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Installation & Operation Manual CE Version

BURGER KINGFLEXIBLE BATCH BROILER

Please read this manual completely before attempting to install, operate or service this equipment

This manual is Copyright © 2013 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 63102Phone: 314-231-1130

Toll Free: 1-800-735-3853Fax: 314-231-2460www.dukemfg.com

P/N 175820R

Installation & Operation Manual for Flexible Batch Broiler - CE Units

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TABLE OF CONTENTSI. General Information .....................................................................................................4 A.BatchBroilerSpecifications ...................................................................................4 A-1. Model Number Key ......................................................................................4 A-2.BroilerDimensions ......................................................................................5II. Installation Instructions ..............................................................................................6 A.QualifiedPersonnel ................................................................................................6 B.DeliveryandInspection ..........................................................................................6 C.BroilerAssembly ....................................................................................................8 D.AdjustmentsatInstallation .....................................................................................9 RaiseorLowerBroiler ........................................................................................9 E.LocationoftheBroiler ..........................................................................................10 F.GasPiping ............................................................................................................10 G.ElectricalConnections .........................................................................................10 H.Ventilation ............................................................................................................10 VentingtoaCanopyExhaustHood ..................................................................10 MaintenanceofVentilationSystem ...................................................................10III. Operation Instructions ............................................................................................. 11 A.BroilerControls .................................................................................................... 11 B.CookingProduct .................................................................................................. 11 B-1.0LightingtheBroiler ................................................................................... 11 B-2.0 Cook Product ...........................................................................................12 B-3.0 Cook Cycle Complete ..............................................................................13 B-4.0FineCookingAdjustment .........................................................................13 B-5.0CancelaCookCycle ...............................................................................13 B-6.0CheckingtheBroilerTemperature ...........................................................13 B-7.0CheckingtheSetPointTemperature .......................................................13 B-8.0ShutdowntheBroiler ...............................................................................13 C.Cleaning ...............................................................................................................13 C-1.Four(4)HourCleaning ..............................................................................15 C-2.DailyCleaning ...........................................................................................16 C-3.WeeklyCleaning ........................................................................................18 C-4.MonthlyCleaning ......................................................................................21 D.Troubleshooting ...................................................................................................22IV. Service and Repair ...................................................................................................25V. Replacement Parts List .............................................................................................26VI. Wiring Schematic .....................................................................................................28

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IMPORTANT WARNING AND SAFETY INFORMATION

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 supplier.

FOR YOUR SAFETY:

Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.

: 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.


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I. GENERAL INFORMATIONA. Batch Broiler Specifications

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

GROSSHEATINPUT

26,3 KW 29,1 KW 31,3 KW 26,3 KW 26,5 KW 28,2 KW 25,2 KW 25,2 KW 26,4 KW 26,5 KW 26,6 KW

GASPIPECONNECTION

12,7mm BSPT

12,7mm BSPT

12,7mm BSPT

12,7mm BSPT

12,7mm BSPT

12,7mm BSPT

12,7mm BSPT

12,7mm BSPT

12,7mm BSPT

12,7mm BSPT

12,7mm BSPT


Supply Pressure

20 mbar 20 mbar 20 mbar 25 mbar 25 mbar 25 mbar30/50 mbar

37/50 mbar

37/50 mbar

37/50 mbar

37/50 mbar

IRBurnerPressure

9,34 mbar

9,34 mbar

9,34 mbar

12,95 mbar

12,95 mbar

12,95 mbar

19,93 mbar

19,93 mbar

19,93 mbar

19,93 mbar

19,93 mbar

LowerBurnerPressure

9,34 mbar

9,34 mbar

9,34 mbar

12,95 mbar

9,34 mbar

9,34 mbar

19,93 mbar

19,93 mbar

19,93 mbar

19,93 mbar

19,93 mbar


ORIFICE–FrontIRBurner

2,35 2,35 2,35 2,35 2,35 2,35 1,40 1,55 1,55 1,55 1,55

ORIFICE–RearIRBurner

2,50 2,50 2,50 2,50 2,50 2,50 1,51 1,61 1,61 1,61 1,61

ORIFICE–LowerBurner

3,05 3,25 3,45 3,05 3,25 3,45 1,70 1,85 1,90 1,95 2,00

SHIPPINGWEIGHT

204Kg(450lbs)

SHIPPINGDIMENSIONS

121,9cmx99,1cmx172,7cm(48”x39”x68”)

