemble two 10-24 bolts, one to the left and one to the right of the inside drip pan area, behind the top section front frame (Fig. 2).

PL-41717

PL-41718

Fig. 1 Fig. 2

4. Carefully remove broiler top section from the bottom section.

5. Leaving the lower far-left and right holes open, reassemble the top finishing back onto the top.

Broilers Shipped in Two Pieces for Restacking

The incorporation of the stacking straps will eliminate the use of the two oval slots, one to the left and one to the right, behind the finishing back of the top section. (See Step 2 under Broilers Shipped PreStacked.)

1. Position broilers as near to installation location as possible. Remember to allow enough room to complete stacking procedures.

2. Carefully lift top section and rest it evenly onto the bottom section.

3. Remove top section drip pan. Align two holes,

STACKING STRAP

one to the left and one to the right of the upper drip pan area, behind the broiler front frame. Insert two 10-24 bolts and assemble the top section to the bottom section.

4. Replace the drip pan.

5. From rear of broiler, remove two 10-24 bolts from the upper corner of the left- and right-hand bottom section finishing back.

PL-56559

6. Using four 10-24 bolts, assemble the stacking strap as shown in Fig. 3. This will complete the

Fig. 3

stacking procedure.

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DRAFT HOOD INSTALLATION - GHCB40 OR GHCB44

All GHCB40's and GHCB44's come equipped with a hood flue diverter that is packaged and laying in the top broiler compartment. This flue diverter must be attached to the unit at the time of installation, following the steps below:

1. If the diverter has protective plastic covering the assembly, remove all the plastic.

2. Place the diverter on top of the unit covering the flue (Fig. 4).

3. Remove four 10-24 sheet metal screws from the top rear flange of the broiler (Fig. 5).

HOOD

FLUE

DIVERTER

FLUE

SCREWS

PL-41719-1

PL-41720-1

Fig. 4 Fig. 5

PL-41721

PL-41722

Fig. 6 Fig. 7

4. Align the four holes/slots in the rear flange of the diverter with the holes in the rear top flange of broiler, and reinstall four 10-24 sheet metal screws (Fig. 6).

5. Diverter installation is now complete (Fig. 7).

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Body Side Extensions

Body side extensions are wrapped separately and packaged lying in the top broiler compartment of each GHCB40/44 Broiler. The use of these extensions is optional. The extensions are intended to help align the broil battery evenly, front to back, with other Vulcan Heavy Duty Ranges. To install, follow the steps below:

1. Locate and unwrap the extensions.

SCREWS

PL-41723-1

Fig. 8 Fig. 9

PL-41724

2. Remove five 10-24 sheet metal screws that attach each body side to the broiler back panel (Fig. 8).

3. Align the holes left by removal of the 10-24 sheet metal screws with predrilled holes in the right and left body extensions. Secure the extensions to the body sides by reinstalling the five 1024 sheet metal screws removed in Step 2 (Fig. 9).

NOTE: Do not align using the square flange openings. The square openings are to access use of ratchet extensions for ease of assembly.

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Fire Brick Installation - GHCB40/44

All GHCB40/44's come equipped with 12 center fire bricks and 8 side bricks.

The bricks must be placed in the broiler at the time of installation. The bricks are packaged in a cardboard box, which is placed in the top broiler compartment for shipping. To install the bricks, follow the steps below:

1. Cut through the shipping wire strap that holds the broiler grid in place if this has not already been done.

2. Place the broiler grid into its lowest position.

PROTRUDING POINTS

SIDE FIRE BRICK

CENTER FIRE BRICK

SIDE BRICK RIDGE

PL-41725-1

Fig. 10

NOTE: Bricks are to be installed with the protruding points facing downward. Installing the side bricks

first will make the job easier (Fig. 10)

3. To install side brick, with brick in hand, points protruding downward, reach up through the broiler grid compartment and rest the brick in the bracketing along side of the cast iron burners. It will be necessary to tilt the bricks to get them between the burner and bracket. Then lift the brick up above the burner and bracket, and set it carefully down in place.

NOTE: The side bricks have a ridge. This ridge should set down inside the far left and right bracket flanges; you will install four bricks along each bracket flange (Fig. 11 and 12).

SIDE BRICK RIDGE

BRACKET FLANGE

BURNER

PL-41726 PL-41727-1

Fig. 11 Fig. 12

– 10 –

4. Center bricks are installed towards the center of the broiler in three rows of four bricks each. Install the center bricks similar to that of the side bricks in Step 3. Angle the bricks and slip them up between the burners, then set them in place.

NOTE: The center bricks are to be installed to rest between two burners on the vertical burner flange (Fig. 13 and 14).

PL-41728 PL-41729

Fig. 13 Fig. 14

LEVELING AND CONNECTING MANIFOLDS - ALL MODELS

The IR2 Model is not designed to be batteried to other heavy duty equipment. After leveling the IR2 Model, as described in Step 2, proceed to Gas Connections.

1. Place the broiler in its exact position or battery lineup.

2. Using a carpenter level, level the broiler from front to rear and from side to side. Unless the broilers are level, they will not give proper cooking results, and equipment being batteried will not draw up tight.

