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BURGER KING
FLEXIBLE BATCH
BROILER
Please read this manual completely before attempting
This manual is Copyright © 2013 Duke Manufacturing Co. All rights reserved.
Reproduction without written permission is prohibited. Duke is a registered
Installation & Operation Manual
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
CE Version
P/N 175820R
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Summary of Contents for Duke FBB-10-230
- Page 1 Please read this manual completely before attempting to install, operate or service this equipment This manual is Copyright © 2013 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 & Operation Manual for Flexible Batch Broiler - CE Units TABLE OF CONTENTS I. General Information .....................4 A. Batch Broiler Specifications ...................4 A-1. Model Number Key ..................4 A-2. Broiler Dimensions ..................5 II. Installation Instructions ....................6 A. Qualified Personnel ....................6 B. Delivery and Inspection ..................6 C. Broiler Assembly ....................8 D. Adjustments at Installation ..................9 Raise or Lower Broiler ..................9 E. Location of the Broiler ..................10 F. Gas Piping ......................10 G. Electrical Connections ..................10... - Page 3 Installation & Operation Manual for Flexible Batch Broiler - CE Units 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.
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Page 4: General Information
Lower Burner SHIPPING 204 Kg (450 lbs) WEIGHT SHIPPING 121,9 cm x 99,1 cm x 172,7 cm (48” x 39” x 68”) DIMENSIONS ELECTRICAL 230V~ 50Hz 1,1A 250W RATING A-1. Model Number Key X identifies Gas Configuration Y = O without Catalyst Y = C with Catalyst DESCRIPTION MODEL DESCRIPTION MODEL I3P(G31) gas w/o Catalyst FBB-10-230 I3P(G31) gas with Catalyst FBB-1C-230 I2H/I2E(G20) gas w/o Catalyst FBB-20-230 I2H/I2E(G20) gas with Catalyst FBB-2C-230 I3B/P(G30) gas w/o Catalyst FBB-30-230 I3B/P(G30) gas with Catalyst FBB-3C-230 I2L(G25) gas w/o Catalyst FBB-50-230 I2L(G25) gas with Catalyst FBB-5C-230... -
Page 5: A-2. Broiler Dimensions
Installation & Operation Manual for Flexible Batch Broiler - CE Units A-2. Broiler Dimensions Note: Dimension shown in centimeters, bracketed [ ]are in inches 44" 111,9 50 3/8" 20 3/4" 8 1/2" 52,9 21,6 63 5/8" 55 5/8" 53 5/8" 161,7 141,4 45 5/8" 136,1 39 1/2" 115,8 100,3 34 3/4"... -
Page 6: Installation Instructions
They are strapped down on heavy wooden skids and may result in damage to the broiler and/or injury to the packed to prevent shipping damage. They have all been operator. carefully inspected before they were packaged and consigned to the carrier. Qualified installation personnel are those individuals, firms, companies or corporations which either in person Upon delivery of your Duke broiler: or through an agent is engaged in and responsible for: • Look over the shipping container, carefully noting • Compliance with the installation in force any exterior damage on the delivery receipt, which in the country in which the appliance is to must also be signed by the driver/ delivery person. - Page 7 6. Remove banding straps (cut with utility knife or scissors: 5 places). 7. Remove box of attachable parts and accessories from the front. 8. Safely lift one end of broiler and tap block towards center and then sideways to remove. Repeat for remaining blocks. This allows casters to touch the pallet. 9. Remove the broiler from the shipping pallet using 3 people to guide and distribute its weight (approx 335 lbs) accordingly. While carefully supporting the broiler, roll it forward until the front casters are clear of the pallet. Lift the broiler 6-8 inches above and away from the pallet, and gently place on floor to avoid damage to casters. 10. Remove protective blue tape from broiler panels, double checking that no tape remains. • Check for concealed damage. The carrier must be notified within fifteen (15) days of the delivery of the broiler and the carton, skid and all packaging materials must be retained for inspection. • Duke Manufacturing Co. cannot assume liability for loss or damage suffered in transit. The carrier assumes full responsibility for delivery in good order when the shipment was accepted. However, we are prepared to assist you with filing your claim.