ELECTRICALRATING

230V~ 50Hz 1,1A 250W

A-1. Model Number Key

XidentifiesGasConfiguration Y=OwithoutCatalyst Y=CwithCatalyst

DESCRIPTION MODEL DESCRIPTION MODEL

X = 1 I3P(G31)gasw/oCatalyst FBB-10-230 I3P(G31)gaswithCatalyst FBB-1C-230

X = 2 I2H/I2E(G20)gasw/oCatalyst FBB-20-230 I2H/I2E(G20)gaswithCatalyst FBB-2C-230

X = 3 I3B/P(G30)gasw/oCatalyst FBB-30-230 I3B/P(G30)gaswithCatalyst FBB-3C-230

X = 5 I2L(G25)gasw/oCatalyst FBB-50-230 I2L(G25)gaswithCatalyst FBB-5C-230

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21,68 1/2"

88,434 3/4"

100,339 1/2"

12850 3/8"

111,944"

52,920 3/4"

161,7

63 5/8"

136,153 5/8"

GAS CONNECTION3/4" BSPT FEMALE

115,845 5/8" 141,4

55 5/8"

HIGH POSITION LOW POSITION

A-2. Broiler Dimensions

Note: Dimensionshownincentimeters,bracketed[]areininches


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A. QUALIFIED PERSONNEL

These installation instructions are for the use ofqualified installation and service personnel only. Installationorservicebyotherthanqualifiedpersonnelmayresultindamagetothebroilerand/orinjurytotheoperator.Qualifiedinstallationpersonnelarethoseindividuals,firms,companiesorcorporationswhicheitherinpersonorthroughanagentisengagedinandresponsiblefor:• Compliance with the installation in force

in the country in which the appliance is to beinstalled.

• This appliance shall be installed with sufficientventilationtopreventtheoccurrenceofunacceptableconcentrationsofsubstancesharmfultohealthintheroominwhichtheapplianceisinstalled.

• Caution - the appliance is mounted on 4wheels.Caremustbetakennottohitkitchenwallsorsimilarhardobjectswhilemovingorinstallingtheappliance.

• Parts protected by the manufacturer, agent, orassigneeshallnotbeadjustedbytheinstaller.

• Thisapplianceisnotintendedforusebypersons(includingchildren)withreducedphysical,sensoryormentalcapabilities,orlackofexperienceandknowledge,unlesstheyhavebeengivensupervisionorinstructionconcerninguseoftheappliancebyapersonresponsiblefortheirsafety.

B. DELIVERY AND INSPECTION

DukeManufacturingCo.doeseverythingwithinitspowerto insureyoureceivedyourbroiler ingoodcondition.Theyarestrappeddownonheavywoodenskidsandpackedtopreventshippingdamage.Theyhaveallbeencarefully inspected before they were packaged andconsignedtothecarrier.

Upon delivery of your Duke broiler:

• Lookovertheshippingcontainer,carefullynotinganyexteriordamageonthedeliveryreceipt,whichmustalsobesignedbythedriver/deliveryperson.

• Unpack and check for any damage, whichwasnotevidentontheoutsideoftheshippingcontainer.

Caution: The Broiler is very heavy! Use adequate help for lifting.

II. INSTALLATION INSTRUCTIONS

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1. Using a utility knife, cut away plasticwrap (notshown).

2. Removethetopcardboardandinnercap.

3. RemoveTrainingMaterialbox.

4. Removecardboardfromthecorners(4places).

5. Removecardboardontheends(2places).

6. Removebandingstraps (cutwithutility knifeorscissors:5places).

7. Removeboxofattachablepartsandaccessoriesfromthefront.

8. Safelyliftoneendofbroilerandtapblocktowardscenterandthensidewaystoremove.

Repeatforremainingblocks.Thisallowscastersto touch the pallet.

9. Removethebroilerfromtheshippingpalletusing3peopletoguideanddistributeitsweight(approx335lbs)accordingly.Whilecarefullysupportingthebroiler,rollitforwarduntilthefrontcastersareclearofthepallet.Liftthebroiler6-8inchesaboveandawayfromthepallet,andgentlyplaceonfloortoavoiddamagetocasters.

10.Removeprotectivebluetapefrombroilerpanels,doublecheckingthatnotaperemains.

• Checkforconcealeddamage.Thecarriermustbenotifiedwithinfifteen(15)daysofthedeliveryofthebroilerandthecarton,skidandallpackagingmaterialsmustberetainedforinspection.

• DukeManufacturingCo.cannotassumeliabilityforlossordamagesufferedintransit.Thecarrierassumesfullresponsibilityfordeliveryingoodorderwhentheshipmentwasaccepted.However,wearepreparedtoassistyouwithfilingyourclaim.

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C. BROILER ASSEMBLYBeforeassemblingandinstallingthebroiler,pleasechecktomakesurethatallnecessarypartsarepresent.

