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FLEXIBLE BATCH
BROILER
MODELS
FBB-EO-208
FBB-EC-208
FBB-EO-230
FBB-EC-230
FBB-EO-240
FBB-EC-240
Please read this manual completely before attempting
This document is prepared for trained Duke service technicians. It is not to be used by anyone not
properly qualified to perform these procedures.
This Service Manual is not all encompassing. If you have not been trained on servicing this product,
be sure to read the manual completely before attempting servicing. Be sure all necessary tools,
test equipment, and skills are available. Those procedures for which you do not have the proper
skills and test equipment must be performed only by a qualified Duke trained service technician.
This manual is Copyright © 2010 Duke Manufacturing Co. All rights reserved.
Reproduction without written permission is prohibited. Duke is a registered
to install, operate or service this equipment
trademark of the Duke Manufacturing Co.
Duke Manufacturing Co.
2305 N. Broadway
St. Louis, MO 63102
Phone: 314-231-1130
Toll Free: 1-800-735-3853
Fax: 314-231-5074
www.dukemfg.com
Service Manual
P/N 177769A
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Table of Contents
Troubleshooting
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Summary of Contents for Duke FBB-EO-208
- Page 1 Please read this manual completely before attempting to install, operate or service this equipment This document is prepared for trained Duke service technicians. It is not to be used by anyone not properly qualified to perform these procedures. This Service Manual is not all encompassing. If you have not been trained on servicing this product, be sure to read the manual completely before attempting servicing.
- Page 2 Service Manual for Flexible Batch Broiler Units IMPORTANT WARNING AND SAFETY INFORMATION THIS MANUAL HAS BEEN PREPARED FOR PERSONNEL QUALIFIED TO INSTALL ELECTRICAL EQUIPMENT, WHO SHOULD PERFORM THE INITIAL FIELD START- UP AND ADJUSTMENTS OF THE EQUIPMENT COVERED BY THIS MANUAL. READ THIS MANUAL THOROUGHLY BEFORE OPERATING, INSTALLING OR PERFORMING MAINTENANCE ON THE EQUIPMENT.
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Page 3: Table Of Contents
Service Manual for Flexible Batch Broiler Units TABLE OF CONTENTS INTRODUCTION ..........................5 INSTALLATION ..........................5 OPERATION ...........................5 CLEANING .............................5 SPECIFICATIONS ..........................6 MODEL NUMBER KEY ........................6 TOOLS............................6 REMOVAL AND REPLACEMENT OF COMPONENTS ...............7 COVERS AND PANELS .........................7 Fuse Access Panel ........................7 Element Connection Access Panel ...................7 Electrical Access Panel ......................7 Product Pan Shelf ........................8 Discharge Hood ........................8... - Page 4 Service Manual for Flexible Batch Broiler Units SEQUENCE OF OPERATION ......................26 TROUBLESHOOTING ........................27 COMPONENT CHECK PROCEDURES ..................27 Checking the Power Switch ....................27 Checking the Control Board ....................27 Testing the Temperature Probe ....................27 Checking the Conveyor Drive Motor ..................27 Testing the Conveyor Drive Motor ..................28 Checking Conveyor Drive Motor Capacitor ................28 Testing the Relays ........................28 Testing the Transformers ......................29...
