Service Manual - AS Catering Supplies
Contents
1. Replace in reverse order 3 5 3 Oven Flame Failure Device Magnet Unit The oven FFD magnet unit is an integral thermostat part Remove thermostat to gain access to FFD For removal details refer to relevant part of Section 3 7 Having removed thermostat undo rear FFD section and withdraw Replace in reverse order 3 5 4 Oven Thermocouple Oven thermocouple is split type which consists of a thermocouple sensor and extension To Remove Thermocouple Extension Remove facia panel end as detailed in Section 3 2 1 Remove hob fitments See Sections 3 2 3 3 3 3 or 3 2 4 as required Remove RH side panel Undo thermocouple extension nut at thermostat rear Open oven doors remove shelves and baseplate Undo split nut and remove thermocouple Replace in reverse order taking care not to overtighten To Remove Thermocouple Sensor Open over doors remove shelves and base plate Undo locknuts which secure thermocouple to burner bracket Undo split nut and remove thermocouple Replace in reverse order and take care not to overtighten 3 5 5 Solid Top Flame Failure Device Magnet Unit The solid top FFD magnet unit is an integral part of the gas tap Remove gas tap in order to gain access to FFD see Section 3 8 Having removed tap undo rear FFD section and withdraw Replace in reverse order 3 5 6 Solid Top Thermocouple Remove hotplate castings burner and combustion chamber box Loosen fixings and remove heat shield2. spark at the burner 3 Having lit the burner continue to press thermostat knob for a further 20 seconds before release Check burner remains lit and turn thermostat to required setting 4 To extinguish oven flame turn thermostat to OFF position Solid Top 1 Ensure mains gas is turned on 2 Remove bullseye castings from solid top hob 3 Push control knob in and turn anti clockwise to ignition position 4 Holding control knob in fully apply a taper to pilot and observe that pilot lights 5 When pilot is lit continue to hold knob fully in for 20 seconds before release If pilot is extinguished wait 3 minutes and repeat from Step 3 6 Having established pilot condition turn control knob anti clockwise to FULL FLAME position to light burner 7 For LOW FLAME operation turn control knob further anti clockwise to LOW FLAME position Check burner pressure as detailed in Section 1 10 2 8 Replace bullseye castings 2 6 INSTRUCTION TO USER Whenever possible the installer should ensure that the user thoroughly understands the instructions for lighting cleaning and correct use of the appliance This is particularly important when FLAME FAILURE DEVICES are fitted It is also important to ensure that the location of the gas isolating cock is made known to the user and that the procedure in an emergency is demonstrated SECTION 3 SERVICING AND CONVERSION Important BEFORE ATTEMPTING ANY SERVICING ENSURE I
3. including the flue clear of unit 3 3 BURNERS 3 3 1 Open Top Remove hob components as Section 3 2 3 Undo burner pipe compression fitting Remove brass securing nut on burner support Take care not to deform it the top surface must remain flat Withdraw burner body Replace in reverse order 3 3 2 Oven Open oven doors and remove base panel Undo lock nut on oven injector and remove the fixings from injector support bracket Undo injector from gas supply pipe and gently lift oven burner to remove injector Replace in reverse order 3 3 3 Solid Top Remove hotplate castings and combustion box Undo fixings which secure burner to support channel and withdraw burner 3 3 4 Solid Top Pilot Assembly Remove hotplate castings and burner tray Undo thermocouple retaining nut at pilot assembly Undo and disconnect pilot pipe at pilot assembly Remove fixings which secure pilot assembly to mounting bracket Remove pilot assembly Replace in reverse order 3 3 5 Cleaning Burners should be cleaned periodically to maintain maximum performance Burners are best cleaned with a wire brush ports being freed from blockage with a metal broach any loose material being shaken out via the burner shank 3 4 INJECTORS 3 4 1 Open Top Remove burner as detailed in Section 3 3 1 Undo and carefully remove injector Replace in reverse order 3 4 2 Oven Remove burner as detailed in Section 3 3 2 Undo injector and remove R
