Installation & Operation Manual
FLEXIBLE BATCH BROILER
Duke Manufacturing Co. |
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2305 N. Broadway • St. Louis, Missouri |
175500L |
800-735-3853 • 314-231-1130 • Fax 314-231-5074 |
AS OF: 2/15/08 |
www.dukemfg.com |
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RESTAURANT |
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37 |
EQUIPMENT |
FLEXIBLE BATCH BROILER |
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MANUAL |
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INDEX |
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I. General Information .......................................................................... |
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A. Batch Broiler Specifications ................................................................................. |
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A-1.0 Model Number Key .................................................................................. |
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A-2.0 Broiler Dimensions................................................................................... |
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II. Installation Instructions.................................................................... |
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A. |
Qualified Personnel ........................................................................................... |
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B. |
Delivery and Inspection ..................................................................................... |
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C. |
Broiler Assembly................................................................................................ |
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D. Adjustments at Installation…………………………………………………………..9 |
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E. Location of the Broiler........................................................................................ |
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F. |
Gas Piping ......................................................................................................... |
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G. |
Electrical Connections....................................................................................... |
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Ventilation .......................................................................................................... |
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III. Operation Instructions..................................................................... |
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A. |
Broiler Controls .................................................................................................. |
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B. |
Cooking Product ................................................................................................ |
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B-1.0 Lighting the Broiler ................................................................................... |
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B-2.0 Cook Product ........................................................................................... |
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B-3.0 Cook Cycle Complete .............................................................................. |
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B-4.0 Fine Cooking Adjustment......................................................................... |
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B-5.0 Cancel a Cook Cycle ............................................................................... |
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B-6.0 Checking the Broiler Temperature........................................................... |
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B-7.0 Checking the Set Point Temperature....................................................... |
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B-8.0 Shutdown the Broiler................................................................................ |
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C. |
Cleaning............................................................................................................. |
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C-1.0 Four (4) Hour Cleaning ........................................................................... |
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C-2.0 Daily Cleaning.......................................................................................... |
17-19 |
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C-3.0 Weekly Cleaning...................................................................................... |
19-22 |
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C-4.0 Monthly Cleaning ..................................................................................... |
23-24 |
D. |
Programming the Control .................................................................................. |
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D-1.0 Entering Program Mode .......................................................................... |
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D-2.0 Navigating the Programming Screens..................................................... |
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D-3.0 Level 1 Programming............................................................................... |
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D-3.1 Product Identifier...................................................................................... |
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D-3.2 Cook Temperature................................................................................... |
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D-3.3 Cooking Profile ........................................................................................ |
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D-3.4 Exit Program Mode .................................................................................. |
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D-4.0 Level 2 Programming............................................................................... |
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D-4.1 F or C Parameter ..................................................................................... |
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D-4.2 Change the Idle Temperature.................................................................. |
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D-4.3 Additional Factory Parameters ................................................................ |
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D-4.4 Exit Program Mode .................................................................................. |
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37 |
EQUIPMENT |
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FLEXIBLE BATCH BROILER |
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MANUAL |
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E. Troubleshooting ................................................................................................. |
27-30 |
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IV. Service and Repair .......................................................................... |
31 |
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A-1.0 Warnings ........................................................................................................ |
32 |
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V. Replacement Parts List ................................................................... |
32-34 |
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VI. Wiring diagram................................................................................. |
35 |
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VII. Customer Assistance ..................................................................... |
36 |
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RESTAURANT
FLEXIBLE BATCH BROILER37 EQUIPMENT
MANUAL
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
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.
THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE.
I. General Information
A. Batch Broiler Specifications
FLEXIBLE BATCH BROILER SPECIFICATIONS
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NATURAL GAS |
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. |
10” – 12” W.C. |
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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.” W.C. |
2.0kPa |
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TOTAL ENERGY RATE |
87000 – 111,000 |
25.5 – 32.5 |
79,000 – |
23.2 – 30.7 |
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BTU/HR |
kW |
105,000 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 |
2.05mm |
#49 |
1.85mm |
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RESTAURANT
FLEXIBLE BATCH BROILER37 EQUIPMENT
MANUAL
A. Batch Broiler Specifications (cont’d)
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SHIPPING WEIGHT: 482 lbs (219 Kg) |
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SHIPPING DIMENSIONS: 47” x 34” x 68” (119.4 x 86.4 x 172.7 cm) |
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MODEL NUMBER |
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ELECTRIC |
NATURAL & LP GAS |
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FBB-NO-120 |
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120VAC, 2A, 60Hz |
87,000 – 111,000 BTU/HR |
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FBB-NC-120 |
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120VAC, 2A, 60Hz |
87,000 – 111,000 BTU/HR |
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FBB-PO-120 |
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120VAC, 2A, 60Hz |
79,000 – 105,000 BTU/HR |
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FBB-PC-120 |
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120VAC, 2A, 60Hz |
79,000 – 105,000 BTU/HR |
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A-1.0 Model Number Key |
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FBB-X Y -120 |
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X = N (NATURAL GAS) |
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P (PROPANE / LP GAS) |
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Y = O (NO CATALYST) |
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C (CATALYST) |
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120 = 120 VOLTS |
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A-2.0 Broiler Dimensions
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FLEXIBLE BATCH BROILER37 EQUIPMENT
MANUAL
II. Installation Instructions
A. Qualified Personnel
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.
