Falcon g3478 User guide

G3478 Steaming Oven
INSTALLATION and
SERVICING INSTRUCTIONS
This appliance 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
Health and Safety at Work etc. Act
Local and National Building Regulations
Fire Precautions Act
National Water Regulations
Detailed recommendations are contained in
Institute of Gas Engineers published documents:
IGE/UP1,IGE/UP/2
BS6173, BS5440 and EN1717
These appliances have been UKCA/CE-marked based on compliance with the GasAppliance Regulations/Product
Safety and Metrology Regulations 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 completion 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 demonstration 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
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.
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 licenced waste handler.
Appliances are designed to be dismantled easily and recycling
of all material is encouraged, whenever practicable.
Falcon Foodservice Equipment
HEAD OFFICE AND WORKS
Wallace View, Hillfoots Road, Stirling, FK9 5PY, Scotland
Phone: [phone]
T100789 Ref.7

SECTION 1 - INSTALLATION
UNLESS OTHERWISE STATED, PARTS WHICH HAVE BEEN PROTECTED BY THE MANUFACTURER
ARE NOT TO BE ADJUSTED BY THE INSTALLER.
1.1 MODEL NUMBERS, NETT WEIGHTS andDIMENSIONS
Model
Width
(mm)
Depth
(mm)
Height
(mm)
Weight
(kg)
G3478
Steaming Oven
600
840
1625
96
1.2 SITING
The appliancemust be installed upon a firm, level floor in a well lit position. It requires to be secured to this surface.
The oven MUST be positioned 150mm away from a combustible wall.
Important
If the appliance is to be installed in suite formation with other matching appliances of the DOMINATOR PLUS
Series, the instructions for all appliances must be consulted to determine the necessary clearance to any
combustible rear wall or overlying surface. Some appliances require greater clearance than others, and the
largest figure quoted in the individual instructions will therefore determine the clearance for the complete
suite of adjoining appliances.
1.3 VENTILATION
The appliance flue discharges vertically at the rear. There must be no direct connection of the flue to any
mechanical extraction system or the outside air. Siting the appliance under a ventilated canopy is the ideal
arrangement.
Adequate ventilation, whether natural or mechanical, must be provided to supply sufficient fresh air* for
combustion and allow easy removal of combustion products that may be harmful to health.
*A minimum of 15 to 20m3/hof air is required.
Recommendations of ventilation for CateringAppliances are given in BS 5440:2.
For multiple installations, the requirements for individual appliances should be added together. Installation should
be made in accordance with local and/or national regulations applying at the time. A qualified installer must
be employed.
1.4 GAS SUPPLY
The incoming service must be of sufficient size to supply full rate without excessive pressure drop.
A meter is connected to the service pipe by gas supplier. Any existing meter should be checked by supplier to
ensure it is of adequate capacity to pass the required rate of gas for the appliance, in addition to any other gas
equipment installed.
Installation pipe work should be fitted in accordance with IGE/UP/2. The pipe work should be of adequate size, but
not be smaller than the appliance gas inlet connection, i.e. Rp½ (½” BSP).
If flexible tube is used, the gas supply tubing or hose shall comply with national requirements in force and shall not
exceed 1.5m in length. These will be periodically examined and replaced as necessary.
An isolating cock must be located close to appliance to allow shut-down during an emergency or servicing.
The installation must be tested for gas tightness. Details of this procedure can be found in IGE/UP/1.
1.5 ELECTRICAL SUPPLY
Not applicable to these appliances.