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Page 8: Broiler Assembly
Installation & Operation Manual for Flexible Batch Broiler - CE Units C. BROILER ASSEMBLY Before assembling and installing the broiler, please check to make sure that all necessary parts are present. ITEM # PART NAME PART # PRODUCT PAN SHELF 175353 DISCHARGE CHUTE 175340 DISCHARGE HOOD 175362 DISCHARGE PAN HOLDER 175358 DISCHARGE GREASE PAN 175357 “V” GREASE PAN 175325 MAIN GREASE PAN 175329 LOADER 175444 Loader Install Tool LOADER TRAY 175430 (Included with Broiler Tools Kit) -
Page 9: Adjustments At Installation
Installation & Operation Manual for Flexible Batch Broiler - CE Units D. ADJUSTMENTS AT INSTALLATION The broiler height can be adjusted via two screws on each leg. Each broiler section and all its component parts have been tested thoroughly and inspected before your broiler Caution: The Broiler is very heavy! was shipped from the factory. However, it is sometimes Use adequate help for lifting. necessary to further test or adjust the broiler once it has been installed. Such adjustments are the responsibility of the Dealer or Installer. These types of adjustments 1. Lift one end of the broiler onto a wide, sturdy stand are not considered defects, rather a normal and routine (not supplied). part of the proper installation of the equipment. 2. Remove (2) screws per leg and raise/lower to These adjustments include but are not limited to: threaded holes. Reinstall screws. -
Page 10: Location Of The Broiler
Installation & Operation Manual for Flexible Batch Broiler - CE Units E. LOCATION OF THE BROILER If the supply cord is damaged, it must be replaced by the manufacture, it's service agent or similarly qualified Proper placement of the broiler will give you the best persons in order to avoid a hazard. results long-term user convenience. We urge you to give adequate thought in the placement of your broiler EXTERNAL EQUIPOTENTIAL prior to its arrival. • The broiler should be placed in an area that is free Terminal provides a connection for bonding to from drafts and accessible for proper operation and equipment enclosure. servicing. • The area around the broiler must be kept clear of This appliance employs an combustible materials as specific below: earthed, safety ground electrical supply system. -
Page 11: Operation Instructions
Installation & Operation Manual for Flexible Batch Broiler - CE Units 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 IF LIGHT ON DO NOT LOAD familiar with the function of the broiler and/or have had experience with operating the equipment described. We recommend following these instructions to insure optimum performance, long life and trouble-free service from your broiler. -
Page 12: B-2.0 Cook Product
Installation & Operation Manual for Flexible Batch Broiler - CE Units B-2.0 Cook Product IF LIGHT ON DO NOT LOAD Place holding pan at discharge. Broiler displays rdY and Place product in front and back rows. Cook light is not on. Pull out loader with Load product. -
Page 13: B-3.0 Cook Cycle Complete
Installation & Operation Manual for Flexible Batch Broiler - CE Units B-3.0 Cook Cycle Complete Pressing the ▲ key at any time (other than in programming mode) will display the actual cavity The chain will rotate and discharge the product. temperature. Do not load product into broiler until the cook light has gone off and rdY is displayed on the control! B-7.0 Checking the Set Point Temperature To prevent thawing of product, it is recommended... - Page 14 Installation & Operation Manual for Flexible Batch Broiler - CE Units those containing chlorine, on broiler parts over the surfaces: use non-abrasive broiler de-greasers night. Chlorine will cause pitting and corrosion. & soft cloths C. Never use chemicals in a stronger concentration Carefully following these recommendations than recommended by the manufacturer. will help this broiler to give satisfactory services to extend its life. D. Use clean water and a soft cloth to wipe cleaning residue from surfaces.
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Page 15: C-1. Four (4) Hour Cleaning
Installation & Operation Manual for Flexible Batch Broiler - CE Units 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 16: C-2. Daily Cleaning
Installation & Operation Manual for Flexible Batch Broiler - CE Units C-2. Daily Cleaning Daily cleaning should also include all items listed in the 4 hour cleaning schedule. Discharge Hood and Chute: Remove h ood a nd c hute c ompletely, clean and replace. D i s c h a r g e P a n : Slide pan up and out of keyhole slots. - Page 17 Installation & Operation Manual for Flexible Batch Broiler - CE Units 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.
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Page 18: C-3. Weekly Cleaning
Installation & Operation Manual for Flexible Batch Broiler - CE Units C-3. Weekly Cleaning With outer front panel Swing the right side of 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 19 Installation & Operation Manual for Flexible Batch Broiler - CE Units C-3. Weekly Cleaning (cont’d) SAFETY CONSIDERATIONS The catalytic converter (catalyst) is normally part of a CLEANING CONSIDERATIONS combustion system, and the general safety practices observed with such systems should be practiced. The following considerations are specific to the catalyst Do not use soap, detergents, portion. degreasers, silicone, sodium salts, bleaches, anti- A: Remove power: Before removing the catalyst, oxidants or any other commercial cleaning agents disconnect power to the broiler and allow to cool...
- Page 20 Installation & Operation Manual for Flexible Batch Broiler - CE Units C-3. Weekly Cleaning (cont’d) Gently tap frame of the catalyst while Begin with a clean sink and remove all foreign matter from any wash holding over a waste bin to dislodge any loose ash/carbon particles.
