Blue Seal Evolution G592 Service Manual Download

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Revision 1/

Blue Seal Evolution Series Gas Chargrills

Gas Chargrills

G592 / G594 / G596 / G598

Service Manual

Summary of Contents for Evolution G592

Page 1: ...Revision 1 Moffat Ltd January 2007 Blue Seal Evolution Series Gas Chargrills Gas Chargrills G592 G594 G596 G598 Service Manual ...

Page 2: ...t Ltd January 2007 Blue Seal Evolution Series Gas Chargrills ALL INSTALLATION AND SERVICE REPAIR WORK MUST BE CARRIED OUT BY QUALIFIED PERSONS ONLY WARNING MAKING ALTERATIONS MAY VOID WARRANTIES AND APPROVALS IMPORTANT ...

Page 3: ...e this manual gives a full explanation as to how and what effects will result Section Page Number 1 Specifications 1 2 Installation 4 3 Operation 8 3 1 Description of Controls 3 2 Explanation of Control System 4 Cleaning Maintenance 10 5 Trouble shooting Guide 12 5 1 Trouble shooting chart 5 2 Fault diagnosis 6 Service Procedures 14 6 1 Access 6 2 Replacement 6 3 Adjustment Calibration 7 Accessori...

Page 4: ...Revision 1 Moffat Ltd January 2007 Blue Seal Evolution Series Gas Chargrills ...

Page 5: ...er Operating Pressure 1 0 kPa 0 95 kPa 2 5 kPa 2 6 kPa 4 w g 3 8 w g 9 8 w g Gas Connection 1 2 BSP Male 3 4 BSP Male 1 2 BSP Male 3 4 BSP Male 10 w g Natural Gas G20 Propane G31 G592 G594 G596 G598 G592 G594 G596 G598 Heat Input nett Nominal 8 8 kW 18 0 kW 27 0 kW 36 0 kW 8 8 kW 18 0 kW 27 0 kW 36 0 kW Reduced 3 5 kW 6 0 kW 9 0 kW 18 0 kW 3 7 kW 6 4 kW 9 6 kW 12 8 kW Gas Rate nett Nominal 0 93 m3...

Page 6: ...2 1 Specifications Revision 1 Moffat Ltd January 2007 Blue Seal Evolution Series Gas Chargrills External Dimensions G592 B NOTE G592 are only available in Bench Model B Option G594 LS Front Side Plan ...

Page 7: ...3 1 Specifications Revision 1 Moffat Ltd January 2007 Blue Seal Evolution Series Gas Chargrills G596 LS G598 LS ...

Page 8: ...nts protected e g paint sealed by manufacturer are only allowed to be adjusted by an authorised service agent They are not to be adjusted by the installation person Unpacking Remove all packaging Check equipment and parts for damage Report any damage immediately to the carrier and distributor Remove protective plastic coating from the side panels Check that the following parts have been supplied w...

Page 9: ... on the underside of the chargrill Se cure each leg hand tight 4 Align the four round cut out holes on the base tray with the four hob legs already fitted to the chargrill Ensure that the base tray is orientated with the sloping edge of the base tray facing the front of the appliance 5 Slot the base tray onto the four hob legs and push fully home 6 Secure the base tray to the front chargrill legs ...

Page 10: ...ible to give maximum supply volume 3 Fit the gas regulator supplied into the gas supply line as close to the appliance as possible The regulator connections are BSP female The connection is BSP male Refer to the Specifications section for the gas supply location dimensions NOTE The gas pressure regulator provided with this appliance is convertible between Natural Gas and LPG and is already convert...

Page 11: ...h Fire Burner Operation b Ensure that the operator has been instructed in the areas of correct lighting operation and shutdown procedure for the appliance 2 The User Manual must be kept by the owner for future reference and a record of Date of Purchase Date of Installation and Serial Number of Unit recorded and kept with the manual These details can be found on the rating plate attached to the und...

Page 12: ...rills Note A full user s operation manual is supplied with the product and can be used for further referencing of installation operation and service Gas Control Knobs OFF Position PILOT Burner HIGH Flame LOW Flame Piezo Igniter with burner flame viewing ports 3 1 Description of Controls ...

Page 13: ...l knob the plunger can be temporarily held open while lighting There s two reasons for this gas has to flow through the safety valve to make it possible to light the pilot burner and secondly the plunger has to be pushed all the way in for the electromagnet to hold it in I e the electromagnet is strong enough to hold the plunger in once there but is not strong enough to pull it in by itself Someti...

Page 14: ...aning The appliance should be switched on briefly to ensure the griddle plates become dry Oil or grease should be spread over the grill surface in order to form a thin protective greasy film Radiants should not need cleaning as any grease or food will be burned off with the intense heat from the burners The radiants can be removed if cleaning is necessary To keep your chargrill clean and operating...

