Installation, Servicing and User Manual
Contents
1. xog TANYA TOHINOD OL OL NOEZ N 8 il 8 XY 1 avi Ld 64 58 78 L 30123134 NOJN ML gt 019634 Isya ama 91 z we 69 NOIN YIMOd t 9 SL 8 d 110201 9 2 Le 6 9 T ei 1 re 56 13534 10901 5 ILS ALadWS Qe sd 1 18 86 ge LINN NOILIN9I STIOWLNOD 01 El 26 16 3904 HDLIMS 7 12 mi 1 38089 YOLSINYSHLOL 8 27 6 ISNA YS HOLIMS 440 NO ALOvS 10 18 Xog TANYA 104102 OL a OL 1041402 OL J NOEZ N NOLLIN I 010037 97 avai 6 7 30123134 Ll 74 M 1 91 72 z 4 3 7 9 L z gt 5 9 ons 96 NONLNODOT U Ay INVA 59 Le pe es 1 6 144 i T 0z 12 ve 2 2 i 56 135381109201 LVS 13305 9 2 Le w 8 LINA E fl 26 16 353 D2. u a IANYA 1OMINOD HUM LY NISNOH DMA AYM 6 30535 390315973 0 31 805855 1078 301191303015 1018 38089 IVLSOWY3HL 8 ONISNOH 7 5 NO3N 10x01 a SI 0 co i 6 01 HOLIMS ONENOH amp ANNA HOLIMS ONISNOH 284 1 LIS X08 AVISOWYSHL 1345 WOOT NI 239 SHIM 40 NA SIHL 278 3131060 803 TANYA 10102 OLHLYY 5 ze XO TOULNO OLHLMVA 0 TWNINUAL HOLIMS 440 NO z 8 l HIVI 2 12079 41079 10 NVYOVIC a 23
3. e The display will now alternate between PrEz and X XX where z is the number of key presses and X XX is action alarm time in minutes and seconds NOTE The time entered here is the time action is required before the end of the total cycle time entered above If NO Action time is required leave at 0 00 Adjust time as c above f Once desired time is reached press P key to accept enter g Prog will again be displayed and another product key can be selected for programming Repeat above steps When no more keys are required to be programmed and Prog is displayed press P key to exit programming mode and return to idle mode SECTION 7 CHANGING FILTERING THE OIL Warning After filtering wait 30 seconds before removing bucket It is dangerous to use shortening that is too old This medium has a reduced flash point temperature and is prone to surge boiling Caution To prevent surge boiling DO NOT EXCEED recommended loads or charge the pan with over wet food items NEVER LEAVE a working appliance unattended Warning When draining solids shortening ensure oil has time to strain through strainer basket Heavily unfiltered oil may overflow Note This could cause pump to block over a period of time and is considered as misuse of equipment Warning When pumping solids shortening back into fryer pan Ensure all trace of solids shortening is emptied from receptacle bucket If oil is n
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5. anti tipping device attached to the fryer Adjust to slide below floor bracket Base fixing 22 Anti tipping brackets Height adjustment holes 1 Floor bracket Figure 1 Anti tipping Bracket 1 2 2 Clearances The unit requires a clearance of at least 150mm to rear between unit and any combustible wall A minimum vertical clearance of 750mm should be allowed between top edge of flue outlet and any overlying combustible surface Important If fryer is to be installed with other appliances then the instructions for every model should be consulted to determine the necessary clearance to any combustible wall or overlying surface Some appliances require greater clearance distances than others The largest clearance will therefore determine overall distance for a complete suite of adjoining appliances 1 3 VENTILATION The appliance ventilation requirements should be in line with national and local regulations The ventilation rate for these models is 26m min The appliance flue discharges vertically from top of unit There must be no direct connection of flue to any mechanical extraction system or outside air The fryer should be installed under a ventilated canopy Adequate ventilation whether natural or mechanical must be provided to ensure sufficient fresh air for combustion and for removal of combustion products which may be harmful to health For multiple installations req
6. 2 5 1 Checking Controller Operation To check operation of controls refer to Using The Controller Section 6 2 3 2 5 2 Checking Oil Filtration Pump To check operation of pump refer to Section 7 Important After installation the responsible technician should check for gas leaks and ensure the appliance is operating safely and satisfactorily before handing over to the user 2 6 TEMPERATURE LIMIT THERMOSTAT The unit is equipped with an additional temperature limit thermostat independent of the main controller In the case of operating thermostat failure allowing oil temperature to rise above predetermined legislation safe zone 230 C limit device will activate and cut power to controller It will also stop the flow of gas to burner To re set temperature limit thermostat refer to Figure 4 G401F and G402F Models a Turn burner and temperature controls ON OFF switch to OFF position b Allow oil to cool below 180 C c Reset red button on limit thermostat with a pen or similar item The button is located behind cabinet door at upper RH below facia panel Turn burner and temperature controls ON OFF switch to ON position e Reselect temperature f If limit thermostat reactivates carry out fault finding on temperature control circuitry 2 7 INSTRUCTION TO USER After installing and commissioning appliance please hand Instructions to user or purchaser and ensure that the person s responsible understands t
