Star 8048CB Service Manual

Star
Manufacturing
International Inc.

10 Sunnen Drive
St. Louis, MO 63143

Phone: [phone]
Fax: [phone]

2M-Z7906 Rev. B 8/25/11

Installation

and

Operating

Instructions

ULTRA-MAX GAS RADIANT CHARBROILER

MODELS

8124RCB, 8136RCB,

8148RCB, 8160RCB, and 8172RCB

ULTRA-MAX GAS LAVA ROCK CHARBROILER

MODELS

8024CB, 8036CB,

8048CB, 8060CB, and 8072CB

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.

FOR YOUR SAFETY: Do not store or use

gasoline or other ammable vapors or liquids

in the vicinity of this or any other appliance.

WARNING: This appliance shall be installed

in accordance with current regulations and
used only in well-ventilated space. Refer to
instructions before installing and using this

appliance.

In addition, there should be posted, in a
prominent location, detailed instructions to
be followed in the event the operator smells
gas. Obtain the instructions from the local

gas supplier.

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These symbols are intended to alert the user to the presence of
important operating and maintenance instructions in the manual
accompanying the appliance.

RETAIN THIS MANUAL FOR FUTURE REFERENCE

NOTICE

Using any part other than genuine Star factory supplied parts relieves the
manufacturer of all liability.

Star reserves the right to change specications and product design without

notice. Such revisions do not entitle the buyer to corresponding changes,
improvements, additions or replacements for previously purchased
equipment.

Due to periodic changes in designs, methods, procedures, policies and

regulations, the specications contained in this sheet are subject to change
without notice. While Star International Holdings Inc., Company exercises
good faith efforts to provide information that is accurate, we are not

responsible for errors or omissions in information provided or conclusions

reached as a result of using the specications. By using the information
provided, the user assumes all risks in connection with such use.

MAINTENANCE AND REPAIRS

Contact your local authorized service agent for service or required maintenance.
Please record the model number, serial number, voltage and purchase date in the area below and have it ready when

you call to ensure a faster service.

SAFETY SYMBOL

Model No.

Serial No.

Voltage

Purchase Date

Business 8:00 am to 4:30 p.m. Central Standard Time
Hours:

Telephone: [phone]
Fax: [phone]

E-mail [e-mail]

[e-mail]

[e-mail]

Website: www.star-mfg.com

Service Help Desk

Authorized Service Agent Listing

Reference the listing provided with the unit

or

for an updated listing go to:

Website: www.star-mfg.com
E-mail [e-mail]

Mailing Address: Star International Holdings Inc., Company

10 Sunnen Drive
St. Louis, MO 63143
U.S.A

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SPECIFICATIONS
8124RCB - Radiant, 8024CB - Lava Rock

Type: Manual Control
4 Controls, 80,000 BTUH (20,000 BTUH Nat/LP per burner)
603 sq. in. (3,890 sq. cm) Grid Area
Approximate Weight: Installed - 174 Lb s (78.9 kg), shipping - 240 Lbs (108.9 kg)
Dimensions: 24" - Width, 30 5/8" - Depth, 18" - Height
(61 cm - Width, 77.8 cm - Depth, 45.7 cm - Height)

8136RCB - Radiant, 8036CB - Lava Rock

Type: Manual Control
6 Controls, 120,000 BTUH Total (20,000 BTUH Nat/LP per burner)
906 sq. in. (5,845 sq. cm) Grid Area
Approximate Weight: Installed - 240 Lbs (108.9 kg), shipping - 316 Lbs, (143.3 kg)
Dimensions: 36" - Width, 30 5/8" - Depth, 18" - Height
(91.4 cm - Width, 77.8 cm - Depth, 45.7 cm - Height)

