Falcon G3840XP Installation, Servicing And User Instructions Manual

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G3840 SERIES FRYERS
INSTALLATION, SERVICING and USER INSTRUCTIONS
CAUTION: Read the instructions before using the appliance
These appliances 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 & Safety at work, etc Act
Local and National Building Regulations
Detailed recommendations are contained in DW172 Institute of Gas Engineers published documents:
IGE/ UP/ 1, IGE/ UP/ 2, IGE/ UP/ 4, BS6173 and BS5440
These appliances have been UKCA/CE-marked based on compliance with the Gas Appliance
Regulations/Product Safety and Metrology Regulations, Electrical and Electromagnetic Compatibility
(EMC) Regulations/Directives for the Countries, Gas Types and Pressures as stated on the data plate.
WARNING - TO PREVENT SHOCKS, ALL APPLIANCES, 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 user instructions should be handed over to the user,
having had a demonstration of the operation and cleaning of the appliance.
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.
We recommend that the oil level sensor (UK Patent Serial No. GB2584184) in the
G3840X/G3840FX/G3840XP/G3840FXP models should be serviced annually.
WEEE Directive Registration No. WEE/DC0059TT/PRO
At end of unit life, dispose of appliance and any replacement parts in a safe
manner, via a licenced waste handler. Units are designed to be dismantled
easily and recycling of all material is encouraged whenever practicable.
This equipment is ONLY FOR PROFESSIONAL USE and shall be operated by QUALIFIED persons.
It is the responsibility of the supervisor or equivalent to ensure that users wear SUITABLE
PROTECTIVE CLOTHING and to draw attention to the fact that some parts will, by necessity, become
VERY HOT and will cause burns if touched accidentally.
Falcon Foodservice Equipment
Wallace View, Hillfoots Road, Stirling, FK9 5PY, Scotland
Phone: 01786 455200
I.E.E. Regulations for Electrical Installations
Electricity at Work Regulations
Fire precaution Act
T100806 Ref.19

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Summary of Contents for Falcon G3840XP

  • Page 1 We recommend that the oil level sensor (UK Patent Serial No. GB2584184) in the G3840X/G3840FX/G3840XP/G3840FXP models should be serviced annually. WEEE Directive Registration No. WEE/DC0059TT/PRO At end of unit life, dispose of appliance and any replacement parts in a safe manner, via a licenced waste handler.
  • Page 2: Table Of Contents

    STARTING UP ..............................16 PRE-COMMISSIONING CHECK .......................... 20 TEMPERATURE LIMIT THERMOSTAT ........................ 21 OIL LEVEL SENSOR (G3840X/G3840XP/G3840FX/G3840FXP only) ..............21 INSTRUCTION TO USER ............................ 21 SERVICING, MAINTENANCE AND CONVERSION ....................21 GAS CONVERSION (Natural to propane or propane to natural) ..............22 INTEGRAL COMPONENTS ..........................
  • Page 3 TEMPERATURE LIMIT THERMOSTAT ........................ 25 5.16 OIL LEVEL SENSOR (G3840X/G3840FX/G3840XP/G3840FXP only, Figure 7) ........... 25 5.17 TOP UP AND LOW OIL LEVEL LEDS (G3840X/G3840FX/G3840XP/G3840FXP only, Figure 7) ......26 5.18 OIL LEVEL SENSOR EVALUATION UNIT (G3840X/G3840FX/G3840XP/G3840FXP only, Figure 7) ....26 5.19 RELAYS &...
  • Page 4 13.15 G3840FX CIRCUIT DIAGRAM ..........................54 13.16 G3840FXP CIRCUIT DIAGRAM .......................... 55...
  • Page 5: Safety Guidance

    1.0 SAFETY GUIDANCE GENERAL SAFETY 1.1.1 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. 1.1.2 These appliances have been UKCA/CE-marked based on compliance with the Gas Appliance Regulations/Product Safety and Metrology Regulations, Electrical and Electromagnetic Compatibility (EMC) Regulations/Directives for...
  • Page 6: Installation Safety

    1.1.15 Record the training that you provide and support it by providing safe system of work (SSOW) documents that set out procedures to be followed for potentially hazardous tasks. 1.1.16 For further help and information on risk assessments we would refer you to you the Health and Safety Executive website;...
  • Page 7: Gas Safety