ITEM # PART NAME PART #1 PRODUCTPANSHELF 1753532 DISCHARGECHUTE 1753403 DISCHARGEHOOD 1753624 DISCHARGEPANHOLDER 1753585 DISCHARGEGREASEPAN 1753576 “V”GREASEPAN 1753257 MAINGREASEPAN 1753298 LOADER 1754449 LOADERTRAY 175430

10 LOADERBRACKET 17543811 DOOR 17542912 LOADERRAMP 17574113 IMPEDANCEPAN 17522614 CATALYST(OPTIONAL) 17548015 CATALYSTGUARD(OPTIONAL) 17548216 SANITATIONPAIL 175842

Loader Install Tool (Included with Broiler Tools Kit)

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13 15

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9

8

7654

32

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Setup: Installallitemsasshownbelow.

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.)

OPTIONAL SERVICE PARTS & ACCESSORIESPARTSKIT–I2H/I2E(G20)&I2L(G25)(w/Controller&CookChain) 176351 PARTSKIT-(Burner,Arrestor,Loader,&Burner

Shield) 176353

PARTSKIT–I3B/P(G30)&I3P(G31) (w/Controller&CookChain) 176352 KIT–CEGASHOSECONNECTOR 175831

PARTSKIT-(Burner&FlameArrestor) 176354 KIT–CEGASHOSECONNECTOR-UK 175827

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Thebroilerheightcanbeadjustedviatwoscrewsoneachleg.

Caution: The Broiler is very heavy! Use adequate help for lifting.

1. Liftoneendofthebroilerontoawide,sturdystand(notsupplied).

2. Remove (2) screws per leg and raise/lower tothreadedholes.Reinstallscrews.

3. Removestandandsafelyraise/lowerbroiler.

4. Placeplasticholeplugs(suppliedattachtostand)inanyunusedholes.

D. ADJUSTMENTS AT INSTALLATION

Eachbroilersectionandallitscomponentpartshavebeentestedthoroughlyandinspectedbeforeyourbroilerwasshippedfromthefactory.However,itissometimesnecessarytofurthertestoradjustthebroileronceithasbeeninstalled.SuchadjustmentsaretheresponsibilityoftheDealerorInstaller.Thesetypesofadjustmentsarenotconsidereddefects,ratheranormalandroutinepartoftheproperinstallationoftheequipment.

Theseadjustmentsincludebutarenotlimitedto:

•Adjustmentstothegaspressureregulator

•Broilerheightadjustment(ifrequired)

No installation should be considered completewithoutproper inspectionand, ifnecessary,anyadjustments by qualified service or installationpersonnel.

It isalso importantnot toobstruct thenatural flowofcombustionandventilationair if thebroiler is tooperateproperly.Thisbroilershouldnotbeinstalledonacurbbaseorsealedtothewall.Eitherconditioncanrestricttheflowofairtothecombustioncompartmentorpreventproperventilationoftheunit.Beforemakinganyconnectionstothebroiler,checktheratingsplatetobesurethebroilerspecificationsconcurwiththetypeofgasandvoltagetobesuppliedtothebroiler.

Theratingplateislocatedonthebackofthecontrolcompartmentcoverpanelontherightendoftheunit.

Theplatebearingthebroiler’smodelnumberandserialnumberisattachedtothebacksideoftheunit.

Raise or Lower Broiler

Support broiler here

Screw

Screw

Slide Leg. Reinstall screws.

Plastic Hole Plug


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E. LOCATION OF THE BROILER

Properplacementofthebroilerwillgiveyouthebestresultslong-termuserconvenience.Weurgeyoutogiveadequatethoughtintheplacementofyourbroilerpriortoitsarrival.

• Thebroilershouldbeplacedinanareathatisfreefromdraftsandaccessibleforproperoperationandservicing.

• Theareaaroundthebroilermustbekeptclearofcombustiblematerialsasspecificbelow:

COMBUSTIBLE SURFACE SPACING

DischargeEnd(leftside) 305 mm

AccessPanelEnd(rightside) 76 mm

Rear 102 mm

Floor/Table 0 mm

F. GAS PIPING

The standard broiler consumes gas at a total of100,000 BTU/hr, 29.4 KW.Theoverallpipingplanof the kitchen must support the supply rating tosupportappliancetoachievetheperformancerating.

Generally, piping should be sized to provide a gassupplysufficienttomeetthemaximumdemandofallgasappliancesonalinewithoutunduelossofpressuretotheequipment.ThetotalBTUrequirementsofallequipmentbeingservedandthepipinglengthfromthemeteraremajorconsiderationsintheproperdesignofthegassupplysystem.

