Falcon G1808X User guide

T100472 Ref. 5
G1808X, G1838X, G1848X
DEEP FAT FRYERS
INSTALLATION and
SERVICING INSTRUCTIONS
These appliances must only e installed, serviced and converted for use with other gases y a
competent person as stipulated y the Gas Safety (Installation & Use) Regulations.
IMPORTANT
The installer ust ensure that the installation of the appliance is in confor ity with these instructions and
National Regulations in force at the ti e 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
These units have been CE- arked on the basis of co pliance with the Gas Appliance Directive, Gas Types
and Pressures as stated on the Data Plate.
WARNING - TO PREVENT SHOCKS, ALL APPLIANCES WHETHER
GAS OR ELECTRIC, MUST BE EARTHED
On co pletion 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
de onstration 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 axi u perfor ance fro this unit we would reco end that a Maintenance Contract be
arranged with AFE SERVICELINE . Visits ay then be ade at agreed intervals to carry out adjust ents and
repairs. A quotation will be given upon request to the contact nu bers below.
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
Detailed recommendations are contained in
Institute of Gas Engineers pu lished
documents :
IGE/ UP/ 1, IGE/ UP/ 2, BS6173 and BS5440

Model kW (net) Btu/hr (gross)
G1808X 18.1 68,000
G1838X 32.5 122,000
G1848X 2 x 18.1 2 x 68,000
Model Pilot Burner Main Burner
G1808X NG No. 18 ù2.38
G1838X NG No. 18 ù3.2
G1848X NG No. 18 2 x ù2.38
Main Burner
ù1.57
ù2.15
2 x ù1.57
Model Pilot Burner
G1808X LP No. 11
G1838X LP No. 11
G1848X LP No. 11
Natural Gas Propane Gas
NG No. 26 LP No. 16
SECTION 1 - INSTALLATION
The unit should be installed on a level, fireproof floor
in a well lit, draught free position. A clear space of
150 should be left between the rear and sides of
the fryer and any co bustible wall.
1.3 VENTILATION
Adequate ventilation, either natural or echanical,
ust be provided to supply sufficient fresh air for
co bustion. This should allow easy re oval of
co bustion products which ay be har ful to health.
Reco endations for Ventilation of Catering
Appliances are given in BS5440:2. Further ore, to
ensure sufficient roo ventilation, guidance on the
volu e of air required to ventilate different types of
catering equip ent is provided in the table below. For
ultiple installations, the require ents 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 ti e. A co petent
installer MUST be e ployed.
The flue discharges vertically fro the rear of the unit
at a height of 1200 fro floor level.
A clear distance of 610 ust be left between
the top edge of the flue and any overhanging object.
There ust be no direct connection of the flue to the
outside air or to a ehanical extraction syste .
Placing the unit below a ventilated canopy is the ost
suitable arrange ent.
1.4 GAS SUPPLY
The inco ing service ust be of sufficient size to
supply full rate gas without excessive pressure drop.
A gas eter is connected to the service pipe by the
Gas Supplier. Any existing eter should be checked
by the Gas Supplier to ensure that such a eter is of
adequate capacity to pass the required rate of gas for
the unit, in addition to any other gas equip ent which
has been installed.
The gas control unit has an in-built governor therefore
an external device does not require to be fitted.
Installation pipework should be fitted in accordance
with IGE/UP/2. Pipework should not be s aller than
the fryer gas inlet connection. G1808X: Rp
1
/
2
(
1
/
2
" BSP), G1838X and G1848X: Rp
3
/
4
(
3
/
4
" BSP).
An isolating cock ust be located close to the unit to
allow shutdown during an e ergency or servicing.
The installation should be checked for gas soundness
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 SIZES -
1.8.1 Natural Gas
1.8.2 Propane Gas
1.8.3 Cross-Lighting Burners
EQUIPMENT
Ventilation Rate Required
3
/ in ft
3
/ in
Range, Unit Type 17 600
Pastry Oven 17 600
Fryer 26 900
Grill 17 600
Steak Grill 26 900
Boiling Pan 17 600
Stea er 17 600
Sterilizing Sink 14 500
Bains Marie 11 400
Tea/ Coffee Machine 8.5 - 14 300 - 500
UNLESS OTHERWISE STATED, PARTS WHICH HAVE BEEN PROTECTED BY THE MANUFACTURER
ARE NOT TO BE ADJUSTED BY THE INSTALLER
MODEL WIDTH
DEPTH HEIGHT WEIGHT kg WEIGHT lbs
G1808X 300 850 870 64 141
G1838X 600 850 870 92 202
G1848X 600 850 870 116 225
1.1 MODEL NUMBERS, NETT WEIGHTS
and DIMENSIONS