8148RCB - Radiant, 8048CB - Lava Rock

Type: Manual Control
8 Controls, 160,000 BTUH Total (20,000 BTUH Nat/LP per burner)
1,209 sq. in. (7,800 sq. cm) Grid Area
Approximate Weight: Installed - 314 Lbs (142.4 kg), shipping - 398 Lbs, (180.5 kg)
Dimensions: 48" - Width, 30 5/8" - Depth, 18" - Height
(122 cm - Width, 77.8 cm - Depth, 45.7 cm - Height)

8160RCB - Radiant, 8060CB - Lava Rock

Type: Manual Control
10 Controls, 200,000 BTUH Total (20,000 BTUH Nat/LP per burner)
1,512 sq. in. (9,754 sq. cm) Grid Area
Approximate Weight: Installed - 386 Lbs (175.1 kg), shipping - 486 Lbs, (220.4 kg)
Dimensions: 60" - Width, 30 5/8" - Depth, 18" - Height
(152.4 cm - Width, 77.8 cm - Depth, 45.7 cm - Height)

8172RCB - Radiant, 8072CB - Lava Rock

Type: Manual Control
12 Controls, 240,000 BTUH Total (20,000 BTUH Nat/LP per burner)
1,815 sq. in. (11,710 sq. cm) Grid Area
Approximate Weight: Installed - 530 Lbs (240 kg), shipping - 665 Lbs, (301 kg)
Dimensions: 72" - Width, 30 5/8" - Depth, 18" - Height
(182.9 cm - Width, 77.8 cm - Depth, 45.7 cm - Height)

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CAUTION

GENERAL INSTALLATION DATA

CAUTION

This equipment is designed and sold for commercial use only by personnel trained and
experienced in its operation and is not sold for consumer use in and around the home
nor for use directly by the general public in food service locations.

The Ultra-Max™ series gas charbroiler is equipped for the type of gas indicated on the
nameplate mounted on the front panel. All units are shipped from the factory for use with
natural gas. The unit can easily be converted for use with propane gas: see propane
gas.

-IMPORTANT­Be sure to remove all paper protection and packing material from unit prior to
lighting.

INSTALL IN NON-COMBUSTIBLE LOCATIONS ONLY! Clearance from non­combustible construction must be 3" minimum from back and sides. For servicing,
6" is recommended from back of unit.

The installation of the Appliance must conform to the NATIONAL FUEL GAS
CODE "ANSI Z223.1 - LATEST EDITION" AND ALL LOCAL GAS COMPANY
RULES AND REGULATIONS.

IN CANADA INSTALLATION SHALL BE IN ACCORDANCE WITH THE
CURRENT CAN/CGA-B149.1 NATURAL GAS INSTALLATION CODE OR CAN/
CGA-B149.2 PROPANE INSTALLATION CODE AND LOCAL CODES WHERE
APPLICABLE.

NOTICE

When this appliance is installed with casters, it must be installed with the casters supplied, a
connector complying with either ANSI Z21.69 or CAN/CGA-6.16 and a quick-disconnect device
complying with either ANSI Z21.41 or CAN1-6.9. It must also be installed with restraining means to

guard against transmission of strain to the connector, as specied in the appliance manufacturer's

instructions.

For your protection, we recommend a qualied installing agency install this appliance.

They should be familiar with gas installations and your local gas requirements. In any

case, your gas company should be called to approve the nal installation.

This appliance, its pressure regulator and its individual shutoff 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. This appliance and its pressure regulator must be isolated from the gas
supply piping system by closing its individual manual shutoff valve during any pressure testing

of the gas supply piping system at test pressures equal to or less than 1/2 PSIG.

EXHAUST CANOPY

Open hearth broilers inherently create a good deal of heat and smoke and should be installed

under an efcient exhaust hood with ame proof lters. A vertical distance of not less than 48"
shall be provided between the top of the appliance and lters or any other combustible material.

Exhaust installation must conform to local codes.

CAUTION

AIR SUPPLY

Provisions for adequate air supply must be provided.

CAUTION

Air for combustion enters from the bottom of the unit. Do not obstruct this area.

