Falcon G3840 User guide

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T100806 Ref.17
These appliances must be installed and serviced by a qualified person as stipulated by the Gas Safety
(Installation & Use) Regulations.
IMPORTANT
The installer must ensure that the installation of the appliance is in conformity with these instructions
and National Regulations in force at the time of installation. Particular attention MUST be paid to –
Gas safety (Installation & Use) regulations
I.E.E. Regulations for Electrical Installations
Health & Safety at work, etc Act
Electricity at Work Regulations
Local and National Building Regulations
Fire precaution Act
Detailed recommendations are contained in DW172 Institute of Gas Engineers published documents:
IGE/ UP/ 1, IGE/ UP/ 2, IGE/ UP/ 4, BS6173 and BS5440
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.
WARNING - TO PREVENT SHOCKS, ALL APPLIANCES, GAS OR ELECTRIC, MUST BE EARTHED.
On completion of the installation, these instructions should be left with the Engineer-in-Charge for
reference during servicing. Further to this, the user instructions should be handed over to the user,
having had a demonstration of the operation and cleaning of the appliance.
PREVENTATIVE MAINTENANCE CONTRACT
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.
We recommend that the oil level sensor (UK Patent Serial No. GB2584184)in the G3840X/G3840FX
model should be serviced annually.
WEEE Directive Registration No. WEE/DC0059TT/PRO
At end of unit life, dispose of appliance and any replacement parts in a safe
manner, via a licenced waste handler. Units are designed to be dismantled
easily and recycling of all material is encouraged whenever practicable.
This equipment is ONLY FOR PROFESSIONAL USE, and shall be operated by QUALIFIED
persons. It is the responsibility of the supervisor or equivalent to ensure that users wear SUITABLE
PROTECTIVE CLOTHING and to draw attention to the fact that some parts will, by necessity,
become VERY HOT and will cause burns if touched accidentally.
FalconFoodserviceEquipment
Wallace View, Hillfoots Road, Stirling, FK9 5PY,Scotland
Phone: [phone]
G3840/G3840X/G3840F/G3840FX
FRYERS
INSTALLATION,SERVICING and USER INSTRUCTIONS
CAUTION: Read the instructions before using the appliance

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IMPORTANTINFORMATION
ELECTRICAL SAFETY AND ADVICE REGARDING SUPPLEMENTARY ELECTRICAL PROTECTION
Commercial kitchens and foodservice areas are environments where electrical appliances may be located
close to liquids, or operate in and around damp conditions or where restricted movement for installation
and service is evident.
The installation and periodic inspection of the appliance should only be undertaken by a qualified, skilled
and competent electrician; and connected to the correct power supply suitable for the load as stipulated
by the appliance data label.
The electrical installation and connections should meet the necessary requirements to the local electrical
wiring regulations and any electrical safety guidelines.
We recommend:-
•Supplementary electrical protection with the use of a type A residual current device (RCD)
•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.
Your attention is drawn to:-
BS 7671:2018–Guidance Note 8 - 8.13 : Other locations of increased risk
It is recognized that there may be locations of increased risk of electric shock other than those specifically
addressed in Part 7 of BS 7671. Examples of such locations could include laundries where there are
washing and drying machines in close proximity and water is present, and commercial kitchens with
stainless steel units, where once again, water is present.
Where because of the perception of additional risks being likely, the installation designer decides that an
installation or location warrants further protective measures, the options available include:
•Automatic Disconnection of Supply (ADS) by means of a residual current device having a residual
operating current not exceeding 30mA;
•Supplementary protective equipotential bonding; and
•Reduction of maximum fault clearance time.
The provision of RCDs and supplementary bonding must be specified by the host organization’s appointed
installation designer or electrical contractor and installed by a suitably qualified and competent electrician
so as to comply with Regulations 419.2 and 544.2

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.
For further help and information on training and competence we would refer you the Health and 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.
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.
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.
Cleaning and maintenance
When removing heavy items to aid cleaning or maintenance particular care should be taken. A manual
handling risk assessment is the best way to determine the level of risk to anyone using or maintaining
this equipment. To help with such an evaluation we have included the weights of individual components
that may present significant risk.
For further help and information on manual handling and associated risk assessment we would refer
you to you the Health and Safety Executive website; www.hse.gov.uk document ref: manual handling
at work INDG143. International customers should default to the health and safety guidelines provided
by your government body.
The cleaning of fryers or other products that use hot oil present significant risks to end users and
particular care should be taken. Cold water and hot oil for example are an explosive mix and should be
avoided at all costs.
Other useful references for health and safety issues
www.hse.gov.uk
Essentials of health and safety at work ISBN978
Noise at work INDG362
Safe systems of work
Other notes added to the body of the instructions

