Falcon G2522 User manual

T100576 Ref. 3
G2522 GRILL
INSTALLATION and
SERVICING INSTRUCTIONS
These appliances ust be installed and serviced by a co petent person as stipulated by 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 An Safety At Work etc. Act
Local an National Buil ing Regulations
Fire Precautions Act
These appliances have been CE- arked on the basis of co pliance 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 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 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.
WEEE Directive Registration No. WEE/DC0059TT/PRO
At end of unit life, dispose of appliance and any replace ent parts in a safe anner,
via a licenced waste handler.
Units are designed to be dis antled easily and recycling of all aterial is
encouraged whenever practicable.
Detaile recommen ations are containe in
Institute of Gas Engineers publishe
ocuments :
IGE/ UP/ 1, IGE/ UP/ 2
BS6173 an BS5440
Falcon Foo service Equipment
HEAD OFFICE AND WORKS
Wallace View, Hillfoots Road, Stirling. FK9 5PY. Scotland.
SERVICELINE CONTACT -
PHONE - 01438 363 000 FAX - 01438 369 900

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 co ission visits.
Replace ent of any parts where da age has been caused by isuse.
Engineer waiting ti e will be chargeable.
Routine aintenance 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 aintained.
Blocked drains.
Independent stea generation syste s.
Gas, water and electrical supply external to unit.
Light bulbs.
Re-installing vacuu in kettle jackets.
Replace ent of grill burner cera ics when da age has been clearly caused by isuse.
Where an engineer finds no fault with a product that has been reported faulty.
Re-setting or adjust ent of ther ostats when unit is operating to specification.
Cleaning and unblocking of fryer filter syste s due to custo er isuse.
Lubrication and adjust ent of door catches.
Cleaning and Maintenance
Cleaning of burner jets
Poor co bustion caused by lack of cleaning
Lubrication of oving parts
Lubrication of gas cocks
Cleaning/adjust ent of pilots
Correction of gas pressure to appliance.
Renewing of electric cable ends.
Replace ent of fuses
Corrosion caused by use of che ical cleaners.

SECTION 1 - INSTALLATION
The grill ay be ounted on any of the following
options -
Bench legs, floor stan or wall bracket.
1.2 SITING
There ust be 150 clearance all around the grill
fro any co bustible wall or object liable to da age
when overheated.
There ust be a ini u vertical clearance of
900 above the top edge of the flue to ensure no
overheating of overlying co bustible surfaces.
A ini u clearance of 400 fro the sides
should be provided to allow re oval of outer panels
for service access. Methods of ounting the unit are
available as detailed in Section 1.1. No grill should be
ounted directly upon a table.
Note
Upper sections of the unit are likely to beco e very
hot. It should therefore be positioned in a anner
which ini ises the risk of accidental touching.
1.3 VENTILATION
The grill MUST be installed level in a well lit and
draught free position. Adequate ventilation, whether
natural or echanical, ust be provided to ensure
sufficient air for co bustion and 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 ventilation air required for
different types of catering equip ent is provided in
the following table.
For ultiple installations, require ents for individual
appliances should be added together.
Installation should be ade in accordance with local
and/or national regulations applying at the ti e.
The flue discharges vertically fro the top of the unit.
There ust be no direct connection of the flue to a
echanical extraction syste or the outside air.
Positioning the grill below a ventilated canopy is the
ost suitable arrange ent.
Warning
Re e ber, dirty extraction filters and drip trays
beco e co bustible, hence the i portance of
adhering to the specified flue clearance distance to
these ite s. Regular cleaning of extraction filters and
drip trays ust be carried out.
1.4 GAS SUPPLY
The inco ing service ust be of sufficient size to
supply the full rate without excessive pressure drop.
A gas eter is connected to the service pipe by the
Gas Supplier.
An existing eter should be checked, preferably by
the Gas Supplier, to ensure that it is adequate to cope
with the rate of gas supply required. Installation pipes
should be fitted in accordance with IGE/UP/2.
The pipework size, fro the eter to the unit, ust
not be less than the appliance inlet connection, Rp
1
/
2
(
1
/
2
" BSP).
An isolating cock ust be located close to the
appliance (on the inlet side of the governor on Natural
Gas odels) to allow shut down during an e ergency
or routine service.
The installation MUST BE TESTED FOR GAS
SOUNDNESS, details of which can be found in
IGE/UP/1.
1.5 ELECTRICAL SUPPLY
Not applicable to this appliance.
1.6 WATER SUPPLY
Not applicable to this appliance.
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) GAS CONN.
G2522 900 585 505 74 Rp
1
/
2
1.1 MODEL NUMBERS, NETT WEIGHTS
an DIMENSIONS