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LEVELING UNIT

This charbroiler is supplied with 4 feet or oor stand

legs which must be screwed into the body. Unit must
be level. Level unit by adjusting the (4) feet which
have an adjustment of 1-3/4" for accurate and perfect
line-up with other units.

STIFFENING SUPPORTS ON 8148, 8160,
AND 8172 MODELS ONLY

CAUTION

DO NOT INSTALL WITHOUT ATTACHING FEET
OR SUPPLIED STAND LEGS AND SHELF - DO
NOT REMOVE FEET.

SCREW LEGS INTO MOUNTING NUTS ON BOTTOM

Caster Kits: Casters can be used with oor stand models or optional equipment stand. For installation, carefully

mark and cut off from the bottom of each leg using a straight cutting saw and de-burr the inside tube wall prior
to installing the caster. Cut leg should measure 19" tube length, not overall length. Casters add about 6-1/4" of
height to the unit. Be sure to use approved strain relief means for protecting gas line connection. If an appliance
is equipped with casters and is gas connected with a quick connect coupling, all personnel must be aware that
there is a restraint on the appliance and if disconnected for service or cleaning it must be reconnected as originally
installed prior to use.

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GENERAL INSTALLATION DATA (continued)

PLACING RADIANTS - RCB SERIES

After the unit is unpacked and installed, place 1 radiant above each burner. Install each radiant
on 2 slots of the rear wall and on 1 pin of the front wall of the liner weld assembly. Refer to the
exploded view in this manual for orientation of the radiants.

PLACING LAVA ROCKS- CB SERIES

Open the lava rock bags and place rock evenly on the lower internal grates - not the top cooking
grates. Spread the lava rock evenly on the grates approximately 1 layer thick. Do not cover
the grates with more than two layers of lava rock. Do not put more than 5 pounds of rock per
burner section.

GAS PIPING

Gas piping shall be of such size and so installed as to provide a supply of gas sufcient to meet

the full gas input of the appliance. If the appliance is to be connected to existing piping, it shall
be checked to determine if it has adequate capacity. Joint compound shall be used sparingly and
only on the male threads of the pipe joints. Such compounds shall be resistant to the action of
L.P. gases. WARNING: Any loose dirt or metal particles which are allowed to enter the gas lines
on this appliance will damage the valve and affect its operation. When installing this appliance,

all pipe and ttings must be free from all internal loose dirt.

GAS PRESSURE REGULATOR

A convertible pressure regulator is provided with each charbroiler. It should be connected to the
inlet pipe at the rear of the unit. The gas supply is then connected to it. The supply pressure to
the regulator is not to exceed 1/2 PSIG. It is shipped set for 5" water column manifold pressure
for use with natural gas.

MANUAL SHUT OFF VALVE

A manual shut off valve should be installed upstream from the manifold and within six feet of
the charbroiler.

CONNECTING GAS SUPPLY LINE

The gas inlet of the charbroiler is sealed at the factory to prevent entry of dirt. Do not remove
this seal until the actual connection is made to the gas supply line.

PROPANE GAS - CONVERSION

This charbroiler is equipped with xed orice hoods and is shipped from the factory for use with
natural gas. To convert to propane gas, install the burner orice hoods, located in the water

pan, as follows:

1. Remove grates, radiants and burners.

2. Remove the burner orice hoods and install the orice hoods supplied.

3. Replace the burners, radiants, and grates.

4. Set manifold pressure to (10) inch water column. A 1/8" pipe plug on the burner manifold

can be removed for attaching a pressure gauge. Remove the slotted, or hex-threaded plug
from the pressure regulator. Invert the plug and re-install. The letters "LP" should now be
visible on the plug. The regulator is now set for 10" (25.4 cm) water column. Attach the
conversion label, supplied with the unit, close to the nameplate.

CHECKING FOR GAS LEAKS

Check entire piping system for leaks. Soap and water solution or other material acceptable for
the purpose, shall be used in locating gas leakage.

CAUTION

CAUTION

Matches, candle ame or other sources of ignition shall not be used for locating

gas leaks.

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