Blue Seal G592 Service Manual

Blue Seal G592 Service Manual

Evolution series gas chargrills

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Gas Chargril ls
G592 / G594 / G596 / G598
S e r v i c e M a n u a l
Blue Seal Evolution Series Gas Chargrills
© Moffat Ltd, January 2007
Revision 1/

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Summary of Contents for Blue Seal G592

  • Page 1 Gas Chargril ls G592 / G594 / G596 / G598 S e r v i c e M a n u a l Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 2 ALL INSTALLATION AND SERVICE REPAIR WORK MUST BE CARRIED OUT BY WARNING: QUALIFIED PERSONS ONLY. IMPORTANT: MAKING ALTERATIONS MAY VOID WARRANTIES AND APPROVALS. Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 3: Table Of Contents

    Exploded Parts Diagrams ................ 21 G592 300mm Chargrill G594 600mm Chargrill G596 900mm Chargrill G598 1200mm Chargrill Service Contacts ..................32 Appendix A: Gas Type Conversion ..............34 Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 4 Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 5 G592 G596 G592 G596 G598 G598 Main Burner Injectors 2.70 mm 1.65 mm Pilot Burner Injectors 0.35 0.41 0.25 0.25 Unit Weights (Net) G592 G594 G596 G598 Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 6 Specifications External Dimensions NOTE: G592 are only available in Bench Model (- B) Option. G592-B Plan Front Side G594-LS Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 7: Specifications

    Specifications G596-LS G598-LS Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 8 Blue Seal chargrills are designed to provide years of satisfactory service, and correct installation is essential to achieve the best performance, efficiency and trouble-free operation. This appliance must be installed in accordance with National installation codes and in addition, in accordance with relevant National / Local codes covering gas and fire safety.
  • Page 9: Fitting Leg Stand To Chargrill

    NOTE: This appliance is fitted with adjustable feet / rear rollers to enable the appliance to be positioned securely and level. This should be carried out on completion of the gas connection. Refer to the ‘Gas Connection’ section. Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 10: Gas Connection

    NOTE: ALL GAS FITTING MUST ONLY BE CARRIED OUT BY AN AUTHORISED PERSON. Blue Seal Chargrills do not require an electrical connection, as they function on the gas supply only. It is essential that the gas supply is correct for the Chargrill to be installed and that adequate supply pressure and volume is available.
  • Page 11: Installation

    (Refer to the “Gas Connection” section). NOTE: If for some reason it is not possible to get the appliance to operate correctly, contact the supplier of this appliance. Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 12 Note: A full user’s operation manual is supplied with the product and can be used for further referencing of installation, operation and service. Description of Controls Gas Control Knobs OFF Position PILOT Burner HIGH Flame LOW Flame Piezo Igniter (with burner flame viewing ports). Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 13: Operation

    7 and 30 millivolts when heated in the can be attributed to not pushing the plunger all pilot flame. the way in. Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 14 • Clean with hot water, a recommended detergent solution and a scrubbing brush. Dry all components thoroughly with a dry cloth. Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 15: Cleaning / Maintenance

    • Clean the griddle surface thoroughly with a wire brush or a flexible spatula. If necessary use a griddle stone or a scotch bright pad on the griddle surface. Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 16: Trouble-Shooting Guide

    Burner flame incorrect colour Burner aeration incorrectly set. Adjust burner aeration. (yellow) Gas control stiff to operate Gas control requires regreasing. Regrease gas control. (Refer service section 6.3.1) Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 17: Fault Diagnosis

    (e.g. the body of the gas control). This should read approximately 30mV. If this reading less than 10mV then thermocouple is faulty—replace. Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 18 ALL INSTALLATION AND SERVICE REPAIR WORK MUST BE CARRIED OUT BY QUALIFIED PERSONS ONLY. ENSURE GAS SUPPLY IS SWITCHED OFF BEFORE SERVICING WARNING: ALWAYS CHECK / TEST FOR GAS LEAKS AFTER SERVICE REPAIRS ON THE GAS SYSTEM Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 19: Service Procedures

    3) Undo the thermocouple from the gas control. The thermocouple can now be removed. 4) Replace and reassemble in reverse order. Figure 6.1.1 Thermocouple connection Figure 6.2.1b Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 20: Pilot Injector

    Note: Inspect spark electrode to make sure that Two screws ceramic cracked damaged before installing. Figure 6.2.4b Spark electrode 4) Replace pilot burner and reassemble in reverse order. Figure 6.2.3 Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 21: Main Burner

