Installation and
Operation Manual
BURGER KING
FLEXIBLE
BATCH BROILER
WITH TOUCH
SCREEN CONTROL
Please read this manual completely before attempting to install, operate or service this equipment
This manual is Copyright © 2017 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: 314-231-5074 www.dukemfg.com
P/N 176747B 03/06/2017
Installation and Operation of Flexible Batch Broiler With Touch Screen Control
2
Installation and Operation of Flexible Batch Broiler |
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With Touch Screen Control |
TABLE OF CONTENTS |
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IMPORTANT WARNING AND SAFETY INFORMATION................................................... |
4 |
I. GENERAL INFORMATION........................................................................................... |
5 |
A. BATCH BROILER SPECIFICATIONS................................................................ |
5 |
II. INSTALLATION INSTRUCTIONS............................................................................... |
7 |
A. VENTILATION...................................................................................................... |
7 |
B. INSTALLATION SPECIFICATIONS.................................................................... |
8 |
C. DELIVERY AND INSPECTION........................................................................... |
8 |
D. BROILER ASSEMBLY....................................................................................... |
10 |
E. ADJUSTMENTS AT INSTALLATION................................................................ |
11 |
F. LOCATION OF THE BROILER.......................................................................... |
12 |
G. GAS PIPING....................................................................................................... |
12 |
H. ELECTRICAL CONNECTIONS......................................................................... |
12 |
III. OPERATION INSTRUCTIONS................................................................................ |
14 |
A. DAILY BROILER START-UP.............................................................................. |
15 |
B. COOKING PRODUCT........................................................................................ |
16 |
C. SPECIAL FUNCTION SCREENS...................................................................... |
18 |
D. CLEANING.......................................................................................................... |
23 |
IV. SERVICE AND REPAIR............................................................................................ |
31 |
V. REPLACEMENT PARTS LIST................................................................................. |
33 |
VI. ELECTRICAL SCHEMATIC..................................................................................... |
35 |
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Installation and Operation of Flexible Batch Broiler With Touch Screen Control
IMPORTANT WARNING AND SAFETY INFORMATION
WARNING
CAUTION
HAZARD WHICH COULD RESULT IN DEATH OR SERIOUS INJURY
HAZARD WHICH COULD RESULT IN MINOR OR MODERATE INJURY
ELECTRICAL SHOCK HAZARD WHICH COULD RESULT IN DEATH OR SERIOUS INJURY AND/OR EQUIPMENT DAMAGE
HOT SURFACE WHICH COULD RESULT IN MINOR OR MODERATE INJURY.
TASKS MUST BE PERFORMED ONLY FOLLOWING PROPER TRAINING
•Read all instructions before using equipment
•Do not attempt to defeat the grounded connector
•Install or locate the equipment, only for its intended use, as described in this manual.
•Do not use corrosive chemicals, water jet equipment, or other pressurized liquid spraying equipment to clean this unit.
•Do not block any openings on the unit.
•Unit may start operating with inadvertent contact with the touch screen display or from other extraneous sources. Turn off external mains supply disconnect and/or unplug the unit from the mains supply, should abnormal or unwanted operations occur.
•This appliance is not intended for use by children or persons 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. Children shall not play with the appliance.
•Turnoff the external mains supply disconnect or disconnect the appliance line supply cord and allow the unit to cool down before servicing or performing maintenance.
•The procedures in this manual may include the use of chemical products. You must read the Material Safety Data Sheets (MSDS) before using any of these products.
•Properly rated all poles mains protection and earthing compliance with local codes are required for safe operation of this unit.
•Disposal of this unit must be in accordance with local environmental codes and/or other applicable codes.
•Consult the local gas supplier for instructions to be followed in the event user smells gas.
•Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.
