Gas Fryers GT45 / GT46 / GT60 Service Manual 1 Blue Seal Evolution Series GT45 / GT46 / GT60 Revision 1/ © Moffat Ltd, January 2007
WARNING: ALL INSTALLATION AND SERVICE REPAIR WORK MUST BE CARRIED OUT BY QUALIFIED PERSONS ONLY. IMPORTANT: MAKING ALTERATIONS MAY VOID WARRANTIES AND APPROVALS.
Contents This manual is designed to take a more in depth look at the GT45, GT46 and GT60 gas fryers for the purpose of making the units more understandable to service people. There are settings explained in this manual that should never require to be adjusted, but for completeness and those special cases where these settings are required to change, this manual gives a full explanation as to how, and what effects will result. Section Page Number 1. Specifications............................................
Blue Seal Evolution Series GT45 / GT46 / GT60 Revision 1/ © Moffat Ltd, January 2007
Specifications 1 External dimensions: GT45 Legend - Gas connection entry point - ¾” BSP male Dimensions shown in millimetres 1 Blue Seal Evolution Series GT45 / GT46 / GT60 Revision 1/ © Moffat Ltd, January 2007
1 Specifications External dimensions: GT46 Legend - Gas connection entry point - ¾” BSP male Dimensions shown in millimetres 2 Blue Seal Evolution Series GT45 / GT46 / GT60 Revision 1/ © Moffat Ltd, January 2007
Specifications 1 External dimensions: GT60 legend - Gas connection entry point - ¾” BSP male Dimensions shown in millimetres 3 Blue Seal Evolution Series GT45 / GT46 / GT60 Revision 1/ © Moffat Ltd, January 2007
1 Specifications Gas supply (Non-UK models) Natural Gas 90 MJ/hr (85,300 Btu/hr) 1.13 - 2.00 kPa (4.5” - 8.0” w.c.) 0.98 kPa (3.9” w.c.) Input Rating (N.H.G.C.) Supply Pressure Burner Operating Pressure Gas Connection LP Gas (Propane) 90 MJ/hr (85,300 Btu/hr) 2.75 - 3.00 kPa (11” - 12” w.c.) 2.50 kPa (10.0” w.c.) ¾” BSP Male Gas supply (UK models) Natural Gas (G20) Propane (G31) Heat Input (nett) Gas Rate 22.5 kW 2.26 m3/hr 22.5 kW 1.
Installation 2 Installation Requirements NOTE: • It is most important that this appliance is installed correctly and that operation is correct before use. Installation shall comply with local, gas, health and safety requirements. • This appliance shall be installed with sufficient ventilation to prevent the occurrence of unacceptable concentrations of health harmful substances in the room, the appliance is installed in.
2 Installation 4. All air for burner combustion is supplied from underneath the appliance. The legs must always be fitted and no obstructions placed on the underside or around the base of the appliance, as obstructions will cause incorrect operation and/or failure of the appliance. 5. Components having adjustments 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.
Installation 2 NOTE: It is important that adequately sized piping runs directly to the connection joint on the appliance, with as few tees and elbows as possible to give maximum supply volume. 3. A suitable joining compound which resists the breakdown action of LPG must be used on every gas line connection, unless compression fittings are used. The connection to the appliance is 3/4” BSP male. NOTE: A Manual Isolation Valve must be fitted to the individual appliance supply line. 4. 5. 6. 7.
2 Installation Commissioning The following commissioning checks must be carried out before the fryer is handed over for use, to ensure that the unit operates correctly and the operator(s) understand the correct operating procedure. 1. 2. Before leaving the new installation; a. Check the following functions in accordance with the operating instructions specified in the “Operation” section of the User manual. • Light the Pilot Burners. • Light the Main Burners.
Operation 3.
3 Operation Single Tank GT60 Controls Thermostat Control Knob Flame Failure Button Gas Control Valve Piezo Igniters 10 Blue Seal Evolution Series GT45 / GT46 / GT60 Revision 1/ © Moffat Ltd, January 2007
Operation Lighting the Pilot Burners 3 GT46 Fryer (Twin Tank) 1. With the fryer tank full of frying medium, the pilot burners can be lit. 2. Check that the gas supply is turned on at the mains supply. 3. Open the access door at the front of the appliance to access the control panel. 4. Rotate the right hand gas control knob to the position marked "PILOT" and hold depressed. 5. Depress the right hand piezo igniter until the right hand pilot ignites. 6.
3 Operation 3.2 Explanation of Control System - GT45/GT60 (Single tank fryers) 3.3 Explanation of Control System - GT46 (Twin tank fryers) The gas control circuit in these fryers is operated by two millivolt circuits. The first is the pilot system which consists of the thermocouple, the pilot burner and the gas control. The gas control circuit in these fryers is operated by three millivolt circuits.