Natural Gas Propane Gas
Model bar in. w.g. bar in. w.g.
All 20 8 37 14.8
Natural Gas Propane Gas
Model bar in. w.g. bar in. w.g.
All 15 6 34.5 13.8
Ther ostat
connection
Ther ostat &
ther opile
connection
Ther opile
connection
Ther ocouple
connection
Pilot
adjust ent
screw
Pilot
outlet
Main
inlet
Governor
adjust ent
Main
operating
knob
Outlet Inlet
pressure pressure
test point test point
TP TH TP TH
1.9 SUPPLY PRESSURE
1.10 GAS PRESSURE ADJUSTMENT
A pressure test point is fitted on the burner anifold
and the operating pressure is shown in the table
above. On the G1848X odel, the burner pressure
should be set with both pans turned on.
An adjustable governor is included in the
ultifunctional control on Natural Gas odels
(see Figure 1).
1.11 BURNER ADJUSTMENTS
1.11.1 Pilot
An adjust ent screw is located on the ultifunctional
control to regulate pilot fla e (see Figure 1).
Adjust pilot screw to provide a fla e approxi ately
3
/
4
" long, projecting fro each inverted channel of
pilot burner. (A fla e larger than this will roar
excessively.)
Main Burner
No aeration adjust ent is necessary however,
gas pressure should be set as per value shown in
Section 1.9.
Figure 1
SECTION 2 - ASSEMBLY and
COMMISSIONING
2.1 ASSEMBLY
The unit is packed as a co plete asse bly .
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 ust be fitted with a brake or locking
device. This should be accessible to the operator
fro the front or fro the side.
2.3 CONNECTION TO A GAS SUPPLY
The unit is supplied with the following fittings -
G1808X: Rp
1
/
2
(
1
/
2
" BSP), G1838X and G1848X:
Rp
3
/
4
(
3
/
4
" BSP). Gas supply piping and appliance
connection ust be installed in accordance with the
regulations listed on the front page of this docu ent.
A gas isolating cock ust be fitted to the supply in a
position readily accessible to the 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 aterial
has been re oved fro the unit.
2.6.1 Setting The Gas Pressure
a) It is necessary to check gas pressure during
co issioning. A suitable pressure gauge ust
be connected to the test point on supply anifold.
b) Turn on ain gas valve at supply.
c) Light burners as detailed in User Instructions.
The supply pipes ay contain air, therefore it ay
be necessary to repeat the lighting procedure.
d) Adjust ultifuncional control pressure governor to
relevent settiing as detailed in Section 1.9 of this
docu ent. The screw should be turned clockwise
to increase pressure and anti-clockwise to reduce
it. Check again after 15 inutes of operation.
e) Disconnect pressure gauge fro test point.
Replace sealing screw and test for gas
soundness.
2.7 INSTRUCTION TO USER
After installing and co issioning fryer, hand User
Instructions to the operator or purchaser. Ensure that
details to light, turn off, use and clean are properly
understood. The ain gas isolating valve location
should be ade known to the user and the procedure
for operation in event of an e ergency should be
de onstrated.