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Page 5: Introduction
Service Manual for Flexible Batch Broiler Units INTRODUCTION INSTALLATION CLEANING For detailed installation instructions, refer to the For specific cleaning instructions, refer to the Installation and Operation Manual. Installation and Operation Manual. OPERATION For specific operating instructions, refer to the Installation and Operation Manual. -
Page 6: Specifications
Service Manual for Flexible Batch Broiler Units SPECIFICATIONS ELECTRICAL PHASE POWER CATALYST MODEL NUMBER VOLTAGE AMPS CYCLE FBB-EO-208 23.5 kW FBB-EC-208 23.5 kW FBB-EO-230 23.5 kW FBB-EC-230 23.5 kW FBB-EO-240 23.5 kW FBB-EC-240 23.5 kW SHIPPING WEIGHT BATCH BROILER (STANDARD) -
Page 7: Removal And Replacement Of Components
Service Manual for Flexible Batch Broiler Units REMOVAL AND REPLACEMENT OF COMPONENTS COVERS AND PANELS 1. First remove Fuse Access Panel. Refer to the COVERS and PANELS section of the manual. 2. Remove Element Connection Access Panel by lifting up and removing from broiler WARNING 3. -
Page 8: Product Pan Shelf
Service Manual for Flexible Batch Broiler Units 2. To install the pan shelf, slide the keyholes over the two screws and slide pan shelf down. Product Shelf Discharge Hood Discharge Chute Hook Discharge Chute Discharge Pan The Discharge Pan is located on the discharge Product Pan Shelf and Discharge Hood side of the broiler below the Discharge Hood and is used to support the Product Pan (not supplied). -
Page 9: Discharge Grease Pan
Service Manual for Flexible Batch Broiler Units 1. Tilt Discharge Grease Pan up to unhook and pull forward to remove. 2. When installing the Discharge Grease Pan, be sure to tilt up and push all the way back. NOTE: Correct positioning will not allow pan removal without upward tilt. -
Page 10: Main Grease Pan
Service Manual for Flexible Batch Broiler Units Grease V-Pan 2. Remove Loader Tray from the Loader Brackets by pulling forward and disengaging ears on The Grease V-Pan is located on the front of the Loader Tray from keepers on the Loader broiler under the Loader Tray. -
Page 11: Conveyor Drive Motor Cover
Service Manual for Flexible Batch Broiler Units 2. Remove the three screws securing the cover 3. Reverse procedure to install the perforated to the broiler. Top Service Panel. 3. Lift Conveyor Drive Motor Cover off the broiler. Catalyst Guard Service Panel Conveyor Drive... -
Page 12: Removing The Front Panel
Service Manual for Flexible Batch Broiler Units 4. Pull the Grease V-Pan out of the front of the broiler. 5. Lift Front Panel up and away from broiler. 6. Reverse these steps to reinstall these parts. Front Access Panel Rear Access Panel Removing the Element Cover Panel 1. -
Page 13: Component Removal
Service Manual for Flexible Batch Broiler Units COMPONENT REMOVAL CONVEYOR DRIVE MOTOR ASSEMBLY 7. Reverse procedure to install a new motor. Ensure that one of the sprocket set screws is The Conveyor Drive Motor Assembly is located tightened to the flat side of the motor shaft. in the lower front of the broiler at the discharge end. -
Page 14: Conveyor Drive Chain
Service Manual for Flexible Batch Broiler Units NOTE: When installing the new chain, be sure WARNING to engage the chain on the motor sprocket and conveyor sprocket. Then adjust the tension DISCONNECT THE ELECTRICAL on the chain to allow 3/16" chain deflection, POWER TO THE BROILER AND as described in the procedure DRIVE FOLLOW LOCKOUT / TAGOUT... -
Page 15: Conveyor Drive Motor Capacitor
Service Manual for Flexible Batch Broiler Units CONVEYOR DRIVE MOTOR CAPACITOR 5. Reverse procedure to install a new Conveyor Drive Motor Capacitor. WARNING DISCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT / TAGOUT Conveyor Drive Motor PROCEDURES. Capacitor 1. -
Page 16: Cook Chamber Temperature Probe
Service Manual for Flexible Batch Broiler Units COOK CHAMBER TEMPERATURE PROBE 9. Slide new compression nut, fitting and sleeve onto Temperature Probe sheath. The Cook Chamber Temperature Probe connects 10. Insert Temperature Probe into tube fully and to the bottom of the Control Board and is located tighten compression nut. -
Page 17: Control Board
Service Manual for Flexible Batch Broiler Units Control Board Step-Down Transformer The Control Board is located on the front of the The Step-down Transformer is accessible by broiler. Control Board programming is preset at removing the Electrical Access Panel. The the factory with standard BURGER KING recipes. -
Page 18: Solid-State Relays
Service Manual for Flexible Batch Broiler Units SOLID-STATE RELAYS MAIN POWER SWITCH The Solid-State Relays are accessible by removing The Main Power Switch is located on the front of the Electrical Access Panel. There are a total of the broiler below the Control Board. Seven SSR’s. -
