Falcon G402F, G401F Installation, Servicing And User Instructions Manual

Page 1

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: 01438 363 000 Fax: 01438 369 900

T100745 Ref. 9

Page 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

Topic

Installation

Page No.

1 - 4

Assembly and Commissioning

4 - 7

Servicing

7 - 8

Spare parts

Critical dimensions

Operating instructions

10 - 13

Changing/filtering oil

Cleaning and maintenance

Preparation of solid fats/oil

10.

Cooking Hints

11.

Wiring Diagrams

16 - 19

Circuit Diagrams

20 - 23

Page 3

SECTION 1 - INSTALLA

TION

UNLESS OTHERWISE STATED, PAR

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.

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

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

- 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

governor. The inlet pressure inlet test nipple using

a manometer

should be set at test nipple

on burner

means of a manometer

Page 4 (for either natural achieved by removing

brass

governor and adjusting

governor

screwdriver - clockwise

rotation

Note: Propane requires

governor

clockwise to maximum

adjustment.

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

Page 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.

Page 5

2.4.1 G401F Fryer Control Panel (See Figure 2)

2 5 3

Figure 2 – G401F Control Panel

ON/OFF and Temperature Control Knob

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

Fat Melt Position

Feature for slow pulsed heating of solid fats.

Power on indicator.

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

Four Digit LED Display

Displays Set temp, Actual temp, cook time remaining and also used for programming purposes.

Program Button

Used to enter timer programme mode (to change each of the 4 pre-set timer select channels - See Section 6).

Temperature Button

Used to view Actual/Set temperature and also to enter Set temperature mode (See Section 6).

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).

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.

Burner and Temperature Controls ON/OFF Switch

Cuts power to burner and temp controls.

Burner Lockout Indicator

Indicates flame failure.

Page 6

Figure 4 – G401F & G402F -

Additional

Burner Lock-Out Reset Switch

Resets burner for further lighting

attempts,

lockout indicator is illuminated.

Filtration Pump Switch

Energises filtration pump when

burner

OFF (O) position.

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

Clean out pan thoroughly using

detergent. Rinse out and dry

thoroughly.

Note

For further detail with regard to

cleaning,

Section 8.

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

(maximum

indicated on basket hanging rail.

(See

Note: MAX refers to maximum hot

fill

With gas supply still shut off, turn

on electrical

supply.

Open door and press

temperature

reset button (red), refer to

Section

switch to Position 'I' (ON position).

Turn control knob to desired

temperature

(G401F only) and heat

demand

illuminate (Figure 2, item 4).

G402F is factory preset

for

(See Section 6.3 - how

Fryer ignition sequence may be heard

before unit

Note: Ignition system

will

14 seconds after completion

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).

The neon next to

burner

illuminate to indicate

that

that no burner flame Additional controls -

Item

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.

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

Page 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:

Oil ingress to electrical components.

Flue for any blockages.

Visual inspection of components and fryer pan.

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.

Page 8

3.7 BURNER RESET SWITCH, ON/OFF SWITCH

and FILTRATION PUMP SWITCH

a) Remove control panel by undoing fixings at top and

bottom of control panel and unplug control panel. b) Hinge down switch mounting panel. c) Remove electrical connections from switch. Remove

switch by squeezing side fixings and pushing it

through aperture. d) Replace part in reverse order.

3.8 BURNER LOCK OUT NEON

a) Remove control panel by undoing fixings at top and

bottom of control panel and unplug control panel. b) Hinge down switch mounting panel. c) Remove electrical connections from neon and remove

neon retention nut. d) Replace part 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.

3.10 MAINS ON and HEAT DEMAND NEONS

a) Remove control panel by undoing fixings at top and

bottom of control panel. Disconnect control panel. b) Remove electrical connections from neon. Undo neon

retention nut. c) Carefully replace in reverse order.

3.11 DRAIN VALVE

a) Remove burner as detailed in Section 3.6 b) Ensure fry pot is empty. Refer to Section 8. c) Remove nut from handle and lift handle off. d) Remove front panel fasteners. e) Disconnect wiring, noting all connections. f) Remove front panel to access drain valve. g) Undo drain pipe. Use appropriate size of spanner to

remove drain valve. h) Replace in reverse order and check for oil leaks.

