Falcon G1808X Chieftain Single Basket Gas Fryer Instruction Manual

G1808X, G1838X, G1848X Fryers
INSTALLATION and SERVICING INSTRUCTIONS 

G1808X Chieftain Single Basket Gas Fryer

This appliance 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:
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/UP1, IGE/UP/2
BS6173 and BS5440
These appliances have been UKCA/CE-marked based on compliance with the Gas Appliance Regulations/Product Safety and Metrology Regulations for the Countries, Gas Types and Pressures as stated on the data plate.
WARNING: TO PREVENT SHOCKS, ALL APPLIANCES WHETHER 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 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
To obtain maximum performance from this unit regular servicing of the appliance should be undertaken to ensure correct operation, it is functioning as intended, and safe to use. We recommend servicing in accordance with SFG20 Maintenance Schedules and as a minimum, after 2,500 hours of use, or annually, whichever comes first and that a maintenance contract be arranged with an appointed service contact. Visits may then be made at agreed intervals to carry out adjustments and repairs.
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.
Falcon Foodservice Equipment
HEAD OFFICE AND WORKS**
Wallace View, Hillfoots Road, Stirling. FK9 5PY.
Scotland.
Phone: 01786 455200
T100916 Ref. 5

SAFETY GUIDANCE

S.1 GENERAL SAFETY
S.1.1 These instructions are only valid if the country code appears on the appliance. If the code does not appear on the appliance, refer to the technical instructions for adapting the appliance to the conditions for use in that country.
S.1.2 These appliances have been UKCA/CE-marked based on compliance with the Gas Appliance Regulations/Product Safety and Metrology Regulations, Electrical and Electromagnetic Compatibility (EMC) Regulations/Directives for the Countries, Gas Types and Pressures as stated on the data plate.
S.1.3 This equipment is for professional use only and must be used by qualified persons.
S.1.4 Never leave this appliance unsupervised when in use and always turn products off at the end of service.
S.1.5 The installer must instruct the responsible person(s) of the correct operation and maintenance of the appliance.
S.1.6 Check that no damage has occurred to the appliance or supply cord during transit. If damage has occurred, do not use this appliance.
S.1.7 If fitted to the appliance, ensure the supply cord is routed free from the appliance to avoid damage.
S.1.8 Min-Level Mark: Medium should never be allowed to drop below the mark.
Should this occur, top up immediately or switch off the fryer.
S.1.9 Suitable Protective clothing must be worn when topping up whilst the fryer is hot.
S.1.10 To prevent surge boiling. DO NOT EXCEED recommended loads or charge pan with over-wet food items. NEVER leave a working appliance unattended.
S.1.11 If the appliance is fitted with an oil bucket, take care when removing as oil bucket is heavy when full.
S.1.12 Training and Competence: To help ensure the safe use of this appliance there is a requirement for you to provide whatever information, instruction, training and supervision as is necessary to ensure, so far as is reasonably practicable, the health and safety of all users.
S.1.13 For further help and information on training and competence we refer you to the Health & Safety Executive website; www.hse.gov.uk document ref: health and safety training INDG345. International customers should default to the health and
safety guidelines provided by your government body.
S.1.14 Risk Assessment: As part of managing the health and safety of your business you must control any risks identified in your commercial kitchen. To do this you need to think about what might cause harm to people and decide whether you are taking reasonable steps to prevent that harm. This is known as risk assessment. It is important to consider the environment around the product as well as the product itself. For example, oil or food spills will present a significant risk so users so the need to immediately clean up such spills must be reflected in staff training.
S.1.15 Record the training that you provide and support it by providing safe system of work (SSOW) documents that set out procedures to be followed for potentially hazardous tasks.
S.1.16 For further help and information on risk assessments we would refer you to you the Health and Safety Executive website; www.hse.gov.uk document ref: risk assessment INDG163. International customers should default to the health and safety guidelines provided by your government body.
S.2 INSTALLATION SAFETY
