Falcon G1532 User guide

RZZ 84 Ref. 2
G1532 STEAKHOUSE GRILL
INSTALLATION and
SERVICING INSTRUCTIONS
These Appliances must be installed and ser iced by a competent person as stipulated by the Gas
Safety (Installation & Use) Regulations.
IMPORTANT
The installer must ensure that the installati n f the appliance is in c nf rmity with these instructi ns and
Nati nal Regulati ns in f rce at the time f installati n. Particular attenti n MUST be paid t -
Gas Safety (Installation & Use) Regulations
Health And Safety At Work etc. Act
Local and National Building Regulations
Fire Precautions Act
These Appliances have been CE-marked n the basis f c mpliance with the Gas Appliance Directive f r the
C untries, Gas Types and Pressures as stated n the Data Plate.
WARNING - TO PREVENT SHOCKS, ALL APPLIANCES WHETHER
GAS OR ELECTRIC, MUST BE EARTHED
On c mpleti n f the installati n, these instructi ns sh uld be left with the Engineer-in-Charge f r reference
during servicing. Further t this, The Users Instructi ns sh uld be handed ver t the User, having had a
dem nstrati n f the perati n and cleaning f 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 rder t btain maximum perf rmance fr m this unit we w uld rec mmend that a Maintenance C ntract be
arranged with FALCON SERVICE LINE. Visits may then be made at agreed intervals t carry ut adjustments
and repairs. A qu tati n will be given up n request t the FALCON SERVICE LINE c ntact numbers bel w.
Falcon Foodser ice Equipment
HEAD OFFICE AND WORKS
PO B x 37, F undry L an, Larbert.
Stirlingshire. Sc tland. FK5 4PL
AFE SERVICE LINE CONTACT -
PHONE - 01438 751111 FAX - 01438 369900
Detailed recommendations are contained in
Institute of Gas Engineers published
documents :
IGE/ UP/ 1, IGE/ UP/ 2, BS6173 and BS5440
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GAS RATE
kW Btu/hr
6.65 22,600
SECTION 1 - INSTALLATION
The grill may be m unted n any f the f ll wing
pti ns -
Bench Legs.
Floor Stand
Wall Bracket
1.2 SITING
There must be 150mm clearance all r und the
appliance fr m any c mbustible wall r bject liable
t damage when verheated.
There must be a minimum vertical clearance f
900mm ab ve the t p edge f the grill flue t ensure
N verheating f verlying surfaces.
A minimum clearance f 400mm fr m the sides
sh uld be pr vided t all w rem val f uter panels
f r service access.
Note
The upper secti ns f the unit are likely t bec me
very h t. It sh uld theref re be p siti ned in a
manner which minimises the risk f accidental
t uching.
1.3 VENTILATION
The grill MUST be installed level in a well lit and
draught free p siti n. Adequate ventilati n, whether
natural r mechanical, must be pr vided t ensure
sufficient air f r c mbusti n and rem val f c m-
busti n pr ducts, which may be harmful t health.
Rec mmendati ns f r Ventilati n f Catering Ap-
pliances are given in BS5440:2.
Furtherm re, t ensure sufficient r m ventilati n,
guidance n the v lume f ventilati n air required f r
different types f catering equipment is pr vided in
the f ll wing table.
F r multiple installati ns, requirements f r individual
appliances sh uld be added t gether.
Installati n sh uld be made in acc rdance with l cal
and/ r nati nal regulati ns applying at the time.
The grill flue discharges vertically fr m the t p f the
unit.
There must be n direct c nnecti n f the flue t a
mechanical extracti n system r the utside air.
P siti ning the grill bel w a ventilated can py is the
m st suitable arrangement.
1.4 GAS SUPPLY
The inc ming service must be f sufficient size t
supply the full rate with ut excessive pressure dr p.
A gas meter is c nnected t the service pipe by the
Gas Supplier.
An existing meter sh uld be checked, preferably by
the Gas Supplier, t ensure that it is adequate t c pe
with the rate f gas supply required. Installati n pipes
sh uld be fitted in acc rdance with IGE/UP/2.
