MONTAGUE E36W36, EC36, EV136W36, E236W36, E43W36 Instructional Manual

INSTRUCTIONAL

MANUAL

GAS FIRED BROILERS

E36W36 EV136W36 EC36
E43W36 E236W36 EC45
E136W36 E243W36

Please read this manual completely before attempting

to install or operate this equipment! Notify carrier of

damage. Inspect all components immediately.

RETAIN THIS MANUAL FOR FUTURE REFERENCE.

DESTINATION COUNTRIES: IE, GB, RO

THE MONTAGUE COMPANY

1830 Stearman Avenue • P.O. BOX 4954 • HAYWARD,CA 94540-4954 •TEL: [phone] • FAX: [phone]

See page 4.

0359-10

IMPORTANT FOR YOUR SAFETY

THE INSTALLATION INSTRUCTIONS CONTAINED HEREIN ARE FOR THE USE OF
QUALIFIED INSTALLATION AND SERVICE PERSONNEL ONLY. INSTALLATION OR
SERVICE BY OTHER THAN QUALIFIED PERSONNEL MAY RESULT IN DAMAGE TO THE
UNIT AND/OR INJURY TO THE OPERATOR.

IF YOU SMELL GAS

1. TURN OFF THE APPLIANCE AT THE GAS INLET COCK AND OPEN ALL DOORS
AND WINDOWS.

2. DO NOT OPERATE ANY ELECTRICAL SWITCHES AND EXTINGUISH ALL NAKED
FLAMES.

3. CONTACT THE LOCAL GAS AUTHORITY IMMEDIATELY.

THE FOLLOWING INSTRUCTIONS SHOULD BE READ CAREFULLY AS THE

MANUFACTURER CANNOT BE HELD RESPONSIBLE FOR ANY DAMAGE TO

PROPERTY, PERSONS OR ANIMALS CAUSED BY INCORRECT INSTALLATION OR

OPERATION OF THE APPLIANCE.

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.

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

IMPORTANT

IN THE EVENT A GAS ODOR IS DETECTED, SHUT DOWN UNITS AT MAIN SHUTOFF

VALVE AND CONTACT THE LOCAL GAS COMPANY OR 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, servicing, or operating

this equipment.

SAVE THESE INSTRUCTIONS FOR FUTURE USE.