•SAVE THESE INSTRUCTIONS
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Installation and Operation of Flexible Batch Broiler
With Touch Screen Control
I.GENERAL INFORMATION
A.Batch Broiler Specifications
FLEXIBLE BATCH BROILER SPECIFICATIONS
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NATURAL GAS |
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PROPANE |
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ALTITUDE (MAXIMUM) |
2000 FT |
607 m |
2000 FT |
607 m |
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GAS PIPE CONNECTION |
3/4" F-NPT |
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3/4" F-NPT |
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INLET PRESSURE RANGE |
7" – 12" W.C. |
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10" – 12” W.C. |
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NOTE: High Pressure Kit is required if supply pressures are greater than 12.0” W.C. (3.0 kPa) |
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Reference Duke P.N. 175689 |
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MANIFOLD PRESSURE |
MANIFOLD PRESSURE |
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INFRARED BURNERS (TOP) |
3.75" W.C. |
0.93 kPa |
8.0" W.C. |
2.0kPa |
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LOWER BURNER |
3.75" W.C. |
0.93 kPa |
8.0" W.C. |
2.0kPa |
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TOTAL ENERGY RATE |
87000 – 111,000 |
25.5 – 32.5 |
79,000 – 105,000 |
23.2 – 30.7 |
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BTU/HR |
kW |
BTU/HR |
kW |
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BURNER ORIFICE SIZE |
BURNER ORIFICE SIZE |
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FRONT INFRARED BURNER |
#40 |
2.49mm |
#52 |
1.61mm |
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BACK INFRARED BURNER |
#36 |
2.70mm |
#51 |
1.70mm |
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LOWER BURNER |
#31 |
3.05mm |
#49 |
1.85mm |
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SHIPPING WEIGHT: 482 lbs (219 Kg)
SHIPPING DIMENSIONS: 47” x 34” x 68” (119.4 x 86.4 x 172.7 cm)
MODEL NUMBER |
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ELECTRIC |
NATURAL & LP GAS |
FBBT-NO-120 |
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120VAC, 2A, 60Hz |
87,000 – 111,000 BTU/HR |
FBBT-NC-120 |
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120VAC, 2A, 60Hz |
87,000 – 111,000 BTU/HR |
FBBT-PO-120 |
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120VAC, 2A, 60Hz |
79,000 – 105,000 BTU/HR |
FBBT-PC-120 |
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120VAC, 2A, 60Hz |
79,000 – 105,000 BTU/HR |
A-1.0 Model Number Key |
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FBBT-XY-120 |
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X = N (NATURAL GAS) |
OR |
P (PROPANE / LP GAS) |
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Y = O (NO CATALYST) |
OR |
C (CATALYST) |
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120 = 120 VOLTS |
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Installation and Operation of Flexible Batch Broiler
With Touch Screen Control
A-2.0 Broiler Dimensions
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50 3/8" |
44" |
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(128 CM) |
(111.9 CM) |
8 1/2" |
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20 3/4" |
(21.6 CM) |
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(52.9 CM) |
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63 5/8" |
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(161.7 CM) |
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53 5/8" |
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(136.1 CM) |
39 1/2" |
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(100.3 CM) |
34 3/4" |
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(88.4 CM) |
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Installation and Operation of Flexible Batch Broiler With Touch Screen Control
II. INSTALLATION INSTRUCTIONS
The installation must conform with local codes, or in the absence of local codes, with the National Fuel Gas Code,
WARNING
IMPROPER INSTALLATION,
ADJUSTMENT, ALTERATION, SERVICE, OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY, OR DEATH. READ THE INSTALLATION, OPERATING, AND MAINTENANCE INSTRUCTIONS BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.
Installation and/or service repair of gas appliances requires Skilled or Qualified Personnel. Skilled or Qualified Personnel are individuals, firms, companies or corporations which are directly authorized by Duke Manufacturing (Assignee) or meet the requirements of governmental authority having jurisdiction for the task.
Electrical wiring tasks must be in conformance with National Electrical Code ANSI/NFPA70
Gas supply interconnection must be in conformance with National Fuel Gas Code ANSI Z223.1/NFPA54 and Natural Gas and Propane Installation Code CSAB149 including the following:
•The appliance must have an individual manual shutoff valve at the connection to the gas supply piping system during any pressure testing of that system at test pressures in excess of ½ psi (3.5kPa).
•The appliance must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply systems at test pressures equal to or less than ½ psi (3.5kPa).
For a broiler mounted on casters, the installation must be made with a connector
that complies with ANSI Z21.69 / CSA 6.16 Connectors for Moveable Gas Appliances and a quick-disconnect device that complies with ANSI Z21.4 / CSA 6.9 Quick –Disconnect Devices for Use with Gas Fuel.
When installing a broiler mounted on casters with quick-disconnect hose, adequate means must be provided to limit the movement of the broiler without depending on the connector, hose, or system piping to limit movement. A restraining device may be attached to the rear vertical portion of the broiler’s base frame.
A. VENTILATION:
This appliance requires a ventilation system to prevent unacceptable concentrations of
substances harmful to health in the room where the appliance is installed.
Ventilation System Specifications:
Must be a Mechanically Driven Exhaust Hood System
Minimum Capacity: 1,700 m3/hr (1,000 cfm) Minimum Opening: 39.4” x 51.2” (100cm x 130cm)
The Ventilation System must be inspected, maintained, and annually serviced by
Qualified Personnel as part of or in addition to governmental requirements
NOTE: Ventilation Systems for multiple or additional appliances must have capacity in addition to the specifications for this appliance.
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Installation and Operation of Flexible Batch Broiler With Touch Screen Control
Maintenance of Ventilation System
Theventilationsystemmustbemaintainedandannually inspectedbyQualifiedPersonnelconcurrentaspartof or in addition to governmental requirements.
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 airflow through the unit—resulting in poor cooking performance.
B. INSTALLATION SPECIFICATIONS:
The broiler has been fully tested before shipping with adjustments to optimize operation of the gas system IR (top) burners and bottom burner. The Skilled or Qualified Personnel installing the broiler must verify gas systems adjustments to verify adjustments were not impacted during transit shipping. Please contact Duke Manufacturing Co. for adjustment procedures.