Cleaning / Maintenance CAUTION: Daily Cleaning a. At the end of each day or at the end of each shift, if the frying schedule is heavy, the frying medium should be drained and strained into a receptacle. b. Use a drain stick, if necessary, to stir up any solid medium into the top medium to melt it. Slip a muslin or other suitable bag over the drain valve. Crumbs will be caught in the bag but frying medium will strain freely through bag into the receptacle.
4 Cleaning / Maintenance Weekly Cleaning a. Proceed as for “Daily Cleaning” to drain and filter the tank. Do not refill the tank with frying medium until it has been cleaned as shown below. b. Fill the fryer with cold water to the normal fill level and add a high quality commercial cleaner that has been specifically formulated for fryers. All purpose cleaners are not recommended. NOTE: Never use a caustic or lye solution, as this will leave a fat destroying film on the tank. c. d. e.
Trouble-shooting WARNING: 5.1 5 ALL INSTALLATION AND SERVICE REPAIR WORK MUST BE CARRIED OUT BY QUALIFIED PERSONS ONLY. Trouble shooting chart Fault Piezo ignitor not sparking Pilot won’t light Possible Cause Remedy Short in high tension lead. (Refer fault diagnosis 5.2.2) Replace lead. (Refer service section 6.2.14) Piezo faulty. (Refer fault diagnosis 5.2.2) Replace piezo. (Refer service section 6.3.12) No gas supply Ensure gas is connected and on and bottles not empty.
5 Trouble-shooting Fault Pilot goes out when main burner comes on Pilot goes out while frying, won’t re-light Pilot goes out while frying, can relight Possible Cause Incorrect gas pressure. Check supply / adjust pressure. (Refer specifications section) Faulty gas control. Replace gas control. (Refer service section 6.2.10/6.2.11) Over-temperature thermostat faulty (oil below 205ºC/401ºF). (Refer fault diagnosis 5.2.1) Replace over-temperature thermostat. (Refer service section 6.2.
Trouble-shooting Fault Pilot flame yellow / lazy Burners do not burn correctly (roar / light back / incorrect colour) Set temperature not reached Possible Cause 5 Remedy Gas pressure incorrect. Check gas supply pressure. (Refer specifications section) Restriction in pilot spud or aeration. Clean or replace as required. (Refer service section 6.2.3) Incorrect supply pressure. Check supply pressure. Pilot too small or to large. Adjust pilot size. (Refer service section 6.2.
5 Trouble-shooting 5.2 Fault Diagnosis 5.2.1 Pilot drops out couple the thermocouple is faulty—replace. If the voltage is over 10mV then there is a fault with the flame failure valve electromagnet— replace. To test the thermocouple connected to the main gas control, ignite the pilots and whilst holding in the gas control button, measure the voltage between the pilot burner side of the connector block to earth. This should be approximately 30mV.
Trouble-shooting 5 Overtemp tripped Piezo ignitor faulty Check the oil temp with the thermometer. If the oil temperature has reached over 220 ° C the overtemp should have tripped (open circuit), and will not reset until the temperature has dropped below 192 ° C. If the oil temperature is below 180°C and the overtemp is still open circuit then the overtemp is faulty. If no spark at all can be generated, remove piezo ignitor and hold close to cabinet body .
5 Trouble-shooting Thermostat or Gas control faulty With cold fryer, disconnect thermostat wires from gas control and check continuity through thermostat. If no continuity rotate shaft anti-clockwise one full turn to check if the thermostat is out of calibration. If there is still no continuity then replace the thermostat. Figure 5.2.3b If there is continuity through the thermostat connection then set gas control knob to main flame position.
Service Procedures Section 6 Page Number 6.1 Access......................................................................................................22 6.1.1 Control Panel.......................................................................................................22 6.2 Replacement............................................................................................22 6.2.1 Thermocouple (Gas Control).................................................................................22 6.
6 Service Procedures 6.1 Access 6.2 Replacement 6.1.1 Control panel 6.2.1 Thermocouple (gas control) 1) Disconnect thermocouple from gas control. 1) Remove two screws from the underside of facia panel. Panel should now drop down and be removed. Thermocouple Thermostat Knob Securing screws Figure 6.2.1a 2) Unscrew the overtemp thermostat wires from the connector block on the thermocouple. Figure 6.1.1a 3) Unscrew thermocouple securing nut from pilot burner.
Service Procedures 6.2.2 Thermocouple (flame failure valve - single tank models) 6 6.2.4 Pilot burner 1) Disconnect the thermopile and/or the thermocouple and/or the piezo electrode from the pilot burner. 1) Remove front panel. 2) Disconnect thermocouple from flame failure valve. 2) Disconnect pilot supply tube from pilot burner by unscrewing nut and olive. Figure 6.2.2 Figure 6.2.4 3) Remove screw securing the pilot burner to front of the fryer, and remove pilot burner assembly.