4. DOMINATOR GAS RANGE APPLIANCES Refer to Section 1 1 for the models covered by this document INSTALLATION and SERVICING INSTRUCTIONS These appliances must be installed and serviced by a competent person as stipulated by the Gas Safety Installation amp 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 amp Use Regulations Detailed recommendations are contained in Health And Safety At Work etc Act Institute of Gas Engineers published documents Local and National Building Regulations IGE UP 1 IGE UP 2 BS6173 and BS5440 Fire Precautions Act These appliances have been CE marked on the basis of compliance 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 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 P
5. ON 4 SPARES When ordering spare parts always quote the appliance type and serial number This information will be found on the data badge attached to the base plate A list of parts available for this range of appliances can be found in the Spares section of this document pack
6. ROCEDURES MAY RESULT IN DAMAGE OR THE NEED FOR A SERVICE CALL PREVENTATIVE MAINTENANCE CONTRACT In order to obtain maximum performance from this unit we would recommend that a Maintenance Contract be arranged with AFE SERVICELINE Visits may then be made at agreed intervals to carry out adjustments and repairs A quotation will be given upon request to the contact numbers below Falcon Foodservice Equipment RZZ 331 Ref 1 HEAD OFFICE AND WORKS PO Box 37 Foundry Loan Larbert Stirlingshire Scotland FK5 4PL A F E AFE SERVICE CONTACT PHONE 01438 751111 FAX 01438 369900 FOODSERVICE EQUIPMENT 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 and DIMENSIONS MODEL WIDTH DEPTH HEIGHT WEIGHT mm mm mm kg G2101 07 OPEN TOP RANGES 900 770 870 129 G2107 SOLID TOP RANGE 900 770 870 147 G2121 OPEN TOP B Table 900 770 870 70 G2127 SOLID TOP B Table 900 770 870 88 G2117 OVEN on Stand 900 770 1470 129 G2117 OVEN G2117 2 Two tier oven 900 770 1 700 1 95 G2161 67 OPEN TOP RANGES 600 770 870 88 G2124 OPEN TOP B Table 600 770 870 50 1 2 SITING The appliance should be installed on a level fireproof surface in a well lit and draught free position Should the floor be of combustible material then local fire requirements shoul
7. SOLATING COCK IS TURNED OFF AND CANNOT BE INADVERTANLY TURNED ON AFTER ANY 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 FOR GAS SOUNDNESS 3 1 GAS CONVERSION CHECK LIST For conversion to NATURAL GAS add correct governor and set burner pressure For conversion to PROPANE GAS remove governor from gas circuit Other considerations CHANGE INJECTORS CHANGE BY PASS SCREW AND SET LOW RATE CHANGE BURNER AERATION SETTING Refer to Section 1 10 CHANGE DATA PLATE 3 2 REMOVAL OF CONTROL PANELS Various panels are removed as follows 3 2 1 To Remove Facia Panel Remove control knobs Undo fixings along underside and top Pull facia panel forward while slightly easing bottom edge upward to remove 3 2 2 To Access Oven Controls Open oven door remove shelves and base plate 3 2 3 To Remove Open Top Hob Remove pan supports and brass burner heads which sit loosely upon the burner venturies For models with a semi sealed hob the hob is retained by a ballstud Lift hob clear to access burner support bracket For models with drip sheds remove these by undoing the fixings which retain them to the hob structure 3 2 4 To Remove Worktop Remove fixings which secure front hob support and those which secure flue to back panel Lift full hob area
8. d be checked to ensure compliance A clear space of 150mm should be left between the back of the appliance and any combustible wall There should be a minimum vertical clearance of 1220mm above the top edge of the range and boiling table flues and 450mm above the oven flues Important If the appliance is to be installed in suite formation with other matching appliances the instructions for all models must be consulted to determine the necessary clearances to any combustible rear wall or overlying surface Some appliances require greater clearances than others and the largest figure quoted in the individual instructions will therefore determine the clearance of the complete suite adjoining appliances The appliance flue discharges vertically