Falcon G9081, F900 SERIES, G9181, G9042A, G9042 User, Installation And Servicing Instructions

1

F900 SERIES

User, installation and servicing instructions

SOLID TOP & RANGES

G9081/G9181

Read these instructions before use

T100892

Rev 9

Published: 08/09/2016

DATE PURCHASED:

MODEL NUMBER:

SERIAL NUMBER:

DEALER:

SERVICE PROVIDER:

2

Falcon Foodservice Equipment

HEAD OFFICE

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

WEEE Directive Registration No. WEEE/DC0059TT/PRO
At end of appliance life, dispose of appliance and any replacement parts in a safe

manner, via a licensed waste handler. Appliances are designed to be dismantled
easily and recycling of all material is encouraged whenever practicable.

Dear Customer,
Thank you for choosing Falcon Foodservice Equipment.

This manual can be downloaded from www.falconfoodservice.com Or scan
here

IMPORTANT: Please keep this manual for future reference.

3

SYMBOLS

• SPANNER • SCREWDRIVER • COOKING OIL • GREASE

• SPARK IGNITION • FLAME • WARNING • VIEWPORT

• ALLEN KEY •IGNITER

4

These instructions are only valid if the country code appears on the appliance.
If the code does not appear on the appliance, refer to the technical instructions
for adapting the appliance to the conditions for use in that country.

Installation must meet national or local regulations. Attention must be paid to:
gas safety (installation & use) regulations, health and safety at work act, local
and national building regulations, fire precautions act.

To prevent shocks, all appliances must be earthed.

This equipment is for professional use only and must be used by qualified
persons.

The installer must instruct the responsible person(s) of the correct operation
and maintenance of the appliance.

Only competent persons are allowed to service or convert the appliance to
another gas type.

Gas appliances must have a stop cock fitted in the supply pipe work. The user
must be familiar with the location and operation of this device in order to turn
off the supply of gas in the event of an emergency.

Unless otherwise stated, parts which have been protected by the manufacturer
must not be adjusted by the installer.

Take care when moving an appliance fitted with castors.

The appliance must be serviced regularly by a qualified person.
Service intervals should be agreed with the service provider.

This appliance may be discolored due to testing.

5

Contents

1.0 APPLIANCE INFORMATION ......................................................................................................... 6

2.0 OPERATION ................................................................................................................................. 7

2.1 COMPONENT PARTS ............................................................................................................... 7

2.2 CONTROLS ............................................................................................................................... 8

2.3 USING THE APPLIANCE ............................................................................................................ 9

2.4 TURNING THE BURNERS OFF ................................................................................................ 11

3.0 CLEANING AND MAINTENANCE ................................................................................................ 11

3.1 HOB ....................................................................................................................................... 11

3.2 OVEN ..................................................................................................................................... 11

3.3 FLUE CAPPER ......................................................................................................................... 12

4.0 SPECIFICATION .......................................................................................................................... 13

4.1 TABLE A – Technical Data ...................................................................................................... 13

4.2 TABLE B – Heat Inputs ........................................................................................................... 14

5.0 DIMENSIONS / CONNECTION LOCATIONS ................................................................................ 15

6.0 INSTALLATION ........................................................................................................................... 16

6.1 SITING / CLEARANCES ........................................................................................................... 16

6.2 VENTILATION ......................................................................................................................... 16

6.3 GAS SUPPLY & CONNECTION ................................................................................................ 17

6.4 ASSEMBLY ............................................................................................................................. 17

6.5 COMMISSIONING - HOB ........................................................................................................ 18

6.6 COMMISSIONING – OVEN ..................................................................................................... 18

6.7 SUITING ................................................................................................................................. 19

7.0 CONVERSION ............................................................................................................................. 21

7.1 GAS CONVERSION CHECK LIST .............................................................................................. 21

8.0 SERVICING ................................................................................................................................. 22

8.1 CONTROL PANEL ................................................................................................................... 22

8.2 INJECTOR (HOB) .................................................................................................................... 23

8.3 PILOT (HOB) ........................................................................................................................... 23

8.4 REMOVAL OF DOOR .............................................................................................................. 24

8.5 INJECTOR (OVEN) .................................................................................................................. 25

8.6 PILOT (OVEN) ........................................................................................................................ 26

8.7 AERATION (HOB) ................................................................................................................... 26

8.8 GAS VALVE (HOB) .................................................................................................................. 27

8.9 GAS VALVE (OVEN) ................................................................................................................ 28

8.10 PRESSURE ADJUSTMENT ....................................................................................................... 29

8.11 GOVERNOR ............................................................................................................................ 29

9.0 FAULT FINDING ......................................................................................................................... 30

10.0 SPARE PARTS ............................................................................................................................. 31

11.0 SERVICING INFORMATION ........................................................................................................ 32

6

1.0 APPLIANCE INFORMATION

This appliance has been CE-marked on the basis of compliance with the relevant EU
directives for the heat inputs, gas pressures and voltages stated on the data plate.