2

TABLE OF CONTENTS

IMPORTANT FOR YOUR SAFETY ………. 2

INTRODUCTION ………. 4

GENERAL ………. 4

MODELS ………. 4

DATA PLATE LOCATION ………. 4

SERIAL NUMBER LOCATION ………. 4

RECEIVING AND INSPECTING THE EQUIPMENT ………. 4

SPECIFICATIONS ………. 5

INSTALLATION ………. 6

STATUTORY REGULATIONS ………. 6

CLEARANCES ………. 6

VENTILATING HOOD ………. 6

VENTILATION AIR ………. 6

ASSEMBLY ………. 6

Legs ………. 6

Ceramic Radiants ………. 7

LOCATION ………. 7

SITING ………. 7

BATTERY ARRANGEMENT ………. 7

Setting in Place ………. 7

Floor Mounted Ranges ………. 8

GAS SUPPLY ………. 8

GAS CONNECTION ………. 8

GAS PRESSURE REGULATOR ………. 9

Adjustment Procedure ………. 10

PILOT INITIAL ADJUSTMENT ………. 11

BURNER ADJUSTMENT ………. 11

OPERATION ………. 14

GENERAL ………. 14

OPERATING CONTROLS ………. 14

Gas Control ………. 14

Lighting/Relighting Pilot and Main Burner ………. 14

Shutdown ………. 15

Grid Height Adjustment ………. 15

GENERAL MAINTENANCE ………. 17

GENERAL CLEANING ………. 17

Daily ………. 17

PAINTED SURFACES ………. 17

Exterior ………. 17

Interior ………. 17

STAINLESS STEEL SURFACES ………. 17

VENTILATION ………. 18

SERVICING ………. 18

SAFETY ………. 18

C36 & C45 EXPLODED VIEW ………. 19

C36 & C45 PARTS LIST ………. 20

36W36 & 43W36 EXPLODED VIEW ………. 21

36W36 & 43W36 PARTS LIST ………. 22

PARTS REMOVAL AND REPLACEMENT PROCEDURES ………. 23

COVERS AND PANELS ………. 23

Venturi Cover ………. 23

Control Panel Cover ………. 23

DRIP DEFLECTOR ………. 24

DRIP TRAY AND HORIZONTAL GREASE CONTAINER ………. 24

PILOT ASSEMBLY AND INJECTOR ………. 25

MAIN BURNER ………. 26

Burner Assembly, Orifice, and Venturi ………. 26

Burner Valve Removal/Replacement ………. 26

CARRIAGE POSITION HANDLE ………. 27

Black Ball Knob ………. 27

Chrome Sleeve ………. 27

Threaded Stud ………. 27

Gear and Tube Assembly ………. 27

Compression Spring ………. 28

Gear with Bracket ………. 28

SERVICE AND ADJUSTMENT PROCEDURES ………. 29

GAS PRESSURE REGULATOR ADJUSTMENT PROCEDURE ………. 29

PILOT BURNER CLEANING AND ADJUSTMENT PROCEDURE ………. 30

GAS TAPS ………. 30

CLEANING BURNER HEADS ………. 30

CLEANING BURNER VENTURI ………. 30

CARRIAGE POSITION HANDLE ADJUSTMENT PROCEDURE ………. 30

Handle Tension Adjustment ………. 30

CARRIAGE TENSION SPRING ADJUSTMENT PROCEDURE ………. 31

MISCELLANEOUS ………. 31

TROUBLESHOOTING CHART ………. 32

EC36 & E45 EXPLODED VIEW ………. 33

EC36 & E45 PARTS LIST ………. 34

E36W36 & E43W36 EXPLODED VIEW ………. 36

E36W36 & E43W36 PARTS LIST ………. 38

3

INTRODUCTION

GENERAL

The gas broilers covered in this manual are
manufactured for use with the type of gas indicated
on the nameplate. Some models include a cabinet,
conventional oven or convection oven. Ovens are
covered in separate manuals. This manual only
covers the broiler.

Montague gas broilers are produced with the best
possible material and workmanship. Proper
installation is essential for safe, efficient, trouble­free operation.

MODELS

MODEL CONSISTS OF

E36W36 Cabinet Base Broiler with

Warming Oven

E43W36 Cabinet Base Broiler with

Warming Oven

E136W36* Broiler with Conventional

EV136W36* Broiler with Convection

Oven and Warming Oven

Oven

E236W36 Double Broiler

E243W36 Double Broiler

EC36 Broiler Only

EC45 Broiler Only

Note: A suffix of ―SHB‖ designates searing plate
option.

DATA PLATE LOCATION

The Data Plate is located on the front of the unit,
or inside the oven burner.

SERIAL NUMBER LOCATION

Always have the serial number of your unit availa­ble when calling for parts or service. The serial
number is on the nameplate that also includes the
model number. A typical identification plate is
shown in Figure 1.

* ―W‖ may be replaced with ―C‖ indicating no warm­ing oven. ―36‖ may be replaced with ―45‖, indicating
a 45‖ broiler.

MODEL:

SERIAL NO.:

HEAT INPUT: kW

CATEGORY:

SUPPLY PRESSURE: mbar

GAS: SET PRESS: mbar

ELECTRICAL

V Hz Ph W

COUNTRY:

P.I.N:

GAS CATERING EQUIPMENT
SALAMANDER– TYPE A

0359-10

THE MONTAGUE COMPANY

HAYWARD, CALIFORNIA USA

Figure 1. Typical Nameplate

RECEIVING AND INSPECTING
THE EQUIPMENT

Care should be taken during unloading so the
equipment is not damaged while being moved
into the building.