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CONTENTS
1.0 INSTALLATION........................................................................................................................................................6
1.1 MODEL NUMBERS, NETT WEIGHTS & DIMENSIONS..........................................................................................6
1.2 SITING.................................................................................................................................................................6
1.2.1 Anti-tipping Kit.........................................................................................................................6
1.2.2 Clearances.............................................................................................................................. 7
1.3 VENTILATION......................................................................................................................................................7
1.4 GAS SUPPLY (All Models) ...................................................................................................................................7
1.5 ELECTRICAL SUPPLY............................................................................................................................................8
1.6 TOTAL RATED HEAT INPUTS...............................................................................................................................9
1.7 INJECTOR SIZES ..................................................................................................................................................9
2.0 ASSEMBLY and COMMISSIONING..........................................................................................................................9
2.1 ASSEMBLY ..........................................................................................................................................................9
2.2 CONNECTION TO A GAS SUPPLY........................................................................................................................9
2.3 CONNECTION TO AN ELECTRICAL SUPPLY .......................................................................................................10
2.4 STARTING UP....................................................................................................................................................10
2.4.1 G3840/F Fryer Control Panel (See Figure 2).........................................................................10
2.4.2 G3840X/G3840FX Fryer Control Panel (See Figure 3)..........................................................11
2.4.3 G3840 & G3840F - Additional Controls - (See Figure 4)........................................................11
2.4.4 G3840 and G3840F Controller Diagnostic Indicators............................................................. 12
2.5 PRE-COMMISSIONING CHECK..........................................................................................................................12
2.5.1 Checking Controller Operation ..............................................................................................13
2.5.2 Checking Oil Filtration Pump................................................................................................. 13
2.6 TEMPERATURE LIMIT THERMOSTAT................................................................................................................13
2.7 OIL LEVEL SENSOR (G3840X/G3840FX only)....................................................................................................13
2.8 INSTRUCTION TO USER ....................................................................................................................................13
3.0 SERVICING AND CONVERSION .............................................................................................................................14
3.1 GAS CONVERSION ............................................................................................................................................15
3.2 INTEGRAL COMPONENTS.................................................................................................................................15
3.3 ACCESS PROCEDURES.......................................................................................................................................15
3.4 GAS CONTROL VALVE.......................................................................................................................................15
3.5 PILOT/IGNITER/SENSOR ASSEMBLY.................................................................................................................15
3.6 BURNER............................................................................................................................................................16
3.7 BURNER RESET SWITCH, ON/OFF SWITCH and FILTRATION PUMP SWITCH...................................................16
3.8 BURNER LOCK OUT NEON................................................................................................................................16
3.9 OPERATING THERMOSTAT (Thermistor) PROBE..............................................................................................16
3.10 TEMPERATURE PCBCONTROLLER (Operating Thermostat Board) ...................................................................16
3.11 MAINS ON and HEAT DEMAND NEONS............................................................................................................17
3.12 DRAIN VALVE....................................................................................................................................................17
3.13 FILTRATION PUMP ...........................................................................................................................................17
3.14 IGNITION CONTROL BOX..................................................................................................................................17
3.15 TEMPERATURE LIMIT THERMOSTAT................................................................................................................17

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3.16 OIL LEVEL SENSOR (G3840X/G3840FX only, Figure 5) .....................................................................................18
3.17 TOP UP AND LOW OIL LEVEL LEDS (G3840X/G3840FX only, Figure 5) ............................................................18
3.18 OIL LEVEL SENSOR EVALUATION UNIT (G3840X/G3840FX only, Figure 5)......................................................18
3.19 RELAYS & RELAY BASES (G3840X/G3840FX only, Figure 5) .............................................................................18
3.20 POWER SUPPLY UNIT (G3840X/G3840FX only, Figure 5) ................................................................................18
4.0 SPARES .................................................................................................................................................................19
5.0 CRITICAL DIMENSIONS.........................................................................................................................................20
6.0 OPERATING INSTRUCTIONS .................................................................................................................................21
6.1 APPLIANCE CONTROLS.....................................................................................................................................23
6.2 LIGHTING and OPERATION Safety Precautions................................................................................................23
6.2.1 Lighting Instructions ..............................................................................................................23
6.2.2 Fryer maximum basket loading.............................................................................................. 23
6.2.3 Using the Controller...............................................................................................................23
7.0 CHANGING/FILTERING THE OIL............................................................................................................................24
7.1 STARTING THE FILTRATION PROCESS ..............................................................................................................24
7.2 G3840F MODEL................................................................................................................................................25
8.0 CLEANING and MAINTENANCE ............................................................................................................................26
8.1 CLEANING THE APPLIANCE...............................................................................................................................26
9.0 PREPARATION OF SOLID FATS / SHORTENING.....................................................................................................28
10.0 COOKING HINTS ...................................................................................................................................................29
11.0 WIRING DIAGRAMS..............................................................................................................................................30
11.1 G3840 WIRING DIAGRAM ................................................................................................................................30
11.2 G3840X WIRING DIAGRAM..............................................................................................................................31
11.3 G3840F WIRING DIAGRAM ..............................................................................................................................32
11.4 G3840FX WIRING DIAGRAM ............................................................................................................................33
11.5 G3840 CIRCUIT DIAGRAM................................................................................................................................34
11.6 G3840X CIRCUIT DIAGRAM..............................................................................................................................35
11.7 G3840F CIRCUIT DIAGRAM ..............................................................................................................................36
11.8 G3840FX CIRCUIT DIAGRAM ............................................................................................................................37

