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FLEXIBLE BATCH
BROILER, CE VERSION
MODELs
FBB-XY-230-AAB
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 © 2014 Duke Manufacturing Co. All rights reserved.
Reproduction without written permission is prohibited. Duke is a registered
SM-BR-BR-0007
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: 314-231-2460
www.dukemfg.com
Service Manual
6/19/2014
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Summary of Contents for Duke FBB-XY-230-AAB
- 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, CE Version IMPORTANT WARNING AND sAFETY INFORMATION IMPORTANT FOR YOUR sAFETY THIs MANUAL HAs BEEN PREPARED FOR PERsONNEL QUALIFIED TO INsTALL GAs EQUIPMENT. THE QUALIFIED INsTALLER sHOULD PERFORM THE INITIAL FIELD sTART-UP AND ADJUsTMENTs OF THE EQUIPMENT COVERED BY THIs MANUAL.
- Page 3 Service Manual for Flexible Batch Broiler, CE Version How to Determine Manufacture Date from Duke Equipment Serial Numbers All units currently manufactured in St. Louis and Sedalia, Missouri (After 2/1/2013): 08 03 0202 Month Manufactured Sequential Number Year Manufactured (Example: 08030202 = Indicates the unit was manufactured in August of 2003) Units Manufactured in St.
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Page 4: Table Of Contents
Service Manual for Flexible Batch Broiler, CE Version TABLE OF CONTENTs INSTALLATION ............................5 OPERATION ..............................5 CLEANING ..............................5 CE SPECIFICATIONS ..........................5 TOOLS ................................. 5 REMOVAL AND REPLACEMENT OF COMPONENTS ................6 COVERS AND PANELS......................... 6 Upper Lift Off Panel ......................... 6 PHU Pan Shelf .......................... - Page 5 Service Manual for Flexible Batch Broiler, CE Version TABLE OF CONTENTs (Cont.) ADJUSTMENTS ............................25 COMBO GAS VALVE ........................... 25 DRIVE CHAIN DEFLECTION ADJUSTMENT ..................25 CONVEYOR POSITION ADJUSTMENT ..................... 26 UPPER IR BURNER AIR SUPPLY ...................... 27 LOWER BURNER AIR SUPPLY ......................27 TROUBLESHOOTING ..........................
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Page 6: Installation
Y = O No Catalyst • Gas Leakage Tester or method to test for gas Y = C With Catalyst leaks • Conveyor Link Removal Pliers AA = ISO 2 Digit Country Code • Duke Testing Harness B = Future use 6/19/2014 SM-BR-BR-0007... -
Page 7: Removal And Replacement Of Components
Service Manual for Flexible Batch Broiler, CE Version REMOVAL AND REPLACEMENT OF COMPONENTs COVERs AND PANELs Lower Control side service Panel The Lower Control Side Service Panel provides access to the Combo Gas Valves, Ignition Modules, Transformers, Blower Motor, WARNING Conveyor Motor Capacitor, and electrical connections to the Control Board. -
Page 8: Phu Pan Shelf
Service Manual for Flexible Batch Broiler, CE Version PHU Pan shelf Discharge Chute The PHU Pan Shelf is located on the discharge side The Discharge Chute is located under the of the broiler and holds the unused holding pans. Discharge Hood and guides the patties from the conveyor into the Discharge Pan. -
Page 9: Discharge Pan
Service Manual for Flexible Batch Broiler, CE Version Discharge Pan Discharge Grease Pan The Discharge Pan is located on the discharge The Discharge Grease Pan is located below the side of the broiler below the Discharge Hood Discharge Pan and catches any grease drippings. and is used to support the PHU Holding Pan (not 1. -
Page 10: Discharge Access Panel
Service Manual for Flexible Batch Broiler, CE Version Discharge Access Panel Main Grease Pan 1. Remove the PHU Pan Shelf. The Main Grease Pan is located on the front of the broiler under the V Grease Pan. 2. Remove Discharge Hood. Remove the Main Grease Pan by sliding straight 3. -
Page 11: Loader Tray
Service Manual for Flexible Batch Broiler, CE Version Conveyor Drive Motor Cover Loader Tray The Conveyor Drive Motor Cover, located on the The Loader Tray is located on the front of the lower front of the broiler on the discharge side, broiler and slides into the channels on the Loader covers the Drive Chain Motor. -
Page 12: Top Service Panel
Service Manual for Flexible Batch Broiler, CE Version Top service Panel 5. Lift the Front Panel up and away from the broiler. The perforated Top Service Panel provides access 6. Reverse these steps to reinstall these parts. to the two Infrared Burners 1. -
Page 13: Component Removal
