Falcon G6478 User guide

RZZ 349 Ref. 1
G6478 STEAMING OVEN
INSTALLATION and
SERVICING INSTRUCTIONS
The appliance must be installed and serviced by a c mpetent pers n as stipulated by the Gas Safety
(Installati n & Use) Regulati ns.
IMPORTANT
The installer m st ens re that the installation of the appliance is in conformity with these instr ctions and
National Reg lations in force at the time of installation. Partic lar attention MUST be paid to -
Gas Safety (Installati n & Use) Regulati ns
Health And Safety At W rk etc. Act
L cal and Nati nal Building Regulati ns
Fire Precauti ns Act
The appliance has been CE-marked on the basis of compliance with the Gas Appliance Directive for the
Co ntries, Gas Types and Press res 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 instr ctions sho ld be left with the Engineer-in-Charge for reference
d ring servicing. F rther to this, The Users Instr ctions sho ld 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
In order to obtain maxim m performance from this nit we wo ld recommend that a Maintenance Contract be
arranged with AFE SERVICELINE. Visits may then be made at agreed intervals to carry o t adj stments and
repairs. A q otation will be given pon req est to the contact n mbers below.
Falc n F dservice Equipment
HEAD OFFICE AND WORKS
PO Box 37, Fo ndry Loan, Larbert.
Stirlingshire. Scotland. FK5 4PL
AFE SERVICE LINE CONTACT -
PHONE - 01438 363 000 FAX - 01438 369 900
Detailed rec mmendati ns are c ntained
in Institute f Gas Engineers
published d cuments :
IGE/ UP/ 1, IGE/ UP/ 2
BS6173 and BS5440

kW (net) Bt /hr (gross)
12.1 45,400
Main B rner Pilot B rner
SIT No. 36
SIT No. 19
ù 3.2mm
ù 1.9mm
NATURAL
PROPANE
mbar inches w.g.
3.8
14.8
9.5
37
NATURAL
PROPANE
mbar inches w.g.
20 8
37 14.8
B rner Press re S pply Press re
SECTION 1 - INSTALLATION
1.2 SITING
The appliance m st be installed on a firm, level floor
in a well lit position.
This nit can be positioned to within 150mm of a
comb stible wall.
Imp rtant
If nit is to be installed with other appliances, the
Instr ctions for all models m st be cons lted to
determine the necessary clearance to any
comb stible rear wall or overlying s rface. Some
nits req ire greater clearance than others and the
largest fig re q oted in the individ al Instr ctions will
determine the clearance for the complete s ite of
adjoining appliances.
1.3 VENTILATION
The appliance fl e discharges vertically at the rear.
There m st be no direct connection of the fl e to any
mechanical extraction system or the o tside air.
Siting the appliance nder a ventilated canopy is
the ideal arrangement.
Adeq ate ventilation, whether nat ral or mechanical,
m st be provided to ens re s fficient fresh air for
comb stion and for removal of comb stion prod cts,
which may be harmf l to health. Recommendations
for ventilation for Catering Appliances are given in
BS 5440:2. F rther, to ens re s fficient room
ventilation, g idance on the vol me of ventilation air
req ired for different kinds of catering eq ipment is
given in the table.
For m ltiple installations, the req irements sho ld be
added together. Installation sho ld be made in
accordance with local and/ or national reg lations
applying at the time, and a competent installer m st
be employed.
1.4 GAS SUPPLY
The incoming service m st be of s fficient size to
s pply f ll rate witho t excessive press re drop.
A gas meter is connected to the service pipe by the
Gas S pplier. Any existing meter sho ld be checked
by the Gas S pplier to ens re the meter is of
adeq ate capacity to pass the req ired rate of gas
for the nit in addition to any other gas eq ipment
installed.
Installation pipe work sho ld be fitted in accordance
with IGE/UP/2. The pipe work sho ld not be smaller
than the nit gas inlet connection, ie. Rp
1
/
2
(
1
/
2
" BSP). An isolating cock m st be located close
to the appliance to allow sh t-down d ring an
emergency or servicing. The installation m st be
tested for gas so ndness. details of this proced re
can be fo nd in IGE/UP/1.
1.5 ELECTRICAL SUPPLY
Not applicable to this appliance.
1.6 WATER SUPPLY
The appliance is intended for connection to a main
water s pply only, connection is
1
/
2
" BSP.
S pply press re m st be within the range of 2.5 to
7 bar. A stop cock m st be fitted in an easily
accessible position on the s pply to enable sh t off
for cleaning and maintenance.
The front tro gh drain sho ld be sited over a floor
grating where possible.
1.7 GAS RATE - NATURAL and PROPANE GAS
1.8 INJECTOR SIZE -
NATURAL and PROPANE GAS
1.9 OPERATING PRESSURE
EQUIPMENT
Ventilation Rate Req ired
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
Boiling Pan 17 600
Steamer 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
mm DEPTH mm HEIGHT mm WEIGHT kg
G6478 600 840 1590 110
1.1 MODEL NUMBERS, NETT WEIGHTS
and DIMENSIONS