Qualified installation personnel are those individuals, firms, companies or corporations which either in person or through an agent is engaged in and responsible for:
•The installation or replacement of gas piping or the connection, installation, repair or servicing of equipment, who are experienced in such work, familiar with all precautions required, and have complied with all requirements of state and local authorities having jurisdiction. See: National Fuel Gas Code NFPA 54 (ANSI Z223.1).
•The installation of electrical wiring from the electric meter, main control box or service outlet to the electrical appliance. Qualified installation personnel must be familiar with all precautions required and have complied with all requirements of state and local authorities having jurisdiction. See: National Electrical Code, ANSI/NFPA70.
The installation must conform with local codes, or in the absence of local codes, with the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code, CSA B149.1 as applicable, including:
•The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of ½ psi (3.5 kPa).
•The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than ½ psi (3.5 kPa).
For a broiler mounted on casters, the installation shall be made with a connector that complies with the Standard for Connectors for Movable Gas Appliances, ANSI Z21.69/CSA 6.16 and a quick-disconnect device that complies with the Standard for Quick-Disconnect Devices for Use with Gas Fuel, ANSI Z21.4/CSA 6.9. When installing the broiler with casters and quickdisconnect hose, adequate means must be provided to limit the movement of the broiler without depending on the connector and the quick disconnect device or its associated piping to limit the broiler movement. A means for restraining may be attached to the vertical portion of the base frame in the rear of the broiler.
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FLEXIBLE BATCH BROILER |
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EQUIPMENT |
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37 |
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MANUAL |
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B. Delivery and Inspection |
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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.
•Check for concealed damage. The carrier must be notified within fifteen (15) days of the delivery of the broiler and the carton, skid and all packaging materials must be retained for inspection.
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 in filing your claim.
Caution: The Broiler is very heavy! Use adequate help for lifting.
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 & 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 it’s 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 floor to avoid damage to casters.
10)Remove protective blue tape from broiler panels, double checking that no tape remains.
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FLEXIBLE BATCH BROILER37 EQUIPMENT
MANUAL
C. Broiler Assembly
Before assembling and installing the broiler, please check to make sure that all necessary parts are present.
Item |
Part Name |
Part |
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Number |
1 |
PRODUCT PAN SHELF |
175353 |
2 |
DISCHARGE CHUTE |
175340 |
3 |
DISCHARGE HOOD |
175778 |
4 |
DISCHARGE PAN HOLDER |
175358 |
5 |
DISCHARGE GREASE PAN |
175357 |
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“V” GREASE PAN |
175325 |
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MAIN GREASE PAN |
175329 |
8 |
LOADER |
175444 |
9 |
LOADER TRAY |
175430 |
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LOADER BRACKET |
175438 |
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DOOR |
175429 |
12 |
LOADER RAMP |
175741 |
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IMPEDANCE PAN |
175226 |
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CATALYST (OPTIONAL) |
175480 |
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CATALYST GUARD (OPTIONAL) |
175482 |
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SANITATION PAIL |
175842 |
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KIT, CLEANING TOOLS/INSTALLATION |
175700 |
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TOOL CLEANING – LOWER BURNER |
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FLAME ROD TUBE CLEANER |
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BRUSH, TUBE CLEANER |
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TOOL-LOADER INSTALL |
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WRENCH, ALLEN, 3/16” |
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KIT – BROILER SVC. PARTS, NAT. GAS W/ |
175725 |
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CONTROLLER W/COOK CHAIN (OPTIONAL) |
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KIT – BROILER SVC. PARTS, PROPANE, W/ |
175740 |
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CONTROLLER W/COOK CHAIN (OPTIONAL) |
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KIT – USER REPLACEABLE, BOTTOM |
175726 |
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BURNER, FLAME ARRESTOR, LOADER & |
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BURNER SHIELD (OPTIONAL) |
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KIT – USER REPLACEABLE, BOTTOM |
175750 |
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BURNER & FLAME ARRESTOR (OPTIONAL) |
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KIT – GAS HOSE CONNECTOR ASSEMBLY |
175690 |
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(OPTIONAL) |
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KIT – HIGH SUPPLY GAS PRESSURE |
175689 |
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REGULATOR (OPTIONAL) |
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Setup
Install all items as shown below.
