mastro ABE0001, ACE0005 Maintenance Instructions

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052_03

Installation, operating and maintenance instructions

GAS PASTA COOKER

03/2006

ABE0001 ACE0005

Page 2

Models and dimensions page 3

Data of appliances 4

Technical data 4-5

Operating instructions 6

Construction, equipment installed

and safety devices 6

Assembly 6

Location 6

Legal and technical requisites 6

Installation 6

Installation procedure 6

Gas connection 6

Plumbing connection 6

Gas venting 6

Commissioning the appliance 7

Before commissioning the appliance 7

Start-up 7

Testing the power rating 7

Checking input pressure 7

Checking power rating using

the volumetric method 7

Checking power rating when using

LP gas 7

Checking the pilot light 8

Checking the primary air 8

Checking the functions 8

Note for the installer 8

Running the appliance on other types

of gas page 8

Replacing the main burner nozzle 8

Pilot injector replacement 8

Adjusting the low flame 8

Maintenance 8 Replacing parts 9

Ignition plung 9

Gas tap 9

Thermocouple 9

Using the appliance 10

First-time use of the appliance 10 Ignition 10

Turning the pilot burner on 10

Turning the main burner on and adjusting

the temperature 10

Turning the appliance off 10

Turning the appliance off during

normal operation 10

Turning the appliance off

in an emergency 10

What to do if something goes wrong or if

not using the appliance for a long time 10

Taking care of the appliance frequency of maintenance 11

Daily cleaning 11

Precautions during use 11

Protection of stainless steel 11

Warning 12

INDEX

052-03 - Gas pasta cooker

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052-03 - Gas pasta cooker

A B C D E F

Drainage tap Inlet tap Gas control knob Piezo electric lighter Water inlet Gas connection

Models and dimensions

600

400

655

300

BDAC

600

400

700

300

BDAC

ABE00001

600 x 650 x 300 weight approx.33,6 kg

ACE00005

600 x 700 x 300 weight approx35,6 kg

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052-03 - Gas pasta cooker

3 - TECHNICAL DATA

2 - DATA OF APPLIANCES

The instructions contained in this manual apply to our gas cookers in the II2H3+ category (see table on page 5). The data plate is located on the front of the appliance and

on the control panel. It contains all necessary reference data such as the name of the manufacturer, input pressure, gas type setting, etc.

0051

TIPO/TYPE

CAT/KAT GAS/GAZ G30 G31 G20 G25

II2H3B/P P mbar 30 30 20 -

II2H3+ P mbar 30 37 20--

II2H3+ P mbar 28 37 20 -

25II2L3B/P P mbar 30 30

II2ELL3B/P P mbar 50 50 20 20

II2E+3+ P mbar 28 37 20 25

II2H3B/P P mbar 50 50 20 -

I2E P mbar - - 20 -

--II2H3B/P P mbar 30 30

II2H3+ P mbar 28 37 20 -

I3B/P P mbar 30 30

I3+ P mbar 28 37

SE FI DK CZ SK SI

IT CH PT

ES IE GB GR

FR BE

AT CH

EE LV LT

NO MT CY IS HU

MOD.

ART.

Qn kW

m3/h

MADE IN ITALY

Predisposto a gas: - Gas preset: - Prevu pour gaz:

Eingestelt für Gas: - Preparado para gas: -

Geschuckt voor:

V AC kW Hz

THE APPLIANCE MUST BE CONNECTED IN COMPLIANCE WITH THE LAWS IN FORCE AND INSTALLED IN A WELL-VENTILATED ROOM. READ THE INSTRUCTION MANUALS BEFORE INSTALLING AND USING THE APPLIANCE. THE APPLIANCE MUST BE INSTALLED BY QUALIFIED PERSONNEL.

G30/G31 28/37 mbar

G20 20 mbar

Model

ABE00001

ACE00005

51BQ2902

External dimensions

(LxPxH+H1) - mm

Plumbing

connection - mm

Water

outlet

Gas connection Tank

capacity (lt)

600 x 650 x300

600 x 700 x 300

Ø 12

front panel

R 1/2" ISO R228

R 1/2" ISO R2283434

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052-03 - Gas pasta cooker

Primary air distance “A”

