Falcon G3830 Installation And Servicing Instructions

INSTALLATION and SERVICING INSTRUCTIONS This appliance must be installed and serviced by a competent person as stipulated by the Gas Safety (Installation & Use) Regulations. IMPORTANT The installer must ensure that the installation of the appliance is in conformity with these instructions and National Regulations in force at the time of installation. Particular attention MUST be paid to: Gas Safety (Installation & Use) Regulations Health And Safety At Work etc. Act Local and National Building Regulations Fire Precautions Act The appliance has been CE-marked on the basis of compliance with the Gas Appliance Directive for the Countries, Gas Types and Pressures as stated on the data plate. WARNING: TO PREVENT SHOCKS, ALL APPLIANCES WHETHER GAS OR ELECTRIC, MUST BE EARTHED. On completion of the installation, these instructions should be left with the Engineer-in-Charge for reference during servicing. Further to this, The Users Instructions should be handed over to the User, having had a demonstration of the operation and cleaning of the Appliance. IT IS MOST IMPORTANT THAT THESE INSTRUCTIONS BE CONSULTED BEFORE INSTALLING AND COMMISSIONING THIS APPLIANCE. FAILURE TO COMPLY WITH THE SPECIFIED PROCEDURES MAY RESULT IN DAMAGE OR THE NEED FOR A SERVICE CALL. PREVENTATIVE MAINTENANCE CONTRACT In order to obtain maximum performance from this unit we would recommend that a maintenance contract be arranged with SERVICELINE. Visits may then be made at agreed intervals to carry out adjustments and repairs. A quotation will be given upon request to the contact numbers below. WEEE Directive Registration No. WEE/DC0059TT/PRO At end of unit life, dispose of appliance and any replacement parts in a safe manner, via a licenced waste handler. Units are designed to be dismantled easily and recycling of all material is encouraged whenever practicable. Falcon Foodservice Equipment HEAD OFFICE AND WORKS Wallace View, Hillfoots Road, Stirling. FK9 5PY. Scotland. SERVICELINE CONTACT Phone: 01438 363 000 Fax: 01438 369 900 T100760 Ref.1 Detailed recommendations are contained in Institute of Gas Engineers published documents: IGE/UP1, IGE/UP/2 BS6173 and BS5440

Warranty does not cover :- • Correcting faults caused by incorrect installation of a product. • Where an engineer cannot gain access to a site or a product. • Repeat commission visits. • Replacement of any parts where damage has been caused by misuse. • Engineer waiting time will be chargeable. • Routine maintenance and cleaning. • Gas conversions i.e. Natural to Propane gas. • Descaling of water products and cleaning of water sensors where softeners/ conditioners are not fitted, or are fitted and not maintained. • Blocked drains • Independent steam generation systems. • Gas, water and electrical supply external to unit. • Light bulbs • Re-installing vacuum in kettle jackets. • Replacement of grill burner ceramics when damage has been clearly caused by misuse. • Where an engineer finds no fault with a product that has been reported faulty. • Re-setting or adjustment of thermostats when unit is operating to specification. • Cleaning and unblocking of fryer filter systems due to customer misuse. • Lubrication and adjustment of door catches. • Cleaning and Maintenance • Cleaning of burner jets • Poor combustion caused by lack of cleaning • Lubrication of moving parts • Lubrication of gas cocks • Cleaning/adjustment of pilots • Correction of gas pressure to appliance. • Renewing of electric cable ends. • Replacement of fuses • Corrosion caused by use of chemical cleaners.