Model kW Btu/hr
G2522 13.2 45,000
Model Plaques CENTRE
SUPPORT END SUPPORT X-LIGHTING BURNER
G2502 4 - 4 -
G2512 8 3 4 1
G2522 12 6 4 2
G2532 6 4 4 -
Model Main Burners X-lightingBurners Pilot Burner
G2522 3 x A al 380 2 x A al 20 SIT No. 30
Model Main Burners X-lightingBurners Pilot Burner
G2522 3 x A al 140 2 x A al 10 SIT No. 19
Gas Type bar inches w.g.
Natural 15 6
Propane 37 14.8
Support
angle Support angle
Plaque
Plaque
Plaque Plaque
Centre
support
Burner
Burner Burner
Plaque
LH Support
bar
LH Support
bar
RH Support
bar
1.7 HEAT INPUTS -
Natural an Propane Gas
1.8 INJECTOR DIAMETERS -
Natural Gas
Propane Gas
1.9 SETTING PRESSURE
A spring loaded governor, supplied with the appliance
MUST BE FITTED to natural gas odels.
No governor is required on propane odels.
A pressure test point is accessible upon re oval of
the control panel.
1.10 BURNER ADJUSTMENT
Burner Aeration
The burners are fitted with fixed injectors. Aeration is
adjustable by eans of a screw, positioned at the
burner inlet.
After setting pressure, the stability of the fla e cones
should be checked. If necessary, the aeration screw
should be adjusted to achieve satisfactory cross
lighting of burners on both HIGH and LOW settings.
This will also prevent yellow tipping of the fla e or
lift-off.
SECTION 2 - ASSEMBLY an
COMMISSIONING
2.1 ASSEMBLY
2.1.1 Grill Unit
Unpack grill and check that all co ponents are
unda aged. Parts supplied loose are specified in
the contents list below
Bran er Drip Trough Bran er Plate
Gri Shelf Drip Tray
Gas Governor (Natural Gas only)
Additionally, the necessary plaques, supports and
cross-lighting burners are supplied as follows:-
2.1.2 Appliance Mounting Accessories
Details of various ounting options can be obtained
by contacting Falcon Sales, distributor or place of
purchase.
Refer to the individual instructions supplied with the
individual eans of ounting.
Adherence to positioning clearances indicated in
Section 1.2 of this anual is andatory.
2.1.3 Assembly of Support Bars an Plaques
a) When tunit has been installed in desired location,
the centre support bars can be positioned between
the burner lugs. Si ilarly LH and RH plaque
supports are located between burner lugs and
support angle. See Figure 1 below.
b) With support bars in position, plaques ay be
inserted by placing these upon bars as illustrated
below.
Figure 1

2.2 CONNECTION TO THE GAS SUPPLY
Installation should be carried out in accordance with
the various regulations listed on the cover of this
docu ent.
On NATURAL gas appliances, the adjustable
governor supplied, MUST be fitted to gas circuit and
securely fixed in a position that enables adjust ent to
be carried out during co issioning.
PROPANE appliances do not require a governor.
Ensure that a gas Isolating cock is fitted to the supply
in convenient proxi ity to the grill.
2.3 CONNECTION TO AN ELECTRICAL SUPPLY
Not applicable to this appliance.
2.4 CONNECTION TO A WATER SUPPLY
Not applicable to this appliance.
2.5 COMMISSIONING
2.5.1 Testing an Purging
Pressure test installation for gas soundness and
purge any air fro the supply.
2.5.2 Gas Pressure an Burner Flame A justment
a) Re ove RH Side Panel.
b) Fit a pressure gauge to test point and light grill.
c) With burner at Full Fla e position, setting pressure
should be as detailed in Section 1.9. On Natural
gas odels, adjust governor as required.
d) With gas control in the Full Fla e position, check
the fla e cone is approxi ately 30 in length.
If necessary, adjust by eans of the aeration
screw in burner throat. Tighten locknut when
co plete. (Refer to Section 1.10)
e) Check all burner parts cross light satisfactorily.
f) Turn control to Low Fla e position and check that
fla e cone reduces in length.
Note
LOW FLAME position is set at factory. Re-setting is
NOT necessary.
2.5.3 Soun ness Checking an Re-assembly
Whilst grill is lit, test all integral gas carrying joints and
co ponents for gas soundness. Use a suitable leak
detection fluid (i.e. Soap Solution).
TURN OFF gas control tap. REMOVE pressure
gauge and replace test point sealing screw.
ENSURE THAT A GAS TIGHT JOINT IS MADE.
Re-asse ble all panels and co ponents re oved
during installation and co issioning. The drip tray,
wire grid and brander can then be placed in position.
2.6 INSTRUCTION TO USER
Hand over User anual. Ensure user understands
the procedures for lighting, cleaning and correct use
of appliance. Point out the location of the isolating
cock which ay require to be shut down in event of
an e ergency.
SECTION 3 - SERVICING an
CONVERSION
Important
Before carrying out any inspection, servicing or
exchange of co ponents, turn OFF the gas at the
isolating cock and take steps to ensure that it is not
inadvertently turned on. Always re ove the brander
and grid shelf.
After any aintenance task, check the appliance to
ensure that it perfor s correctly and carry out any
necessary adjust ents 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
To convert from NATURAL to PROPANE gas -
Change injectors
Re ove governor and adjust inlet pressure
accordingly
Adjust aeration
Change data plate
To convert from PROPANE to NATURAL gas -
Change injectors
Connect governor and adjust inlet pressure
accordingly
Adjust aeration
Change data plate
3.2 REMOVAL of PLAQUES an BURNERS
3.2.1 Plaques Only
a) Re ove drip tray, grid shelf and brander.
b) Plaques ay be replaced by reaching inside
co part ent top and placing your fingers on
plaque face. Push plaque up carefully to dislodge
it fro seating between bars and support angle.
c) Carefully replace plaque so that it is properly
seated on bar and support angle. The plaque
should be positioned hard against the burner.
3.2.2 Burners
a) Undo botto fixings fro LH outer side panel.
Re ove botto and side fixings fro outer back
and lift clear.
b) Re ove upper inner rear panel above burners by
undoing two fixings and lift it clear.
c) Reach inside top of co part ent and re ove
plaques and support bars.
d) The burner(s) without pilot bracket ay now be
re oved fro injector seating.
e) To re ove burner with pilot, refer to Section 3.2.2 ,
d) to e).
f) The burner is exposed and ay be lifted fro
injector seating.

