Duke FBB-30-230 Installation Manual

Installation & Operation Manual

BURGER KING
FLEXIBLE BATCH
BROILER

CE Version

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: [phone]

Toll Free: 1-800-735-3853

Fax: [phone]

www.dukemfg.com

P/N 175820N

Installation & Operation Manual for Flexible Batch Broiler - CE Units

TABLE OF CONTENTS

I. General Information .....................................................................................................4

A. Batch Broiler Specications ...................................................................................4

A-1. Model Number Key ......................................................................................4

A-2. Broiler Dimensions ......................................................................................5

II. Installation Instructions ..............................................................................................6

A. Qualied 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

H. Ventilation ............................................................................................................10

Venting to a Canopy Exhaust Hood ..................................................................10

Maintenance of Ventilation System ...................................................................10

III. Operation Instructions ............................................................................................. 11

A. Broiler Controls .................................................................................................... 11

B. Cooking Product .................................................................................................. 11

B-1.0 Lighting the Broiler ................................................................................... 11

B-2.0 Cook Product ...........................................................................................12

B-3.0 Cook Cycle Complete ..............................................................................13

B-4.0 Fine Cooking Adjustment .........................................................................13

B-5.0 Cancel a Cook Cycle ...............................................................................13

B-6.0 Checking the Broiler Temperature ...........................................................13

B-7.0 Checking the Set Point Temperature .......................................................13

B-8.0 Shutdown the Broiler ...............................................................................13

C. Cleaning ...............................................................................................................13

C-1. Four (4) Hour Cleaning .............................................................................. 15

C-2. Daily Cleaning ...........................................................................................16

C-3. Weekly Cleaning ........................................................................................18

C-4. Monthly Cleaning ...................................................................................... 21

D. Troubleshooting ...................................................................................................22

IV. Service and Repair ...................................................................................................25

V. Replacement Parts List .............................................................................................26

VI. Wiring Schematic .....................................................................................................28

VII. Customer Assistance .............................................................................................31

2

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 ammable vapors or liquids
in the vicinity of this or any other appliance.

: Improper installation, adjustment, alteration, service or
maintenance can cause property damage, injury or death. Read the
installation, operating and maintenance instructions thoroughly before
installing or servicing this equipment.

THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE.

3

Installation & Operation Manual for Flexible Batch Broiler - CE Units

I. GENERAL INFORMATION

A. Batch Broiler Specications

I3B/

P(G30)

12,7mm

BSPT

I3B/

P(G30)

30/50

mbar

19,93

mbar

19,93

mbar

I3B/

P(G30)

GROSS HEAT
INPUT

GAS PIPE
CONNECTION

Supply
Pressure

IR Burner
Pressure

Lower Burner
Pressure

ORIFICE –
Front IR Burner

ORIFICE –
Rear IR Burner

ORIFICE –
Lower Burner

I2H/I2E(G20) I2L(G25)

26,3 KW 29,1 KW 31,3 KW 26,3 KW 26,5 KW 28,2 KW 25,2 KW 25,2 KW 26,4 KW 26,5 KW 26,6 KW

12,7mm

BSPT

20 mbar 20 mbar 20 mbar 25 mbar 25 mbar 25 mbar

9,34

mbar

9,34

mbar

2,35 2,35 2,35 2,35 2,35 2,35 1,40 1,55 1,55 1,55 1,55

2,50 2,50 2,50 2,50 2,50 2,50 1,51 1,61 1,61 1,61 1,61

3,05 3,25 3,45 3,05 3,25 3,45 1,70 1,85 1,90 1,95 2,00

12,7mm

BSPT

I2H/I2E(G20) I2L(G25)

9,34

mbar

9,34

mbar

I2H/I2E(G20) I2L(G25)

12,7mm

BSPT

9,34

mbar

9,34

mbar

12,7mm

BSPT

12,95

mbar

12,95

mbar

12,7mm

BSPT

12,95

mbar

9,34

mbar

12,7mm

BSPT

12,95

mbar

9,34

mbar

12,7mm

BSPT

37/50

mbar

19,93

mbar

19,93

mbar

I3P(G31)

12,7mm

BSPT

I3P(G31)

37/50

mbar

19,93

mbar

19,93

mbar

I3P(G31)

12,7mm

BSPT

37/50

mbar

19,93

mbar

19,93

mbar

12,7mm

BSPT

37/50

mbar

19,93

mbar

19,93

mbar

SHIPPING
WEIGHT

SHIPPING
DIMENSIONS

ELECTRICAL
RATING

204 Kg (450 lbs)

121,9 cm x 99,1 cm x 172,7 cm (48” x 39” x 68”)