The pipew rk size, fr m the meter t the unit, must
n t be less than the appliance inlet c nnecti n, Rp
1
/
4
(
1
/
4
" BSP).
An is lating c ck must be l cated cl se t the
appliance ( n the inlet side f the g vern r n Natural
Gas m dels) t all w shut d wn during an emergency
r r utine service.
The installati n MUST BE TESTED FOR GAS
SOUNDNESS, details f which can be f und in
IGE/UP/1.
1.5 ELECTRICAL SUPPLY
N t applicable t this appliance.
1.6 WATER SUPPLY
N t applicable t this appliance.
1.7 HEAT INPUTS -
NATURAL and PROPANE GAS
EQUIPMENT
Ventilati n Rate Required
m
3
/ min ft
3
/min
Range, Unit Type 17 600
Pastry Oven 17 600
Fryer 26 900
Grill 17 600
Steak Grill 26 900
B iling Pan 17 600
Steamer 17 600
Sterilizing Sink 14 500
Bains Marie 11 400
Tea/ C ffee 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
(mm) DEPTH (mm) HEIGHT (mm) WEIGHT (kg) GAS CONN.
G1532 784 330 350 36 Rp
1
/
2
1.1 MODEL NUMBERS, NETT WEIGHTS
and DIMENSIONS
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mbar inches w.g.
NATURAL 15 6
PROPANE 37 14.8
NATURAL PROPANE
Main Burner 2.05mm Amal 210
Pil t Burner SIT N .30 SIT N .19
1.8 INJECTOR DIAMETERS -
Natural and Propane Gas
1.9 SETTING PRESSURE
A spring l aded g vern r, supplied with the appliance
MUST BE FITTED t natural gas m dels.
N g vern r is required n pr pane m dels.
A pressure test p int is accessible up n rem val f
the c ntr l panel.
1.10 BURNER ADJUSTMENT
Burner Aeration
The burners are fitted with fixed inject rs. The
aerati n is adjustable by means f a screw which
is p siti ned at the burner inlet.
After setting the pressure, the stability f the c nes
sh uld be checked. If necessary, the aerati n screw
sh uld be adjusted t achieve satisfact ry cr ss
lighting f the burners n b th HIGH and LOW
settings. This will als prevent yell w tipping f the
flame r lift- ff.
SECTION 2 - ASSEMBLY and
COMMISSIONING
2.1 ASSEMBLY
2.1.1 Grill Unit
Unpack the grill and check that all c mp nents are
undamaged. Parts supplied l se are specified in the
c ntents list bel w
Brander Drip Trough
Brander Plate
Grid Shelf
Drip Tray
Gas Go ernor (Natural Gas only)
Additi nally, 6 refract ry plaques, 4 centre supp rt
bars f d uble c nstructi n and 4 end supp rt bars.
Appliance Mounting Accessories
Details f the vari us grill m unting pti ns are
detailed in secti n 1.1.
Indi idual Check Lists for Mounting Options
Bench Legs
Pack c ntains -
4 legs and screw pack in p lythene bag.
2.1.2 Bench Legs Assembly
Bench legs when supplied, must be fitted t the
underside f the grill using the screws and washers
pr vided (see Figure 1). It is rec mmended that the
legs be fitted at the start f assembly and that the
perati n is facilitated by placing the grill n its back.
Each f t is secureded by tw fixings. Use H les 1
and 3 as indicated in each sketch.
The leg l cating brackets are then secured t the
w rkt p surface using w dscrews r b lts as
appr priate. The fixing h le centres are indicated in
the diagram ab ve. The brackets sh uld be r tated t
ensure that the threaded h le c rresp nds with the
side fixing h le in each leg.
The grill is then lifted int the brackets up inside the
tubular legs. Each leg is then secured t a respective
bracket using the fixings pr vided.