7. NOT TO BE ADJUSTED BY THE INSTALLER Please ensure that any plastic coatings are removed prior to use Before operation pan requires to be thoroughly cleaned and dried Discolouration of heated parts is caused by factory testing to ensure a satisfactory unit It does not affect quality or performance 1 1 MODEL NUMBERS NETT WEIGHTS and DIMENSIONS Width Depth Height Weight Model mm mm mm kg G401F Fryer 400 840 1200 94 G402F Fryer 400 840 1200 94 Pan oil capacity 18 litres cold good quality oil to C mark 1 2 SITING The unit must be installed on a firm level floor in a well lit draught free position The fryer should not be installed in a position where the possibility of sideways tipping is likely when force is applied The means of restraint may be the manner of installation such as connection to battery of appliances or installing the fryer in an alcove or by separate means such as adequate ties 1 2 1 Anti tipping Accessory anti tipping mechanism is also available as accessory If these are to be fitted the brackets must be fitted to locate the fryer in the correct position relative to any walls as detailed below Fixing holes are provided in the fryer base to accommodate the bracket The bracket should be fitted as detailed in Figure 1 The retaining chain has a quick release eyelet Secure to fixing point and secure bracket to floor after alignment with
8. a Unpack appliance b Unpack fryer baskets and accessories c Place basket support grid and basket in pan d Level appliance and fit all service protection kits Anti tilt kit if ordered as accessory 2 2 CONNECTION TO A GAS SUPPLY Connect gas supply and test for gas tightness Caution Ensure that pan contains an acceptable level of liquid before igniting burner Due to the presence of mains electrics integral pipe work should be checked for gas tightness using an appropriate gas leak detector Caution Installation engineers should note that for first time connection of appliance to supply it is essential that inlet gas supply to fryer is completely purged of air prior to first lighting attempt Otherwise since this is a light pilot first every time system it will take a significant number of tries to light due to the small amount of air bled from pipe by pilot at each attempt This should not initially be treated as a fault Please note that several attempts will still be required after air purge to fryer for first time lighting This is due to capacity of valve and governor 2 3 CONNECTION TO AN ELECTRICAL SUPPLY Ensure flexible cable does not come into contact with any hot parts The fuse rating should be 13A The colour coding of power supply cables are as follows Live Brown Neutral Blue Earth Green Yellow 2 4 STARTING UP If you are in the fat melting cycle FMC G401F only and loading solid
9. appliance inlet connection A 3 4 BSP inlet connection is fitted to unit An isolating valve must be located close to the appliance to facilitate shut down during an emergency or routine servicing The cock must be easily accessible to the user The installation must be tested for gas tightness as stated in IGE UP 1 Domestic type flexible rubber tube connections must NOT be used with this appliance Only tube complying with BS669 Part 2 Specification for corrugated metallic flexible hoses for catering appliances shall be used 1 5 ELECTRICAL SUPPLY The unit is equipped with a 3 core flexible cord with standard 3 pin plug fitted with a 13A fuse A regular 13A socket outlet can be used If supply is through a distribution fuse box this must be via a fuse with a maximum rating of 13A In the event of mains cable being replaced any new cable should comply with 60245 IEC 57 designation 05 RN F Rated Voltage G401F G402F 230V Rated Current 3 55amps THE APPLIANCE MUST BE EARTH BONDED 1 6 TOTAL RATED HEAT INPUTS Natural and Propane Gas 23kW 86 300 btu h gross 1 7 INJECTOR SIZES Natural gas Burner Pilot 2 x O2 7mm Polidora G31 2 Propane gas Burner Pilot 2 1 Polidora G25 4 SECTION 2 ASSEMBLY and COMMISSIONING The gas supply piping and connection to appliance must be installed in accordance with the various regulations listed on the cover of this manual 2 1 ASSEMBLY
10. burner lock out reset switch h If burner repeatedly fails to light switch off electrical and gas supplies Call service engineer 6 2 2 Fryer maximum basket loading Both models Pre blanched chilled fries 2 x 1 5kg baskets Frozen fries 2 x 1 2kg baskets 6 2 3 Using the Controller G401F Models Only Manually Operated When unit is lit as detailed in Section 6 2 1 lighting instructions above fryer may be operated as follows a If using solid fat turn control knob clockwise to select FMC Fat Melt Cycle b When solid shortening has liquefied select desired temperature Warning Do not select any setting other than FMC when using solid fats as this will trip the safety thermostat or in a worst case scenario ignite the liquefied oils c Fat or oil temperature will then be governed by controller to desired set temperature selected by user on the control knob G402F Models only Programmable When unit is lit as detailed in Section 6 2 1 lighting instructions above fryer may be operated as follows NOTES 1 There is NO solid fat melt pulsing cycle FMC incorporated in this controller 2 The oil temperature will be governed by controller at a factory preset temperature of 180 C See Section 6 3 for instructions on how to change set temperature 3 When actual temperature is within 10 C of set point the display reads redy See Section 6 3 instructions on how to display actual or set tempera