1.6 WATER SUPPLY (IRN R001)
Warning - The unit shall not be used empty.
The unit must be connected in accordance with R160 and that an `Approved` double check valve, or some
other no less effective device providing backflow prevention protection to at least fluid category three, shall be
fitted at the point of connection(s) between the water supply and the fitting or appliance.
Supply pressure must be within range of 0.5 to 5 bar. The installation shall be connected to the potable water
supply in accordance with national regulations. A stop cock must be fitted in an easily accessible position on
the supply to enable shut off for cleaning and maintenance.
Front trough drain should be situated over a floor grating, where possible.
1.7 HEAT INPUTS
Full Rate
Gas type
kW (nett)
Btu/hr (gross)
Natural gas
12.1
45,400
Propane gas
12.7
47,700
Low Rate
Gas type
kW (nett)
Btu/hr (gross)
Natural gas
6
22,500
Propane gas
6.5
24,500
Pilot Rate
Gas type
kW (nett)
Btu/hr (gross)
Natural gas
0.18
675
Propane gas
0.18
675
1.8 INJECTOR SIZES
Gas type
Main burner
Pilot burner
Natural gas
Ø3.2mm
SIT No. 36
Propane gas
Ø1.9mm
SIT No. 19
1.9 GAS PRESSURES
Full Rate
Burner Pressure
Supply Pressure
Gas type
mbar
inches
w.g.
mbar
inches
w.g.
Natural gas
9.5
3.8
20
8
Propane gas
37
14.8
37
14.8
Low Rate
Gas type
mbar
inches w.g
Natural Gas
2
0.8
Propane Gas
7.5
3
1.10 BYPASS RATE SETTING
The burner has a fixed aeration inlet and injector orifice. NOADJUSTMENT ISAVAILABLE.

SECTION 2 - ASSEMBLY and COMMISSIONING
2.1 ASSEMBLY
1. Position appliance and level by adjusting screwed feet. Secure to floor using fixing points provided. (See
Figure 1)
2. Ensure all packing material is removed from oven and cistern. Check also that steam vent is clear.
3. Hang shelf runners inside compartment and insert trays or baskets.
Figure 1
2.2 CONNECTION TO GAS SUPPLY
The gas supply piping and connection to appliance must be installed in accordance with the various regulations
listed on the cover of this manual.
On natural gas appliances, an adjustable governor MUST be fitted in the supply. The governor is factory-
fitted to internal inlet pipework. This is located behind lower door.
On propane appliances, a governor is NOT fitted. A straight internal inlet pipe is provided as visible behind lower
door.
2.3 CONNECTION TO WATER SUPPLY
1. Connect water services including overflow from cistern.
2. Turn on water and allow cistern to fill. Ensure that water depth within oven chamber well is up to 60mm level
mark. Adjust ball arm valve if necessary. An additional mark is provided on cistern inner wall to assist
adjustment.
2.4 CONNECTION TO ELECTRICITY SUPPLY
Not applicable to this appliance.
2.5 PRE-COMMISSIONING CHECK
After installation and assembly, the following checks must be carried out to ensure satisfactory operation of the
appliance. Failure to do this may result in damage to appliance or necessitate a service call for rectification.
2.5.1 Gas Tightness
Turn on main gas supply and check gas tightness.
2.5.2. Burner Operating Pressure
Fit a pressure gauge to test point on burner inlet manifold. Turn on main gas cock and purge service
pipework of air. Light pilot and main burner as instructed in User instructions. Check pressures at full rate (See
Section 1.9).
An adjustable governor is provided for use on NATURAL GAS MODELS ONLY. This is situated behind lower door.
The pressure may be set by removing screwed cap and inserting a screwdriver. Turning the inner adjusting screw
clockwise will increase pressure whilst anti-clockwise rotation will decrease it.
Supply pressure adjustment on PROPANE MODELS must be made at supply regulator. No adjustment is
provided on the appliance.
2.5.3 Low Flame Setting
Turn control knob to low flame position and check that pressure corresponds with details in Section 1.9.
On completion, turn burner OFF. Remove pressure gauge and replace test point screw.
2.5.4 Ignition
Having adjusted burner pressure, carry out lighting procedure to check smooth ignition of pilot and main
burner.
Important Note
It is essential the above checks are carried out before appliance is put into service. Failure to do so may result in
damage to appliance, or necessitate a service call.