    GAS SAFETY 1.4.1 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. 1.4.2 Before Inspection, Servicing or Conversion, Turn Off Gas at isolator.
  • Page 8: Maintenance Safety

    1.5.9 Ensure that the appliance, surrounding work area and extraction system are regularly cleaned, (at least weekly) to avoid the build-up of fats oils and greases that could present a fire risk. A deep clean should be undertaken at least every 6 months by a specialist contractor.
  • Page 9 1.6.11 If the thermostats or capillaries are damaged, then do not turn the appliance on and contact Falcon or you approved service provider to undertake the necessary repairs. 1.6.12 In the extraordinary event that the oil level sensor does come into contact with fire the probe should be replaced.
  • Page 10: Symbols & Labels

    2.0 SYMBOLS & LABELS SCREWDRIVER SPANNER COOKING OIL GREASE WARNING SPARK IGNITION FLAME VIEWPORT ALLEN KEY IGNITER C SPANNER REMOVE DEVICE PLUG REMOVER WARNING READ MANUAL ELECTRICITY...
  • Page 11: Transport & Installation

    3.0 TRANSPORT & 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.
  • Page 12: Model Numbers, Nett Weights & Dimensions

    Weight Fryer Model (mm) (mm) (mm) (kg) Model (mm) (mm) (mm) (kg) G3840 1090 G3840P 1090 G3840X 1090 G3840XP 1090 G3840F 1090 G3840FP 1090 G3840FX 1090 G3840FXP 1090 Pan oil capacity: 18 litres cold, good quality oil (to –MIN- mark)
  • Page 13: Siting

    The fresh air requirement for this appliance at a rate of 2M³/hour per kW is 44 M³ is as follows: COMBUSTION AIR REQUIREMENTS APPLIANCE VENTILATION ATE APPLIANCE VENTILATION ATE G3840 44 m G3840P 44 m G3840X 44 m G3840XP 44 m G3840F 44 m G3840FP 44 m G3840FX 44 m G3840FXP 44 m...
  • Page 14: Gas Supply (All Models)

    GAS SUPPLY (All Models) To be checked at installation, gas conversion or repair. Note: Governor setting may be checked at burner manifold without the need to remove the right-hand side panel. To adjust appliance pressure; The SIT gas valve, situated at rear RH side of unit and accessible by removing RH side, has an in-built governor.
  • Page 15: Electrical Supply

    G3840 / G3840X / G3840F / G3840FX / Rated Voltage Rated Current G3840P / G3840XP / G3840FP / G3840FXP 230V~ 3.55amps TOTAL RATED HEAT INPUTS BTU/Hr...
  • Page 16: Assembly And Commissioning

    4.0 ASSEMBLY and COMMISSIONING The gas supply piping and connection to appliance must be installed in accordance with the local regulations in conjunction with those listed on the cover of this manual. ASSEMBLY Unpack appliance. Unpack fryer baskets and accessories. Place basket support grid and basket in pan.
  • Page 17 G3840/F Fryer Control Panel (See Figure 2) Figure 2 – G3840 Control panel ON/OFF and Temperature Control Knob Temperature Selection (140 - 190°C). (Unit is off when control is in position indicated). Fat Melt Position Feature for slow pulsed heating of solid fats. Power on indicator.
  • Page 18 A small green dot after the first digit. Illuminates when thermostat demands heat, i.e., oil is more than 2ºC below programmed set temperature. Will extinguish when desired setting is reached. G3840XP/FXP Fryer Control Panel (See Figure 5) Figure 5 – G3840XP/G3840FXP Control Panel...
  • Page 19 Four Digit LED Display Displays Set temp, Actual temp, cook time remaining and used for programming purposes. Program Button Used to enter timer programme mode (to change each of the 4 pre-set timer select channels - See Section 6). Temperature Button Used to view Actual/Set temperature and to enter Set temperature mode (See Section Timer Keys (1 –...
  • Page 20: Pre-Commissioning Check

    G3840, G3840X, G3840F & G3840FX Controller Diagnostic Indicators (On printed circuit board of controller, behind control panel) Green LED ‘ON’ indicates heat demand. Green LED ‘OFF’ indicates no heat demand. Red LED flashes if temperature probe is either short or open circuited. Red LED is permanently ‘ON’...
  • Page 21: Temperature Limit Thermostat