from the top of the unit It must not be directly connected to any flue mechanical extraction system or ducting etc leading to outside the building The appliance is best discharged under an open canopy which connects with a ventilating system 1 3 VENTILATION Adequate ventilation whether natural or mechanical must be provided to supply sufficient fresh air for combustion and allow easy removal of combustion products which may be harmful to health Recommendations for Ventilation of Catering Appliances are given in BS5440 2 Furthermore to ensure sufficient room ventilation guidance on the volume of ventilation air required for different types of catering equipment is provided in the
9. d replace fillings etc d Check open top remove tape packing etc from hob area and ensure that all burners and pan supports are secured in position Burner head fits loosely on to aluminium bezels which are a lift off construction 2 2 CONNECTION TO GAS SUPPLY Connect appliance to gas supply and ensure that a governor is fitted on NATURAL gas installations Test for gas soundness The integral gas supply downstream of gas valve may be checked by applying leak detection spray with burner lit Appliance inlet connection terminates at upper rear RH side in Rp 2 4 BSP female 2 3 CONNECTION TO ELECTRICAL SUPPLY Not applicable to these appliances 2 4 CONNECTION TO WATER SUPPLY Not applicable to these appliances 2 5 COMMISSIONING THE APPLIANCE Important Prior to operation ensure ALL packing material has been removed 2 5 1 Setting The Gas Pressure a It is necessary to check the gas pressure during commissioning and a suitable pressure gauge must be connected to pressure test point on RH side of gas supply manifold situated behind front control facia b Now turn on main gas valve at supply to unit c Light approximately half of the burners on the unit as described in Section 2 5 3 As gas supply pipes may contain air continue to repeat lighting procedure d Adjust gas pressure governor NATURAL gas installations only at unit rear to relevant pressure setting found in Section 1 9 To increase press
10. eplace in reverse order 3 4 3 Solid Top Remove burner as detailed in Section 3 3 3 Undo injector and remove Replace in reverse order 3 4 4 Solid Top Pilot Injector Remove hotplate castings and burner tray Undo and disconnect pilot pipe at pilot assembly Remove pilot injector Replace in reverse order 3 4 5 Cleaning Injectors are best cleaned with a wooden splinter or soft fuse wire Metal reamers may distort or increase orifice size and their use should be avoided Ensure burners are dry and free from any cleaning material before replacing Check adjustment as in Section 1 3 5 THERMOCOUPLES and FLAME FAILURE DEVICE FFD 3 5 1 Open Top Flame Failure Device Magnet Unit All open top burners are protected by FFD they are also fitted with thermocouple s To remove and replace FFD Magnet Unit the following procedures must be followed Remove Gas Tap see Section 3 8 Having removed gas tap undo FFD section at tap rear and withdraw Repeat for all hob burners Replace in reverse order 3 5 2 Open Top Thermocouple Remove facia panel as detailed in Section 3 2 1 Remove hob pan supports and burner heads as detailed in Section 3 2 3 Burner support bracket is situated directly below hob well Remove nut which secures thermocouple to burner support bracket and pull thermocouple through support bracket from underside Undo thermocouple connection at FFD section of gas tap and carefully remove thermocouple
11. he oven release the clips which secure thermostat capillary to oven side wall Undo fixings which secure thermostat to manifold Remove thermostat by carefully feeding capillary and phial through crown plate Replace all parts in reverse order Renew gasket if necessary 3 7 2 Thermostat Calibration The thermostat should not be calibrated If temperature is outwith specified tolerances then replace thermostat and return faulty stat to the Falcon Quality Department 3 8 GAS TAPS Open and Solid Top Taps 3 8 1 Service Remove control knobs and facia panel as detailed in Section 3 2 1 Remove fixings from front of tap body Withdraw spindle and niting arrangement to allow plug to be eased out Earth pi SRD Thermocouple Clean