A
B
C
3
1
2
A press re test point is provided on b rner inlet
s pply, accessible when facia panel is removed.
1.10 BURNER ADJUSTMENT
The b rner has a fixed air inlet and gas injector.
NO ADJUSTMENT IS REQUIRED.
The press re m st be checked as detailed in
Section 1.9.
SECTION 2 - ASSEMBLY and
COMMISSIONING
2.1 ASSEMBLY
The oven is normally a basic freestanding nit and
when specified, a separate package of s ite-ing
components are s pplied. Assemble these
components as follows while referring to Fig re 1.
1. Remove rear bottom screws (C) from each side.
2. Loosen cistern fixing screws (B) by approximately
three t rns. Insert flange of each side extension
panel (3) behind cistern flanges ntil slots engage
aro nd loose screws (B). Tighten screws (B) and
replace rear bottom screws (C) to sec re side
extension panels.
3. Remove screws (A), position rear cover panel (1)
against nit rear. Replace screws (A) to sec re
whilst p shing pwards to close against top panel.
4. Position rear extension panel (2) over side
extensions (3) and against rear cover panel (1).
Use screws provided to sec re (2) to (1) and (3).
For all nits, contin e assembly as follows:-
5. Position nit and level. A levelling bolt is provided
in each foot with facility for floor fixing if req ired.
SUITING ASSEMBLY
6. Ens re all packing material is removed from oven
and cistern. Check also that steam vent is clear.
7. Hang shelf r nners inside compartment and insert
trays or baskets.
2.2 CONNECTION TO GAS SUPPLY
The gas s pply piping and connection to appliance
m st be installed in accordance with the vario s
reg lations listed on the cover of this man al.
On NATURAL GAS appliances, an adj stable
governor MUST be fitted in the s pply. It is sit ated
behind the lower door. On appliances b rning
PROPANE, a governor m st NOT be fitted.
2.3 CONNECTION TO WATER SUPPLY
1. Connect water services incl ding overflow from
cistern.
2. T rn on water, allow cistern to fill and check that
water depth within the compartment is correct
(70mm). Adj st ball arm valve if necessary.
Figure 1