1. Visually inspect the exterior of the package and
skid or container. Any damage should be noted and
reported to the delivering carrier immediately.

2. If damaged, open and inspect the contents with
the carrier.

3. In the event that the exterior is not damaged, yet
upon opening, there is concealed damage to the
equipment, notify the carrier. Notification should be
made verbally as well as in written form.

4. Request an inspection by the shipping company
of the damaged equipment. This should be done
within 10 days from receipt of the equipment.

5. Freight carriers can supply the necessary
damage forms upon request.

6. Retain all shipping materials until an inspection
has been made or waived.

4

SPECIFICATIONS

Table A: Heat Input

MODEL No. Burners

(broiler only)

E36W36 2 12.3 ea. 12.3 ea. 4.6

G20 kW G31 kW Total kW

E43W36 3 12.3 ea. 12.3 ea. 36.9

E136W36 2 12.3 ea. 12.3 ea. 36.3

EV136W36 2 12.3 ea. 12.3 ea. 36.3

E236W36 4 12.3 ea. 12.3 ea. 49.2

E243W36 6 12.3 ea. 12.3 ea. 73.8

EC36 2 12.3 ea. 12.3 ea. 24.6

EC45 3 12.3 ea. 12.3 ea. 36.9

Table B: Setting Pressure/Injector Size

Manifold Pressure Orifices

G20: 15 mbar Fixed for specified gas type
G31: 25 mbar G20: 2.95mm (#32 DMS)
G30: 25 mbar G31: 1.99mm (#47 DMS)

Gas Inlet Size:
3/4‖ BSP at lower left rear
(all models)

NOTE: The pressure must be measured at the pressure test nipple located at the
manifold pipe with the burner lit.

MODEL G20mm G30mm G31mm

E36W36 25 32 32 12.5

E43W36 25 32 32 12.5

PILOT FLAME

LENGTH mm

E136W36 25 32 32 12.5

EV136W36 25 32 32 12.5

E236W36 25 32 32 12.5

E243W36 25 32 32 12.5

EC36 25 32 32 12.5

EC45 25 32 32 12.5

5

INSTALLATION

CAUTION: Provision must be made to
assure adequate air supply to unit for
proper burner operation.

STATUTORY REGULATIONS

The installation of this appliance must be
carried out by a competent person in accord­ance with the relevant regulations, standards,
codes of practice, and the related publications
of the country of destination.

CLEARANCES

The following are minimum clearances from
combustible and noncombustible materials.

Location Combustible

Construction

Noncombustible
Construction

Back Wall 152 mm 0 mm

Left Side 152 mm 0 mm

Right Side 152 mm 0 mm

With 152mm legs: Suitable for installation on
combustible floors.

Without legs: For use with special insulated
base on noncombustible floors only.

VENTILATING HOOD

The broiler(s) must be installed under a proper­ly designed ventilating hood. The hood should
extend at least 152 mm beyond all sides of the
unit. The hood should be connected to an
adequate mechanical exhaust system.

VENTILATION AIR

The following notes are intended to give
general guidance. For detailed recommenda­tions, refer to the applicable code(s) in the
country of destination.

NOTE 1: The room containing the appliance is
required to have a permanent air vent. The
minimum effective area of the vent is related to
the maximum rated hear input of the appliance
and shall be 4.5 cm² per kW in excess of 7kW.

NOTE 2: Air vents should be of such a size to
compensate for the effects of any extract fan in
the premises.

It is also necessary that sufficient room air
ingress be allowed to compensate for the
amount of air removed by the ventilating
system. Otherwise, a subnormal atmospheric
pressure will occur which may interfere with
burner performance or may extinguish the pilot
flame. In case of unsatisfactory broiler
performance, check with the exhaust fan in the
―OFF‖ position.

This appliance is to be installed with
sufficient ventilation to prevent the occurrence
of unacceptable concentrations of substances
harmful to health in the room in which it is
installed.