    Re-select temperature. If limit thermostat reactivates carry out fault finding on temperature control circuitry. OIL LEVEL SENSOR (G3840X/G3840XP/G3840FX/G3840FXP only) The unit is equipped with an additional Oil Level Sensor (Patent No. GB2584184). When the oil level drops to at least 40mm below the MIN mark, then the Top Up Oil LED will indicate (Orange oil can symbol) warning the user that the oil level has dropped considerably.
  • Page 22: Maintenance Check

    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. BEFORE ATTEMPTING ANY SERVICING, TURN OFF GAS SHUTOFF VALVE AND ELECTRICAL SUPPLY.
  • Page 23: Integral Components

    1. Change Main Jets. 2. Change Pilot injector. 3. Adjust Governor. 4. Change Data badge. INTEGRAL COMPONENTS Check and service the following parts regularly: Oil ingress to electrical components. Flue for any blockages. Visual inspection of components and fryer pan. Temperatures limit thermostat calibration.
  • Page 24: Burner Reset Switch, On/Off Switch And Filtration Pump Switch

    Disconnect wires connected to board from loom. G3840/G3840X/G3840F/G3840FX only Remove Control Knob. From front of control panel, remove fixings to enable controller to be removed. G3840P/G3840XP/G3840FP/G3840FXP only Disconnect electrics and remove fixings to enable controller to be removed. Carefully replace in reverse order. 5.11 MAINS ON and HEAT DEMAND NEONS Remove control panel by undoing fixings at top and bottom of control panel.
  • Page 25: Drain Valve

    - carefully tap capillary sealing washers through to control compartment. Remove thermostat. Disconnect thermostat wires. Carefully replace in reverse order. Check for oil leaks and that thermostat calibration is within specification. 5.16 OIL LEVEL SENSOR (G3840X/G3840FX/G3840XP/G3840FXP only, Figure 7) a) Ensure fry pot is empty b) Remove back panel.
  • Page 26: Top Up And Low Oil Level Leds (G3840X/G3840Fx/G3840Xp/G3840Fxp Only, Figure 7)

    In the extraordinary event that the oil level sensor does come into contact with fire. The probe should be replaced. 5.17 TOP UP AND LOW OIL LEVEL LEDS (G3840X/G3840FX/G3840XP/G3840FXP only, Figure 7) a) Remove control panel by undoing fixings at top and bottom of control panel. Disconnect control panel.
  • Page 27: Spares

    Figure 7 – Oil level sensor circuit components 6.0 SPARES When ordering spare parts, always quote appliance type and serial number. This information will be found on unit data plate, located inside the fryer door on LH leg support face. Operating Controller Operating Controller Knob Operating Controller Temperature Sensing Probe...
  • Page 28: Critical Dimensions

    7.0 CRITICAL DIMENSIONS thermi stor Figure 8 – Critical dimensions...
  • Page 29: Operating Instructions

    G3840FX – Manual control model with inbuilt filtration and oil level sensor. G3840P – Programmable control model. G3840XP - Programmable control model with oil level sensor. G3840FP - Programmable control model with inbuilt filtration. G3840FXP – Programmable control model with inbuilt filtration and oil level sensor.
  • Page 30 Warning This appliance should only be used with both oil temperature controlling Thermostat and Thermal limit (safety) Thermostat in working condition. NEVER leave a working unit unattended. Medium must always be maintained within fry pot. Cold Medium - when filling with cold medium (see Figure 9), DO NOT FILL MEDIUM PAST -MIN- LEVEL MARK (Maximum cold fill mark) also, for Solid Medium - See Section 9.
  • Page 31: Appliance Controls

    Refer to individual unit info below. G3840/G3840X/G3840F/G3840FX only - Heat demand indicator will illuminate. G3840P/G3840XP/G3840FP/G3840FXP only – Display will illuminate with figures 8888 for 2 secs, CTT for 2 secs, r 02 for 2 secs and SEt dEg flashes. Press ↓1 or 4↑ on control panel, last temperature will display, if temperature acceptable press...
  • Page 32 Fat or oil temperature will then be governed by controller to desired set temperature, selected by user on the control knob. G3840P/G3840XP/G3840FP/G3840FXP Models only – Programmable When unit is lit as detailed in Section 7.2. lighting instructions above, fryer may be...
  • Page 33: Programming The G3840P/G3840Xp/G3840Fp/G3840Fxp