Page 19: Mechanical Relays
Service Manual for Flexible Batch Broiler Units MECHANICAL RELAYS REPLACING CONVEYOR LINKS The Mechanical Relays are accessible by removing the Electrical Access Panel. There are WARNING Two Mechanical Relays that are used in the Safety Panel Interlock system. DISCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT / TAGOUT WARNING... -
Page 20: Heating Elements
Service Manual for Flexible Batch Broiler Units HEATING ELEMENTS WARNING DISCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 2. Lift and remove rear access panel. NOTE: In the event of an element failure, the 3. Remove the element cover panel. Refer to the Controller will display an error message and COVERS and PANELS section of the manual. - Page 21 Service Manual for Flexible Batch Broiler Units 6. Disengage the clip by first removing the 9. Slide element module in place and reengage retaining pin on both top and bottom of clips and re-insert retaining pins. element module. 10. Reengage clips and re-insert retaining pins. 7.
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Page 22: Fuse Replacement
Service Manual for Flexible Batch Broiler Units FUSE REPLACEMENT 4. Replace any blown fuse(s) with correctly rated replacement fuse(s). 1. Check the fuses on the Fuse Panel. A lit Indicator lamp means a blown fuse. 5. Close the fuse holder. Plug in the broiler and check the indicator lamps. -
Page 23: Adjustments
Service Manual for Flexible Batch Broiler Units ADJUSTMENTS DRIVE CHAIN DEFLECTION ADJUSTMENT CONVEYOR POSITION ADJUSTMENT The Conveyor position is adjusted by adding The Drive Chain connects the drive motor to the shims between the Conveyor Shaft Bearing and Conveyor. the frame. 1. -
Page 24: Ash Scraper Bracket Adjustment
Service Manual for Flexible Batch Broiler Units ASH SCRAPER BRACKET ADJUSTMENT LOADER DOOR SEAL BRACKET The Ash Scraper Bracket support the Ash Scraper The Loader Door Seal Bracket supports the Loader Door and assists to seal any gap between the on the Discharge end of the Broiler. -
Page 25: Product Stop Bracket Adjustment
Service Manual for Flexible Batch Broiler Units Product Stop Bracket Adjustment The Product Stop Bracket sits above the cook chain on the back wall of the cook cavity. It prevents product from being loaded and pushed up on top of the cook chain links. 1. -
Page 26: Sequence Of Operation
Service Manual for Flexible Batch Broiler Units SEQUENCE OF OPERATION TURN ON Read†Temperature NOTE: Diagnostics – See TROUBLESHOOTING for possible Display results. Diagnostics Read†Temperature Loop†Until†Temperature †“iSEt”†(740F†[393C]) Idle Cycle: Top Elements Temperature cycle by “iPL” = 6 †740F†(393C)? ON: 6 sec, OFF: 4 sec Turn LEDs for Product Keys with Non-Zero... -
Page 27: Troubleshooting
Service Manual for Flexible Batch Broiler Units TROUBLESHOOTING The following troubleshooting information includes NOTE: If the Control Board is still not performing checking procedures for various electrical properly, try these procedures: components in order to help identify faulty components. The troubleshooting guide below is 1. -
Page 28: Testing The Conveyor Drive Motor
Service Manual for Flexible Batch Broiler Units 3. Discharge the Capacitor by shorting both Testing the Conveyor Drive Motor terminals to ground at the same time. The Conveyor Drive Motor may be tested without 4. Use an Ohmmeter to test the Capacitor. removing it from the broiler. -
Page 29: Testing The Transformers
Service Manual for Flexible Batch Broiler Units The Conveyor Drive Motor runs when the Drive TESTING THE MECHANICAL RELAYS Motor Relay is energized by the Control. The two Mechanical Relays work in conjunction The Solid State Relay that controls the Conveyor with the safety interlocks to allow safe access to Drive Motor, utilizes a 4.5 - 32 VDC (typically 6 the various areas of the Broiler. -
Page 30: Control Diagnostics
Service Manual for Flexible Batch Broiler Units CONTROL DIAGNOSTICS The Broiler Control consists of two programming modes and two diagnostic modes. To enter any of these 4 modes, it is required to first hold down the ENTER button for a few seconds until CODE is displayed. Then enter the 4 digit passcode provided below and press ENTER. - Page 31 Service Manual for Flexible Batch Broiler Units 2. Failure Counts The Control Board keeps track of how many times product buttons are depressed. It also tracks Element failures and other various failures as shown below. Passcode: 1 2 3 4 Prd1 = Prd1 depressions Prd2 = Prd2 depressions Prd3 = Prd3 depressions...