ASSEMBLY

Uncrate broiler as near to final location as
possible. For easier and lighter handling of
broiler, remove grids, grid frame, drip tray and
grease container. Remove all packing materials
and accessories from broiler interior.

Legs

Some broilers are mounted on legs.

1. Screws the legs into the modular stand.

2. Tightly screw the complete leg assembly
into the mounting holes in the bottom of the
broiler at each corner. If the unit is intended
for curb installation, no legs are provided.
The curb must be noncombustible material.

6

Ceramic Radiants

Ceramic radiants, Figure 2, are located on
each side of the burners. Ceramic end pieces
are installed at both ends of each burner
assembly. Five (5) ceramic radiants are
installed on each side of the burner with the
pointed side facing down and the side holes
facing up, Figure 3.

Figure 2. Ceramic Radiants Positioning

Figure 3. Ceramic Radiants

1. Insert ceramic end pieces at front and rear
of the burner frame. Four (4) are required for
each burner.

2. Tilt ceramic radiants sideways to clear
burner and frame assembly, then lower
radiant into position with one flange resting
on burner ledge and one flange resting on
frame edge.

3. Install the remaining ceramic radiants so
that five (5) ceramic radiants are located on
each side of the burner.

LOCATION

Adequate clearance for service and proper
operation must be provided at the front, top,
sides, and back. The combustion air openings
are provided in the front of the unit and must
not be obstructed.

SITING

The floor on which the range is to be sited must
be capable of adequately supporting the weight
of the appliance and any ancillary equipment.
Once in position, check that the unit is level,
both front to back and side to side. Adjust if
necessary, using the adjusting foot on each
leg.

BATTERY ARRANGEMENT

Carefully remove range from crate. Burner tie
wires and other packing materials must be
removed from the unit. On stainless steel units,
the protective material covering the stainless
steel must be removed immediately after unit is
installed.

Setting in Place

Model Nos. E36W36, E43W36, E136W36 and
EV136W36. (―W‖ may be replaced with ―C‖ in­dicating no warming oven. ―36‖ may be re­placed with ―45‖ indicating a 45‖ broiler.)

7

Floor Mounted Ranges

1. Place the first unit in the exact position it will
occupy in the battery.

2. Using a carpenter’s level, level the unit front-
to-rear and side-to-side. AN UNLEVELED UNIT
WILL ADVERSELY AFFECT PERFORMANCE.
Adjust as follows:

FLOOR INSTALLATION ON LEGS: Level by
turning foot on leg.

CURB INSTALLATION: Place shim under the low
side. This operation is important since variations
in floors and curbs are common. Unless units are
level, aligning the gas supply manifold will be
difficult and the units will not fit together tightly.

3. Remove the valve panel from the broiler.

4. Move the next unit into position.

5. Engage union nut on manifold with male fitting
on next unit and draw up union nut hand tight. Be
sure appliances meet together both front and rear.
If manifolds do not align, then units are not level.
In extreme cases, it may be necessary to loosen
manifold bolts and adjust.

6. Continue leveling and connecting gas supply
manifolds together until all appliances in battery
are connected.

7. Tighten manifold gas union. Use backup
wrench to prevent manifold from rotating.

FAILURE TO DO THIS MAY RESULT IN
DAMAGE TO THE PILOTS AND GAS VALVES.

GAS SUPPLY

The local gas region should be consulted at the
installation planning stage in order to establish the
availability of an adequate supply of gas and to
ensure that the meter is adequate for the required
flow rate. The pipe work from the meter to the
appliances must be of appropriate size. Where a
number of appliances are installed in a battery, no
more than five should be served by any one
supply pipe.

All fixed (non-mobile) appliances MUST be fitted
with a manual gas cook upstream of the appli­ance to provide a means of isolation for servicing
and cleaning. A union or similar means of discon­nection must be provided between the gas cook
and the appliance.

A manually operable valve must be fitted to the
gas supply to the kitchen to enable it to be isolat­ed in an emergency. Wherever practical, this shall
be located either outside the kitchen or near an
exit in a readily accessible position.

