Falcon G1006X Gas Chieftain Range Boiling Tables And Ovens Instruction Manual

Falcon G1006X Gas Chieftain Range Boiling Tables And Ovens

Product Information

Specifications

• Model: G1006X Four Burner Open Top Oven Range
• Width: 900mm
• Depth: 940mm
• Height: 890mm
• Weight: 240kg

Siting

• The appliance must be installed on a firm-level, non-combustible floor in a well-lit position.
• It should be installed next to non-combustible walls and have a minimum clearance of 200mm all around.
• There should also be a minimum vertical clearance of 1220mm above the top edge of the range and boiling table flues.
• If the appliance is to be installed in suite formation with other matching appliances, it is important to consult the instructions for all appliances to determine the necessary clearance to any rear wall or overlying surface. Some appliances may require greater clearances than others, and the largest figure quoted in the individual instructions will determine the clearance for the complete suite of adjoining appliances.

Product Usage Instructions

Installation and Servicing

• The appliance must be installed and serviced by a qualified person by the Gas Safety (Installation & Use) Regulations.
• The installer should ensure that the installation conforms with these instructions and the National Regulations in force at the time of installation.
• It is important to pay particular attention to Gas Safety (Installation and Use) Regulations, Health and Safety at Work, etc. Act, Local and National Building Regulations, and Fire Precautions Act.
• Detailed recommendations can be found in the Institute of Gas Engineers published documents: IGE/UP1, IGE/UP/2 BS6173, and BS5440.

Important Safety Instructions

• To prevent shocks, all appliances, whether gas or electric, must be earthed. It is essential to consult these instructions before installing and commissioning the appliance.
• Failure to comply with the specified procedures may result in damage or the need for a service call.
• After installation, these instructions should be left with the Engineer-in-Charge for reference during servicing.
• The User Instructions should be handed over to the User, along with a demonstration of the operation and cleaning of the Appliance.
• At the end of the unit’s life, the appliance and any replacement parts should be disposed of safely, via a licensed waste handler.
• The units are designed to be easily dismantled, and recycling of all materials is encouraged whenever practicable.

Contact Information

• Falcon Foodservice Equipment
• Head Office and Works: Wallace View, Hillfoots Road, Stirling, FK9 5PY, Scotland
• Phone: 01786 455200

FAQ

What are the dimensions and weights of the different models?

Below are the dimensions and weights for each model:

• G1006X Four Burner Open Top Oven Range: Width 900mm, Depth 940mm, Height 890mm, Weight 240kg
• G1006BX Single Bullseye Solid Top Oven Range: Width 900mm,  Depth 940mm, Height 890mm, Weight 245kg
• G1006FX Twin Bullseye Solid Top Oven Range: Width 900mm, Depth 940mm, Height 890mm, Weight 253kg
• G1016X General Purpose Oven: Width 900mm, Depth 940mm, Height 890mm, Weight 177kg
• G1026X Four Burner Open Top Boiling Table: Width 900mm, Depth 940mm, Height 890mm, Weight 141kg
• G1026BX Single Bullseye Solid Top Boiling Table: Width 900mm, Depth 940mm, Height 890mm, Weight 159kg
• G1060X Six Burner Open Top Boiling Table: Width 900mm, Depth 940mm, Height 890mm, Weight 159kg
• G1066X Six Burner Open Top Oven Range: Width 900mm, Depth 940mm, Height 890mm, Weight 255kg

GAS CHIEFTAIN RANGES BOILING TABLES and OVENS

Installation and Servicing Instructions

• The appliance 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 conforms 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 User’s 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 under 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 the end of unit life, dispose of the appliance and any replacement parts in a safe manner, via a licensed waste handler.
• Units are designed to be dismantled easily and recycling of all material is encouraged whenever practicable.