Figure 1
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Floor Stand
Cart n c ntains
2.1.3 Floor Stand Assembly Instructions
a) Lay the tw end supp rts (A & D) n their backs n
the fl r. Slip the b tt m shelf (E) ver the cr ss
bars and secure thr ugh the side flanges int the
h les in the cr ss bar.
b) Slip the shelf (C) between the vertical tubes and
secure thr ugh the flanges int the h les in the
inside f the tubes.
c) Raise the partly assembled stand n t its feet and
fr m the rear, place the tw back skirts (B)
between the rear using the nuts and b lts pr vided.
d) Lift the grill and p siti n it carefully n t p f the
assembled stand. Secure in p siti n thr ugh the
tw h les in the centre f the upper panel (F).
Wall Bracket
Cart n c ntains -
Figure 3
The installer must make
sure that the wall n
which the grill is t be
m unted is suitable t
carry the unit weight and
can be suitably plugged
t take N . 8
w dscrews f a
minimum length.
Using the shelf as a
template, h ld it against
the wall at the required
height. Whilst
maintaining the t p
surface h riz ntal, mark
fixing screw p siti ns.
Rem ve the shelf and
drill the wall t
acc m date suitable
plugs f r N . 8 screws.
Firmly secure the shelf in
p siti n.
Place the grill n the
shelf and place screws
thr ugh h les numbered
6 t c rresp nding h les
in the frame f the grill.
2.1.5 Assembly of Support Bars and Plaques
a) Rem ve the enamelled facia by und ing the fixings
which secure it at the b tt m edge. Ease the panel
f rward at the b tt m and lift it clear f the hidden
l cati n screws.
b) Rem ve the t p panel by und ing the tw fixings at
the rear and slide the panel backward, clear f the
fr nt l cati n.
c) Rem ve the inner t p panel t exp se the burners.
d) Place the cast ir n supp rt bars between the
burner and the fr nt and rear l cating sl ts. Insert
the bars with the lugs facing upwards. This will
enable the plaques t be held in p siti n against
the burner, see Figure 4.
A - LH Supp rt (1 ff)
B - Back Skirt (2 ff)
C - T p Shelf (1 ff)
D - RH Supp rt (1 ff)
E - B tt m Shelf (1 ff)
F - Upper Panel (1 ff)
G - Adjustable Feet (4 ff)
and the f ll wing fixings - M5 x 10mm Hex Screws (22 ff), M5 Hex Nuts (4 ff)
and M5 Shakepr f Washers (18 ff)
Figure 2
Bracket and screwpack.
Note - Rawlplugs and woodscrews are NOT
supplied
2.1.4 Wall Bracket Mounting Instructions
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Figure 4
e) Carefully place the plaques n their supp rt bars
with the pips p inting d wnward. Ensure they are
pr perly l cated and that they lay flat n the bars.
f) Replace the inner t p panel and ensure that it is
pr perly p siti ned and l cated ver the cast ir n
c mpartment sides.
g) Replace the uter t p panel.
2.2 CONNECTION TO THE GAS SUPPLY
Installati n sh uld be carried ut in acc rdance with
the vari us regulati ns listed n the c ver f this
d cument.
On NATURAL gas appliances, the adjustable
g vern r supplied, MUST be fitted t the gas circuit
and securely fixed in a p siti n which enables
adjustment t be carried ut during c mmissi ning.
PROPANE appliances d n t require a g vern r.
Ensure that a gas Is lating c ck is fitted t the supply
at a c nvenient pr ximity t the grill.
2.3 CONNECTION TO AN ELECTRICAL SUPPLY
N t applicable t this appliance.
2.4 CONNECTION TO A WATER SUPPLY
N t applicable t this appliance.
2.5 COMMISSIONING
2.5.1 Testing and Purging
Pressure test the gas installati n f r s undness and
purge any air fr m the supply.