As of January 1998, Vulcan-Hart appliances use Ward gas unions instead of Stockham gas unions. If you are installing a new battery range to an existing field appliance, the union on the existing field appliance must be checked against the union being used on the new range. The union manufacturer’s name around the face surface of the union nut must match. The new range has been shipped with a Ward union. If the old appliance has something different, i.e., Stockham, it must be replaced with a Ward union. Failure to replace this union could result in a gas leak (Fig. 15).

If a Ward gas union is needed for installation, purchasing information may be obtained through the Vulcan-Hart Parts Department.

– 11 –

Fig. 15

Questions or concerns regarding the installation procedures may be addressed by calling the VulcanHart Service Department 1-800-814-2028.

3. Engage union nut on manifold pipe of broiler with the male fitting on the next broiler, and draw up union hand-tight. Be sure broilers butt both front and rear.

NOTE: Broilers are mounted on a steel, skid-type base, so a crowbar may be used to jockey units. If the manifolds do not line up, then the broilers are not level.

4. Continue to level up and connect manifold pipe until all broilers in the battery are connected, then tighten all manifold unions gas-tight.

– 12 –

GAS CONNECTIONS

CAUTION: All gas supply connections and any pipe joint compound used must be resistant to the action of propane gases.

Connect gas supply to the broiler(s). Make sure the pipes are clean and free of obstructions, dirt and piping compound.

Codes require that a gas shutoff valve be installed in the gas line ahead of the broiler.

Natural gas broilers and propane gas broilers are equipped with fixed orifices and no adjustment is necessary.

Model IR Broilers for operation on natural or propane gas are also equipped with a factory-preset pressure regulator, with an outlet pressure of 6" (1.49 mb) Water Column for natural gas supply and 10" (2.49 mb) Water Column for propane gas supply. No further adjustment should be required.

Models GHCB40 and GHCB44 also require a pressure regulator (not supplied). The regulators must have:

• C.S.A. design certification.

• Enough regulation capacity for the total connected gas load.

• Pressure adjustment range to allow adjustment for the manifold pressure marked on the rating plate.

Unless the manifold pressure on all connected broilers is the same, a separate regulator must be supplied for each broiler having different manifold pressures.

If the front plates do not line up perfectly, adjust by using bolts under the front plate.

WARNING: PRIOR TO LIGHTING, CHECK ALL JOINTS IN THE GAS SUPPLY LINE FOR LEAKS. USE SOAP AND WATER SOLUTION. DO NOT USE AN OPEN FLAME.

Ensure that burner heads are connected.

After piping has been checked for leaks, all piping receiving gas should be fully purged to remove air.

TESTING THE GAS SUPPLY SYSTEM

When test pressures exceed

/2 psig (3.45 kPa), the broiler and its individual shutoff valve must be

disconnected from the gas supply piping system.

When test pressures are

/2 psig (3.45 kPa) or less, the broiler must be isolated from the gas supply

system by closing its individual manual shutoff valve.

FLUE CONNECTIONS

DO NOT obstruct the flow of flue gases from the flue duct located on the rear of the broiler. It is recommended that the flue gases be ventilated to the outside of the building through a ventilation system installed by qualified personnel.

From the termination of the broiler flue vent to the filters of the hood venting system, an 18" (457 mm) minimum clearance must be maintained.

Information on the construction and installation of ventilating hoods may be obtained from the standard for "Vapor Removal from Cooking Equipment," NFPA No. 96 (latest edition), available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

– 13 –

ELECTRICAL CONNECTIONS

WARNING: ELECTRICAL AND GROUNDING CONNECTIONS MUST COMPLY WITH THE

APPLICABLE PORTIONS OF THE NATIONAL ELECTRICAL CODE AND/OR OTHER LOCAL ELECTRICAL CODES.

WARNING: DISCONNECT THE ELECTRICAL POWER TO THE MACHINE AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.

If the broiler is not equipped with a grounding plug and electrical supply is needed, ground the broiler by using the ground lug provided (refer to the wiring diagram located inside the lower cabinet section).

Infrared broilers Models IR2 and GHIR44 are equipped with a 4' (122 cm) long supply cord.

WARNING: APPLIANCES EQUIPPED WITH A FLEXIBLE ELECTRIC SUPPLY CORD ARE PROVIDED WITH A THREE-PRONG GROUNDING PLUG. IT IS IMPERATIVE THAT THIS PLUG BE CONNECTED INTO A PROPERLY GROUNDED THREE-PRONG RECEPTACLE. IF THE RECEPTACLE IS NOT THE PROPER GROUNDING TYPE, CONTACT AN ELECTRICIAN. DO NOT REMOVE THE GROUNDING PRONG FROM THIS PLUG.

Do not connect broiler to electrical supply until after gas connections have been made.

MINIMUM BYPASS SETTING - MODEL GHCB40 OVEN

Adjust the oven pilot and burner for proper adjustment of minimum bypass setting. See instructions under LIGHTING INSTRUCTIONS - MODEL GHCB40 OVEN.