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.

G. ELECTRICAL CONNECTIONS

Yourbroilermustbesuppliedfroma230Volt50Hz,groundedcircuitwithasupplycordforeachcountry’srequirements.Awiringdiagramisattachedtothebroilercontrolcompartmentandwiththismanual.

The Main Supply safety / earth ground wire mustbe longer than main conductors at the unit'sinterconnectionstopreventstressunderpull.

Ifthesupplycordisdamaged,itmustbereplacedbythemanufacture,it'sserviceagentorsimilarlyqualifiedpersonsinordertoavoidahazard.

EXTERNAL EQUIPOTENTIAL

Terminal provides a connection for bonding toequipmentenclosure.

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

H. VENTILATION

This appliance shall be installed with sufficientventilationtopreventtheoccurrenceofunacceptableconcentrationsofsubstancesharmfultohealthintheroominwhichtheapplianceisinstalled.

Venting to a Canopy Exhaust HoodAmechanically driven exhaust hood must have aminimumcapacityof1700m3/hr (1000cfm)withaminimum100cmby130cm(39.4inby51.2in)openingto adequately vent this appliance. The specifiedcapacityandopeningisrequiredinadedicatedhoodfor this appliance or in addition to other applianceventedthroughacommoncanopyexhausthood.

Maintenance of Ventilation SystemThe ventilation system must be maintained andannuallyinspectedbyQualifiedPersonnelconcurrentaspartoforinadditiontogovernmentalrequirements.

This inspection/maintenance should consist of, butnotbelimitedto:

• Inspectionforblockagesorbuildupwhichmightinterferewiththeventingofthebroiler.

• Repairofsuchblockages.

• Inspectionoftheventingcanopy,itsdrivemotorsandbells,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.

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Theinformationinthissectionisintendedfortheuseofqualifiedoperatingpersonnel.QualifiedOperatingPersonnel are those individualswho have carefullyread the information contained in this manual, arefamiliarwiththefunctionofthebroilerand/orhavehadexperiencewithoperating theequipmentdescribed.Werecommendfollowingtheseinstructionstoinsureoptimumperformance,longlifeandtrouble-freeservicefromyourbroiler.

The controller is pre-programmed at the factory forknownrecipesatthetimeofmanufacture.Theproductkeysmustbeprogrammedwithanapprovedrecipeandthebroilerproperlycalibratedpriortouse.

A. Broiler Controls1. Power Switch –TurnsthebroilerONorOFF.The

broilerisself-lighting.

2. Product Selection Keys –Selects theproductrecipetorun.Alsofunctionsasnumberkeys1-8inprogrammingmode.

3. Arrow Keys

Up-Arrow: Displays the current broi lertemperaturewhenpressedinrunmode.Scrollsbackwardthroughparameterswhenpressedinprogrammode.

Down-Arrow: Displays the broiler set-pointtemperaturewhenpressedinrunmode.Scrollsbackward through parameterswhen pressed inprogrammode.

Left-Right Arrows:Movesbetweencharactersorparametersinprogrammode.Alsousedasnumerals0and9keys.

4. Display

5. Enter Key–Pressandholdfor5secondstoenterprogrammode.Alsousedtomovethoughandenterparametersinprogrammingmode.

6. Cook Light – Thislightislitduringpreheatandtheentirecook.Theoperatorshouldnotloadthebroilerwhilethelightislit.

DO NOTLOAD

IF LIGHT ON

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B. Cooking Product

B-1.0 Lighting the Broiler

• Start Ventilation System.

• TurnON/OFFswitchtotheON(1)position.

• ThecontrolwilldisplayPrEduringthepre-heatcycle.

• TheLED'snexttoallproductkeyswithnon-zerocooktimeswillbered.

• ThecontrolwilldisplayrdYatthecompletionofthepre-heatcycleandtheLED’snexttoallproductkeyswithnon-zerocooktimeswillbegreen.

• (Toshutdownthebroiler,seesectionB-8.0)

III. OPERATION INSTRUCTIONS


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B-2.0 Cook Product

DO NOTLOAD

IF LIGHT ON

Broiler displays rdY and Cook light is not on.

Place holding pan at discharge. Place product in front and back rows.

Load product. Push forward as shown.

Rotate handle down to lift inside bar over product.

Pull out loader with handle rotated.

Press appropriate product key.

Youwill have 15 seconds topressanotherproductkeyifawrongselectionismade.

The display will alternatelydisplay the time remainingandthefour-characterproductidentifier.

TheLEDnexttotheselectedproductkeywillflashred.

DO NOTLOAD

IF LIGHT ON

The cook light will be lit.