2.6 INSTRUCTION TO USER
After installing and commissioning appliance, hand User Instructions to user, or purchaser, and ensure person(s)
responsible understands the instructions for lighting, cleaning and correct use of the appliance. Particular
emphasis should be given to safe operation of drain valve. It is important to ensure that the location of gas
isolating cock is made known to user and the procedure for operation in an emergency demonstrated.
SECTION 3 - SERVICING and CONVERSION
SERVICE INFORMATION
This unit carries an extensive mainland UK warranty. The warranty is in addition to and does not change
your statutory or legal rights.
The warranty policy can be found on our website which details the conditions of the warranty and the
exclusions.
https://www.falconfoodservice.com/info-centre/policy
Service calls to equipment under warranty will be carried out in accordance with the conditions of sale.
Warranty calls can be made between 8:30 am and 5:00 pm weekdays only.
To ensure your warranty enquiry is handled as efficiently as possible, ensure you have the following
appliance information prior to calling us:
1. Model number –found on data plate
2. Serial number –found on data plate
3. Brief description of the issue
To contact Falcon for a warranty issue dial (UK only) 01786 455 200 and select Warranty Issues from the
menu.
Important
BEFORE ATTEMPTING ANY SERVICE OPERATION, TURN OFF ISOLATING COCK AND TAKE STEPS TO
ENSURE IT IS NOT INADVERTENTLY TURNED ON DURING TASK.
ENSURE APPLIANCE HAS COOLED SUFFICIENTLY TO ALLOW SAFE MAINTENANCE TO BE CARRIED
OUT.
AFTER ANY SUCH MAINTENANCE TASK, CHECK APPLIANCE TO ENSURE THAT IT PERFORMS
CORRECTLY AND CARRY OUT ANY NECESSARY ADJUSTMENTS AS DETAILED IN SECTION 1.
After carrying out any servicing or exchange of gas carrying components - ALWAYS CHECK GAS
TIGHTNESS!

3.1 GAS CONVERSION CHECK LIST
For conversion to NATURAL GAS, add governor and pipe, and set burner pressure.
For conversion to PROPANE GAS, remove governor from gas circuit and fit replacement supply pipework.
Other considerations:
CHANGE INJECTORS
ADJUST BY-PASS SCREW AND SET LOW RATE
CHANGE DATAPLATE
3.2 TO REMOVE CONTROL PANEL
Remove control knob and fixing bracket. Undo fixings from underside. Ease panel out and down to clear top
locating pins.
3.3 BURNERS
3.3.1 To Remove Burner Assembly
Remove pilot assembly (refer to section 3.3.2) to gain access to burner. Undo union supply pipe at burner inlet.
Remove fixings that secure burner brackets to cast iron base plate and lower burner away from base.
3.3.2 To Remove Pilot Burner Assembly
Undo pilot and thermocouple unions from gas valve. Also, remove nut that retains igniter lead to electrode
(see Figure 3).
Undo pilot burner bracket from below burner. Withdraw pilot burner assembly from appliance.
Undo fixings to remove pilot burner from bracket.
3.4 INJECTORS
3.4.1 To Remove Burner Injector
Remove injector, located inside air box of burner, with a 16mm short armed spanner.
Note
When cleaning injector orifice, a soft fuse wire or wooden splint should be used.
METAL REAMERS MUST NOT BE USED, TO AVOID ENLARGING THE ORIFICE.
3.4.2 To Remove Pilot Injector
Undo pilot union at pilot end of supply pipe and withdraw pipe from pilot burner (see Figure 3).
The injector is located by pilot pipe and care must be taken to avoid losing this upon withdrawal.
3.5 TO REMOVE THERMOCOUPLE
Undo thermocouple retaining nut from pilot burner and slide thermocouple from pilot block (see Figure 3).
Remove thermocouple nut at gas tap body.
Note
When replacing, union nut on gas valve end must be finger tight plus one sixth of a spanner turn. DO NOT
OVERTIGHTEN.
3.6 PIEZO IGNITER / SPARK ELECTRODE
3.6.1 To Remove Piezo Igniter
Pull off lead connection and remove fixings that secure igniter to bracket.
3.6.2 To Remove Spark Electrode
Undo electrode retaining nut and withdraw (See Figure 3).
3.7 GAS VALVE
3.7.1 To Remove Gas Valve
Ensure knob is in OFF position.
Undo unions on inlet and outlet of valve; loosen unions on pilot supply and thermocouple.
Remove fixing at RH side of spindle and push valve back to clear mounting panel. Remove valve through bottom
compartment.