3.12 FILTRATION PUMP

a) Remove back panel and flexi-hose at filtration pump. b) Disconnect electrical coupling plug and connections

from start.

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

order.

Note: Remember to check for oil leaks before replacing any panels.

3.13 IGNITION CONTROL BOX

a) Remove rear compartment cover. b) Unplug valve and control plugs. Remove ignition,

detector and earth connections. c) Undo three fixings (one at rear, two at front). d) Remove ignition control box. e) Replace in reverse order & test.

3.14 TEMPERATURE LIMIT THERMOSTAT

a) Open control panel. b) Remove probe and safety thermostat protective cover

(ensuring insulation is removed intact). c) Remove phial and probe protective cage inside pan. d) Undo two phial bracket retention nuts and remove

thermostat phial from bracket. e) Undo safety thermostat capillary nut. Using a thin

screwdriver inserted in boss from inside pan, carefully

tap capillary sealing washers through to control

compartment. f) Remove thermostat. g) Disconnect thermostat wires. h) Carefully replace in reverse order. Check for any oil

leaks and that thermostat calibration is within

specification.

SECTION 4 - SPARES

When ordering spare parts, always quote appliance type and serial number. This information will be found on unit data plate, located inside the fryer door on LH leg support face.

Page 9

187

Operating thermostat probe

Safety thermostat probe

Operating and Safety Thermostat

17. 5

24 min 26 max

Timer

Settings

Set

3.6

Set to 10 minutes

258

Pilot to Burner

Dimension

Pump

for 230V

Set to 0.8

Set to F

Page 10

SECTION 6 OPERATING INSTRUCTIONS

The fryers are of single pan type and the following units are covered by this manual.

G401F - Manual control model with built-in filtration. G402F - Four product key electronic control model

with built-in filtration.

USE OF OILS/SHORTENING/SOLIDS

(COOKING MEDIUM)

As these are highly flammable when in their liquid state, caution should always be taken when using cooking medium.

Recommendation

PPE (Personal Protective Equipment) should be used when cleaning or handling medium within this fryer.

Medium should not be overheated as this will increase the risk of fire.

Note: Fryer is fitted with a thermal safety device. This will stop heating of medium if it becomes overheated.

This appliance will always fail safe. Note: NEVER leave a working unit unattended. Medium must always be maintained within fry pot.

Cold Medium - when filling with cold medium (see Figure

5), DO NOT FILL MEDIUM PAST -MIN- LEVEL MARK (Maximum cold fill mark) also, for Solid Medium -

See Section 9.

-MIN- Level Mark: Medium should NEVER be allowed to drop below this mark. Should this occur, top up immediately or switch fryer OFF.

Hot Medium and Topping Up Medium

DO NOT FILL MEDIUM PAST -MAX- LEVEL MARK

(Maximum Hot Fill Mark). (See Figure 5).

Figure 5

CAUTION: SUITABLE PROTECTIVE CLOTHING MUST BE WORN when topping up whilst fat in fryer is hot.

Medium and Foodstuffs

As foodstuffs increase volume during cooking - follow these rules:

DO NOT ADD WATER TO FRYING MEDIUM AT ANY TIME!

WARNING

No attempt must be made to operate this appliance during a power supply failure.

Please ensure that any plastic coated items 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 unit is satisfactory. It will not affect quality or performance.

All Models

A neon indicator is incorporated to indicate flame failure when illuminated.

An electronic thermostat with temperature probe is fitted to automatically control oil temperature. The burner is protected by an electronic flame sensor device.

An additional temperature limit thermostat is also fitted, independent of main thermostat.

Operating thermostat failure could allow oil temperature to exceed the legislated maximum safe temperature (230⁰C). In such condition, the limit thermostat will activate and cut power to controller and it will also stop the flow of gas to burner.

To find location of re-set limit thermostat, refer to Figure 4 on Page 6 of this manual.

