Service Manual FLEXIBLE BATCH BROILER MODELS FBB-NO-120 FBB-NC-120 FBB-PO-120 FBB-PC-120 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.
Service Manual for Flexible Batch Broiler Units 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 STARTUP AND ADJUSTMENTS OF THE EQUIPMENT COVERED BY THIS MANUAL. IMPORTANT THE INSTRUCTIONS TO BE FOLLOWED IN THE EVENT THE SMELL OF GAS IS DETECTED SHOULD BE POSTED IN A PROMINENT LOCATION. THIS INFORMATION CAN BE OBTAINED FROM THE LOCAL GAS SUPPLIER.
Service Manual for Flexible Batch Broiler Units TABLE OF CONTENTS INSTALLATION....................................................................................................................5 OPERATION.........................................................................................................................5 CLEANING...........................................................................................................................5 SPECIFICATIONS....................................
Service Manual for Flexible Batch Broiler Units TABLE OF CONTENTS (CONTINUED) Solid-State Relays.........................................................................................................23 Main Power Switch......................................................................................................................24 Blower Motor...............................................................................................................................24 Replacing Conveyor Links...
Service Manual for Flexible Batch Broiler Units INTRODUCTION INSTALLATION CLEANING For detailed installation instructions, refer to the Installation and Operation Manual. For specific cleaning instructions, refer to the Installation and Operation Manual. OPERATION For specific operating instructions, refer to the Installation and Operation Manual.
Service Manual for Flexible Batch Broiler Units SPECIFICATIONS NATURAL GAS PROPANE MANIFOLD PRESS. TOP BURNERS 3.75″ WC 0.93 kPa 8″ WC 2.0 kPa MANIFOLD PRESS. BOT. BURNER 3.75″ WC 0.93 kPa 8″ WC 2.0 kPa ALTITUDE (MAXIMUM) 2000 FT 607 m 2000 FT 607 m GAS PIPE CONNECTION 3/4" F-NPT 3/4" F-NPT INLET PRESSURE RANGE 7"–12" W.C. 10"–12" W.C. TOTAL ENERGY RATE 87,000 – 111,000 BTU/HR 25.5 –32.5 kW 79,000 –105,000 BTU/HR 23.2 –30.
Service Manual for Flexible Batch Broiler Units REMOVAL AND REPLACEMENT OF COMPONENTS COVERS AND PANELS WARNING DISCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. Caution: If the broiler has been operating, broiler panels and components may be hot. Use PROPER PROTECTION.
Service Manual for Flexible Batch Broiler Units PHU Pan Shelf The PHU Pan Shelf is located on the discharge side of the broiler and holds the unused holding pans. Hood and guides the patties from the conveyor into the Discharge Pan. 1. Remove PHU Pan Shelf. 1. Lift the pan shelf up and remove. 2. Remove the Discharge Hood. 2. To install the pan shelf, slide the keyholes over the two screws and slide pan shelf down. 3. Remove Discharge Chute by lifting off of the two side pins. 4.
Service Manual for Flexible Batch Broiler Units Discharge Pan Discharge Grease Pan The Discharge Pan is located on the discharge side of the broiler below the Discharge Hood and is used to support the PHU Holding Pan (not supplied). The Discharge Grease Pan is located below the Discharge Pan and catches any grease drippings. 1. Remove the PHU Holding Pan if present. 2. Slide Discharge Pan up and out of keyhole slots. 3. Install Discharge Pan by lowering it into the thumbscrews. Discharge Pan 1.
Service Manual for Flexible Batch Broiler Units 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. 3. Remove Discharge Chute. 4. Remove Discharge Pan. Remove the Main Grease Pan by sliding straight out of broiler. 5. Remove Discharge Grease Pan. V Grease Pan 6. Remove Discharge Access Panel by lifting it up and out.
Service Manual for Flexible Batch Broiler Units Loader Tray Conveyor Drive Motor Cover The Loader Tray is located on the front of the broiler and slides into the channels on the Loader Brackets. The Conveyor Drive Motor Cover, located on the lower front of the broiler on the discharge side, covers the Drive Chain Motor. 1. Remove Loader by sliding it out of the Loader Tray. 2.
Service Manual for Flexible Batch Broiler Units Top Service Panel The perforated Top Service Panel provides access to the two Infrared Burners Front Access Panel 1. Remove the four screws securing the perforated Top Service Panel. 2. Remove the perforated Top Service Panel from the broiler. 3. Reverse procedure to install the perforated Top Service Panel. Flue Restrictor Top Service Panel Front Panel Removing the Rear Panel 1. Lift the Rear Panel up and away from the broiler. 2.
