Marshall Air FR69BG Service Manual

This document contains the installation and operating instructions for:

MODEL: FR69BG AUTOBROIL™

FOR YOUR SAFETY

DO NOT STORE OR USE GASOLINE OR OTHER

FLAMMABLE VAPORS OR LIQUIDS IN THE

VICINITY OF THIS OR ANY OTHER APPLIANCE.

INSTRUCTIONS TO PURCHASER:

1. ANSI Z83.11 STANDARDS REQUIRE THAT YOU POST IN A PROMINENT LOCATION THE PROCEDURES TO FOLLOW IN THE EVENT THE USER SMELLS GAS. THIS INFORMATION SHALL BE OBTAINED FROM THE LOCAL GAS SUPPLIER.

2. THIS MANUAL NEEDS TO BE RETAINED FOR FUTURE REFERENCE.

WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE, INJURY OR DEATH. READ THE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR SERVICING THIS EQUIPMENT.

ILLUSTRATIONS

FR69BG Dimensions.................................................................................................... Figure 1

Exploded View............................................................................................................... Figure 2

Conveyor Drive Shaft Assembly................................................................................... Figure 2A

Hamburger Slide........................................................................................................... Figure 3

Burner Assembly........................................................................................................... Figure 4

Gas Distribution System................................................................................................ Figure 5

Conveyor........................................................................................................................ Figure 6

Axle Scraper.................................................................................................................. Figure 6

Restraining Device........................................................................................................ Figure 7

Burner Shield Installation.............................................................................................. Figure 8

Wiring Diagram.............................................................................................................. #128386

MODEL FR69BG TABLE OF

CONTENTS

I. MACHINE SETTINGS (Quick Reference)......................................................................... 2

II. MACHINE INSTALLATION................................................................................................. 3

Pre-lnstallation............................................................................................................. 3

Appliance Location....................................................................................................... 4

Electrical Information................................................................................................... 4

Gas Piping To Appliance ............................................................................................. 4

Pre-Operation Check................................................................................................... 4-5

Lighting and Shut-Off Instructions ............................................................................... 5

Performance Criteria.................................................................................................... 6

III. OPERATING INSTRUCTIONS.......................................................................................... 6

Broiler and Toaster Adjustment-Daily......................................................................... 6-7

Setting Temperature Controller For Proper High/Low Operation-Weekly................ 7

Setting Holding Temperature-Weekly......................................................................... 8

IV. SCHEDULED MAINTENANCE.......................................................................................... 8

Daily Cleaning Procedures.......................................................................................... 8

Monthly Cleaning Procedures..................................................................................... 9

Quarterly Cleaning Procedures and Preventive Maintenance................................... 10

V. TROUBLESHOOTING...................................................................................................... 10-13

VI. ASSEMBLY & DISASSEMBLY INSTRUCTIONS.............................................................. 13

VII. REPLACEMENT PARTS.................................................................................................... 14-18

BROILER LIMITED WARRANTY................................................................................ i

BROILER WARRANTY PROCEDURES.................................................................... ii

I. MACHINE SETTINGS

AUTOBROIL™

MODEL: FR69BG

SERIAL NUMBER: ______________________________________________________________________ TYPE OF GAS: _________________________________________________________________________ BROILER HIGH/LOW TEMPERATURE SETTING: _____________________________________________

GAS PRESSURE: HIGH ___________ LOW ____________ SPEED SELECTOR SETTING: ____________________________________________________________ PASS-THRU TIME: 6" Conveyor ___________________________ 9" _____________________________ HOLDING TEMPERATURE SETTING: _____________________________________________________

START-UP TECHNICIAN: _______________________________________________________________

START-UP DATE: _____________________________________________________________________

COMMENTS: _________________________________________________________________________

_____________________________________________________________________________________

II. MACHINE INSTALLATION

PRE-INSTALLATION

1. After uncrating the Autobroil™ unit, inspect for shipping damage. Check that all control knobs are intact on the electrical cabinet front. Contact the factory if there are obvious problems. Set the unit in place and use the plastic bag to protect it from the debris and trash of building construction. DO NOT remove plug from gas inlet pipe. Leave this for the Qualified Service Company. Check that machine has not been dented or damaged by the carrier. Notify your freight carrier immediately to file a concealed damage claim, following the instructions attached to the outside of the shipping crate. Your warranty will not cover freight damage.