Page 15: ...ers removed Clean the interior and exterior surfaces of the chargrill with hot water detergent solution and a soft scrubbing brush Note that the gas control knobs are a push fit onto the gas control valve spindles and can be removed to allow cleaning of the front control panel Dry all components thoroughly with a dry cloth and polish with a soft dry cloth To remove any discolouration use an approv...

Page 16: ... 2 10 Pilot goes out when main burners come on Incorrect gas pressure Faulty thermocouple Refer fault diagnosis 5 1 2 Faulty gas control valve Check supply adjust pressure Replace thermocouple Refer service section 6 2 1 Replace gas control valve Refer service section 6 2 9 Main burners will not light Wrong size or blocked injectors Faulty gas control valve Incorrect supply pressure Replace clean ...

Page 17: ...rt in high tension lead If repeated sparking of the piezo shows intermittent sparking at the electrode then the lead should be traced to find area of short This can normally be visually seen as the spark arcs If the lead is shorting the best solution is to replace it as the electrical insulation strength of the lead may have deteriorated If the spark arc can be seen at the electrode insulator at t...

Page 18: ... 16 6 2 5 Main Burners 17 6 2 6 Main Burner injectors 17 6 2 7 Piezo ignitor 17 6 2 8 H T Lead 17 6 2 9 Gas Control Valve 18 6 2 10 Gas Control Magnet 18 6 3 Adjustment Calibration 19 6 3 1 Gas Control Re greasing 19 6 3 2 Low Fire Rate Adjustment 19 ALL INSTALLATION AND SERVICE REPAIR WORK MUST BE CARRIED OUT BY QUALIFIED PERSONS ONLY ENSURE GAS SUPPLY IS SWITCHED OFF BEFORE SERVICING ALWAYS CHEC...

Page 19: ...l 2 Remove 2 cap screws securing control panel to barbecue 3 Panel can now be removed from unit 4 H T leads may be required to be disconnected if control panel is to be removed away from the BBQ 1 Remove control panel refer 6 1 1 2 Undo the thermocouple from the pilot assembly 3 Undo the thermocouple from the gas control The thermocouple can now be removed 4 Replace and reassemble in reverse order...

Page 20: ...nel refer 6 1 1 2 Remove thermocouple piezo and pilot supply tube and injector from the pilot burner 3 Remove the two screws securing the pilot burner to the barbecue Figure 6 2 4b Thermocouple Gas pilot line H T piezo lead Two screws Pilot Injector 6 2 3 Spark electrode 1 Remove control panel refer 6 1 1 2 Remove HT lead from spark electrode 3 Remove spark electrode from pilot burner 4 Replace an...

Page 21: ...5 Main burner 1 Remove control panel refer 6 1 1 2 Remove the HT lead from the piezo ignitor by pulling firmly away 3 Unscrew the nut securing the piezo ignitor to the control panel Figure 6 2 7 4 Replace and reassemble in reverse order 1 Remove the top grate and radiant castings relevant to the burner to be removed 2 Slide the burner out from its supports 4 Replace and reassemble in reverse order...

Page 22: ...rol 6 Extract gas magnet 7 Replace and reassemble in reverse order Figure 6 2 9 Gas Control Magnet Rear Nut 6 2 10 Gas control magnet 1 Remove control panel refer 6 1 1 2 Undo pilot supply main supply and disconnect pilot thermocouple from gas control 3 Undo compression nut securing gas control to the manifold assembly 4 Replace gas control and re assemble in reverse order Note Ensure that the cor...

Page 23: ...sing needle nose pliers or similar pull out gas control spindle again noting its orientation 4 Apply a suitable high temperature gas cock grease or lubricant such as ROCOL A S P Anti scuffing paste Dry Moly Paste to the outside of the spindle 5 Replace spindle and re assemble gas control in reverse order 6 3 2 Low fire rate adjustment 1 Remove control panel refer 5 2 1 2 Light barbecue and set gas...

Page 24: ...20 7 Accessories Revision 1 Moffat Ltd January 2007 Blue Seal Evolution Series Gas Chargrills ...

Page 25: ...URNER RADIENT 3 229577 SPLASHBACK WA 4 227960 BLUE SEAL BADGE 5 229569 BURNER SUPPORT 6 229555 GRATE SUPPORT 7 227286 BURNER 8 229679 SIDE HEAT SHIELD 9 229550 INNER RADIATION PANEL 10 229578 NOSE RAIL WA 11 229579 CONTROL PANEL 12 229580 FRONT TRIM 13 227508 PIEZO SIT 14 228010 PIEZO HOUSING 15 229531 DRIP TRAY 16 013908 SPACER FOOT ASSY 17 229541 FRAME WA 18 227189 TUBE STOPPER 19 228173 SPLASHB...

