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Falcon F900 Series User, Installation And Servicing Instructions

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F900 SERIES
User, installation and servicing instructions
INDUCTION SOLIDTOP
COUNTER
I9097
Read these instructions before use
DATE PURCHASED:
MODEL NUMBER:
SERIAL NUMBER:
DEALER:
SERVICE PROVIDER:
Rev 2
Published: 23/05/2023
T101080

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  • Page 1 F900 SERIES User, installation and servicing instructions INDUCTION SOLIDTOP COUNTER I9097 Read these instructions before use DATE PURCHASED: MODEL NUMBER: SERIAL NUMBER: DEALER: SERVICE PROVIDER: Rev 2 Published: 23/05/2023 T101080...
  • Page 2 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. Falcon Foodservice Equipment HEAD OFFICE Wallace View, Hillfoots Road, Stirling. FK9 5PY. Scotland.
  • Page 3 SYMBOLS SCREWDRIVER SPANNER COOKING OIL GREASE WARNING SPARK IGNITION FLAME VIEWPORT ALLEN KEY IGNITER C SPANNER REMOVE DEVICE NON-IONISING PLUG REMOVER ELECTROMAGNETIC RADIATION...
  • Page 4 • This appliance may be discoloured due to testing. • 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. •...
  • Page 5 Training and competence To help ensure the safe use of this appliance there is a requirement for you to provide whatever information, instruction, training and supervision as is necessary to ensure, so far as is reasonably practicable, the health and safety of all users. For further help and information on training and competence we would refer you the Health and Safety Executive website;...

  • Page 6: Table Of Contents

    CONTENTS APPLIANCE INFORMATION ..................1 OPERATION ......................2 COMPONENT PARTS .................... 3 CONTROLS ......................4 USING THE APPLIANCE ..................5 DO NOT PLACE POT OR PAN OVER DIGITAL DISPLAY ........6 WARNING WHEN USING MULTIPLE PANS ON THE SAME HOB ......6 BUZZING NOISE OR TONE WHEN IN OPERATION ..........
  • Page 7 FUSE REMOVAL ....................26 CONTROL SWITCHES REMOVAL ..............27 HOB COOLING THERMOSTAT REMOVAL ............27 FRONT COOLING FAN REMOVAL ..............28 HOB REMOVAL ....................29 LED DIGITAL DISPLAY PCB REPLACEMENT ............ 30 DISCONECT GENERATOR POWER CABLES ............ 31 7.10 DISCONECT COIL POWER CABLES ............... 32 7.11 GENERATOR REMOVAL .................

  • Page 8: Appliance Information

    1.0 APPLIANCE INFORMATION This appliance has been UKCA/CE marked based on compliance with the relevant Electrical and Electromagnetic Compatibility (EMC) Regulations/Directives for the voltages stated on the data plate. A - Serial No B - Model No C - Flue Type D - Gas Category E - Gas Pressure F - Gas Type...

  • Page 9: Operation

    2.0 OPERATION IF GLASS-CERAMIC TOP IS CRACKED OR BROKEN IMMEDIATELY DISCONNECT APPLIANCE FROM POWER SUPPLY AND CONTACT YOUR SERVICE AGENT. THE AIR INTAKE FILTERS MUST BE IN POSITION DURING OPERATION IT SHOULD BE CLEANED REGULARLY AND DO NOT OBSTRUCT AIR FILTER ENTRY BELOW. USERS MUST BE MADE AWARE THAT INDIVIDUALS FITTED WITH A PACEMAKER SHOULD CONSULT THEIR DOCTOR IF IN A CLOSE PROXIMITY TO THIS UNIT.

  • Page 10: Component Parts

    2.1 COMPONENT PARTS Glass hob Filter Hob zone control switch...

  • Page 11: Controls

    2.2 CONTROLS Power neon (red) Induction zone indicator Induction control switch Induction zone digital display...

  • Page 12: Using The Appliance

    2.3 USING THE APPLIANCE 2.3.1 Ensure you use the correct size of pot for each zone. Front and rear zone Ø120 – Ø250 <Ø120 Centre zone Ø120 – Ø300 <Ø120 Left hand and right hand zone Ø120 – Ø250 <Ø120 2.3.2 Ensure you use the correct type of pot...