    (C or F depending on how controller is programmed – See Section 7.3). If temperature key is not pressed again within 5 seconds, display returns to idle or timer mode. PROGRAMMING THE G3840P/G3840XP/G3840FP/G3840FXP Display Descriptions Set dEg – Indicates that the operator needs to set a temperature.
  • Page 34: Changing/Filtering The Oil

    Select a product key to program (1 to 4). The display will alternate between “ti-z” and “X:XX” where z is the number of the key pressed and X:XX is the set time in minutes and seconds. Adjust the time up or down using the DOWN (key 1) and the UP (key 4) keys. The longer key is held, the faster time will scroll.
  • Page 35: Starting The Filtration Process

    Ensure all shortening has been pumped from receptacle before topping up pan. Switch filtration pump off. Top up fryer if required. Please Note If the G3840X/G3840FX/G3840XP/G3840FXP pan has not been refilled until at least the low oil level indication (Flashing hazard triangle) clears, then the fryer will not light.
  • Page 36: Cleaning And Maintenance

    10.0 CLEANING and MAINTENANCE BEFORE ANY CLEANING IS UNDERTAKEN, ISOLATE APPLIANCE FROM MAINS POWER SUPPLY AT ISOLATOR SWITCH. SUITABLE PROTECTIVE CLOTHING MUST BE WORN WHEN CLEANING THIS APPLIANCE. NEVER PUMP WATER THROUGH THE FILTRATION PUMP AT ANY TIME WATER AND HOT OIL ARE AN EXPLOSIVE MIXTURE.
  • Page 37 SERVICE PROVIDER TO UNDERTAKE THE NECESSARY REPAIRS. Location of Safety and Operating Thermostat Probes Slide up the oil level sensor guard (G3840X/G3840FX/G3840XP/G3840FXP only). Oil level sensor guard raised for cleaning Clean guard and sensor probe using a soft, clean cloth and hot soapy water (G3840X/G3840FX/G3840XP/G3840FXP only).
  • Page 38: Preparation Of Solid Fats / Shortening

    Oil level sensor guard lowered for normal operation Remove oil bucket by pulling forward then upward. Use handles and lift oil bucket to sink. Pour away soiled water. Note – All spills onto this product and on the floor should be cleaned up immediately. Thoroughly wash, rinse and dry oil bucket and oil suction pipe.
  • Page 39: Cooking Hints

    When topping up with oil, ensure oil level does not exceed -MIN- line when cold and -MAX- line when hot. Never overfill baskets with food product. Warning (G3840X/G3840FX/G3840XP/G3840FXP only) Do not pour food stuffs directly onto the oil level sensor guard, as this may affect the performance of the oil level sensor.
  • Page 40: Wiring Diagrams

    13.0 WIRING DIAGRAMS 13.1 G3840 WIRING DIAGRAM...
  • Page 41: G3840X Wiring Diagram

    13.2 G3840X WIRING DIAGRAM...
  • Page 42: G3840P Wiring Diagram

    13.3 G3840P WIRING DIAGRAM...
  • Page 43: G3840Xp Wiring Diagram

    13.4 G3840XP WIRING DIAGRAM...
  • Page 44: G3840F Wiring Diagram

    13.5 G3840F WIRING DIAGRAM...
  • Page 45: G3840Fp Wiring Diagram

    13.6 G3840FP WIRING DIAGRAM...
  • Page 46: G3840Fx Wiring Diagram

    13.7 G3840FX WIRING DIAGRAM...
  • Page 47: G3840Fxp Wiring Diagram

    13.8 G3840FXP WIRING DIAGRAM...
  • Page 48: G3840 Circuit Diagram

    13.9 G3840 CIRCUIT DIAGRAM...
  • Page 49: G3840X Circuit Diagram

    13.10 G3840X CIRCUIT DIAGRAM...
  • Page 50: G3840P Circuit Diagram

    13.11 G3840P CIRCUIT DIAGRAM...
  • Page 51: G3840Xp Circuit Diagram

    13.12 G3840XP CIRCUIT DIAGRAM...
  • Page 52: G3840F Circuit Diagram

    13.13 G3840F CIRCUIT DIAGRAM...
  • Page 53: G3840Fp Circuit Diagram

    13.14 G3840FP CIRCUIT DIAGRAM...
  • Page 54 13.15 G3840FX CIRCUIT DIAGRAM...
  • Page 55 13.16 G3840FXP CIRCUIT DIAGRAM...

This manual is also suitable for:

G3840xG3840fxG3840 seriesG3840fxp

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