Falcon E401, E402, E401F, E402F Installation, Servicing And User Instructions Manual

E401/E402
E401F/E402F FRYERS

INSTALLATION, SERVICING
and USER INSTRUCTIONS

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 -

BS7671 IEE Wiring Regulations
Electricity at Work Regulations
Health And Safety At Work Act
Fire Precautions Act

This appliance has been CE-marked on the basis of compliance with the Low Voltage and EMC
directives for the voltages stated on the data plate.

WARNING -THIS APPLIANCE 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 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.

Falcon Foodservice Equipment

HEAD OFFICE AND WORKS

Wallace View, Hillfoots Road, Stirling. FK9 5PY. Scotland.

SERVICELINE CONTACT

Phone: [phone] Fax: [phone]

T100750 Ref. 8

IMPORTANT INFORMATION
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
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.

2

sensors where softeners/ conditioners are not fitted,

SECTION 1 - INSTALLA

TION

TS

MANUFACTURER

INSTALLER.

are

caused

It

WEIGHTS

firm

fryer

possibility

applied.

installation,

means,

must

relative

provided

chain

bracket

floor

Bracket

clearance

combustible

clearance

edge

surface.

with

clearance

greater

largest

requirements

regulations.

requirements should

regulations

a

supply

code

be

incorporating

UNLESS OTHERWISE STATED, PAR
BEEN PROTECTED BY THE
NOT TO BE ADJUSTED BY THE

Please ensure that any plastic coatings
to use. Before operation, the pan
thoroughly cleaned and dried.

Discolouration of heated parts is
testing to ensure a satisfactory unit.
quality or performance.

1.1 MODEL NUMBERS, NETT

and DIMENSIONS

Model

E401 Fryer

E402 Fryer

E401F Fryer
E402F Fryer

Width

(mm)

400 800
400 800
400 800
400 800

Depth

(mm)

WHICH HAVE

ARE

removed prior

requires to be

by factory

does not affect

Height

(mm)

880 63
880 63
880 74
880 74

Weight

(kg)

1.2.2 Clearances

The unit requires a
rear between unit and any

A minimum vertical
allowed between top
overlying combustible

Important

If fryer is to be installed
instructions for each unit
determine the necessary
wall or overlying surface.

Some appliances require
than others. The
determine overall distance
adjoining appliances.

1.3 VENTILATION

The appliance ventilation
with national and local

of at least 100mm to the

wall.

of 750mm should be

of flue outlet and any

other appliances then the

should be consulted to

to any combustible

clearance distances

clearance will therefore

for a complete suite of

should be in line

1.2 SITING

The unit must be installed on a
well-lit draught free position. The
installed in a position where the
tipping is likely when force is
restraint may be the manner of
connection to a battery of appliances
fryer in an alcove, or by separate
quate ties.

1.2.1 Anti-tipping Bracket

An anti-tipping mechanism is also
accessory. If fitted, the brackets
locate the fryer in the correct position
as detailed below. Fixing holes are
to accommodate the bracket. Details
found in Figure 1 below. The retaining
release eyelet. Attach securely to fixing
bracket to floor after alignment with
the fryer. Adjust bracket to slide below

Figure 1 - Anti-tipping

level floor in a

should not be

of sideways

The means of

such as

or installing the

such as ade-

available as an

be installed to

to any walls

in fryer base

of fitting can be

has a quick

point and secure

attached to

bracket.

For multiple installations,
together. Installations should
local and/or national
A competent engineer must
work.

1.4 ELECTRICAL SUPPLY

The unit is supplied with
connection to a 400V 3N~
isolating switch.

Phase Loading

L1: 29A, L2: 29A, L3: 29A

1.5 CABLE SUPPLY

A cable conforming to
(eg. H07RH-F5G4) must
400V 3N~ supply

be added

be made in accordance with

applying at the time.

be used for any installation

2 metre 5-core cord for

incorporating a suitable

designation 0245 IEC 57
used for connection to a

a suitable isolating switch.

SECTION 2 - ASSEMBLY and

COMMISSIONING

The electrical cable must be connected in accordance
with the various regulations listed on the cover of this
manual.

2.1 ASSEMBLY

a) Unpack appliance
b) Unpack fryer baskets and accessories.
c) Place element guard and baskets in pan.
d) Level appliance and fit all service protection kits.
(Anti-tilt kit, if ordered as accessory).

2.2 CONNECTION TO AN ELECTRICAL SUPPLY

The supply cable must be connected to a suitable
isolator switch as follows:

Phase 1: Brown, Phase 2: Black, Phase 3: Grey
Neutral: Blue, Earth: Green/Yellow

2.3 STARTING UP

2.3.1 E401/401F Fryer Control Panel (See Figure 2)

3

2

1

4

2.3.2 E402/402F Fryer Control Panel (See Figure 3)

1 / 5

2

4

Figure 3 – E402/402F 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 & 4
also used to change times or temperatures when in
either set mode (See Section 6).

5.

Heat demand LED indicator

3

Figure 2 – E401/401F Control Panel

1.

ON/OFF and Temperature Control Knob

Temperature Selection (140 - 190°C). (Unit is off when in
position indicated).

2.

Fat Melt Position

Feature for slow pulsed heating of solid fats.