3.7.2 To Re-grease Tap Plug
Undo fixings that retain securing plate to valve body. Remove securing plate, spindle and brass disc to expose
plug.
Withdraw plug and clean it, and the body, with a soft rag before re-greasing with an approved high temperature
lubricant. DO NOT OVERGREASE.
During re-assembly, it will be noticed that steel pin in operating spindle end will only locate in one position.
Re-assemble in reverse order.
Important
Following re-assembly, tap operation should be checked at all settings. Ensure that red spot on knob indicates
correct position (i.e. check thatspindle adaptor has been replaced in correct position).
3.7.3 Setting Low Rate
Low rate is set by adjustment. Remove test point screw and attach pressure gauge. Turn burner on. Turn control
knob to low flame position. Turn low flame adjustment screw clockwise to reduce pressure. Value is indicated in
Section 1.9. (See Figure 2).
Low flame
Burner feed adjustment
screw
Figure 2
Gas in
Upon completion, turn burner OFF. Remove pressure gauge and replace test point screw.
3.8 GOVERNOR (NATURAL GAS ONLY)
This component is maintenance free. Check that blue dust cap for vent is fitted and in good condition. This
protects breather hole. Ensure flow direction arrow points toward appliance inlet.
3.9 DOUBLE CHECK VALVE
This component is maintenance free.
This water supply safety feature must always be fitted to prevent backflow. Ensure flow direction arrow points
toward ball valve inlet.
3.10 TO CLEAN BALL VALVE
Turn OFF mains water supply and drain steamer tank at draw off tap.
Remove cistern lid.
Remove split pin from valve body.
Raise ball valve arm slightly and withdraw from valve socket.
Unscrew cap at valve end and extract valve plug.
Clean all components with a soft rag. DO NOT USE ABRASIVES.
Replace in reverse order and test soundness. Flush out pipes to steaming oven and re-fit tank. Check water
level as detailed in Section 2.3.

3.11ADJUSTING DOOR FIT
Check that door seal is in good condition.
When oven is operating on full steam there, should be no escape of steam around the door periphery. Condensed
water should not drip into the trough when the door is securely close.
If the seal is damaged, remove the seal by pulling away from the door.
Replace seal by firmly pushing the new seal into the door frame until fully home.
To adjust door catch:
Undo lock nut on the door catch
Adjust catch
Tighten lock nut
3.12 IGNITION SYSTEM FAULTS
a) If spark igniter does not light pilot, check for a spark and gas. If no spark is evident, inspect electrode to
ensure ceramic is not cracked and that igniter lead is correctly located. Check insulation on lead for damage.
Having established a spark, check gas flow to pilot by lighting with a flame. If there is no gas, inspect that pilot
injector is not blocked.
b) If spark ignites pilot, but goes out when knob is released, ensure FFD operates correctly by following procedure
detailed in Section 3.13.
Electrode
Spark gap 4mm
Thermocouple
Thermocouple
retaining nut
Electrode retaining nut
Pilot pipe retaining nut
Figure 3
FLAME FAILURE DEVICE FAULTS
It is IMPORTANT that pilot burner is kept clean and properly adjusted. Frequency of cleaning will depend on
the prevailing conditions in the kitchen.
Should FFD fail to engage, the following points should be checked. Details of access to individual components can
be found in Section 3.
1. Ensure gas supply to appliance is turned ON.
2. Check pilot gas supply to ensure connecting pipes and/or pilot burner injector are not blocked.
3. Check position of pilot flame in relation to thermocouple. Flame should envelop and heat 10mm of
thermocouple tip. Thermocouple tip should be at flame centre.
4. Ensure thermocouple is located firmly in the seating on pilot burner. Take care not to over-tighten retaining nut.
5. Check thermocouple connection to valve is clean and that satisfactory contact is made. The nut should be
screwed (finger tight) into valve and a further sixth of a spanner turn (one spanner flat) to secure. The
connection MUST NOT BE OVER-TIGHTENED, as this may cause damage to valve or thermocouple. No
thread compound should be used as this is an electrical connection.
6. Press burner tap knob IN, turn to ignition setting and hold. Press igniter button fully in and release it. Check
resultant spark has lit pilot burner.

If electrode fails to spark, check both electrode and igniter (see Section 3.12). If either component is faulty,
pilot may be lit with a flame.
With pilot established, continue to hold tap knob IN for a further 20 seconds, then release. The pilot should
now remain lit.
Should appliance fail to respond to these checks, then a replacement FFD magnet unit or thermocouple is
required.
SECTION 4 - SPARE PARTS
When ordering spares, always quote unit type and serial number.
This information will be found on the data plate.
The following parts may require replacing during unit life:
Spark ignition lead
Pilot burner assembly (Natural gas)
Pilot burner assembly (Propane gas)
Injector (Natural gas)
Injector (Propane gas)
Door seal
Door handle
Door pin (single action)
Drip tray
Control knob Shelf