  • Page 13: Do Not Place Pot Or Pan Over Digital Display

    2.3.3 Ensure you use a clean flat bottom pan. 2.4 DO NOT PLACE POT OR PAN OVER DIGITAL DISPLAY 2.4.1 This can result on digital display overheating. 2.5 WARNING WHEN USING MULTIPLE PANS ON THE SAME HOB 2.5.1 Do not arrange pans as below. Pans contacting each other as below can result in welding pans together:...

  • Page 14: Buzzing Noise Or Tone When In Operation

    2.5.2 Example of arrangement of pans that can make contact but do not create a stray electrical flows. 2.6 BUZZING NOISE OR TONE WHEN IN OPERATION When using large empty pans that straddle multiple zones, you may experience a buzzing noise/tone coming from the hob.

  • Page 15: Hob Settings 1-9

    2.8 HOB SETTINGS 1-9 2.8.1 Each cooking zone is controlled by a marked, variable control from 1 (lowest) to 9 (highest). 2.9 PAN DETECTION 2.9.1 This prevents the zones being turned on without a pan being present. It also switches the zone off as soon as a pan is removed.

  • Page 16: How To Operate

    2.12 HOW TO OPERATE 2.12.1 To adjust settings, turn the control switch clockwise and select your preference incrementally Note: As per solid top the centre zone or “bullseye” has the strongest output. Moving towards the sides , rear and front the output decreases. These zones do no deliver the same power output as the centre.

  • Page 17: Cleaning And Maintenance

    3.0 CLEANING AND MAINTENANCE When removing heavy items to aid cleaning or maintenance particular care should be taken. A manual handling risk assessment is the best way to determine the level of risk to anyone using or maintaining this equipment. To help with such an evaluation we have included the weights of individual components that may present significant risk.

  • Page 18: Cleaning

    3.1 CLEANING 3.1.1 Switch off appliance and allow appliance to cool down CLEAN THE AIR INTAKE FILTERS REGULARLY. FAILURE TO CLEAN THE FILTER REGULARLY MAY CAUSE PROBLEMS WHICH WILL NOT BE COVERED BY WARRANTY. THE AIR INTAKE FILTER MUST BE IN-PLACE DURING OPERATION. DO NOT ATTEMPT TO REPAIR OR REPLACE ANY PART OTHER THAN THE AIR INTAKE FILTER.

  • Page 19: Specification

    4.0 SPECIFICATION 4.1 APPLIANCE WEIGHT TABLE APPLIANCE UNIT WEIGHT (kg) PACKED WEIGHT (kg) I9097 4.2 ELECTRICAL DATA TABLE: Power 21.5kW Supply voltage 400VAC 3ph N Current per phase 32A Frequency 50/60Hz IF ANY CURRENT IS OUT WITH THESE TOLERANCES, THE CAUSE MUST BE INVESTIGATED AND RECTIFIED.

  • Page 20: Dimensions / Connection Locations

    5.0 DIMENSIONS / CONNECTION LOCATIONS...

  • Page 21: Installation

    6.0 INSTALLATION ELECTRICAL SAFETY AND ADVICE REGARDING SUPPLEMENTARY ELECTRICAL PROTECTION Commercial kitchens and foodservice areas are environments where electrical appliances may be located close to liquids, or operate in and around damp conditions or where restricted movement for installation and service is evident. The installation and periodic inspection of the appliance should only be undertaken by a qualified, skilled and competent electrician;...

  • Page 22: Siting / Clearances

    6.1 SITING / CLEARANCES THIS APPLIANCE CAN BE SITED AGAINST A COMBUSTABLE WALL. IF SUITING, THE NECESSARY CLEARANCES TO ANY COMBUSTIBLE WALL MUST BE THE LARGEST FIGURE GIVEN FOR INDIVIDUAL APPLIANCE INSTRUCTIONS.

  • Page 23: Assembly

    6.1 ASSEMBLY 6.1.1 Position the appliance and level using feet or castor adjusters as shown below. Adjustable feet 6.1.2 To adjust height of unit with feet twist lower half of feet as necessary. Adjustable castor 6.1.3 To adjust height of castor loosen grub screw and twist body of castor as necessary. 6.1.4 Once height set to required position tighten grub screw to secure.

