G350-12!Service Manual
Contents
1. BURNER Gas Type NATURAL PROPANE BURNER 2 85mm SIT No 36 1 70mm SIT No 19 1 9 GAS PRESSURE NATURAL and PROPANE GAS mbar inches w g NATURAL 15 6 PROPANE 37 14 8 1 10 BURNER ADJUSTMENTS No adjustments are provided since the burners have fixed injectors and aeration SECTION 2 ASSEMBLY and COMMISSIONING 2 1 ASSEMBLY 1 Check parts supplied Check that each pan is equipped with two chip baskets a pan base panel and a dust cover These parts may be packed separately On NATURAL gas models an ad justable governor is also supplied 2 Place the unit in position and level using the feet adjusters For safety reasons both units must be fixed to the floor Holes are provided in the feet for this purpose 2 2 CONNECTION TO THE GAS SUPPLY Installation should be carried out in accordance with the various regulations listed on the cover of this manual On NATURAL gas appliances the adjustable governor supplied must be fitted in the supply being securely fixed in a position enabling adjustment to be made during commissioning On appliances burning PROPANE gas do not fit a governor 2 3 CONNECTION TO AN ELECTRICITY SUPPLY Not applicable to these appliances 2 3 CONNECTION TO A WATER SUPPLY Not applicable to these appliances 2 5 PRE COMMISSIONING CHECK After connecting the gas supply fit a pressure gauge to the pressure test point and check the installation for gas s2. pilot supply pipe from the pilot assembly taking care not to lose the injector which will be removed with the union nut ii Disconnect the spark ignitor lead at the pilot iii Remove the two hexagon nuts securing the pilot bracket to the lower side of the burner and remove the pilot burner complete with bracket Replace in reverse order ensuring that the pilot injector is correctly located in the annular groove in the compression nut Check all connections for gas soundness 3 4 INJECTORS 3 4 1 To Remove Main Injector The injector can be removed without the necessity for removing the burner i Using a 16mm open ended spanner reach inside the burner air entry and engage the spanner on the hexagon body of the injector ii Slacken the injector then reach inside and completely unscrew by hand If the injector needs cleaning soak it in a suitable solvent Do not use metal objects to clear it 3 5 FLAME FAILURE THERMOCOUPLE To remove the thermocouple from the pilot assembly undo the split nut and withdraw To disconnect the overheat limit device from the circuit pull off the spade connections at the inter rupter To disconnect the thermocouple from the valve undo the hex nut at the valve body 3 6 PIEZO IGNITER SPARK ELECTRODE 3 6 1 Piezo Igniter To remove the piezo unit pull off the lead at the back then remove the fixing nut at the rear of the unit 3 6 2 Spark Electrode This is an integral
3. DETAILED IN SECTION 1 After carrying out any servicing or exchange of gas carrying components ALWAYS CHECK FOR GAS SOUNDNESS 3 1 CONVERSION PROCEDURE CHECK LIST To convert from NATURAL to PROPANE GAS Change injectors Remove the governor and adjust for new inlet pressure Change data plate To convert from PROPANE to NATURAL GAS Change injectors Install the governor and adjust the inlet pressure accordingly For detailed procedures refer to the appropriate sections of this document Change data plate 3 2 ACCESS TO GAS CIRCUIT COMPONENTS Access can be gained by opening the door on the front of the appliance On the G350 12 model double pan the circuit components associated with a particular pan are mounted on the same side of the support box as the pan itself 3 3 BURNERS Burners should be cleaned periodically to maintain maximum performance 3 3 1 Main Burner To Remove i Remove the burner pipe by unscrewing the compression fittings at each end ii From underneath the burner remove the two M5 nuts securing the pilot bracket to the burner Ease the pilot burner assembly clear of the burner by moving it slightly downwards iii Remove the four screws securing the burner support straps to the body of the fryer thus allowing the burner to be manipulated clear iv Replace in reverse order and check all connexions for gas soundness 3 3 2 Pilot Burner Assembly To Remove i Remove the thermocouple