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Page 21: C-4. Monthly Cleaning
Installation & Operation Manual for Flexible Batch Broiler - CE Units C-4. Monthly Cleaning L IG Remove top panel by Use caution and safely remove the Locate the flame sensors lifting up and out. sensor by holding onto the black for the upper burners. -
Page 22: Troubleshooting
Installation & Operation Manual for Flexible Batch Broiler - CE Units D. TROUBLESHOOTING SYMPTOM CAUSE REMEDY Control display does not light up No power Ensure broiler is plugged into a proper voltage/Hz receptacle (per name plate rating) and receptacle as power. Check dedicated circuit breaker. Raw or undercooked product with no Product not loaded properly. Review loading technique. controller error messages displayed. Product button was depressed prior to Ensure product button is depressed loading product. immediately after product is loaded into broiler. Wrong product button was depressed. Ensure proper product button is being depressed. Lower burner not lighting properly. If broiler is hot, attempt to clean burner in (Observe bottom burner through slits in place with broiler cleaning tool. lower grease tray) If broiler is cold or allowed to cool down, remove lower burner by removing access... - Page 23 Installation & Operation Manual for Flexible Batch Broiler - CE Units SYMPTOM CAUSE REMEDY Control display is reading “Hi” Contact Duke Manufacturing Co. or a Duke Authorized Service agent. Control display is reading “Lo” If broiler is hot, attempt to clean burner in place with broiler cleaning tool. Lower burner not lighting properly. If broiler is cold or allowed to cool down, (Observe bottom burner through slits in remove lower burner by removing access lower grease tray) panels, clean, and reinstall. Remove lower flame sensor and clean with a soft cloth & isopropyl alcohol. Infrared burners not lighting properly. Remove upper control compartment panel (Observe Infrared through discharge end and clean 2 upper flame sensors with a soft of broiler. Note: Burners should remain lit cloth & isopropyl alcohol. in idle mode) Clean flame sensor tube with flame sensing tube cleaning brush. Grease pan is not installed Install grease pan Impedance pan or catalyst is not installed.
- Page 24 Installation & Operation Manual for Flexible Batch Broiler - CE Units SYMPTOM CAUSE REMEDY Control display is reading “gAS Broiler not receiving gas supply. Ensure that gas valve(s) in line with the toP” broiler are in the ON position. Infrared burners not lighting properly. Remove upper control compartment panel (Observe Infrared through discharge end and clean 2 upper flame sensors with a soft of broiler. Note: Burners should remain lit cloth & isopropyl alcohol. in idle mode) Clean flame sensor tube with flame sensing tube cleaning brush. Control display is reading “gAS Broiler not receiving gas supply. Cycle broiler off and back on. If this error bot” persists, proceed with the next steps. Ensure that gas valve(s) in line with the broiler are in the ON position. Lower burner not lighting properly. If broiler is hot, attempt to clean burner in (Observe bottom burner through slits in place with broiler 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...
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Page 25: Service And Repair
Company Service Department at the USA worldwide : Proper clearances must be headquarters (telephone: 011-800-735-3853) for maintained during servicing and when installed assistance with selecting qualified service personnel. -
Page 26: Replacement Parts List
Installation & Operation Manual for Flexible Batch Broiler - CE Units V. REPLACEMENT PARTS LIST Parts that will likely require replacement during the life of the broiler are identified with a “ ” in the Replacement Parts List. The “ ” symbol in the list identifies parts that are protected and shall not be or cannot be adjusted by the user. Parts identified with a “-” should not require adjustment or replacement during the broiler life, but are listed to assist qualified service personnel if replacement is necessary. DESCRIPTION 175503 SWITCH, LIGHTED, DPST 175780 BURNER, INFRARED 176350 KIT, BURNER, ADJUSTABLE 175875 MOTOR-CONVEYOR 175517 SPROCKET, B21X3/8 BORE (MOTOR) 175037 SHAFT, DISCHARGE SIDE 175038 SHAFT, RIGHT SIDE 175802 CAPACITOR, MOTOR-CONVEYOR 175876 MODULE IGNITION (7-5-3) CE (PROPANE, LOWER BURNER ONLY) 175877 MODULE IGNITION (24-5-3) CE 175765... - Page 27 Installation & Operation Manual for Flexible Batch Broiler - CE Units DESCRIPTION 175534 SENSOR-LOWER BURNER 175535 SENSOR-IR BURNER 175536 IGNITER 175537 IGNITION SUPPRESSION CABLE-IR 175538 IGNITION SUPPRESSION CABLE-LOWER 175674 CHAIN, COOK 175525 BUSHING BLOCK, CONVEYOR 175430 LOADER TRAY 175438 LOADER MOUNTING BRACKET 175444 LOADER 175741 LOADER RAMP 175429 DOOR 175293 FLAME ARRESTOR 176349 BURNER SHIELD 175340 DISCHARGE CHUTE 175778...
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Page 28: Wiring Schematic
Installation & Operation Manual for Flexible Batch Broiler - CE Units VI. WIRING SCHEMATIC ELECTRICAL SCHEMATIC – CE FLEXIBLE BATCH BROILER DUKE MFG. 175806 Rev.E Gas Valve – IR Gas Valve – Burners Lower Burner J1 & J 2 View... - Page 29 Installation & Operation Manual for Flexible Batch Broiler - CE Units NOTES:...
- Page 30 Installation & Operation Manual for Flexible Batch Broiler - CE Units NOTES:...
- Page 31 Installation & Operation Manual for Flexible Batch Broiler - CE Units NOTES:...
- Page 32 Installation & Operation Manual for Flexible Batch Broiler - CE Units 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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