Falcon G2844F, G2845F Installation, Servicing And User Instructions Manual
G2844F/G2845F PREMIX
FRYERS
CAUTION: Read the instructions before
using the appliance
INSTALLATION, SERVICING
and USER INSTRUCTIONS
These appliances must be installed and serviced by a qualified 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 -
Gas Safety (Installation & Use) Regulations I.E.E. Regulations for Electrical Installations
Health And Safety At Work etc. Act Electricity at Work Regulations
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
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, 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 user instructions should be handed over to the user, having
had a demonstration of the operation and cleaning of the appliance.
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.
This equipment is ONLY FOR PROFESSIONAL USE, and shall be operated by QUALIFIED persons. It is the
responsibility of the supervisor or equivalent to ensure that users wear SUITABLE PROTECTIVE
CLOTHING and to draw attention to the fact that some parts will, by necessity, become VERY HOT and will
cause burns if touched accidentally.
Falcon Foodservice Equipment
HEAD OFFICE AND WORKS
Wallace View, Hillfoots Road, Stirling. FK9 5PY. Scotland.
SERVICELINE CONTACT
Phone: 01438 363 000 Fax: 01438 369 900
2
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 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.
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Contents
Section
1.
Topic
Installation
Page No.
1 - 4
2.
Assembly and Commissioning
4 - 6
3.
Servicing
7 - 8
4.
Spare parts
8
5.
Critical dimensions/Troubleshooting
9 - 10
6.
Operating instructions
11 - 13
7.
Changing/filtering oil
14 - 15
8.
Cleaning and maintenance
16
9.
Preparation of solid fats/oil
17
10.
Cooking Hints
17
11.
Circuit / Wiring Diagrams
18 - 19
3
SECTION 1 – INSTALLATION
UNLESS OTHERWISE STATED, PARTS WHICH HAVE BEEN PROTECTED BY THE MANUFACTURER ARE
NOT TO BE ADJUSTED BY THE INSTALLER.
Please ensure that any plastic coatings are removed prior to use. Before operation, pan requires to be thoroughly
cleaned and dried.
Discolouration of heated parts is caused by factory testing to ensure a satisfactory unit. It does not affect quality
or performance.
1.1 MODEL NUMBERS, NETT WEIGHTS and DIMENSIONS
Model
Width
(mm)
Depth
(mm)
Height
(mm)
Weight
(kg)
G2844F Fryer
400
840
1200
94
G2845F Fryer
400
840
1200
94
Pan oil capacity: 16 litres cold, good quality oil
(to -MIN- mark)
1.2 SITING
Each unit must be installed on a firm level floor in a well-lit draught free position. The fryer should be installed in a
freestanding position to prevent any possibility of sideways tipping under force. The means of restraint may be the
manner of installation, such as connection to a battery of appliances or installing the fryer in an alcove, or by
separate means, such as adequate ties.
1.2.1 Anti-tipping Accessory
An anti-tipping mechanism is also available as an accessory. If these are to be fitted, the brackets must be fitted to
locate the fryer in the correct position relative to any walls as detailed below. Fixing holes are provided in the fryer
base to accommodate the bracket. The bracket should be fitted as detailed in Figure 1. The retaining chain has a
quick release eyelet. Secure to fixing point and secure bracket to floor after alignment with anti-tipping device
attached to the fryer. Adjust to slide below floor bracket.
Figure 1 - Anti-tipping Bracket
1.2.2 Clearances
The unit requires a clearance of at least 150mm all round between unit and any combustible wall.
A minimum vertical clearance of 750mm should be allowed between top edge of flue outlet and any overlying
combustible surface.
Important
If fryer is to be installed with other appliances then instructions for every model should be consulted to
determine necessary clearance to any combustible wall or overlying surface.
Some appliances require greater clearance distances than others. The largest clearance will therefore
determine overall distance for a complete suite of adjoining appliances.
1.3 VENTILATION
The appliance ventilation requirements should be in line with national and local regulations applying at the time.
The ventilation rate for these models is 26m³/min.
The appliance 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 and
cooking vapours, which may be harmful to health.
4
This appliance is to be installed with sufficient ventilation to prevent the occurrence of unacceptable concentrations of
substances harmful to health in the room which they are installed.
The fresh air requirement for this appliance at a rate of 2M³/hour per kW is 44 M³ of fresh air per hour.
Care must be taken not to disturb the air for combustion admission and evacuation of products of combustion.
Recommendations for Ventilation of Catering Appliances are given in BS5440:2.
For multiple installations the requirements for individual appliances should be added together. A competent installer
MUST BE employed.
The appliance flue discharges vertically through the grille at the top of the unit. There must be no direct connection of
the flue to any mechanical extraction system or the outside air. Siting the unit under a ventilated canopy is the ideal
arrangement. Remember, dirty extraction filters and drip trays may become a fire hazard due to drip-down on to
equipment below. Regular cleaning of extraction filters and drip trays must be carried out.
