Chieftain G2522 Gas Grill Installation & Service Instructions
Contents
1. 2 1 2 Appliance Mounting Accessories Details of various mounting options can be obtained by contacting Falcon Sales distributor or place of purchase Refer to the individual instructions supplied with the individual means of mounting Adherence to positioning clearances indicated in Section 1 2 of this manual is mandatory 2 1 3 Assembly of Support Bars and Plaques a When tunit has been installed in desired location the centre support bars can be positioned between the burner lugs Similarly LH and RH plaque supports are located between burner lugs and support angle See Figure 1 below b With support bars in position plaques may be inserted by placing these upon bars as illustrated below This will also prevent yellow tipping of the flame or Plaque Burner lift off Support LLH Support RH Support Support angle bar bar angle Plaque Burner Burner bar S LH Support Plaque Plaque A d Centre support Figure 1 2 2 CONNECTION TO THE GAS SUPPLY Installation should be carried out in accordance with the various regulations listed on the cover of this document On NATURAL gas appliances the adjustable governor supplied MUST be fitted to gas circuit and securely fixed in a position that enables adjustment to be carried out during commissioning PROPANE appliances do not require a governor Ensure that a gas Isolating cock is fi2. drip tray wire grid and brander can then be placed in position 2 6 INSTRUCTION TO USER Hand over User manual Ensure user understands the procedures for lighting cleaning and correct use of appliance Point out the location of the isolating cock which may require to be shut down in event of an emergency SECTION 3 SERVICING and CONVERSION Important Before carrying out any inspection servicing or exchange of components turn OFF the gas at the isolating cock and take steps to ensure that it is not inadvertently turned on Always remove the brander and grid shelf After any maintenance task check the appliance to ensure that it performs correctly 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 SOUNDNESS 3 1 GAS CONVERSION CHECK LIST To convert from NATURAL to PROPANE gas Change injectors Remove governor and adjust inlet pressure accordingly Adjust aeration Change data plate To convert from PROPANE to NATURAL gas Change injectors Connect governor and adjust inlet pressure accordingly Adjust aeration Change data plate 3 2 REMOVAL of PLAQUES and BURNERS 3 2 1 Plaques Only a Remove drip tray grid shelf and brander b Plaques may be replaced by reaching inside compartment top and placing your fingers on plaque face Push plaque up carefully to dislodge it from seating between bars and
3. support angle O Sai Carefully replace plaque so that it is properly seated on bar and support angle The plaque should be positioned hard against the burner 3 2 2 Burners a Undo bottom fixings from LH outer side panel Remove bottom and side fixings from outer back and lift clear oz Remove upper inner rear panel above burners by undoing two fixings and lift it clear c Reach inside top of compartment and remove plaques and support bars ox a The burner s without pilot bracket may now be removed from injector seating e To remove burner with pilot refer to Section 3 2 2 d to e f The burner is exposed and may be lifted from injector seating 3 3 REMOVAL OF INJECTOR Following removal of burner the injector may be cleaned or replaced as desired See Section 1 8 for injector dimension details 3 4 BURNER and INJECTOR CLEANING Burners require to be cleaned periodically to ensure that ports are free from blockage This may be facilitated by means of wire brushing Individual ports may be cleared with a suitable metal instrument Dislodged material should then be shaken out of open burner end Should it become necessary to wash the burner s ensure that they are completely dry and free from cleaning materials before re fitting to the appliance The injectors also require regular inspection and may be cleaned with a wooden splinter or fuse wire Hard metal impliments MAY DAMAGE THE ORIFICE