11. 98 82 AMBER 95 98 99 NOTE WHEN FITTING FERRITE BEAD TWIST WIRES WITH ONE LOOP ROUND DO NOTTIE IN WITH OTHER WIRES G402F Control Panel Wiring Diagram 93 94 4WAY CRIMP TERMINAL HOUSING 92 T J 28 FERRITE BEAD 94 4000 5 OOO 6 DOQ E 8 9 FAST CTT PROGRAMMABLE CONTROLLER 16 NOTE WHEN FITTING FERRITE BEAD TWIST WIRES WITH ONE LOOP ROUND DO NOTTIE IN WITH OTHER WIRES 17 xog TANYA 108102 OL ie 3308 01 10102 OL 7 3 NOLLIND 8 OLavaT1H VII 2 8 NOJN 1 3 BRZ at 012134 Wd D 28 NOIN YIMOd at 43 7 06 6 9 66 1 SL 79 55 110207 5 9 Ts 1 1 9 Z T S r ets z 13538 1109201 5 LVLS 4 5 18 86 LINN 15 El 6 16 ISNI D 38044 HOLSINYSHL OL we HOLIMS 440 NO LOYO 10 NVYOVIG
12. G401F G402F FRYERS INSTALLATION SERVICING and USER INSTRUCTIONS These appliances must be installed and serviced by a qualified person as stipulated by the Gas Safety Installation amp 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 amp Use Regulations 1 Regulations for Electrical Installations Health And Safety At Work etc Act Electricity at Work Regulations Local and National Building Regulations Fire Precautions Act Detailed recommendations are contained in Institute of Gas Engineers published documents IGE UP 1 IGE UP 2 BS6173 and BS5440 These appliances have 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 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 user instructions should be handed over to the user having had a demonstration of the operation and cleaning of the appliance PREVENTATIVE MAINTENANCE CONTRACT In order to obtain maximum performance from this unit we would recommend that a Maintenance Contract be arra
13. OR GAS LEAKS 6 2 1 Lighting Instructions Remove lid if fitted and baskets and set these aside Ensure fryer pan is clean and completely dry Ensure also that drain valve is closed Pour clean cold oil to MIN pan level mark on basket hanging rail Both Models a Ensure pan is filled with solid shortening to indicated level and gas supply is established b Ensure burner switch is in off position O c Press burner switch to on position 1 d Refer to individual unit info below i G401F only Turn knob to select temperature If solid fat is used Select FMC fat melt cycle Warning Do not select any setting other than FMC when using solid fats as this will trip safety thermostat or in a worst case scenario ignite the liquefied oils ii G402F only Factory preset for a temperature of 180 C See Section 6 3 for instructions on how to change set temperature e Refer to individual unit info below i G401F Heat demand indicator will illuminate ii G402F only Display will illuminate with figures 8888 for 2 secs CTT for 2 secs r 06 for 2 secs and then displays Louu Heat demand LED indicator will illuminate f If burner fails to light lock out indicator will illuminate Note Ignition system will try a second ignition sequence 14 secs after completion of first attempt if no flame is detected during first attempt Unit will only lock out after 2nd attempt g Reset burner by pressing
14. an be done whilst oil is below 180 C 5 It is advised that a skimmer is used continuously between frying batches to remove any floating debris Failure to do this can result in the oil becoming bitter to taste 6 During quiet spells it is recommended that thermostat is turned down to a lower setting This will conserve energy in addition to extending expected oil life 7 To ensure a good eating experience fry food as near to serving time as possible 8 After serving and when fryer has been turned off replace lid to ensure that no foreign bodies can contaminate frying medium Section 11 Wiring Circuit Diagrams G401F Control Panel Wiring Diagram 9 WAY FEMALE PLUG HOUSING 2 WAY CRIMP TERMINAL HOUSING FERRITE BEAD 65 FASTRON CONTROLLER 91 92 POWER ON NEON RED RED LED OF 9 99 82 GREEN LED OOOH 8 UOH ODE 94 81 77 fr 7 9 97 RELAY 94 84 HEAT ON NEON 93
15. been shut off and cannot be accidentally turned back on b Allow oil to cool before any operation that requires pan to be drained c Only use parts specified by the manufacturer d All components replaced MUST be fully checked after fitting to ensure safe operation e A full pre commissioning check as detailed in Section 2 5 should be carried out 3 4 GAS CONTROL VALVE a Remove RH side panel fixing behind control panel hex bolt below panel at front and 3 fixings at rear and rear control compartment cover 3 fixings b Unplug valve control wires b Split pipe work from both sides of valve c Disconnect pilot pipe d Remove screws holding valve to bracket Replace in reverse order Check system for gas leaks 3 5 PILOT IGNITER SENSOR ASSEMBLY a Open door and remove oil bucket splash cover by means of two screws on each leg at front and slide out through door b Disconnect electrode and ignition wires c Using a screwdriver and 8mm spanner remove pilot assembly and bracket from burner d Drop assembly and remove pilot pipe e Replace parts in reverse order Ensure that a good earth connection has been made 3 6 BURNER a Remove pilot igniter sensor assembly as Section 3 5 b Remove drain handle Split incoming gas connection to manifold d Undo two middle mounting bolts and remove two front burner retention bolts and slide burner forward until it clears rear retention moun