1.4 GAS SUPPLY (Both models)
Inlet pressure
Natural Gas (I2H) 20mbar
Propane Gas (I3P) 37mbar
The incoming service must be of sufficient size to supply full rate without excessive pressure drop. A gas meter
is connected to service pipe by gas supplier. Any existing meter should be checked preferably by the gas
supplier to ensure that it is adequate to deal with the rate of gas supply required.
Installation pipe work should be fitted in accordance with IGE/UP/2. The size of the pipes from meter to appliance
must not be less than that of appliance inlet connection. A ¾" BSP inlet connection is fitted to the unit.
An isolating valve 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 tightness as stated in
IGE/UP/1.
Domestic type, flexible rubber tube connections must NOT be used with this appliance.
Only tube complying with BS669 Part 2, Specification for corrugated metallic flexible hoses for
catering appliances, shall be used. These hoses must be no longer than 1.5 Metres, and should
be periodically checked / replaced as necessary.
1.5 ELECTRICAL SUPPLY
The unit is equipped with a 3-core flexible cord with standard 3 pin plug fitted with a 13A fuse. A regular 13A
socket outlet can be used.
If supply is through a distribution fuse box, this must be via a fuse with a maximum rating of 13A.
In the event of mains cable being replaced, any new cable should comply with 60245 IEC 57 designation.
(H05 RN - F)
Rated Voltage
Rated Current
G2845F
230V~
1.37amps
G2844F
230V~
1.37amps
THE APPLIANCE MUST BE EARTH BONDED.
Check that no damage has occurred to the appliance, power cable and plug face during transit. If damage has
occurred do not use the appliance.
Ensure that the mains power cable is routed free from the appliance to avoid damage.
We recommend supplementary electrical protection with the use of a residual current device (RCD). Periodical
testing, repair and fixing wiring connection should only be undertaken by a skilled and competent electrician.
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 a conductor having a normal cross-sectional area of up to 10mm². it is located on the rear
panel and is identified by the following symbol and must only be used for bonding purposes.
5
1.6 TOTAL RATED HEAT INPUTS
Natural (I2H)
and
Propane (I3P) Gas
22kW (net), 82,500 btu/hr (gross).
SECTION 2 - ASSEMBLY and
COMMISSIONING
The gas supply piping and connection to appliance must be installed 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 basket support grid and basket in pan.
d) Level appliance and fit all service protection kits.
(Anti-tilt kit, if ordered as accessory).
2.2 CONNECTION TO A GAS SUPPLY. (also refer to section 1.4 above)
Connect gas supply and test for gas tightness.
Caution - Ensure that pan contains an acceptable level of liquid before igniting burner.
If you are in the fat melting cycle <<fat melting cycle>> (FMC) and loading solid fat for the first time, always
remove basket support plate as detailed in Section 9. Solid fat should be in direct contact with fryer pan.
Refer to Section 9.
Due to the presence of mains electrics, integral pipe work should be checked for gas tightness using an appropriate gas
leak detector.
Caution - Installation engineers should note that for first time connection of appliance to supply, it is essential that inlet
gas supply to fryer is completely purged of air prior to first lighting attempt. Otherwise initial lighting attempts may fail,
resulting in burner reset switch having to be used. This should not initially be treated as a fault.
Please note that several attempts will still be required after air purge to fryer for first time lighting. This is due to
capacity of valve and governor.
2.3 CONNECTION TO AN ELECTRICAL SUPPLY. (also refer to section 1.5 above)
Ensure flexible cable does not come into contact with any hot parts. The fuse rating should be 13A.
The colour codings of power supply cables are as follows: Live - Brown, Neutral - Blue, Earth - Green/Yellow
2.4 STARTING UP
If you are in the fat melting cycle <<fat melting cycle>> (FMC) and loading solid fat for the first time, always
remove basket support plate as detailed in Section 9. Solid fat should be in direct contact with fryer pan.
Refer to Section 9.
6
2.4.1 G2844F Fryer Control Panel
(See Figure 2)
1
2 5 3
4
Figure 2 – G2844F 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 program 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
This indicator will illuminate when thermostat demands heat, i.e. oil is more than 2⁰C below the programmed set
temperature.
The indicator will extinguish when desired setting is reached.
2.4.2 G2845F Fryer Control Panel
(See Figure 3).
3
2
4
1 5
Figure 3 – G2845F 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.
7
4. Heat Demand Indicator
This indicator will illuminate when thermostat demands heat, i.e. oil temperature is more than 5 ⁰C below the
temperature setting.
The indicator will extinguish when desired setting is reached.
5. Burner Lock-Out Indicator
Indicates flame failure (burner is not lit).
Filtration Pump Switch (2845F only)
(See Figure 4.)
Energises filtration pump when burner switch is in OFF (O) position.
Temperature Safety Limiter Reset Button
(See Figure 4.)
Inside red recess.