Limit Thermostat Reset

a) Turn burner and temperature controls ON/OFF switch

to OFF position. b) Allow oil to cool below 180⁰C.

c) Unscrew black protective cap from limit thermostat

reset button, button is located behind cabinet door at

upper RH below fascia panel. d) Reset red button on limit thermostat with a pen or

similar item. e) Turn burner and temperature controls ON/OFF switch

to ON position. f) Reselect temperature. g) If limit thermostat reactivates an investigation to

determine the reason must be carried out by a

qualified technician.

6.1 APPLIANCE CONTROLS

Refer to Sections 2.4.1, 2.4.2 and 2.4.3 for controls layout and description.

Page 11

6.2 LIGHTING and OPERATION Safety Precautions

The installer must fit a gas shut-off valve in the gas pipe which supplies the unit.

The user MUST be familiar with the location and operation of this valve for shutting off gas in event of an emergency.

IF A SMELL OF GAS IS EVIDENT: a) TURN OFF GAS SUPPLY. b) VENTILATE AREA. c) CALL YOUR LOCAL GAS SUPPLIER. NEVER USE AN OPEN FLAME TO CHECK FOR GAS

LEAKS!

6.2.1 Lighting Instructions

Remove lid (if fitted) and baskets and set these aside. Ensure fryer pan is clean and completely dry. Ensure also that drain valve is closed. Pour clean, cold oil to -MINpan level mark on basket hanging rail.

Both Models

a) Ensure pan is filled with solid/shortening to indicated

level and gas supply is established. b) Ensure burner switch is in off position (O). c) Press burner switch to on position (I). d) Refer to individual unit info below.

(i) G401F only - Turn knob to select temperature. (If solid

fat is used - Select FMC fat melt cycle).

Warning: Do not select any setting other than FMC when using solid fats as this will trip safety thermostat or in a worst case scenario, ignite the liquefied oils.

(ii) G402F only - Factory preset for a temperature of

180⁰C (See Section 6.3 for instructions on how to

change set temperature). e) Refer to individual unit info below. (i) G401F - Heat demand indicator will illuminate.

(ii) G402F only – Display will illuminate with figures 8888

for 2 secs, CTT for 2 secs, r 06 for 2 secs and then

displays Louu. Heat demand LED indicator will

illuminate. f) If burner fails to light, lock-out indicator will illuminate.

Note: Ignition system will try a second ignition

sequence - 14 secs after completion of first attempt if

no flame is detected during first attempt. (Unit will only

lock out after 2nd attempt).

g) Reset burner by pressing burner lock-out reset switch. h) If burner repeatedly fails to light, switch off electrical

and gas supplies. Call service engineer.

6.2.2 Fryer maximum basket loading (Both models)

Pre-blanched chilled fries– 2 x 1.5kg baskets. Frozen fries – 2 x 1.2kg baskets.

6.2.3 Using the Controller G401F Models Only - Manually Operated

When unit is lit as detailed in Section 6.2.1 lighting instructions above, fryer may be operated as follows:-

a) If using solid fat, turn control knob clockwise to select

FMC (Fat Melt Cycle).

b) When solid/shortening has liquefied, select desired

temperature.

Warning: Do not select any setting other than FMC when using solid fats as this will trip the safety thermostat or in a worst case scenario, ignite the liquefied oils.

c) Fat or oil temperature will then be governed by

controller to desired set temperature, selected by user on the control knob.

G402F Models only – Programmable

When unit is lit as detailed in Section 6.2.1 lighting instructions above, fryer may be operated as follows:-

NOTES:

1) There is NO solid fat melt pulsing cycle (FMC) incorporated in this controller.

2) The oil temperature will be governed by controller at a

factory preset temperature of 180⁰C. See Section 6.3 for instructions on how to change set temperature.

3) When actual temperature is within 10⁰C of set point

the display reads redy. See Section 6.3 for instructions on how to display actual or set temperature).

4) Before carrying out any cooking operations, controller

should be set up for particular application of use

(e.g. up to four timer programmes, product frying temperature, ⁰C/⁰F). This can all be carried out using

the following guide in Section 6.3.