Ther opile
Pilot Burner Spark Electrode
Ther ocouple
SECTION 3 - SERVICING and
CONVERSION
Important
BEFORE ATTEMPTING ANY SERVICING,
ENSURE THAT THE ISOLATING COCK IS
TURNED OFF AND THAT IT CANNOT BE
INADVERTENTLY TURNED BACK ON.
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 co ponents -
ALWAYS CHECK FOR GAS SOUNDNESS!
3.1 GAS CONVERSION CHECK LIST
CHANGE MAIN INJECTORS
CHANGE PILOT INJECTORS
CHANGE MULTIFUNCTIONAL CONTROL
CHANGE DATA PLATE
CHANGE CROSS LIGHTING INJECTOR
3.2 REMOVAL OF CONTROL PANEL
Pull off the ther ostat knob and undo the fixings.
3.3 BURNERS
Burners should be cleaned periodically to aintain
axi u perfor ance. These are best cleaned with
a wire brush with blocked parts requiring to be
cleared using a etal broach. Any aterial pushed
into burner should be shaken out via the air inlet.
3.3.1 Removal of Burner Assem ly
Turn off ain gas supply to unit. Re ove fixings
which secure pilot asse bly to ain burner and drop
pilot asse bly slightly. Disconnect co pression joint
above anifold. Re ove fixings which retain burner
asse bly front cross strap to side runners.
Pull burner asse bly forward an inch (approx.) and
drop slightly to clear front cross strap.
While supporting weight of burner asse bly, push
this back to clear rear strap fro runners, lower and
withdraw asse bly. Replace in reverse order.
3.3.2 Removal of Pilot Burner
Isolate ain gas supply to unit. Disconnect pilot
supply pipe co pression nut and re ove pipe fro
pilot burner. Withdraw injector. Undo ther ocouple
retaining nut and re ove ther ocouple fro pilot
burner. Undo ther opile retaining nut and withdraw
ther opile. Pull HT lead fro spark electrode.
Undo nuts which secure pilot burner bracket to
RH ain burner. Withdraw pilot burner asse bly.
Replace in reverse order.
Figure 2
3.4 CLEANING THE INJECTORS
Injectors should be periodically cleaned using a
wooden splinter or soft wire. Avoid using etal
rea ers as these ay distort or increase the orifice
size.
3.4.1 Removal of the Main Burner Injectors
Isolate ain gas supply.
Use a 10 open-ended spanner to re ove injector.
3.4.2 Removal of Pilot and
Cross-Lighting Injectors
Isolate ain gas supply.
Undo pilot supply pipe co pression nut and re ove
pipe fro pilot burner. Withdraw injector.
Replace in reverse order.
3.5 FLAME FAILURE THERMOCOUPLE
Undo nuts at pilot asse bly and valve body.
Disconnect safety ther ostat wires at ther ocouple
interrupter.
3.6 PIEZO IGNITER/SPARK ELECTRODE
The igniter is of the piezo spark type and the device
co prises generator housing, lead and electrode.
The lead has a push-on connection at either end and
the ignition button projects downward fro the
bracket ounting. This is secured to the inner front
wall, inside the door, as follows:
G1808X - LH side
G1838X - RH side
G1848X - LH & RH sides
3.6.1 Removal of Igniter Generator
Re ove igniter lead connection to generator.
Undo fixings which secure generator flange to control
co part ent wall and re ove device. Replace in
reverse order.
3.6.2 Removal of Electrode
Re ove igniter lead connection fro electrode nut
located below pilot burner bracket. Tilt electrode
slightly to clear pilot burner hood and withdraw
upward fro pilot burner bracket. Replace in reverse
order.