The incoming service must be of sufficient size to supply full rate gas without excessive pressure drop. A gas meter is connected to the service pipe by Gas Supplier. Any existing meter should be checked by the supplier to ensure that it is of adequate capacity to pass required rate of gas for the unit, in addition to any other gas equipment that has been installed. The multifunctional control has an in-built governor therefore an external device does not require to be fitted. Installation pipework should be fitted in accordance with IGE/UP/2. This should not be smaller than gas inlet connection. G3830 - Rp½ (½" BSP) G3860 - Rp¾ (¾" BSP) G3865 - 2 x Rp½ (½" BSP) An inlet manifold may be purchased to connect G3865 to 1 x Rp¾ (¾" BSP) mains inlet. An isolating cock must be located close to the unit to allow shutdown during an emergency or servicing. The installation should be checked for gas tightness and purged as specified in IGE/UP/1. 1.5 ELECTRICAL SUPPLY Not applicable to these units. 1.6 WATER SUPPLY Not applicable to these units. 1.7 TOTAL GAS RATES - NATURAL and PROPANE GAS 1.1 MODEL NUMBERS, NETT WEIGHTS and DIMENSIONS 1.2 SITING The unit should be installed on a level, fireproof surface in a well lit, draught free position. A clear space of 150mm should be left between the rear and sides of the fryer and any combustible wall. If the floor is constructed of combustible material, then local fire requirements should be checked to ensure compliance. Important If appliance is to be installed in suite formation with other matching units, the instructions for all models must be consulted to determine the necessary clearances to any combustible rear wall or overlying surface. Some models require greater clearances than others and the largest figure quoted in individual instructions will therefore determine clearance of complete suite adjoining appliances. 1.3 VENTILATION Adequate ventilation must be provided to supply sufficient fresh air for combustion. This should allow easy removal of combustion products which may be harmful to health. Recommendations for Ventilation of Catering Appliances are given in BS5440:2. For multiple installations, the requirements for individual units require to be added together. Installation should be carried out in accordance with local and/or national regulations which apply at the time. A competent installer MUST be employed. Model Width (mm) Depth (mm) Height (mm) Weight (kg) G3830 Fryer 300 770 870 59 G3860 Fryer 600 770 870 74 G3865 Fryer 600 770 870 99 SECTION 1 - INSTALLATION UNLESS OTHERWISE STATED, PARTS WHICH HAVE BEEN PROTECTED BY THE MANUFACTURER ARE NOT TO BE ADJUSTED BY THE INSTALLER. Model kW Btu/hr G3830 Fryer 18.1 61,757 G3860 Fryer 32.5 110,890 G3865 Fryer 2 x 18.1 2 x 61,757

1.8.1 Natural Gas 1.8.2 Propane Gas 1.8.3 Cross-Lighting Burners 1.9 GAS PRESSURE ADJUSTMENT 1.9.1 Supply Pressures A pressure test point is fitted on the burner manifold and the operating pressure is shown in the tables below. On G3865 model, burner pressure should be set with both pans turned on. An adjustable governor is included in the multifunctional control on Natural Gas models. Supply Pressure 1.9.2 All Models Burner Pressure 1.10 BURNER ADJUSTMENTS 1.10.1 Pilot An adjustment screw is located on the multifunctional control to regulate pilot flame. Adjust pilot screw to provide a flame approximately ¾" long, projecting from each pilot burner channel. A flame larger than this will roar excessively. Main Burner No aeration adjustment is necessary, however gas pressure should be set as per value shown in Section 1.9. Gas type mbar inches w.g Natural Gas 20 8 Propane Gas 37 14.8 SECTION 2 - ASSEMBLY and COMMISSIONING 2.1 ASSEMBLY The unit is packed as a complete assembly, except the flue. To fit this, slide flue over upstand on hob rear and secure with fixings along lower front and rear edges. Slot basket hanger over knurled nuts and hand-tighten. 2.2 APPLIANCES ON CASTORS For units on castors, refer to guidelines in BS6173. These state that where wheels, castors or rollers are used, these must be fitted with a brake or locking device. This should be accessible to operator from front or side. 2.3 CONNECTION TO A GAS SUPPLY Gas supply piping and unit connection must be installed in accordance with regulations listed on front page of this document. A gas isolating cock must be fitted to the supply in a position that is readily accessible to operator. 2.4 CONNECTION TO AN ELECTRICAL SUPPLY Not applicable to these units. 2.5 CONNECTION TO A WATER SUPPLY Not applicable to these units. 2.6 PRE-COMMISSIONING CHECK Prior to operation, ensure that all packing material has been removed from unit. 2.6.1 Setting The Gas Pressure a) It is necessary to check gas pressure during commissioning. A suitable pressure gauge must be connected to test point on supply manifold. b) Turn on main gas valve at supply. c) Light burners as detailed in User Instructions. The supply pipes may contain air therefore it may be necessary to repeat lighting procedure. d) Adjust multifuncional control pressure governor to relevent settiing as detailed in Section 1.9 of this document. The screw should be turned clockwise to increase pressure and anti-clockwise to reduce it. Check again after 15 minues of operation. e) Disconnect pressure gauge from test point. Replace sealing screw and test gas soundness. Model Pilot Burner Main Burner G3830 Fryer NG No. 18 Ø2.38mm G3860 Fryer NG No. 18 Ø3.2mm G3865 Fryer NG No. 18 2 x Ø2.38mm Natural Propane NG No. 26 LP No. 16 Model Pilot Burner Main Burner G3830 Fryer LP No. 11 Ø1.57mm G3860 Fryer LP No. 11 Ø2.15mm G3865 Fryer LP No. 11 2 x Ø1.57mm Gas type mbar inches w.g Natural Gas 15 6 Propane Gas 34.5 13.8