Service Manual for Flexible Batch Broiler Units COMPONENT REMOVAL CONVEYOR DRIVE MOTOR ASSEMBLY The Conveyor Drive Motor Assembly is located in the lower front of the broiler at the discharge end. The motor drives the Conveyor by use of a drive chain. Screws Motor Assembly WARNING DISCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 1. Remove the Conveyor Drive Motor Cover. Refer to the COVERS and PANELS section of the manual. 2. Disconnect wires to motor.
Service Manual for Flexible Batch Broiler Units Conveyor Drive Chain The Conveyor Drive Chain connects the drive motor to the Conveyor. Conveyor Sprocket WARNING DISCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. Chain Motor Sprocket 1. Remove Conveyor Drive Motor Cover. Refer to the COVERS and PANELS section of the manual. 2. Remove Discharge Access Panel. Refer to the COVERS and PANELS section of the manual. 3. Disconnect motor wires. 4.
Service Manual for Flexible Batch Broiler Units 8. Reverse procedure to install a new Conveyor Drive Motor Sprocket, ensuring that one set screw is tightened to the flat side of the motor shaft.
Service Manual for Flexible Batch Broiler Units 1. Remove Upper Lift Off Panel. Refer to the COVERS and PANELS section of the manual. Mounting Guide 2. Loosen Blower Hose clamp at output of Blower Motor. 3. Loosen hose clamp at center of air supply to upper burners. Porcelain Insulator 4. Remove Blower Hose. 5. Reverse procedure to install Blower Hose. Air Tube Clamp Flame Sensors Infrared Air Tube Flame Sensor Wire Upper Flame Sensor 4.
Service Manual for Flexible Batch Broiler Units 3. Disengage Lower Flame Sensor from guide and bracket and pull out of guide and bracket. Sensor/Igniter Support Bracket Ground Wires Nut Igniters Bracket Cables Upper Igniters 4. Disconnect the cable and ground wire from the Igniter. 5. Remove Blower Hose. Lower Flame Sensor Lower Flame Sensor 6. Remove the two remaining screws that secure the Air Box Cover and remove the Air Box Cover. 4.
Service Manual for Flexible Batch Broiler Units 4. Reverse procedure to install a new Lower Igniter Assembly, ensuring the replacement Igniter has the proper 1/8" spark gap. For proper ignition, the spark should be approximately 3/4" above the lower burner. Upper Infrared Burner Assembly There are two Infrared Burners located on the top of the broiler. These Infrared Burners can be accessed by removing the Top Service Panel and Impedance Pan.
Service Manual for Flexible Batch Broiler Units 8. Remove the Main Grease Pan and V Grease Pan. 9. Remove Front Panel. Refer to the COVERS and PANELS section of the manual. 10. Disengage J Burner bracket from stud at discharge end, and move J Burner toward discharge end to disengage from its orifice. 11. Carefully slide J Burner Assembly out of front of broiler, taking care not to damage the Igniter Assembly.
Service Manual for Flexible Batch Broiler Units WARNING Flame Sensor Wires ALL JOINTS PRIOR TO THE COMBO GAS VALVE MUST BE CHECKED BEFORE LIGHTING THE UNIT. WARNING Lower Ignition Module Screws Upper Ignition Module Ignition Modules NOTE: Combo Gas Valves are not serviceable and must not be disassembled. 1. Shut off gas to broiler. Combo Gas Valves WARNING DISCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT / TAGOUT PROCEDURES.
Service Manual for Flexible Batch Broiler Units Upper Combo Gas Valve Input Gas Lines Burner Gas Lines 5. Pinch the two grommets in the electrical compartment to remove them. 6. Slide the Cook Chamber Temperature Probe out of the broiler. 7. Reverse procedure to install a Cook Chamber Temperature Probe, ensuring the two grommets are reinstalled. 8. Ensure the Cook Chamber Temperature Probe is seated correctly on the its mounting bracket. The notch on the sheath must be locked on the bracket.
Service Manual for Flexible Batch Broiler Units 6. Reverse procedure to install a new Control Board. 7. Alert the restaurant manager the Control Board has been replaced and fine adjustments may be required. Screws 9-Pin and 12-Pin Connectors Cook Chamber Temperature Probe Cook Chamber Temperature Probe Mounting Control Board The Control Board is located on the front of the broiler. Control Board programming is preset at the factory with standard BURGER KING® recipes.
