Southbend GCX-2S Service Manual

COMPARTMENT STEAMER

GAS BOILER

(Manual Section CS)

OWNER'S MANUAL

INSTALLATION USER'S GUIDE

SERVICE

PARTS

COMPARTMENT STEAMER

GAS BOILER

MODELS: GCX-2S

These instructions should be read thoroughly before attempting installation. Set up, installation and Performance Check should be performed by a qualified service technician. The Manufacturer, Southbend (1100 Old Honeycutt Rd., Fuquay-Varina, North Carolina 27526), informs you that unless the installation instructions for the above described Southbend product are followed and performed by a qualified service technician, (a person experienced in and knowledgeable concerning the installation of commercial gas and/or electrical cooking equipment) then the terms and conditions of the Manufacturer's Limited Warranty will be rendered void and no warranty of any kind shall apply.

If the equipment has been changed, altered, modified or repaired by other than a qualified service technician during or after the 12-month limited warranty period, then the manufacturer shall not be liable for any incidental or consequential damages to any person or to any property which may result from the use of the equipment thereafter. Some States do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion thereto may not apply to you.

In the event you have any question concerning the installation, use, care, or service of the product, write Customer Service Department, Southbend Corporation, 1100 Old Honeycutt Rd., Fuquay-Varina, North Carolina 27526.

southbend

A MIDDLEBY COMPANY

Congratulations! You have just purchased one of the finest pieces of heavy-duty, commercial cooking equipment on the

manual carefully.

CAUTION:

WATER QUALITY IS THE MAJOR FACTOR AFFEC

TING THE PERFORMANCE OF

WARNING

— WARRANTY WILL BE VOID IF

1100

Old Honeycutt Road

market today. You will find that your new equipment, like all Southbend equipment, has been designed and manufactured to some of

the toughest standards in the industry — those of Southbend Corporation. Each piece of Southbend equipment has been carefully engineered and designs have been verified through laboratory tests and field installations in some of the more strenuous commercial cooking applications. With proper care and field maintenance, you will experience years of reliable, trouble-free operation from your Southbend equipment. To get the best results, it's important that you read this

TABLE OF CONTENTS:

SECTION ONE — INSTALLATION

Warranty 1 Dimensions 2 Service Connections 3 Start Up 3

SECTION TWO — STEAM FUNCTION

Functioning Mode 5

SECTION THREE —MAINTENANCE

Periodic Maintenance 7

SECTION FOUR — OPERATION

Operating Instructions 12

SECTION FIVE — COOKING CHART

Time Schedules 13

SECTION SIX — SERVICE

Service Information 16

SECTION SEVEN — PARTS

Parts List 20

SECTION EIGHT — WIRING

Wiring Diagrams 33

YOUR APPLIANCE. INCOMING WATER HARDNESS SHOULD NOT EXCEED 2.0 PPM GRAINS AND THE pH SHOULD NOT EXCEED 7.5. IF YOU ARE UNSURE OF WATER CONDITIONS. HAVE IT ANALYZED. CONSULT YOUR LOCAL WATER DEPARTMENT OR A COMPETENT WATER CONDITIONER AGENCY. FAILURE OR MALFUNCTION OF THIS APPLIANCE DUE TO POOR QUALITY OF WATER IS NOT COVERED UNDER THE WARRANTY.

Retain this manual for future reference.

A. SERVICE WORK IS PERFORMED BY OTHER THAN A QUALIFIED TECHNICIAN.

B. OTHER THAN GENUINE SOUTHBEND REPLACEMENT PARTS ARE INSTALLED.

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

KEEP AREA AROUND APPLIANCES FREE AND CLEAR FROM COMBUSTIBLES. IN THE EVENT A GAS ODOR IS DETECTED, SHUT DOWN EQUIPMENT AT THE MAIN SHUTOFF VALVE

AND CONTACT THE LOCAL GAS COMPANY OR GAS SUPPLIER FOR SERVICE.