Service Manual for Flexible Batch Broiler, CE Version COMPONENT REMOVAL CONVEYOR DRIVE MOTOR AssEMBLY Screws Motor The Conveyor Drive Motor Assembly is located Assembly in the lower front of the broiler at the discharge end. The motor drives the Conveyor by use of a drive chain. -
Page 14: Conveyor Drive Chain
Service Manual for Flexible Batch Broiler, CE Version Conveyor Drive Chain The Conveyor Drive Chain connects the drive motor to the Conveyor. Conveyor Sprocket WARNING Chain DIsCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT / TAGOUT Motor PROCEDUREs. Sprocket 1. -
Page 15: Conveyor Drive Motor Capacitor
Service Manual for Flexible Batch Broiler, CE Version 7. Loosen the two setscrews on motor sprocket Conveyor Drive Motor Capacitor and remove sprocket from motor shaft. 8. Reverse procedure to install a new Conveyor Drive Motor Sprocket, ensuring that one set WARNING screw is tightened to the flat side of the motor shaft. -
Page 16: Blower Hose
Service Manual for Flexible Batch Broiler, CE Version Blower Hose WARNING DIsCONNECT THE ELECTRICAL WARNING POWER TO THE BROILER AND DIsCONNECT THE ELECTRICAL FOLLOW LOCKOUT / TAGOUT POWER TO THE BROILER AND PROCEDUREs. FOLLOW LOCKOUT / TAGOUT PROCEDUREs. 1. Remove the Control Side Access Panel. Refer to the COVERS and PANELS section of the 1. -
Page 17: Upper Igniter Assemblies
Service Manual for Flexible Batch Broiler, CE Version Upper Igniter Assemblies 9. Reverse procedure to install a new Upper Igniter, ensuring the replacement Igniter has The Upper Igniter Assemblies are accessible by the proper 3.175 mm spark gap. For proper removing the Upper Lift Off Panel. -
Page 18: Lower Igniter Assembly
Service Manual for Flexible Batch Broiler, CE Version 5. Pinch tabs on the wire grommet to remove it. 6. Feed the wire through the hole to fully remove WARNING the Flame Sensor Assembly. sHUT OFF THE GAs sUPPLY 7. Reverse procedure to install a new Lower BEFORE sERVICING THE UNIT. -
Page 19: Lower J Burner Assembly
Service Manual for Flexible Batch Broiler, CE Version NOTE: Use Anti-Seize Technologies TFE1400 on all pipe threads when reassembling the Infrared Burner gas fittings. Connection NOTE: Clean excess silicone sealer from Air Box and Burner Venturi if reinstalling burner. Reapply high temp silicone sealer before installing burner. -
Page 20: Ignition Modules
Service Manual for Flexible Batch Broiler, CE Version Combo Gas Valves Ignition Modules The Ignition Modules are accessible by removing the Lower Control Side Service Panel. The Ignition Modules are at the bottom of the compartment WARNING behind the Relays. DIsCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT / TAGOUT... -
Page 21: Cook Chamber Temperature Probe
Service Manual for Flexible Batch Broiler, CE Version NOTE: Combo Gas Valves are not serviceable Cook Chamber Temperature Probe and must not be disassembled. The Cook Chamber Temperature Probe connects to the bottom of the Control Board and is located 1. -
Page 22: Control Board
Service Manual for Flexible Batch Broiler, CE Version Cook Chamber Temperature WARNING Probe Connection DIsCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT / TAGOUT PROCEDUREs. 1. Remove the Lower Control Side Service Panel. Refer to the COVERS and PANELS section of the manual. -
Page 23: Step-Down Transformers
Service Manual for Flexible Batch Broiler, CE Version step-Down Transformers solid-state Relays Two Step-down Transformers are accessible by Two Solid-State Relays are accessible by removing removing the Lower Control Side Service Panel. the Lower Control Side Service Panel. One Solid- Both Transformers reduce the incoming 230 VAC State Relay controls the Conveyor Drive Motor. -
Page 24: Main Power Switch
Service Manual for Flexible Batch Broiler, CE Version Main Power switch Blower Motor The Main Power Switch is located on the front of The Blower Motor is located on the Control Board the broiler below the Control Board. side of the broiler and is accessed by removal of the Upper Lift Off and Lower Control Side Service Panels. -
Page 25: Replacing Conveyor Links
Service Manual for Flexible Batch Broiler, CE Version Replacing Conveyor Links WARNING DIsCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT / TAGOUT PROCEDUREs. 1. Turn off and unplug the broiler. 2. Remove the front operator parts and panels. Refer to the COVERS and PANELS section of the manual. -
Page 26: Adjustments
Service Manual for Flexible Batch Broiler, CE Version ADJUsTMENTs COMBO GAs VALVE 5. Turn gas supply on. The two Combo Gas Valves are located next NOTE: The pressure regulator is an integral part to each other and are accessible by removing of the Combo Gas Valve. -
