Duke FBB-XY-230-AAB Service Manual

FLEXIBLE BATCH BROILER

MODELS FBB-XY-230-AAB

Service Manual

CE Version

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 qualied 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. Be sure all necessary tools, test equipment, and skills are available. Those procedures for which you do not have the proper skills and test equipment must be performed only by a qualied Duke trained service technician.

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.dukemfg.com

P/N 175922B

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 START-UP 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.

IMPORTANT

IN THE EVENT A GAS ODOR IS DETECTED, SHUT DOWN BROILER AT MAIN SHUTOFF VALVE AND CONTACT THE LOCAL GAS COMPANY OR GAS SUPPLIER FOR SERVICE.

IMPORTANT FOR YOUR SAFETY

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

WARNING

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.

WARNING

IN THE EVENT OF A POWER FAILURE, DO NOT ATTEMPT TO OPERATE THIS DEVICE.

Service Manual for Flexible Batch Broiler Units

TABLE OF CONTENTS

INSTALLATION ...................................................................................................................5

OPERATION ........................................................................................................................5

CLEANING .......................................................................................................................... 5

SPECIFICATIONS ............................................................................................................... 6

TOOLS ..............................................................................................................................6

Standard .......................................................................................................................6

REMOVAL AND REPLACEMENT OF COMPONENTS ...................................................... 7

COVERS AND PANELS ...................................................................................................... 7

Upper Lift Off Panel ......................................................................................................7

Lower Control Side Service Panel ................................................................................7

Discharge Tray .............................................................................................................8

Discharge Hood ............................................................................................................8

Discharge Chute ...........................................................................................................8

Discharge Pan ..............................................................................................................9

Discharge Grease Pan .................................................................................................9

Discharge Access Panel ...............................................................................................10

Main Grease Pan .........................................................................................................10

Grease V Pan ...............................................................................................................10

Loader Tray ..................................................................................................................11

Conveyor Drive Motor Cover ........................................................................................11

Top Service Panel ........................................................................................................12

Removing the Front Panel ............................................................................................12

Removing the Rear Panel ............................................................................................12

COMPONENT REMOVAL ................................................................................................... 13

Conveyor Drive Motor Assembly ..................................................................................13

Conveyor Drive Chain .................................................................................................14

Conveyor Drive Motor Sprocket ...................................................................................14

Conveyor Drive Motor Capacitor ..................................................................................15

Blower Hose .................................................................................................................16

Upper Flame Sensor Assembly ....................................................................................16

Upper Igniter Assembly ................................................................................................17

Lower Flame Sensor Assembly ....................................................................................17

Lower Igniter Assembly ................................................................................................18

Upper Infrared Burner Assembly ..................................................................................18

Lower J Burner ............................................................................................................19

Ignition Modules ...........................................................................................................20

Combo Gas Valves .......................................................................................................20

Cook Chamber Temperature Probe..............................................................................21

Control Board ...............................................................................................................22

Step-Down Transformers .............................................................................................23

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 ............................................................................................25

ADJUSTMENTS ..................................................................................................................26

Combo Gas Valves .......................................................................................................26

Drive Chain Deection ..................................................................................................27

Conveyor Position Adjustment .....................................................................................27

Upper Infrared Burner Air Supply .................................................................................28

Lower Burner Air Supply ...............................................................................................28

TROUBLESHOOTING CHART ...........................................................................................29

SCHEMATIC DIAGRAM ...................................................................................................... 39

REPLACEMENT PARTS LIST ............................................................................................40

Service Manual for Flexible Batch Broiler Units

INTRODUCTION

INSTALLATION

For detailed installation instructions, refer to the Installation and Operation Manual.

OPERATION

For specic operating instructions, refer to the Installation and Operation Manual.

CLEANING

For specic cleaning instructions, refer to the Installation and Operation Manual.