  • Page 24: Electric Supply & Connection

    6.2 ELECTRIC SUPPLY & CONNECTION The location of the electrical inlet is as seen in section 5.0. this unit is suitable for AC supplies only. The standard terminal arrangement is Three phase (400V 3N~) for all variants. To install the mains cable, remove terminal cover and feed the cable through the cable gland and connect the mains supply to the terminal block.
  • Page 25 A suitable supply cord is supplied that conforms to BSEN 50525-2-51, cable type JZ-500 HMH-C. This appliance is designed to, and must, be connected to suitably rated isolator. A suitable rated isolating switch with contact separation of at least 3mm in all poles must be installed and wiring executed in accordance with relevant regulations On this model.

  • Page 26: Energy Optimization (According To Din 18875)

    6.3 ENERGY OPTIMIZATION (ACCORDING TO DIN 18875) The Solid top Hob system is capable of supporting energy optimization in Accordance with DIN 18875. A 4 -pin OPT interface on the generator can be directly connected to a power optimization system (LOA) via a 24V interface module specified in accordance with DIN 18875. The power can be reduced to the pre-set value which is defined with the parameter “PMG Reduction max”, it will be reduced by a percentage.
  • Page 27 More than one generator can be connected to the same 24V signal module. For activation the energy optimization over the ABCD-interface, the parameter “PMG Enable” needs to be set to “5”. Gland nut position shown for ref 4 Pin Opt Interface generator plugs positions shown for ref Energy optimization kit is an accessory see section 8.1 for further information.

  • Page 28: Commissioning

    6.4 COMMISSIONING Refer to section 2.0 for operation Carry out the following operation: 6.4.1 Turn on mains power supply on. 6.4.2 Ensure red neon(s) illuminates, 6.4.3 Ensure LED on Hob Illuminates and begins to flash. 6.4.4 Switch controls to “0” 6.4.5 Place a pan suitable for induction cooker tops, filled with water, upon a cooking zone.

  • Page 29: Suiting

    The DLS system Patent no. GB 2540131 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 6.6.1 Before levelling and suiting units ensure the units are fully built, including all...
  • Page 30 6.6.5 Run a bead of silicon 5mm from profile edge as highlighted below. 6.6.6 Slide suited units into position 6.6.7 (A) 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.
  • Page 31 6.6.10 (D) Replace fixings on the rear hob and tighten screw caps into position. 6.6.11 Replace control panel.

  • Page 32: Servicing

    7.0 SERVICING BEFORE ATTEMPTING ANY MAINTENANCE, ISOLATE THE APPLIANCE AT THE MAINS SWITCH AND TAKE STEPS TO ENSURE THAT IT IS NOT INADVERTENTLY SWITCHED ON. 7.1 CONTROL PANEL REMOVAL 7.1.1 7.1.1 Remove fixings at top control panel 7.1.2 When replacing panel, take care not to trap any connecting wires. Replace shake proof washers below fixings.

  • Page 33: Fuse Removal

    7.3 FUSE REMOVAL 7.3.1 Remove control panel as detailed in section 7.1 7.3.2 7.3.2 Remove fuse.

  • Page 34: Control Switches Removal

    7.4 CONTROL SWITCHES REMOVAL 7.4.1 Remove control panel as detailed in Section 7.1. 7.4.1 7.4.1 Remove switch connections and note wire arrangement. Pull off control knob. Undo fixings to release switch. 7.4.2 Fit replacement switch, ensuring that shake proof washers are fitted below the fixings 7.5 HOB COOLING THERMOSTAT REMOVAL 7.5.1 The hob chamber temperature is controlled with a thermostat, the thermostat is self- resetting.

  • Page 35: Front Cooling Fan Removal

    7.6 FRONT COOLING FAN REMOVAL 7.6.1 Remove control panel as detailed in section in 7.1 7.6.2 Disconnect generator power cables as detailed in section 7.8 7.6.3 7.6.3 Rotate catch on generator tray to enable tray to slide out. 7.6.4 Gently slide out generator tray ensuring not to snag any cabling within the unit. 7.6.7 7.6.5 7.6.6...