gas tap plug with a soft rag and regrease using an approved high temperature lubricant taking care not to over grease as surplus may cause blockage in the gasways Replace parts in correct order and check gas soundness Note Plugs and bodies are machined in pairs and are therefore not interchangeable Always clean one tap at a time Replace in reverse order 3 8 2 Removal Remove control knobs and facia panel as detailed in Section 3 2 1 Remove hob fitments as detailed in Sections 3 2 3 or 3 3 3 as appropriate Disconnect thermocouple connection at gas tap rear Disconnect burner supply pipe Undo fixings which secure tap to manifold Replace all parts in re
12. ners have fixed injectors and aeration shroud Adjustment required see Figure 1 Natural Propane Model mm mm Solid Top Omm Omm 900mm Oven Fully Open Fully Open 600mm Oven 4mm 6mm Figure 1 4 a X as Solid Top Burner X Oven Burner 1 10 2 Bypass Screw Diameters Minimum gas flow to burner is governed by the size of the fixed by pass screw hole as follows Natural Propane Model mm mm Open Top 0 84 0 5 900mm Oven 0 85 0 55 600mm Oven 0 75 0 45 Minimum glas flow for solid top is set by adjustment Connect a manometer to the burner pressure test point on the injector block Gas Type mbar inches w g Natural 2 0 8 Propane 5 2 SECTION 2 ASSEMBLY and COMMISSIONING 2 1 ASSEMBLY 2 1 1 Assembly of Ranges and GP Ovens Note The following paragraphs should be read as applicable to the unit being assembled a Unpack appliance and place unit in position using the feet adjusters to level appliance b Open oven door pull out shelves and loose base panel Check burner spark igniter arrangements are correctly located and secured Ensure ALL packing etc is removed from oven Replace all parts in reverse sequence c Check solid top by removing bullseye ring and filling plates Ensure burner is located correctly upon both the injector and support strap Remove any loose packing an
13. panel behind controls Undo nuts which secure thermocouple to FFD and pilot assembly Withdraw thermocouple Replace in reverse order 3 6 OVEN IGNITERS and ELECTRODES Igniter is piezo spark type and contains no batteries Unit comprises piezo housing lead and electrode assembly Lead is push fit at piezo and electrode ends Oven igniter electrode earth pin and burner ports should be aligned as indicated in Figure 2 3 6 1 Oven Igniter To remove igniter open doors and remove oven shelves and base plate Remove spark igniter cover and pull off igniter lead Undo nut which secures igniter in position Remove Igniter Replace in reverse order 2 5mm Outline of burner 1mm 5mm A Burner ports evens o I 2 at a o i 3 5mm Figure 2 Ignition electrode 3 6 2 Oven Electrode Remove oven shelves and base plate Disconnect igniter lead from electrode Undo fixing securing electrode to burner bracket Remove electrode and replace in reverse order ensuring position is as indicated in Figure 2 Note Care should be taken not to damage the electrode 3 7 OVEN THERMOSTAT Remove control knobs and facia panel as detailed in Section 3 2 1 Remove hob fitments as detailed in Sections 3 2 3 3 3 3 or 3 2 4 as appropriate Undo thermocouple connection at thermostat rear Disconnect the oven burner pipe From inside t
14. t amp Btu hr gross 1 7 1 Total Inputs Model kW Btu hr G2101 OT 35 7 134 000 G2107 OT 128 000 G2107 SB 65 000 107 000 38 500 G2121 OT G2127 SB G2117 Oven 26 500 G2161 OT 88 500 G2167 OT 22 8 85 500 G2124 OT 18 8 70 500 1 7 2 Individual Inputs kW net amp Btu hr gross Model kW Btu hr Open Top Std 4 5 16 000 Open Top Boost 5 3 20 000 Solid Top 10 2 38 500 900mm Ovens 7 1 26 500 600mm Ovens 4 8 18 000 1 8 INJECTOR DIAMETERS NATURAL and PROPANE GAS Open Top Std 1 75mm 1 07mm Open Top Boost 1 95mm 1 2mm Solid Top 2 65mm Solid Top Pilot SIT 36 2 3mm 1 8mm 900mm Oven 600mm Oven 1 9 GAS PRESSURE ADJUSTMENT NATURAL and PROPANE GAS The following supply pressures apply to all units Gas Type mbar inches w g Natural 20 8 Pressure test point is located on RH side of gas manifold situated behind front control facia An adjustable governor BSP is provided on Natural Gas units This should be adjusted to achieve an operating pressure at the control manifold of 15mbar 6 inches w g For multi burner systems approximately half of the burners should be on when setting governor pressure 1 10 BURNER ADJUSTMENT NATURAL and PROPANE GAS 1 10 1 Burner Aeration Open top hob burners are fitted with fixed injectors and set aeration apertures NO ADJUSTMENT is possible Solid top and oven bur