Service Manual for Flexible Batch Broiler Units 3. Remove screws securing Transformer to frame. 4. Remove Transformer. 5. Reverse procedure to install a Transformer. Control Board Step-Down Transformer Ignition Module Step-Down Transformer Step-Down Transformers Solid-State Relays Two Solid-State Relays are accessible by removing the Lower Control Side Service Panel. The left Solid-State Relay controls the Conveyor Drive Motor. The right Solid-State Relay controls the Blower Motor.
Service Manual for Flexible Batch Broiler Units frame. 6. Reverse procedure to install a new Blower Motor. Replace gasket when installing new Blower Motor. Control Board Main Power Switch Main Power Switch Hose Clamp Screws Blower Motor The Blower Motor is located on the Control Board side of the broiler and is accessed by removal of the Upper Lift Off and Lower Control Side Service Panels. WARNING DISCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 1.
Service Manual for Flexible Batch Broiler Units 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. 3. Spread the damaged link with Link Tool at both ends. 4. Remove the damaged link. 5. Install the new link. 6. Use pliers to close both ends of the link. 7. Check for proper operation.
Service Manual for Flexible Batch Broiler Units ADJUSTMENTS INCOMING GAS PRESSURE WARNING THE BROILER IS DESIGNED TO OPERATE WITH INCOMING NATURAL GAS PRESSURES BETWEEN 7" AND 12" WATER COLUMN (WC). SERVICE PRESSURES ABOVE 12" WC AND LESS THAN 2 PSI, WILL REQUIRE DUKE’S HIGH SUPPLY NATURAL GAS KIT (P/N 175689). THE KIT INCLUDES COMPONENTS TO ADD AN EXTERNAL REGULATOR TO THE BROILER. THE REGULATOR SHOULD BE ADJUSTED AFTER INSTALLATION TO 7" WC PER THE ENCLOSED INSTRUCTIONS.
Service Manual for Flexible Batch Broiler Units DRIVE CHAIN DEFLECTION ADJUSTMENT CONVEYOR POSITION ADJUSTMENT The Drive Chain connects the drive motor to the Conveyor. The Conveyor position is adjusted by adding shims between the Conveyor Shaft Bearing and the frame. 1. Check that the deflection in the Drive Chain does not exceed 3/16″ inch maximum. If the chain requires adjustment, proceed to step 2. 1. Remove Discharge Hood to provide visual access to the Conveyor. 2. Remove Discharge Access Panel.
Service Manual for Flexible Batch Broiler Units UPPER IR BURNER AIR SUPPLY The adjustments for the Upper IR Burner air supply are accessible by removing the Upper Lift Off Panel. There are two air adjustment screws located on each side of the blower hose. Air Adjustment Screws 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.
Service Manual for Flexible Batch Broiler Units TROUBLESHOOTING The following troubleshooting information includes checking procedures for various electrical components in order to help identify faulty components. The troubleshooting guide below is designed to identify various symptoms and provide the suggested remedy. COMPONENT CHECK PROCEDURES Checking the Power Switch The Power Switch has a built-in LED that lights red when the switch is in the on position.
Service Manual for Flexible Batch Broiler Units NORMAL MOTOR RESISTANCE (120V, 60 HZ) Wires to Test Resistance Black and Brown 24.2 Ω Black and Orange 24.2 Ω Brown and Orange3 49.2 Ω CHECKING CONVEYOR DRIVE MOTOR CAPACITOR If the motor tests OK, check the Capacitor. The Capacitor is located in the service area on the control side of the broiler. WARNING DISCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT / TAGOUT PROCEDURES. 1. Remove the Lower Control Side Service Panel.
Service Manual for Flexible Batch Broiler Units Testing the Transformers There are two 24-volt Step-Down Transformers in the broiler. One supplies power to the Control Board, the other provides power to the Ignition Modules. Either a voltage or a resistance check can be used to test the Transformers. Voltage Test 1. Make sure the broiler is turned off. 2. Remove the Lower Control Side Service Panel. Refer to the COVERS and PANELS section of the manual. 3. Disconnect the secondary winding. 4.
Service Manual for Flexible Batch Broiler Units • If one Flame Sensor is dirty, clean them all. Allow the Flame Sensor to cool and clean it with an alcohol pad. • Replace a Flame Sensor with damaged porcelain. • Check for debris between the Flame Sensor tip and burner. • Adjust the Flame Sensor if the tip is touching ground. • 32 Make sure all of the Flame Sensor connections are tight. Checking the Igniters Another item to check, if the broiler is not lighting properly, is the Igniters.