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Page 32: Troubleshooting Chart
Service Manual for Flexible Batch Broiler Units TROUBLESHOOTING CHART Symptom Cause Remedy Verify 208/240 VAC, 3 phase, present at receptacle. Confirm 208 VAC or 240 VAC on Serial Number Label. No Power Ensure 208/240 VAC, line-to-line, at incoming terminal block. Control display does not Ensure 208/240 VAC across input / output of light up... - Page 33 Service Manual for Flexible Batch Broiler Units Symptom Cause Remedy Identify correct Heater location and test Element continuity. Fuse Test continuity of appropriate Fuse. Display shows “hT:Er” – Ensure Solid State Relay switches ON / OFF (Possible error during “PrE”) Solid State Relay at appropriate intervals.
- Page 34 Service Manual for Flexible Batch Broiler Units Symptom Cause Remedy High Limit Test continuity on Thermostat located on Thermostat Relay Heat Sink. Ensure Cooling Fan runs when On / Off Cooling Fan Display shows “triP” Switch is turned ON. Clean Cooling Fan and any other item which Cooling may not be allowing Relay Heat Sink to obstruction...
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Page 35: Preventive Maintenance
Service Manual for Flexible Batch Broiler Units PREVENTIVE MAINTENANCE SEMIANNUAL 2. Perform a visual inspection of the Broiler, noting and repairing any electrical connection which It is recommended to perform preventative appears damaged. maintenance on the Broiler every 6 months. Over 3. -
Page 36: Electrical Schematic - Flexible Batch Broiler
Service Manual for Flexible Batch Broiler Units ELECTRICAL SCHEMATIC – FLEXIBLE BATCH BROILER Heatsink Electric FBB, 208/240V~ 3P WHT 51 Thermo YEL 50 WHT 51 Limit *Shown with power ON & in normal operation mode RED 71 177623C BLK 41 PUR 70 BLK 28 BLK 31... - Page 37 Service Manual for Flexible Batch Broiler Units NOTES...
- Page 38 Service Manual for Flexible Batch Broiler Units NOTES...
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Page 39: Customer Assistance
Phone: +420 257-741-033 Fax: 314-231-5074 UK & IRELAND ASIA Duke Mfg UK Asia Office Duke House Duke Food Service Equipment Unit 10, Greendale Business Park (shanghai) Company Limited Woodbury Salterton 1F, Building #17-2, Exeter 658 Nong Jin Zhong Road Devon - UK EX5 1EW... - Page 40 Devon - UK EX5 1EW Tel: +44 (0) 1395 234140 FAX: +44 (0) 1395 234154 Asia Office Duke Food Service Equipment (shanghai) Company Limited 1F, Building #17-2, 658 Nong Jin Zhong Road Shanghai, China 200335 Tel: +86 21 6876 9272...
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