230V~ 50Hz 1,1A 250W

A-1. Model Number Key

X identies Gas Conguration Y = O without Catalyst Y = C with Catalyst

DESCRIPTION MODEL DESCRIPTION MODEL

X = 1 I3P(G31) gas w/o Catalyst FBB-10-230 I3P(G31) gas with Catalyst FBB-1C-230

X = 2 I2H/I2E(G20) gas w/o Catalyst FBB-20-230 I2H/I2E(G20) gas with Catalyst FBB-2C-230

X = 3 I3B/P(G30) gas w/o Catalyst FBB-30-230 I3B/P(G30) gas with Catalyst FBB-3C-230

X = 5 I2L(G25) gas w/o Catalyst FBB-50-230 I2L(G25) gas with Catalyst FBB-5C-230

4

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

20 3/4"

52,9

8 1/2"

21,6

50 3/8"

128

39 1/2"

100,3

34 3/4"

88,4

GAS CONNECTION
3/4" BSPT FEMALE

53 5/8"

136,1

HIGH POSITION

63 5/8"

161,7

45 5/8"

115,8

55 5/8"

141,4

LOW POSITION

5

Installation & Operation Manual for Flexible Batch Broiler - CE Units

II. INSTALLATION INSTRUCTIONS

A. QUALIFIED PERSONNEL

These installation instructions are for the use of
qualied installation and service personnel only.
Installation or service by other than qualied personnel
may result in damage to the broiler and/or injury to the
operator.

Qualied installation personnel are those individuals,
rms, companies or corporations which either in person
or through an agent is engaged in and responsible
for:

• Co mpliance w ith the in sta lla tion in fo rce
in the country in which the appliance is to
be installed.

• This appliance shall be installed with sufcient
ventilation to prevent the occurrence of unacceptable
concentrations of substances harmful to health in
the room in which the appliance is installed.

• Caution - the appliance is mounted on 4
wheels. Care must be taken not to hit kitchen walls
or similar hard objects while moving or installing
the appliance.

• Parts protected by the manufacturer, agent, or
assignee shall not be adjusted by the installer.

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.

Upon delivery of your Duke broiler:

• Look over the shipping container, carefully noting
any exterior damage on the delivery receipt,
which must also be signed by the driver/ delivery
person.

• Unpack and check for any damage, which
was not evident on the outside of the shipping
container.

Caution: The Broiler is very heavy!

Use adequate help for lifting.

• This appliance is not intended for use by
persons (including children) with reduced
physical, sensory or mental capabilities, or lack
of experience and knowledge, unless they have
been given supervision or instruction concerning
use of the appliance by a person responsible for

their safety.

6

Installation & Operation Manual for Flexible Batch Broiler - CE Units

1. Using a utility knife, cut away plastic wrap (not
shown).

2. Remove Training Material box.

3. Remove the top cardboard and inner cap.

4. Remove cardboard from the corners (4 places).

5. Remove cardboard on the ends (2 places).

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 oor 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
notied within fteen (15) days of the delivery of
the broiler and the carton, skid and all packaging
materials must be retained for inspection.

2

4

3

5

4

5

4

7

8

6

4

• 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 ling your claim.

7

Installation & Operation Manual for Flexible Batch Broiler - CE Units

12

13 15

11

10

9

8

7

6

5

4

3

2

1

16

C. BROILER ASSEMBLY

Be fo re asse mbling and insta lling t he broi le r, pleas e check
to m ake sur e that al l neces sary pa rt s are p resent.

ITEM # PART NAME PART #

1 PRODUCT PAN SHELF 175353

2 DISCHARGE CHUTE 175340

3 DISCHARGE HOOD 175362

4 DISCHARGE PAN HOLDER 175358

5 DISCHARGE GREASE PAN 175357

6 “V” GREASE PAN 175325

7 MAIN GREASE PAN 175329

8 LOADER 175444

9 LOADER TRAY 175430

10 LOADER BRACKET 175438

11 DOOR 175429

12 LOADER RAMP 175741

13 IMPEDANCE PAN 175226

14 CATALYST (OPTIONAL) 175480

15 CATALYST GUARD (OPTIONAL) 175482

16 SANITATION PAIL 175842

(Included with Broiler Tools Kit)

Loader Install Tool

OPTIONAL SERVICE PARTS & ACCESSORIES

PARTS KIT – I2H/I2E(G20) & I2L(G25) (w/
Controller & Cook Chain)

PARTS KIT – I3B/P(G30) & I3P(G31) (w/
Controller & Cook Chain)

PARTS KIT - (Burner & Flame Arrestor) 176354 KIT – CE GAS HOSE CONNECTOR - UK 175827

176351

176352 KIT – CE GAS HOSE CONNECTOR

PARTS KIT ­Shield)

(Burner, Arrestor, Loader, & Burner

176353

175831

Setup: Install all items as shown below.

