Lincat Opus 800, OG8401, OG8402, OG8403 User, Installation, Servicing And Conversion Instructions

Please make a note of your product details for
future use:

Date Purchased:_________________________
Model Number:__________________________
Serial Number:__________________________
Dealer:_________________________________
_______________________________________

User, Installation, Servicing and Conversion
Instructions

Opus 800 Gas Chargrills
OG8401, OG8402 & OG8403

IS589 ECN4504

1

Dear Customer,
Thank you for purchasing this Lincat product.

This is just one of over 450 different items of catering equipment available
which is constantly being extended and improved. Details are available from
your local distributor or direct from us.
Used for the purposes for which it is intended, and with careful maintenance
as outlined in this User Guide, your Lincat product will give you years of
trouble free service.

For use in GB & IE

IMPORTANT INFORMATION

Please read all of the safety and operating instructions carefully before using this
product. Please pay particular attention to all sections of this User Guide that carry
warning symbols and notices.

WARNING!

This is a Warning symbol. This symbol is used throughout the user guide whenever
there is a risk of personal injury. Ensure that these warnings are read and understood
at all times.

CAUTION!

This is a Caution symbol. This symbol is used throughout the user guide whenever
there is a risk damaging your Lincat product. Ensure that these warnings are read and
understood at all times.

NOTE:

This is a Note symbol. This symbol is used throughout the user guide to provide additional
information, hints and tips.

IS589 ECN4504

2

CONTENTS

WARNINGS AND PRECAUTIONS

Contents Page

Customer Information………………………………………………………. 2
Warnings and Precautions………………………………………………… 3
Technical Data……………………………………………………………….. 4
Commissioning………………………………………………………………. 5
Check List of Enclosures………………………………………………….. 5
Installation…………………………………………………….……………… 6-7
Conversion of Gas Types………………………………………………….. 8-10
User…………………………………………………………………………….. 11-12

Servicing ……………………………………………………………………… 13
Component Replacement ………………………………………….……… 14

Spare Parts List……………………………………………………………… 15
Fault Finding…………………………………………………………………. 16
Service information………………………………………………………….. 17
Guarantee………………………………………………………….………….. 17

It is mandatory that all appliances are installed, commissioned and serviced by a
qualified and competent person as defined by the regulations in force in the country of
installation.

Failure to comply will invalidate the warranty.

WARNING!

This appliance must be installed by a competent installation engineer in accordance with the
installation instructions, and should conform to the following requirements:

Do not obstruct or block the appliance flue.
Installation must include sufficient ventilation to prevent the occurrence of unacceptable

concentrations of substances harmful to health in the room in which they are installed.
It is recommended that this appliance is sited under an extraction canopy for the removal of

combustion products.
After operation, some parts of the appliance will remain hot for a period of time. Please take care

to avoid accidental burns.

CAUTION!

All equipment must be equi-potentially earth bonded.
Do not connect directly to any flue, ducting or mechanical extraction system.
Installation should allow for a sufficient flow of fresh air for gas combustion.
Parts which have been protected by the manufacturer or his agent must not be adjusted by the

installer or user.
The gas supply hose and or tubing shall comply with local regulations and periodically inspected

for conformity.

IS589 ECN4504

3

TECHNICAL DATA

Model

OG8401

OG8402

OG8403

Dimensions

Overall Height (mm)

650

Width (mm)

600

900

1200

Depth (mm)

800

Weight (kg)

160

Cooking Surface w x d (mm)

500 X 620

700 X 620

1100 X 620

Cooking Grid Area (m2)

0.31

0.43

0.68

Heat Input

Total Heat Input Natural (Gross)

13.8kW

23kW

32.2kW

Total Heat Input Propane (Gross)

12.6kW

21kW

29.4kW

Individual Burner Heat Input

Heat Input Natural (Gross)

4.6kW

Heat Input Propane (Gross)

4.2kW

Burners per appliance

3 5 7

Connection and Supply Pressures

Gas Inlet Connection

½" BSP (RP ½)

Supply Pressure - Natural

20mbar

Supply Pressure - Propane

37mbar

Note: Propane appliances are regulated – see page 7

Gas Consumption Full Rate

Total Gas Rate – Natural

1.31m3h-1

2.19m3h-1

3.07m3h-1

Total Gas Rate – Propane

0.9kgh-1

1.5kgh-1

2.1kgh-1

Gas Rate – Natural

0.44m3h-1

Gas Rate – Propane

0.30kgh-1

Gas Consumption Low Rate

Total Gas Rate – Natural

0.63m3h-1

1.05m3h-1

1.47m3h-1

Total Gas Rate – Propane

0.41kgh-1

0.68kgh-1

0.95kgh-1

Gas Rate – Natural

0.21m3h-1 (2.2kW)