6 Service Procedures 6.2.6 Thermopile 6.2.8 Main burners 1) Unscrew the two thermopile leads from the gas control terminal block. 1) Unscrew 2 screws from pilot mounting bracket from side from which burner is to be replaced. 2) Unscrew (2 screws) burner box underside panel from side from which burner is to be replaced. 3) Unscrew and remove corner support panel from underside of burner intake throat (2 screws) NOTE: There may be a tie wire located at the rear of the burner.
Service Procedures 6 5) Unscrew thermostat. Replace with new thermostat ensuring sealant suitable for 250 °C is used on threads (Loctite 567 recommended). Avoid rotating shaft on thermostat as internal damage may occur. 6) Once the rear is supported the front can be pushed up into its location. The small notch in each side of the venturi visible externally from the burner body is for the front to back location and should be located up into the top corner panels when pushing up at the burner at front.
6 Service Procedures 6.2.10 Gas control (Single tank models) 6.2.11 Gas control (Twin tank models) Note: Ensure gas is isolated at main supply before any alterations are carried out on main gas controls. Note: Ensure gas is isolated at main supply before any alterations are carried out on main gas controls. 1) Remove control panel (refer 6.1.1). 1) Remove control panel (refer 6.1.1). 2) Disconnect thermocouples, thermopile and thermostat leads, and pilot supply from gas flame failure valve.
6 Service Procedures 6.2.12 Piezo ignitor 6.2.15 Flame failure valve 1) Remove control panel (refer 6.1.1). 1) Remove control panel (refer 6.1.1) 2) Remove piezo ignitor and replace. 2) Remove thermocouple, gas inlet and outlet pipes. 3) Undo bracket securing nut. Gas supply line Piezo Securing Nut Thermocouple Figure 6.2.12 Gas Outlet line 6.2.13 Piezo Electrode 4) Remove flame failure valve. 1) Remove nut securing piezo electrode to pilot assembly. 5) Replace and reassemble in reverse order.
6 Service Procedures 6.3 6.3.3 Operating Adjustment / Calibration 6.3.1 Pilot pressure 1) Unscrew operating pressure test point on the gas control valve. adjustment 2) Fit manometer (pressure meter) to test point. 1) Open door, and using screwdriver turn the pilot adjustment screw. 3) Light main burners. Turning the screw anticlockwise increases the pilot flow. 4) Remove regulator cap. 5) Adjust operating pressure by turning regulator screw until correct operating pressure is achieved.
Accessories Joining strip (Part no. 228600) Drain adaptor (Part no. 024705) Side splash panel LH (Part no. 228898) RH (Part no. 228899) Side splash panel joiner for griddle - chargrill LH (Part no. 228894) RH (Part no. 228895) 7 Drain extension kit (Part no.
8 Exploded Parts Diagrams 8.1 GT45 8.1.
Exploded Parts Diagrams 8 8.1.
8 Exploded Parts Diagrams 8.1.3 GT45 Main Burners ITEM PART NO 20 022575 21 022845 22 018089K 23 019237 24 227508 25 032310 032190 INJECTOR 26 227636 27 227638 28 227639 29 227131 30 020628 31 018111 32 227779 33 229511 34 227694 DESCRIPTION BURNER KIT TUBE,FLEXIBLE,SS,1/2"O.Dx12" NOVA MILLIVOLT VALVE KIT FLAME FAILURE VALVE M1A/HP PIEZO IGNITOR M18 INJECTOR 3.10mm NAT 1.
Exploded Parts Diagrams 8 8.1.4 GT45 Pilot Burners and Thermostat ITEM PART NO 35 018022K 36 018021K 37 228569 38 018145 39 018171 40 018094 41 227865 42 018090K 43 018744 44 018743 45 018091 018092 018972 018971 46 018093 DESCRIPTION OVERTEMP CONTROL KIT THERMOSTAT KIT LABEL TEMP CONTROL GT45 KNOB #8010-A SPECIAL-BLACK THERMOSTAT STOP -PLATED THERMOCOUPLE INTERRUPTED THERMOCOUPLE 850mm M8 PILOT BURNER KIT ELECTRODE THERMOCOUPLE SPACER PILOT SPUD - NAT 0.62mm PILOT SPUD - LPG 0.35mm PILOT INJECTOR 0.
8 Exploded Parts Diagrams 8.2 GT46 8.2.
Exploded Parts Diagrams 8 8.2.