16. d fill mark indicated on basket hanging rail See Figure 5 Note MAX refers to maximum hot fill mark 3 With gas supply still shut off turn on electrical mains supply 4 Open door and press temperature limit thermostat reset button red refer to Section 2 6 Set burner switch to Position ON position 5 Turn control knob to desired temperature 140 C G401F only and heat demand indicator will illuminate Figure 2 item 4 6 G402F is factory preset for a temperature of 180 C See Section 6 3 how to change set temperature 7 Fryer ignition sequence will commence and spark may be heard before unit locks out Note Ignition system will try a second sequence 14 seconds after completion of first attempt if no flame is detected during first attempt Unit will only lock out after 2nd attempt 8 The neon next to burner switch inside door will illuminate to indicate that lockout has occurred and that no burner flame is present G401F G402F Additional controls Item 2 on Figure 4 9 Turn gas supply on 10 Press lockout reset switch See Figure 4 Lock out indicator will extinguish 11 Burner will ignite and heat indicator will illuminate to signify that burner is on If lockout should occur repeat Steps 10 11 until air is bled from supply and burner lights 12 When burner flame is established check for gas leaks Care should be taken because mains voltage is present Isolate after gas checks
17. dO 1109201 co 4 SNISNOH WNIWHAL ND HOLIMS 13538 LNOYDO1 YAWYOISNVYL 079 93130128134 enor 284 1 5 HOLIMS 440 NO 00 31 8 031105835 805855 390815373 1014 1014 SNISNOH INVA YWIS D 4 3 L 129 SNISNOH TWNIWYSIL ola NID AVM 8 OL 2 X08 TOMINOD OL HIV 22019 1 SNIVW AVISOWYIHLALIIVS 3 TOYO LOYO 10 NVYOVIC 21 KINO 4 0 8E9 4 109 0103133015633 15 71 8 310 h LE 1 did 135 30151538 15 8 OHE 03130123139
18. fat for the first time always remove basket support plate as detailed in Section 9 Solid fat should be in direct contact with fryer pan Refer to Section 9 2 4 1 G401F Fryer Control Panel See Figure 2 Figure 2 G401F Control Panel 1 ON OFF and Temperature Control Knob Temperature Selection 140 190 C Unit is off when control is in position indicated 2 Fat Melt Position Feature for slow pulsed heating of solid fats 3 Power on indicator 4 Heat Demand Indicator when thermostat demands heat i e temperature is more than 5 C below temperature setting Extinguishes when desired temperature is reached OF 2 4 2 6402 Fryer Control Panel See Figure 3 Figure 3 G402F Control Panel 1 Four Digit LED Display Displays Set temp Actual temp cook time remaining and also used for programming purposes 2 Program Button Used to enter timer programme mode to change each of the 4 pre set timer select channels See Section 6 3 Temperature Button Used to view Actual Set temperature and also to enter Set temperature mode See Section 6 4 Timer Keys 1 4 Used to start cancel pre set cook times Buttons 1 amp 4 also used to change times or temperatures when in either set mode See Section 6 5 Heat demand LED indicator when thermostat demands heat i e oil is more than 2 C below programmed set temperature Wi
19. he instructions to correctly operate and clean unit in a safe manner Emphasis should be given to safe operation and use of drain valve and oil bucket Oil bucket should not be overfilled to allow safe movement Oil should be allowed to cool before any manual handling Note The oil container may be heavy Drain small amounts at a time if necessary before lifting container Manual handling regulations should be observed It is important to ensure that location of gas shutoff valve is made known to user and that procedure for operation in an emergency be demonstrated SECTION 3 SERVICING AND CONVERSION BEFORE ATTEMPTING ANY SERVICING TURN OFF GAS SHUTOFF VALVE AND ELECTRICAL SUPPLY TAKE STEPS TO ENSURE THAT THESE CANNOT BE INADVERTENTLY TURNED ON AFTER ANY MAINTENANCE TASK CHECK UNIT TO ENSURE THAT PERFORMS SAFELY AND CORRECTLY AS DESCRIBED IN SECTION 2 5 ALWAYS CHECK FOR GAS LEAKS 3 1 GAS CONVERSION Natural to propane or propane to natural This model is suitable for field conversion A kit with fitting instructions can be supplied upon request 3 2 INTEGRAL COMPONENTS The following parts must be checked and serviced regularly 1 Oil ingress to electrical components 2 Flue for any blockages 3 Visual inspection of components and fryer pan 4 Temperature limit thermostat calibration 3 3 ACCESS PROCEDURES Before removal of any fryer components a Ensure appliance electrical and gas supply has
20. il level capacity is 18 litres Solid Fat If solid fat is to be used remove fish plate and cut fat into small pieces Place 17kg in fry pot and pack it down Position fish plate upon the top of fat Push front end into fat lightly until front edge is below temperature probe Ensure that FAT MELT CYCLE G407F only is selected for this process Note Fish plate will lower slowly into fry pot as solid fat melts Warning If fish plate does not sit flat lift plate from centre slightly and lower carefully to ensure that no splashing of hot shortening occurs Check that correct shortening level is achieved when all solid fat has melted Required temperature may then be set Solid fat should always be heated this way to prevent overheating and burning WARNING It is dangerous to use shortening that is too old Such shortening has a reduced flash point temperature and is prone to surge boiling CAUTION To prevent surge boiling DO NOT EXCEED recommended loads or charge pan with over wet food items NEVER leave a working appliance unattended SECTION 10 COOKING HINTS Frying food involves many variables and the following information is a guide only 1 Ensure frying medium is clean and free of debris 2 When topping up with oil ensure oil level does not exceed MIN line when cold and MAX line when hot 3 Never overfill baskets with food product 4 Filter oil as often as is practically possible Remember this c