LIGHTING INSTRUCTIONS - MODELS GHCB44 AND GHCB40 BROILERS

1. Remove au gratin oven bottom, baffle and burner box cover.

2. Remove oven bottom and baffles (Model GHCB40 only).

3. Remove manifold panel.

4. Turn gas supply ON.

5. Place the ceramics, with the projections down, to the rear of broiler burners. The lugs on the burners will properly position themselves. The ceramics are sized at the factory.

6. Place the au gratin oven baffle and bottom, but leave the burner box cover off.

7. Turn the gas valve ON and allow air in the line to be exhausted. When gas begins to flow, turn gas valve OFF and wait 5 minutes before lighting pilots and burner with a taper. The burner

flame should be sharp when the broiler is cold, with a blue cone of flame about on natural gas and

/2" (12.7 mm) long on propane gas. The flame will soften out and curl around

/4" (19 mm) long

the ceramics as the broiler gets hot. The length of the flame is determined by the adjustment of the nozzle. The sharpness of the flame is determined by the air shutter adjustment.

8. Adjust broiler pilots at the pilot valve on the left end of the pilot manifold pipe. Adjust the flame to approximately

/4" (19 mm) long. Replace the burner box front.

9. Replace manifold panel and other parts that had been removed.

NOTE: Be sure pilots remain lit after installation.

– 14 –

Carbonization of Ceramics

If the ceramics take on a black sooty accumulation, the burners are receiving an insufficient amount of air. Open the air shutters further to provide more air. If carbonization occurs during initial adjustment, it will burn off as soon as proper adjustment is achieved.

Burner Performance

If, after a period of satisfactory operation, the burner flame characteristics should change or the length of burner flame should be reduced, either the air mixer opening or the gas valve orifice has become restricted. The burners should be cleaned every 60 days, or more often as required, by an authorized servicer.

LIGHTING INSTRUCTIONS - MODEL GHCBO40 OVENS

1. If the oven pilot is out, turn the burner OFF. Wait 5 minutes before relighting.

2. Depress the red ignition button located on the oven control panel and ignite the pilot. Hold 60 seconds until pilot remains ON.

3. Adjust the oven pilot and burner for proper adjustment of minimum bypass setting. This adjustment must be made at the time the broiler is installed. To adjust this flame:

• Be sure oven burner pilot flame is ignited.

• With oven cold, slowly turn dial (Fig. 16) counterclockwise from OFF until main burner gas snaps on.

• Remove dial.

• With a screwdriver, turn bypass adjustment screw (Fig. 16) counterclockwise to increase the bypass flame, or clockwise to decrease it, until flame over entire burner is approximately

/8"

(3.175 mm) high.

• Replace dial.

CAUTION: While making this adjustment, if the oven should become heated while the dial is set at a low range (below 350°F [177°C]), the bypass flame will shut off completely. If this occurs, turn dial counterclockwise slowly until bypass gas snaps on. Then check bypass adjustment as stated above.

DIAL

POINTER "A"

O L

MODEL FDO

CALIBRATION PLATE

Fig. 16

– 15 –

BY-PASS ADJUSTMENT SCREW

CALIBRATION SCREWS

SCREW CLEARANCE SLOTS

PL-56560

LIGHTING INSTRUCTIONS - MODELS HCB2

1. Remove burner box front cover and turn gas supply ON.

2. Place the ceramics, with the projections down, to the rear of broiler burners. The lugs on the burners will properly position themselves. The ceramics are sized at the factory.

3. Turn the gas valve ON and allow air in the line to purge. When gas begins to flow, turn gas valve

OFF and wait 5 minutes before lighting the pilots. The pilot flame should be about

/4" high and burner with a taper. The burner flame should be high enough to touch the ceramic bricks. The length of the burner flame is determined by the adjustment of the burner nozzle. When the burner flame is cold, the flame should appear as a sharp blue cone. As the flame gets hot, it will soften in color and begin to curl around the ceramics. The sharpness of the flame is controlled by the setting of the burner air shutter (Fig. 17).

PL-41730

Fig. 17

Pilot Burner Adjustment

Turn the pilot burner valve (located in the lower compartment) ON. Each burner is provided with a standing pilot burner. Adjust the pilot flame to approximately

/4" (19 mm) flame height. The adjusting valve is installed in the inlet of the pilot burner manifold, located behind the removable front panel above the grid area.

Carbonization of Ceramics

Burner Performance

– 16 –

LIGHTING INSTRUCTIONS - MODELS IR2 AND IR44 (INFRARED)

1. Remove burner box cover.

2. Turn gas supply ON.

3. Turn pilot burner B valve (located in the lower left-hand compartment) (Fig. 18) ON and light

pilots (one pilot per burner) with a taper (Fig. 19).

4. If the pilots go out, turn B valve (Fig. 18) OFF and wait 5 minutes, then repeat Step 3.

BURNER B VA LVE

TOGGLE SWITCH

INDICATOR LIGHT

PL-41731-1

Fig. 18 Fig. 19

PL-41732

– 17 –

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