2. Installation must be performed by a Qualified Service Company. The term "Qualified Service Company" means any individual, firm, corporation or company which is either engaged in and is responsible for the installation or replacement of gas piping on the outlet side of the meter, or the service regulator when a meter is not provided, or the connection, installation or repair of gas appliances, who is experienced in such work, familiar with all precautions required, and has complied with all the requirements of the authority having jurisdiction.

3. A remote gas shut-off valve must be provided and interlocked to exhaust system when in operation.

A gas shut-off control is located in the gas piping (behind the left side panel) for emergency shutoff of gas supply to this appliance.

4. Because this unit is power fan exhausted, it is necessary to provide adequate make up air equal to the amount removed. In addition to this, any other exhausts, flues, or air removal systems must be taken into consideration. Examples of this are heat removal fans or hot water heater flues.

5. The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system attest pressures in excess of 1/2 psig (3.45 kPa).

6. The appliance must be isolated from the gas supply piping system by closing its individual shutoff valve during any pressure testing of the gas supply piping system attest pressures equal to or less than 1/2 psig (3.45 kPa).

APPLIANCE LOCATION WARNING: IF NOT INSTALLED, OPERATED AND MAINTAINED IN ACCORDANCE WITH THE

MANUFACTURER'S INSTRUCTIONS, THIS PRODUCT COULD EXPOSE YOU TO SUBSTANCES IN FUEL OR FROM FUEL COMBUSTION WHICH CAN CAUSE DEATH OR SERIOUS ILLNESS AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.

1. Position Autobroil™ to properly align with exhaust hood (refer to equipment plan).

2. The hood/ventilator for the appliance should be located in accordance with the National Fire Protection Association Standard #96, "Removal of Smoke and Grease-Laden Vapors from Commercial Cooking Equipment" and any local applicable requirements.

3. For proper installation, the minimum clearance from combustible construction is 6" from sides and 6" from back.

4. Adequate clearance should be maintained to allow easy access to loading and unloading areas of the machine.

5. For servicing, unit must be moved two feet clear from all construction.

CAUTION: KEEP THE APPLIANCE AREA FREE AND CLEAR FROM COMBUSTIBLES.

ELECTRICAL INFORMATION

1. The appliance is cord connected and requires a 120 volt, A.C., 60 HZ, Single Phase, 2 wire w/ground 15 AMP circuit or a 240 volt, A.C., 50 HZ, Single Phase, 2 wire w/ground 10 AMP circuit. Appliance must be electrically grounded in accordance with local codes, or in the absence of local codes, with the National Electrical code ANSI/NFPA No. 70-latest edition.

2. There is a Wiring Diagram located in the Owner's Manual and inside the control cabinet.

GAS PIPING TO APPLIANCE

1. Installation of this appliance must conform with local codes, or in the absence of local codes, with the National Fuel Gas Code, ANSI Z-223.1-latest edition.

2. In Canada, this appliance is to be installed in accordance with Standard CGA B149.1 or B149.2 Installation Codes for gas burning appliances and equipment and any local applicable requirements.

3. The appliance is supplied with a 3/4" female pipe thread. The installer must make the pipe connection to the unit in accordance with the "National Fuel Gas Code," ANSI Z-223.1-latest edition. The gas line connected to the 3/4" female pipe thread cannot be less than a 3/4" pipe. The gas pressure and gas volume required by this appliance is shown on Page 6. Gas piping from source to broiler must be adequate to satisfy these requirements when all other gas appliances in the restaurant are operating at maximum demand.

4. A flexible AGA approved gas line is available. Instructions are (1) the installation shall be made with a connector that complies with the Standard for Connectors for Movable Gas Appliances, ANSI Z21.699-latest edition, and Addenda, Z21.69a-latest edition, and a quick-disconnect device that complies with the Standard for Quick-Disconnect Devices for Use With Gas Fuel, ANSI Z21.41-latest edition, and Addenda, Z21.41 a-latest edition and Z21.41 b-latest edition, and (2) adequate means must be provided to limit the movement of the appliance without depending on the connector and the quick-disconnect device or its associated piping to limit the appliance movement. See Figure 7 for details.

5. See Page 3, Items 5 and 6, for instructions on gas supply line pressure testing.

CAUTION: DO NOT OBSTRUCT THE FLOW OF COMBUSTION AND VENTILATION AIR.