Gas Rate – Propane

0.14kgh-1 (1.9kW)

Individual Burner Gas Consumption Full Rate

Individual Burner Gas Consumption Low Rate

IS589 ECN4504

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NOTE

COMMISSIONING

CHECK LIST OF ENCLOSURES

Model

OG8401

OG8402

OG8403

Tick

Warranty Card

1 1 1

Branding Grids

5 8 11

Grid Scraper

1 1 1

Spatula

1 1 1

User Instructions

1 1 1

Barrel Nipple

1 1 1

Male – Female Elbow

1 1 1

Pressure Regulator

1 1 1

Serial Number

PREPARATION

Remove all packaging and protective coatings prior to installation.
VENTILATION

The area in which this equipment is to be installed should have sufficient fixed ventilation to
comply with local legislation requirements. It is recommended that a room, or internal space,
be provided with a minimum free area of 4.5cm2 per kW of total heat input.

Please ensure the following items are included with this piece of equipment:

For LPG (Propane) Appliances only

SERIAL NUMBER

Each appliance manufactured at Lincat has a unique identifying number found in the
top right hand corner of the data plate attached at the rear of the appliance. Please
record that number in the space provided should it be required for future reference.

IS589 ECN4504

5

INSTALLATION

SITING

The installer must ensure that all local regulations in force are met and that there is an
unobstructed minimum distance of 1000mm from the top of the cooking grid to the extraction
canopy, which must be of non-combustible material.
The appliance should be installed on a level surface ensuring the unit is stable and firmly
located.
Any partitions, walls or kitchen furniture in close proximity must be of non-combustible
materials and not be closer than 100mm from the sides and rear of the appliance.
There must be a minimum of 600mm clearance from the front of the appliance in which to
operate the appliance.

COUNTER TOP

If the appliance is to be installed on a counter top it shall be of a sturdy construction to hold
the weight of the appliance.
The counter top shall be of a non-combustible material.
The appliance when installed on a suitable countertop shall be level.
The surface of the grid shall be at a safe working height.
To level the appliance on the counter top the feet of the appliance can be rotated until the
appliance level is found.
The counter top and the appliance on which it is to be installed shall be beneath an extraction
canopy and shall comply with the conditions of SITING above.

GAS SUPPLY AND CONNECTION
The gas inlet connection is at the rear of the appliance on the right hand under side when
viewed from the front.
The gas inlet is ½" BSP (Rp ½)
It is recommended that the gas supply line for the OG8402 and OG8403 have a diameter not
less than 22mm or ¾" nominal bore.

The gas supply tubing or hose should be periodically inspected and replaced as necessary.
All joints made must be leak free.

Final gas connection to the appliance and gas supply shall comply with local regulations.
When making the connection to the appliance an isolating cock should be fitted into the

supply line for closing the gas supply in case of emergency shutdown or servicing purposes.
The isolating cock should have unrestricted access.

The appliances listed above have been designated Cat I & Cat II for 2nd and 3rd family gases.
They are flue type A1

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SUPPLY AND OPERATING PRESSURES

The appliance is connected directly to the gas supply where the gas supply pressure is
controlled at the source of inlet in the building or via the regulator attached to bottled gases.

Natural gas appliances are connected directly to the gas supply provided the inlet pressure is
regulated up stream to 20mbar.

Propane gas appliances require the fitting of a regulator at the inlet of the appliance where
the upstream pressure is regulated to 37mbar.
The set pressure for propane appliances is 30mbar with all burners in operation.

To gain access to the gas pressure test nipple the fascia panel requires removal. The test
nipple is situated at the left hand end of the manifold rail.
Remove the blanking screw and attach a pressure gauge to the boss of the test nipple to
check the supply pressure and/operating pressure.

FIRST TIME LIGHTING
The procedure for first time lighting may only be carried out by registered personnel.
To light any individual burner it may be necessary to purge all pipe work of air. To do this
through the pilots alone could take some considerable time. With the fascia panel removed
the test nipple plug can be removed to bleed the pipe work of air. When there is evidence of
gas flow at the test nipple the plug is to be refitted and made secure/leak free.
Refit the fascia panel and control knobs. A small amount of air will need to be purged from
each of the pilot lines.