S.2.1 Installation must meet national or local regulations. Attention must be paid to: safety (installation & use) regulations, health and safety at work act, local and national building regulations, fire precautions act.
S.2.2 The installer must instruct the responsible person(s) of the correct operation and maintenance of the appliance.
S.2.3 On gas appliances, only competent persons are allowed to service or convert the appliance to another gas type.
S.2.4 Put a documented system in place for periodic inspections, testing and maintenance of our gas/ electrical appliances. Check that the fixed electrical installation has been inspected and tested by a competent electrical contractor
(e.g. NICEIC-approved or ECA member) as prescribed in BS7671, within the last 5 years.
S.3 ELECTRICAL SAFETY
S.3.1 To prevent shocks, this appliance must be earthed.
S.3.2 This unit is fitted with an equipotential connection at the rear on the base.
S.3.3 Before attempting any maintenance, isolate the appliance at the mains switch and take steps to ensure that it is not inadvertently switched on.
S.3.4 We recommend, Supplementary electrical protection with the use of a type A residual current device (RCD).
S.3.5 Fixed wiring appliances incorporate a locally situated switch disconnector to connect to, which is easily accessible for switching off and safe isolation purposes. The switch disconnector must meet the specification requirements of IEC 60947.
S.4 GAS SAFETY
S.4.1 Gas appliances must have a stop cock fitted in the supply pipe work. The user must be familiar with the location and operation of this device in order to turn off the supply of gas in the event of an emergency.
S.4.2 Before Inspection, Servicing or Conversion, Turn Off Gas at isolator.
S.5 FIRE SAFETY
Fryers can present various hazards in the catering environment if not correctly used, operated, and maintained. Hazards including fire, burns from hot oil, contact with hot surfaces, fumes from boiling cleaning chemicals, eye injuries from splashes and slips from oil spillages.
Operator Competency and Training
S.5.1 Ensure you are trained in the safe and proper use of the fryer and know how to turn it off and switch the power or gas off at the mains.
S.5.2 Ensure you are familiar with the kitchen fire safety procedures and the location and proper use of correct fire safety equipment.
Fryer Safety Equipmen
S.5.3 1.5.3 Provide an appropriate BS compliant fire blanket, and an adequate number of fire extinguishers that comply with BS EN 3 (parts 1-6) and carry a BAFE or LPCB approval mark. At least one must be appropriate for use on electrical fires, and one for deep-fat fryers (Class F).
Fryer Suppression System
S.5.4 We recommend kitchen equipment and extraction systems are protected with a fire suppression system. Check your insurance as this may also be a condition of your policy.
S.5.5 1.5.5 Protect cooking and extraction equipment (including any associated extraction ductwork and hoods inside the building) by having an extinguishing system installed, in line with (or the equivalent of) LPS 1223. The system should include a local alarm, automatic activation by a detection system and manual activation – located a safe distance away from the cooking equipment, preferably by a fire escape route door.
Operational Fryer Safety
S.5.6 Do not leave the fryer unattended when powered on or when it is in use.
S.5.7 Always switch the fryer off and replace the pan cover/ lid when not in use.
Cleaning
S.5.8 Ensure fryers are regularly cleaned serviced and maintained by a qualified and competent service provider, and there is enough room around the appliance to do so.
S.5.9 Ensure that the appliance, surrounding work area and extraction system are regularly cleaned, (at least weekly) to avoid the build-up of fats oils and greases that could present a fire risk. A deep clean should be undertaken at least every 6 months by a specialist contractor.
Oil Safety
S.5.10 Do not operate the fryer with no or low oil levels.
S.5.11 Solid Fat (e.g. Beef Tallow) must be melted using the fat melt mode in order to avoid fire caused by burning of the fat and/or overheating. We do not recommend using Solid Fat if the fryer control does not have a Fat Melt Cycle.
S.5.12 Regularly change your cooking oil. Use colour charts to check on oil quality.
S.5.13 If you see the cooking oil or fat smoking, switch the fryer off, allow to cool, drain oil, clean and dry fryer pan thoroughly and replace with fresh oil. If the clean fryer oil smokes when heated, switch off immediately and contact service engineer. Do not switch fryer back on.
S.5.14 Never add water to the fryer medium at any time.

