Installation & Operation Manual Australia Version BURGER KING FLEXIBLE BATCH BROILER Please read this manual completely before attempting to install, operate or service this equipment This manual is Copyright © 2011 Duke Manufacturing Co. All rights reserved. Reproduction without written permission is prohibited. Duke is a registered 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.
Installation & Operation Manual for Flexible Batch Broiler Australian Units 2
Installation & Operation Manual for Flexible Batch Broiler Australian Units TABLE OF CONTENTS PAGE I. General Information.......................................................................................................5 A. Batch Broiler Specifications.......................................................................................5 A-1.0 Model Number Key.......................................................................................5 A-2.0 Broiler Dimensions......................
Installation & Operation Manual for Flexible Batch Broiler Australian 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. • Do not spray aerosols in the vicinity of this appliance while it is in operation.
Installation & Operation Manual for Flexible Batch Broiler Australian Units I. GENERAL INFORMATION A. Batch Broiler Specifications NATURAL GAS PROPANE GAS ALTITUDE (MAXIMUM) 607 m 607 m GAS PIPE CONNECTION 12.7mm BSPT 12.7mm BSPT BURNER AERATION SHUTTER SETTING OPEN 9.55 mm OPEN 8.00 mm Supply Pressure (KPa) 1.13 2.75 IR Burner Pressure (KPa) 0.93 1.99 Lower Burner Pressure (KPa) 0.93 1.99 ORIFICE – Front IR Burner (mm) 2.35 1.55 ORIFICE – Rear IR Burner (mm) 2.50 1.
Installation & Operation Manual for Flexible Batch Broiler Australian Units A-2. Broiler Dimensions Note: Dimension shown in centimeters, bracketed [ ]are in inches 50 3/8" 128 8 1/2" 21.6 39 1/2" 100.3 44" 111.9 20 3/4" 52.9 63 5/8" 161.7 53 5/8" 136.1 31 1/2" 80 34 3/4" 88.4 GAS CONNECTION* 3/4" BSPT FEMALE 45 5/8" 115.8 HIGH POSITION ELECTRICAL CONNECTION* FOR 250cm [98"] LONG INTERNATIONAL ELECTRICAL CORDSET 3 7/8" 9.7 36 1/4" 92.2 28 1/4" 71.
Installation & Operation Manual for Flexible Batch Broiler Australian Units II. INSTALLATION INSTRUCTIONS A. QUALIFIED PERSONNEL B. DELIVERY AND INSPECTION These installation instructions are for the use of qualified installation and service personnel only. Installation or service by other than qualified personnel may result in damage to the broiler and/or injury to the operator. Duke Manufacturing Co. does everything within its power to insure you received your broiler in good condition.
Installation & Operation Manual for Flexible Batch Broiler Australian Units 1. Using a utility knife, cut away plastic wrap (Not shown). 2 2. Remove Training Material Box. 4 3. Remove the top cardboard and inner cap 4. R e m o v e c a r d b o a r d f r o m t h e c o r n e r s (4 places). 5. Remove cardboard on the ends (2 places). 6. Remove banding straps (Cut with utility knife or scissors: 5 places). 3 5 7. Remove box of attachable parts & accessories from the front. 8.
Installation & Operation Manual for Flexible Batch Broiler Australian Units C. BROILER ASSEMBLY Before assembling and installing the broiler, please check to make sure that all necessary parts are present.
Installation & Operation Manual for Flexible Batch Broiler Australian Units OPTIMAL SERVICE PARTS & ACCESSORIES PARTS KIT – NATURAL GAS (w/ Controller & Cook Chain) 175850 PARTS KIT – PROPANE GAS (w/ Controller & Cook Chain) 175852 PARTS KIT - NATURAL AND PROPANE GAS (Burner & Flame Arrestor) 10 175520 PARTS KIT - NATURAL AND PROPANE GAS (Burner, Arrestor, Loader, & Burner Shield) 175526 KIT – CE GAS HOSE CONNECTOR 175831
Installation & Operation Manual for Flexible Batch Broiler Australian Units D. ADJUSTMENTS AT INSTALLATION Raise or Lower Broiler 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. Such adjustments are the responsibility of the Dealer or Installer.