maximum performance and are best cleaned with a wire brush. Blocked parts require to be cleared using a metal broach. Any material pushed into burner should be shaken out via air inlet. 3.2.1 Removal of Burner Assembly Turn off main gas supply to unit. Remove fixings that secure pilot and cross-lighter assemblies to main burner and drop assemblies slightly. Disconnect compression joint above manifold. Remove fixings that retain burner assembly front cross strap to side runners. Pull burner assembly forward (approx. 25mm) and drop it slightly to clear front cross strap. While supporting weight of assembly, push it back to clear rear strap from runners and lower to withdraw. Replace in reverse order. 3.2.2 Removal of Pilot Burner Isolate main gas supply to unit. Disconnect pilot supply pipe compression nut and remove pipe from pilot burner. Withdraw injector. Undo thermocouple retaining nut and remove thermocouple from pilot burner. Undo thermopile retaining nut and withdraw thermopile. Pull lead from spark electrode. Undo nuts that secure pilot burner bracket to burner. Withdraw pilot burner assembly. Replace in reverse order. 3.3 CLEANING THE INJECTORS Injectors should be periodically cleaned using a wooden splinter or soft wire. Avoid use of metal reamers as these may distort or increase size of orifice. 3.3.1 Removal of Main Burner Injectors Isolate main gas supply. Use a 10mm open-ended spanner to remove injector. 3.3.2 Removal of Pilot/Cross-Lighting Injectors Isolate main gas supply. Undo pilot/cross lighter supply pipe compression nut and remove pipe from pilot/cross lighter burner. Withdraw injector. Replace in reverse order. 3.4 FLAME FAILURE THERMOCOUPLE Undo nuts at pilot assembly and valve body. Disconnect thermocouple interrupter from terminal block. 2.7 INSTRUCTION TO USER After installing and commissioning the fryer, hand User Instructions to operator or purchaser. Ensure details to light, turn off, use and clean are properly understood. The main gas isolating valve location should be made known to user and the procedure for operation in event of an emergency should be demonstrated. SECTION 3 - SERVICING and CONVERSION Important BEFORE ATTEMPTING ANY SERVICING, ENSURE ISOLATING COCK IS TURNED OFF AND THAT IT CANNOT BE INADVERTENTLY TURNED BACK ON. FRYER REQUIRES TO BE COOLED AND DRAINED PRIOR TO MAINTENANCE. AFTER ANY SUCH MAINTENANCE TASK, CHECK THE APPLIANCE TO ENSURE CORRECT PERFORMANCE AND CARRY OUT ANY NECESSARY ADJUSTMENTS AS DETAILED IN SECTION 1. After carrying out any servicing or exchange of gas carrying components - ALWAYS CHECK FOR GAS TIGHTNESS! 3.1 GAS CONVERSION CHECK LIST CHANGE MAIN INJECTORS CHANGE PILOT INJECTORS MODIFY MULTIFUNCTIONAL CONTROL CHANGE DATA PLATE CHANGE CROSS LIGHTING INJECTOR To convert from Natural to Propane gas, remove regulator mechanism. Replace with blanking plate that is supplied with kit. To convert from Propane to Natural gas, remove blanking plate. Replace with regulator mechanism supplied in kit. All relevant injectors to be changed to suit gas type. Pressure must also be adjusted to suit gas type. Refer to Section 1.9.