Gas and Electrical Isolation Points
S.5.15 Ensure any separate gas shut off switches and electric switches provided for cooking equipment and/or extractor fans are accessible and clearly labelled.

Care and Maintenance of Thermal and Operational Safety Devices
S.5.16 Your fryer is fitted with a thermal safety device. This will stop heating of medium if it becomes overheated. This appliance will always fail safe so long as there is no damage to the thermal safety device.
S.5.17 Failure to clean and check the safety and operational thermostats can impact the performance of the appliance and increase the risk of an appliance fire.
S.5.18 Damage to the thermostat sensors or their capillaries can increase the risk of overheating or fire.
S.5.19 Do not operate the fryer if the safety devices located within the fryer pan appear to be dislodged or damaged.
S.6 MAINTENANCE SAFETY
S.6.1 Unless otherwise stated, parts which have been protected by the manufacturer must not be adjusted by the installer or end user.
S.6.2 Before any cleaning is undertaken, isolate appliance from mains power supply at isolator switch.
S.6.3 Suitable protective clothing must be worn when cleaning this appliance.
S.6.4 If filtration is fitted, never pump water through the filtration pump at any time! Water and hot oil are an explosive mixture.
S.6.5 Oil must be allowed to cool to a safe temperature before draining. Do not overfill oil bucket. All spills onto the product and on the floor should be cleaned up immediately.
S.6.6 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.
S.6.7 Failure due to lack of proper cleaning is not covered by warranty.
S.6.8 Particular attention must be paid to cleaning the Thermostat bulb and Capillaries.
S.6.9 Take care when cleaning not to dislodge or damage thermostat sensors mounted on the base and side of the pan.
S.6.10 If the thermostats or capillaries are damaged then do not turn the appliance on and contact Falcon or you approved service provider to undertake the necessary repairs.
S.6.11 To obtain maximum performance from this unit regular servicing of the appliance should be undertaken to ensure correct operation, it is functioning as intended, and safe to use. We recommend servicing in accordance with SFG20 Maintenance Schedules and as a minimum, after 2,500 hours of use, or annually, whichever comes first and that a maintenance contract be arranged with an appointed service contact. Visits may then be made at agreed intervals to carry out adjustments and repairs.
S.6.12 During Servicing of the appliance, where applicable, please ensure seals are checked. If the integrity of the seal is compromised, it must be replaced.

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)
---|---|---|---|---
G1808X Fryer| 300| 850| 925| 64
G1838X Fryer| 600| 850| 925| 92
G1848X Fryer| 600| 850| 925| 116

1.2 SITING
The unit should be installed on a level, fireproof surface in a well lit, draught free position. A clear space of 150mm should be left between the rear and sides of the fryer and any combustible wall.
If the floor is constructed of combustible material, then local fire requirements should be checked to ensure compliance.
Important
If appliance is to be installed in suite formation with other matching units, the instructions for all models must be consulted to determine the necessary clearances to any combustible rear wall or overlying surface. Some models require greater clearances than others and the largest figure quoted in individual instructions will therefore determine clearance of complete suite adjoining appliances.

1.3 VENTILATION
Adequate ventilation must be provided to supply sufficient fresh air for combustion. This should allow easy removal of combustion products which may be harmful to health. Recommendations for Ventilation of Catering Appliances are given in BS5440:2.
For multiple installations, the requirements for individual units require to be added together. Installation should be carried out in accordance with local and/or national regulations which apply at the time. A competent installer MUST be employed.