21. ll extinguish when desired setting is reached 2 4 3 G401F amp G402F Additional Controls See Figure 4 The following additional controls are located behind cabinet door 1 Burner and Temperature Controls ON OFF Switch Cuts power to burner and temp controls 2 Burner Lockout Indicator Indicates flame failure 2 2 gt 9 26 2 2 2 2 amp 2 IG j a WHEN LIT 1 BURNER RESET 5 Figure 4 G401F amp G402F Additional Controls 3 Burner Lock Out Reset Switch Resets burner for further lighting attempts when burner lockout indicator is illuminated 4 Filtration Pump Switch Energises filtration pump when burner switch is in OFF O position 5 Temperature Safety Limiter Reset Button Inside red recess 2 4 4 G401F Controller Diagnostic Indicators Refer to Control Panel Wiring Diagram Page 16 Green LED ON indicates heat demand Green LED OFF indicates no heat demand Red LED flashes if temperature probe is either short or open circuited Red LED is permanently ON to indicate system is OK Set point is 7 C of mid set point 2 5 PRE COMMISSIONING CHECK 1 Clean out pan thoroughly using hot water and detergent Rinse out and dry thoroughly Note For further detail with regard to cleaning refer to Section 8 2 Ensure drain valve is closed Fill pan with clean cooking oil to MIN maximum col
22. move oil bucket by pulling forward then upward 15 Use handles and lift oil bucket to sink 16 Pour away soiled water 17 Thoroughly wash rinse and dry oil bucket and oil suction pipe 18 Replace strainer and micro filter in oil bucket and return oil bucket to cradle 19 Fill fry pot with clean oil solid shortening to MIN mark To relight refer to Section 6 2 SECTION 9 PREPARATION SOLID FATS SHORTENING COOKING HINTS Allow approximately 10 minutes for unit to heat up from cold to required operating temperature CHOICE OF FRYING MEDIUM Select a top quality medium to obtain optimum results Shortening or solid fats can be used if necessary Solid fats MUST be heated carefully as these have a lower smoke point temperature than shortening The G401F is equipped with a fat melt cycle that will pulse heat into the fryer A quality shortening is a more stable frying medium It allows longer periods of use without smoking or foaming It will also give food a better flavour Quality shortening has a higher flashpoint temperature and will reduce gumming around the pan Regular filtering will help improve lifespan of the medium WARNING NEVER MIX SHORTENING AND SOLID FAT Charging The Pan Prior to operation clean fry pot out using hot water and detergent Rinse out and dry thoroughly Ensure drain valve is closed Fill fry pot with cold shortening to MIN level mark on fish plate Approximate maximum o
23. ng audible alarm 6 3 1 Programming temperature set point and temperature scale Factory set for 180 C range available is 30 C to 190 C a Press and hold temperature key for 3 seconds Prog will be displayed Then press DOWN key 1 or UP key 4 key b The display will show either C or F degrees celsius or degrees fahrenheit Once desired temperature scale is displayed press temperature key to accept enter Display will now alternate between Sett and 2 where X denotes temperature and Z indicates temperature scale d Adjust temperature using DOWN key 7 and UP key 4 keys The longer key is pressed the faster temperature scrolls e When desired temperature has been reached press temperature key to accept enter f To exit temperature programming press temperature key again 6 3 2 Programming a Product Cycle Time and Action Alarm a Press and hold P key for 3 seconds Prog will display Note Programming mode will exit automatically if no keys are pressed within 2 minutes b Select a product key to program 1 to 4 The display will alternate between ti z and X XX where z is the number of the key pressed and is the set time in minutes and seconds c Adjust the time up or down using the DOWN key 7 and the UP key 4 keys The longer key is held the faster time will scroll 9 Once desired time is reached press P key to accept enter
24. ng of water sensors where softeners conditioners are not fitted or are fitted and not maintained Blocked drains e Independent steam generation systems e Gas water and electrical supply external to unit e Light bulbs e Re installing vacuum in kettle jackets e Replacement of grill burner ceramics when damage has been clearly caused by misuse e Where an engineer finds no fault with a product that has been reported faulty e Re setting or adjustment of thermostats when unit is operating to specification Cleaning and unblocking of fryer filter systems due to customer misuse e Lubrication and adjustment of door catches e 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 Contents Section Topic Page No 1 Installation 1 3 2 Assembly and Commissioning 4 6 3 Servicing 7 8 4 Spare parts 8 5 Critical dimensions 9 6 Operating instructions 10 12 7 Changing filtering oil 13 8 Cleaning and maintenance 14 9 Preparation of solid fats oil 15 10 Cooking Hints 15 11 Wiring Diagrams 16 17 Circuit Diagrams 18 19 SECTION 1 INSTALLATION UNLESS OTHERWISE STATED PARTS WHICH BEEN PROTECTED BY THE MANUFACTURER ARE