4. E CONTROL PHIAL IS THE LOWER PHIAL v Remove the phial guard and ease the control thermostat sensor towards the rear of the pan to clear the locating brackets then draw the capillary tube through the glands to enable the sensor to be suspended out of the oil when the pan is to be refilled to the marked level vi Tighten the small gland nut to temporarily compress the seal onto the capillary tube vii Temporarily refit the phial guard over the high limit device sensor viii Refill the pan with oil to the marked level ix Install a means of measuring the oil tempeature A thermocouple type instrument is preferable but a mercury thermometer capable of measuring up to 300 C can be used The measuring sensor i e thermocouple or thermometer bulb must be suspended 25mm below the surface of the oil in the centre of the pan x Light the fryer and carefully observe the rising oil temperature The safety thermostat if functioning properly will shut off the gas when the oil temperature is between 218 C and 224 C maximum xi If the safety thermostat fails to operate at the maximum of 224 C shut off the fryer immediately by depressing the off button on the gas control valve see Section 2 5 and Figure 1 Allow the oil to cool before investigating the fault xii All safety thermostats are accurately calibrated and checked on new appliances during manufacture and it is unlikely that the calibration will need servi
5. G350 11 and G350 12 FREESTANDING FRYERS INSTALLATION and SERVICING INSTRUCTIONS These Appliances must be installed and serviced by a competent 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 Health And Safety At Work etc 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 Local and National Building Regulations Fire Precautions Act 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 Particular emphasis should be made with regard to safe operation of the drain valve IT IS MOST IMPORTANT THAT THESE INSTRUCTIONS BE CONSULTED BEFORE INSTALLING AND COMMISSIONING THIS APPLIANCE FAI
6. LURE 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 FALCON SERVICE LINE Visits may then be made at agreed intervals to carry out adjustments and repairs A quotation will be given upon request to the FALCON SERVICE LINE contact numbers below Falcon Catering Equipment HEAD OFFICE AND WORKS PO Box 37 Foundry Loan Larbert Stirlingshire Scotland FK5 4PL SERVICE LINE CONTACT PHONE 01438 751111 FAX 01438 369900 SECTION 1 INSTALLATION UNLESS OTHERWISE STATED PARTS WHICH HAVE BEEN PROTECTED BY THE MANUFACTURER ARE NOT TO BE ADJUSTED BY THE INSTALLER 1 1 MODEL NUMBERS NETT WEIGHTS and DIMENSIONS WIDTH DEPTH HEIGHT WEIGHT WEIGHT MODEL mm mm kg Ibs G350 11 350 870 46 102 G350 12 700 650 870 84 185 1 2 SITING These appliances must be installed on a firm level floor in a well lit position The fryers can be positioned to within 75mm of a compustible wall but to allow space for the removal of side panels a clearance of about 150mm should be provided at the back There should be a minimum vertical clearance of 900mm above the top edge of appliance flue to any overhanging combustible sur face IMPORTANT If the appliance is to be installed with other matching appliances of th
7. ce adjustment assuming the thermostat is not otherwise faulty xiii Once satisfied that the safety thermostat is functioning correctly the control thermostat sen sor must be re located in its normal position A reversal of procedures i to viii will achieve this condition Note Replace the seal on the control thermostat gland and ensure that no oil leaks are present Diagram of Thermostat Stuffing Box and Components Item Description Gland Main Body Washer Washer Lock Nut Split Washers Seal Tubing Nut 4 5 6 7 3 8 GAS CONTROL VALVE To Remove i Drain the pan ii Remove the gas pipe between the control valve at the burner iii Undo the compression fitting at the lower end of the gas inlet pipe on the G350 11 model and at the tee piece on the G350 12 model iv Remove the compression nut fixing the pilot supply pipe to the back of the control valve at the top v Remove the two nuts and bolts securing the valve to its brackets vi Remove the four screws and withdraw the top bracket from the valve vii Ease the valve forward sufficiently to enable the thermocouple to be removed at the back of the valve also the electrical connections to the thermocouple interruptor viii Unscrew the four fixing screws and remove the controls chamber base panel ix Undo the small gland nut sealing the capillary tube where it enters the pan of the fryer See Figure 2 x Re