Page 27: Conveyor Position Adjustment
Service Manual for Flexible Batch Broiler, CE Version NOTE: Leading edge of Discharge Chute should INSIDE VIEW be about an 3.175 mm above the center line of Motor Mount the Conveyor shaft. When correctly adjusted, the Conveyor link should just graze the backside of the chute. -
Page 28: Upper Ir Burner Air Supply
NOTE: The air adjustment is factory set and must not be changed unless authorized to do so by Duke Manufacturing. 1. Remove the Upper Lift Off Panel. 2. If found loose, it may be necessary to re-adjust and re-tighten the locking nuts which secure the air adjustment screws. -
Page 29: Troubleshooting
Service Manual for Flexible Batch Broiler, CE Version TROUBLEsHOOTING The following troubleshooting information includes 3. Check each connection on the back of checking procedures for various electrical the Control Board. Make sure they are all components in order to help identify faulty connected correctly. -
Page 30: Checking Conveyor Drive Motor Capacitor
Service Manual for Flexible Batch Broiler, CE Version NORMAL MOTOR REsIsTANCE (230VAC 50Hz) Wires to Test Resistance WARNING Black and Brown 100Ω DIsCONNECT THE ELECTRICAL Black and Orange 100Ω POWER TO THE BROILER AND FOLLOW LOCKOUT / TAGOUT Brown and Orange 200Ω... -
Page 31: Testing The Transformers
Service Manual for Flexible Batch Broiler, CE Version Testing the Transformers to terminals TH and GND on the Lower Ignition Module. The Lower Ignition Module first performs There are two 24-Volt Step-Down Transformers a diagnostic check. After the diagnostic, the Lower in the broiler. -
Page 32: Checking The Flame Sensors
Service Manual for Flexible Batch Broiler, CE Version Checking the Igniters Upper Ignition Module Diagnostic Indicators: Another item to check, if the broiler is not lighting 1. Steady On: Indicates an internal control failure. properly, is the Igniters. It is possible for these 2. - Page 33 Service Manual for Flexible Batch Broiler, CE Version Troubleshooting FlowChart Quick Index Define the Problem... Complaint... Consult STEP... Display flashing “gAS” and…. SEnb SEnt STEP 2 STEP 3 STEP 2 STEP 3 STEP 2-3 and 6 Display flashing “tESt” and “Prod” STEP 2 Display showing “Hi”...
- Page 34 Service Manual for Flexible Batch Broiler, CE Version Troubleshooting FlowChart TURN BROILER ON (Cavity temperature under 149C) Does Controller Display Verify 230 VAC present at receptacle. light up? Ensure 230 VAC at incoming terminal block. Faulty switch. Ensure 230 VAC across input / output of on / off switch.
- Page 35 Service Manual for Flexible Batch Broiler, CE Version Troubleshooting FlowChart Is there spark Is there spark Is there spark and Upon reaching 260C, do present at both present at both ignition on both upper the upper infrared burners the upper the upper igniters, burners, but burner(s) ignite and stay lit?
- Page 36 Service Manual for Flexible Batch Broiler, CE Version Troubleshooting FlowChart Does the Broiler reach setpoint temperature and display “rdY”? (Lower Display flashing Display flashing Display flashing Display flashing burner may cycle on/off “gAS” and…. “tESt Prod” “Hi” or “Lo” “Prob” repeatedly before displaying “rdY”) Faulty Probe.
- Page 37 Service Manual for Flexible Batch Broiler, CE Version Troubleshooting FlowChart Does the Lower Burner cycle on and off to maintain idle temperature? See Step 2 (Cycle on 354C Cycle off 360C) Cycling of During a cook cycle, Spark and ignition Spark present at upper burners do the upper burners...
- Page 38 Service Manual for Flexible Batch Broiler, CE Version Troubleshooting FlowChart At the end of a cook Improperly installed. Discharge chute is not properly in cycle, does the cook chain place. discharge properly? Belt hanging up. Cook chain is catching on another item, i.e.
- Page 39 Service Manual for Flexible Batch Broiler, CE Version ELECTRICAL sCHEMATIC – CE FLEXIBLE BATCH BROILER DUKE MFG. 175806 Rev.E Gas Valve – IR Gas Valve – Burners Lower Burner J1 & J 2 View Load Light BRN 8 ORG 8...
- Page 40 Service Manual for Flexible Batch Broiler, CE Version ...
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Page 41: Customer Assistance
Phone: +86 21 59153525 / 59153526 service-dispatch@dukemfg.com Fax: +86 21 33600628 service.asiapac@dukemfg.com DUKE EMEA - EUROPE, DUKE EMEA – UK, IRELAND MIDDLE EAsT, AFRICA, RUssIA Phone: +44 (0) 1395 234140 Duke Manufacturing CR, s.r.o. Fax: +44 (0) 1395 234154 Na Dlouhem 86 service.emea@dukemfg.com... - Page 42 Service Manual for Flexible Batch Broiler, CE Version 6/19/2014 SM-BR-BR-0007...
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