A - Serial No
B - Model No
C - Flue Type
D - Gas Category
E - Gas Pressure
F - Gas Type
G - Gas Rate
H - Total Heat Input
I - Electrical Rating
J - Total Electrical Power
K - Magnetic Field Frequency
L - Electrical Phase Loading

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2.0 OPERATION

2.1 COMPONENT PARTS

A – Outer Ring
B – Inner Ring
C – Cast Plate
D – Flue Capper
E – Hob Tray
F – Hob Burner

G – Oven Control
H – Viewport
I – Door
J – Hob Control
K – Hob Pilot

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2.2 CONTROLS

A – Solid Top Burner
B – Oven Pilot OFF
C – Oven Pilot ON

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2.3 USING THE APPLIANCE

2.3.0 Before use, clean the appliance. See section 3.0.

2.3.1 Oven - Ignite the Pilot burners as shown. Push the knob in to turn.

2.3.2 Use temperature control knob to adjust temperature. (Oven only)
Initial oven heat up time will be approximately 30 minutes from ambient.

Caution: Opening the oven door will result in the escape of hot air. Care should be taken to avoid
being burned by such action.

10

2.3.3 Hob – Ignite the Pilot burners as shown. Push the knob in to turn.

The minimum temperature of the hottest point of the solid top is 270˚C.

11

IF A BURNER TURNS OFF, WAIT 3 MINUTES BEFORE RE-LIGHTING.

2.4 TURNING THE BURNERS OFF

2.4.0 Oven - Turn pilot knob to ‘OFF’ position. Look through the view port to make sure the
pilot is off.

2.4.1 Hob – Turn control knob to “OFF” position.

3.0 CLEANING AND MAINTENANCE

3.1 HOB

3.1.0 When unit has cooled down.

3.1.1 Remove cast components.

3.1.2 Clean hob and oven chamber using soap and water.

3.1.3 Clean cast components using soap and water.

3.2 OVEN

12

3.2.0 Turn off and wait until unit has cool down.

3.2.1 Remove base tray, base and shelf hangers

3.2.2 Clean oven chamber.

3.2.3 Clean shelves and base tray.

3.3 FLUE CAPPER

3.3.0 The flue capper can be removed for cleaning but must be replaced for use.

FAILURE DUE TO LACK OF PROPER CLEANING IS NOT
COVERED BY WARRANTY

13

4.0 SPECIFICATION

4.1 TABLE A – Technical Data

TECHNICAL DATA – TABLE A

G20

G31

G30

Solid Top

Injector

Ø2.65mm

AMAL 360

Pilot Injectors

N18

L10

Low Rate Screw

185

97

Supply Pressure

mbar

20

37

29

50

Inches w.g

8.0

14.9

11.6

20.1

Operating Pressure

mbar

15

37

29

Inches w.g

6.0

14.9

11.6

Low Rate Pressure

mbar

2

5.5

4.3

Inches w.g

0.8

2.2

1.7

Oven

Injector

230

130

Pilot Injectors

31.2

25

Supply Pressure

mbar

20

37

29

50

Inches w.g

8.0

14.9

11.6

20.1

Operating Pressure

mbar

14

37

29

Inches w.g

6.0

14.9

11.6

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4.2 TABLE B – Heat Inputs

HEAT INPUTS – G20 (kW net & Btu/hr gross)

G9181

G9081

Total Input

kW

17.8

10.3

Btu/hr

66826

38,669

Reduced Heat Input

kW

4.0

4.0

Btu/hr

15017

15017

HEAT INPUTS –G30-G31 (kW net & Btu/hr gross)

G9181

G9081

Total Input

kW

17.3

10.3

Btu/hr

64,949

38,669

Reduced Heat Input

kW

4.0

4.0

Btu/hr

15017

15017

15

5.0 DIMENSIONS / CONNECTION LOCATIONS

16

6.0 INSTALLATION

6.1 SITING / CLEARANCES

CAUTION: WALLS CLOSER THAN 150mm TO THE APPLIANCE MUST BE
NON COMBUSTABLE. IF SUITING THE NECESSARY CLEARANCES TO
ANY CUMBUSTIBLE WALL MUST BE THE LARGEST FIGURE GIVEN FOR
INDIVIDUAL APPLIANCES INSTRUCTIONS.