2.4 CONNECTION TO ELECTRICITY SUPPLY
Not applicable to this appliance.
2.5 PRE-COMMISSIONING CHECK
After installation and assembly, the following checks
m st be carried o t to ens re satisfactory operation
of the nit. Fail re to do this may res lt in damage to
the appliance or necessitate a service call for
rectification.
2.5.1 Gas S undness
T rn on main gas s pply and check so ndness.
2.5.2. Burner Operating Pressure
Fit a press re ga ge to test point on b rner inlet
s pply. T rn on main gas cock and p rge service
pipework of air. Light pilot then main b rner as
instr cted in User instr ctions. Adj st press re at f ll
on rate (See Section 1.9)
An adj stable governor is provided for se on
NATURAL GAS MODELS ONLY. This is sit ated
behind the lower door. The press re may be set by
removing the screwed cap and inserting a
screwdriver. Rotating the inner adj sting screw
clockwise will increase press re whilst anti-clockwise
rotation will decrease it.
Adj stment on PROPANE MODELS m st be made at
main reg lator. No adj stment is provided on the nit.
2.5.3 L w Flame Setting
Upon completion of above, t rn b rner tap back to
low flame position (Mark 3) and check that press re
corresponds with the following -
If adj stment is req ired, remove control panel and
t rn low flame adj stment screw clockwise to red ce
press re. (see Fig re 2 below)
Low Flame Adj stment Screw
Figure 2
On completion, t rn b rner OFF. Remove press re
ga ge and replace test point screw.
2.5.4 Flame Failure Device
It is IMPORTANT that the pilot b rner is kept clean
and properly adj sted. The freq ency of cleaning will
depend on the prevailing conditions in the kitchen.
Sho ld FFD fail to engage, the following points
sho ld be checked. Details of access to individ al
components can be fo nd in Section 3 - Servicing.
1. Ens re gas s pply to appliance is t rned ON.
2. Check pilot gas s pply to ens re there is no
stoppage or blocking of the connecting t bes and
pilot b rner injector.
3. Check position of pilot flame in relation to
thermoco ple. This sho ld envelop and heat
10mm of thermoco ple end . The thermoco ple
end sho ld be at centre of flame.
4. Ens re thermoco ple is located firmly in the
seating on pilot b rner. Take care not to
overtighten clamping screw retaining n t.
5. Check thermoco ple connections to valve is clean
and that satisfactory contact is made. The n t
sho ld be screwed, finger tight into valve and a
f rther sixth of a spanner t rn (one spanner flat) to
sec re. The connection MUST NOT BE
OVER-TIGHTENED as this may ca se damage
to valve or thermoco ple. No thread compo nd
sho ld be sed as this is an electrical connection.
6. Press b rner tap knob IN, t rn to ignition setting
and hold. Press igniter b tton f lly in and release
it. Check res ltant spark has lit pilot b rner.
If electrode fails to spark, check both electrode
and igniter (see Section 3). If either component is
fa lty, pilot may be lit with a taper.
Sho ld pilot fail to light, press and release igniter
b tton once again. This operation sho ld not be
attempted more than 4 times before t rning gas
OFF and waiting at least 3 min tes before trying
again.
With pilot established, contin e to hold tap knob
IN for a f rther 20 seconds then release. The pilot
sho ld now remain lit.
Sho ld appliance fail to respond to these checks
then a new FFD magnet nit or thermoco ple will
req ire to be fitted.
2.5.5 Igniti n
Having adj sted b rner press re, carry o t lighting
proced re to check smooth ignition of pilot and main
b rner.
Imp rtant N te
It is essential the above checks are carried o t before
nit is p t into service. Fail re to do so may res lt in
damage to appliance or necessitate a service call.
GAS TYPE mbars inches w.g.
NATURAL 2 0.8
PROPANE 7.5 3

2.6 INSTRUCTION TO USER
After installing and commissioning appliance, hand
User Instr ctions to ser or p rchaser and ens re the
person(s) responsible nderstands the instr ctions
for lighting, cleaning and correct se of the appliance.
Partic lar emphasis sho ld be given to safe operation
of the drain valve. It is important to ens re that the
location of the gas isolating cock is made known to
the ser and the proced re for operation in an
emergency demonstrated.
SECTION 3 - SERVICING and
CONVERSION
Imp rtant
BEFORE ATTEMPTING ANY SERVICE
OPERATION, TURN OFF ISOLATING COCK AND
TAKE STEPS TO ENSURE IT IS NOT
INADVERTENTLY TURNED ON DURING TASK.
AFTER ANY SUCH MAINTENANCE TASK, CHECK
THE APPLIANCE TO ENSURE THAT IT
PERFORMS CORRECTLY AND CARRY OUT ANY
NECESSARY ADJUSTMENTS AS DETAILED IN
SECTION 1.
After carrying o t any servicing or exchange of gas
carrying components -
ALWAYS CHECK FOR GAS SOUNDNESS!
3.1 GAS CONVERSION CHECK LIST
For conversion to NATURAL GAS, add governor and
pipe and set b rner press re.
For conversion to PROPANE GAS, remove governor
from gas circ it and fit replacement s pply pipework.
Other considerations :
CHANGE INJECTORS
ADJUST BY-PASS SCREW AND SET LOW RATE
CHANGE DATA PLATE
3.2 TO REMOVE THE CONTROL PANEL
Remove control knob. Undo fixings from nderside.
Ease panel o t and down to clear top locating pins.
3.3 BURNERS
3.3.1 T Rem ve the Burner Assembly
Remove pilot assembly to gain access to b rner.
Undo nion s pply pipe at b rner inlet.
Remove fixings which sec re b rner brackets to cast
iron base plate and lower b rner away from base.
3.3.2 T Rem ve the Pil t Burner Assembly
Undo the pilot and thermoco ple nions from the gas
valve. Also the n t which retains the igniter lead to the
electrode (see Fig re 3).
Undo pilot b rner bracket from below b rner (2 n ts)
and withdraw pilot b rner assembly from appliance.
Undo fixings to remove pilot b rner from bracket.
3.4 INJECTORS
3.4.1 T Rem ve the Burner Inject r
Remove injector, located inside air box of b rner with
a 16mm short armed spanner.
N te
When cleaning injector orifice, a soft f se wire or
wooden splint sho ld be sed.
METAL REAMERS MUST NOT BE USED TO
AVOID ENLARGING THE ORIFICE.
3.4.2 T Rem ve Pil t Inject r
Undo pilot nion at pilot end of s pply pipe and
withdraw pipe from pilot b rner (see Fig re 3).
The injector is located by the pilot pipe and care m st
be taken to avoid losing it pon withdrawal.
3.5 TO REMOVE THERMOCOUPLE
Undo thermoco ple retaining n t from pilot b rner
and slide thermoco ple from pilot block (see Fig re
3). Remove thermoco ple n t at gas tap body.
N te
When replacing, the nion n t on gas valve end m st
be finger tight pl s one sixth of a spanner t rn.
DO NOT OVERTIGHTEN.
3.6 PIEZO IGNITER / SPARK ELECTRODE
3.6.1 T Rem ve Piez Igniter
P ll off lead connection and remove the fixings which
sec re igniter to bracket.
3.6.2 T Rem ve Spark Electr de
Undo electrode retaining n t and withdraw (See
Fig re 3).
3.7 GAS VALVE
3.7.1 T Rem ve Gas Valve
Ens re knob is in OFF position.
Remove control panel as detailed in Section 3.2.
Undo nions on inlet and o tlet of valve, loosen
nions on pilot s pply and thermoco ple.
Remove fixing at RH side of the spindle and p sh
valve back to clear mo nting panel. Remove valve
thro gh bottom compartment.
3.7.2 T Regrease the Tap Plug
Remove control panel as detailed in Section 3.2.
Undo fixings which retain sec ring plate to valve
body. Remove sec ring plate, spindle and brass disc
to expose pl g.
Withdraw pl g and clean it and the body with a soft
rag before regreasing with an approved high
temperat re l bricant. DO NOT OVERGREASE.
D ring re-assembly, it will be noticed that the steel pin
in the operating spindle end will only locate in one
position.
Re-assemble in reverse order.