2.5.2 Gas Pressure and Burner Flame Adjustment
a) Rem ve the RH Side Panel.
b) Fit a suitable pressure gauge t the test p int and
light the grill.
c) On NATURAL gas appliances, with the burner at
the FULL FLAME p siti n, the setting pressure
sh uld be 15mbar (6 inches w.g.). Adjust the
g vern r as required.
d) With the gas c ntr l in the FULL FLAME p siti n,
check that the flame c ne is appr ximately 30mm
in length. If necessary, adjust by means f the
aerati n screw in the burner thr at. Tighten the
l cknut when c mplete.
e) Check that all burner parts CROSS LIGHT
satisfact rily.
f) Turn the c ntr l t the LOW FLAME p siti n and
check that the flame c ne reduces in length.
Note
LOW FLAME p siti n is set at fact ry. Re-setting is
NOT necessary.
2.5.3 Soundness Checking and Re-assembly
Whilst the grill is lit, test all integral gas carrying j ints
and c mp nents f r s undness. Use a suitable leak
detecti n fluid (i.e. S ap S luti n).
TURN OFF the gas c ntr l tap. REMOVE the
pressure gauge and replace the test p int sealing
screw.
ENSURE THAT A GAS TIGHT JOINT IS MADE.
Re-assemble all panels and c mp nents rem ved
during the installati n and c mmissi ning. The drip
tray, wire grid and brander can then be placed in
p siti n.
2.6 INSTRUCTION TO USER
Hand ver the Users Instructi n manual. Ensure that
the user understands the pr cedures f r lighting,
cleaning and c rrect use f appliance. P int ut the
l cati n f the is lating c ck which may require t be
shut d wn in event f an emergency.
SECTION 3 - SERVICING and
CONVERSION
Important
Bef re carrying ut any inspecti n, servicing r
exchange f c mp nents, turn OFF the gas at the
is lating c ck and take steps t ensure that it is n t
inadvertently turned n. Always rem ve the brander
and grid shelf.
After any maintenance task, check the appliance t
ensure that it perf rms c rrectly and carry ut any
necessary adjustments as detailed in Secti n 1.
After carrying ut any servicing r exchange f gas
carrying c mp nents -
ALWAYS CHECK FOR GAS SOUNDNESS!
3.1 GAS CONVERSION CHECK LIST
To con ert from NATURAL to PROPANE gas -
Change inject rs
Rem ve the g vern r and adjust the inlet pressure
acc rdingly
Adjust aerati n
Change Data Plate
To con ert from PROPANE to NATURAL gas -
Change inject rs
C nnect a g vern r and adjust the inlet pressure
acc rdingly
Adjust aerati n
Change Data Plate
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3.2 REMOVAL OF PANELS
a) Rem ve the enamelled fr nt facia by und ing the
fixings which secure it at the b tt m edge. Ease
the panel f rward at the b tt m and lift it clear f
the hidden l cati n screws.
b) Rem ve the t p panel by und ing ut the fixings at
the rear and slide the panel backward clear f the
fr nt l cati n.
c) Rem ve the inner t p panel t exp se the burners.
d) Rem ve the side and rear panels by und ing the
appr priate fixings.
3.3 REMOVAL of PLAQUES and BURNERS
3.3.1 Plaques Only
a) Rem ve the drip tray, grid shelf and brander and
als the uter panels as detailed in Secti n 3.2.
b) Plaques may be replaced by reaching inside the
t p f the grill c mpartment and placing y ur
fingers n the plaque face. Push the plaque up
carefully t disl dge it fr m the seating between
the bars and the supp rt angle.
c) Carefully replace the plaque s that it is pr perly
seated n the bar and supp rt angle. The plaque
sh uld be p siti ned hard against the burner.
3.3.2 Burner
a) Rem ve the fixings at the rear and b tt m f the
RH uter side panel and lift clear.
b) Rem ve the supp rt bars and plaques. Place
these in a safe l cati n until servicing is c mplete.
c) Und the nut which secures the pil t pipe t the
c ntr l tap and rem ve the pipe.
d) Und the nut which secures the therm c uple t
the c ntr l and rem ve the therm c uple.
e) Rem ve the igniter lead fr m the Piez igniter. Lift
the burner ab ve the inject r and withdraw.
f) The pil t may n w be rem ved fr m the burner by
und ing the fixings which secure it.