IS589 ECN4504

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CONVERSION OF GAS TYPES

Model

Gas

Inlet

Pressure



Mark

Part

Number

All

G20

20mbar

1.51

310

JE45

G31

37mbar

1.06

150

JE34

Model

Gas  Mark

Part

Number

All

G20

1.10 N JE136

G31

0.72 P JE137

Model

Gas

Mark

Part

Number

All

G20

27.2

JE19

G31

22.1

JE20

The valve by-pass injector is fitted to the right of the
valve spindle.

Remove the by-pass injector 'Y' by screwing
anti-clockwise.

The rubber 'O' ring fitted to the by-pass injector
will offer some resistance. It may be necessary
to complete the withdrawal of the by-pass
injector using long nose pliers.

Replace the by-pass injector applicable to the
relevant gas type. Ensure the by-pass injector is
screwed fully home

Y

When converting to Propane an external
regulator must be fitted to the appliance gas

inlet in conjunction with a barrel nipple and or ½”

BSP Male-Female 90o elbow
NP01 – Barrel nipple
CO136 – 90o male/female elbow
PG10 - Regulator

CONVERSION OF GAS TYPE

Burner Injector Changes

Valve Bypass Injector Changes

Pilot Assembly Changes

Conversion from One Gas Type to Another

To convert the appliance from one gas type to another it will be necessary to remove the
fascia panel.
Remove all the control knobs from the valve spindles. Ensure the control knob spring clips
are not dislodged and become lost.
The fixing screws for the fascia panel are located on the underside of the fascia panel.
Remove the fixing screws and pull the fascia panel free from its locating lugs.
Each burner will require 1 pilot injector, 1 burner injector and washers, 1 bypass injector.
Follow the step by step guide to changing the necessary components for the gas conversion
process.
When converting from Natural gas to Propane an external regulator must be fitted at the gas
inlet of the appliance.

Valve By-pass Injector

IS589 ECN4504

8

B

C

JExx

A

D

To change the pilot injector very carefully loosen the ignitor retaining nut A and withdraw the ignitor B
Loosen and the pilot feed pipe nut C and withdraw the pilot feed pipe from the pilot assembly
The pilot injector, JExx, can be removed and replaced with the appropriate injector applicable to gas type
Refit the pilot feed pipe and secure nut C
Refit the ignitor B
Secure the ignitor with the retaining nut A taking care as to not to over tighten.
Note: Over tightening nut A can lead t fracture of the ignitor, B

Remove the screws S from the bracket
Loosen the the burner feed pipe nut at the valve, this will allow the pipe and bracket to swivel

S

Pilot Injector Removal

Remove the fascia panel as detailed previously to gain access to the valves and pilot
assemblies.

Burner Injector

IS589 ECN4504

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Remove the injector JEx together with the fibre washer (if applicable) and the copper washer W
Replace with the new injector applicable to the gas type being converted with a new copper washer, the
injector should be tightened to 2.5Nm and the thread should have a 0.5mm covering of Loctite 577.
Refit the bracket
Tighten the burner feed pipe nut
Check connections are leak free

IS589 ECN4504

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USER INSTRUCTION

APPLIANCE USE

This appliance is only for professional use and should only be used by qualified personnel.
Ensure that the person responsible understands how to light, safely operate, clean and shut
down the appliance and is made aware of the position and operation of the gas isolating cock
in the event of an emergency.

ROUTINE CLEANING

It is important that users of the appliance shall systematically check and clean down as
necessary areas of the grill that have accumulated oils, fats and other combustible
debris from previous cooking.
This is to prevent the potential risk of fire.
Cleaning of the appliance and its parts must be done when the appliance is cold and
before the start of service.

Areas to Check
 Branding grids – The spaces between the grids may become clogged and will need

to be cleaned to ensure even and clean cooking. Regular use of the scraper supplied
with the appliance will help keep the tops and the spaces of the branding grid clean
and clear.

 Radiant caps – The tops of the radiant caps will require brushing down to remove

build up of debris and ash that may have accumulated from previous cooking. They
may be removed to ease cleaning and must be refitted before use.

 Debris Collection Drawers – The drawers will need to be emptied of debris and

cleaned from old fats and oils that may have accumulated from previous cooking.