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Operating the Controller:

a) Start a timing cycle: Press any product key (1 to 4)

to start a timing cycle. If key is programmed, the correct time will be displayed and will immediately start to count down and LED above key will flash. DONE will display when cook cycle has ended and alarm will sound. If DONE is displayed immediately and alarm sounds, the key has not been programmed See Section 6.3 for programming details.

b) Stop a timing cycle: Press and hold an active

product key for 3 seconds, or press key 3 times within 2 seconds.

c) Respond to a DONE alarm: Cancel signal by pressing

same product key used to start timing cycle.

d) Multiple timing cycles: If a second or third product

key is pressed while the first is still active, the shortest time remaining key is displayed and only the LED above key flashes, the other(s) remain constantly lit. Once shortest time programme ends and is accepted, next shortest is displayed and LED above flashes. Note: All product key timers will count down although not displayed until shorter one ends.

e) Action Alarms (Shake, etc.): If control is programmed

for action alarm, they will signal at a preset time during the timing cycle. The signal, a dual-rhythm beeping, will last 5 seconds and then self-cancel. The display will flash action alarm time and then will continue counting towards 0:00.

f) Viewing Actual/Set Temperatures: Pressing the

temperature key once will display “AXXX” where XXX is actual temperature in degrees (C or F depending on

how controller is programmed – See Section 6.3).

Pressing the temperature key again within 5 seconds will display “PXXX” where XXX is the programmed Set temperature of the controller in degrees (C or F

depending on how controller is programmed – See Section 6.3). If temperature key is not pressed again

within 5 seconds, display returns to idle or timer mode.

6.3 PROGRAMMING THE G402F Display Descriptions

Louu

Controller is in operating mode. Actual vat temperature is more than 10° below programmed vat temperature.

rEdy

Controller is in operating mode. Actual vat temperature is within proper cooking temperature range. Vat is ready to begin a cook cycle.

Controller is in operating mode. Actual vat temperature is more than 30° above highest programmed vat temperature.

Prob

Control probe is either open circuited or short circuited. Display will be accompanied by an audible alarm if shorted. Check or replace probe.

2:30

The control is in operating mode and a cook cycle is in progress.

done

The control is in operating mode and a cook cycle has been completed. Display will be accompanied by a pulsing audible alarm.

6.3.1 Programming temperature set point and

temperature scale. (Factory set for 180

⁰⁰⁰⁰

range available is 30

⁰⁰⁰⁰

C to 190

⁰⁰⁰⁰

a) Press and hold temperature key for 3 seconds.

“Prog” will be displayed. Then press DOWN (key 1) or UP (key 4) key.

b) The display will show either “⁰C” or “⁰F” (degrees

celsius or degrees fahrenheit). Once desired temperature scale is displayed, press temperature key to accept/enter.

c) Display will now alternate between “Sett” and

“XXXZ” (where X denotes temperature and Z indicates temperature scale).

d) Adjust temperature using DOWN (key 1) and UP (key

4) keys. The longer key is pressed, the faster

temperature scrolls.

e) When desired temperature has been reached, press

temperature key to accept/enter.

f) To exit temperature programming, press temperature

key again.

6.3.2 Programming a Product Cycle Time

and Action Alarm

a) Press and hold P key for 3 seconds. “Prog” will

display. Note: Programming mode will exit automatically if no keys are pressed within 2 minutes.

b) Select a product key to program (1 to 4). The display

will alternate between “ti-z” and “X:XX” where z is the number of the key pressed and X:XX is the set time in minutes and seconds.

c) Adjust the time up or down using the DOWN (key 1)

and the UP (key 4) keys. The longer key is held, the faster time will scroll.

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d) Once desired time is reached, press P key to

accept/enter.

e) The display will now alternate between “PrEz” and

“X:XX” where z is the number of key presses and X:XX is action alarm time in minutes and seconds.

NOTE: The time entered here is the time action is

required before the end of the total cycle time entered above. If NO Action time is required, leave at “0:00”. Adjust time as c) above.

f) Once desired time is reached, press P key to

accept/enter.

g) “Prog” will again be displayed and another product

key can be selected for programming. Repeat above steps. When no more keys are required to be programmed and “Prog” is displayed, press P key to exit programming mode and return to idle mode.

