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Service Manual Floor type Gas Convection Steamer Series: Gemini Models 24CGA6.2ES, 24CGA10.2ES 1333 East 179 th Street Cleveland, Ohio Phone: (216) Fax: (216)
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Service Manual Floor type Gas Convection Steamer Series: Gemini Models 24CGA6.2ES, 24CGA10.2ES 1333 East 179 th Street Cleveland, Ohio Phone: (216) Fax: (216) FOR THE INSTALLER FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. WARNING WARNING Improper installation, adjustment, alterations, services or maintenance can cause property damage, injury or death. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment. Disconnect power before servicing IMPORTANT IT IS IMPORTANT TO POST INSTRUCTIONS WHICH ARE TO BE FOLLOWED IN THE EVENT THE USER SMELLS GAS. THESE INSTRUCTIONS SHOULD BE LOCATED IN A PROMINENT LOCATION, AND BE FULLY UNDERSTOOD BY ALL USERS OF THIS EQUIPMENT. THIS INFORMATION SHOULD BE OBTAINED FROM YOUR LOCAL GAS SUPPLIER. ALL SERVICE MUST BE PERFORMED BY A QUALIFIED CLEVELAND RANGE AUTHORIZED TECHNICIAN. The wiring diagram is located on the back of the lower front panel. RETAIN THIS MANUAL FOR YOUR REFERENCE Cleveland STATEMENT OF POLICIES L I M I T E D W A R R A N T Y CLEVELAND RANGE products are warranted to the original purchaser to be free from defects in materials and workmanship under normal use and service for the standard warranty period of one year from date of installation or 18 months from date of shipment, which ever comes first. CLEVELAND RANGE agrees to repair or replace, at its option, f.o.b. factory, any part which proves to be defective due to defects in material or workmanship during the warranty period, providing the equipment has been unaltered, and has been PROPERLY INSTALLED, MAINTAINED, AND OPERATED IN ACCORDANCE WITH THE CLEVELAND RANGE OWNER S MANUAL. CLEVELAND RANGE agrees to pay any FACTORY AUTHORIZED EQUIPMENT SERVICE AGENCY (within the continental United States, and Hawaii) for reasonable labor required to repair or replace, at our option, f.o.b. factory, any part which proves to be defective due to defects in material or workmanship, during the labor warranty period. This warranty includes travel time not to exceed two hours and mileage not to exceed 50 miles (100 miles round-trip), BUT DOES NOT INCLUDE POST START- UP, TIGHTENING LOOSE FITTINGS, MINOR ADJUSTMENTS, MAINTENANCE, CLEANING OR DESCALING. The standard labor warranty allows factory payment of reasonable labor required to repair or replace such defective parts. Cleveland Range will not reimburse the expense of labor required for the repair or replacement of parts after the standard warranty period, unless an Extended Labor Warranty Contract has been purchased to cover the equipment for the balance of the warranty period from the date of equipment installation, start-up, or demonstration. PROPER INSTALLATION IS THE RESPONSIBILITY OF THE DEALER, THE OWNER-USER, OR INSTALLING CONTRACTOR, AND IS NOT COVERED BY THIS WARRANTY. Many local codes exist, and it is the responsibility of the owner and installer to comply with these codes. Cleveland Range equipment is built to comply with applicable standards for manufacturers, including UL, ANSI, NSF, ASME/Ntl. Bd., CSA, and others. BOILER (Steam Generator) MAINTENANCE IS THE RESPONSIBILITY OF THE OWNER-USER AND IS NOT COVERED BY THIS WARRANTY. The use of good quality feed water is the responsibility of the Owner-User (see Water Quality Recommendations below). THE USE OF POOR QUALITY FEED WATER WILL VOID EQUIPMENT WARRANTIES. Boiler maintenance supplies, including boiler hand hole gaskets, are not warranted beyond the first 90 days after the date the equipment is placed into service. Preventive maintenance records must be available showing descaling per applicable Cleveland Operator Manual for Boiler Proration Program considerations. WATER QUALITY RECOMMENDATIONS TOTAL DISSOLVED SOLIDS less than 60 parts per million TOTAL ALKALINITY less than 20 parts per million SILICA less than 13 parts per million CHLORIDE less than 30 parts per million ph FACTOR greater than 7.5 The foregoing shall constitute the sole and exclusive remedy of original purchaser and the full liability of Cleveland Range for any breach of warranty. THE FOREGOING IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER WRITTEN, ORAL, OR IMPLIED, INCLUDING ANY WARRANTY OF PERFORMANCE, MERCHANTABILITY, OR FITNESS FOR PURPOSE, AND SUPERSEDES AND EXCLUDES ANY ORAL WARRANTIES OR REPRESENTATIONS, OR WRITTEN WARRANTIES OR REPRESENTATIONS, NOT EXPRESSLY DESIGNATED IN WRITING AS A WARRANTY OR GUARANTEE OF CLEVELAND RANGE MADE OR IMPLIED IN ANY MANUAL, LITERATURE, ADVERTISING BROCHURE OR OTHER MATERIALS. CLEVELAND RANGE S liability on any claim of any kind, including negligence, with respect to the goods or services covered hereunder, shall in no case exceed the price of the goods or services, or part thereof, which gives rise to the claim. IN NO EVENT SHALL CLEVELAND RANGE BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OR ANY DAMAGES IN THE NATURE OF PENALTIES. LIMITED EXTENDED WARRANTY COVERAGE The purchase of a Limited Extended Warranty Contract extends the standard warranty coverage to the purchased period of time (one to two years) from the date of installation, start-up, or demonstration, whichever is sooner. *An additional two years Parts and Labor Warranty can be purchased with each piece of Cleveland equipment for an additional 2% of the List Price per year. The 2% of list price charge will be the net invoice amount for each year of extended warranty purchased. - Extended warranty must be purchased at the same time the equipment is purchased. - Extended Warranty has the same exclusions as stated in our standard warranty. Second year limited extended warranty coverage on Cleveland Steamers when purchased with a water filter applies to water related components only. CHAPTER 1 PRODUCT IDENTIFICATION Cleveland Range, Inc. assigns two product identification numbers to each steamer: a model number and a serial number. The model number identifies the product characteristics. The serial number identifies the individual unit. A. MODEL NUMBER This manual covers the Gemini Model No. 24CGA6.2S, 24CGA6.2SES, 24CGA10.2, and 24CGA10.2ES Dual Steam Generator and Convection Steamer. Each character of this model number identifies a characteristic of the steamer. The Gemini Model No. 24CGA10.2ES is 24 inches wide, a Convection steamer, Gas powered, and an Atmospheric steam generator with a capacity for 10 cooking pans, this model has the extra suffix.2 to differentiate it from our standard 10 pan model that does not have two separate generators and Energy Saver for models designed for high efficiency operation. This manual covers all standard features and options available on Gemini gas steamers. Model 24CGA6.2S and 24CGA10.2 are steamers designed for high capacity operation. The burners that supply steam and the condenser spray to the compartments are on continuously while the unit is in timed cooking mode or in the manual cooking mode. The burners and condenser spray stay on until the cooking operation is complete. Model 24CGA6.2SES and 24CGA10.2ES are steamers designed for high efficiency operation. The energy saver models provide steam in a similar manner to our high capacity models except that the flow of steam is regulated by cycling the burners off once the desired cooking temperatures is reached. When the temperature drops to a set point below the desired cooking temperature the burners will turn back on to bring the cooking compartment back up to temperature. The burners will continue to cycle on and off as necessary to maintain temperature until the cooking operation is complete. The condenser spray is activated periodically to cool the condensate water to the drain automatically through the use of a thermostat control. NOTE TO INSTALLER: There are some significant differences in the installation procedures between the 24CGA6.2S, 24CCG10.2 and the 24CGA6.2SES, 24CGA10.2ES units. Pay close attention to section headings for specific installation instructions for each model listed. B. SERIAL NUMBER During manufacture, Gemini Steamers are assigned individual serial numbers. Whenever any inquiry is made with Cleveland Range regarding a steamer the serial number should be referenced. C. PRODUCT INFORMATION PLATE The Product Information Plate on the left side of the unit lists the model and serial number of the steamer. Figure 1-1 illustrates a typical Gemini Product Information Plate. The rating plate also lists power and wiring requirements. Figure 1-1 Gemini Product Information Plates 1 D. GENERATOR VENT IMPORTANT IMPORTANT When installing this steamer, under no circumstances should the Steam Vent (See Figure 1-2), be removed, capped or attached to piping of any kind. This fitting is an auxiliary safety intended to prevent any pressure from building up in the generator in the unlikely event the steam outlets of the steamer should become plugged or restricted. CHAPTER 2 INSTALLATION INSTRUCTIONS Figure 1-2 Generator Vent A. GENERAL This equipment should only be installed by qualified, professional plumbers, pipe fitters, and electricians. The steamer is to be installed to comply will the applicable Federal, State or Local Plumbing Codes, with the National Fuel Gas Code, ANSI Z223.1-(latest edition) or the Natural Gas Installation Code CAN/CGA-B149.1 or the Propane Installation Code CAN/CGA-B149.2 as applicable, The National Electrical Code, ANSI/NFPA No. 70-(latest edition) or the Canadian Electrical Code, CSA C22.2 as applicable, the Food Service Sanitation Manual of the Food and Drug Administration (FDA) and all applicable state and local codes and regulations. The installation instructions must be read in their entirety before starting the installation of this steamer. WARNING DEATH, INJURY, AND EQUIPMENT DAMAGE could result from the improper installation, adjustment, alteration, service or maintenance of a steamer or