PRE-OPERATION CHECK

Before lighting and operating your Autobroii™, make a quick check of critical items as follows:

1. Remove both side panels and check to see that all parts are in place and that none are damaged.

2. Start conveyor chain and check for proper operation. The conveyor chain should run free and not be catching on anything.

3. The speed of the conveyor chain should be modulated from low to high, and back again without the chain stopping.

4. Before first use, and after any special cleaning, it is necessary to "season" the broiler chain. This is done by bringing chain to operating temperature and then (with burner still lit) applying liquid shortening from a saturated cloth over the full width of the broiler chain while the chain makes 5 or 6 complete revolutions.

5. Check that gas pressure at appliance is correct (see Performance Criteria on Page 6).

6. Check that grease pan is in place under unit (Figure 1).

LIGHTING INSTRUCTIONS FOR ELECTRONIC IGNITION SYSTEM

1. Turn exhaust system on.

2. Make sure filters are in place in the hood.

3. Turn conveyor chain on and set speed at approximate mid-point.

4. Remove left side cover.

5. Turn gas control switch on top of Honeywell valve to "ON".

6. The broiler heat switch on the control panel will now cycle the burners on and off. Set broiler temperature controller on left side of control cabinet to 400°F (190°C) (see Item 3 of setting temperature controller on Page 8).

7. Turn on heat switch. Ignition is electronic (does not require manual lighting of pilot).

8. If pilot flame or burners fail to light turn heat switch off and wait five minutes before attempting to relight.

SHUT-OFF INSTRUCTIONS

1. Turn heat switch off.

2. Wait 30 minutes.

3. Turn conveyor switch off.

4. Turn ventilator off.

PERFORMANCE CRITERIA

1. The manifold pressure for each burner and appliance inlet pressure and gas amount is listed below:

TYPE OF GAS PRESSURE AT THE APPLIANCE

MANIFOLD PRESSURE

TOTAL GAS AMOUNT

Manifold pressure is measured by a pressure gauge on the outlet side of the Honeywell gas valve. With the unit on for at least twenty minutes and the broiler temperature controller set at 400°F (190°C) (see Item 3 on Page 8), the pressure should be at 4.0 IWC (7.0 IWC for propane). With the broiler temperature controller set for 800°F (412°C) the high fire pressure is 5.0 IWC (10.3 IWC for propane). High pressure is adjusted using the regulator in the top of the gas safety valve. Low fire is adjusted using the gas pressure regulator. See Figure 5 for gas system layout.

2. The burners in the appliance are a special infrared type. All of the air for combustion must be injected through the venturis. This makes orifice design and alignment very critical. The orifice design, in combination with the correct natural or propane gas pressure will result in adequate air aspiration and mixing. There are no air shutters. No air adjustment is needed. The proper orifice part numbers are found in Section VII - Replacement Parts.

CAUTION: DO NOT STACK BOXES OR IN ANY WAY BLOCK AREA IN IMMEDIATE VICINITY OF

VENTURIS OR IN ANY OTHER WAY OBSTRUCT FLOW OF COMBUSTION AIR.

- Natural or Propane

- 6.0-10.0 IWC for Natural

- 11.0 IWC for Propane

- Low 4.0 IWC; High 5.0 IWC for Natural

- Low 7.0 IWC; High 10.3 IWC for Propane

- 61,000 BTUH @ 100% High Fire

3. Pilot burner flame is fixed and is not adjustable.

4. All burners will be bright orange when burning properly. If a dull red is observed after 30 minutes of warm-up

with a blue flame above the burner face, the orifice is not aligned properly. "Popping," or burning back at the orifice of the burner, is a result of the burner screen being loose or a faulty gasket under the burner screen. LP machines may exhibit a light "popping" sound when the unit is turned off;

this is normal.

NOTE: IF BURNER SCREEN IS TORN OR HAS A HOLE, OR IF A GASKET IS LEAKING, THE BURNER

MUST BE REPAIRED. See Figure 4.

III. OPERATING INSTRUCTIONS

BROILER ADJUSTMENT - DAILY

LIGHTING INSTRUCTIONS FOR ELECTRONIC IGNITION SYSTEM

1. Turn exhaust system on.

2. Make sure filters are in place in the hood.

3. Turn conveyor chain on and set speed at approximate mid-point.

4. Remove left side cover.

5. Turn gas control switch on top of Honeywell valve to "ON".

7. Turn on heat switch. Ignition is electronic.

8. If pilot flame or burners fail to light turn heat switch off and wait five minutes before attempting to

relight.