Description Part No.
Plaque (single) 531600010
Ther ocouple 531600030
Pilot burner body 531600050
Pilot orifice (Natural Gas) 531600070
Pilot orifice (Propane Gas) 531600075
Governor 535900001
Gas control 537560020
Knob for gas control 535900000
Disc for grid shelf handle 531600410
Handle for grid shelf 531600420
Grid shelf 531620130
Brander plate 531620110
Burner 531600230
Injector (Natural gas) 531600220
Injector (Propane gas) 531600225
X-lighting burner 531610150
X-lighting injector (Natural) 531610140
X-lighting injector (Propane) 531610145
Drip trough 531630140
Brick support - centre 531550130
Brick support - end 531540120
3.3 REMOVAL OF INJECTOR
Following re oval of burner, the injector ay be
cleaned or replaced as desired. See Section 1.8 for
injector di ension details.
3.4 BURNER an INJECTOR CLEANING
Burners require to be cleaned periodically to ensure
that ports are free fro blockage. This ay be
facilitated by eans of wire brushing. Individual ports
ay be cleared with a suitable etal instru ent.
Dislodged aterial should then be shaken out of
open burner end.
Should it beco e necessary to wash the burner(s),
ensure that they are co pletely dry and free fro
cleaning aterials before re-fitting to the appliance.
The injectors also require regular inspection and ay
be cleaned with a wooden splinter or fuse wire.
Hard etal i pli ents MAY DAMAGE THE ORIFICE
and MUST NOT be used.
Upon re-fitting, check adjust ent and fla e picture
as described in Section 2.5.2.
3.5 FLAME FAILURE THERMOCOUPLE
a) Re ove RH outer side panel.
b) Undo nut that secures ther ocouple to SIT pilot
bracket using a 10 spanner.
c) Undo nut that secures ther ocouple to gas tap.
d) Withdraw faulty ther ocouple and replace.
3.6 GAS VALVE
3.6.1 To Remove
Proceed as follows -
a) Pull off control knobs and re ove front facia panel.
b) Undo nut that secures burner feed pipe to control.
c) Release pilot tubing nut fro control and ease pilot
tube clear of location.
d) Re ove fixings that secure control to gas pipe.
e)Manoeuvre control to enable re oval of
ther ocouple.
f) Withdraw control.
3.6.2 To Re-grease Control Tap
a) Re ove fixings that retain front securing plate
while holding plate against internal spring
pressure.
b) Carefully withdraw plate, co plete with operating
spindle.
c) Withdraw exposed rod, spring, brass washer, and
sealing washer, taking care not to lose any parts.
d) Withdraw plug and clean with a soft rag and also
clean ating surfaces in control body. Sparingly
re-grease plug with an approved heat-resistant
grease.
Re-asse ble in reverse order taking care with the
central pin asse bly. Fit spring to pin first, then brass
washer and finally sealing washer.
Ensure sealing washer fits snugly into recess at base
of plug. When re-fitting operating spindle, ensure
niting pin engages in plug slot.
3.7 GOVERNOR
3.7.1 General
The governor will nor ally require little servicing.
Before proceeding with any inspection or servicing,
TURN OFF THE GAS AT ISOLATING COCK.
3.7.2 Proce ure
Check and if necessary, clear air breather hole of any
blockage. Ensure valve and seating are clean and
that diaphrag is in good condition.
ALWAYS RE-CHECK GAS PRESSURE at test point
after servicing governor.
SECTION 4 - SPARES
When ordering spare parts, ALWAYS quote
appliance TYPE and SERIAL No. This infor ation
can be found on the data badge. A list of ite s
available, together with codes, is as follows -