8 Exploded Parts Diagrams 8.2.3 GT46 Burner and Thermostat Assembly ITEM PART NO DESCIPTION 20 022575 BURNER KIT 21 022845 TUBE,FLEXIBLE,SS,1/2"O.Dx12" 22 227131 MANIFOLD 450 FRYER 23 018089K NOVA MILLIVOLT VALVE KIT 24 227508 PIEZO IGNITOR M18 25 228572 LABEL TEMP CONTROL GT46 26 018145 KNOB #8010-A SPECIAL-BLACK 27 018171 THERMOSTAT STOP -PLATED 28 227649 PILOT SUPPLY TUBE RH 29 227647 PILOT SUPPLY TUBE LH 30 229511 INJECTOR ELBOW x3/8T 31 032310 INJECTOR 3.10mm 032190 INJECTOR 1.
Exploded Parts Diagrams 8 8.3 GT60 8.3.
8 Exploded Parts Diagrams 8.3.
Exploded Parts Diagrams 8 8.3.3 GT60 Main Burner Assembly ITEM PART NO DESCRIPTION 21 022575 BURNER KIT 22 022845 TUBE,FLEXIBLE,SS,1/2"O.Dx12" 23 018089K NOVA MILLIVOLT VALVE KIT 24 019237 FLAME FAILURE VALVE M1A/HP 25 227508 PIEZO IGNITOR M18 26 032310 INJECTOR 3.10mm 032190 INJECTOR 1.
8 Exploded Parts Diagrams 8.3.4 GT60 Pilot and Thermostat Assembly ITEM PART NO DESCIPTION 37 018022K OVERTEMP CONTROL KIT 38 018021K THERMOSTAT KIT 39 228634 LABEL TEMP CONTROL GT60 40 018145 KNOB #8010-A SPECIAL-BLACK 41 018171 THERMOSTAT STOP -PLATED 42 018094 THERMOCOUPLE INTERRUPTED 43 227865 THERMOCOUPLE 850mm M8 44 018090K PILOT BURNER KIT 45 018744 ELECTRODE 46 018743 THERMOCOUPLE SPACER 47 018091 PILOT SPUD - NAT 0.62mm 018092 PILOT SPUD - LPG 0.35mm 018972 PILOT INJECTOR 0.
Circuit Schematics 9.1 9 GT45 – Single Tank Fryer MAIN GAS CONTROL SIT NOVA 820mV IGNITION FLAME FAILURE VALVE SIT M1/A TP TH TP TH THERMOSTAT OVER TEMP THERMOPILE L.H. PILOT T/C R.H.
9 9.2 Circuit Schematics GT60 – Single Tank Fryer IGNITION MAIN GAS CONTROL SIT NOVA 820mV IGNITION FLAME FAILURE VALVE SIT M1/A TP TH TP TH THERMOSTAT L.H. PILOT THERMOPILE OVER TEMP T/C R.H.
Circuit Schematics 9.3 9 GT46 - Fryer—Twin Tank Fryer MAIN GAS CONTROL SIT NOVA 820mV TP TH TP IGNITION MAIN GAS CONTROL SIT NOVA 820mV IGNITION TP TH TH TP TH THERMOSTATS OVER TEMPS.
10 Service Contacts Australia VICTORIA - MOFFAT PTY HEAD OFFICE AND MAIN WAREHOUSE 740 Springvale Road Mulgrave VIC 3170 Spare Parts Department Tel (03) 9518 3888 Fax (03) 9518 3838 Free Call 1800 337 963 Fax (03) 9518 3895 NEW SOUTH WALES - MOFFAT PTY Unit 3/142 James Ruse Drive Rosehill NSW 2142 Spare Parts Tel (02) 8833 4111 Free Call 1800 337 963 Fax (03) 9518 3895 QUEENSLAND - MOFFAT PTY 30 Prosperity Place Geebung QLD 4034 Spare Parts Tel (07) 3630 8600 Free Call 1800 337 963 Fax (03) 9518 3895
Service Contacts 10 United Kingdom Utensils Direct 0845 873 6600 www.utensilsdirect.co.
A Appendix A: Gas Type Conversion C AUTION : Ensure the unit is isolated from the gas supply before commencing servicing. NOTE: • These conversions should only be carried out by qualified service persons. All connections must be checked for leaks before re-commissioning the appliance. • For all relevant information and specifications refer to the table at the end of this section. 1. 2. 3. Ensure that the gas supply has been turned off.
Appendix A: Gas Type Conversion A Gas Controller NOTE: For Twin Tank Fryers only, the units will be fitted with 2 gas controllers. These controllers operate independently of each other. The gas regulators and pilot adjustment will need to be carried out separately for each gas controller. Main Burner Operating Pressure Adjustment a. Connect a manometer to the lower test point (Burner Pressure) on the gas control valve located through the access hole in the control panel. b.
A Appendix A: Gas Type Conversion Gas Type Identification Label On completion of the gas conversion, replace the gas type identification label located at:- The rear of the appliance, 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. WARNING: DO NOT USE A NAKED FLAME 2. TO CHECK FOR GAS LEAKAGES.
Utensils Direct 0845 873 6600 www.utensilsdirect.co.