southbend

MIDDLEBY COMPANY

FOR YOUR SAFETY

Fuquay-Varina. NC 27526 (919) 552-9161 FAX (919) 552-9798 (800) 348-2558

COMPARTMENT STEAMER

GAS BOILER

USER'S GUIDE

LIMITED WARRANTY

Southbend warrants that the equipment as supplied by the factory to the original purchasers, is free from defects in materials and workmanship. Should any part thereof become defective as a result of normal use within the period and limits defined below, then at the option of Southbend such parts will be repaired or replaced by Southbend or its Authorized Service Agency. This warranty is subject to the following conditions:

If upon inspection by Southbend or its Authorized Service Agency it is determined that this equipment has not been used in an appropriate manner has been modified has not been properly maintained, or has been subject to misuse or misapplication. neglect, abuse, accident, damage during transit or delivery, fire. flood, riot or Act of God, then this warranty shall be void.

Specifically excluded under this warranty are claims relating to installation: examples are improper utility connections and improper utilities supply. Claims relating to normal care and maintenance are also excluded: examples are calibration of controls. and adjustments to pilots and burners.

Equipment failure caused by inadequate water quality is not covered under the warranty. WATER QUALITY must not exceed the following limits: Total Dissolved Solids (TDS) - 60 PPM (Parts Per Million). Hardness - 2 Grains or 35 PPM. PH Factor - 7.0 to 7.5. Water pressure 30 PSI minimum. 60 PSI Maximum. Boiler maintenance is the responsibility of the owner and is not covered by warranty.

This equipment is intended for commercial use only. Warranty is void if equipment is installed in other than commercial application.

Repairs under this warranty are to be performed only by a Southbend Authorized Service Agency- Southbend can not be responsible for charges incurred from other than Authorized Southbend Agencies.

THIS WARRANTY MUST BE SHOWN TO AN AUTHORIZED SERVICE AGENCY WHEN REQUESTING IN-WARRANTY SERVICE WORK. THE AUTHORIZED SERVICE AGENCY MAY AT HIS OPTION REQUIRE PROOF OF PURCHASE DATE.

This warranty does not cover services performed at overtime or premium labor rates nor does Southbend assume any liability for extended delays in replacing or repairing any items in the equipment beyond the control of Southbend. "Southbend shall not be liable for consequential or special damages of any nature that may arise in connection with such product or part." Should service be required at times which normally involve overtime or premium labor rates, the owner shall be charged for the difference between normal service rates and such premium rates.

In all circumstances a maximum of one hundred miles in travel and two and one half hours (2-5) travel time shall be allowable. In all cases the closest Southbend Authorized Agency must be used.

The actual warranty time periods and exceptions are as follows: This warranty only covers product shipped into the 48 Contiguous United States and Hawaii, one year labor, one year parts

effective from the date of original purchase. There will be no labor coverage for equipment located on any island not connected by roadway to the mainland.

Exceptions to standard warranty, effective within above limitations: Glass Windows. Door Gaskets. Rubber Seals. Light Bulbs, Ceramic Bricks.

Sight Glasses, Cathodic Descalers or Anodes ........................................................................................ 90 days material and labor.

Stainless Steel Fry Pot ...................................................................... 4 years extended material warranty on fry pot only - No labor.

Stainless Steel Open Top Burners .................................................. 4 years extended material warranty on burners only - No labor.

Pressure Steam Boiler Shell ..................................................... Prorated 4 years extended warranty on boiler shell only - No labor.

(Boiler shells which have not been properly maintained will not be covered by warranty.)

In all cases parts covered by a five year warranty will be shipped FOB the factory after the first year. Our warranty on all replacement parts which are replaced in the field by our Authorized Service Agencies will be limited to three

months on labor six months on materials (parts) effective from the date of installation. See LIMITED WARRANTY - REPLACEMENT PARTS for conditions and limitations.

If the equipment has been changed altered modified, or repaired by other than a qualified service technician during or after the one year limited warranty period then the manufacturer shall not be liable for any damages to any person or to any property which may result from the use of the equipment thereafter.