    (refer specifications remove HT lead from piezo ignitor. section). 2) Remove HT lead from piezo electrode, replace and reassemble in reverse order. Main injector Figure 6.2.8 Figure 6.2.6 Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 22: Gas Control Valve

    5) On suitable work surface, remove rear nut from gas control. 6) Extract gas magnet. 7) Replace and reassemble in reverse order. Rear Nut Gas Control Magnet Figure 6.2.10 Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 23: 6.3 Adjustment / Calibration

    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. Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 24: Accessories

    Accessories Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 25: Exploded Parts Diagrams

    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 SPLASHBACK ENDS Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 26 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) Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 27 Exploded Parts Diagrams G594 Chargrill 8.2.1 G594 Main assembly Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 28 SCREW 5/8"X1 HEX SET ZP 229673 LEG RING PLATE PLAIN 227408 BASE TRAY 600MM 227854 LEG EXTENSION 430 X Ø63.5 227667 FRAME WA 227189 TUBE STOPPER 228173 SPLASHBACK ENDS Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 29 PILOT SUPPLY TUBE 227378 KNOB BSEAL 8mm GAS PF 022686 6" FLEXITUBE 037270 INJECTOR NAT GAS 2.70 mm 037165 INJECTOR LPG/PROPANE 1.65mm 227404 GAS VALVE 21S 019624 ELECTRODE Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 30 Exploded Parts Diagrams G596 Chargrill 8.3.1 G596 Main assembly Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 31 SCREW 5/8"X1 HEX SET ZP 229673 LEG RING PLATE PLAIN 227407 BASE TRAY 900MM 227854 LEG EXTENSION 430 X Ø63.5 227671 FRAME WA 227189 TUBE STOPPER 228173 SPLASHBACK ENDS Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 32 PILOT SUPPLY TUBE 227378 KNOB BSEAL 8mm GAS PF 022686 6" FLEXITUBE 037270 INJECTOR NAT GAS 2.70 mm 037165 INJECTOR LPG/PROPANE 1.65mm 227404 GAS VALVE 21S 019624 ELECTRODE Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 33 Exploded Parts Diagrams G598 Chargrill 8.4.1 G598 Main assembly Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 34 SCREW 5/8"X1 HEX SET ZP 229673 LEG RING PLATE PLAIN 227409 BASE TRAY 1200MM 227854 LEG EXTENSION 430 X Ø63.5 227669 FRAME WA 227189 TUBE STOPPER 228173 SPLASHBACK ENDS Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 35 PILOT SUPPLY TUBE 227378 KNOB BSEAL 8mm GAS PF 022686 6" FLEXITUBE 037270 INJECTOR NAT GAS 2.70 mm 037165 INJECTOR LPG/PROPANE 1.65mm 227404 GAS VALVE 21S 19624 ELECTRODE Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 36 AUCKLAND - MOFFAT LTD 4 Waipuna Road Tel (09) 574 3150 Mt Wellington Fax (09) 574 3159 Auckland Spare Parts Free Call 0800 MOFFAT (0800 66 33 28) Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 37: Service Contacts

    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) Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 38: Appendix A: Gas Type Conversion

    Replace with the correct size injectors. Unscrew here with 13mm Spanner Refit the main burner castings, griddle plates and inner radiants to the Chargrill. Fig 11 Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 39 Re-connect the gas supply tube to the base of the pilot burner and tighten. Thermocouple/Pilot Burner/Igniter Retaining Plate Fig 13 Pilot Burner Thermocouple Piezo Igniter Unscrew Gas Supply Tube Here Fig 14 Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 40 Unscrew and remove the nut from the base of the Pilot Burner using a 11 mm A/F spanner. Pilot Bracket Securing Screws Using a small flat blade screwdriver, unscrew and Fig 19 Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 41 Refit the left and right inner radiation panels (These are a slot fit onto either side of the chargrill). Refit the inner radiants and castings to the Chargrill. Fig 22 Main Burner Fig 23 Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 42 Refit the gas control knobs to the gas control valves. Low Fire The gas control knobs are a push fit onto the shaft of Adjustment Screw Fig 24 the gas control valves. Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 43 NOTE: If for some reason it is not possible to get the unit to operate correctly, shut off the gas supply and contact the supplier of this unit. Blue Seal Evolution Series Gas Chargrills © Moffat Ltd, January 2007 Revision 1/...
  • Page 44: Gas Specifications

    * - The burner operating pressure is to be measured at the manifold test point with one burner for G592 Model or two burners for other models operating at full setting. The operating pressure is ex-factory set and not to be adjusted, apart from when converting between gases, if required.

This manual is also suitable for:

G596G594G598

Table of Contents