1.4 GAS SUPPLY
The incoming service must be of sufficient size to supply full rate gas without excessive pressure drop. A gas meter is connected to the service pipe by Gas Supplier.
Any existing meter should be checked by the supplier to ensure that it is of adequate capacity to pass required rate of gas for the unit, in addition to any other gas equipment that has been installed.
The multifunctional control has no in-built governor therefore an external device must be fitted to natural gas models.
Installation pipework should be fitted in accordance with IGE/UP/2. This should not be smaller than gas inlet connection.
G1808X – Rp½ (½” BSP)
G1838X – Rp¾ (¾” BSP)
G1848X – 2 x Rp½ (½” BSP)
An inlet manifold is supplied with the G1848X to enable connectionto 1x Rp¾ (¾” BSP) mains inlet (if required).
If flexible tube is used, the gas supply tubing or hose shall comply with national requirements in force. These should be periodically examined and replaced as necessary.
An isolating cock must be located close to the unit to allow shutdown during an emergency or servicing.
The installation should be checked for gas tightness and purged as specified in IGE/UP/1.

1.5 ELECTRICAL SUPPLY
Not applicable to these units.

1.6 WATER SUPPLY
Not applicable to these units.

1.7 TOTAL GAS RATES –
NATURAL and PROPANE GAS

1.8 INJECTOR SIZE
1.8.1 Natural Gas

1.8.2 Propane Gas

1.9 GAS PRESSURE ADJUSTMENT
1.9.1 Supply Pressures
A pressure test point is fitted on the burner manifold and the operating pressure is shown in the tables below.
On G1848X model, burner pressure should be set with both pans turned on.
An adjustable governor is required on Natural Gas models.

1.9.2 Natural Gas Burner Pressures

1.9.3 Propane Gas Burner Pressures

1.10 BURNER ADJUSTMENTS
1.10.1 Pilot
No adjustment is available.

Main Burner
No aeration adjustment is necessary, however gaspressure should be set as per value shown in Section 1.9

SECTION 2 – ASSEMBLY and COMMISSIONING

2.1 ASSEMBLY
The unit is packed as a complete assembly.

2.2 APPLIANCES ON CASTORS
For units on castors, refer to guidelines in BS6173.
These state that where wheels, castors or rollers are used, these must be fitted with a brake or locking device.
This should be accessible to operator from front or side.

2.3 CONNECTION TO A GAS SUPPLY
Gas supply piping and unit connection must be installed in accordance with regulations listed on front page of this document.
A gas isolating cock must be fitted to the supply in a position that is readily accessible to operator.

2.4 CONNECTION TO AN ELECTRICAL SUPPLY
Not applicable to these units.

2.5 CONNECTION TO A WATER SUPPLY
Not applicable to these units.

2.6 PRE-COMMISSIONING CHECK
Prior to operation, ensure that all packing material has been removed from unit.

2.6.1 Setting The Gas Pressure
a) It is necessary to check gas pressure during commissioning. A suitable pressure gauge must be connected to test point on supply manifold.
b) Turn on main gas valve at supply.
c) Light burners as detailed in User Instructions.
The supply pipes may contain air therefore it may be necessary to repeat lighting procedure.
d) Natural gas models only. Adjust governor to setting as detailed in Section 1.9.
e) Disconnect pressure gauge from test point. Replace sealing screw and test gas soundness.

2.7 INSTRUCTION TO USER
After installing and commissioning the fryer, hand User Instructions to operator or purchaser. Ensure details to light, turn off, use and clean are properly understood.
The main gas isolating valve location should be made known to user and the procedure for operation in event of an emergency should be demonstrated.