Falcon Foodservice Equipment

• HEAD OFFICE AND WORKS
• Wallace View, Hillfoots Road, Stirling, FK9 5PY, Scotland
• Phone: 01786 455200

INSTALLATION

• UNLESS OTHERWISE STATED, PARTS THAT HAVE BEEN PROTECTED BY THE MANUFACTURER ARE NOT TO BE ADJUSTED BY THE INSTALLER.
• Warning – Take care when removing or installing cast components as they are heavy items Pan Supports – (G1006x, G1026x) – 12kg each, (G1066x, G1060x)- 15kg each Solid top Castings – 24kg each
• Twin Bullseye Castings – 12kg each
• Flue – 13.5kg

Model Numbers, Nett Weights and Dimensions

Siting

• The appliance must be installed on a firm-level, non-combustible floor in a well-lit position.
• All models must only be installed next to non-combustible walls. All models should have a 200mm minimum clearance all round. There should be a minimum vertical clearance of 1220mm above the top edge of the range and boiling table flues.
• Important – If the appliance is to be installed in suite formation with other matching appliances, the instructions for all appliances must be consulted to determine the necessary clearance to any rear wall or overlying surface. Some appliances require greater clearances than others. The largest figure quoted in the individual instructions will therefore determine the clearance for the complete suite of adjoining appliances.

Ventilation

• The fresh air requirement for this appliance is a rate of 3m³/hr per kW.
• A qualified installer must be employed.
• This appliance must be installed in a suitably ventilated room under the regulations in force.
• Adequate ventilation, whether natural or mechanical, must be provided to ensure sufficient fresh air for combustion and the removal of combustion and cooking vapors.
• This appliance is to be installed with sufficient ventilation to prevent the occurrence of unacceptable concentrations of substances harmful to health in the room in which they are installed.
• The appliance flue discharges vertically at the rear. There must be no direct connection of the flue to outside air or a mechanical extraction system.
• Standing the appliance below a ventilated canopy is the most suitable arrangement.
• Recommendations for ventilation for catering appliances are given in BS 5440:2.
• For multiple installations, the requirements should be added together. Installation should be made under local and/ or national regulations applying at the time, and a competent installer must be employed.
• Care must be taken not to disturb the air for combustion admission and evacuation of products of combustion on appliances fitted with open burners.

Gas Supply

• The incoming service must be of sufficient size to supply the full rate without excessive pressure drop. A gas meter is connected to the service pipe by the Gas Supplier.
• An existing meter should be checked, preferably by the Gas Supplier, to ensure that it is of adequate capacity to supply the appliance and other associated equipment.
• Installation pipework should be fitted under IGE/UP/2.
• The size of pipework from the meter system to the appliance must not be less than that of the inlet connection. R¾ (¾” BSP female) with regulator for Natural Gas, and without regulator for Propane Models.
• Gas supply tubing or hose shall comply with the national requirements in force, and shall be periodically examined and replaced as necessary. The tubing or Flexible hose must not exceed 1.5m in length.

Important – Check for gas tightness

• An isolating cock must be located close to the appliance and accessible to the user to allow shutdown during an emergency or servicing.
• The installation MUST BE TESTED FOR GAS SOUNDNESS, details are given in IGE/UP/1.
• The adjustable governor supplied must be fitted to natural gas appliances in an accessible and spillage-free position and downstream of the isolating cock.

Electrical Supply

• Not applicable to this appliance.

Water Supply

• Not applicable to this appliance.

Total Rated Heat Inputs – Natural Gas (I2H)

Model| kW (nett)| Btu/hr (gross)|  | Individual Burner Heat Inputs – Natural Gas
---|---|---|---|---
G1006X O/T| 40| 150,100| Configuration| kW (nett)| Btu/hr (gross)
G1006BX S/T| 20| 75,060| Open Top| 7.5| 28,100
G1006FX T/B| 23.5| 88,200| Solid Top| 10| 37,500
G1016X| 10| 37,500| Twin Bullseye| 6.75| 25,300
G1026X O/T| 30| 112,500| Oven| 10| 37,500
G1026BX S/T| 10| 37,500| Pilot| 0.25| 940
G1060X O/T| 45| 168,900|
G1066X O/T| 55| 206,400

Total Rated Heat Inputs – Propane Gas (I3P)