Installation & Operation Manual for Flexible Batch Broiler Australian Units E. LOCATION OF THE BROILER G. ELECTRICAL CONNECTIONS Proper placement of the broiler will give you the best results long-term user convenience. We urge you to give adequate thought in the placement of your broiler prior to its arrival. Your broiler must be supplied from a 230 Volt 50 Hertz, grounded circuit with a detachable line cord for each country’s requirements.
Installation & Operation Manual for Flexible Batch Broiler Australian 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 familiar with the function of the broiler and/or have had experience with operating the equipment described.
Installation & Operation Manual for Flexible Batch Broiler Australian Units B-2.0 Cook Product IF LIGHT ON DO NOT LOAD Broiler displays rdY and Cook light is not on. Place holding pan at discharge. Place product in front and back rows. Load product. Push forward as shown. Rotate handle down to lift inside bar over product. Pull out loader with handle rotated. You will have 15 seconds to press another product key if a wrong selection is made.
Installation & Operation Manual for Flexible Batch Broiler Australian Units B-3.0 Cook Cycle Complete B-6.0 Checking the Broiler Temperature The chain will rotate and discharge the product. Pressing the ▲ key at any time (other than in programming mode) will display the actual cavity temperature. Do not load product into broiler until the cook light has gone off and rdY is displayed on the control! To prevent thawing of product. it is recommended not to place product onto the loader no more than 5 B-7.
Installation & Operation Manual for Flexible Batch Broiler Australian Units B. Never leave the chemical compounds, particularly those containing chlorine, on broiler parts over night. Chlorine will cause pitting and corrosion. E. Never use ordinary steel wool or scouring pads on the surfaces: use non-abrasive broiler de-greasers & soft cloths C. Never use chemicals in a stronger concentration than recommended by the manufacturer.
Installation & Operation Manual for Flexible Batch Broiler Australian 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. Caution: Hot surface! Wear insulated gloves.
Installation & Operation Manual for Flexible Batch Broiler Australian Units 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. 1 Discharge Pan: Slide pan up and out of keyhole slots. Clean and replace. 2 1 Engage hooks on pins for reinstallation of chute 2 Discharge Grease Pan: Tilt up to un-hook and pull forward for removal. Clean pan, area and replace.
Installation & Operation Manual for Flexible Batch Broiler Australian Units C-2. Daily Cleaning (cont’d) Discharge End Panel: Remove discharge accessories and lift panel up while swinging out and down. Discharge Scraper: Lift up and pull forward. Discharge Scraper: Pull out removing locating pins from slots. Clean scraper and area. Replace. Clean the top of the burner with the brush end of the “Tube Burner Cleaning Tool”. For heavy build-up, use the scraper end of the “Tube Burner Cleaning Tool”.
Installation & Operation Manual for Flexible Batch Broiler Australian Units C-3. Weekly Cleaning With outer front panel removed, lift up the combustion chamber panel. Swing the right side of the panel out as shown. Clean and set aside. 1 2 Remove burner shield. Remove discharge panel and scraper as was performed for daily cleaning. Orifice Hood 2 1 Lift flame arrestor up to Lift rear of burner out of saddle Pull burner off of orifice and through broiler wall. Remove from chamber.
Installation & Operation Manual for Flexible Batch Broiler Australian Units C-3. Weekly Cleaning (cont’d.) SAFETY CONSIDERATIONS Catalyst Guard Catalyst Assembly Front of Broiler CLEANING CONSIDERATIONS : Do not use soap, detergents, degreasers, silicone, sodium salts, bleaches, antioxidants or any other commercial cleaning agents to clean the catalyst. Use of these chemicals will damage the catalyst and render it inoperable NOTE: Do not clean catalyist in a dishwasher or ultrasonic cleaner.
Installation & Operation Manual for Flexible Batch Broiler Australian Units C-3. Weekly Cleaning (cont’d.) Gently tap frame of the catalyst while holding over a waste bin to dislodge any loose ash/carbon particles. Partially fill wash basin, that is large enough to accommodate the catalyst, with enough clean hot water (100-130ºF) to completely cover the catalyst when placed into the basin. Agitate the catalyst up and down in the water a few times and then let it soak for 20 minutes.