6.2 VENTILATION

These appliances are to be installed with sufficient ventilation to prevent the occurrence of
unacceptable concentrations of substances harmful to health in the room in which they are
installed. Installer must consult any additional local / national regulations.

COMBUSTION AIR REQUIREMENTS

G9181

G9081

G20

10m³h

10m³h

G30

16m³h

17m³h

G31

16m³h

17m³h

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6.3 GAS SUPPLY & CONNECTION

6.3.0 Installation pipe work should be fitted in accordance with local / national
standards. The pipe work must not be smaller than unit gas inlet connection,

i.e. Rp¾ (¾” B.S.P.). If using flexible hosing, the hose must be sized to

conform with the hose manufacturers specifications and must not exceed

1.5m. An isolating valve must be located close by for shut-down during an
emergency or servicing.

6.3.1 If flexible hose is used, it shall comply with national requirements. These must
be periodically examined and replaced as necessary. If a retention chain is
required then attach this to the fixing shown below.

6.3.2 This appliance is also provided with a terminal for connection of an external
equipotential conductor. This terminal is in effective electrical contact with all fixed
exposed metal parts of the appliance and shall allow the connection of conductor
having a nominal cross-section area of up to 10mm².

It is located at the rear of the unit and identified by the following label and must only be
used for bonding purposes.

6.4 ASSEMBLY

6.4.0 Position appliance and level using feet or caster adjusters as shown below.

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6.4.1 Connect appliance to gas supply and test for gas tightness.

6.5 COMMISSIONING - HOB

6.5.0 Remove control panel. (see 8.1)

6.5.1 Ensure line gas pressure is correct. (see 4.0)

6.5.2 Light pilot and ensure it stays lit.

6.5.3 Turn on burner. Ensure correct lighting occurs.

6.5.4 Check for flame stability.

6.5.5 Operate controls ensuring they turn smoothly.

6.5.6 Turn off appliance.

6.5.7 Replace control panel.

6.6 COMMISSIONING – OVEN

6.6.0 Remove oven base tray and panel. (see 3.2 & 8.5)

6.6.1 Ensure burner pressure is correct. (see 4.0 & 8.9)

6.6.2 Light pilot and ensure it stays lit.

6.6.3 Turn on burner. Ensure correct lighting occurs.

6.6.4 Check for flame stability.

6.6.5 Operate controls ensuring they turn smoothly.

Note: Oven temperature should be checked against the dial with the solid top on.

6.6.6 Turn off appliance.

6.6.7 Replace oven base tray and panel.

6.6.8 Replace control panel.

If the appliance does not operate correctly please refer to section 9.0 and rectify the
problem.

PLEASE FILL OUT THE INFORMATION TABLE ON THE FRONT COVER
AFTER COMMISSIONING.

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6.7 SUITING

“Patent pending, application no. GB 1511389.7”

6.7.1 Before leveling and suiting units ensure the units are fully built, including all
accessories and castings.

6.7.1 Undo the 4 fixing screws on the control panel and remove.

6.7.2 Remove the hob rear infill and replace with rear suiting plate and fixings.

6.7.3 Remove the front side panel countersunk screw and suiting plate.

NOTE: The DLS system is designed to give a quick and easy suiting solution. If

you require an improved seal between appliances we recommend you
use, a food grade, high temperature silicon sealant. This can be
supplied by Falcon part no – 523400021

6.7.4 Run a bead of silicon 5mm from profile edge as highlighted below.

Fig. 1

20

6.7.6 Slide suited units into position.

6.7.7 (A) Right hand unit: Screw the M5 x 40 screw (supplied in the kit) into one of the
suiting plates as shown and then insert through the front fixing holes of both units.

6.7.8 (B) Left hand unit: Slide the penny and lock washer on to the screw and secure using
the M5 nut.

6.7.9 (C) Remove the front bolts from feet, insert base tie plate and secure the bolts back
into position.

6.7.10 (D) Replace fixings on the rear hob and tighten screw caps into position.

6.7.11 Replace control panel.

A B C

D

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7.0 CONVERSION

BEFORE INSPECTION, SERVICING OR CONVERSION, TURN OFF
GAS AT ISOLATOR.

7.1 GAS CONVERSION CHECK LIST

Change injectors in burners and pilots (see 8.2 8.3– 8.5)
Change low rate screw on hob gas valve (see 4.1 & 8.8)
Change aeration setting on hob burner (see 8.7)
Adjust pressure of oven valve stated in section 4.1(see 8.10)
Change gas type label.
If supply pressure of G30 is 50mbar fit governor. Set to values stated in section 4.0.