Page 26: ... M9x1 23 227404 GAS VALVE 21S 24 229720 SPARK ELECTRODE SIT 100 BENT 25 229719 PILOT ASSY 3 WAY 0 35MM 227985 PILOT INJECTOR 0 35mm NAT GAS 227984 PILOT INJECTOR 0 25mm LPG PROPANE 26 229731 HT LEAD 250mm RING TERMINAL 27 229566 PILOT TUBE 28 227378 KNOB BSEAL 8mm GAS PF 29 022686 6 FLEXITUBE 30 227375 INJECTOR MOUNTING BUSH 31 037270 INJECTOR 2 70mm NAT GAS 037165 INJECTOR 1 65mm LPG PROPANE 13 2...

Page 27: ...23 8 Exploded Parts Diagrams Revision 1 Moffat Ltd January 2007 Blue Seal Evolution Series Gas Chargrills 8 2 G594 Chargrill 8 2 1 G594 Main assembly ...

Page 28: ...228440 BBQ SIDE HEAT SHEILD 9 227271 INNER RADIATION PANEL 10 228655 NOSE RAIL WA 11 227544 CONTROL PANEL 12 227584 FRONT TRIM BSEAL 13 228010 PIEZO HOUSING 14 227508 PIEZO 15 228488 CRUMB TRAY 16 227075 SILL 600mm WA 17 227851 LEG 150MM X Ø63 5 EXTD THEARD 18 229674 REAR ROLLER ASSEMBLY 19 748010 SCREW 5 8 X1 HEX SET ZP 20 229673 LEG RING PLATE PLAIN 21 227408 BASE TRAY 600MM 22 227854 LEG EXTENS...

Page 29: ... BSPT 28 227248 MANIFOLD 29 019464K PILOT BURNER KIT 30 019593 PILOT SPUD NAT 0 41mm 31 019218 THERMOCOUPLE 450MM 32 227287 PILOT SUPPLY TUBE 33 227378 KNOB BSEAL 8mm GAS PF 34 022686 6 FLEXITUBE 35 037270 INJECTOR NAT GAS 2 70 mm 36 227404 GAS VALVE 21S 37 019624 ELECTRODE 7 227286 BURNER 019594 PILOT SPUD LPG PROPANE 0 25mm 037165 INJECTOR LPG PROPANE 1 65mm 8 2 2 G594 Gas assembly ...

Page 30: ...26 8 Exploded Parts Diagrams Revision 1 Moffat Ltd January 2007 Blue Seal Evolution Series Gas Chargrills 8 3 G596 Chargrill 8 3 1 G596 Main assembly ...

Page 31: ... BBQ SIDE HEAT SHEILD 9 227200 INNER RADIATION PANEL RH 10 227199 INNER RADIATION PANEL LH 11 228658 NOSE RAIL WA 12 227543 CONTROL PANEL 13 227580 FRONT TRIM BSEAL 14 228010 PIEZO HOUSING 15 227508 PIEZO BLACK BUTTON 16 228487 CRUMB TRAY 17 227901 SILL 900mm WA 18 227851 LEG 150MM X Ø63 5 EXTD THEARD 19 229674 REAR ROLLER ASSEMBLY 20 748010 SCREW 5 8 X1 HEX SET ZP 21 229673 LEG RING PLATE PLAIN 2...

Page 32: ...ON BRASS CONICAL BSPT 29 227187 MANIFOLD 30 019464K PILOT BURNER KIT 31 019593 PILOT SPUD NAT 0 41mm 32 019218 THERMOCOUPLE 450MM 33 227287 PILOT SUPPLY TUBE 34 227378 KNOB BSEAL 8mm GAS PF 35 022686 6 FLEXITUBE 36 037270 INJECTOR NAT GAS 2 70 mm 37 227404 GAS VALVE 21S 38 019624 ELECTRODE 019594 PILOT SPUD LPG PROPANE 0 25mm 037165 INJECTOR LPG PROPANE 1 65mm 8 3 2 G596 Gas assembly ...

Page 33: ...29 8 Exploded Parts Diagrams Revision 1 Moffat Ltd January 2007 Blue Seal Evolution Series Gas Chargrills 8 4 G598 Chargrill 8 4 1 G598 Main assembly ...

Page 34: ... BBQ SIDE HEAT SHEILD 9 227273 INNER RADIATION PANEL RH 10 227272 INNER RADIATION PANEL LH 11 228659 NOSE RAIL WA 12 227542 CONTROL PANEL 13 227581 FRONT TRIM BSEAL 14 228010 PIEZO HOUSING 15 227508 PIEZO BLACK BUTTON 16 228489 CRUMB TRAY 17 227902 SILL 1200 WA 18 227851 LEG 150MM X Ø63 5 EXTD THEARD 19 229674 REAR ROLLER ASSEMBLY 20 748010 SCREW 5 8 X1 HEX SET ZP 21 229673 LEG RING PLATE PLAIN 22...