LIGHTING SEQUENCE

The operation of each burner is identical. Each valve has its own built in piezo ignition.
To light the gas at a burner, select the corresponding control knob.

If the appliance has stood unused for any length of time it may be necessary to purge
the pilot lines of air. To purge the pilot lines of air depress and rotate a control knob
until spring tension is felt. Maintain the knob in the depressed position for 20­30seconds and then fully rotate to the ignition position. Repeat as necessary until the
gas ignites at the pilot.

 Depress the control knob and rotate 90o anti-clockwise to the position marked with a

stylized star to light the gas at the pilot.

Should the pilot not light the first time maintain the control knob in this position
for a few seconds to allow a free flow of gas through to the pilot. Return the
control knob to the 'OFF' position and repeat the lighting sequence.

A portion of the pilot flame can be seen through the viewing port on the fascia
panel.

 After establishing the flame at the pilot; maintain the control knob in the depressed

position for approximately 15 seconds to retain the flame at the pilot. Confirmation of the
established flame is made by releasing the control knob.

IS589 ECN4504

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If the pilot flame goes out repeat the process until the flame is maintained.

Leave the pilot lit for a further 45-60 seconds to allow the flame failure sensing element to
heat to its full potential.

 To light the gas at the corresponding burner rotate the control knob to any point between

the low rate and full rate as denoted by the small and large stylized flames on the control
knob. When lit a portion of the flame at the burner can be seen through the viewing port
on the fascia. After a few minutes there will be an evident glow radiating from the burner
through the radiant cap.

LIGHTING WHEN HOT

When a burner has become hot and the pilot has been extinguished ionization may occur at
the piezo ignition point when attempting to relight the pilot burner. In such a case then the
pilot in question should be allowed to cool for approximately 10 minutes or the pilot can be
relit using a taper provided the control knob is rotated to the ignition point and held in the
depressed state. Access to the pilot is through the viewing port on the fascia panel.

COOKING ZONES

Cooking zones are controlled by the gas valves. The cooking temperature can be controlled
at any point between the low rate and the full rate.
After lighting, each zone can be left on pilot standby.

DEBRIS COLLECTION DRAWERS

It is recommended that each drawer is filled with a small volume of water before the
start of service. Any fats or oils from the cooking process falling through to the drawers
will form a film on the water whilst heavier pieces of debris will lie on the base of the
drawer.
At regular intervals during quieter times of service the drawers should be periodically
checked for the level of water and emptied of collected debris as necessary.

USING THE APPLIANCE

For first time use it is recommended that the branding grids are 'seasoned'.
To season the grids, lightly coat the cooking surfaces with cooking oil. Place the grids back
on to the appliance and heat the grids to season.

Before the start of daily service flip the branding grids and heat at full power for 10 minutes to
carbonize the previous day's deposits. Remove debris using the scraper. Lower the
temperature of the zones to the desired cooking temperature.

Use of griddle plates or large pans covering a significant portion of the cooking grid is
not recommended.

12

IS589 ECN4504

SERVICING

SERVICE

The only end user service operation permitted is the routine cleaning and inspection of
external parts of the appliance. The only maintenance operation permitted is the replacement
of parts by approved and qualified representatives appointed by Lincat Ltd.
Visual inspection shall determine that:

 Branding grids are not clogged and excessive carbon build up has been removed
 Debris collection drawers are in an acceptable clean condition including surge bars
 Radiant caps are free from excessive build up of carbon
 Splash back and hob top are in an acceptable clean condition
 Equi-potential earth bond is attached
 Flexible gas supply hose (where fitted) is of a sound condition and the safety restraint

chain/cable is attached

 All gas taps function correctly in terms of lighting pilots and burners

13

IS589 ECN4504

AA

BB

CC

DD

EE

COMPONENT REPLACEMENT

Loosen the pilot feed pipe nut AA and withdraw the pilot feed pipe from the valve body
Loosen the valve inlet nut BB
Loosen the burner feed pipe nut CC and free the burner feed pipe from the valve body
Loosen the valve body nut DD
Loosen and remove the thermocouple nut EE (not shown) at the rear of the valve
Disconnect the ignitor lead from the ignitor at the pilot assembly (not shown)
After the valve has been replaced and fitted all pipework connections must be checked and verified leak
free.