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1.0 INSTALLATION
UNLESS OTHERWISE STATED, PARTS WHICH HAVE BEEN PROTECTED BY
THE MANUFACTURER ARE NOT TO BE ADJUSTED BY THE INSTALLER.
Please ensure that any plastic coatings are removed prior to use. Before operation, pan requires to be
thoroughly cleaned and dried.
Discolouration of heated parts is caused by factory testing to ensure a satisfactory unit. It does not affect
quality or performance.
1.1 MODEL NUMBERS, NETT WEIGHTS & DIMENSIONS.
Model
Width (mm)
Depth (mm)
Height (mm)
Weight (kg)
G3840 Fryer
400
770
1090
83
G3840X Fryer
400
770
1090
85
G3840F Fryer
400
770
1090
94
G3840FX Fryer
400
770
1090
96
Pan oil capacity:
18 litres cold, good quality oil (to –MIN- mark)
1.2 SITING
Each unit must be installed on a firm level floor in a well- lit draught free position. The fryer should
be installed in a freestanding position to prevent any possibility of sideways tipping under force.
The means of restraint may be the manner of installation, such as connection to a battery of
appliances or installing the fryer in an alcove, or by separate means, such as adequate ties.
Anti-tipping Kit
An anti-tipping mechanism is supplied with unit. If these are to be fitted, the brackets must be fitted
to locate the fryer in the correct position relative to any walls as detailed below. Fixing holes are
provided in the fryer base to accommodate the bracket. The bracket should be fitted as detailed
in Figure 1. The retaining chain has a quick release eyelet. Secure to fixing point and secure
bracket to floor after alignment with anti-tipping device attached to the fryer. Adjust to slide below
floor bracket.
Figure 1 - Anti-tipping Bracket

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Clearances
The unit requires a clearance of at least 150mm all round between unit and any walls. The unit
must only be installed next to non combustible walls. A minimum vertical clearance of 750mm
should be allowed between top edge of flue outlet and any overlying combustible surface.
Important
If fryer is to be installed with other appliances then the instructions for
every model should be consulted to determine the necessary clearance
to any wall or overlying surface.
Some appliances require greater clearance distances than others. The
largest clearance will therefore determine overall distance for a
complete suite of adjoining appliances.
1.3 VENTILATION
This appliance MUST 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. Installer must consult any additional local / national regulations.
The fresh air requirement for this appliance at a rate of 2M³/hour per kW is 44 M³ is as follows:
COMBUSTION AIR REQUIREMENTS
APPLIANCE
VENTILATION RATE
G3840
44 m3/h
G3840X
44 m3/h
G3840F
44 m3/h
G3840FX
44 m3/h
1.4 GAS SUPPLY (All Models)
To be checked at installation, gas conversion or repair.
Note: Governor setting may be checked at burner manifold without the need to remove the right
hand side panel.
To adjust appliance pressure;
The SIT gas valve, situated at rear RH side of unit and accessible by removing RH side, has
an in-built governor.
The supply pressure should be checked at valve inlet test nipple using a manometer.
Burner pressure should be set at test nipple on burner manifold using a manometer.
Checking / Setting values are indicated below (for either natural or propane gas).
This is achieved by removing brass dust screw from valve governor and adjusting governor
accordingly using an approved VDE insulated screwdriver - clockwise rotation increases pressure.
(see illustration) insulated
Warning: To avoid risk of electric shock, all adjustments to the governor
should be made with the appliance switched off and unplugged.
Note: Propane (I3P) appliances require governor to be adjusted clockwise to maximum
adjustment.