8. ce with local and or national regulations applying at the time and a competent installer must be employed 1 4 GAS SUPPLY The incoming service must be of sufficient size to supply full rate without excessive pressure drop A gas meter is connected to the service pipe by the Gas Supplier Any existing meter should be checked preferably by the Gas Supplier to ensure that the meter is of adequate capacity to supply the fryer and other associated equipment This is particularly important when a number of units are being installed Installation pipework should be fitted in accordance with IGE UP 2 The size of the pipes from the meter to the appliance must be not less than that of the appliance inlet connection Rp1 2 2 BSP female An isolating cock 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 soundness details are given in IGE UP 1 The adjustable governor supplied must be fitted to natural gas appliances 1 5 ELECTRICAL SUPPLY Not applicable to these appliances 1 6 WATER SUPPLY Not applicable to these appliances 1 7 HEAT INPUTS NATURAL and PROPANE GAS Model kW Btu hr G350 11 11 8 40 250 G350 12 23 6 80 500 The G350 12 incorporates two burner systems identical to that within the G350 11 1 8 INJECTOR SIZES NATURAL and PROPANE GAS MAIN PILOT
9. e Falcon 350 series the Instructions for all units must be consulted to determine the necessary clearance to any combustible rear wall or overlying surface Some appliances require greater clearances than others and the largest figure quoted in the individual Instructions will therefore determine the clearance for the complete suite of adjoining appliances 1 3 VENTILATION The appliance flue discharges vertically through the grille at the rear of the hob There must be no direct connection of the flue to any mechanical extraction system or the outside air Siting the appliance under a ventilated canopy is the ideal arrangement Ventilation Rate Required EQUIPMENT m min ft min Range Unit Type 17 600 Pastry Oven 17 600 26 900 Grill 17 600 Steak Grill 26 900 Boiling Pan 17 600 Steamer 17 600 Sterilizing Sink 14 500 Bains Marie 11 400 Tea Coffee Machine 8 5 14 300 500 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 Recommendations for ventilation for Catering Appliances are given in BS 5440 2 Further to ensure sufficient room venti lation guidance on the volume of ventilation air required for different kinds of catering equipment is given in the table For multiple installations the requirements should be added Installation should be made in accordan
10. move the phial guard and ease the phial through the pan bulkhead fitting xi Ease the control clear of the fryer taking care not to damage the capillary tube Note THE CONTROL PHIAL IS THE LOWER PHIAL Re fit the valve in reverse order again taking care not to kink or otherwise damage the capillary tube Check that the pan does not leak at the capillary gland but do not overtighten this small fitting Check all connections for gas soundness using soap and water solution 3 9 GOVERNOR This applies to NATURAL GAS MODELS ONLY The type of governor used will normally require little servicing The air breather hole should be checked for dirt blockage Always re check the pressure at the test point after governor maintenance
11. oundness To remove protective surface film in the pan clean the pan thoroughly using hot water and detergent Rinse out and dry Ensure the drain valve is closed and fill the pan with oil to the level inscribed on the back wall of the pan Purge air from the system and light the burner using the following procedure Warning If the pilot is extinguished either intentionally or unintentionally wait at least 3 minutes before re lighting the gas i Ensure that the pan contains oil up to the level mark embossed on the rear wall of the pan ii Open the cabinet door giving access to the controls iii Refer to Figure 2 and turn the thermostat knob clockwise to the pilot position iv Depress the rectangular button marked and hold it in v Depress the spark igniter button and observe that the pilot lights If it does not light immediately repeatedly depress and release the spark igniter button until it does vi Hold the ignition button in for a further 20 seconds then release the button Observe that the pilot remains lit If it should go out wait for three minutes then repeat from iv vii Having established the pilot turn the control knob anti clockwise to the maximum setting and the main burner will light viii On NATURAL gas units if necessary adjust the governor to produce the required pressure of 15mbar 6 inches w g on the gauge previously fitted To affect this remove the governor cap to acce