Note: Install loader bracket with (4) ¼-20 nuts.
Use supplied extension tool to remove and
reinstall nuts.
(Nuts are shipped installed on
loader mounting studs.)

8

Installation & Operation Manual for Flexible Batch Broiler - CE Units

D. ADJUSTMENTS AT INSTALLATION

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. These types of adjustments
are not considered defects, rather a normal and routine
part of the proper installation of the equipment.

These adjustments include but are not limited to:

• Adjustments to the gas pressure regulator

• Broiler height adjustment (if required)

No installation should be considered complete
without proper inspection and, if necessary, any
adjustments by qualified service or installation
personnel.

It is also important not to obstruct the natural ow
of combustion and ventilation air if the broiler is to
operate properly. This broiler should not be installed on
a curb base or sealed to the wall. Either condition can
restrict the ow of air to the combustion compartment
or prevent proper ventilation of the unit. Before making
any connections to the broiler, check the ratings plate
to be sure the broiler specications concur with the type
of gas and voltage to be supplied to the broiler.

Raise or Lower Broiler

The broiler height can be adjusted via two screws on
each leg.

Caution: The Broiler is very heavy!

Use adequate help for lifting.

1. Lift one end of the broiler onto a wide, sturdy stand
(not supplied).

2. Remove (2) screws per leg and raise/lower to
threaded holes. Reinstall screws.

3. Remove stand and safely raise/lower broiler.

4. Place plastic hole plugs (supplied attach to stand)
in any unused holes.

The rating plate is located on the back of the control
compartment cover panel on the right end of the
unit.

The plate bearing the broiler’s model number and serial
number is attached to the back side of the unit.

Support broiler here

Screw

Screw

Slide Leg.
Reinstall screws.

Plastic Hole Plug

9

Installation & Operation Manual for Flexible Batch Broiler - CE Units

E. LOCATION OF THE BROILER

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.

• The broiler should be placed in an area that is free
from drafts and accessible for proper operation and
servicing.

• The area around the broiler must be kept clear of
combustible materials as specic below:

COMBUSTIBLE SURFACE SPACING

Discharge End (left side) 305 mm

Access Panel End (right side) 76 mm

Rear 102 mm

Floor/Table 0 mm

F. GAS PIPING

The standard broiler consumes gas at a total of
100,000 BTU/hr, 29.4 KW. The overall piping plan of
the kitchen must support the supply rating to support
appliance to achieve the performance rating.

Generally, piping should be sized to provide a gas
supply sufcient to meet the maximum demand of all
gas appliances on a line without undue loss of pressure
to the equipment. The total BTU requirements of all
equipment being served and the piping length from the
meter are major considerations in the proper design of
the gas supply system.

G. ELECTRICAL CONNECTIONS

Your broiler must be supplied from a 230 Volt 50
Hertz, grounded circuit with a detachable line cord
for each country’s requirements. A wiring diagram is
attached to the broiler control compartment and with
this manual.

: Th is ap plianc e empl o ys an

earthed, safety ground electrical supply system.
DO NOT cut or modify the earthing provisions of
this appliance.

H. VENTILATION

This appliance shall be installed with sufficient
ventilation to prevent the occurrence of unacceptable
concentrations of substances harmful to health in the
room in which the appliance is installed.

Venting to a Canopy Exhaust Hood

A mechanically driven exhaust hood must have a
minimum capacity of 1700 m3/hr (1000 cfm) with a
minimum 100cm by 130cm (39.4 in by 51.2 in) opening
to adequately vent this appliance. The specied
capacity and opening is required in a dedicated hood
for this appliance or in addition to other appliance
vented through a common canopy exhaust hood.

Maintenance of Ventilation System

The vent ilati on sy s tem m ust b e mai ntai n ed
and annually inspected by Qualied Personnel
concurrent as part of or in addition to governmental
requirements.

NOTE: A xed restraint of the proper length
must be incorporated to secure the broiler to
a non-movable surface to eliminate strain on
the gas connector.

10

This inspection/maintenance should consist of, but
not be limited to:

• Inspection for blockages or build up which might

interfere with the venting of the broiler.

• Repair of such blockages.

• Inspection of the venting canopy, its drive motors

and bells, etc.

: Do not place any objects such

as sheet pans, food containers or aluminum foil
on the top of the broiler. This will obstruct the
venting of cooking vapors and airow through the
unit—resulting in poor cooking performance.