Service Manual for Flexible Batch Broiler Units

CE SPECIFICATIONS

G20 G25 G30 G31

ALTITUDE (MAXIMUM) 607 m 607 m 607 m 607 m GROSS HEAT INPUT 26.4 KW 26.4 KW 26.4 KW 26.4KW GAS PIP CONNECTION 12.7 mm BSPT 12.7 mm BSPT 12.7 mm BSPT 12.7 mm BSPT Supply Pressure 20 mbar 25 mbar 28-30 mbar 37-50 mbar IR burner Pressure 9.34 mbar 12.95 mbar 19.93 mbar 19.93 mbar Lower Burner Pressure 9.34 mbar 12.95 mbar 19.93 mbar 19.93 mbar ORIFICE – Front IR burner 2.35 2.35 1.40 1.55 ORIFICE – Rear IR Burner 2.50 2.50 1.51 1.61 ORIFICE – Lower Burner 3.02 3.02 1.61 1.61

SHIPPING WEIGHT 205 KG (450 lbs) SHIPPING DIMENSIONS 121.9 cm x 99.1 cm x 172.7 cm (483 x 393 x683 ) ELECTRICAL RATING 230 Volts 50 Hz 250 W

Model Number Information:

FBB-XY-230-AAB

X = 1 Reference Gas G31

X = 2 Reference Gas G20

X = 3 Reference Gas G30

X = 5 Reference Gas G25

Y = O No Catalyst

Y = C With Catalyst

AA = ISO 2 Digit Country Code

B = Future use

TOOLS

Standard

• Standard set of hand tools.

• VOM with AC current tester (Any quality VOM with a sensitivity of at least 20,000 ohms per volt can be used).

• Manometer

• Pyrometer

• Gas Leakage Tester or method to test for gas leaks

• Conveyor Link Removal Pliers

• Duke Testing Harness

Service Manual for Flexible Batch Broiler Units

Control Side

Access Panel

Control Side

Service Panel

Screws

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.

Upper Lift Off Panel

The Upper Lift Off Panel provides access to the Upper Flame Sensors, Igniters and Blower Hose.

1. Remove Upper Lift Off Panel by lifting up and removing from broiler.

2. Install Upper Lift Off Panel by lowering into the side grooves.

Upper Lift Off Panel

Lower Control Side Service Panel

The Lower Control Side Service Panel provides access to the Combo Gas Valves, Ignition Modules, Transformers, Blower Motor, Conveyor Motor Capacitor, and electrical connections to the Control Board.

1. Remove the six screws securing the Lower Control Side Service Panel.

2. Remove the panel from the broiler.

3. Reverse procedure to install the Lower Control Side Service Panel.

Service Manual for Flexible Batch Broiler Units

PHU

Pan

Shelf

Discharge

Hood

Discharge

Chute Hook

Lower Control Side Service Panel

PHU Pan Shelf

The PHU Pan Shelf is located on the discharge side of the broiler and holds the unused holding pans.

1. Lift the pan shelf up and remove.

2. To install the pan shelf, slide the keyholes over the two screws and slide pan shelf down.

Discharge Chute

The Discharge Chute is located under the Discharge Hood and guides the patties from the conveyor into the Discharge Pan.

1. Remove PHU Pan Shelf.

2. Remove the Discharge Hood.

3. Remove Discharge Chute by lifting off of the two side pins.

4. Reverse procedure to install Discharge Chute, being sure to rest the hooks onto the pins on both sides.

PHU Pan Shelf and Discharge Hood

Discharge Hood

The Discharge Hood is located on the discharge side of the broiler under the PHU Pan Shelf.

1. Remove the PHU Pan Shelf.

2. Remove the Discharge Hood by lifting out.

3. Install Discharge Hood by lowering into the side grooves.

4. Reinstall the PHU Pan Shelf.

Discharge Chute

Service Manual for Flexible Batch Broiler Units

Discharge

Pan

Discharge

Grease

Pan

Discharge 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).

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 Grease Pan

The Discharge Grease Pan is located below the Discharge Pan and catches any grease drippings.

1. Tilt Discharge Grease Pan up to unhook and pull forward to remove.

2. When installing the Discharge Grease Pan, be sure to tilt up and push all the way back.

NOTE: Correct positioning will not allow pan removal without upward tilt.

Discharge Pan

Discharge Grease Pan

Service Manual for Flexible Batch Broiler Units

Discharge

Side

Access

Panel

Discharge

Side

Access

Panel

Main

Grease Pan

Grease

V-Pan

Discharge Access Panel

1. Remove the PHU Pan Shelf.

2. Remove Discharge Hood.

3. Remove Discharge Chute.

4. Remove Discharge Pan.

5. Remove Discharge Grease Pan.

6. Remove Discharge Access Panel by lifting it up and out.

7. Reverse procedure to install Discharge Access Panel.

Main Grease Pan

The Main Grease Pan is located on the front of the broiler under the V Grease Pan.

Remove the Main Grease Pan by sliding straight out of broiler.

V Grease Pan

The V Grease Pan is located on the front of the broiler under the Loader Tray.