Where it is not practical to do this, an automatic
isolation valve system shall be fitted which can be
operated from a readily accessible position near
the exit.

At locations where the manual isolation valve is
fitted or the automatic system can be reset, a
notice MUST be fitted, stating:

―ALL DOWNSTREAM BURNER AND PILOT
VALVES MUST BE TURNED OFF PRIOR TO
ATTEMPTING TO RESTORE THE SUPPLY.
AFTER EXTENDED SHUT OFF, PURGE
BEFORE RESTORING GAS.‖

GAS CONNECTION

Before connecting the broiler(s) to the gas supply
line, be sure that all new piping has been cleaned
and purged to prevent any foreign matter from
being carried into the controls by the gas. In some
cases, filters or drops are recommended. A
separate gas shutoff valve must be installed
upstream from the gas pressure regulator
adjacent to the broiler and located in an accessi­ble area.

It is important that adequately sized piping be run
directly to the point of connection at the broiler
with as few elbows and tees as possible. Consult
your local gas company for proper piping size and
gas pressure. Each broiler has a 3/4" NPT
manifold input located at the lower left rear of the
broiler, Figure 4. On dual broilers, each broiler
must have a separate regulator.

NOTE: Pipe joint compound or thread sealant
that is used should be resistant to action of
liquefied petroleum gases.

8

Figure 4. Gas Inlet

Install the gas pressure regulator with gas
flowing as indicated by the arrow on the regula­tor. The arrow must be pointing in toward the
unit. Use pipe compound or thread sealant and
carefully thread regulator to pipe so that there is
no cross threading, etc., which could cause leak­age.

1. Apply wrench only to the flat areas around the
pipe tapping at the end being threaded to the
pipe to avoid possible damage to the regulator
body which could result in leakage.

2. Connect the gas supply line from the service
gas shutoff valve to the inlet side of the gas
pressure regulator using 3/4" pipe. Avoid kinks
or sharp bends that could restrict gas flow.

NOTE: If flexible or semi-flexible connectors
are used, a CE listed flexible connector
with an I.D. equal to 3/4" pipe must be used.

WARNING!
DO NOT USE A DOMESTIC TYPE
FLEXIBLE GAS CONNECTOR.

3. Turn gas shutoff valve on and carefully check
for gas leaks immediately. Do this before
attempting to operate the broiler.

WARNING!
Test all pipe joints for leaks before operating
broiler. This includes all gas connections
that may have loosened during shipment.
Use a rich soap solution (or other accepted
leak tester) around all pipe connections and
all other joints. Do not use an open flame.
Absolutely no leakage should occur, other­wise there is a danger of fire or explosion
depending upon conditions. Do not use unit
leakage is detected.

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

GAS PRESSURE REGULATOR

WARNING!

THE BROILER(S) IS/ARE DESIGNED FOR
USE WITH A GAS PRESSURE REGULATOR.
THE REGULATOR(S) SUPPLIED WITH THIS
UNIT MUST BE USED.

FOR G20 GAS: This gas pressure regulator is
factory adjusted for 15 mbar manifold pressure.
The rated inlet pressure to the regulator is 3.45
kPa.

FOR G31 and G30 GAS: This gas pressure
regulator is factory adjusted for 25 mbar mani­fold pressure. The rated inlet pressure to the
regulator is 3.45 kPa.

The broiler is equipped with fixed orifices for use
with a manifold pressure of 15 mbar for G20 gas
and 25 mbar for G31 and G30 gas.

Position the gas pressure regulator outside the
broiler as near to the unit as possible.

CAUTION: The gas pressure regulator must
be located out of the heat zone to prevent
damage to the regulator.

The whole of the gas installation, including the
meter, should be inspected, purged, and tested
for soundness in accordance with the codes of
the country of destination.

9

Adjustment Procedure

WARNING!
DO NOT ALLOW UNTRAINED PERSONNEL
TO MAINTAIN OR SERVICE THE GAS
PRESSURE REGULATOR.