15. table below 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 competent installer MUST be employed Ventilation Rate Required EQUIPMENT m min ft min Range Unit Type 17 600 Pastry Oven 17 600 Fryer 26 900 Steak Grill Boiling Pan Steamer Sterilizing Sink 400 300 500 Bains Marie 11 8 5 14 Tea Coffee Machine 1 4 GAS SUPPLY The incoming service must be of sufficient size to supply full rate without excessive pressure drop A gas meter is connected to the service pipe by the Gas Supplier Any existing meter should be checked by the Gas Supplier to ensure that the meter is of adequate capacity to pass the required rate of 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 not be smaller than the gas inlet connection on the appliance ie Rp 4 7 4 B S P An isolating cock must be located close to the appliance to allow shut down during an emergency or servicing The installation must be tested for gas soundness details of this procedure can be found in IGE UP 1 1 5 ELECTRICAL SUPPLY Not applicable to these appliances 1 6 WATER SUPPLY Not applicable on this appliance 1 7 HEAT INPUTS NATURAL and PROPANE GAS kW ne
16. ure turn the screw clockwise or anti clockwise to decrease pressure Check again after 15 minutes of operation e Disconnect pressure gauge from test point Replace test point sealing screw and test for gas soundness 2 5 2 Checking The Performance of the Controls a Light open top solid top or oven as detailed in Section 2 5 3 Check ignition is smooth and without delay Repeat operation several times b Place a thermocouple in centre of oven and select 210 C on thermostat knob Allow oven to heat up and check temperature is 210 7 C If temperature reading is outwith specified range there may be a faulty thermostat in which case the unit should be serviced see thermostat replacement and calibration procedure Turn OFF gas supply to oven and allow a sufficient cool down period before removing thermocouple 2 5 3 Lighting Sequence Important Prior to operation ensure ALL packing material has been removed from appliance Open Top 1 Ensure mains gas is turned on 2 To light hob burners press knob and turn to full flame position Ignite burners using taper or match Hold in knob for 20 seconds and then release burner will remain lit Turn knob to required position Oven 1 Ensure mains gas is turned on 2 To light oven open doors press thermostat knob and turn to maximum This will establish a flow of gas to oven burner Press piezo igniter button situated in recess below oven doors to provide a
17. verse order Renew gasket if necessary 3 9 GOVERNOR This applies to NATURAL GAS UNITS ONLY The type of governor used will normally require little servicing The air breather hole should be checked regularly for dirt blockage Always re check pressure at test point after governor maintenance 3 10 FAULT CHECK LIST If a flame is not established on any burners hob or oven follow this check list 1 Check mains gas is ON 2 Check pressure at pressure test point to ensure gas is flowing to the appliance 3 If pressure does not register then check governor is fully operational or check for line blockage 4 If gas is present then check burner injector for blockage If injector is OK then check FFD is engaging and passing gas 6 Check for spark at spark electrode If there is no spark then check the spark gap and HT lead connections Also check the igniter If a flame is still not present then re check from start If a flame is established but not maintained on the hob or oven burners then follow this check list 1 3 4 If a flame is present but not being maintained then check thermocouple is placed correctly in the burner flame Burner ports must be clean Check also that thermocouple is not damaged and is securely fixed to gas valve FFD section to prevent the FFD from energising Check FFD is energising and maintaining flame If the above are OK then re check from start SECTI
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