Duke Manufacturing FLEXIBLE BATCH BROILER - CE Operation Manual

Installation & Operation Manual

FLEXIBLE BATCH BROILER - CE

Duke Manufacturing Co.

2305 N. Broadway • St. Louis, Missouri

800-735-3853 • 314-231-1130 • Fax [phone]

www.dukemfg.com

175820D

AS OF: 2/15/08

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Page 2 of 31

INDEX

PAGE

I. General Information ..........................................................................3

A. Batch Broiler Specifications................................................................................. 3

A-1.0 Model Number Key .................................................................................. 4

A-2.0 Broiler Dimensions ................................................................................... 4

II. Installation Instructions....................................................................5

A. Qualified Personnel ...........................................................................................5

B. Delivery and Inspection .....................................................................................5

C. Broiler Assembly................................................................................................ 6

D. Adjustments at Installation…………………………………………………………..7

E. Location of the Broiler........................................................................................ 8

F. Gas Piping ......................................................................................................... 8

G. Electrical Connections....................................................................................... 8

H Ventilation.......................................................................................................... 8

III. Operation Instructions.....................................................................9

A. Broiler Controls .................................................................................................. 9

B. Cooking Product ................................................................................................ 10

B-1.0 Lighting the Broiler ................................................................................... 10

B-2.0 Cook Product ........................................................................................... 10-11

B-3.0 Cook Cycle Complete .............................................................................. 11

B-4.0 Fine Cooking Adjustment......................................................................... 11

B-5.0 Cancel a Cook Cycle ............................................................................... 11

B-6.0 Checking the Broiler Temperature........................................................... 11

B-7.0 Checking the Set Point Temperature....................................................... 11

B-8.0 Shutdown the Broiler................................................................................ 11

C. Cleaning............................................................................................................. 12

C-1.0 Four (4) Hour Cleaning ........................................................................... 14

C-2.0 Daily Cleaning.......................................................................................... 15-16

C-3.0 Weekly Cleaning ...................................................................................... 17-21

C-4.0 Monthly Cleaning ..................................................................................... 22-23

D. Troubleshooting................................................................................................. 24-26

IV. Service and Repair ..........................................................................27

V. Replacement Parts List ...................................................................28-29

VI. Wiring diagram.................................................................................30

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

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POST IN A PROMINENT LOCATION

vicinity of this or any other appliance.

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Instructions to be followed in the event the user smells gas. This

information shall be obtained by consulting the local gas supplier.

Do not store or use gasoline or other flammable vapors or liquids in the

FOR YOUR SAFETY:

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

WARNING:

THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE.

I. General Information

A. Batch Broiler Specifications

ALTITUDE (MAXIMUM) 607 m 607 m 607 m 607 m

GROSS HEAT INPUT 29.4 KW 29.4 KW 25.2 KW 25.2 KW

GAS PIPE CONNECTION 12.7mm BSPT 12.7mm BSPT 12.7mm BSPT 12.7mm 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 3.05 3.05 1.70 1.85

SHIPPING WEIGHT

I2H/I2E(G20) I2L(G25) I3B/P(G30) I3P(G31)

I2H/I2E(G20) I2L(G25) I3B/P(G30) I3P(G31)

I2H/I2E(G20) I2L(G25) I3B/P(G30) I3P(G31)

204 Kg (450 lbs)

Page 3 of 31

SHIPPING DIMENSIONS

ELECTRICAL RATING

121.9 cm x 99.1 cm x 172.7 cm (48” x 39” x 68”)

230V~ 50Hz 1.1A 250W

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A-1. Model Number Key

FBB- X Y- 230

X identifies Gas Configuration

Description Model Description Model

X = 1 I3P(G31) gas w/o Catalyst

X = 2 I2H/I2E(G20) gas w/o Catalyst

X = 3 I3B/P(G30) gas w/o Catalyst

X = 5 I2L(G25) gas w/o Catalyst

Y = O without Catalyst

FBB-10-230

FBB-20-230

FBB-30-230

FBB-50-230

A-2. Broiler Dimensions

Dimension shown in centimeters, bracketed [ ]are in inches

Note:

Y = C with Catalyst

I3P(G31) gas with Catalyst

I2H/I2E(G20) gas with Catalyst

I3B/P(G30) gas with Catalyst

I2L(G25) gas with Catalyst

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FBB-1C-230

FBB-2C-230

FBB-3C-230

FBB-5C-230

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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:

 Compliance with the installation in force in

the country in which the appliance is to be
installed

 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

 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.

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Caution: The Broiler is very heavy!

Use adequate help for lifting.

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

2. Remove the top cardboard and inner cap

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

4. Remove cardboard on the ends (2 places)

5. Remove banding straps (Cut with utility knife
or scissors: 5 places)

6. Remove box of attachable parts &
accessories from the front

7. 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

8. While carefully supporting broiler, slowly roll
it off the pallet taking care not to damage the
casters

9.

Remove blue tape from broiler panels.

 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
with filing your claim.

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C. Broiler Assembly

Before assembling and installing the broiler, please check to make sure that all necessary parts are present.

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

OPTIMAL Service Parts & Accessories

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

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

PARTS KIT - I2H/I2E(G20), I3B/P(G30) & I3P(G31)
(Burner & Flame Arrestor)

PARTS KIT - I2L(G25) (Burner & Flame Arrestor)

175850

175851

175852

175520

175854

Loader Install Tool
(Included with Broiler Tools Kit)

PARTS KIT - I2H/I2E(G20), I3B/P(G30) & I3P(G31) (Burner,
Arrestor, Loader, & Burner Shield)

PARTS KIT - I2L(G25) (Burner, Arrestor, Loader, & Burner
Shield)

KIT – CE GAS HOSE CONNECTOR 175831

KIT – CE GAS HOSE CONNECTOR - UK 175827

175526

175853

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.)

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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

Page 7 of 31

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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 specific
below:

Combustible Surface Spacing

305 mm

76 mm

102 mm

0 mm

Discharge End (left side)

Access Panel End (right side)

Rear

Floor/Table

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 sufficient 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.

NOTE: A fixed restraint of the proper length must
be incorporated to secure the broiler to a non­movable surface to eliminate strain on the gas
connector.

G. Electrical Connections

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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:

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.

Do not place any objects such as

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.

WARNING: This appliance employs an
earthed, safety ground electrical supply
system. DO NOT cut or modify the earthing
provisions of this appliance.

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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 set­point 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.

3

6

4

2

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5

1

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B. Cooking Product

B-1.0 Lighting the Broiler

• Start Ventilation System.

• Turn ON/OFF switch to the ON (1)

position.

• The control will display PrE during the
pre-heat cycle.

• The LED's next to all product keys with
non-zero cook times will be red.

• The control will display rdY at the
completion of the pre-heat cycle and the
LED’s next to all product keys with non­zero cook times will be green.

• (To shutdown the broiler, see section B-

8.0)

B-2.0 Cook Product

Page 10 of 31

Broiler displays rdY and
Cook light is not on.

Load product. Push forward
as shown.

Place holding pan at
discharge.

Rotate handle down to lift
inside bar over product.

Place product in front and
back rows.

Pull out loader with handle
rotated.