"THE FOREGOING WARRANTY IS IN LIEU OF ANY AND ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS, AND CONSTITUTES THE ENTIRE LIABILITY OF SOUTHBEND. IN NO EVENT DOES THE LIMITED WARRANTY EXTEND BEYOND THE DURATION OF ONE YEAR FROM THE EFFECTIVE DATE OF SAID WARRANTY."

SOUTHBEND - Effective February 1, 1990

DIMENSIONS & SERVICE CONNECTIONS

SECTION 1:

FIG. 1

STEAM-EX MODEL GCX-

FLOOR MOUNTED CONVECTION STEAMER

A B C D E F 6 H

Inches 11 9 5 101/2 3 5 18 3-1/2 mm 280 228 127 267 76 127 457 89

LEGEND

GC Supply gas through 3/4" pipe with pressure of approx. 7" W.C. For propane use 11" W.C. pressure.

A gas shut off valve must be installed in supply piping convenient and adjacent to appliance.

EC Unless otherwise specified, Field Wire Electrical Connection to be 120 Volts, 60 Hertz single phase

with grounding wire. DR Appliance drain is 2" pipe size. Provide open air gap type drain. CW Cold Water supply. Provide 3/8" copper tube. HW Hot Water supply to Boiler. Provide 3/8" copper tube. A Backflow Prevention Device acceptable to

BOCA Code or equivalent must be installed in this line.

INSTALLATION & SERVICE CONNECTIONS

SECTION 1:

FLOOR MOUNTED CONVECTION STEAMER

STEAM-EX MODEL GCX-

INSTALLATION INSTRUCTIONS

Steam-Ex location should have an exhaust system provided directly above the appliance to exhaust combustion gases generated by the Gas Boiler.

Ascertain that adequate clearance on right side of appliance is available for servicing components contained in Steamer Control Enclosure.

Set Steam-Ex in place and level appliance using spirit level.

APPLIANCE IS INTENDED FOR USE ON NONCOMBUSTIBLE FLOORS. MINIMUM CLEARANCE FROM COMBUSTIBLE CONSTRUCTION, 3" ON SIDES AND 4" FROM BACK.

AN OPEN GAP FLOOR DRAIN IS REQUIRED IMMEDIATELY BELOW THE APPLIANCE DRAIN.

SERVICE CONNECTIONS

Make service connections as indicated in LEGEND (Fig. 1). GAS INSTALLATION TO CONFORM TO LOCAL CODES OR IN THE ABSENCE OF LOCAL CODES TO

NATIONAL FUEL GAS CODE - ANS1 1222.1 - 1984. FURTHER NOTE THAT:

1. THE APPLIANCE AND ITS INDIVIDUAL SHUT-OFF VALVE MUST BE DISCONNECTED FROM THE GAS

SUPPLY PIPING SYSTEM DURING ANY PRESSURE TESTING OF THAT SYSTEM AT TEST PRESSURES IN EXCESS OF 1/2 PSIG (3.45 kPa).

2. THE APPLIANCE MUST BE ISOLATED FROM THE GAS SUPPLY PIPING SYSTEM BY CLOSING ITS

INDIVIDUAL MANUAL SHUT-OFF VALVE DURING ANY PRESSURE TESTING OF THE GAS SUPPLY PIPING SYSTEM AT TEST PRESSURES EQUAL TO OR LESS THAN 1/2 PSIG (3.45 kPa).

ELECTRICAL GROUNDING MUST BE PROVIDED IN ACCORDANCE WITH LOCAL CODES, OR IN THE ABSENCE OF LOCAL CODES, WITH THE NATIONAL ELECTRIC CODE, ANS1/NFPA 70 - 1984.

START UP TEST RUN

Once the unit is installed and proper service connections have been made, your Steam-Ex should be thoroughly tested before operation.

Open manual gas shut off supply valve and if the appliance has a manual Blowdown Valve, close it. Open left cabinet door and turn ON power switch. Pilot light will come on (green) and water will fill Boiler to required level in about 3 minutes. Observe water gauge glass to verify.