Installation & Operation Manual for Flexible Batch Broiler Australian Units C-4. Monthly Cleaning LI GHT DO ON LONOT AD 2 1 IF Remove top panel by lifting up and out. Do not pull on the wire to remove. Locate the two flame sensors for the Infrared burners. Clean the tip of the sensor up to the first ceramic with alcohol pad. Replace the sensor. Take care to insert the sensor all the way into the tube so the metal retaining clip is no longer exposed.
Installation & Operation Manual for Flexible Batch Broiler Australian Units D. TROUBLESHOOTING SYMPTOM Control display does not light up Raw or undercooked product with no controller error messages displayed. CAUSE REMEDY No power Ensure broiler is plugged into a proper voltage/Hz receptacle (per name plate rating) and receptacle as power. Check dedicated circuit breaker. Product not loaded properly. Review loading technique. Product button was depressed prior to loading product.
Installation & Operation Manual for Flexible Batch Broiler Australian Units SYMPTOM CAUSE REMEDY Contact Duke Manufacturing Co. or a Duke Authorized Service agent. Control display is reading “Hi” If broiler is hot, attempt to clean burner in place with broiler cleaning tool. Lower burner not lighting properly. (Observe bottom burner through slits in lower grease tray) Control display is reading “Lo” Infrared burners not lighting properly. (Observe Infrared through discharge end of broiler.
Installation & Operation Manual for Flexible Batch Broiler Australian Units SYMPTOM CAUSE Broiler not receiving gas supply. Control display is reading “gAS bot” Cycle broiler off and back on. If this error persists, proceed with the next steps. Ensure that gas valve(s) in line with the broiler are in the ON position. If broiler is hot, attempt to clean burner in place with broiler cleaning tool. Lower burner not lighting properly.
Installation & Operation Manual for Flexible Batch Broiler Australian Units IV. SERVICE AND REPAIR Periodic service and maintenance of the broiler is not required beyond the user’s daily and weekly cleaning schedule defined in Sections C-1 to C-4. Qualified service personnel must perform service or repair should the broiler develop a fault other than cleaning maintenance.
Installation & Operation Manual for Flexible Batch Broiler Australian 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 “Ǿ” symbol in the list identifies parts that are protected and shall not be or cannot be adjusted by the user.
Installation & Operation Manual for Flexible Batch Broiler Australian Units DESCRIPTION P/N 175534 SENSOR-LOWER BURNER ◄,Ǿ 175535 SENSOR-IR BURNER ◄,Ǿ 175536 IGNITER ◄,Ǿ 175537 IGNITION SUPPRESSION CABLE-IR - 175538 IGNITION SUPPRESSION CABLE-LOWER - 175674 CHAIN, COOK ◄,Ǿ 175525 BUSHING BLOCK, CONVEYOR ◄,Ǿ 175430 LOADER TRAY - 175438 LOADER MOUNTING BRACKET - 175444 LOADER - 175741 LOADER RAMP - 175429 DOOR - 175293 FLAME ARRESTOR ◄,Ǿ 175200 BURNER SHIELD ◄,Ǿ 1753
Installation & Operation Manual for Flexible Batch Broiler Australian Units VI.
Installation & Operation Manual for Flexible Batch Broiler Australian Units VII. 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. MODEL NUMBER: SERIAL NUMBER: DATE OF PURCHASE: DEALER: TELEPHONE: SERVICER: TELEPHONE: DUKE CORPORATE, CANADA, LATIN AMERICA DUKE ASIA PACIFIC 2305 N. Broadway St.
Installation & Operation Manual for Flexible Batch Broiler Australian Units Duke Manufacturing Co. Duke Corporate, Canada, Latin America 2305 N. Broadway St. Louis, MO 63102 Phone: 314-231-1130 Toll Free: 800-735-3853 Fax: 314-231-5074 www.dukemfg.com Duke EMEA - Europe, Middle East, Africa, Russia Duke Manufacturing CR, s.r.o.