Model| kW (nett)| Btu/hr (gross)|  | Individual Burner Heat Inputs – Propane Gas
---|---|---|---|---
G1006X O/T| 38.8| 145,600| Configuration| kW (nett)| Btu/hr (gross)
G1006BX S/T| 20| 75,000| Open Top| 7.2| 27,000
G1006FX T/B| 21| 78,800| Solid Top| 10| 37,500
G1016X| 10| 37,500| Twin Bullseye| 5.5| 20,600
G1026X O/T| 28.8| 108,100| Oven| 10| 37,500
G1026BX S/T| 10| 37,500| Pilot| 0.25| 940
G1060X O/T| 43.2| 162,150|
G1066X O/T| 53.2| 200,000

Minimum Heat Inputs – Natural (I2H) and Propane (I3P)

Individual Burner Heat Inputs – Natural Gas|  | Individual Burner Heat Inputs – Propane Gas
---|---|---
Configuration| kW (nett)| Btu/hr (gross)| Configuration| kW (nett)| Btu/hr (gross)
Open Top| 2.25| 8,445| Open Top| 2.25| 8,445
Solid Top| 4| 15,000| Solid Top| 4| 15,000
Twin Bullseye| 4| 15,000| Twin Bullseye| 5| 18,700
Oven| 1.65| 6,200| Oven| 1.65| 6,200

Injector Sizes – Natural (I2H) and Propane (I3P)

2 x Amal 150

| 6 x Ø0.66mm| Oven/ Solid| N26| L11
Oven| Ø2.6mm| Amal 360|

Gas Pressure

• A test point is located on the manifold, behind the control panel. Access is gained by removing the panel as described in Section 3.2.4.
• An adjustable governor is supplied for natural gas appliances. Propane appliance pressure is controlled by the incoming supply regulator.
• For multiple burner natural gas units, set pressure at 15 bar with approximately half the total heat input of the appliance in operation.

Burner Aeration

• Fixed injectors are fitted and no means of adjusting the full gas rate is provided. After setting working pressure as Section 1.11. Check burner aeration.

Oven

• An aeration shroud is located close to the injector at the end of the oven burner. Check that the aperture dimension areas are shown in Figure 1. This will achieve the desired cone length.
• If the burner is over-aerated, the flame may extinguish at low rates. The correct full-rate cone length for natural gas is 25mm. Slight yellow flame tips are acceptable on propane appliances.

Open Top

• Check aperture dimension for natural and propane gas is as detailed in Figure 2. Check that the flame is stable and that there is no evidence of flame lift.

Solid Top

• The check aeration shroud is located in the position shown in Figure 3A.
• There should be no flame lift or light back.
• Flames should be blue although slightly yellow tipping is acceptable for propane operation.
• The injector should be located centrally within the burner venturi as detailed in Figure 3B.

By-Pass Rates

• These are pre-set.

To check, proceed as follows:

Oven Burner

• Remove the vertical control panel and open the lower front panel as detailed in Section 3. Light burner and heat oven for 45 minutes at a setting of 275ºC before reducing to 125ºC.
• Check flame lengths are approximately 5mm long.
• Check setting by turning the knob to 275ºC and back to 125ºC. The flame should reduce, but not extinguish.
• Open and Solid Top Burners
• Check flame lengths reduce to approximately 5mm when the gas control knob is turned to the low flame setting. The flame should reduce, but not extinguish.

ASSEMBLY AND COMMISSIONING

Positioning and Asse mbly

1. Position appliance and level using feet adjusters. Each foot contains a hole to enable floor fixing if required. Appliances with castors must be installed in such a manner that takes into account manipulation and the restrictions on site.
   If an oven or range is required to be mounted upon a plinth, the areas indicated in Figure 4 MUST be kept clear for aeration purposes.

2. Ovens: Open oven door, pull out shelves, and remove shelf runner. Lift from the bottom, ease the bottom outward, and lower to free top fixing.

   • Lift out stainless steel base plates. Remove sheet metal base baffle, lift and slide to one side. Rest this on the support angle top edge.
   • Raise opposite end to clear side baffle and remove from oven.
   • Check cast iron baffle plates are correctly located over burner, resting on front and rear sloping angles.
   • The two plates should touch at the centre.
   • Note – The top surface of each plate has one lifting lug directed toward the oven center. Replace all parts in reverse sequence.