  • Page 36: Hob Removal

    HOB REMOVAL BEFORE ATTEMPTING ANY MAINTENANCE, ISOLATE THE APPLIANCE AT THE MAINS SWITCH AND TAKE STEPS TO ENSURE THAT IT IS NOT INADVERTENTLY SWITCHED ON. 7.7.2 7.7.1 7.7.1 Remove fixings at rear upper back panel. 7.7.2 Remove fixings on side panels. 7.7.4 7.7.3 7.7.3 Remove screws and bolts from control panel and carefully relocate control panel below...

  • Page 37: Led Digital Display Pcb Replacement

    7.8 LED DIGITAL DISPLAY PCB REPLACEMENT 7.8.1 Remove Hob as detailed in section 7.7 7.8.2 Un-do two screws on LED circuit board guard. 7.8.2 7.8.3 7.8.3 Using a 5.5mm Socket un-do four plastic nuts on LED circuit board. 7.8.4 Un-plug all display cables from rear of board. 7.8.5 When re-fitting ensure all cable connections are restored as detailed in the wiring diagram.

  • Page 38: Disconect Generator Power Cables

    7.9 DISCONECT GENERATOR POWER CABLES BEFORE ATTEMPTING ANY MAINTENANCE, ISOLATE THE APPLIANCE AT THE MAINS SWITCH AND TAKE STEPS TO ENSURE THAT IT IS NOT INADVERTENTLY SWITCHED ON. 7.9.1 Remove rear fan cover as detailed in section 7.2 7.9.2 Disconnect wires from terminal block and push wires back through grommet hole 7.9.3 Un-do screws on fan mounting tray 7.9.4 Tilt and remove fan mounting tray to access the rear of the generators 7.9.3...

  • Page 39: Disconect Coil Power Cables

    7.10 DISCONECT COIL POWER CABLES 7.10.1 Remove control panels as detailed in section 7.1 7.10.2 Remove rear fan cover as detailed in section 7.2 7.10.3 Disconnect generator power cables as detailed in section 7.9 7.10.4 Rotate catch on generator tray to enable tray to slide out. 7.10.4 7.10.3 7.10.5 Gently slide out generator tray ensuring not to snag any cabling within the unit.

  • Page 40: Generator Removal

    7.11 GENERATOR REMOVAL BEFORE ATTEMPTING ANY MAINTENANCE, ISOLATE THE APPLIANCE AT THE MAINS SWITCH AND TAKE STEPS TO ENSURE THAT IT IS NOT INADVERTENTLY SWITCHED ON. 7.11.1 Remove control panel as detailed in section 7.1 7.11.2 Release and open hob as detailed in section 7.7. 7.11.3 Disconnect relevant generator power cables as detailed section 7.9 7.11.4 Un-do screws and release relevant generator exhaust ducts from generator tray 7.11.4...
  • Page 41 7.11.8 Un-do two screws on fixing strap 7.11.9 7.11.8 7.11.9 Push back fixing strap and pull up to release (Note: fixing strap is hooked into generator tray). 7.11.10 Tilt Generator up from rear and lift from tray. 7.11.11 When re-fitting ensure all electrical connections & memory sticks are restored as detailed in the wiring diagram.

  • Page 42: Memory Stick Removal

    7.12 MEMORY STICK REMOVAL Generators have been fitted with external Memory sticks, this contains specific operating parameters for the appliance. 7.12.1 Remove control panels as detailed in section 7.1 7.12.2 Disconnect generator power cables as detailed in section 7.9 7.12.3 Rotate catch on generator tray. 7.12.4 Gently slide out generator tray ensuring not to snag any cabling within the unit 7.12.3 7.12.4...

  • Page 43: Induction Heater Coils Removal

    7.13 INDUCTION HEATER COILS REMOVAL BEFORE ATTEMPTING ANY MAINTENANCE, ISOLATE THE APPLIANCE AT THE MAINS SWITCH AND TAKE STEPS TO ENSURE THAT IT IS NOT INADVERTENTLY SWITCHED ON. 7.13.1 Remove hob as detailed section 7.7. 7.13.1 7.13.2 Disconnect relevant coil power wires as detailed in section 7.10 7.13.3 Disconnect relevant earth wires from coil supports 7.13.4 Whilst feeding sensor and power coil cables lift relevant coil carrier from unit 7.13.5...