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Supply pressure
Burner pressure at manifold
Natural Gas (I2H)
20mbar
14mbar
Propane Gas (I3P)
37mbar
34mbar
The incoming service must be of sufficient size to supply full rate without excessive pressure drop.
A gas meter is connected to service pipe by gas supplier. Any existing meter should be checked
preferably by gas supplier to ensure that it is adequate to deal with rate of gas supply required.
Installation pipe work should be fitted in accordance with IGE/UP/2. The size of pipes from meter
to unit must not be less than that of appliance inlet connection.A3/4" BSP inlet connection is fitted
to unit.
An isolating valve must be located close to the appliance to facilitate shut down during an
emergency or routine servicing. The cock must be easily accessible to the user. The installation
must be testedfor gas soundness as stated in IGE/UP/1.
Domestic type, flexible rubber tube connections must NOT be used with this appliance.
OnlytubecomplyingwithBS669Part2, Specification for corrugated metallic flexible hoses
for catering appliances, shall be used. These hoses must be no longer than 1.5 Metres, and
should be periodically checked / replaced as necessary.
1.5 ELECTRICAL SUPPLY
The unit is equipped with a 3-core flexible cord with standard 3 pin plug fitted with a 13A fuse. A
regular 13A socket outlet can be used.
If supply is provided through a distribution fuse box, it must be via a fuse with a maximum rating
of 13A.
In the event of mains cable being replaced, any new cable should comply with 60245 IEC 57
designation. (H05RN - F)
THE APPLIANCE MUST BE EARTH BONDED.
Check that no damage has occurred to the appliance, power cable and plug face during
transit. If damage has occurred do not use the appliance.
Ensure that the mains power cable is routed free from the appliance to avoid damage.
We recommend supplementary electrical protection with the use of a type A residual
current device (RCD). Periodical testing, repair and fixing wiring connection should only
be undertaken by a skilled and competent electrician.

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This appliance is also provided with a terminal for connection of an
external equipotential conductor. This terminal is in effective
electrical contact with all fixed exposed metal parts of the appliance,
and shall allow the connection of a conductor having a normal cross-
sectional area of up to 10mm². It is located on the rear panel and is
identified by the following symbol and must only be used for bonding
purposes.
G3840/G3840X/G3840F/G3840FX
Rated Voltage
Rated Current
230V~
3.55amps
1.6 TOTAL RATED HEAT INPUTS
Appliance
KW
BTU/Hr (gross)
Pilot
G3840 / G3840X / G3840F / G3840FX
Nat (I2H)
21.5kW
80,700 btu/h
*0.29kw
*Ignites with main burners
G3840 / G3840X / G3840F / G3840FX
Prop (I3P)
22kW
82,600 btu/h
*0.26kw
*Ignites with main burners
1.7 INJECTOR SIZES
Appliance
Main Burners
Pilot
G3840 / G3840X / G3840F / G3840FX
Nat (I2H)
2 x Ø2.6mm
Polidoro G31.2
G3840 / G3840X / G3840F / G3840FX
Prop (I3P)
2 x Ø1.7mm
Polidoro G25
2.0 ASSEMBLY and COMMISSIONING
The gas supply piping and connection to appliance must be installed in accordance with the local
regulations in conjunction with those listed on the cover of this manual.
2.1 ASSEMBLY
a) Unpack appliance
b) Unpack fryer baskets and accessories.
c) Place basket support grid and basket in pan.
d) Level appliance and fit all service protection kits.
(Anti-tilt kit is supplied).
2.2 CONNECTION TO A GAS SUPPLY
Connect gas supply and test for gas soundness.
Caution
Ensure that pan contains an acceptable level of liquid before igniting burner.
Due to the presence of mains electrics, integral pipe work should be checked for
gas soundness using an appropriate gas leak detector.

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Caution
Installation engineers should note that for first time connection of appliance to
supply,it is essential that inlet gas supply to fryer is completely purged of air
prior to first lighting attempt. Otherwise, since this is a light pilot first every time
system, it will take a significant number of tries to light due to the small amount of
air bled from pipe by pilotat each attempt.This should not initially be treated as a
fault.
Please note that several attempts will still be required after air purge for first time
lighting. This is due to the capacity of valve and governor.
2.3 CONNECTION TO AN ELECTRICAL SUPPLY
Ensure flexible cable does not come into contact with any hot parts. The fuse rating should be
13A.
Colour coding of power supply cables is as follows:
Live - Brown, Neutral - Blue, Earth - Green/Yellow
2.4 STARTING UP
G3840/F
If you are in the fat melting cycle and loading solid fat for the first time, always remove basket support
plate as detailed in Section 9. Solid fat should be in direct contact with fryer pan.
Refer to Section 9.
G3840X/G3840FX
It is recommended that fat is pre-melted before pouring it in to the G3840X/G3840FX for the first time.
G3840/F Fryer Control Panel (See Figure 2)
Figure 2 –G3840 Control panel
1. ON/OFF and Temperature Control Knob
Temperature Selection (140 - 190°C). (Unit is off when control is in position indicated).
2. Fat Melt Position
Feature for slow pulsed heating of solid fats.
3. Power on indicator.
4. Heat Demand Indicator
Illuminates when thermostat demands heat, i.e. oil temperature is more than 5⁰C below
temperature setting. Extinguishes when desired temperature is reached.