3. G1006BX / G1026BX Solid Top : Check by removing the bullseye, ring, and filling plates. Remove any loose packing and replace fillings, etc.

4. G1006FX Twin Bullseye: Check by removing bullseyes, rings, and filling plates. Remove any loose packing before replacement of fillings, etc.

5. G1006X / G1026X / G1060X / G1066X Open Top Models: Check the open top section, remove pan supports, and all packing and tape securing burner components.

   • Check that burner caps and spillage trays are correctly positioned before replacing pan supports.

6. A pot rack can be supplied as an optional extra.

• Important: Open Top Burners Must be positioned as per Fig 5 below.
• Two holes in the burner base must be positioned over the two mounting pins on the burner support channel.
• The larger recess in the brass ring must be mounted over the pin in the burner base.
• The burner is correctly in position when the slot in the brass ring is directly under the longer pan support finger. (see Drg).
• Connection to a Gas Supply
  The gas supply piping and connection to the appliance must be installed by the various regulations listed on the cover of this document. On natural gas appliances, the adjustable governor MUST be fitted to the supply, securely fixed in a position that will enable adjustments to be made during commissioning.
  On propane appliances, a governor must not be fitted.
  Ensure isolating cock is fitted close to the range in an accessible and spillage-free position.
  Important: Check installation for gas tightness.
  Connection to an Electricity Supply
  Not applicable to these models.
  Connection to a Water Supply
  Not applicable to these models.

Pre-Commissioning Check

• After installation, the engineer should check that all gas connections are gas-tight and do not leak. Check that the appliance is operating satisfactorily before leaving the kitchen. Burner and gas valve adjustments should be in line with the details in Section 1.12. If adjustment is required, then the appliance is required to be serviced.

Instruction to User

• After installing and commissioning the appliance, please hand User Instructions to the user or purchaser and ensure that the person(s) responsible understands the instructions for lighting, turning off and correct use and care of the appliance.
• It is important to ensure that the gas-isolating cock location is made known to the user. The procedure for operation in an emergency must be demonstrated.

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 under the conditions of sale.
• Warranty calls can be made between 8:30 am and 5:00 pm on weekdays only.
• To ensure your warranty inquiry is handled as efficiently as possible, ensure you have the following appliance information before calling us:

1. Model number – found on the data plate
2. Serial number – found on data plate
3. A 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, that 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 under 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.

Important

• BEFORE ATTEMPTING ANY SERVICING, ENSURE THAT THE ISOLATING COCK IS TURNED OFF AND CANNOT BE INADVERTENTLY TURNED ON.
• AFTER ANY MAINTENANCE TASK, CHECK THE APPLIANCE TO ENSURE THAT IT PERFORMS CORRECTLY AND CARRY OUT ANY NECESSARY ADJUSTMENTS AS DETAILED IN SECTION 1.
• After carrying out any servicing or exchange of gas-carrying components.

Conversion

• For conversion to NATURAL GAS, fit the correct governor and set the burner pressure.
• For conversion to PROPANE GAS, remove the governor from the gas circuit.
• Other considerations
• CHANGE INJECTORS (refer to Section 1.9 for sizes, and section 3.3 for instructions) ADJUST BYPASS SCREW TO SET LOW RATES (Refer to Section 3.8) in gas taps and any oven thermostat.

CHANGE DATA PLATE

Removal of Panels RH Outer Panel

• Remove fixings that secure the panel bottom flange to the underside of the base. Slide the panel back to withdraw two pins which are located rear of the vertical control panel. Pull the panel out slightly at the bottom then draw it down to clear the top flange which engages under the hob edge lip.
• To replace, the stainless steel outer panels are fitted between the hob and base of the appliance approximately 25mm to the rear of their final position.
• Both panels are then slid forward into position, the RH one to engage its locating pins into the slots in the rear of vertical control panels and the LH to align flush with the front frame.
• The fixings (2 off) engage the bottom flange of the side panels up through holes in the edge of the base panel (see Figure 5).