installation of a unit damaged during shipment or storage. Any of these conditions could also void the equipment warranty. DO NOT INSTALL a Gemini steamer that has been damaged. Install the Gemini steamer according to the policies and procedures outlined in this manual. To install this steamer, the following requirements must be considered when selecting a location. a. A suitable drain must be available within 12 ft. of the steamer. Do NOT install the appliance directly over a drain. Steam rising up out of the drain will adversely affect operation, hamper cooling air circulation, and damage electrical and electronic components. NOTE: The drain MUST NOT be located beneath the steamer itself. b. An electrical supply matching the power requirements found on the rating plate must be available, which is not of the GFCI (Ground Fault Interrupter Circuit) type. c. A gas supply matching the fuel requirements found on the rating plate must be available. d. The location must have sufficient space to meet the clearance requirements of the steamer as outlined in Chapter 2, Section B, Part 1, Locating the Steamer. e. A water supply meeting the requirements outlined in Chapter 2, Section B, Part 6 Water Supply Requirements and Installation must be available. B. INSTALLATION OF THE STEAMER After selecting the steamer s operating location the steamer can be positioned, and installed. 1. Locating the Steamer CAUTION Malfunctions and equipment damage may result from improper mounting. Malfunctions and/or damage resulting from improper mounting are not covered by the equipment warranty. The steamer MUST BE LEVEL BOTH FRONT TO BACK AND SIDE TO SIDE in all mounting arrangements. Catastrophic damage will result from shifting the steamer more than 10 o out of level with power supplied to the unit. a. Location and Clearance Requirements of the Steamer For safe and efficient operation, observe the following criteria when selecting an operating location for the Gemini steamer. 1) The unit should be installed in an area that is free and clear of combustible materials. 2) Do NOT install the appliance directly over a drain. Steam rising up out of the drain will adversely affect operation, hamper cooling air circulation, and damage electrical and electronic components. 3) A proper air supply for combustion and ventilation is critical to safe, efficient operation of Gemini gas steamers. 4) Do not install any heat producing equipment near the air vents of the equipment. Do not block the air vents of the unit. Do not store articles on top of the unit. WARNING All clearance requirements above, below, and around the unit are the same for non-combustible locations as for combustible locations. 5) Figure 2-1, 2-2, 2-3, and 2-4 illustrate the dimensions and clearances required for these steamers. Maintain the following minimum dimensions around the unit for safe and efficient operation, maintenance and service. Maintain a 3-inch operating clearance at the sides of the unit, and at least a 3-inch clearance at the back. A 12 in clearance is recommended on the right side for servicing the steamer. Approximately 24 inches of clearance is recommended in front of the unit for opening the door and standard pan clearance. 6) The steamer must be level both front to back and side to side. Select an operating surface that is level enough to allow leveling the unit without extreme adjustment of the legs. 7) The location selected must be capable of supporting 650 lbs. for a Gemini steamer. This includes the weight of the water and the food. A A GAS B ELECTRIC COLD WATER CLEARANCE C DRAINAGE 1-1/4 IPS line size, 3/4 connection 115V-1Phase, 60 Hz. 35 PSI minimum RIGHT = 12.00 for service 2 dia. O.D. NATURAL PROPANE BTU 2 Fans & controls 60 psi maximum SIDES = 3.00 Piping 3/4 NPT Piping 3/4 NPT. 50, watts each (1) 1/2 dia. IPS for D REAR = 3.00 Do not connect other units to each Condenser this drain. Supply pressure Supply pressure Generator FRONT = Drain must be free air vented. 4.50 W.C. Min W.C. Min W.C. Max W.C. Max. 100,000 total Manufacturer must be notified if unit will be used above 2,000 feet (1) 3/8 dia. IPS for E Generator Drain plumbing must be able to withstand 140 F (60 C). The drain must not be located beneath the steamer itself. Figure 2-2 Gemini 24CGA6.2SES Dimensions and Clearances TYP 5.00 A GAS B ELECTRIC COLD WATER CLEARANCE C DRAINAGE 1-1/4 IPS line size, 3/4 connection 115V-1Phase, 60 Hz. 35 PSI minimum RIGHT = 12.00 for service 2 dia. OD NATURAL PROPANE BTU 2 Fans & controls 60 psi maximum SIDES = 3.00 Piping 3/4 NPT Piping 3/4 NPT. 50, watts each (1) 1/2 dia. IPS for D REAR = 3.00 Do not connect other units to each Condenser this drain. Supply pressure Supply pressure Generator FRONT = Drain must be free air vented. 