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BURGER KING
FLEXIBLE
BATCH BROILER -
LOWER BURNER
UPGRADE
Please read this manual completely before attempting
This manual is Copyright © 2014 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
Installation and
Operation Manual
P/N 176483C
10/1/2014
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Summary of Contents for Duke FBB-NO-120
- Page 1 Please read this manual completely before attempting to install, operate or service this equipment This manual is Copyright © 2014 Duke Manufacturing Co. All rights reserved. Reproduction without written permission is prohibited. Duke is a registered trademark of the Duke Manufacturing Co.
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Page 2: Table Of Contents
Installation and Operation of Flexible Batch Broiler TABLE OF CONTENTS IMPORTANT WARNING AND SAFETY INFORMATION ..........4 I. GENERAL INFORMATION .....................5 A. BATCH BROILER SPECIFICATIONS ..............5 A-1.0 Model Number Key ...................5 A-2.0 Broiler Dimensions ...................6 II. INSTALLATION INSTRUCTIONS .................7 A. QUALIFIED PERSONNEL ..................7 B. - Page 3 Installation and Operation of Flexible Batch Broiler D-3.2 Cook Temperature “Sett” ...............25 D-3.3 Cooking Profile “on 1”, “oFF1”, “on 2”, “oFF2” ........25 D-3.4 Exit Program Mode .................26 D-4.0 Level 2 Programming ................26 D-4.1 ºF or ºC Parameter “dEg” ...............26 D-4.2 Change the Idle Temperature “Sett” ............26 D-4.3 Additional Factory Parameters ...............26 D-4.4 Exit Program Mode .................26 E.
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Page 4: Important Warning And Safety Information
Installation and Operation of Flexible Batch Broiler IMPORTANT WARNING AND SAFETY INFORMATION POST IN A PROMINENT LOCATION instructions to be followed in the event the user smells gas. This information shall be obtained by consulting the local gas supplier. FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. -
Page 5: General Information
1.70mm LOWER BURNER 3.26mm 2.06mm SHIPPING WEIGHT: 482 lbs (219 Kg) SHIPPING DIMENSIONS: 47” x 34” x 68” (119.4 x 86.4 x 172.7 cm) MODEL NUMBER ELECTRIC NATURAL & LP GAS FBB-NO-120 120VAC, 2A, 60Hz 94,000 – 100,000 BTU/HR FBB-NC-120 120VAC, 2A, 60Hz 94,000 – 100,000 BTU/HR FBB-PO-120 120VAC, 2A, 60Hz 94,000 – 100,000 BTU/HR... -
Page 6: A-2.0 Broiler Dimensions
Installation and Operation of Flexible Batch Broiler A-2.0 Broiler Dimensions 44" 50 3/8" (111.9 cm) (128 cm) 8 1/2" 20 3/4" (21.6 cm) (52.9 cm) 63 5/8" 55 5/8" 53 5/8" (161.7 cm) (141.4 cm) (136.1 cm) 39 1/2" (100.3 cm) 45 5/8"... -
Page 7: Installation Instructions
Installation and Operation of Flexible Batch Broiler II. INSTALLATION INSTRUCTIONS A. QUALIFIED PERSONNEL The installation must conform with local codes, or in the absence of local codes, with the National Fuel Gas These installation instructions are for the use of qualified Code, ANSI Z223.1/NFPA 54, or the Natural Gas and installation and service personnel only. Installation or Propane Installation Code, CSA B149.1 as applicable, service by other than qualified personnel may result in including: damage to the broiler and/or injury to the operator. • The appliance and its individual shutoff valve must Qualified installation personnel are those individuals, be disconnected from the gas supply piping system firms, companies or corporations which either in person or... -
Page 8: Delivery And Inspection
Installation and Operation of Flexible Batch Broiler B. DELIVERY AND INSPECTION Duke Manufacturing Co. does everything within its power to insure you received your broiler in good condition. They are strapped down on heavy wooden skids and packed to prevent shipping damage. They have all been carefully inspected before they were packaged and consigned to the carrier. -
Page 9: Broiler Assembly
Installation and Operation of Flexible Batch Broiler C. BROILER ASSEMBLY Before assembling and installing the broiler, please check to make sure that all necessary parts are present. ITEM PART NAME PT.NO. ITEM PART NAME PT.NO. PRODUCT PAN SHELF 175353 KIT – USER REPLACEABLE, 600311 BOTTOM BURNER, FLAME DISCHARGE CHUTE 175340 ARRESTOR, LOADER & BURNER SHIELD (OPTIONAL) DISCHARGE HOOD 175778 KIT – USER REPLACEABLE,... -
Page 10: Setup
Installation and Operation of Flexible Batch Broiler Setup D. ADJUSTMENTS AT INSTALLATION Install all items as shown below. Each broiler section and all its component parts have been tested thoroughly and inspected before your broiler was shipped from the factory. However, it is sometimes necessary to further test or adjust the broiler once it has been installed. -
Page 11: Raise Or Lower Broiler
Installation and Operation of Flexible Batch Broiler Raise or Lower Broiler E. LOCATION OF THE BROILER The broiler height can be adjusted via two screws on Proper planning and placement of the broiler will each leg. give you the best results in terms of long-term user convenience and satisfactory performance. -
