Falcon G9440 Manual

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F900 SERIES
User, installation and servicing instructions
GAS CHARGRILL
G9440, G9460, G9490, G94120
Read these instructions before use
T100873
DATE PURCHASED:
MODEL NUMBER:
SERIAL NUMBER:
DEALER:
SERVICE PROVIDER:
REV. 4
Published: 23/08/2016

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Falcon Foodservice Equipment
HEAD OFFICE
Wallace View, Hillfoots Road, Stirling. FK9 5PY. Scotland.
WEEE Directive Registration No. WEE/DC0059TT/PRO
At end of appliance life, dispose of appliance and any replacement parts in a safe
manner, via a licensed waste handler. Appliances are designed to be dismantled
easily and recycling of all material is encouraged whenever practicable.
Dear Customer,
Thank you for choosing Falcon Foodservice Equipment.
This manual can be downloaded from www.falconfoodservice.com or scan
here.
IMPORTANT: Please keep this manual for future reference.

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SYMBOLS
• SPANNER • SCREWDRIVER • COOKING OIL • GREASE
• SPARK IGNITION • FLAME •WARNING • VIEWPORT
•ALLEN KEY •IGNITER

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These instructions are only valid if the country code appears on the
appliance. If the code does not appear on the appliance, refer to the
technical instructions for adapting the appliance to the conditions for use
in that country.
Installation must meet national or local regulations. Attention must be paid
to: gas safety (installation & use) regulations, health and safety at work act,
local and national building regulations, fire precautions act.
To prevent shocks, all appliances must be earthed.
This equipment is for professional use only and must be used by qualified
persons.
The installer must instruct the responsible person(s) of the correct
operation and maintenance of the appliance.
Only competent persons are allowed to service or convert the appliance to
another gas type.
Gas appliances must have a stop cock fitted in the supply pipe work. The
user must be familiar with the location and operation of this device in order
to turn off the supply of gas in the event of an emergency.
Unless otherwise stated, parts which have been protected by the
manufacturer must not be adjusted by the installer.
Take care when moving an appliance fitted with castors.
The appliance must be serviced regularly by a qualified person.
Service intervals should be agreed with the service provider.
This appliance may be discolored due to testing.

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CONTENTS
1.0 APPLIANCE INFORMATION .....................................................................................6
2.0 OPERATION..............................................................................................................7
2.1 COMPONENT PARTS............................................................................................7
2.2 CONTROLS............................................................................................................7
2.3 USING THE APPLIANCE........................................................................................8
3.0 CLEANING AND MAINTENANCE..............................................................................9
4.0 SPECIFICATION......................................................................................................10
5.0 DIMENSIONS / CONNECTION LOCATIONS...........................................................12
6.0 INSTALLATION........................................................................................................13
6.1 SITING / CLEARANCES.......................................................................................13
6.2 VENTILATION.......................................................................................................13
6.3 GAS SUPPLY & CONNECTION ...........................................................................14
6.4 ASSEMBLY...........................................................................................................15
6.5 COMMISSIONING ................................................................................................15
6.6 SUITING ...............................................................................................................16
7CONVERSION.............................................................................................................18
7.4 GAS CONVERSION CHECK LIST........................................................................18
8SERVICING.................................................................................................................19
8.1 BURNERS.............................................................................................................19
8.2 INJECTORS..........................................................................................................21
8.3 CONTROL PANEL................................................................................................22
8.4 PILOT ASSEMBLY................................................................................................22
8.5 GAS VALVE..........................................................................................................23
8.6 GOVERNOR.........................................................................................................24
9FAULT FINDING..........................................................................................................25
10 SPARE PARTS........................................................................................................26
11 SERVICE INFORMATION........................................................................................26

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1.0 APPLIANCE INFORMATION
This appliance has been CE-marked on the basis of compliance with the relevant EU
directives for the heat inputs, gas pressures and voltages stated on the data plate.
A - Serial No
B - Model No
C - Flue Type
D - Gas Category
E - Gas Pressure
F - Gas Type
G - Gas Rate
H - Total Heat Input
I - Electrical Rating
J - Total Electrical Power
K - Magnetic Field Frequency
L - Electrical Phase Loading