SECTION 7 CHANGING/FILTERING THE OIL

Warning

After filtering, wait 30 seconds before removing bucket. It is dangerous to use shortening that is too old.

This medium has a reduced flash point temperature and is prone to surge boiling.

Caution

To prevent surge boiling. DO NOT EXCEED recommended loads or charge the pan with over-wet food items. NEVER LEAVE a working appliance unattended.

Warning

When draining solids/shortening, ensure oil has time to strain through strainer basket. Heavily unfiltered oil may overflow.

Note

This could cause pump to block over a period of time and is considered as misuse of equipment.

Warning

When pumping solids/shortening back into fryer pan. Ensure all trace of solids/shortening is emptied from receptacle (bucket).

If oil is not emptied on a regular basis or if oil is left in the receptacle, it may solidify and overflow or spill on to the kitchen floor to create a hazard.

7.1 STARTING THE FILTRATION PROCESS

Turn burner & temperature controls ON/OFF switch to OFF position and allow oil to cool below 170°C

(or if cold, heat to minimum temperature of 60°C).

Open cabinet door and pull filter bucket forward.

Ensure bucket is clean and emptied of all solid/ shortening and debris. Refer to Section 8 for details of how to clean filter components.

Ensure that strainer and microfilter are clean.

With strainer and microfilter in position, slide bucket

back on to runner cradle and back into fryer.

Please Note - Warning Do not handle filter components or adjacent surfaces when pump is operating.

Components will remain hot for a period after filter. Allow cooling. Use of PPE's is recommended.

Note: Burner and temperature controls ON/OFF switch must be in OFF position before operation of filter pump can begin.

7.2 G401F and G402F MODELS

Press filtration pump switch to turn on pump.

Note: With cabinet door open, switch is located at RH side of drain valve (Refer to Figure 4).

Turn drain handle clockwise.

Pan will drain through strainer basket and microfilter

into bucket and will pump back into pan.

Clear debris from pan.

If pan drain becomes blocked, clear using drain prod.

When debris has been removed from pan, turn valve

handle anti-clockwise to close valve.

Allow pan to refill.

If any solid/shortening remains, repeat Step 1.

Warning

Ensure all shortening has been pumped from receptacle before topping up pan.

Switch filtration pump off.

10.

Top up fryer if required.

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SECTION 8 CLEANING and MAINTENANCE

RECOMMENDATION

Personal protective equipment (PPE's) should be used when cleaning or handling medium within this appliance.

WARNING - NEVER PUMP WATER THROUGH THE FILTRATION PUMP AT ANY TIME!

Warning

The fryer is supplied with castors at rear and should be connected to supply piping by means of a connector for moveable appliances. An anti-tipping restraint can be attached to unit and, if so, this must be disconnected before fryer is moved. Ensure restraint is re-connected when unit is returned to original position.

Moving the fryer with hot or cold oil in fry pot can be dangerous to the operator. Scalding could occur. Spilled oil or fat on the kitchen floor could cause slipping accidents and any such deposit should be cleaned up straight away.

To prevent any such hazard, DO NOT move fryer until all liquid has been drained from fry pot.

The following procedure should be undertaken, AT LEAST DAILY.

IMPORTANT: Disconnect electrical supply before any cleaning is undertaken.

Warning

Oil must be allowed to cool to a safe temperature before draining. Do not overfill draining receptacle.

THE APPLIANCE MUST NOT BE CLEANED WITH A JET OF WATER OR BE STEAM CLEANED. DO NOT USE ACID OR HALOGEN-BASED (e.g. chlorine) DESCALING LIQUIDS, FLAMMABLE LIQUIDS, CLEANING AIDS OR CLEANING POWDERS.

Stainless Steel Surfaces

It should be noted that certain scouring pads including nylon types, could easily mark stainless steel. Care should be exercised during cleaning process.

When rubbing stainless steel with a cloth, always rub along in grain direction.

8.1 CLEANING THE APPLIANCE

1) Carry out actions detailed in Sections 8 and 9.