Electrode
Pilot Pipe
Retaining N t
Electrode Retaining N t
Thermoco ple
Retaining N t
Thermoco ple
Spark gap 4mm
Imp rtant
Following re-assembly, tap operation sho ld be
checked at all settings. Ens re that red spot on knob
indicates correct position. (i.e. Check that spindle
adaptor has been replaced in correct position.)
3.8 GOVERNOR (NATURAL GAS ONLY)
This component is maintenance free. Check that bl e
d st cap for vent is fitted and in good condition.
This protects the breather hole.
3.9 TO CLEAN BALL VALVE
T rn OFF mains water s pply 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 pl g.
Clean all components with a soft rag. DO NOT USE
ABRASIVES.
Replace in reverse order and test so ndness. Fl sh
o t pipes to steaming oven and re-fit the tank.
3.10 ADJUSTING DOOR FIT
Prise off hinge covers with a plain screwdriver.
Sh t door and assess if seal leaks or if hinge binding
is present.
Undo screws which sec re hinges to door.
The serration in the hinges allows door to be adj sted
in or o t to take p slack or prevent hinge bind.
The catch adj stment is accomodated by adding or
removing shims as appropriate.
3.11 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
ens re the ceramic is not cracked and that igniter
lead is correctly located. Check ins lation on lead
for damage also. Use an ins lated screwdriver to
form a spark gap and check igniter operation (see
Fig re 3).
Having established a spark, check gas flow to pilot
by lighting with a taper. If there is no gas, inspect
that pilot injector is not blocked. Carry o t check
detailed in Section 2.5.3 of this doc ment.
b) If spark ignites pilot b t goes o t when knob is
released, ens re FFD thermoco ple connections
are tight and that pilot end of thermoco ple is
enveloped in flame. If this does not res lt in
establishing pilot then replace thermoco ple.
If there is still a fa lt then the gas valve will have
to replaced. See Section 3.8 for proced re.
Figure 3 - Igniti n System
SECTION 4 - SPARES
When ordering spare parts, always q ote appliance
type and serial n mber. This information will be fo nd
on data plate attached to nit base.

G6478 STEAMING OVEN CONTROLS

G6478 STEAMING OVEN FITMENTS