25. nged 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 SERVICELINE 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 a a 2 This equipment is ONLY FOR PROFESSIONAL USE and shall be operated by QUALIFIED persons It is the responsibility of the supervisor or equivalent to ensure that users wear SUITABLE PROTECTIVE CLOTHING and to draw attention to the fact that some parts will by necessity become VERY HOT and will cause burns if touched accidentally Falcon Foodservice Equipment T100745 Ref 6 HEAD OFFICE AND WORKS Wallace View Hillfoots Road Stirling FK9 SPY Scotland SERVICELINE CONTACT Phone 01438 363 000 Fax 01438 369 900 IMPORTANT INFORMATION Warranty Policy Shortlist Warranty does not cover Correcting faults caused by incorrect installation of a product e Where an engineer cannot gain access to a site or a product e Repeat commission visits Replacement of any parts where damage has been caused by misuse e Engineer waiting time will be chargeable e Routine maintenance and cleaning e Gas conversions i e Natural to Propane gas e Descaling of water products and cleani
26. ning Do not overfill draining receptacle THE APPLIANCE MUST NOT BE CLEANED WITH A JET OF WATER OR BE STEAM CLEANED DO NOT USE ACID HALOGEN BASED e g chlorine DESCALING LIQUIDS FLAMMABLE LIQUIDS CLEANING AIDS OR CLEANING POWDERS Stainless Steel Surfaces It should be noted that certain scouring pads including nylon types could easily mark stainless steel Care should be exercised during cleaning process When rubbing stainless steel with a cloth always rub along in grain direction 8 1 CLEANING THE APPLIANCE 1 Carry out actions detailed in Sections 8 and 9 2 Unit should be switched OFF and fry pot drained of oil 3 Remove baskets fish plate and crumb catcher Soak these components in hot soapy water 4 With drain valve open remove any traces of debris from fry pot using a clean damp cloth NOTE Care should be taken not to damage sensors located at pan front 5 Remove strainer and microfilter soak these in hot soapy water 6 Wash rinse and dry removed items thoroughly Set these aside 7 Close drain valve 8 Fill fry pot 3 4 full with hot water 9 Clean pan using a soft clean cloth and hot soapy water rub away stubborn staining with a scouring pad and suitable detergent 10 Open drain valve Drain water into bucket below 11 Use clean water to rinse fry pot and dry thoroughly 12 Close drain valve 13 Return crumb catcher fish plate and baskets to pan 14 Re
27. ont panel fasteners e Disconnect wiring noting all connections f Remove front panel to access drain valve g Undo drain pipe Use appropriate size of spanner to remove drain valve h Replace in reverse order and check for oil leaks 3 12 FILTRATION PUMP a Remove back panel and flexi hose at filtration pump b Disconnect electrical coupling plug and connections from start c Remove nuts from pump mounting bolts accessed through fryer door at rear of oil bucket compartment and lift pump clear d Disconnect pump from bracket Replace in reverse order Note Remember to check for oil leaks before replacing any panels 3 13 IGNITION CONTROL BOX a Remove rear compartment cover b Unplug valve and control plugs Remove ignition detector and earth connections c Undo three fixings one at rear two at front d Remove ignition control box e Replace in reverse order amp test 3 14 TEMPERATURE LIMIT THERMOSTAT a Open control panel b Remove probe and safety thermostat protective cover ensuring insulation is removed intact c Remove phial and probe protective cage inside pan d Undo two phial bracket retention nuts and remove thermostat phial from bracket e Undo safety thermostat capillary nut Using a thin screwdriver inserted in boss from inside pan carefully tap capillary sealing washers through to control compartment f Remove thermostat g Disconnect thermostat wires h Caref
28. ot emptied on a regular basis or if oil is left in the receptacle it may solidify and overflow or spill on to the kitchen floor to create a hazard 7 1 STARTING THE FILTRATION PROCESS Refer to Figure 7 for details of filtration components 1 Turn burner amp temperature controls ON OFF switch to OFF position and allow oil to cool below 170 C or if cold heat to minimum temperature of 60 C Open cabinet door and pull filter bucket forward 2 Ensure bucket is clean and emptied of all solid shortening and debris Refer to Section 9 for details of how to clean filter components 3 Ensure that strainer and microfilter are clean 4 With strainer and microfilter in position slide bucket back on to runner cradle and back into fryer Please Note Warning Do not handle filter components or adjacent surfaces when pump is operating Components will remain hot for a period after filter Allow cooling Use of PPE s is recommended Note Burner and temperature controls ON OFF switch must be in OFF position before operation of filter pump can begin 7 2 G401F and G402F MODELS 1 Press filtration pump switch to turn on pump Note With cabinet door open switch is located at RH side of drain valve Refer to Figure 4 2 Turn drain handle clockwise 3 Pan will drain through strainer basket and microfilter into bucket and will pump back into pan 4 Clear debris from pan 5 If pan drain becomes blocked clear using drain p