(Continued)

SECTION 1: STEAM-EX MODEL: GCX-

Floor Mounted Convection Steamer

START UP TEST RUN (Continued)

The Dial on the gas combination control valve has 3 positions (ON-PILOT-OFF) for manual gas control of main burners and pilot. Turn Dial on gas combination valve to PILOT. Depress Dial and light Pilot Burner maintain Dial in depressed position for about 30 seconds and release. Observe that Pilot Burner flame stays on. If the flame should become extinguished, a 5 minute period for complete shut off of Gas Supply is required before relighting.

Turn Dial to ON and burners ignite. Steam generation will now commence and be completed in about 15 minutes. Observe that Boiler Pressure Gauge indicates steam pressure in range of 9-12 psi. On Series 140K Gas Boilers steam pressure will range between 6 - 7-1/2 psi.

On Cooker Digital Control panel both COOK TIME-MINUTES 'Windows' will display "00" and both READY (green) lights will be on indicating that Steam-Ex is now ready for the cooking cycle. Open both compartment doors and observe that no steam has entered cooking compartments. Close doors.

Touch number 8 twice on both Digital Controls. Observe that all segments of "88" in both display windows light up. As well, touch all other numbers and observe that they function. On both Digital Controls touch CANCEL and display windows will show "00".

Touch number 2 on both Digital Controls and "02" will be displayed. Touch START on both Digital Controls. READY lights will go off and COOK (red) lights will come on and

steam will be heard entering compartments.

After one minute when display windows show "01", open each door and observe for a couple of minutes that steam has ceased to enter each compartment, but COOK lights and cooking times at "01" are maintained.

WARNING: THE COOKING COMPARTMENTS CONTAIN LIVE STEAM AND TO AVOID SCALDING

AND/OR BURNS STAY CLEAR WHEN OPENING EACH DOOR.

Shut doors. Steam generation and cook times will resume. Observe Appliance Drain that live steam from compartments is being cooled by cold water from Cold Water Solenoid Valve (thermostatically controlled).

When each 'Window' shows "00" each buzzer will come on, steam generation will cease, COOK lights will go off and READY lights will go on. To silence buzzers, open and dose each compartment door.

During simulation of the cooking cycle, the burners will cycle on and off to maintain steam pressure in the Boiler.

Turn OFF power switch. Observe that Burners go off and if the appliance is equipped with Automatic Blow Down Solenoid Valve, the Boiler contents water and steam, will be blown out and exhausted through the appliance Drain. The Cold Water Solenoid Valve will now be activated as well. If the appliance is equipped with a manual Blow Down Valve, open it.

FUNCTIONING MODE

SECTION 2:

FLOOR MOUNTED CONVECTION STEAMER

STEAM-EX MODEL GCX-

This Steam-Ex is intended for use in commercial establishments as an appliance utilizing steam in the pressureless mode for cooking a variety of food products. It is floor supported and consists of two sections, the Cabinet and the Cooker, both of which incorporate steel enclosures to contain live electrical parts.

Gas, Power, hot and cold water, must be supplied to these appliances. Refer to Section 1, Service Connections.

The Cabinet is the lower foot supported section of the appliance with two front doors to provide internal access and contains components which control the functioning of the Gas Boiler and hence is the steam supply source to the Cooker. A switch located on the front face of the Generator Control Box, when turned on will provide power for the entire appliance. Once switched ON, the Water Level Control will signal the Water Fill Solenoid Valve not only to supply water to fill the Boiler to the required level but also to replenish and maintain proper level as water is depleted through steam generation. With adequate water level, the gas burners are then permitted to come on and steam generation commences. However, since the Gas Boiler is designed to ASME Code and approved as a steam heating boiler restricted to operate at pressures not to exceed 15 psi, therefore a Pressure Switch is utilized to regulate the cycling of the burners to maintain steam pressures at approximately 9 psi minimum but not to exceed 13 psi since pressure approaching 15 psi will blow the Safety Relief Valve.