12. pan release the thermostat phial from its mounting bracket by moving it slightly towards the rear of the pan and then upwards vii Ease the phial and capillary tube through the pan bulkhead fitting viii Remove the two screws fixing the thermostat to its bracket and remove the complete unit from the fryer Replace in the reverse order taking care not to damage the capillary tube Thereafter ix Depress the red button to ensure the contacts are closed before lighting the fryer x Fill the pan with oil to the level mark xi Check that the sealing gland does not leak but do not overtighten the gland nut xii Heat the pan at maximum temperature setting and allow the control thermostat to cycle once or twice to ensure that the high temperature limit device does not trigger prematurely The operation of the safety thermostat must be checked at regular intervals In order to raise the oil temperature sufficiently to enable the safety thermostat to operate it will be necessary to remove the sensor bulb of the control thermostat from the oil This condition can be accomplished by the following procedure i Drain the pan ii Remove the upper panel above the door by removing the screws in the underside of the panel iii Unscrew the four fixing screws and remove the controls chamber base panel iv Slacken the small gland nut sealing the capillary tube where it enters the pan of the fryer See Figure 2 Note TH
13. part of the pilot burner assembly To Replace i Remove the thermocouple ii Remove the nut securing the lead iii Undo the gland nut fixing the electrode to the body of the pilot burner iv Remove the electrode by withdrawing downwards Replace parts in reverse order Take care not to over tighten the gland nut to avoid the possibility of cracking the ceramic material The spark gap is pre determined and cannot be adjusted Do not attempt to alter the gap by bending the electrode 3 7 HIGH TEMPERATURE LIMIT DEVICE This is an electrical thermostat which interrupts the thermocouple circuit In the event of failure of the control thermostat embodied in the gas control valve the high temperature limit device will sense the excessive oil temperature and open thus allowing the gas valve in the control to close Once triggered the high temperature limit device must be manually re set by depressing the red button on the thermostat body To Remove i Drain the pan ii Remove the front facia panel by removing the two screws in the underside of the panel iii Pull off the electrical connections on the interuptor which are situated at the rear of the gas control valve and release the electrical leads iv Unscrew the four fixing screws and remove the controls chamber base panel v Undo the gland nut sealing the capillary tube where it enters the pan Note THE SAFETY PHIAL IS THE UPPER PHIAL vi From inside the
14. ss the screw and turn it clockwise to increase the pressure and vice versa Replace the governor cap after the correct pressure has been established Allow the pan to heat up and check that the thermostat shuts off the gas to the main burner when maximum temperature has been reached ix When satisfied that the fryer is functioning properly shut off the gas by depressing the OFF button See Figure 1 x Remove the pressure gauge and replace the pressure test point screw Note The main burner can be shut off while leaving the pilot lit by turning the control knob clockwise to the position Figure 1 Gas Control Valve 2 6 INSTRUCTION TO USER After installing and commissioning the appliance hand the User s Instructions to the user or purchaser and ensure that the person s responsible understands the instructions for lighting cleaning and correct use of the appliance Particular emphasis should be given to the safe operation of the drain valve It is important to ensure that the location of the gas isolating cock is made known to the user and that the procedure for its operation in an emergency be demonstrated SECTION 3 SERVICING and CONVERSION Important Before attempting any servicing turn off the isolating cock and take steps to ensure that it is not inadvertently turned on AFTER ANY MAINTENANCE TASK CHECK THE APPLIANCE TO ENSURE THAT IT PERFORMS CORRECTLY AND CARRY OUT ANY NECESSARY ADJUSTMENTS AS
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