Methane gas G20

Liquid gas G30/G31

open

TABLE 1

Model

Category

Construction type

Air necessary for combustion

Nominal thermal power

Minimum thermal power

Connection pressure

Methane gas 2H

Liquid gas 3+

Gas connection values

Methane gas 2H

Liquid gas 3+

Nozzles Ø 1/100 mm

Main burner

G20

G30/G31

(HuB = 9.45 kWh/m

) m3/h

(HuB = 12.87 kWh/kg) kg/h

Nominal capacity

Low flame

Nominal capacity

Low flame

G20

G30/31

20 mbar

30/37 mbar

II2H3+

2x150

adjustable

2x95

No. of nozzles, pilot burner

G20

G30/G31

3.2

ABE00001 ACE00005

0.847

0.631

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Construction, equipment installed and safety devices

Robust steel frame, with 4 legs (adjustable in height). 18/10 chrome-nickel steel outer panelling, tank in AISI

316. The water is heated by 2 tubular stainless steel burners, which is resistant to thermal and mechanical stress. The pilot burner has fixed injector. The combustion chamber and flues are made of electro-galvanised steel sheeting. The temperature is set using the safety taps provided. It goes from low (minimum) to high (maximum) through a range of easily selectable intermediate levels.

ASSEMBLY

Location

The appliance should be installed in a well ventilated room, and under a range hood. The appliance can be installed on its own or alongside other equipment. If the appliance is to be installed near inflammable walls, a minimum distance of 50 mm. around the sides and back should be allowed. If this is impossible, take proper steps to ensure the installation is safe, such as fitting tiles or heat-reflecting material to the walls Before connecting up the appliance to the gas supply, check on the data plate that the appliance is fitted for the type of gas available. If not, consult paragraph “Running the appliance on other types of gas”, page 8.

Legal and technical requisites

During assembly, the following legal and technical requisites should be adhered to:

- relevant national legislation;

- local building and fire safety regulations;

- worksheet “Technical rules for installing gas”;

- worksheet “Technical rules for LP gas”;

- worksheet “Gas installations in industrial kitchens”;

- industrial injury legislation;

- local Gas Board regulations;

- current CEI regulations.

INSTALLATION

Assembly, installation and maintenance, i.e.: assembly, connecting the gas supply, checking power rating, transforming or adapting the appliance to run on other types of gas, and commissioning, must all be done by contractors authorised by the local Gas Board in accordance with local and national legislation. Before doing anything else, seek advice from your Gas Board.

Installation procedure

To level the appliance correctly, adjust the height of the four legs.

Gas connection

The R 1/2” gas off-take can either be permanently fixed to the mains or made detachable using a standard adaptor. If flexible hose is used, it must be in stainless steel. After completing connection, check for leaks using a special leak-detector spray.

Plumbing connection

A rigid or flexible pipe may be used for connection to the water supply. The inlet pipe has a 12 mm diameter.

Gas venting

These appliances are A construction type, thus no gas venting is required. For advice on ventilating the premises where the appliance is installed, observe current regulations.

OPERATING INSTRUCTIONS

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Before commissioning the appliance

Before commissioning the appliance, remove the protective wrapping. Thoroughly clean the work-surface and the outside of the appliance using lukewarm water and detergent. With a damp cloth eliminate all traces of the rust-proofing applied in the workshop then dry with a clean cloth.

Start-up

Before starting the appliance up, check that its specifications (category and type of gas used) match those of the family and group of the gas available locally. If not, adapt the appliance to the gas family or group required (see paragraph “Running the appliance on other types of gas” page 8). To start the appliance up, see the instructions for regular use.

Testing the power rating

Use the specific nozzles for the nominal capacity on the appliance. Capacity can be of two types:

- nominal, as given on the data plate;

- minimum.

These nozzles are shown in table 1 in the assembly instructions. The following are the operating pressure tolerances to obtain the nominal power according to the agreed nozzles:

- from 15 to 22.5 mbar for gases of the second family

- from 25 to 45 mbar for gases of the third family (propane).

The appliance will not work outside the above pressure threshholds. To adjust the capacity to its minimum value, use the data in tables 1 (Gas Flow Regulation table). If you wish to check the nominal capacity further, you may do so using a gas meter according to the so-called ”volumetric method”. It is normally enough, however, simply to check that the nozzles are functioning correctly.

Checking input pressure (Fig. 3)

Input pressure should be measured using a gauge (e.g. a gooseneck pipe, min. resolution 0.1 mbar). Remove screw (22) from the pressure socket and connect it to the tube on the gauge; after measuring, the screw should be retightened absolutely airtight (22).