The Cooker is the upper section of the appliance consisting of two compartments and a Digital Control Panel. Each compartment is provided with its own door, Digital Control, Steam Solenoid Valve and Solid State Boards. Pans, containing food properly portioned, are then placed unto guided compartment racks. With the Door closed and the Digital Control timed for the correct COOK TIME in MINUTES and touching START, the Steam Solenoid Valve is energized and opens allowing constant steam to enter the compartment through eight ports which provide thorough steam coverage of the entire compartment. Since steam is allowed to exhaust through the compartment drain, the chamber cannot ever become pressurized and hence pressureless steam is the cooking mode utilized. With this mode. it should be noted particularly apparent on vegetables, that color, flavor and texture are retained as "fresh from the garden". At the completion of the cooking cycle, the "Window" on the Digital Control will display "00" and an audible buzzer will be set off and can only be silenced by opening the door and presumably the cooked food product removed. Closing the door permits the initiation of the next cooking cycle.

Refer to Periodic Maintenance, Section 3, for detailed version of components and controls.

PARTS LIST

SECTION 7:

FIG. 2

STEAM-EX MODEL GCX-

COOKER CONTROL COMPONENTS

PERIODIC MAINTENANCE

SECTION 3:

FLOOR MOUNTED CONVECTION STEAMER

STEAM-EX MODEL GCX-2

Fig. 2: The Cabinet is the lower section of the Steam-Ex providing not only a base for the Cooker to be positioned at a proper working height but also the enclosure for the Gas Boiler and Controls.

THE APPLIANCE AREA MUST BE KEPT FREE AND CLEAR FROM COMBUSTIBLES. DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATION AIR.

FRONT VIEW

Item A: Gas Boiler weldment assembly.

Item B: Handhole Cover Assembly when unbolted and removed allows internal examination and cleaning of Boiler if required.

Item C: The Water Gauge assembly has a glass tube for visual verification that water level is being maintained in the Boiler during operation. The manual valves at the top and the bottom of this assembly must be fully open and only closed if damage should occur to the glass tube.

AT LEAST TWICE A YEAR REMOVE HANDHOLE COVER ASSEMBLY. INSPECT BOILER INTERIOR FOR SCALANT AND LIME BUILD UP.

OBSERVE THAT THE WATER IS CLEAN AND CLEAR IN THE GLASS TUBE. THE APPEARANCE OF EXTREME MURKINESS IN THE WATER INDICATES INADEQUATE WATER QUALITY AND WILL CAUSE FAILURE OF CONTROLS AND THE APPLIANCE. WARRANTY DOES NOT COVER MALFUNCTION DUE TO POOR WATER CONDITIONS.

Item D: Pilot Burner should remain lit at all times unless appliance will not be in use for an extended period of time.

Item E: Main Burners of aluminized steel tube.

Item F: Gas Combination Control Valve regulates flow of natural gas (or propane) to Burners. Operation is dependent on other controls. Refer to START UP TEST RUN - SECTION 1.

Item G: Safety Sensor, enclosed by the Sensor Cover Box, will shut off the Main Burners when excessive heat occurs should the water level in the Boiler drop below a level sufficient to immerse and protect the Boiler tubes, heads and shell that come in contact with direct heat from the Burners.

Item H: Cold Water Solenoid Valve fastened to the right rear bottom of Generator Control Box supplies cold water to condense live steam before it exhausts into the drain and is controlled by the Thermostat (Item N).

IF AT ANY TIME THE FLAME SHOULD BECOME EXTINGUISHED. A 5 MINUTE PERIOD FOR COMPLETE SHUT OFF OF GAS SUPPLY IS REQUIRED BEFORE RELIGHTING.

FLOOR AREA BENEATH BURNERS MUST BE KEPT FREE AND CLEAR TO PROVIDE AIR FOR COMBUSTION AND VENTILATION.

PERIODIC MAINTENANCE

SECTION 3:

FLOOR MOUNTED CONVECTION STEAMER

STEAM-EX MODEL GCX-

Item I: Hot Water Solenoid Valve fastened to the bottom of Generator Control Box immediately in Front of Item J feeds hot water to the Boiler but its functioning is entirely dependent on the Water Level Control (Item Q).