B B
A A
Key to Controls
A. Drain Valve
B. Access Plate C C
C. Temperature Limit Device
D. Burner switch
E. Burner lockout reset switch
F. Burner lockout reset switch D D
and indicator (G2844/F only)
G. Filtration pump switch E F
G G
G2845F G2844F
Figure 4 – G2844 & G2845 - Additional Controls
2.4.3 G2844F/G2845F
- Additional Controls (See Figure 4)
The following additional controls are located behind cabinet door.
1) Burner and Temperature Controls ON/OFF Switch
Cuts power to burner and temperature controls.
2) Burner Lockout Indicator
Indicates flame failure.
2.5 PRE-COMMISSIONING CHECK
1) Clean out pan thoroughly using hot water and detergent. Rinse out and dry thoroughly.
Note
For further detail with regard to cleaning, refer to Section 8.
2) Ensure drain valve is closed. Fill pan with clean cooking oil to -MIN- (maximum cold fill mark) indicated
on basket hanging rail. (See Figure 6). Note: -MAX- refers to maximum hot fill mark.
3) With gas supply still shut off, turn on electrical mains supply.
4) Open door and press temperature limit thermostat reset button (red), refer to Section 2.6. Set burner switch
to Position 'I' (ON position).
5) Turn control knob to desired temperature (140⁰C) (G2845 only). Heat demand indicator will illuminate (Figure
2, item 4).
8
6) Fryer premix fan will run and spark ignition may be heard before unit locks out.
7) A neon will illuminate to indicate that lockout has occurred and that no burner flame is present.
8) Turn on gas supply.
9) Press lockout reset switch. See Figure 4 (Lock out indicator will extinguish).
10) Burner will ignite and heat indicator will illuminate to signify that burner is on.
Note: If lockout should occur, repeat Steps 9 -10 until air is bled from supply.
2.5.1 Checking Controller Operation
To check operation of controls, refer to “ Appliance controls” - Section 6.1.
2.5.2 Checking Oil Filtration Pump
To check operation of oil filtration pump, refer to Section 7.
Important
After installation, the responsible technician should check for gas leaks and ensure the appliance is operating safely and
satisfactorily before handing over to the user.
2.6 TEMPERATURE LIMIT THERMOSTAT
The unit is equipped with an additional temperature limit 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. It will also stop the flow of gas to burner.
To re-set temperature limit thermostat, refer to Figure 4.
G2844F and G2845F Models
1) Turn burner and temperature controls ON/OFF switch to OFF position.
2) Allow oil to cool below 180⁰C
3) Reset red button on limit thermostat with a pen or similar item. The button is located behind cabinet door at
upper RH, below facia panel.
4) Turn burner and temperature controls ON/OFF switch to ON position.
5) Reselect temperature.
6) If limit thermostat reactivates carry out fault finding on temperature control circuitry.
2.7 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.
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.
Weight of Empty oil bucket + filter – 4.25kg
Each litre of oil – approx 1kg.
It is important to ensure that location of gas shutoff valve is made known to user and that procedure for operation in
an emergency be demonstrated.
9
SECTION 3 SERVICING AND CONVERSION
BEFORE ATTEMPTING ANY SERVICING, TURN OFF GAS SHUT-OFF VALVE AND ELECTRICAL SUPPLY.
TAKE STEPS TO ENSURE THAT THESE CANNOT BE INADVERTENTLY TURNED ON.
AFTER ANY MAINTENANCE TASK, CHECK UNIT TO ENSURE THAT IT PERFORMS SAFELY AND
CORRECTLY AS DESCRIBED IN SECTION 2.5.
ALWAYS CHECK FOR GAS LEAKS.
3.1 GAS CONVERSION
(Natural to propane or propane to natural)
This model is suitable for field conversion.
3.2 INTEGRAL COMPONENTS
The following parts must be checked and serviced regularly:
1) Premix fan - check for dust, grease ingress.
2) Oil ingress to electrical components.
3) Flue for any blockages.
4) Visual inspection of components, gaskets and fryer pan.
3.3 ACCESS PROCEDURES
Before removal of any fryer components:
a) Ensure appliance electrical and gas 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.
3.4 PREMIX FAN
(Preset venturi must not be changed)
a) Remove mains pipework from rear then remove back panel to gain access to fan.
b) Disconnect plug from fan.
c) Remove bolts at flange of pipework.
d) Undo fixing that secures ignition control box to gas valve and remove.
e) Fan and valve assembly may now be lifted clear.
f) Remove fixings that secure fan to valve/venturi system. Replace in reverse order.
Check system for gas leaks.
3.5 GAS CONTROL VALVE
(Preset Venturi Must Not Be Changed)
a) Remove premix fan and valve assembly as detailed in
Section 3.4 and lift clear.
b) Remove bolts to disconnect valve from fan assembly.
c) Replace parts in reverse order and check system for gas leaks.
3.6 BURNER
a) Remove both sides and back panel.
b) Split pipework from both fan and burner.
c) Remove igniter/sensor. Refer to Section 3.9.
d) Disconnect burner bolts and carefully drop burner.
e) Fit new gasket and replace burner.
f) Reconnect in reverse order.
g) Check gasket connection is sealed where fitted.
h) Check all gas connections for leaks.
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