Falcon G2102, G2112 Installation And Servicing Instructions

G2102 FORCED
CONVECTION OVEN RANGE
G2112 FORCED
CONVECTION OVEN (May 2010)

INSTALLATION and SERVICING INSTRUCTIONS

These appliances must be installed and serviced by a competent person as stipulated by the Gas Safety
(Installation & 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 –

BS7671 I.E.E. Wiring Regulations Electricity At Work Regulations
Gas Safety (Installation & Use) Regulations Health And Safety At Work etc. Act
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

The appliances have been CE-marked on the basis of compliance with the Gas Appliance Directive, EMC and Low
Voltage Directive for the Countries, Gas Types, Gas Pressures and voltages as stated on the Data Plate.

WARNING - TO PREVENT SHOCKS, ALL 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 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
licensed 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

PHONE : [phone]

T100732 Ref.5

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 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.

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

MODEL

WIDTH

mm

DEPTH

mm

HEIGHT

mm

WEIGHT

kg

G2102 RANGE

900 855 870 221

G2112 OVEN

ON STAND

900 855 1310

190

G2112/2

DOUBLE TIER

900 855 1465

362

G2112 OVEN

ON LEGS

900 855 870 181

1.2 SITING

All units, other than G2112 oven on stand or legs, must be installed on a non-combustible floor. All units must be
situated on a level surface. Although the appliance feet are adjustable to facilitate levelling, the adjustment range is
limited.
A clearance of at least 150mm must be allowed from any combustible wall.
If practicable, it is recommended that a space of at least 400mm be allowed from any side wall to provide clearance
for adjusting the rear levelling bolts, and to effect the removal of the RH side panel to facilitate servicing.
A vertical clearance of 1200mm minimum must be allowed between the top edge of flue outlet and any overlying
combustible surface.
If unit is being installed as part of a suite, it is also recommended that it be positioned at the RH end to provide
unrestricted access for servicing the controls, etc. Furthermore, if installed in a suite, either central or adjacent to a
wall, with a boxed-in void at the rear, it is vitally important that the void be adequately ventilated to ensure a supply
of air to the motor cooling fan at the rear of the oven.

Important

Care must be taken not to disturb the air combustion admission and evacuation of appliances fitted with open
burners.

1.3 VENTILATION

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 table above. For multiple installations the requirements for individual appliances
should be added together. Installation should be made in accordance with local and/ or national regulations applying
at the time. A competent installer MUST be employed.
The oven flue discharges vertically through the grille at the hob rear.

EQUIPMENT

VENTILATION RATE REQUIRED

m³/min

ft³/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

14

500

Bains Marie

11

400

Tea/Coffee Machine

8.5-14 300-500

There must be no direct connection of the flue to any mechanical extraction system or the outside air. Open top
burners discharge combustion products directly into the room. Siting the appliance under a canopy is the ideal
arrangement.

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 by the Gas Supplier to
ensure the meter is of adequate capacity to pass the required rate of gas.
Installation pipe work should be fitted in accordance with IGE/UP/2. The pipe should be of adequate size but not
smaller than the gas inlet. Connections are as follows:

G2102 Range:

Rp3/4 (3/4" BSP female)

G2112 Oven:

Rp1/2 (1/2"BSP female)
An isolating cock must be located close to the appliance to allow shut-down during an emergency or servicing. The
installation must be tested for gas soundness and purged as specified in IGE/UP/1.

Note

The G2102 open top range is supplied complete with the necessary pipework for linking oven and open top burner
sections. The governor necessary for open top burners is incorporated in this pipework for Natural Gas operation,
and an extra governor must not be fitted to any of these appliances.

1.5 ELECTRICAL SUPPLY

The oven is equipped with a length of 3-core flexible cord for connecting to an electrical supply. A standard 13 amp
socket outlet can be used, in which case the plug must be fitted with a 3 amp fuse. If the supply is through a
distribution fuse box, it must be via a fuse having a maximum rating of 5 amp.

1.6 WATER SUPPLY

Not applicable to these appliances.

1.7 TOTAL GAS RATES -
Natural and Propane Gas

Model

kw

(net)

Btu/hr (gross)

G2102

50.8 190,700

G2112

19

71,300

G2112/2

38

142,600

1.7.1 Individual Burner Ratings -
Natural and Propane Gas

Burner type

kw (net)

Bty/hr (gross)

Open top (x6)

5.3 20,000

oven

19

71,300

1.8 INJECTOR DIAMETERS - Natural & Propane Gas

Natural Gas

Propane Gas

Open top

Ø1.92mm

Ø1.2mm

Oven

Ø3.4mm

Ø2.2mm

Oven Pilot

G29.2

G24.1

1.9 GAS PRESSURE

Supply Pressure

Burner Operating Pressure

Oven Ignition pressure

Nat Prop

Nat Prop

Nat Prop

mbar

20 37 15 37 5 12

1.10 BURNER ADJUSTMENTS

1.10.1 Burner Aeration

All burners have fixed aeration, and no modifications to the size of air-entry should be attempted.

1.10.2 Open Top - Bypass Screw Details

The minimum flow to burner is governed by the size of the fixed hole in bypass screw as detailed below:-

Natural

Gas No.76

Propane Gas

No.51

1.11 FAN UNIT

This fan has two impellors, directly mounted on the motor shaft. The main impellor is inside the oven, its purpose
being to circulate air across the heat-exchangers and around the cooking space, while a smaller, externally mounted
impellor serves to cool the motor and control compartment.

SECTION 2 - ASSEMBLY and COMMISSIONING

2. 1 ASSEMBLY

2.1.1 G2102 Open Top Range

a) Unpack unit, open oven doors and remove inter-connecting pipework (and governor on natural gas appliances)
from inside.
b) Fit interconnecting pipework, leaving incoming pipe entry facing in desired direction to suit service pipe.
c) Place unit into desired location, if necessary adjust levelling bolts. Access to these, at front, is gained upon
removing burner grille below oven doors. The rear bolts are accessible via openings in outer back panel. Do not raise
unit more than is absolutely necessary to effect levelling.
d) Connect to gas supply and test for gas soundness, using soap solution or leak detection fluid.
e) Connect to electrical supply ensuring flexible cord does not make contact with flue or other hot areas.
The wires of flexible cord must be connected to supply as follows:

Brown to Live
Blue to Neutral
Green/Yellow to Earth
This appliance MUST be earthed.

2.1.2 G2112 Oven on Legs

Installation procedure is as Section 2.1.1, but omit (b) and for (c) it is not necessary to remove lower front panel.
Levelling is now effected by turning lower parts of the feet.

2.1.3 G2112 Oven on Stand

Installation procedure is as follows:
a) Unpack oven and stand that is packed separately in a dismantled state.
b) Assemble stand (see Figure 1) using this procedure:

1. Position bottom shelf (A) over frame (B) and secure stand legs (C) to frame (B) using M8 fixings to secure from
below.

2. Fit adjustable legs (D) and stiffening plates (E) to frame (B) using M6 fixings provided.

3. Using pliers or a similar tool, bend and remove tabs from front brackets.

4. Lift oven carefully upon stand and ensure mounting brackets are secured to oven base, lined up with the leg top
brackets. Secure oven to stand using M6 fixings through holes indicated in Figure 1.