SECTION 3 – SERVICING and CONVERSION

SERVICE INFORMATION
This unit carries an extensive mainland UK warranty. The warranty is in addition to and does not change your statutory or legal rights.
The warranty policy can be found on our website which details the conditions of the warranty and the exclusions.

https://www.falconfoodservice.com/info-centre/policy

Service calls to equipment under warranty will be carried out in accordance with the conditions of sale.
Warranty calls can be made between 8:30 am and 5:00 pm weekdays only.
To ensure your warranty enquiry is handled as efficiently as possible, ensure you have the following appliance information prior to calling us:

1. Model number – found on data plate
2. Serial number – found on data plate
3. Brief description of the issue

To contact Falcon for a warranty issue dial (UK only) 01786 455 200 and select Warranty Issues from the menu.
MAINTENANCE CHECK
Regular servicing of the appliance should be undertaken to ensure correct operation, it is functioning as intended, and safe to use. We recommend servicing after 2,500 hours of use, or annually, whichever comes first.
Any maintenance schedule should be carried out in accordance with SFG20 Maintenance Schedules.
Should any issues with the integrity of the components be identified these should be replaced. If the appliance is not considered safe the unit should be removed from service and the responsible person advised why the unit is not safe to use and what remedial  action is needed. Contents of the maintenance schedule should be agreed with the maintenance provider.
BEFORE ATTEMPTING ANY SERVICING, ENSURE ISOLATING COCK IS TURNED OFF AND THAT IT CANNOT BE INADVERTENTLY TURNED BACK ON. FRYER REQUIRES TO BE COOLED AND DRAINED PRIOR TO MAINTENANCE.
AFTER ANY SUCH MAINTENANCE TASK, CHECK THE APPLIANCE TO ENSURE CORRECT PERFORMANCE AND CARRY OUT ANY NECESSARY ADJUSTMENTS AS DETAILED IN SECTION 1.
After carrying out any servicing or exchange of gas carrying components –
ALWAYS CHECK FOR GAS TIGHTNESS!
3.1 GAS CONVERSION CHECK LIST
CHANGE MAIN INJECTORS CHANGE PILOT INJECTOR
CHANGE CROSS LIGHTING INJECTOR CHANGE DATA PLATE
To convert from natural to propane gas, remove governor.
To convert from propane to natural gas, fit external govenor. Adjust unit manifold pressure as detailed in Section 1.9.2.
All relevant injectors to be changed to suit gas type.
3.2 BURNERS
Burners should be cleaned periodically to maintain maximum performance and are best cleaned with a wire brush. Blocked parts require to be cleared using a metal broach. Any material pushed into burner should be shaken out via air inlet.
3.2.1 Removal of Burner Assembly
Turn off main gas supply to unit. Remove fixings that secure pilot and cross- lighter assemblies to main burner and drop assemblies slightly. Disconnect compression joint above manifold. Remove fixings that retain burner assembly front cross strap to side runners. Pull burner assembly forward (approx. 25mm) and drop it slightly to clear front cross strap. While supporting weight of assembly, push it back to clear rear strap from runners and lower to withdraw. Replace in reverse order.
Removal of Pilot Burner
Isolate main gas supply to unit. Disconnect pilot supply pipe compression nut and remove pipe from pilot burner.
Withdraw injector. Undo thermocouple retaining nut and remove thermocouple from pilot burner. Pull lead from spark electrode.
Undo nuts that secure pilot burner bracket to burner.
Withdraw pilot burner assembly. Replace in reverse order.
3.3 CLEANING THE INJECTORS
Injectors should be periodically cleaned using a wooden splinter or soft wire. Avoid use of metal reamers as these may distort or increase size of orifice.
3.3.1 Removal of Main Burner Injectors
Isolate main gas supply.
Use a 10mm open-ended spanner to remove injector.
3.3.2 Removal of Pilot/Cross-Lighting Injectors
Isolate main gas supply. Undo pilot/cross lighter supply pipe compression nut and remove pipe from pilot/cross lighter burner.
Withdraw injector. Replace in reverse order.
3.4 FLAME FAILURE THERMOCOUPLE
Undo nuts at pilot assembly and valve body brass interruptor.
Disconnect white wires from thermocouple to safety thermostat.
3.5 PIEZO IGNITER/SPARK ELECTRODE