4. 14 500 Bains Marie 11 400 Tea Coffee Machine 8 5 14 300 500 Positioning the grill below a ventilated canopy is the most suitable arrangement Warning Remember dirty extraction filters and drip trays become combustible hence the importance of adhering to the specified flue clearance distance to these items Regular cleaning of extraction filters and drip trays must be carried out 1 4 GAS SUPPLY The incoming service must be of sufficient size to supply the full rate without excessive pressure drop A gas meter is connected to the service pipe by the Gas Supplier An existing meter should be checked preferably by the Gas Supplier to ensure that it is adequate to cope with the rate of gas supply required Installation pipes should be fitted in accordance with IGE UP 2 The pipework size from the meter to the unit must not be less than the appliance inlet connection Rp 2 2 BSP An isolating cock must be located close to the appliance on the inlet side of the governor on Natural Gas models to allow shut down during an emergency or routine service The installation MUST BE TESTED FOR GAS SOUNDNESS details of which can be found in IGE UP 1 1 5 ELECTRICAL SUPPLY Not applicable to this appliance 1 6 WATER SUPPLY Not applicable to this appliance 1 7 HEAT INPUTS Natural and Propane Gas Model G2522 kW 13 2 Btu hr 45 000 1 8 INJECTOR DIAMETERS Natural G
5. G2522 GRILL 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 Detailed recommendations are contained in Health And Safety At Work etc Act Institute of Gas Engineers published documents IGE UP 1 IGE UP 2 BS6173 and BS5440 Local and National Building Regulations Fire Precautions Act 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 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 MAI
6. NTENANCE 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 T100576 Ref 3 HEAD OFFICE AND WORKS Wallace View Hillfoots Road Stirling FK9 5PY Scotland SERVICELINE CONTACT PHONE 01438 363 000 FAX 01438 369 900 Warranty Policy Shortlist 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 ke
7. and MUST NOT be used Upon re fitting check adjustment and flame picture as described in Section 2 5 2 3 5 FLAME FAILURE THERMOCOUPLE a Remove RH outer side panel b Undo nut that secures thermocouple to SIT pilot bracket using a 10mm spanner c Undo nut that secures thermocouple to gas tap d Withdraw faulty thermocouple and replace 3 6 GAS VALVE 3 6 1 To Remove Proceed as follows a Pull off control knobs and remove front facia panel b Undo nut that secures burner feed pipe to control c Release pilot tubing nut from control and ease pilot tube clear of location d Remove fixings that secure control to gas pipe e Manoeuvre control to enable removal of thermocouple f Withdraw control 3 6 2 To Re grease Control Tap a Remove fixings that retain front securing plate while holding plate against internal spring pressure b Carefully withdraw plate complete with operating spindle c Withdraw exposed rod spring brass washer and sealing washer taking care not to lose any parts d Withdraw plug and clean with a soft rag and also clean mating surfaces in control body Sparingly re grease plug with an approved heat resistant grease Re assemble in reverse order taking care with the central pin assembly Fit spring to pin first then brass washer and finally sealing washer Ensure sealing washer fits snugly into recess at base of plug When re fitting operating spindle ensure niting pin en
8. as Model Main Burners X lightingBurners Pilot Burner G2522 3 x Amal 380 2 x Amal 20 SIT No 30 Propane Gas Model Main Burners X lightingBurners Pilot Burner G2522 3 x Amal 140 2 x Amal 10 SIT No 19 1 9 SETTING PRESSURE Gas Type mbar inches w g Natural 15 6 Propane 37 14 8 A spring loaded governor supplied with the appliance MUST BE FITTED to natural gas models No governor is required on propane models A pressure test point is accessible upon removal of the control panel 1 10 BURNER ADJUSTMENT Burner Aeration The burners are fitted with fixed injectors Aeration is adjustable by means of a screw positioned at the burner inlet After setting pressure the stability of the flame cones should be checked If necessary the aeration screw should be adjusted to achieve satisfactory cross lighting of burners on both HIGH and LOW settings SECTION 2 ASSEMBLY and COMMISSIONING 2 1 ASSEMBLY 2 1 1 Grill Unit Unpack grill and check that all components are undamaged Parts supplied loose are specified in the contents list below Brander Drip Trough Brander Plate Grid Shelf Gas Governor Natural Gas only Drip Tray Additionally the necessary plaques supports and cross lighting burners are supplied as follows node Paves SNE eee Slee G2502 4 4 G2512 8 3 4 i G2522 12 6 4 3 G2532 6 4 4