SHUT-OFF INSTRUCTIONS

1. Turn heat switch off.

2. Wait 30 minutes.

3. Turn conveyor switch off.

4. Turn ventilator off.

SETTING TEMPERATURE CONTROLLER FOR PROPER HIGH/LOW OPERATION-WEEKLY

1. Follow the procedure in Step 3 on Page 8 in order to set temperature control for 400°F (190°C)

doing this, turn on the broiler.

2. Allow the broiler burners and conveyor chain to warm up for 60 minutes (with the chain at

approximately the correct speed).

3. Observe the temperature displayed: push "SET" and release to view the "SET POINT." To change

set point push "SET" and, within three seconds, use the arrows to select a new set point. When setting the High/Low for proper operation, make the set point THE SAME as the observed temperature made after the sixty minute warming. Broiler High/Low control is now set. The setting should be between 650°F (343°C) and 800°F (412°C). If not at least 650°F (343°C), the high and low gas pressures, as discussed on Page 6 under Performance Criteria, may require adjustment or the hood exhaust may be excessive. The broiler will work but will cook slower.

4. Place one meat patty on the broiler chain. Based on the appearance of the broiled patty, reset the

Digital Speed Control for the desired broiling quality. (Note: this single patty should be cooked to the maximum degree of the Minimum/Maximum doneness tolerance.)

NOTE: THE HIGHER THE NUMERICAL VALUE SET ON THE DIGITAL SPEED CONTROL,

THE FASTER THE CONVEYOR CHAIN WILL RUN.

SETTING HOLDING TEMPERATURE-WEEKLY

1. The temperature controller on the front of the unit has been preset at 195°F (76°C). Push and release

the "SET" button to observe the set point. If this setting has been inadvertently changed, it is necessary to reset the proper valve. This may be done using the arrows on the control within three seconds of pushing and releasing the "SET" button. Afterwards the actual temperature is displayed.

IV. SCHEDULED MAINTENANCE

DAILY CLEANING PROCEDURES CAUTION: Do not touch the broiler section immediately after appliance shut-down. The temperature inside

enclosures is in excess of 500°, which eliminates the need to clean any parts inside the enclosures for sanitary purposes. Any grease that may build up on the exterior of the enclosures should be cleaned off with a damp cloth and a minimum amount of detergent. Never use a large amount of water on the enclosure or allow burner faces

to get wet as this could cause premature burner or gasket failure. Disconnect the power supply to the appliance before cleaning or servicing.

WARNING: THE BURNER AND REVERBERATING SCREENS (LOCATED UNDER THE TOP BURNERS),

CAUTION: Under no circumstances should oven cleaner be used on this appliance. IT WILL EAT HOLES

CAUTION: KEEP THE APPLIANCE AREA FREE AND CLEAR FROM COMBUSTIBLES.

1. Allow broiler burners and chain to operate for 30 minutes after cooking last patty to burn off excess grease on

broiler components. Then turn the unit off and allow to cool. (This applies every time a meat chain is turned off — regardless of what time of day meat chain is shut down - and regardless of how few patties were broiled in the last 30 minutes, last hour, etc.) This will clean some parts of the cooking chamber. Failure to perform this procedure daily will result in poor cooking times.

2. Remove all exterior panels except those which are attached with screws. Be careful not to touch any hot internal

broiler components.

3. Remove burners from right side of unit and shake all debris off burners after they cool. DO NOT WASH

BURNER AS IT WILL DESTROY GASKET. Brush surface of burner mesh with soft brush.

4. Remove lower burner shields as shown in Figure 8. Brush or scrape residue.

5. Remove the following items and wash with hot soapy water.

ARE MADE FROM INCONEL METAL MESH. THIS MATERIAL DETERIORATES WITH USE. INSPECT THESE SCREENS DAILY AND REPLACE IF SCREEN IS SEVERELY CORRODED. FAILURE TO DO SO CAN RESULT IN METAL PARTICLES BEING SERVED TO YOUR

CUSTOMERS.

IN THE ALUMINUM GAS VALVES AND GAS LINES, CAUSTIC FUMES CAUSE ELECTRICAL COMPONENT DAMAGE, AND WILL CAUSE MANY OTHER PROBLEMS IF USED TO CLEAN THIS BROILER.

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