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2.0 OPERATION
2.1 COMPONENT PARTS
A –Scraper
B –Lifting Tool
C –Brander Bar
D –Burner Baffle
E –Splashguard
F –Burner
G –Control Knob
H –Spark Igniter
I –Drip Tray
J* –Deflector
K –Fat Jug
* Not required in G9440.
2.2 CONTROLS
A –Spark Igniter
B –Zone Indicator

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2.3 USING THE APPLIANCE
2.3.1 Before use, clean the appliance inside and out. See section 3.
2.3.2 Position burner baffles and brander bars correctly.
A - High position
B –Low position
C –Burner Baffle
D –Baffle support
E–Lightly oil bars
2.3.3 Fill about a 1/3 of the drip tray with water.
2.3.4 Ignite the burners as shown. Push the knob in to turn.

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THE DRIP TRAY DEFLECTORS MUST ALWAYS BE IN PLACE
WHEN THE CHARGRILL IS IN OPERATION.
IF A BURNER TURNS OFF, WAIT 3 MINUTES BEFORE RE-
LIGHTING.
2.3.5 Ensure water in drip tray does not dry up by topping up periodically.
2.3.6 TURNING THE BURNER OFF
Turn knob to ‘Off’ position. Look through the view port to make sure the burner is
off.
3.0 CLEANING AND MAINTENANCE
3.1 Turn off and cool down.
3.2 Remove brander bars.
3.3 Scrape off burnt on food.
3.4 Remove other debris using a cloth.
3.5 Dry and brush with vegetable oil.
3.6 Remove splashguard, burner baffles and fat jug and clean.
3.7 Wipe burners with a damp cloth.
3.8 Clean internal area occasionally with a chemical spray. Refer to product’s instructions
for use.
3.9 Remove drip tray and deflectors and clean.
3.10 Dry and replace all removed components.
DRIP TRAY DEFLECTORS MUST BE REPLACED AFTER
CLEANING.
THIS APPLIANCE MUST BE CLEANED BEFORE USE TO AVOID
RISK OF FIRE FROM OILS FROM PREVIOUS COOKING.
FAILURE DUE TO LACK OF PROPER CLEANING IS NOT COVERED BY
WARRANTY.

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4.0 SPECIFICATION
INJECTOR SIZES
Gas Type
G20
G30
G31
G9440
Ø2.5
Amal 310
Amal 310
G9460
Ø2.5
Amal 310
Amal 310
G9490
Ø2.5
Amal 300
Amal 300
G94120
Ø2.5
Amal 310
Amal 310
Pilot Injectors
31.2
25
25
Supply
Pressure
mbar
20
29/50
37
Operating
Pressure
mbar
15
29
37
HEAT INPUTS (kW)
G20
G30
G31
Full
Low
Full
Low
Full
Low
G9440
8.4
5.5
9
5.5
9
5.5
G9460
16.8
11.0
18
11.0
18
11.0
G9490
25.2
16.5
27
16.5
27
16.5
G94120
33.6
22.0
36
22.0
36
22.0

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5.0 DIMENSIONS / CONNECTION LOCATIONS
A –GAS INLET

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6.0 INSTALLATION
6.1 SITING / CLEARANCES
CAUTION: WALLS CLOSER THAN 150mm TO THE APPLIANCE
MUST BE NON COMBUSTABLE. IF SUITING THE NECESSARY
CLEARANCES TO ANY CUMBUSTIBLE WALL MUST BE THE
LARGEST FIGURE GIVEN FOR INDIVIDUAL APPLIANCES
INSTRUCTIONS.
6.2 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.
COMBUSTION AIR REQUIREMENTS
G9440
G9460
G9490
G94120
G20
7.5m3/h
15m3/h
22.5m3/h
30m3/h
G30
7.8m3/h
15.6m3/h
23.4m3/h
31.2m3/h
G31
7.8m3/h
15.6m3/h
23.4m3/h
31.2m3/h