9. e provided to allow removal of outer panels for service access Methods of mounting the unit are available as detailed in Section 1 1 No grill should be mounted directly upon a table Note Upper sections of the unit are likely to become very hot It should therefore be positioned in a manner which minimises the risk of accidental touching 1 3 VENTILATION The grill MUST be installed level in a well lit and draught free position Adequate ventilation whether natural or mechanical must be provided to ensure sufficient air for combustion and removal of combustion products which may be harmful to health Recommendations for Ventilation of Catering Appliances are given in BS5440 2 Furthermore to ensure sufficient room ventilation guidance on the volume of ventilation air required for different types of catering equipment is provided in the following table For multiple installations requirements for individual appliances should be added together Installation should be made in accordance with local and or national regulations applying at the time The flue discharges vertically from the top of the unit There must be no direct connection of the flue to a mechanical extraction system or the outside air Ventilation Rate Required EQUIPMENT m3 min ft min Range Unit Type 17 600 Pastry Oven 17 600 Fryer 26 900 Grill 17 600 Steak Grill 26 900 Boiling Pan 17 600 Steamer 17 600 Sterilizing Sink
10. gages in plug slot 3 7 GOVERNOR 3 7 1 General The governor will normally require little servicing Before proceeding with any inspection or servicing TURN OFF THE GAS AT ISOLATING COCK 3 7 2 Procedure Check and if necessary clear air breather hole of any blockage Ensure valve and seating are clean and that diaphragm is in good condition ALWAYS RE CHECK GAS PRESSURE at test point after servicing governor SECTION 4 SPARES When ordering spare parts ALWAYS quote appliance TYPE and SERIAL No This information can be found on the data badge A list of items available together with codes is as follows Description Part No Plaque single 531600010 Thermocouple 531600030 Pilot burner body 531600050 Pilot orifice Natural Gas 531600070 Pilot orifice Propane Gas 531600075 Governor 535900001 Gas control 537560020 Knob for gas control 535900000 Disc for grid shelf handle 531600410 Handle for grid shelf 531600420 Grid shelf 531620130 Brander plate 531620110 Burner 531600230 Injector Natural gas 531600220 Injector Propane gas 531600225 X lighting burner 531610150 X lighting injector Natural 531610140 X lighting injector Propane 531610145 Drip trough 531630140 Brick support centre 531550130 Brick support end 531540120
11. tted to the supply in convenient proximity to the grill 2 3 CONNECTION TO AN ELECTRICAL SUPPLY Not applicable to this appliance 2 4 CONNECTION TO A WATER SUPPLY Not applicable to this appliance 2 5 COMMISSIONING 2 5 1 Testing and Purging Pressure test installation for gas soundness and purge any air from the supply 2 5 2 Gas Pressure and Burner Flame Adjustment a Remove RH Side Panel b Fit a pressure gauge to test point and light grill c With burner at Full Flame position setting pressure should be as detailed in Section 1 9 On Natural gas models adjust governor as required d With gas control in the Full Flame position check the flame cone is approximately 30mm in length If necessary adjust by means of the aeration screw in burner throat Tighten locknut when complete Refer to Section 1 10 e Check all burner parts cross light satisfactorily f Turn control to Low Flame position and check that flame cone reduces in length Note LOW FLAME position is set at factory Re setting is NOT necessary 2 5 3 Soundness Checking and Re assembly Whilst grill is lit test all integral gas carrying joints and components for gas soundness Use a suitable leak detection fluid i e Soap Solution TURN OFF gas control tap REMOVE pressure gauge and replace test point sealing screw ENSURE THAT A GAS TIGHT JOINT IS MADE Re assemble all panels and components removed during installation and commissioning The
12. ttle 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 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 GAS MODEL mm mm mm kg CONN G2522 900 585 505 74 Rp 2 The grill may be mounted on any of the following options Bench legs floor stand or wall bracket 1 2 SITING There must be 150mm clearance all around the grill from any combustible wall or object liable to damage when overheated There must be a minimum vertical clearance of 900mm above the top edge of the flue to ensure no overheating of overlying combustible surfaces A minimum clearance of 400mm from the sides should b
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