The igniter is a piezo spark type. The electrode is mounted upon pilot burner bracket. Push button is located below valve mounted to control panel inside door at RH side.
Two wires are connected to push button at one end. One is orange in colour and the other is a green/yellow earth wire. Both must be connected at each end for igniter to function properly.
3.5.1 Removal of Igniter Switch
Remove igniter and earth lead connections from push button. Undo large nut that that secures push button flange to control compartment and remove device.
Replace in reverse order.
3.5.2 Removal of the Electrode
Remove igniter lead connection from electrode and remove nut located below electrode. Withdraw electrode downward from pilot burner bracket.
Replace in reverse order.
3.6 THERMOSTATS
For removal of User thermostat, refer to Section 3.7.
The safety thermostat when activated interrupts the millivolt signal from thermocouple tip and subsequently shuts down the gas supply in the event of user thermostat failing, causing oil to overheat.
Note
Manual intervention is required to reset safety thermostat if operated.
3.6.1 Re-setting Safety Thermostat
The safety thermostat is located behind door within main controls compartment. It is situated above the user thermostat temperature knob on RH of compartment.
Unscrew black plastic safety cover to expose spindle.
The reset button is at the spindle centre The button may be pushed to reset safety thermostat when oil temperature drops below 200ºC.
Warning: Fully investigate reason for safety thermostat trip. Do not operate fryer unless both user and safety thermostats operating to specification.
3.6.2 Checking the User Thermostat Calibration
Using a reliable thermometer immersed 25mm below oil surface at pan centre. Measure oil temperature when a steady condition has been established.
3.6.3 Replacement of Safety Thermostat
Isolate gas supply and drain cool oil from pan. Undo fixings that secure controls cover panel.
Remove fixings securing upper panel to LH side of controls cover panel.
Ease upper panel out and pull controls cover panel away from control valve knobs.
Remove nut that secures spindle of safety thermostat to controls cover panel.
Remove two wires from spark igniter push button terminals. Controls cover panel may now be removed.
Undo nuts that secure thermostat capillary to pan front.
From inside pan, gently remove two nuts that secure safety thermostat bracket to pan base.
Release safety thermostat bulb from mounting bracket.
Carefully pull mounting bracket guard tube assembly free from thermostat capillary. Remove capillary through front of pan.
Remove white thermostat wires on thermocouple interruptor.
Re-assemble parts in reverse order. Ensure small compression nut is not secured before thermostat is ecured to mounting bracket inside pan.
3.7 REMOVAL OF GAS CONTROL VALVE INCORPORATING USER THERMOSTAT
Isolate gas supply and drain cool oil from pan.
Undo fixings that secure controls cover panel.
Remove fixings that secure upper panel to LH side of controls cover panel.
Ease the upper panel out and pull controls cover panel away from control valve knobs.
Remove nut that secures spindle of safety thermostat to controls cover panel.
Remove two wires from spark igniter push button terminals.
Controls cover panel may now be removed.
From inside pan, remove two fixings that secure thermostat bulb guard and bulb securing clamp to front face of pan.
Remove bulb guard and pull thermostat from bulb securing clamp.
Undo pan boss nuts that secure thermostat capillary to pan front. Gently pull thermostat bulb through pan boss.
Remove gas inlet and outlet at control valve.
Remove thermocouple from brass interruptor block. Remove pilot pipe connection.
Control valve/user thermostat may now be removed.
Re-assemble parts in reverse order. Ensure pan boss nuts are not secured before thermostat is fixed to mounting bracket.
3.8 GOVERNOR
An external governor must be fitted to natural gas units. No in-built governor is fitted to this appliance.

SECTION 4 – SPARES

When ordering spare parts, always quote unit type and serial number.
This information will be found on data badge on upper panel behind door.

References

• HSE: Information about health and safety at work
• Policy Documents :: Falcon Foodservice Equipment

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