Remove pan by sliding straight out from broiler.

Discharge Access Panel

V Grease Pan and Main Grease Pan

Service Manual for Flexible Batch Broiler Units

Loader

Carriage

Loader

Bracket

Ear

Conveyor

Drive Motor Cover

Loader Tray

The Loader Tray is located on the front of the broiler and slides into the channels on the Loader Brackets.

1. Remove Loader by sliding it out of the Loader Tray.

2. Remove Loader Tray from the Loader Brackets by pulling forward and disengaging ears on Loader Tray from keepers on the Loader Brackets.

3. Install Loader Tray by sliding it into bracket and engaging ears with keepers.

Conveyor Drive Motor Cover

The Conveyor Drive Motor Cover, located on the lower front of the broiler on the discharge side, covers the Drive Chain Motor.

1. Remove the Main Grease Pan and the V Grease Pan.

2. Remove the three screws securing the cover to the broiler.

3. Lift Conveyor Drive Motor Cover off the broiler.

Loader Tray

Conveyor Drive Motor Cover

Service Manual for Flexible Batch Broiler Units

Top

Service

Panel

Flue

Restrictor

Front Access Panel

Rear Access Panel

Top Service Panel

The perforated Top Service Panel provides access to the two Infrared Burners

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.

5. Lift the Front Panel up and away from the broiler.

6. Reverse these steps to reinstall these parts.

Front Panel

Removing the Front Panel

1. Slide the Loader out of the Loader Tray.

2. Unlatch the Loader Tray and slide it out of the Loader Tray Mounting Brackets.

3. Pull the Main Grease Pan out of the front of the broiler.

4. Pull the V Grease Pan out of the front of the broiler.

Removing the Rear Panel

1. Lift the Rear Panel up and away from the broiler.

2. Reverse to reinstall the Rear Panel.

Top Service Panel

Rear Panel

COMPONENT REMOVAL

Motor

Assembly

Screws

Motor

Mounting

Plate

Chain

Motor

Sprocket

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.

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.

Service Manual for Flexible Batch Broiler Units

Conveyor Drive Motor Assembly

2. Disconnect wires to motor.

3. Remove Discharge Access Panel. Refer to the COVERS and PANELS section of the manual.

4. Remove four screws securing motor to mounting plate and remove motor.

5. Raise motor mounting plate to disengage drive chain from motor pulley.

6. Remove sprocket from motor shaft. Sprocket is secured to motor shaft by two set screws.

7. Reverse procedure to install a new motor. Ensure that one of the sprocket set screws is tightened to the at side of the motor shaft.

NOTE: When installing the new motor, be sure to engage the chain on the motor sprocket. Adjust the tension on the chain to allow 4.763 mm chain deection, as described in the procedure DRIVE CHAIN DEFLECTION ADJUSTMENT in the ADJUSTMENT Section, before tightening the motor mounting plate screws.

Motor Sprocket and Drive Chain

Service Manual for Flexible Batch Broiler Units

Conveyor

Sprocket

Motor

Sprocket

Chain

Conveyor Drive Chain

The Conveyor Drive Chain connects the drive motor to the Conveyor.

WARNING

DISCONNECT THE ELECTRICAL

POWER TO THE BROILER AND

FOLLOW LOCKOUT / TAGOUT

PROCEDURES.

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.

Drive Chain and Sprockets

3. Disconnect motor wires.

4. Remove four screws securing motor mounting plate.

5. Raise motor mounting plate to disengage drive chain from motor sprocket.

6. Disengage chain from conveyor sprocket.

7. Remove chain from broiler by removing the master link.

8. Reverse procedure to install a new chain.

NOTE: When installing the new chain, be sure to engage the chain on the motor sprocket and conveyor sprocket. Then adjust the tension on the chain to allow 4.763 mm chain deection, as described in the procedure DRIVE CHAIN DEFLECTION ADJUSTMENT in the ADJUSTMENT Section, before tightening the motor mounting plate screws.

Conveyor Drive Motor Sprocket

The Conveyor Drive Motor Sprocket is attached to the motor shaft.

WARNING

DISCONNECT THE ELECTRICAL

POWER TO THE BROILER AND

FOLLOW LOCKOUT / TAGOUT

PROCEDURES.

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 the motor wires.

4. Remove the four screws securing motor mounting plate.

5. Raise motor mounting plate to disengage drive chain from motor sprocket.

6. Disengage drive chain from motor sprocket.

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