Falcon G402F, G401F Installation, Servicing And User Instructions Manual

G401F/G402F FRYERS

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: [phone] Fax: [phone]

T100745 Ref. 9

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 - 7

3.

Servicing

7 - 8

4.

Spare parts

8

5.

Critical dimensions

9

6.

Operating instructions

10 - 13

7.

Changing/filtering oil

13

8.

Cleaning and maintenance

14

9.

Preparation of solid fats/oil

15

10.

Cooking Hints

15

11.

Wiring Diagrams

16 - 19

Circuit Diagrams

20 - 23

SECTION 1 - INSTALLA

TION

UNLESS OTHERWISE STATED, PAR

TS

BEEN PROTECTED BY THE

MANUFACTURER

NOT TO BE ADJUSTED BY THE

INSTALLER.

Please ensure that any plastic coatings

are

to use. Before operation, pan requires
cleaned and dried.

Discolouration of heated parts is

caused

testing to ensure a satisfactory unit.

It

quality or performance.

1.1 MODEL NUMBERS, NETT

WEIGHTS

and DIMENSIONS

Model

Width

(mm)

Depth

(mm)

G401F Fryer

400

840

G402F Fryer

400

840

Pan oil capacity:
18 litres cold, good quality oil (to -

MIN

1.2 SITING

The unit must be installed on a firm,

level

lit draught free position. The fryer

should

in a position where the possibility of

sideways

likely when force is applied. The

means

be the manner of installation, such

as

a battery of appliances or installing the

fryer

or by separate means, such

as adequate

1.2.1 Anti-tipping Accessory

An anti-tipping mechanism is also
accessory. If these are to be fitted, the

brackets

fitted to locate the fryer in the correct

position

any walls as detailed below. Fixing

holes are provided in

the fryer base to accommodate the

bracket.

should be fitted as detailed in Figure
chain has a quick release eyelet.

Secure

and secure bracket to floor after
anti-tipping device attached to the

fryer.

below floor bracket.

Figure 1 - Anti-tipping

Bracket

WHICH HAVE

ARE

removed prior

to be thoroughly

by factory

does not affect

Height

(mm)

Weight

(kg)

1200

94

1200

94

- mark)

floor in a well-

not be installed

tipping is

of restraint may

connection to

in an alcove,

ties.

available as an

must be

relative to

The bracket

1. The retaining
to fixing point

alignment with

Adjust to slide

1.2.2 Clearances

The unit requires a

clearance

between unit and any

combustible

A minimum vertical

clearance

allowed between top

edge

overlying combustible

surface.

Important

If fryer is to be installed

with

instructions for every

model

determine the necessary

clearance

wall or overlying surface.
Some appliances require

greater

than others. The

largest

determine overall distance
adjoining appliances.

1.3 VENTILATION

The appliance ventilation

requirements

with national and local

regulations.

The ventilation rate for

these

The appliance flue

discharges

There must be no direct

connection

mechanical extraction

system

should be installed under a

ventilated

Adequate ventilation,

whether

be provided to ensure

sufficient

and for removal of

combustion

harmful to health.
For multiple installations,

requirements should

together. Installations should
local and/or national

regulations

A competent engineer must
work.

1.4 GAS SUPPLY (Both

models)

To be checked

at installation,

The SIT gas valve, situated
accessible by removing

RH

governor. The inlet pressure
inlet test nipple using

a manometer

should be set at test nipple

on burner

means of a manometer

as

Page 4 (for either natural
achieved by removing

brass

governor and adjusting

governor

screwdriver - clockwise

rotation

Note: Propane requires

governor

clockwise to maximum

adjustment.