Checking power rating using the volumetric method

Using a gas meter and a chronometer, you can read the volume of gas output per time unit. The correct volume will be the value of “E” expressed in litres per hour (It/hr) or litres per minute (It/min). The following formula is used to calculate the value of “E”:

Capacity should only be measured when the appliance is at a standstill. The heat value can be obtained from your local Gas Board. To obtain the nominal and minimum capacities in relation to the nominal pressure, consult table (1- Gas Flow Setting).

WARNING

It is not possible to adjust nominal capacity in advance.

Checking power rating when using LP gas

Check that the type of nozzles used match table 1 specifications. Check that the output pressure regulator installed collaterally to the plant conforms to the specifications laid down in paragraph "Testing the power rating" (see data plate and measure the pressure).

Capacity

Heat value

E =

COMMISSIONING THE APPLIANCE

6 1

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Checking the pilot light

When correctly adjusted, the pilot light flame will completely surround the thermocouple and will not flicker.

Checking the primary air

The appliance can be adjusted. Air volume flow is correct when there is sufficient protection against the flame rising when the burner is cold or light-back when it is hot. Position the ring at measurement “A” (Fig. 1) indicated in table 1 for type of gas.

Checking the functions

- Start the appliance in accordance with the instructions;

- Check the gas tubes for leaks;

- Check that the flame on the main burner lights properly and is correctly formed, even on low;

- Check that the pilot light is correctly regulated;

- Draw up a servicing and maintenance contract.

Note for the installer

- Explain and demonstrate to the user how the machine works according to the instructions, and hand him this manual.

- Remind the user that any structural alterations to the room housing the appliance may affect the combustion air supply. Once the alterations have been completed, the appliance and its functions should be thoroughly checked.

Running the appliance on other types of gas

When changing to another type of gas, e.g. from natural to LP, or to another gas group, consult the “TECHNICAL DATA” table to determine the correct nozzles to use. The nozzles for the main burners and pilot light for different types of gas, marked in 100ths of mm, are in a case supplied with the appliance. When the appliance has been transformed or adapted, recheck its functions as described in paragraph "Checking the functions".

Main burner injector replacement (Fig. 1)

To replace the injector (30) dismount the front panel. Dismount the holding injector collector unscrewing the nut 31 and the nut 32 on the gas cock. With a 12 spanner unscrew the holding injector and replace them with new one (see schedule “technical data”). Reassemble in the reverse order.

Pilot injector replacement (Fig. 2)

To replace the pilot injector (36) dismantle the front panel with a screwdriver and unscrew the screw nut (35), now the injector can be reached inside the body pilot, replace it with a new one (see technical data) when finished screw again the screw nut (35).

Adjusting the low flame (Fig. 3)

Referring to the “TECHNICAL DATA” table, set the low flame screw (2) as follows:

- if the appliance is to run on LP gas, tighten the low flame screw as far as it will go;

- if the appliance is to run on natural gas, turn the low flame screw while simultaneously adjusting the primary air:

- read off the setting in It/min which corresponds to the heat value (calculated by the “Volumetric Method”) in the Gas Flow Setting Table (2); start the appliance up according to the instructions;

- after allowing the appliance to run for same mins., turn the knob to low and set minimum gas flow by turning screw (2) (to the right = gas flow decreases; to the left = gas flow increases).

MAINTENANCE

The following maintenance programme should be carried out at least once a year:

- Check that all the safety and setting devices are working properly;

- Check that the burners are working properly with regard to:

- ignition

- combustion safety;

- Check the functions of the appliance as described in paragraph "Checking the functions".

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REPLACING PARTS

All parts must be replaced by authorised technicians only!

To replace the following parts, first remove the control knobs, slide out the fat tray and remove the control panel (after unscrewing its fixing screws).

Ignition plug (Fig. 2)

The ignition plug (37) is removed by loosening screws (36). Disconnect the ignition lead, loosen the lock nut and insert a new plug.

Gas tap (Fig. 3)

Loosen the gas piping and thermocouple hoses, then loosen the screws fixing the gas supply to the gas ramp and insert a new tap.

Thermocouple (Figs. 2 & 3)

Loosen the screws fixing the thermocouple (38) to the gas (6) tap and the pilot burner (34); insert the new part. After replacing the parts, fit the control panel and its parts back in the right order.

WARNING

Every time a replacement involving gas input parts is made, recheck all functions and test for leakage.