Page 35: ...PLY PIPE WA 28 016044 UNION BRASS CONICAL BSPT 29 227249 MANIFOLD 30 019464K PILOT BURNER KIT 31 019593 PILOT SPUD NAT 0 41mm 32 019218 THERMOCOUPLE 450MM 33 227287 PILOT SUPPLY TUBE 34 227378 KNOB BSEAL 8mm GAS PF 35 022686 6 FLEXITUBE 36 037270 INJECTOR NAT GAS 2 70 mm 37 227404 GAS VALVE 21S 38 19624 ELECTRODE 037165 INJECTOR LPG PROPANE 1 65mm 019594 PILOT SPUD LPG PROPANE 0 25mm ...

Page 36: ...D 4034 Spare Parts Free Call 1800 337 963 Fax 03 9518 3895 WESTERN AUSTRALIA MOFFAT PTY 67 Howe St Tel 08 9202 6820 Osbourne Park WA 6017 Fax 08 9202 6836 Spare Parts Free Call 1800 337 963 Fax 03 9518 3895 NATIONAL COVERAGE FOR 24 HOUR SERVICE OR MAINTENANCE DIAL FREE CALL 1800 622 216 AUSTRALIA ONLY Canada SERVE CANADA 22 Ashwarren Rd Tel 416 631 0601 Downview Fax 416 631 0315 Ontario M3J1Z5 New...

Page 37: ...dom BLUESEAL LTD 67 Gravelly Industrial Park Tel 0121 327 5575 Erdington Fax 0121 327 9711 Birmingham B24 8TQ England United States of America MOFFAT INC 3765 Champion Blvd Winston Salem Tel 1800 551 8795 NC27115 Fax 336 661 9546 NATIONAL COVERAGE FOR SERVICE OR MAINTENANCE DIAL FREE CALL 1800 551 8795 USA ONLY ...

Page 38: ...n the front lower edges of the control panel and remove the panel from the front of the Chargrill 3 Remove the Chargrill castings griddle plates and inner radiants to reveal the burners 4 Carefully push the main burners forwards and negotiate between the shield brackets fitted over the end of the burners and remove the burners from the Chargrill to reveal the main burner injectors 5 Unscrew the ma...

Page 39: ... pilot burner and using a small screwdriver withdraw injector from inside the pilot burner 3 Determine the correct injector size for the corre sponding gas from the rating plate attached to the inner bulkhead adjacent to the manifold test point behind the front control panel 4 Fit the new pilot injector into the rear of the pilot burner and push fully home 5 Re connect the gas supply tube to the b...

Page 40: ...fixed behind the control panel next to the manifold test point 11 Replace with the correct size injectors 12 Check adjust the main burner aeration gap This gap should be fully open Pilot Burner 1 To remove the pilot burner unscrew the 2 screws securing the pilot burner shield panel to the front inner face of the chargrill Remove the panel from the chargrill 2 Remove the 2 burner supports from the ...

Page 41: ...s ensuring that the pilot burner thermocouple and piezo igniter electrode are correctly positioned and secured Tighten up the 2 x 8 mm screws 13 Re connect the gas supply tube to the base of the pilot burner and tighten using a 11 mm A F spanner 14 Refit the main burner supports to the base of the char grill ensuring that they locate into the cut outs at the front and rear of the chargrill burner ...

Page 42: ...rement shown in the Gas Specifications table at the end of this section NOTE The Low Fire Adjustment Screw should be sealed with coloured paint on completion of the low fire adjustment 2 Refit the front control panel to the chargrill and secure in position by tightening the 2 screws on the front lower edges of the control panel 3 Refit the gas control knobs to the gas control valves The gas contro...

Page 43: ...completion of the gas conversion replace gas type labels located at The rear of the unit above the gas connection Beside the rating plate Commissioning Before leaving the converted installation 1 Check all gas connections for leakages using soapy water or other gas detecting equipment 2 Check the following functions in accordance with the operating instructions specified in the Operation section o...

Page 44: ...is ex factory set and not to be adjusted apart from when converting between gases if required Refer to the Gas Conversion section for details Natural Gas G20 LP Gas Propane G31 G592 G594 G596 G598 G592 G594 G596 G598 Main Burner Injectors 2 70 mm 1 65 mm Pilot Burner Injectors 0 35 0 41 0 25 0 25 Low Fire Adjustment 11 4 turns out ccw turn out ccw Operating Pressure Non UK 1 0 kPa 0 95 kPa 2 5 kPa...

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Blue Seal Evolution G592, Service Manual

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