Page 12: Notice To Installer
Gas supply pressure must be checked prior to installation. If supply pressure is in excess of 12" W.C., A mechanically driven exhaust hood must have a The HIGH SUPPLY PRESSURE KIT, Duke P/N 175689 minimum capacity of 1700 m3/hr (1000 cfm) with a shall be installed and adjusted, per kit instructions, for minimum 100cm by 130cm (39.4 in by 51.2 in) opening to an outlet pressure of: adequately vent this appliance. The specified capacity... -
Page 13: Operation Instructions
Installation and Operation of Flexible Batch Broiler III. OPERATION INSTRUCTIONS The information in this section is intended for the use of qualified operating personnel. Qualified Operating Personnel are those individuals who have carefully read the information contained in this manual, are familiar with the function of the broiler and/or have had IF LIGHT ON experience with operating the equipment described. -
Page 14: Cooking Product
Installation and Operation of Flexible Batch Broiler B. COOKING PRODUCT • The LED's next to all product keys with non-zero B-1.0 Lighting the Broiler cook times will be red. • Start Ventilation System. • The control will display rdY at the completion of • Turn ON/OFF switch to the ON (1) position. the pre-heat cycle and the LED’s next to all product keys with non-zero cook times will be green. -
Page 15: B-3.0 Cook Cycle Complete
Installation and Operation of Flexible Batch Broiler B-3.0 Cook Cycle Complete The first press of the key brings up the adjustment screen. The control will display the total The chain will rotate and discharge the product. product cook time including the previous fine cooking Do not load product into broiler until the cook light has adjustment. -
Page 16: Cleaning
Installation and Operation of Flexible Batch Broiler C. CLEANING or mar the tile surfaces or cause blockage of the gas ports in the tile faces. Do not spray flame sensing The exterior stainless steel on your broiler can be kept rods with any foreign materials. Chemical cleaners, clean with a good non-abrasive stainless steel cleaner, degreasers and soap solutions must never be many of which are on the market. - Page 17 Installation and Operation of Flexible Batch Broiler CLEANING SCHEDULE WHAT’S TO BE CLEANED BROILER DISCONNECT COOL POWER 4 HOUR CLEANING (Sanitize in place) SANITIZE LOADER & TRAY (CAUTION: HOT SURFACES, WEAR INSULATED GLOVES WHILE CLEANING) SANITIZE DISCHARGE CHUTE DAILY CLEANING (Remove and Wash/Rinse/Sanitize) DISCHARGE PAN (CAUTION: HOT SURFACES, WEAR INSULATED GLOVES WHILE CLEANING) DISCHARGE HOOD DISCHARGE GREASE PANS MAIN GREASE PANS DISCHARGE END PANEL...
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Page 18: C-1. Four (4) Hour Cleaning
Installation and Operation of Flexible Batch Broiler C-1. Four (4) Hour Cleaning All components that are in contact with food product must be cleaned and sanitized every 4 hours. Loader and Carriage: Remove loader from carriage and sanitize food contact areas. Caution: Hot surface near door! Wear insulated gloves. Discharge Chute: With discharge hood removed, sanitize outside chute surface. -
Page 19: C-2. Daily Cleaning
Installation and Operation of Flexible Batch Broiler C-2. Daily Cleaning Daily cleaning should also include all items listed in the 4 hour cleaning schedule. Discharge Hood and Chute: Remove hood and chute completely, clean and replace. Discharge Pan: Slide pan up and out of keyhole slots. - Page 20 Installation and Operation of Flexible Batch Broiler C-2. Daily Cleaning (cont’d.) Discharge End Panel: Discharge Scraper: Discharge Scraper: Remove discharge accessories Lift up and pull forward. Pull out removing locating pins and lift panel up while swinging from slots. Clean scraper and out and down.
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Page 21: C-3. Weekly Cleaning
Installation and Operation of Flexible Batch Broiler C-3. Weekly Cleaning Swing the right side of With outer front panel the panel out as shown. removed, lift up the Clean and set aside. combustion chamber panel. Remove burner shield. Remove discharge panel and scraper as was performed for daily cleaning. -
Page 22: Cleaning Considerations
Installation and Operation of Flexible Batch Broiler C-3. Weekly Cleaning (cont’d) SAFETY CONSIDERATIONS The catalytic converter (catalyst) is normally part CLEANING CONSIDERATIONS of a combustion system, and the general safety practices observed with such systems should be practiced. The following considerations are specific Do not use soap, detergents, to the catalyst portion. - Page 23 Installation and Operation of Flexible Batch Broiler C-3. Weekly Cleaning (cont’d) Gently tap frame of the catalyst while Begin with a clean sink and remove holding over a waste bin to dislodge any all foreign matter from any wash loose ash/carbon particles. basin used, before starting the catalyst washing process.