3

of at least 150mm to rear

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

models is 26m³/min.

vertically from top of unit.

of flue to any

or outside air. The fryer

canopy.

natural or mechanical must

fresh air for combustion
products which may be

be added

be made in accordance with

applying at the time.

be used for any installation

gas conversion or repair.

at rear RH side of unit and

side, has an in-built

should be checked at valve

and burner pressure

manifold, again by

per values indicated on

or propane gas). This is

dust screw from valve

accordingly using a

increases pressure.

to be adjusted

4

Inlet Burner pressure
pressure at manifold

Natural Gas 20mbar 14mbar (+/- 0.75mbar)
Propane Gas 37mbar 34mbar (+/- 1mbar)

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 gas supplier to
ensure that it is adequate to deal with rate of gas
supply required.

Installation pipe work should be fitted in accordance with
IGE/UP/2. The size of pipes from meter to unit must not
be less than that of appliance inlet connection. A 3/4" BSP
inlet connection is fitted to 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 soundness 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.

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

G401F/G402F 230V~ 3.55amps
THE APPLIANCE MUST BE EARTH BONDED.

1.6 TOTAL RATED HEAT INPUTS
Natural and Propane Gas

23kW (net) 86,300 btu/h (gross)

1.7 INJECTOR SIZES
Natural gas

Burner Pilot
2 x Ø2.7mm Polidora G31.2

Propane gas

Burner Pilot
2 x Ø1.7mm Polidora G25

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

Connect gas supply and test for gas soundness.
Caution - Ensure that pan contains an acceptable level

of liquid before igniting burner.
Due to the presence of mains electrics, integral pipe work

should be checked for gas soundness 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, since this is a light pilot
first every time system, it will take a significant number of
tries to light due to the small amount of air bled from pipe
by pilot at each attempt. 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

Ensure flexible cable does not come into contact with any
hot parts. The fuse rating should be 13A.

The colour coding 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 (FMC – G401F only)
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.

5

2.4.1 G401F Fryer Control Panel (See Figure 2)

2

1

3

2 5 3

1

4

4

Figure 2 – G401F Control Panel

1.

ON/OFF and Temperature Control Knob

Temperature Selection (130 - 190°C). (Unit is off when
control is 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.

2.4.2 G402F Fryer Control Panel (See Figure 3)

Figure 3 – G402F 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

Illuminates when thermostat demands heat, i.e. oil is
more than 2⁰C below programmed set temperature. Will
extinguish when desired setting is reached.

2.4.3 G401F & G402F - 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 temp controls.

2.

Burner Lockout Indicator

Indicates flame failure.

6

3

1

2

Figure 4 – G401F & G402F -

Additional

3.

Burner Lock-Out Reset Switch

Resets burner for further lighting

attempts,

lockout indicator is illuminated.

4.

Filtration Pump Switch

Energises filtration pump when

burner

OFF (O) position.

5.

Temperature Safety Limiter Reset

Button

Inside red recess.

2.4.4 G401F Controller Diagnostic

Indicators

(

On printed circuit board of controller,

behind control panel)

Green LED ‘ON’ indicates heat

demand.

Green LED ‘OFF’ indicates no heat

demand.

Red LED flashes if temperature probe
open circuited.

Red LED is permanently ‘ON’ to

indicate

Set point is +/-7⁰C of mid-set point.

2.5 PRE-COMMISSIONING CHECK

1.

Clean out pan thoroughly using

detergent. Rinse out and dry

thoroughly.

Note

For further detail with regard to

cleaning,

Section 8.

2.

Ensure drain valve is closed. Fill
cooking oil to - MIN -

(maximum

indicated on basket hanging rail.

(See

Note: MAX refers to maximum hot

fill

3.

With gas supply still shut off, turn

on electrical

supply.

4.

Open door and press

temperature

reset button (red), refer to

Section

switch to Position 'I' (ON position).

5.

Turn control knob to desired

temperature

(G401F only) and heat

demand

illuminate (Figure 2, item 4).

4

6.

G402F is factory preset

for

(See Section 6.3 - how

to

7.