The igniter is a piezo spark type. The electrode is mounted upon pilot burner bracket and switch is adjacent to MFC. The lead has a push on connection at both ends. 3.5.1 Removal of Igniter Switch Remove igniter lead connection to switch. Undo fixings that secure switch flange to control compartment and remove device. Replace in reverse order. 3.5.2 Removal of the Electrode Remove igniter lead connection from electrode and remove nut located below electrode. Withdraw electrode downward from pilot burner bracket. Replace in reverse order. 3.6 THERMOSTATS The user thermostat is an EGO, snap action electric control with a centre stem adjustment of temperature up to 190°C. The safety stat is an EGO model with interrupter with a maximum fixed setting of 230°C. This interrupts thermocouple signal from pilot and subsequently shuts down gas supply if user thermostat fails and causes the oil to overheat. Note Manual intervention is required to reset control in event of cut-out. To Reset Remove black plastic safety cover and push reset button when oil temperature drops below 200°C. In the event of repeated failure, replace safety stat. 3.6.1 Removal of Operating Thermostat Isolate main gas supply and drain cool oil from pan. Remove control knob from user thermostat and undo fixings alongside user thermostat spindle. Undo control panel fixings. Follow thermostat phial capillary tube to pan boss in front wall and undo small compression nut that seals tube. Remove phial cover plate from inside pan and withdraw thermostat phial. Disconnect thermostat electrical connections prior to removing thermostat. Replace in reverse order. 3.6.2 Recalibration of User Thermostat Remove knob from thermostat spindle taking care not to rotate it in either direction as this would change setting. Steady spindle and rotate calibration screw clockwise to decrease and anti-clockwise to increase the temperature. 3.6.3 Checking the User Thermostat Calibration Using a reliable thermometer immersed 25mm below oil surface at pan centre. Measure oil temperature when a steady condition has been established. 3.6.4 Replacementl of Safety Thermostat Isolate gas supply and drain the cool oil from pan. Undo fixings that secure safety thermostat to bracket. Follow thermostat phial capillary tube to pan boss in front wall and unscrew small compression nut that seals tube. Remove phial cover plate from pan and withdraw phial. Disconnect wires from terminal block. Re-assemble parts in reverse order. 3.7 MULTIFUNCTIONAL GAS CONTROL (MFC) Unit is fitted with an SIT 820 Nova mV control incorporating cock, governor, valve and flame failure device. 3.7.1 Removal of Multifunctional Control (MFC) Isolate main gas supply. Remove cover plates that surround MFC. Disconnect thermocouple connection on MFC and pull thermocouple clear. Undo thermopile connections and withdraw. Undo main gas inlet and outlet connections to MFC and withdraw control. Replace in reverse order taking care when reconnecting thermocouple. DO NOT overtighten as this may cause damage, hand tight plus a quarter turn is sufficient. 3.8 GOVERNOR A governor is built in to the multifunctional control. Refer to Sections 1.9 and 3.8. Pilot adjustment screw TH TP TH/TP Burner pressure adjustment screw SIT Nova Multifunctional Control (MFC)

When ordering spare parts, always quote unit type and serial number. This information will be found on data badge attached to base plate.