Service Manual for Flexible Batch Broiler Units Quick Index Define the Problem... 1 2 3 4 5 6 Display flashing “gAS” and…. bot toP SEnb SEnt STEP 2 STEP 3 STEP 2 STEP 3 Display flashing “tESt” and “Prod” STEP 2-3 and 6 Display showing “Hi” STEP 2 Display showing “Lo” STEP 2 Display showing “Prob” Faulty Probe. Test and replace probe.
Service Manual for Flexible Batch Broiler Units TURN BROILER ON Does Controller Display light up? NO Verify 120 VAC present at receptacle. Ensure 120 VAC at incoming terminal block. Faulty switch. Ensure 120 VAC across input / output of on / off switch. Faulty transformer. Ensure 24 VAC across transformer secondary winding. YES Check for broken or improper wire connection.
Service Manual for Flexible Batch Broiler Units YES Upon reaching 500 F, do the upper infrared burners ignite and stay lit? YES Consult next page NO Is there spark present at both the upper igniters? YES Is there spark present at both the upper igniters, but no ignition? Is there spark and ignition on both upper burners, but burner(s) do not stay lit? NO NO NO Faulty igniter or insufficient spark gap. Ensure upper igniters have sufficient spark gaps and spark is not arcing elswehere. No Gas.
Service Manual for Flexible Batch Broiler Units YES Does the Broiler reach setpoint temperature and display RDY? NO Display flashing “gAS” and…. NO Display flashing “tESt Prod” NO Display flashing “Hi” or “Lo” NO Display flashing “Prob” YES YES YES See Steps 2-3 and 6 See Step 2 Faulty Probe. Test and replace probe.
Service Manual for Flexible Batch Broiler Units YES Does the Lower Burner cycle on and off to maintain idle temperature? (Typically 680 F) NO See Step 2 YES During a cook cycle, do the upper burners cycle on and off according to the programmed cook cycle? NO No spark present at an upper burner. NO Spark and ignition present on both burners, but burner(s) does not stay lit. NO Cycling of upper burners does not follow programmed cook cycle.
Service Manual for Flexible Batch Broiler Units YES At the end of a cook cycle, does the conveyor belt discharge properly? NO Improperly installed. Discharge chute is not properly in place. Belt hanging up. Conveyor belt is catching on another item, i.e. ash scraper, loader ramp, flame arrestor. YES Loose drive chain. Deflection of chain should be approximately 3/16". Broiler Working Properly Loose motor sprocket.
Service Manual for Flexible Batch Broiler Units
Service Manual for Flexible Batch Broiler Units REPLACEMENT PARTS LIST DESCRIPTION Switch, Main Power Burner, Infrared Burner, Tube, J Style (Natural Gas Only) Burner, Tube, J Style (LP Gas Only) Motor, Conveyor Sprocket, B21X3/8 Bore (Motor) Shaft, Discharge Side Shaft, Right Side Capacitor, Motor-Conveyor Ignition Module, Lower Burner Ignition Module, Upper Burners Transformer, 40VA, 120VAC-24VAC Probe, Temperature C-Chamber Light, Cook Relay, Solid State Chain, Drive Controller Gasket, Control Bezel G
Service Manual for Flexible Batch Broiler Units REPLACEMENT PARTS LIST, CONTINUED DESCRIPTION Sensor, Lower Burner Sensor, IR Burner Igniter Ignition Suppression Cable, IR Ignition Suppression Cable, Lower Burner Cook, Chain Bushing Block, Conveyor Loader Tray Loader Mounting Bracket Loader Loader Ramp Door Flame Arrestor Burner Shield Discharge Chute PART NUMBER 175534 175535 175536 175537 175538 175674 175525 175430 175878 175444 175741 175429 175293 175200 175340 QTY 1 2 3 2 1 1 4 1 1 1 1 1 1 1
Service Manual for Flexible Batch Broiler Units NOTES: 42
Service Manual for Flexible Batch Broiler Units CUSTOMER ASSISTANCE To aid in reporting this unit in case of loss or theft, please record below the model number and serial number located on the unit. We also suggest you record all the information listed and retain for future reference.
Service Manual for Flexible Batch Broiler 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 EU Headquarter Office Duke Manufacturing CR s.r.o.