3.7 THERMOSTATS
The user ther ostat is a Robertshaw RX odel, snap
action electric control with a centre ste adjust ent
of te perature up to 190
o
C.
The safety stat is an EGO odel with interrupter with
a axi u fixed setting of 230
o
C. This interrupts the
ther ocouple signal fro pilot and will subsequently
shut down gas supply should user ther ostat fail and
cause the oil to overheat.
Note
Manual intervention is required to reset the control in
event of a cut-out.
To Reset
Push button at control base when oil te perature
drops below 215
o
C.
3.7.1 Removal of Operating Thermostat
Isolate ain gas supply and drain oil fro pan.
Re ove control knob fro user ther ostat and undo
fixing at either end of control panel. Pull panel forward
while easing botto edge up slightly. Undo fixings
alongside user ther ostat spindle and withdraw
ther ostat. Follow ther ostat phial lead to stuffing
box in pan front wall and undo s all co pression nut
which seals lead in position. Re ove stuffing box nut
and withdraw ther ostat phial. Undo ther ostat
electrical connections prior to re oval of ther ostat.
Replace in reverse order.
3.7.2 Recali ration of User Thermostat
Re ove knob fro ther ostat spindle taking care not
to rotate it in either direction. This would change the
setting. Steady spindle and rotate calibration screw
clockwise to decrease and anti-clockwise to increase
te perature. The approxi ate effect of a quarter turn
is 27
o
C. Replace control knob and allow unit to
operate until te perature has stabilised before
aking a final check.
3.7.3 Checking the User Thermostat Cali ration
Using a reliable ther o eter i ersed 25 below
oil surface at pan centre, easure oil te perature
when a steady condition has been established.
3.7.4 Removal of Safety Thermostat
Isolate gas supply and drain oil fro pan.
Undo fixings which secure safety stat to bracket.
Undo fixing which retains ther ocouple capillary to
pan base and re ove packing. Withdraw phial and
undo wires fro interrupter. Fit replace ent stat
bracket and reposition parts in reverse order.
3.8 MULTIFUNCTIONAL GAS CONTROL
Unit is fitted with an SIT 820 Nova control
incorporating cock, governor, valve and fla e failure
device.
Removal of the Multifunctional Control
Isolate ain gas supply.
Disconnect ther ocouple connection on MFC and
pull ther ocouple clear. Undo ther opile
connections and withdraw. Undo ain gas inlet and
outlet connections to MFC and withdraw control.
Replace in reverse order taking care when
reconnecting ther ocouple. DO NOT overtighten as
this ay cause da age, hand tight plus a quarter turn
is sufficient.
3.9 GOVERNOR
A governor is built in to ultifunctional control. Refer
to Sections 1.9 and 3.8.

Check Test Check Test CONNECT METER LEADS
TO TERMINALS THERMOSTAT CONTACTS Reading should be:
ACo plete Syste TP&TH Closed Check Test
B Ther opile Output TH/TP & TP Open > 325 V
CSyste Resistance TH/TP & TH Closed < 80 /oh s
D Pilot Dropout TH/TP & TP Open between 120 and 30 V
SECTION 4 - MILLI-VOLT
SYSTEM CHECK
Before checking operation of illivolt syste ,
the following operations should be perfor ed and
observations ade;
1. Inspect syste for correctly routed wiring.
2. Ther ostat leads and all wiring connections should
be cleaned and tightened to eli inate all
unnecessary resistance.
3. Clean and/or adjust pilot for axi u fla e
i pinge ent on ther opile.
The illivolt syste and co ponents should be
checked with an accurate eter which operates in
the 0 - 1000 V range.
Conduct each check listed in table below by
connecting eter leads to indicated ter inals.
All eter readings are closed circuit.
TEST A
COMPLETE MILLIVOLT SYSTEM CHECK
a) If reading is above 100 V and auto atic valve still
does not respond, replace auto atic valve
operator.
b) If closed circuit reading 'A' is below 100 V
deter ine cause of low reading by following this
procedure;
TEST B
THERMOPILE OUTPUT READING CHECK
If ini u V rating is not obtainable, re-adjust pilot
for axi u V output. If this is still below specified
ini u , replace ther opile.
TEST C
SYSTEM RESISTANCE CHECK
If reading is ore than is specified, the syste
resistance is excessive and requires to be reduced.
To correct this;
a) Clean and tighten ther ostat leads and
connections.
b) Shorten ther ostat lead wires and/or replace with
heavier gauge wire leads.
c) Cycle ther ostat by turning knob back and forth
rapidly to clean contacts.
TEST D
PILOT DROPOUT CHECK
a) Hold MFC dial pushed inward in pilot position and
light pilot. Keep knob pushed in until V output
beco es stable at axi u level. Extinguish pilot
and observe eter.
b) Pilot agnet dropout should occur between
120 and 30 V. If dropout occurs outwith these
li its, replace MFC.

Gas Feed Pipe (asse bled by installers)
Description No. Off
Pipe
1
/
2
" 2
Union elbow -
1
/
2
" ale to
1
/
2
" fe ale 2
Tee
1
/
2
"x
1
/
2
"x
3
/
4
" 1
300
1
/
2
"
1
/
2
"
1
/
2
"
1
/
2
"
3
/
4"
1
/
2
"
1
/
2
"
Gas Supply Pipe Assem ly