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START-UP

FIRST-TIME USE OF THE APPLIANCE Important!

Before using the appliance for the first time, thoroughly clean the tank with lukewarm water and detergent, using a soft cloth to eliminate all traces of swarf; dry with a clean cloth.

IGNITION

Turning the pilot burner on (Fig. 4)

Press knob (4) and turn it to the left . Keep the knob pressed down while repeatedly pressing piezo ignition button (6) until you can see through aperture (10) on the combustion chamber that the flame has caught. Keep the knob pressed down for another 15-20 seconds; if the flame goes out after the knob is released, start again.

Turning the main burner on and adjusting the temperature (Fig. 4)

To light the main burner, turn the knob to the right until it is on ‘high’ , or else continue until it reaches low ; the heating capacity must be set between these two positions.

TURNING THE APPLIANCE OFF

Turning the appliance off during normal operation

To turn the main burner off only, simply turn the knob to ; this way only the pilot burner will stay on.

To turn the appliance off completely, turn the knob to ●;

this will turn the pilot burner off as well.

Turning the appliance off in an emergency

In an emergency turn off the gas supply.

What to do if something goes wrong or if not using the appliance for a long time

If the appliance is not to be used for a long time, or if it breaks down or works incorrectly, close the tap to the gas mains located outside the appliance. clean thoroughly (see cleaning and protection of steel). If anything goes wrong, call the aftersales department.

USING THE APPLIANCE

052-03 - Gas pasta cooker

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TAKING CARE OF THE APPLIANCE FREQUENCY OF MAINTENANCE

Giving the appliance a thorough clean every day (after turning it off) will keep it in perfect working order and make it last longer.

Daily cleaning

Frequently clean the surfaces using a damp cloth; water and soap or common detergents may be used provided they do not contain abrasives or chlorine-based sub- stances, such as sodium hypochlorite (bleach), hydrochloric acid (muriatic acid), or other solutions: stainless steel is quickly and irreversibly corroded by these products. Under no circumstances use the above-mentioned products to clean the floor under the equipment or nearby, as fumes or any drops may produce similar destructive effects on the steel. Only rub in the direction of the satin finish. Rinse thoroughly with clean water and dry carefully. Never use running water, as this could infiltrate into the inner parts.

Food stains and encrusted food particles:

wash with hot water before they harden. Should food particles have already become hard, use water and soap or chlorine-free detergents, if necessary using a wooden spatula or fine stainless steel wool: rinse and dry thoroughly.

Scale encrustations:

scale deposits on the bottom of tanks, pans, etc. should be removed using descaling products on the market and following the relative instructions.

Scratches:

should the surfaces become scratched, they must be smoothed using extra fine stainless steel wool or abrasive sponges made of fibrous synthetic material, rubbing in the direction of the satin finish. Rinse and dry thoroughly. Never use wire wool for cleaning stainless steel or leave it in contact with the steel, as very small ferrous deposits could remain on the surface and cause the formation of rust by contamination.

Precautions during use

Sauces and condiments:

all the stainless steel containers used for notoriously acid ingredients (vinegar, salt, lemon juice, tomatoes, etc.) should be thoroughly washed to remove any residue. In particular salt solutions should not be left to evaporate or dry on the stainless steel surface. Never use coarse cooking salt which, being heavy, deposits on the bottom without dissolving completely and over a period of time can therefore cause points of contact with consequent corrosion. It is therefore advisable to add salt in small amounts to water which is already boiling, or to dissolve it in a separate container; never add it to cold water in the tanks and certainly never put it into an empty tank. Whenever the tanks are not being used, they should preferably remain uncovered.

Protection of stainless steel

Should the equipment not be used for a certain period of time, clean the external stainless steel surfaces and when they are completely dry, protect by spreading over them a thin film of vaseline oil, or better still specific products to be found on the market. Apart from giving the steel a uniform, polished appearance, these products prevent penetration of humidity and dirt which can also cause corrosion. These products, basically consisting of a mixture of oily substances and detergents, are now available in easy-touse, practical spray cans.

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WARNING

DUE TO ITS POLICY OF CONTINUAL PRODUCT IMPROVEMENT, THE MANUFACTURER RESERVES THE RIGHT TO MAKE ANY CHANGES DEEMED NECESSARY.

THE MANUFACTURER CANNOT BE HELD RESPONSIBLE IF THE INSTRUCTIONS CONTAINED IN THIS MANUAL ARE NOT OBSERVED.