  • Page 44: Rear Cooling Fan Removal

    7.14 REAR COOLING FAN REMOVAL 7.14.1 Remove fan rear cover as per section 7.2 7.14.2 Disconnect relevant fan leads from terminal block and undo four screws on fan to release. 7.14.2 Note: Two fans extract the hot air from inside the appliance. 7.14.3 When re-fitting ensure all electrical connections are restored as detailed in the wiring diagram.

  • Page 45: Capacitor Removal

    7.15 CAPACITOR REMOVAL BEFORE ATTEMPTING ANY MAINTENANCE, ISOLATE THE APPLIANCE AT THE MAINS SWITCH AND TAKE STEPS TO ENSURE THAT IT IS NOT INADVERTENTLY SWITCHED ON. WARNING: UNIT IS FITTED WITH A CAPACITOR BEFORE REMOVING ANY LINKS FROM THE MAINS TERMINAL OR DISCONNECTING THE MAINS LEADS, ENSURE THE CAPACITOR IS DISCHARGED OF ANY STORED VOLTAGE.

  • Page 46: Circuit Diagrams

    7.16 CIRCUIT DIAGRAMS 7.16.1 I9097 Circuit Diagram...

  • Page 47: Wiring Diagrams

    7.17 WIRING DIAGRAMS 7.17.1 I9097 Fan & neon wiring diagram...
  • Page 48 I9097 Generator A wiring diagram...
  • Page 49 7.17.2 I9097 Generator B wiring diagram.
  • Page 50 I9097 Control and data wiring diagram...

  • Page 51: Accessories

    8.0 ACCESSORIES 8.1 ENERGY OPTIMIZATION KIT (DIN 18875)

  • Page 52: Fault Finding

    9.0 FAULT FINDING 9.1 ERROR CODES 9.1.1 Most faults can be rectified by simply switching unit off for 10 seconds. After this time, turn power back on at mains supply. If fault continues to occur after such action then please refer to the table. This will provide a solution to rectify the condition. POSSIBLE CAUSE OF ERROR CODE DESCRIPTION...
  • Page 53 POSSIBLE CAUSE OF • ERROR CODE DESCRIPTION REMEDY ERROR Error/interruption of data • Communication error Call engineer • Reduce the cooking level • Switch of appliance and let the appliance cool down. Hob excessive temperature • ControlInduc® pans should not be used in continuous operation.
  • Page 54 POSSIBLE CAUSE OF ERROR CODE DESCRIPTION REMEDY ERROR Check mains voltage Check mains connection • Overload Magnetic coupling to others Call engineer Induction systems reduce Check connection of application specific temperature sensor of coil A Application sensor connection • Call engineer error Change configuration of device...
  • Page 55 POSSIBLE CAUSE OF • ERROR CODE DESCRIPTION REMEDY ERROR Turn off customer specific coil and let cool-down. • Coil excess temperature Call engineer Change configuration of device Check wiring of temperature sensor of customer-specific Connection-error coil coil • Call engineer temperature sensor Change configuration of device...
  • Page 56 POSSIBLE CAUSE OF • ERROR CODE DESCRIPTION REMEDY ERROR • Turn knob briefly off and Protection of restart after Change configuration of select cooking level again. disruption of current device • Call engineer • Switch off cooking zone Insufficient air flow to High heat sink temperature and allow to cool down.

  • Page 57: Spare Parts

    10.0 SPARE PARTS PART DESCRIPTION Power neon red LED digital display Control panel Control knob Knob coding switch Front hob cooling fan Fuse Capacitor Rear hob cooling fan Hob cooling thermostat Generator A Generator B Memory Stick ID1 Memory Stick ID2 Memory Stick ID3 Memory Stick ID4 Induction Heater On Carrier (Front or Rear Zone)

  • Page 58: Service Information

    11.0 SERVICE INFORMATION It is recommended to have a maintenance contract with a local service provider. To contact Falcon for a warranty issue dial (UK only) 01786 455 200 and select Warranty Issues from the menu. For our warranty policy please go to...

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