This broiler must not be installed on a curb base or sealed to a wall. The area around the broiler must be clear of combustible materials.
Minimum clearances to combustible or noncombustible surfaces are:
Discharge end: 12.0” (305mm)
Rear of unit: 4.0” (102mm)
Side Access Panel (Control): 3.0” (76mm) Floor / Table: 0” (0mm)
ELECTRICAL SPECIFICATIONS:
Electrical Rating: 120V~ 2A 60Hz
Line Connection: NEMA 15
WARNING
ELECTRICAL SHOCK HAZARD UNIT MUST BE SAFETY GROUNDED, EARTHED.
DO NOT MODIFY OR DEFEAT ELECTRICAL CONNECTIONS
C.DELIVERY AND INSPECTION
•The shipping carrier assumes liability and responsibility for delivering the appliance without damage. Duke Manufacturing Co. can assist with resolution of any shipping related issues if a problem arises.
•Look over the outer shipping container carefully when delivered with the person making the delivery.
•Note any exterior damage on the delivery receipt before signing.
•The person making the delivery for the shipping carrier must agree and sign the receipt to document damage to the outer shipping container.
•Unpack the broiler and inspect for any damage not evident on the outer shipping container and other concealed damage. The shipping carrier must be notified any damages within fifteen (15) days of receipt.
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7 |
4 |
8 |
6 |
CAUTION
The broiler is very heavy!
Use adequate help when lifting.
1.Cut away the plastic outer wrap.
2.Remove the top cardboard and inner cap (Item 2)
3.Remove training material box (Item 7)
4.Remove cardboard corner covers (Item 4)
5.Remove cardboard ends (Item 5)
6.Cut banding straps with a utility knife or scissors (Items 6)
7.Remove accessories box (Item 8) checking that no tape remains.
8.Lift one end of the broiler and tap the wood block toward the center and then sideways to remove. Repeat for the remaining blocks allowing the casters to rest on the pallet.
Installation and Operation of Flexible Batch Broiler With Touch Screen Control
9.A minimum of three (3) people are required to support and balance the broiler while removing from the palate.
a.Roll the broiler forward until the front caster are clear of the palate
b.Lift the broiler rear caster above the palate and slide out the palate from under the broiler.
c.Gently lower the broiler to the floor to avoid damage to casters
10.Remove the protective blue tape protecting the broiler stainless steel panels. Verify all blue tape is removed before installing and operating the unit.
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Installation and Operation of Flexible Batch Broiler With Touch Screen Control
D. BROILER ASSEMBLY
Before assembling and installing the broiler, please check to make sure that all necessary parts are present.
ITEM |
PART NAME |
PT.NO. |
1 |
PRODUCT PAN SHELF |
175353 |
2 |
DISCHARGE CHUTE |
175340 |
3 |
DISCHARGE HOOD |
175778 |
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 |
17 |
KIT, CLEANING TOOLS/INSTALLATION |
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TOOL CLEANING – LOWER BURNER |
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FLAME ROD TUBE CLEANER BRUSH, |
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TUBE CLEANER TOOL– LOADER |
175700 |
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INSTALL WRENCH, ALLEN, 3/16” |
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18 |
KIT – BROILER SVC. PARTS, |
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NAT. GAS W/ CONTROLLER W/COOK |
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CHAIN (OPTIONAL) |
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19 |
KIT – BROILER SVC. PARTS, PROPANE, |
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W/ CONTROLLER W/COOK CHAIN |
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(OPTIONAL) |
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20 |
KIT – USER REPLACEABLE, BOTTOM |
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BURNER, FLAME ARRESTOR, LOADER & |
175726 |
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BURNER SHIELD (OPTIONAL) |
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21 |
KIT – USER REPLACEABLE, BOTTOM |
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BURNER & FLAME ARRESTOR |
175750 |
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(OPTIONAL) |
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22 |
KIT – GAS HOSE CONNECTOR |
175690 |
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ASSEMBLY (OPTIONAL) |
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23 |
KIT – HIGH SUPPLY GAS PRESSURE |
175689 |
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REGULATOR (OPTIONAL) |
Setup
Install all items as shown below.
Loader Install Tool |
(Included with Broiler |
Tools Kit) |
Install loader bracket with (4) 1/4-20 nuts.
Use supplied extension tool to remove and reinstall nuts. (Nuts are shipped installed on loader mounting studs.)
13 15
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2 |
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1 |
3 |
11 |
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6 12
10
9
4 |
5 |
8
16
7
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E. ADJUSTMENTS AT INSTALLATION
Each broiler section and all its component parts have beentestedthoroughlyandinspectedbeforeyourbroiler 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 flow 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 flow 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 specifications concur with the type of gas and voltage to be supplied to the broiler.
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.
Installation and Operation of Flexible Batch Broiler With Touch Screen Control
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.
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