Bottom Front Panel

• Lift to unhook and lower. Undo the lower RH hinge pin and remove a panel. Replace in reverse order.

Vertical Control Panel

• Pull off control knobs. Remove fixings that secure the panel bottom flange to the base plate. Withdraw the panel outward slightly at the bottom to clear control spindles and pull it down to free the top locating flange. Replace in reverse order.

Top Facia Panel

• To remove the control panel, remove the control knobs and pull the panel toward the front of the appliance to unclip.
• To replace, line bullets up with clips and push until you hear a click.

Oven Door

• a) Remove the control panel as detailed in Section 3.2.3

• b) Unhook the bottom front panel and lower down.

• c ) Close the oven door.

• d) Using a screwdriver for leverage, unhook door quadrant springs. Support door to prevent accidental opening whilst removing springs. Open the door approximately three-quarters of its travel and lift slightly to clear hinge pins.
  Pull forward to allow quadrants to slide through the front frame apertures.

• e) Replace in reverse order.

Burner and Injectors

Note

• Burners and injectors should be cleaned periodically to maintain maximum performance. Burners are best cleaned with a wire brush and washed, drilled ports freed from blockage with a metal broach, and loose material being shaken out via the burner venturi. Injectors are best cleaned with a wooden splinter or soft fuse wire, metal reamers may distort or increase the orifice size and must not be used.
• Ensure that burners are dry and free from any cleaning material before replacing them. Check adjustment as in Section 1.

Open Top

• Remove pan supports and burner head components. Injectors are removed by undoing the compression joint between the gas pipe and the injector holder. Undo the injector grub screw inside the burner assembly. Withdraw the injector and holder from the burner inlet. Replace in reverse order. Ensure the injector holder is fitted fully forward in the burner assembly.
• Aeration should be as detailed in Section 1.11. Lock the aeration screw after any adjustment.
• To remove the burner venturi, remove two screws around the collar in the burner support channel
• Important: When re-positioning Open Top Burners, the Burners Must be positioned as per Fig 5. (Section 2.1)
• Two holes in the burner base must be positioned over the two mounting pins on the burner support channel.
• The larger recess in the brass ring must be mounted over the pin in the burner base.
• The burner is correctly in position when the slot in the brass ring is directly under the longer pan support finger. (see Drg in Section 2.1).

Solid Tops (Single & Twin)

• Remove bullseyes, rings, and hob fillings. Clean burner(s) using a wooden splinter or fuse wire as detailed above.
• Replace in reverse order.
• To remove/replace the main burner injector(s),

Single Bullseye

• Remove bullseye, ring, and hob fillings. Remove the inner burner tray. Remove the screw holding burner fixing bracket. Slide the main burner forward, off the injector. Remove the main injector.
• Replace in reverse order.

Twin Bullseye

• Remove bullseyes, rings, and hob fillings. Remove the four screws securing the center support. Remove the center divider plate. Remove the two screws securing the controls cover panel. Remove the control cover panel. Undo burner head/injector assembly from float rail, using a spanner. Separate the injector from the burner head by unscrewing it.

Replace in reverse order

• Ensure aeration is set as detailed in Section 1.11. After any adjustment, lock the shroud in position.

Oven Burner Removal

• Open the bottom front panel and oven door. Lift out oven shelves and shelf supports.
• Remove base plates and baffle tray (lift one end and rest on the edge of the support angle, slide sideways then lift the other end to clear side angle supports). Remove cast iron heat shields.
• Disconnect thermocouple, electrode and pilot gas supply from pilot burner.
• Undo fixings that secure the front end of the burner to the base and slide the burner rearwards from the injector and retaining bracket on the base.
• Replace in reverse order.

Injector Removal

• Open the bottom front panel. Disconnect the flexible hose compression fitting at the injector elbow. Remove the two screws securing the injector bracket to the oven base.
• Carefully withdraw the injector elbow, complete with a securing bracket. Disconnect the injector from the elbow.