29. pliance will always fail safe Note NEVER leave a working unit unattended Medium must always be maintained within fry pot Cold Medium when filling with cold medium see Figure 5 DO NOT FILL MEDIUM PAST MIN LEVEL MARK Maximum cold fill mark also for Solid Medium See Section 10 MIN Level Mark Medium should NEVER be allowed to drop below this mark Should this occur top up immediately or switch fryer OFF Hot Medium and Topping Up Medium DO NOT FILL MEDIUM PAST MAX LEVEL MARK Maximum Hot Fill Mark See Figure 5 Figure 5 CAUTION SUITABLE PROTECTIVE CLOTHING MUST BE WORN when topping up whilst fat in fryer is hot Medium and Foodstuffs As foodstuffs increase volume during cooking follow these rules DO NOT ADD WATER TO FRYING MEDIUM AT ANY TIME WARNING No attempt must be made to operate this appliance during a power supply failure Please ensure that any plastic coated items are removed prior to use Before operation pan requires to be thoroughly cleaned and dried Discolouration of heated parts is caused by factory testing to ensure unit is satisfactory It will not affect quality or performance All Models neon indicator is incorporated to indicate flame failure when illuminated An electronic thermostat with temperature probe is fitted to automatically control oil temperature The burner is protected by an electronic flame sensor device An additional temperature limit thermostat i
30. rod 6 When debris has been removed from pan turn valve handle anti clockwise to close valve 7 Allow pan to refill 8 If any solid shortening remains repeat Step 1 Warning Ensure all shortening has been pumped from receptacle before topping up pan 9 Switch filtration pump off 10 Top up fryer if required 8 RECOMMENDATION Personal protective equipment PPE s should be used when cleaning or handling medium within this appliance WARNING NEVER PUMP WATER THROUGH THE FILTRATION PUMP AT ANY TIME Warning The fryer is supplied with castors at rear and should be connected to supply piping by means of a connector for moveable appliances An anti tipping restraint can be attached to unit and if so this must be disconnected before fryer is moved Ensure restraint is re connected when unit is returned to original position Moving the fryer with hot or cold oil in fry pot can be dangerous to the operator Scalding could occur Spilled oil or fat on the kitchen floor could cause slipping accidents and any such deposit should be cleaned up straight away To prevent any such hazard DO NOT move fryer until all liquid has been drained from fry pot The following procedure should be undertaken AT LEAST DAILY IMPORTANT Disconnect electrical supply before any cleaning is undertaken Warning Oil must be allowed to cool to a safe temperature before drai
31. s also fitted independent of main thermostat Operating thermostat failure could allow oil temperature to exceed the legislated maximum safe temperature 230 C In such condition the limit thermostat will activate and cut power to controller and it will also stop the flow of gas to burner To find location of re set limit thermostat refer to Figure 4 on Page 6 of this manual Limit Thermostat Reset a Turn burner and temperature controls ON OFF switch to OFF position b Allow oil to cool below 180 C c Unscrew black protective cap from limit thermostat reset button button is located behind cabinet door at upper RH below fascia panel d Reset red button on limit thermostat with a pen or similar item e Turn burner and temperature controls ON OFF switch to ON position f Reselect temperature g If limit thermostat reactivates an investigation to determine the reason must be carried out by a qualified technician 6 1 APPLIANCE CONTROLS Refer to Sections 2 4 1 2 4 2 and 2 4 3 for controls layout and description 6 2 LIGHTING and OPERATION Safety Precautions The installer must fit a gas shut off valve in the gas pipe which supplies the unit The user MUST be familiar with the location and operation of this valve for shutting off gas in event of an emergency IF ASMELL OF GAS IS EVIDENT a TURN OFF GAS SUPPLY b VENTILATE AREA c CALL YOUR LOCAL GAS SUPPLIER NEVER USE AN OPEN FLAME TO CHECK F
32. signal a dual rhythm beeping will last 5 seconds and then self cancel The display will flash action alarm time and then will continue counting towards 0 00 f Viewing Actual Set Temperatures Pressing the temperature key once will display AXXX where XXX is actual temperature in degrees C or F depending on how controller is programmed See Section 6 3 Pressing the temperature key again within 5 seconds will display where XXX is the programmed Set temperature of the controller in degrees C or F depending on how controller is programmed See Section 6 3 If temperature key is not pressed again within 5 seconds display returns to idle or timer mode 6 3 PROGRAMMING THE G402F Display Descriptions Louu Controller is in operating mode Actual vat temperature is more than 10 below programmed vat temperature rEdy Controller is in operating mode Actual vat temperature is within proper cooking temperature range Vat is ready to begin a cook cycle HI Controller is in operating mode Actual vat temperature is more than 30 above highest programmed vat temperature Prob Control probe is either open circuited or short circuited Display will be accompanied by an audible alarm if shorted Check or replace probe 2 30 The control is in operating mode and a cook cycle is in progress done The control is in operating mode and a cook cycle has been completed Display will be accompanied by a pulsi