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6.3 GAS SUPPLY & CONNECTION
6.3.1 Installation pipe work should be fitted in accordance with local / national standards.
The pipe work must not be smaller than unit gas inlet connection, i.e. Rp¾ (¾”
B.S.P.). If using flexible hosing, the hose must be sized to conform with the hose
manufacturers specifications and the length must not exceed 1.5m. An isolating valve
must be located close by for shut-down during an emergency or servicing.
6.3.2 If flexible hose is used, it shall comply with national requirements. These must be
periodically examined and replaced as necessary. If a retention chain is required
then attach this to the fixing shown below.
6.3.3 Supplied governor must be fitted to the rear of the appliance. (see 8.6)
6.3.4 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 conductor
having a nominal cross-section area of up to 10mm². It is located at the rear of the
unit and identified by the following label and must only be used for bonding purposes.

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6.4 ASSEMBLY
6.4.1 Position appliance and level using feet adjusters as shown below.
6.4.2 Connect appliance to gas supply and test for gas tightness (see 6.3)
6.5 COMMISSIONING
6.5.1 Remove brander bars and burner baffles.
6.5.2 Ensure burner pressure is correct (see 4.0 for operating pressures. See 8.6 for
governor adjustment)
6.5.3 Light all pilots and ensure all stay lit.
6.5.4 Turn on main burners. Ensure correct cross lighting occurs.
6.5.5 Check for flame stability.
6.5.6 Operate taps between ‘high’ and ‘low’ settings ensuring they operate correctly.
6.5.7 Turn off appliance.
6.5.8 Replace brander bars and burner baffles.
If the appliance does not operate correctly please refer to section 8.0 and rectify the
problem.
PLEASE FILL OUT THE INFORMATION TABLE ON THE FRONT
COVER AFTER COMMISSIONING.

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6.6 SUITING
“Patent pending, application no. GB 1511389.7”
6.6.1 Before leveling and suiting units ensure the units are fully built, including all
accessories and castings.
6.6.2 Undo the 4 fixing screws on the control panel and remove.
6.6.3 Remove the hob rear infill and replace with rear suiting plate and fixings.
6.6.4 Remove the front side panel countersunk screw and suiting plate.
NOTE: The DLS system is designed to give a quick and easy suiting solution. If
you require an improved seal between appliances we recommend you
use, a food grade, high temperature silicon sealant. This can be
supplied by Falcon part no –523400021
6.6.5 Run a bead of silicon 5mm from profile edge as highlighted below.

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6.6.6 Slide suited units into position.
6.6.7 Right hand unit: Screw the M5 x 40 screw (supplied in the kit) into one of the suiting
plates as shown and then insert through the front fixing holes of both units.
6.6.8 (B) Left hand unit: Slide the penny and lock washer on to the screw and secure using
the M5 nut.
6.6.9 (C) Remove the front bolts from feet, insert base tie plate and secure the bolts back
into position.
6.6.10 (D) Replace fixings on the rear hob and tighten screw caps into position.
6.6.11 Replace control panel. .
A
D
B
C

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7 CONVERSION
BEFORE INSPECTION, SERVICING OR CONVERSION, TURN OFF
GAS AT ISOLATOR AND REMOVE BRANDER BARS AND
BURNER BAFFLES.
7.4 GAS CONVERSION CHECK LIST
Change injectors in burner(s) and pilots(s) (see 8.2 & 8.4).
Adjust by-pass screw for LP by turning screw fully clockwise. To convert back to Ng,
ensure screw is turned fully clockwise and then turn screw two complete turns anti-
clockwise. (see 8.5). As a reference, the flame on turndown should be approximately
60% of that on high.
Change gas type label.
Adjust burner aeration shroud (see 8.1.4).
For G31, remove governor.
For G30, remove governor if supply pressure is 29mb or adjust governor if supply
pressure is higher than 29mb (see 8.6).

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8 SERVICING
8.1 BURNERS
8.1.1 Remove burners as shown.
8.1.2 Clean burners (see section 3).
8.1.3 Clean ports.

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8.1.4 For conversion, adjust aeration shroud as shown.