1. Before adjusting the regulator, check the
incoming gas line pressure into the regulator.
Incoming pressure must be 20 mbar for G20
gas, 37 mbar for G31 gas, or 30 mbar for G30
gas.

2. If incoming pressure is not correct, have the
gas source checked and adjusted.

3. Make sure that the regulator is mounted in
the horizontal position with the arrow pointing
in the direction of the gas flow. SEE PAGE 14,
LIGHTING/RELIGHTING PILOT AND
BURNER.

4. Remove the main burner control valve
knobs,
Figure 5.

Figure 5. Control Valve Knobs

6. Connect a manometer to the pressure tap
provided on the broiler unit gas piping
manifold, Figure 6. Turn all gas taps to the full
―O‖ position.

7. Check the manometer reading. The
reading must be 15 mbar for G20 gas, 25 mbar
for G31 gas, or 25 mbar for G30 gas, per Table
B on PAGE 5.

8. If incoming line pressure is not correct,
adjust the regulator. Remove the seal cap
on the top of the regulator.

9. Insert a blade-type screwdriver into the top
hole of the regulator.

10. Turn the adjustment screw clockwise to
increase the pressure, or counter clockwise
to decrease the pressure.

While watching the manometer, turn the
adjustment screw to set proper regulator outlet
pressure to the manifold.

5. Remove the control valve panel by
removing two screws.

Figure 6. Gas Pressure Tap

10

PILOT INITIAL ADJUSTMENT

Each burner has a separate pilot burner. The
pilot flame is adjusted through access holes in
the valve control panel, Figure 7. Pilot access
is through the broiler opening.

1. Turn the main gas shut off valve to the ON
position.

2. Light each pilot.

3. Ensure that each pilot burner has a steady
blue flame, Figure 7, per Table C on PAGE

5.

4. The pilot flame should envelop the tip of the
thermocouple. The pilot flame can be
viewed up through the opening of the broiler
compartment.

1. Lift off the venturi cover to access the air
shutter for each main burner.

2. Turn on the main burner control valve for
the main burner to be adjusted by rotating
the main burner control valve fully counter­clockwise to the ―O‖ position.

3. Increase the air shutter openings until the
flame on the burner begins to ―lift‖. Then
close the shutter until flame no longer
floats, and lock in place. A yellow streaming
flame indicates insufficient air. Correct this
condition by increasing air shutter opening.
The correct setting is shown on Table C on
PAGE 5.

Figure 7. Pilot Burner

Replace the control valve panel and the main
control valve handles.

BURNER ADJUSTMENT

The efficiency of the broiler depends on a
delicate balance between the supply of air and
the volume of gas at each main burner
resulting in complete combustion. Whenever
this balance is disturbed, poor operating
characteristics occur. An air shutter, Figure 8,
on the front of each main burner controls the
air supply.

NOTE: Pilots should be lit, SEE PAGE 12,
before adjusting the main burners.

Figure 8. Main Burner Air Shutter

4. After all main burners are properly adjusted,
reinstall the venturi cover.

5. Turn all main burner control valves fully
clockwise to the ―O‖ position to turn the
main burner off.

11

OVEN MINIMUM FLAME SETTING

This is the flame that must be maintained on the burner when the oven has come up to the
temperature set on the dial. Enough gas must be bypassed by the control to keep the entire burner
lit. The thermostat regulates the flame from high to low in accordance with the oven temperature
and will automatically turn down to this minimum flame when the temperature set on the dial is
attained in the oven.

P/N 01061-8

1. Light the oven, set thermostat to 100°C and allow 5 minutes for the oven temperature to
stabilize.

2. After oven temperature rises and remains constant, turn dial back to low. This closes the main
valve and permits only the bypass gas to the burner.

3. Remove dial.

4. With a screwdriver, turn the bypass flame adjustor screw counterclockwise to increase the
bypass flame or clockwise to decrease it until the flame over the entire burner is approximately
4mm high. Replace dial.

12