33. tings Carefully drop burner e Re connect in reverse order f Gas leak check manifold and pilot gas connections 3 7 BURNER RESET SWITCH ON OFF SWITCH and FILTRATION PUMP SWITCH a Remove control panel by undoing fixings at top and bottom of control panel and unplug control panel b Hinge down switch mounting panel c Remove electrical connections from switch Remove switch by squeezing side fixings and pushing it through aperture d Replace part in reverse order 3 8 BURNER LOCK OUT NEON a Remove control panel by undoing fixings at top and bottom of control panel and unplug control panel b Hinge down switch mounting panel c Remove electrical connections from neon and remove neon retention nut d Replace part in reverse order 3 9 TEMPERATURE CONTROLLERS a Remove control panel by undoing fixings at top and bottom of control panel and unplug control panel b Disconnect electrics loom and remove fixings to enable controller to be removed c Carefully replace in reverse order 3 10 MAINS ON and HEAT DEMAND NEONS a Remove control panel by undoing fixings at top and bottom of control panel Disconnect control panel b Remove electrical connections from neon Undo neon retention nut c Carefully replace in reverse order 3 11 DRAIN VALVE a Remove burner as detailed in Section 3 6 b Ensure fry pot is empty Refer to Section 8 c Remove nut from handle and lift handle off d Remove fr
34. ture 4 Before carrying out any cooking operations controller should be set up for particular application of use e g up to four timer programmes product frying temperature C F This can all be carried out using the following guide in Section 6 3 Operating the Controller a Start a timing cycle Press any product key 7 to 4 to start a timing cycle If key is programmed the correct time will be displayed and will immediately start to count down and LED above key will flash DONE will display when cook cycle has ended and alarm will sound If DONE is displayed immediately and alarm sounds the key has not been programmed See Section 6 3 for programming details Stop a timing cycle Press and hold an active product key for 3 seconds or press key 3 times within 2 seconds c Respond to a DONE alarm Cancel signal by pressing same product key used to start timing cycle d Multiple timing cycles If a second or third product key is pressed while the first is still active the shortest time remaining key is displayed and only the LED above key flashes the other s remain constantly lit Once shortest time programme ends and is accepted next shortest is displayed and LED above flashes Note All product key timers will count down although not displayed until shorter one ends Action Alarms Shake etc If control is programmed for action alarm they will signal at a preset time during the timing cycle The
35. uirements should be added together Installations should be made in accordance with local and or national regulations applying at the time competent engineer must be used for any installation work 1 4 GAS SUPPLY Both models To be checked at installation gas conversion or repair The SIT gas valve situated at rear RH side of unit and accessible by removing RH side has in built governor The inlet pressure should be checked at valve inlet test nipple using a manometer and burner pressure should be set at test nipple on burner manifold again by means of a manometer as per values indicated on Page 4 for either natural or propane gas This is achieved by removing brass dust screw from valve governor and adjusting governor accordingly using a screwdriver clockwise rotation increases pressure Note Propane requires governor to be adjusted clockwise to maximum adjustment Inlet Burner pressure pressure at manifold Natural Gas 20mbar 14mbar 0 75mbar Propane Gas 37mbar 32mbar The incoming service must be of sufficient size to supply full rate without excessive pressure drop A gas meter is connected to service pipe by gas supplier Any existing meter should be checked preferably by gas supplier to ensure that it is adequate to deal with rate of gas supply required Installation pipe work should be fitted in accordance with IGE UP 2 The size of pipes from meter to unit must not be less than that of
36. ully replace in reverse order Check for any oil leaks and that thermostat calibration is within specification SECTION 4 SPARES When ordering spare parts always quote appliance type and serial number This information will be found on unit data plate located inside the fryer door on LH leg support face 187 24 Settings 26 max Set for 230V a a Operating thermostat probe Set to 0 8 10 minutes _ 00 Safety thermostat probe Operating and Safety Thermostat ag RE E 258 Pilot to Burner Dimension 6 OPERATING INSTRUCTIONS The fryers are of single pan type and the following units are covered by this manual G401F Manual control model with built in filtration G402F Four product key electronic control model with built in filtration USE OF OILS SHORTENING SOLIDS COOKING MEDIUM As these are highly flammable when in their liquid state caution should always be taken when using cooking medium Recommendation PPE Personal Protective Equipment should be used when cleaning or handling medium within this fryer Medium should not be overheated as this will increase the risk of fire Note Fryer is fitted with a thermal safety device This will stop heating of medium if it becomes overheated This ap
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