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Page 24: C-4. Monthly Cleaning
Installation and Operation of Flexible Batch Broiler C-4. Monthly Cleaning L IG Remove top panel by Locate the flame sensors Use caution and safely remove the lifting up and out. for the upper burners. sensor by holding onto the black boot at the base of the sensor. -
Page 25: Programming The Control
Installation and Operation of Flexible Batch Broiler D. PROGRAMMING THE CONTROL keys will move backward through the parameters. keys will scroll through parameter settings and also function as numbers 0 and 9. Product keys 1-8 also function as number keys 1-8. D-3.0 Level 1 Programming Enter the password 1-8-2-7 and press the ENTER key. -
Page 26: D-3.4 Exit Program Mode
Installation and Operation of Flexible Batch Broiler The product keys 1-8 are used for entering numbers D-4.2 Change the Idle Temperature Sett 1-8. The keys are used to enter numbers This is the set-point temperature for the broiler during 0 and 9. the preheat and idle cycles. -
Page 27: Troubleshooting
Ensure docking plate and locking tab are correctly in place. mangled upon loading Flame arrestor is not properly in place Ensure flame arrestor is correctly in place and tabs are slotted correctly. Control display is reading “Hi” Contact Duke Manufacturing Co. or a Duke Authorized Service agent. Control display is reading Lower burner not lighting properly. If broiler is hot, attempt to clean burner in place with broiler “Lo”... - Page 28 Installation and Operation of Flexible Batch Broiler E. TROUBLESHOOTING (CONT’D) SYMPTOM CAUSE REMEDY Control Display is reading Lower burner not lighting properly. If broiler is hot, attempt to clean burner in place with broiler “tESt Prod” (Observe bottom burner through slits in cleaning tool. lower grease tray) If broiler is cold or allowed to cool down, remove lower burner by removing access panels, clean, and reinstall. Remove lower flame sensor and clean with a soft cloth and isopropyl alcohol. Infrared burners not lighting properly. Remove upper control compartment panel and clean 2 upper (Observe Infrared through discharge flame sensors with a soft cloth and isopropyl alcohol.
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Page 29: Service And Repair
NOTE: Proper clearances must be maintained during If you should require assistance in the selection servicing. of a qualified service agency, please contact Duke Manufacturing Co.’s Service Department at 800- 735-3853. -
Page 30: Replacement Parts List
Installation and Operation of Flexible Batch Broiler V. REPLACEMENT PARTS LIST ITEM DESCRIPTION SWITCH, LIGHTED, DPST 175503 BURNER, INFRARED 175780 BURNER, TUBE, J STYLE (FOR USE IN US & CANADA) 176370 KIT, BURNER, ADJUSTABLE - LOWER BURNER UPGRADE (FOR USE OUTSIDE US & CANADA) 600313 MOTOR-CONVEYOR 175867 SPROCKET, B21X3/8 BORE (MOTOR) 175517 SHAFT, DISCHARGE SIDE 175037 SHAFT, RIGHT SIDE 175038 CAPACITOR, MOTOR-CONVEYOR 175507 MODULE, IGNITION (LOWER BURNER –NATURAL GAS) 175877 MODULE, IGNITION (LOWER BURNER – PROPANE) 175872 MODULE, IGNITION (UPPER BURNERS) 175869 TRANSFORMER,40VA, 120VAC-24VAC 175526 PROBE, TEMP., C-CHAMBER 175977 LIGHT, COOK 175550... - Page 31 Installation and Operation of Flexible Batch Broiler V. REPLACEMENT PARTS LIST (CONT'D) ITEM DESCRIPTION IGNITER 175536 IGNITION SUPPRESSION CABLE-IR 175537 IGNITION SUPPRESSION CABLE-LOWER 175538 CHAIN, COOK 175674 BUSHING BLOCK, CONVEYOR 175525 LOADER TRAY 175430 LOADER MOUNTING BRACKET 175438 LOADER 175444 LOADER RAMP 175741 DOOR 175429 FLAME ARRESTOR...
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Page 32: Electrical Schematic
Installation and Operation of Flexible Batch Broiler VI. WIRING SCHEMATIC ... - Page 33 Installation and Operation of Flexible Batch Broiler NOTES...
- Page 34 Installation and Operation of Flexible Batch Broiler NOTES...
- Page 35 Installation and Operation of Flexible Batch Broiler NOTES...
- Page 36 Installation and Operation of Flexible Batch Broiler 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...
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