Falcon G1808X Release note

G1808X, G1838X, G1848X Fryers
INSTALLATION and
SERVICING INSTRUCTIONS
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
The appliance has 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 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
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 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.
Falcon Foodservice Equipment
HEAD OFFICE AND WORKS
Wallace View, Hillfoots Road, Stirling. FK9 5PY. Scotland.
SERVICELINE CONTACT
Phone: [phone] Fax: [phone]
T100916 Ref. 2

IMPORTANTINFORMATION
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.

Model
kW
Btu/hr
G1808X Fryer
16.7
57,000
G1838X Fryer
30
102,360
G1848X Fryer
2 x 16.7
2 x 57,000
SECTION 1 - INSTALLATION
UNLESS OTHERWISE STATED, PARTS WHICH HAVE BEEN PROTECTED BY THE MANUFACTURER
ARE NOT TO BE ADJUSTED BYTHE 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. Acompetent 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.Agas 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
connection to 1 x 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
Model
Pilot Burner
Cross-lighter
Main Burner
G1808X
51
0.026
2 x Ø2.38mm
G1838X
51
0.026
2 x Ø3.3mm
G1848X
51
0.026
4 x Ø2.38mm
1.8.2 Propane Gas
Model
Pilot Burner
Cross-lighter
Main Burner
G1808X
35
0.016
2 x Ø1.47mm
G1838X
35
0.016
2 x Ø1.95mm
G1848X
35
0.016
4 x Ø1.47mm
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.
Gas type
mbar
inches w.g
Natural Gas
20
8
Propane Gas
37
14.8
1.9.2 Natural Gas Burner Pressures
Model
mbar
inches w.g.
G1808X
13
5.2
G1838X
11.2
4.48
G1848X
13
5.2
1.9.3 Propane Gas Burner Pressures
Model
mbar
inches w.g.
G1808X
35.6
14.2
G1838X
34.5
13.8
G1848X
35.6
14.2
1.10 BURNER ADJUSTMENTS
1.10.1 Pilot
No adjustment is available.
Main Burner
No aeration adjustment is necessary, however gas
pressure shouldbe setas per valueshownin Section 1.9.
SECTION 2 -
ASSEMBLYand 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 AGAS 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-COMMISSIONINGCHECK
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
Important
BEFORE ATTEMPTING ANY SERVICING, ENSURE
ISOLATING COCK IS TURNED OFF AND THAT IT
CANNOT BE INADVERTENTLYTURNED 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 DATAPLATE
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.
3.2.2 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 is an EGO model. When activated,
this 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
secured 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.