Fryer ignition sequence
may be heard

before unit

Note: Ignition system

will

14 seconds after completion

5

Controls

when burner

switch is in

is either short or

system is OK.

hot water and

refer to

pan with clean

cold fill mark)

Figure 5).

mark.

mains

limit thermostat

2.6. Set burner

(140⁰C)

indicator will

detected during first attempt.

2nd attempt).

8.

The neon next to

burner

illuminate to indicate

that

that no burner flame
Additional controls -

Item

9.

Turn gas supply on.

10.

Press lockout reset

switch.

indicator will extinguish).

11.

Burner will ignite and

heat

signify that burner is on.

If lockout should occur,

repeat

bled from supply and burner

12.

When burner flame is

established,

leaks. Care should be

taken

is present. Isolate

after gas

2.5.1 Checking Controller

Operation

To check operation of

controls,

Controller - Section 6.2.3.

2.5.2 Checking Oil

Filtration

To check operation

of pump,

Important

After installation, the

responsible

for gas leaks and ensure the

appliance

and satisfactorily before

handing over

2.6 TEMPERATURE LIMIT

THERMOST

The unit is equipped with an
thermostat, independent of

the

In the case of operating

thermostat

temperature to rise above

predetermined

zone (230⁰C), limit device

will

controller. It will also stop

the

To re-set temperature limit

thermostat,

G401F and G402F Models

a) Turn burner and

temperature

to OFF position.

b) Allow oil to cool below

180

c) Reset red button on

limit

similar item. The button is
at upper RH, below facia

panel.

a temperature of 180⁰C

change set temperature).

will commence and spark
locks out.

try a second sequence

of first attempt if no flame is

(Unit will only lock out after

switch inside door will

lockout has occurred and

is present. G401F/G402F

2 on Figure 4.

See Figure 4 (Lock out

indicator will illuminate to

Steps 10 -11 until air is

lights.

check for gas

because mains voltage

checks.

refer to Using The

Pump

refer to Section 7.

technician should check

is operating safely

to the user.

AT

additional temperature limit

main controller.

failure, allowing oil

legislation safe

activate and cut power to

flow of gas to burner.

refer to Figure 4.

controls ON/OFF switch

⁰C
thermostat with a pen or

located behind cabinet door

7

d) Turn burner and temperature controls ON/OFF switch

to ON position.

e) Reselect temperature.
f) 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.

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.

SECTION 3 ­SERVICING AND CONVERSION

BEFORE ATTEMPTING ANY SERVICING, TURN OFF
GAS SHUTOFF 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. A kit with fitting
instructions can be supplied upon request.

3.2 INTEGRAL COMPONENTS

The following parts must be checked and serviced
regularly:

1.

Oil ingress to electrical components.

2.

Flue for any blockages.

3.

Visual inspection of components and fryer pan.

4.

Temperature limit thermostat calibration.

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 GAS CONTROL VALVE

a) Remove RH side panel (fixing behind control panel,

hex bolt below panel at front and 3 fixings at rear) and

rear control compartment cover (3 fixings).
b) Unplug valve control wires.
b) Split pipe work from both sides of valve.
c) Disconnect pilot pipe.
d) Remove screws holding valve to bracket.
e) Replace in reverse order. Check system for gas leaks.

3.5 PILOT/IGNITER/SENSOR ASSEMBLY

a) Open door and remove oil bucket splash cover by

means of two screws on each leg at front and slide out

through door.
b) Disconnect electrode and ignition wires.
c) Using a screwdriver and 8mm spanner, remove pilot

assembly and bracket from burner.
d) Drop assembly and remove pilot pipe.
e) Replace parts in reverse order. Ensure that a good

earth connection has been made.

3.6 BURNER

a) Remove pilot/igniter/sensor assembly as Section 3.5.
b) Remove drain handle.
c) Split incoming gas connection to manifold.
d) Undo two middle mounting bolts and remove two front

burner retention bolts and slide burner forward until it

clears rear retention mountings. Carefully drop burner.
e) Re-connect in reverse order.
f) Gas leak check manifold and pilot gas connections.