3.4 REMOVAL OF INJECTOR
F ll wing rem val f the burner, the inject r may be
cleaned r replaced as desired. See Secti n 1.8 f r
inject r dimensi n details.
3.5 BURNER and INJECTOR CLEANING
Burners require t be cleaned peri dically t ensure
that the p rts are free fr m bl ckage. This may be
facilitated by means f wire brushing. Individual p rts
may be cleared with a suitable metal instrument.
Disl dged material sh uld then be shaken ut f the
pen burner end.
Sh uld it bec me necessary t wash the burner(s),
ensure that they are c mpletely dry and free fr m
cleaning materials bef re re-fitting t the appliance.
The inject rs als require regular inspecti n and may
be cleaned with a w den splinter r fuse wire. Hard
metal impliments MAY DAMAGE THE ORIFICE and
MUST NOT be used.
Up n re-fitting, check adjustment and flame picture
as described in Secti n 2.5.2 f this d cument.
3.6 FLAME FAILURE THERMOCOUPLE
a) Rem ve the RH uter side panel.
b) Und the nut which secures the therm c uple t
the SIT pil t bracket using a 10mm spanner.
c) Und the nut which secures the therm c uple t
the gas tap.
d) Withdraw the faulty therm c uple and replace.
3.7 GAS VALVE
3.7.1 To Remo e
Pr ceed as f ll ws -
a) Pull ff the c ntr l kn bs and rem ve the fr nt
facia panel.
b) Und the nut whic secures the burner feed pipe t
the c ntr l.
c) Release the pil t tubing nut fr m the c ntr l and
ease the pil t tube clear f it's l cati n.
d) Rem ve the fixings which secure the c ntr l t the
gas pipe.
e) Man euvre the c ntr l t enable rem val f the
therm c uple.
f ) Withdraw the c ntr l.
3.7.2 To Re-grease The Control Tap
a) Rem ve the fixings which retain the fr nt securing
plate whilst h lding the plate against the internal
spring pressure.
b) Carefully withdraw the plate, c mplete with
perating spindle.
c) Withdraw the exp sed r d, spring, brass washer,
and sealing washer, taking care n t t l se any
parts.
d) Withdraw the plug and clean with a s ft rag and
als clean the mating surfaces in the c ntr l b dy.
Sparingly re-grease the plug with an appr ved
heat resistant grease.
Re-assemble in reverse rder taking care with the
central pin assembly. Fit the spring t the pin first,
then the brass washer and finally the sealing washer.
Ensure that the sealing washer fits snugly int the
recess at the base f the plug. When re-fitting the
perating spindle, ensure that the niting pin engages
in the plug sl t.
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Spares N . Descripti n
531600010 Plaque (single)
531600040 Therm c uple
531600050 Pil t Burner B dy
531600070 Pil t Orifice (Natural Gas)
531600075 Pil t Orifice (Pr pane Gas)
531600110 G vern r
531600140 Gas C ntr l
531600150 Kn b f r Gas C ntr l
531600410 Disc f r Grid Shelf Handle
531600420 Handle f r Grid Shelf
531630010 Inject r (Natural Gas)
531630015 Inject r (Pr pane Gas)
531630110 Grid Shelf
531630120 Brander Plate
531630190 Burner (with Pil t)
3.8 GOVERNOR
3.8.1 General
The g vern r will n rmally require little servicing.
Bef re pr ceeding with any inspecti n r servicing,
TURN OFF THE GAS AT THE ISOLATING COCK.
3.8.2 Procedure
Check and if necessary, clear the air breather h le f
any bl ckage. Ensure that the valve and seating are
clean and that the diaphragm is in g d c nditi n.
ALWAYS RE-CHECK THE GAS PRESSURE at the
Test P int after servicing the g vern r.
SECTION 4 - SPARES
When rdering spare parts, ALWAYS qu te the
appliance TYPE and SERIAL N . This inf rmati n
may be f und n the data badge. A list f items
available, t gether with c des, is as f ll ws -
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