(see 8.11 for pressure adjustment of Falcon supplied governor)

22

8.0 SERVICING

8.1 CONTROL PANEL

8.1.0 Remove control panel as shown

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8.2 INJECTOR (HOB)

8.2.0 Remove injector as shown. Access from top of unit.

8.2.1 Clean injector.

8.2.2 After replacement, check burner performance.

8.3 PILOT (HOB)

8.3.0 Remove pilot assembly as shown.

A – Thermocouple
B – Pilot gas pipe
C – Assembly removal

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8.4 REMOVAL OF DOOR

THE HINGE SPRING IS UNDER TENSION AND NO ATTEMPT
SHOULD BE MADE TO REMOVE THE PINS WHEN THE DOOR IS
OFF.

8.4.0 Turn off oven and cool down.

8.4.1 Open the door fully and push the supplied Ø4mm R pin into the hole on each hinge.

8.4.2 Holding the door with both hands half way down each side, rotate and lift up until the
hinge hits the top of the hinge aperture.

25

8.4.3 Rotate hinge out of hinge aperture and lift door away.

8.4.4 Replace in reverse order.

8.5 INJECTOR (OVEN)

8.5.0 Remove oven base tray (see 3.3)

8.5.1 Remove oven base panel and burner shield.

8.5.2 Remove burner and injector as shown.

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8.6 PILOT (OVEN)

8.6.0 Remove pilot components as shown.

A – Thermocouple
B – Pilot gas pipe
C – Spark electrode
D – Pilot bracket

8.7 AERATION (HOB)

8.7.0 Adjust opening for gas type used.

G20 – Adjust between 3mm and 6mm
G31 – Fully Open
G30 – Fully Open

27

8.8 GAS VALVE (HOB)

8.8.0 Remove gas valve as shown.
A – Valve to bracket

B – Valve bracket
C – Gas supply pipe
D – Pilot gas pipe
E – Main gas pipe
F – Thermocouple
G – Bypass screw

8.8.1 Remove service valve as shown

28

8.9 GAS VALVE (OVEN)

8.9.0 Remove gas valve as shown.

8.9.1 Remove connections as shown.

A – Gas in
B – Gas out
C – Spark electrode
D – Thermocouple

Note: When testing Valve operation, appliance including solid top should be at working

temperature.

29

8.10 PRESSURE ADJUSTMENT

8.11 GOVERNOR

This applies G30 with supply pressure of 50mbar models only.

GOVERNOR SUPPLIED IS MAINTENANCE FREE. ENSURE THE BLUE
DUST CAP COVERING THE VENT IS FITTED AND IN GOOD CONDITION

30

9.0 FAULT FINDING

FAULT

POSSIBLE CAUSES

REMEDY

Slow/Poor/No heating

Valve pressure wrong

Check pressure

Burner ports blocked

Check burner and clean

Low mains gas pressure

Check with gas supplier

Gas supply isolated/off

Restore supply
Check with gas supplier

Piezo oven igniter not
working

Check for short in high
tension lead

Replace lead
Check for electrode fracture

Replace electrode

Burner will not light/stay lit

No gas at burner

Check injector for blockages

Loose thermocouple

Clean and tighten
connections

Damaged thermocouple

Replace thermocouple

Damaged valve

Replace valve

Oven not reaching
temperature

Faulty thermostat

Replace valve

Flame has yellow/orange
tips

Not enough primary air

Check aeration setting

Contamination in burner

Clean burner and retry

Weak flame

Incorrect valve pressure

Check valve pressure

Blocked injector

Clean injector and retry

Incorrect line pressure

Check with gas supplier

Flame ‘lifts’ off burner
Incorrect primary air

Check aeration setting

Incorrect line pressure

Check with gas supplier

31

10.0 SPARE PARTS

Main Spare Parts:

 Oven Valve
 Hob Valve
 Oven Injector G20
 Oven Injector G30/G31
 Hob Burner Injector G20
 Hob Burner Injector G30/G31
 Hob Pilot Injector G20
 Hob Pilot Injector G30/G31
 Oven Pilot Injector G20
 Oven Pilot Injector G30/G31
 Hob Pilot Assembly
 Oven Pilot Assembly
 Hob Thermocouple
 Oven Thermocouple
 Hob Control Knob
 Oven Control Knob

When ordering spare parts please quote the following;

Model Number
Serial number
Gas Type

This information will be found on data plate attached to the appliance. (see 1.0)

Visit our website for further spares information.

32

11.0 SERVICING INFORMATION

It is recommended to have a maintenance contract with a local service provider.

SERVICELINE CONTACT:

(UK only)

Phone: [phone]

Warranty Policy Shortlist

For our warranty policy please go to www.falconfoodservice.com