Valve Body

Thermocouple

To remove the thermocouple loosen the nut D as shown on the pilot injector change details
Loosen the thermocouple nut EE as detailed above.
The nut D is lightly crimped to the thermocouple body; it can be teased free of the
thermocouple and re-used.
Replace the new thermocouple and secure fittings.

Burner Replacement

Replacing the burner requires significant component disassembly; for details contact Service
Agent

IS589 ECN4504

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Part number

Part description

Used on

BP45

Cast Branding Grid

All

BU29/S

Ceramic Plaque Burner

All

CO113

Copper Washer

All

CO248

Olive 8mm

All

CO254

Tube Nut

All

CO52

Stud Elbow 8mm

All

CO53

Lock Nut

All

FE40

Adjustable Foot

All

IG03

Ignitor Electrode

All

IS571

User Manual

All

JE136

Bypass Injector Natural Gas

All

JE137

Bypass Injector Propane Gas

All

JE34

Burner Injector Propane Gas

All

JE45

Burner Injector Natural Gas

All

KN507

Control Knob

All

MA166

Manifold

OG8401

MA167

Manifold

OG8402

MA168

Manifold

OG8403

PI03A

Pilot Body

All

PI03B

Pilot Thermocouple Nut

All

PI03C

Ignitor Nut

All

PI03D

Olive Nut

All

PI03E

Olive

All

RC03M

Radiant Cap

All

SC06

Scraper

All

SP08

Pilot Spacer

All

TU05

Valve Inlet Tube

All

TU08

Flexi Tube 8 X 150

All

TU09

Flexi Tube 4 X 300

All

VA70

Control Valve (complete with fittings)

All

VA70A

Control Valve Body

All

VA70B

Lock Nut

All

VA70C

Compression Nut 8mm

All

VA70D

Compression Nut 4mm

All

VA70E

Olive 4mm

All

SPARE PARTS LIST

IS589 ECN4504

15

FAULT FINDING

User Fault Finding

Pilot not lighting

Check gas supply is on

Turn on the gas supply

Gas supply is on but pilot not lighting

Check for spark at ignitor

The spark can be seen by looking through the inspection slots on the control
panel.

There is a spark at the ignitor

See note on lighting sequence

Spark cannot be seen at ignitor

Contact Service Agent

Service Agent Fault Finding

Gas supply is on but pilot not lighting

Check for short in ignitor lead or ignitor

Replace valve*
or
Replace ignitor electrode

*Ignitor lead is an integral part of the valve

Pilot lighting but will not stay lit

Check thermocouple integrity

Replace thermocouple

IS589 ECN4504

16

 Product code

All available on serial plate

 Type number

 Serial number

SERVICE INFORMATION

For help with the installation, maintenance and use of your Lincat equipment, please
contact our service department:

For non-UK customers, please contact your local Lincat dealer
All service work, other than routine cleaning MUST be carried out by qualified

personnel and a record kept of any remedial actions taken and at least cover the
requirements of the service schedule of this document. We cannot accept
responsibility for work carried out by other persons.

To ensure your service enquiry is handled as efficiently as possible, please tell us:
 Brief details of the problem

Lincat reserve the right to carry out any work under warranty, given reasonable access
to the appliance, during normal working hours, Monday to Friday, 08:30 to 17:00.

DECLARATION

All Lincat products capable of burning gaseous fuels, satisfy the requirements of the
Gas Appliance Regulations 2016/426.

 UK: 01522 875520

GUARANTEE

This unit carries a comprehensive UK mainland warranty. The guarantee is in addition
to, and does not diminish your statutory or legal rights. Contact Lincat for terms and
conditions

The guarantee does not cover:

 Accidental damage, misuse or use not in accordance with the manufacturer’s

instructions

 Consumable items (such as filters, glass, bulbs, slot toaster elements and door

seals.)

 Damage due to incorrect installation, modification, unauthorised service work or

damage due to scale, food debris build-up, etc.

The manufacturer disclaims any liability for incidental, or consequential damages.

Attendance is based on reasonable access to the appliance to allow the authorised
personnel to carry out the warranty work.

Service calls to equipment under warranty will be carried out in accordance with the
conditions of sale. Unless otherwise specified, a maximum of 15 minutes of administrative
time, not spent directly carrying out servicing work, is provided for within the warranty. Any
requirement for staff attending the call to spend greater time than 15 minutes due to
administrative requirements, such as on health and safety risk assessments, will be
chargeable at the prevailing rate.

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