4.50 W.C. Min W.C. Max W.C. Min W.C. Max. 100,000 total (1) 3/8 dia. IPS for E Generator Drain plumbing must be able to withstand 140 F (60 C). Manufacturer must be notified if unit will be used above 2,000 feet The drain must not be located beneath the steamer itself. Figure 2-4 Gemini 24CGA10.2ES Dimensions and Clearances Exhaust Hood Requirements The Gemini gas steamer MUST be installed under a suitable ventilation hood as required by the National Fuel Gas Code, ANSI Z223.1/NFPA 54. The venting hood system must also include an interlock to prevent the operation of this steamer without the operation of the ventilation hood. The exhaust hood must extend over the gas flue opening on top of the steamer and meet the following requirements: 1). The Gemini gas steamer must be vented in accordance with all local, state and national codes for venting gas fired appliances. 2). The exhaust hood must be sized for the cumulative ventilation requirements of all the gasfired appliances in the area including the Gemini. Figures 2-1, 2-2, 2-3 and 2-4 contains the dimensions, gas flow, and BTU per hour data required to calculate the minimum required hood dimensions and minimum ventilation capacity (c.f.m.) for the Gemini 6 and 10 pan steamers. 3). Do not connect the exhaust hood directly to the flue outlet of the steamer. 4). If an existing hood cannot be used, a new one should be constructed over the steamer. b. Positioning and Leveling the Steamer NOTE: If there is not enough room to work on the drain, electrical, gas and water lines with the unit in place, postpone positioning and leveling the unit until all site preparation is completed. After the lines are prepared, position and level the steamer then connect the utility lines. WARNING INJURY AND EQUIPMENT DAMAGE could result from improper lifting. A Gemini Steamer weighs approximately 545 pounds. Use enough workers with experience lifting heavy equipment to place the steamer on the supporting surface Move the steamer into position. Using a level, adjust the adjustable legs until the unit is level. 2. Install Slide Racks a. Refer to Figure 2-5. Each rack has four loops: two at the top and two at the bottom. Hold the slide rack so the ends of the hanger loops are towards the cavity wall, as shown in the figure. b. Slide one rack into the compartment with loops toward one side. c. Hook the loops over the top and bottom pins. d. Repeat steps a. through c. for the other racks. Figure 2-5 Slide Rack Installation 3. Drain Installation for Models 24CGA6.2SES & 24CGA10.2ES (high efficiency) Only Furnishing and installing the drain line is the responsibility of the owner and/or installer. Figure 2-7 illustrates a drain layout recommended by Cleveland Range. WARNING DEATH, INJURY, AND EQUIPMENT DAMAGE could result from improper installation of the drain outlet lines. Improper installation of these lines could void the Gemini Steamers warranty. The following restrictions are critical to the safety of personnel and equipment, and must not be violated under any circumstances. Do not connect the drain line into any drain material that cannot sustain 140 o F. Do not connect drains from any other equipment to the drain line of the Gemini Steamer. Do not connect the drain outlet extension line directly to a floor drain or sewer line. The drain line must be free air vented, have gravity flow from the steamer, and terminate outside the perimeter of the unit. 1. The drain lines must be installed in compliance with the Food Service Sanitation Manual of the Food and Drug Administration (FDA) and WITH THE applicable Federal State, or Local plumbing codes. 2. Do not install the steamer directly over a drain. Steam rising up out of the drain will adversely affect operation, cooling air ventilation and may damage electrical components. 3. The total length of pipe and number of bend fittings required to reach the open drain determines the pipe size used to extend the drain line to an open drain. If the drain outlet extension requires 6 feet or less of pipe, and no more than two elbows are required, 1- ½ inch ID pipe and fittings are acceptable. If the drain outlet extension requires 6 to 12 feet of pipe, or requires three or more elbows, 2-inch ID pipe and fittings are required. 4. The drain line must have a gravity flow from the steamer drain outlet to the floor drain. Do not install a trap in the drain line. 5. Free air venting requires a minimum of 1 inch of clearance between the end of the drain line and the top of the floor drain. 6. Do not connect the steamer drain directly to drains or plumbing of any other equipment. 7. Connect the drain to the steamer as described below: The steamer is supplied with a 2 in tube connection at the bottom of the unit and a no-hub connector, included (Figure 2-7). When assembling the pipes and fittings of the drain outlet extension, apply a hardening type pipe sealant to the threads, and thread them together FINGER TIGHT ONLY. DO NOT USE A WRENCH. DRAIN D 1 CLEARANCE MINIMUM REAR DRAIN Figure 2-7 Typical Drain Connection DRAIN LINE 4. Install Gas Supply Lines a. Gas Supply Requirements 1) Make sure the gas supply type matches the type of gas shown on the rating plate. 2) Make sure that the gas su
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