Loader Install Tool
(Included with Broiler Tools Kit)
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.)
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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 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.
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.
Support broiler here
Screw
Screw
Slide Leg.
Reinstall screws.
Plastic Hole
Plug
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RESTAURANT
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MANUAL
E. Location of the Broiler
Proper planning and placement of the broiler will give you the best results in terms of long-term user convenience and satisfactory performance. 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. A minimum
clearance |
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Combustible |
Non- |
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Combustible |
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Discharge End |
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12" |
(305) |
12” (305) |
Access Panel End |
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3" |
(76) |
3” (76) |
Rear |
4" |
(102) |
4” (102) |
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Floor/Table |
0" |
(0) |
0” (0) |
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NOTE: Using the Loader Tray to support heavy items or an individual’s body weight can damage components of the broiler.
F. Gas Piping
The standard broiler consumes gas at a total of 100,000 BTU/hr. In order to achieve the degree of performance for which the unit has been designed, the overall piping plan of the kitchen, properly sized, is essential. The installation of this broiler must conform with all local codes, or in the absence of any local codes, to the National Fuel Gas Code, NFPA 54 and ANSI Z 223.1.
Your local gas supplier should consult the National Fuel Gas Code for proper sizing and installation of gas piping. Generally, piping should be sized to provide a gas supply sufficient to meet the maximum demand of all gas appliances on a line without undue loss of pressure at the outlet to the equipment. The total BTU requirements of the equipment being served and the length of the piping from the meter to the appliances are major considerations in the proper design of the gas supply system.
NOTICE TO INSTALLER:
THIS APPLIANCE SHALL BE CONNECTED TO A GAS SUPPLY IN THE RANGE OF:
NATURAL GAS 7” TO 12” W.C.
PROPANE GAS 10” TO 12” W.C.
Gas supply pressure must be checked prior to installation. If supply pressure is in excess of 12” W.C., The HIGH SUPPLY PRESSURE KIT, Duke P/N 175689 shall be installed and adjusted, per kit instructions, for an outlet pressure of:
Natural Gas - 7” W.C.
Propane Gas – 11” W.C.
NOTE: A fixed restraint of the proper length must be incorporated to secure the broiler to a non-movable surface to eliminate strain on the gas connector. If the broiler is removed from its normal position, the restraint must then be reattached when returned.
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MANUAL
G. Electrical Connections
Your broiler is supplied for connection to a dedicated 120 volt, grounded circuit. The electric motors, indicator lights and control circuits are connected through a seven-foot electric supply cord found at the rear of the broiler.
Before making any connections to these units, check the rating plate to assure that the voltage and phase of the broiler is compatible with the electrical supply. When installing, all broilers must be electrically grounded in accordance with local codes, or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70 (in Canada - CSA Std. C22.2). Wiring diagrams are located in the control compartment area of the broiler. Standard wiring schematics are also provided with this manual.
WARNING: This appliance is equipped with a three-prong (grounding) plug for your protection against shock hazard and should be plugged directly into a properly grounded three-prong receptacle. DO NOT cut or otherwise remove the grounding prong from this plug.
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 specified 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 ventilation system must be maintained and annually inspected by Qualified Personnel concurrent as part of 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.
Warning: 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.
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MANUAL
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. We recommend following these instructions to insure optimum performance, long life and trouble-free service from your broiler.
The controller is pre-programmed at the factory for known recipes at the time of manufacture. The product keys must be programmed with an approved recipe and the broiler properly calibrated prior to use.
A.Broiler Controls
•1. Power Switch – Turns the broiler ON or OFF. The broiler is self-lighting.
•2. Product Selection Keys – Selects the product recipe to run. Also functions as number keys 1-8 in programming mode.
•3. Arrow Keys
Up-Arrow: Displays the current broiler temperature when pressed in run mode. Scrolls backward through parameters when pressed in program mode.
Down-Arrow: Displays the broiler set-point temperature when pressed in run mode. Scrolls backward through parameters when pressed in program mode.
Left-Right Arrows: Moves between characters or parameters in program mode. Also used as numerals 0 and 9 keys.
•4. Display
•5. Enter Key – Press and hold for 5 seconds to enter program mode. Also used to move though and enter parameters in programming mode.
•6. Cook Light – This light is lit during preheat and the entire cook. The operator should not load the broiler while the light is lit.
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