Replace in reverse order

• Ensure aeration is set as detailed in Section 1.11.
• Lock the aeration screw after any adjustment.
• Removal of thermocouple / Flame Failure Device.

Open Top Thermocouple

• a) Remove pan support
• b) Disconnect the thermocouple nut at FFD.
• c) Undo the nut that secures the thermocouple head to the mounting bracket and withdraw.
• d) Replace in reverse order. Position the thermocouple head as indicated in Figure 6. Ensure the FFD nut is not over-tightened.
• A quarter–turn past hand tight is sufficient to prevent a fracture of the electrical point.
• e) Replace all parts in reverse order.
• Important: If Open Top Burners are disturbed, these must be re-positioned as per the illustration in Section 2.1 for burners to function correctly.

Oven Flame Failure Device /Gas Cock

• a) Remove the vertical control panel and RH outer panel as described in Sections 3.2.3 & 3.2.1
• b) Undo the pilot supply pipe compression nut. Ease pipe forward and clear.
• c) Undo two compression nuts on the control inlet and outlet pipes.
• d) Remove fixings that secure Z bracket support. Partly withdraw control.
• e) Undo the thermocouple nut.
• f) Remove the Z bracket and fit it on the new control.
• g) Replace all parts in reverse order. Check gas joints for gas tightness. Adjust the by-pass screw to achieve a flame cone height of approx. 5mm.
• Check flame stability by turning the control knob between high and low flame operation.

Oven Thermocouple

• a) Remove the vertical control panel and RH outer panel as described in Sections 3.23 and 3.2.1
• b) Undo the thermocouple nut at FFD rear after partially removing the control.
• c) Open the bottom front panel and disconnect the nut which secures the thermocouple head to the pilot assembly and withdraws.
• d) Fit new thermocouple. Ensure the head is pushed firmly into position before tightening the nut and that the FFD nut is not over-tightened.
• A quarter turn past hand tight must only be employed to prevent fracture of this electrical joint.
• e) Replace panels in reverse order.

Solid Top Flame Failure device / Gas Cock

• a) Remove the control panel. See Section 3.2.4.
• b) Remove solid top hob fillings and inner tray.
• c) Undo both large compression nuts on the inlet and outlet pipes.
• d) Disconnect the thermocouple nut.
• e) Undo the pilot supply pipe on the ignition flame supply pipe.
• f) Undo fixings that secure the control fixing plate to the bracket.
• g) Remove the fixing plate from the old control and secure it for replacement.
• h) Replace all parts in reverse order.
• Solid Top Thermocouple (G1006BX / G1026BX)
• a) Remove bullseye rings, hob fillings, and inner trays.
• b) Undo thermocouple to FFD nut.
• c ) Undo locknuts which secure the thermocouple to the bracket.
• Withdraw thermocouple.
• d) Replace in reverse order. Position thermocouple tip, 38mm above base as shown in Figure 7.
• Twin Bullseye (Thermocouple Replacement)
• a) Remove Bullseye rings and hob castings.
• b) Remove burner center support.
• c) Remove burner controls cover panel.
• d) Remove the control panel as detailed in Section 3.2.4.
• e) Remove the burner closest to the thermocouple for clear access to the thermocouple nut.
• f) Undo the thermocouple nut at the gas control tap.
• g) Remove the thermocouple.
• h) Replace in reverse order.

Oven piezo Unit Removal

• a) Open the bottom front panel
• b) Remove fixings that secure the piezo unit bracket to the base plate. Partly withdraw the piezo unit and pull the igniter lead off.
• c) Remove the existing piezo unit from the fixing bracket and fit the replacement.
• d) Attach igniter lead to replacement piezo before positioning.
• e) Replace the panel in reverse order.

Removal of Oven Spark Electrode

• a) Open bottom front panel.
• b) Remove the thermocouple. See Section 3.4.3
• c) Undo the nut that secures electrode lead.
• d) Undo gland nut and withdraw electrode.
• e) Replace in reverse order and ensure the thermocouple head is correctly positioned as detailed in Section 3.4.3. The electrode conductor terminal should be clear of any adjacent metal parts.