Item J: Operating Pressure Switch fastened to the inside bottom front of the Generator Control Box is plumbed to sense the pressure in the Boiler and thence control the operating cycle of the Gas Combination Control Valve (Item I). This switch is factory set to energize the Gas Combination Control Valve and ignite the Main Burners at 6 psi but to de-energize the Valve and turn off Burners at 7-1/2 psi thus maintaining a pressure range in the Boiler between 6 psi to approximately 8 psi (override considered).

Item K: Hi-Limit Pressure Switch similar to and located directly behind the above switch is a protective device intended to shut off the Gas Combination Control Valve and Burners at approximately 14 psi and will only function if the Operating Pressure Switch fails.

Item L: Power Switch fastened to the front face of the Generator Control Box when switched ON will automatically begin the steam generating process in the Boiler.

Item M: Pilot Light is located directly above the Power Switch and when lit (green) indicates power is ON.

Item N: A Thermostat mounted on the back wall of the Generator Control Box has its heat sensing capilliary bulb fastened to the appliance Drain. When excessive heat (i.e.. steam) comes in contact with the bulb, the Thermostat will energize the Cold Water Solenoid Valve (Item J).

Item 0: The Pressure Gauge is directly above and threaded to the Water Level Control. It should read '0' during shut down and function in a range of approximately 6 to 7.5 psi during operation of the appliance.

Item P: Safety Valve is a protective device set at 15 psi. Malfunction or improper setting of controls may allow the pressure to exceed 15 psi in the Boiler and will consequently set off this valve.

Item Q: The Water Level Control is a mechanical switch intended to maintain proper water level in the Boiler. A Float is contained within the chamber of the Water Level Control and when it drops, it will trip the switch in the control and demand sufficient water to replenish it to the proper level.

Item R: A Thermostatic Steam Trap is plumbed to the steam supply piping from the Boiler and is a mechanical device that closes on high temperatures and opens when the temperature drops. This Trap allows air and water formed from condensed steam to exhaust into the appliance Drain but will retain steam being of a higher temperature.

ONCE A WEEK THIS VALVE SHOULD BE TRIPPED DURING OPERATION TO ASSURE THAT IT FUNCTIONS PROPERLY.

A MANUAL VALVE LOCATED DIRECTLY BELOW THE WATER LEVEL CONTROL CHAMBER MUST BE OPENED BRIEFLY AT LEAST ONCE A WEEK TO BLOWDOWN SEDIMENT AND SCALANT THAT MAY BE LODGED IN THE CHAMBER. FAILURE TO DO SO MAY CAUSE EXCESSIVE ACCUMULATION. SEIZURE OF THE FLOAT AND EVENTUAL MALFUNCTION OF THE WATER LEVEL CONTROL.

PERIODIC MAINTENANCE

SECTION 3:

STEAM-EX MODEL GCX-

FLOOR MOUNTED CONVECTION STEAMER

LEFT SIDE VIEW

Item R: A Thermostatic Steam Trap is plumbed to the Boiler and is a mechanical device that closes on high temperatures and opens when the temperature drops. This Trap allows both water formed from condensed steam and air trapped in the Boiler initially at start-up to exhaust into the appliance Drain but will retain steam being of a higher temperature.

Item S: Drain for compartments and Boiler approximately 2" pipe size. Must be provided with open air gap type floor drain.

Item T: Boiler Blowdown Valve is plumbed to the drain pipe of the Boiler and when specified as automatic will be a solenoid (electrically operated) valve which will close when energized in order to facilitate maintenance of proper water level in the Boiler.

HOWEVER, THE STEAMER SHOULD BE SWITCHED OFF AT LEAST ONCE DAILY WHICH WILL DE-ENERGIZE AND OPEN THE VALVE IN ORDER FOR THE BLOWDOWN PROCEDURE TO OCCUR AND REMOVE SEDIMENTS, SCALANTS AND LIME BUILD-UP IN THE BOILER. IF THE APPLIANCE IS SUPPLIED WITH A MANUAL VALVE, IT SHOULD BE OPENED DAILY WHEN THE APPLIANCE IS SHUT DOWN.

PERIODIC MAINTENANCE

SECTION 3:

FLOOR MOUNTED CONVECTION STEAMER

STEAM-EX MODEL GCX-

FIG. 3

+ 26 hidden pages