2) Unit should be switched OFF and fry pot drained of oil.

3) Remove baskets, fish plate and crumb catcher.

Soak these components in hot soapy water.

4) With drain valve open, remove any traces of debris

from fry pot using a clean, damp cloth.

NOTE: Care should be taken not to damage sensors located at pan front.

5) Remove strainer and microfilter, soak these in hot

soapy water.

6) Wash, rinse and dry removed items thoroughly.

Set these aside.

7) Close drain valve.

8) Fill fry pot 3/4 full with hot water.

9) Clean pan using a soft, clean cloth and hot soapy

water, rub away any stubborn staining with a scouring pad and suitable detergent.

10) Open drain valve. Drain water into bucket below.

11) Use clean water to rinse fry pot and dry thoroughly.

12) Close drain valve.

13) Return crumb catcher, fish plate and baskets to pan.

14) Remove oil bucket by pulling forward then upward.

15) Use handles and lift oil bucket to sink.

16) Pour away soiled water.

17) Thoroughly wash, rinse and dry oil bucket and oil

suction pipe.

18) Replace strainer and micro filter in oil bucket and

return oil bucket to cradle.

19) Fill fry pot with clean oil/solid/shortening to -MIN-

mark. To relight, refer to Section 6.2.

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SECTION 9 - PREPARATION OF SOLID FATS/SHORTENING

COOKING HINTS

Allow approximately 10 minutes for unit to heat up from cold to required operating temperature.

CHOICE OF FRYING MEDIUM

Select a top quality medium to obtain optimum results. Shortening or solid fats can be used if necessary.

Solid fats MUST be heated carefully as these have a lower smoke point temperature than shortening.

The G401F is equipped with a fat melt cycle that will pulse heat into the fryer.

A quality shortening is a more stable frying medium. It allows longer periods of use without smoking or foaming. It will also give food a better flavour.

Quality shortening has a higher flashpoint temperature and will reduce gumming around the pan.

Regular filtering will help improve lifespan of the medium. WARNING - NEVER MIX SHORTENING AND SOLID

FAT!

Charging The Pan

Prior to operation, clean fry pot out using hot water and detergent. Rinse out and dry thoroughly.

Ensure drain valve is closed. Fill fry pot with cold shortening to -MIN- level mark on fish plate.

Approximate maximum oil level capacity is 18 litres.

Solid Fat

If solid fat is to be used, remove fish plate and cut fat into small pieces. Place 17kg in fry pot and pack it down.

Position fish plate upon the top of fat. Push front end into fat lightly until front edge is below temperature probe.

Ensure that FAT MELT CYCLE (G401F only) is selected for this process.

Note

Fish plate will lower slowly into fry pot as solid fat melts.

Warning

If fish plate does not sit flat, lift plate from centre slightly and lower carefully to ensure that no splashing of hot shortening occurs.

Check that correct shortening level is achieved when all solid fat has melted. Required temperature may then be set.

Solid fat should always be heated this way to prevent overheating and burning.

WARNING: It is dangerous to use shortening that is too old. Such shortening has a reduced flash point temperature and is prone to surge boiling.

CAUTION: To prevent surge boiling. DO NOT EXCEED recommended loads or charge pan with over-wet food items. NEVER leave a working appliance unattended.

SECTION 10 - COOKING HINTS

Frying food involves many variables and the following information is a guide only.

Ensure frying medium is clean and free of debris.

When topping up with oil, ensure oil level does not

exceed -MIN- line when cold and -MAX- line when hot.

Never overfill baskets with food product.

Filter oil as often as is practically possible. Remember,

this can be done whilst oil is below 180°C.

It is advised that a skimmer is used continuously between frying batches to remove any floating debris. Failure to do this can result in the oil becoming bitter to taste.

During quiet spells, it is recommended that thermostat

is turned down to a lower setting. This will conserve energy in addition to extending expected oil life.

To ensure a good eating experience, fry food as near

to serving time as possible.

After serving and when fryer has been turned off,

replace lid to ensure that no foreign bodies can contaminate frying medium.

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