Thermostat

Oven Control Thermostat

• a) Remove the vertical control panel and RH outer panel. (See Sections 3.2.3 and 3.2.1)
• b) Undo inlet and outlet pipes compression nuts.
• c ) Remove fixings that secure the right-angled bracket to the Z bracket.
• d ) Open the oven door and release the vial by removing clips that secure it to the roof baffle.
• e ) Gently pull the vial and capillary tube through the oven side hole and withdraw the thermostat.
• f ) Remove the right-angled bracket from the existing thermostat and fit it to the replacement.
• g ) Replace all parts in reverse order and check gas joints for tightness.

To Check and Adjust the Thermostat

• a) Remove the control panel as detailed in Section 3.2.3.
• b) Replace the knob and turn to the 200ºC position. This should be the temperature in this setting.
• c) Place a temperature measuring device at the geometric center of the oven and light oven.
• d) Allow the oven to heat up for 30 minutes. Observe temperature is steady. Compare the value obtained with the required value of 200ºC.
• Example – Oven at 190ºC

Action

• Turn the knob to a higher setting until a temperature of 200ºC ±5ºC is obtained. Pull the knob off without rotating the spindle. Undo fixings on adjusting the flange at the spindle base.
• Replace the knob and turn it back to 200ºC setting. Remove the knob and tighten the adjusting flange fixings. Check temperature remains steady at the new setting of 200ºC.
• Reverse action if the oven temperature is above or below 200º.
• e) Turn the thermostat to the lowest setting and adjust the bypass screw to achieve a flame cone length of approximately 5mm. Check flame stability as detailed in Section 1.12.

Gas Taps and FFD

• Replacement Taps for Open Top (G1006X / G1026X / G1060X / G1066X) and Solid Top Burners (G1006BX / G1026BX)
• a) Remove the control panel as detailed in Section 3.2.4.
• b) Remove hob lift-off components.
• c) Undo inlet/outlet pipe compression nuts.
• d) Disconnect the thermocouple nut.
• For solid top appliances, proceed with e) to g).
• e) Undo the pilot supply pipe.
• f) Undo fixings that secure the control location plate to the bracket.
• g) Remove the fixing plate from the previous control and secure it for replacement.
• Replace parts in reverse order.
• Also, check the FFD thermocouple position at low flame operation. Check open-top flame stability on low flame settings by turning control between high and low settings.
• To set a Low rate, aim for flame cone lengths of approximately 5mm, for both Natural and Propane Models.

Twin Bullseye (G1006FX)

• a) Remove bullseye rings and hob castings.
• b) Remove center support
• c) Remove burner controls cover panel.
• d) Remove the control panel as detailed in Section 3.2.4.
• e) Undo saddle clamp plate to float rail.
• f) Unscrew the burner assembly and manifold bracket from the side panel and crown plate.
• g) Remove burner assembly c/w with gas tap and manifold bracket to gain complete access to pipework.
• h) Remove the pilot pipe, main feed pipe, and thermocouple nut from the tap.
• i) Replace in reverse order.

Gas taps (Cleaning and greasing)

• Note: Plugs and bodies are machined as matching pairs and are non-interchangeable. To avoid mix-ups, clean one tap at a time. Check for proper function after maintenance.
• a) Remove the top facia panel (see Section 3.2.4)
• b) Remove fixings from the tap body front. Withdraw the spindle and niting arrangement to allow the plug to be eased out.
• c) Clean plug and body with a soft rag and re-grease with an approved high-temperature lubricant. Apply grease sparingly, DO NOT block the gas passageways of plug and body.
• d) Ensure that the plug is inserted into the body in the correct position for operation.
• e) Secure end cap to body. Note that fixing holes line up in one way only.

Governor (Natural Gas Appliances only)

• The type of governor supplied is maintenance-free. Check that the blue dust cap covering vent is fitted and in good condition as this protects the breather hole.

SPARE PARTS

• When ordering spare parts, ALWAYS quote appliance TYPE and SERIAL No.
• This information can be found on the data plate attached to the appliance.

References

• Policy Documents :: Falcon Foodservice Equipment

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