3.

Power on indicator.

4.

Heat Demand Indicator

illuminates when thermostat demands heat, i.e. oil
temperature is more than 5⁰C below temperature setting.
Extinguishes when desired temperature is reached.

4

Illuminates when thermostat demands heat,
i.e. oil temperature is more than 2⁰C

set temperature. Will extinguish when desired setting is
reached.

below programmed

2.3.3 All models - Additional Controls (See

Figure 4)

Figure 4 – All models - Additional Controls

The following additional controls are located behind
cabinet door.

1.

Fryer ON/OFF Switch

Cuts power to appliance.

2.

Filtration Pump Switch – E401F & E402F only

Energises filtration pump.

3.

Temperature Safety Limiter Reset Button

Located on rear of element box, below black dust cap,
refer to Figure 5.

Figure 5

2.3.4 E401/401F Controller Diagnostic
Indicators (Refer to Wiring Diagrams)

On PCB Controller

safety button

2.4 PRE-COMMISSIONING CHECK

2.4.1 Checking Controller Operation

To check operation of controls, refer to Using The
C

ontroller - Section 6.2.1.

2.4.2 Checking Oil Filtration Pump E401F & E402F
only.

To check operation of oil filtration pump, refer to
Section 7.

2.5 TEMPERATURE LIMIT THERMOSTAT

The unit is equipped with an additional temperature
thermostat, independent of the main controller.

In the case of operating thermostat failure, allowing oil
temperature to rise above predetermined legislation safe
zone (230⁰C), limit device will activate and cut power to
controller and elements.

To re-set temperature limit thermostat: (Refer to Figure 5)

All models

a) Turn fryer ON/OFF switch to OFF position.
b) Allow oil to cool below 180⁰C

c) To reset limit thermostat, remove black dust cap

located at element box rear. Push reset button using a
blunt instrument. (i.e. a pen) and replace cap.

d) Turn fryer ON/OFF switch to ON position.
e) Reselect temperature.

f) If limit thermostat reactivates carry out fault f

temperature control circuitry.

limit

inding on

2.6 INSTRUCTION TO USER

After installing and commissioning appliance, please
hand Instructions to user or purchaser and ensure that
the person(s) responsible understands the instructions to

correctly operate and clean unit in a safe manner.
CR2,Green LED ‘ON’ indicates heat demand.
CR2,Green LED ‘OFF’ indicates no heat demand.

CR9,Red LED flashes if temperature probe is either
short or open circuited.

CR9,Red LED is permanently ‘ON’ to indicate system is
OK. Set point is +/-7⁰C of mid-set point.

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.

5

SECTION 3 ­SERVICING AND CONVERSION

BEFORE ATTEMPTING ANY SERVICING, TURN OFF
THE ELECTRICAL SUPPLY. TAKE STEPS TO ENSURE
THAT THESE CANNOT BE INADVERTENTLY TURNED
ON.

AFTER ANY MAINTENANCE TASK, CHECK THE
APPLIANCE TO ENSURE THAT IT PERFORMS
SAFELY AND CORRECTLY AS DESCRIBED IN
SECTION 2.5.

3.1 INTEGRAL COMPONENTS

3.10 MAINS ON and HEAT DEMAND NEONS

a) Remove control panel by undoing fixings at top an

bottom of control panel and unplug control panel.

b) Remove electrical connections from neon. Undo neon

retention nut.

c) Carefully replace in reverse order.

3.11 DRAIN VALVE

a) Ensure fry pot is empty. Refer to Section 8.

b) Remove nut from handle and lift handle off.

c) Remove front panel fasteners.

d

The following parts must be checked and serviced
regularly:

1.

Oil ingress to electrical components.

2.

Visual inspection of components and fryer pan.

3.

Temperature limit thermostat calibration.

3.2 ACCESS PROCEDURES

Before removal of any fryer components:
a) Ensure appliance electrical supply has 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.

3.3 ELEMENTS

d) Disconnect wiring, noting all connections.
e) Remove front panel to access drain valve.
f) Undo drain pipe. Use appropriate size of spanner

remove drain valve.

g) Replace in reverse order and check for oil leaks.

3.12 FILTRATION PUMP

a) Remove rear access panel. Disconnect pipe at filtration

pump.

b) Disconnect electrical coupling plug and start capacitor

connections.

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

rder. Note: Remember to check for oil leaks before

o
replacing any panels.

3.13 TEMPERATURE LIMIT THERMOSTAT

a) Remove element box cover plate.

to

a) Remove five fixings from element box top and release

element cables.
b) Tilt element box and rest in upright position.
c) Remove four fixings from element mounting plate.
d) Remove element and seal.
e) Replace 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.

b) Lift elements and secure in raised position.
c) Undo phial retention nut.
d) Release phial from retaining clip.
e) Disconnect phial wire plug and cut off plug.
f) Pull down phial to remove.
g) Carefully replace in reverse order. Check for any oil

leaks and that thermostat calibration is within
specification.

3.8 CONTACTORS & FILTRATION PUMP TIMER

a) Remove 8 fixings from rear control compartment cove

a) Disconnect wiring from faulty component, noting all

connections.
b) Replace and rewire component.
c) Replace cover.

r.

6