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B-3.0 Cook Cycle CompleteThechainwillrotateanddischargetheproduct.

Do not load product into broiler until the cook light has gone off and rdY is displayed on the control!

To prevent thawing of product, it is recommended not to place product onto the loader no more than 5 minutes prior to loading.

B-4.0 Fine Cooking AdjustmentUsethisfunctiontoaddorsubtractupto30secondsfromaproductcookcyclerecipe.Thisshouldbeusedin theeventproductcookingneeds tobeoptimizedoutsideoftheprogrammingenvironment.Thisfunctionworksasfollows:

Press and hold the ▲and▼keysfor3seconds.

ThecontrolwilldisplayAdJ.

AllproductLED’sforproductswithaprogrammedtimewilllightred.

Selectaproductkeytoadjust.

TheselectedproductLEDwillremainredandallotherproductLED’swillgoblank.

Thecontrolwillflash AdJfollowedbytheproductidentifier.

The ▲and▼keys are used to set the fine cooking adjustment.

Thefirstpressofthe ▲or▼keybringsuptheadjustmentscreen.Thecontrolwilldisplaythetotalproductcooktimeincludingthepreviousfinecookingadjustment.

Subsequentpressesofa ▲or▼keyaddsorsubtracts1secondfromthecooktime.

Thecooktimecanbeincreasedordecreasedbyupto30secondswiththisfunction.

Toexit this functionandsave thesetting,press theENTERkey.

B-5.0 Cancel a Cook CyclePressingandholdingaproductkeyfor3secondswillcancelacookcycleanddischargetheproduct.

B-6.0 Checking the Broiler Temperature

Pressing the ▲ key at any time (other than inprogramming mode) will display the actual cavitytemperature.

B-7.0 Checking the Set Point TemperaturePressing the ▼ key at any time (other than inprogrammingmode)willdisplay theset-pointcavitytemperature.

B-8.0 Shutdown the BroilerTurn ON/OFF switch to the OFF (O) position.

C. CleaningTheexterior stainless steel on your broiler canbekeptcleanwithagoodnon-abrasivestainlesssteelcleaner,manyofwhichareonthemarket.MoistenaclothandwipedownthebroilerwhileitisCOLD.Wipingdownabroilerwhileitishotwillcausestreakingandotherwiseunsatisfactoryresults.Oncethebroileriscleanitcanbewipeddownwithlightoil.

Tohelpmakeyouruseofthisbroilertrouble-freeandtomaintainthewarranty,thefollowingrecommendationsmustbefollowed:

A. Donotexposethebroilertoprolongedcontactwith detergents, cleansers, bleaches, etc.Shield the IR burners and flame sensingrodsfromallcleaningfluids.DonotsprayIRburnerswithanyforeignmaterials.Chemicalcleaners, degreasers, bleaches and soapsolutionsmustneverbeallowedtocomeintocontactwiththeIRburnermetalhousingsorceramicburnertilesastheymaydamagethesesurfacesand/orcausebroilermalfunctionandwillvoid thewarranty.Topreventdamage totheceramicburnertiles,neverallowphysicalcontactwithcleaningtoolsorotherobjectsthatmayscratchormarthetilesurfacesorcauseblockageofthegasportsinthetilefaces.Donotsprayflamesensingrodswithanyforeignmaterials. Chemical cleaners, degreasersandsoapsolutionsmustneverbeallowedtocomeintocontactwiththeflamesensingrodsastheymaydamagethesesurfacesorcausebroilermalfunctionandwillvoidthewarranty.Ifrequired,cleantheflamesensingrodsonlyafterallowingtocoolofftoroomtemperature,and using a l ight wiping act ion with a pre-saturated alcohol pad to remove anycarbonbuildup.

B. Neverleavethechemicalcompounds,particularly


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thosecontainingchlorine,onbroilerpartsovernight.Chlorinewillcausepittingandcorrosion.

C. Neverusechemicalsinastrongerconcentrationthanrecommendedbythemanufacturer.

D. Usecleanwaterandasoftclothtowipecleaningresiduefromsurfaces.

E. Neveruseordinarysteelwoolorscouringpadson

thesurfaces:usenon-abrasivebroilerde-greasers&softcloths

Carefully following these recommendations will help this broiler to give satisfactory services to extend its life.

CLEANING SCHEDULE RECOMMENDATION BROILER COOL

DISCONNECT POWER

4 Hour Cleaning by the User (Sanitize in place)

SANITIZELOADER&TRAY(CAUTION:HOTSURFACES,WEARINSULATEDGLOVESWHILECLEANING)

SANITIZEDISCHARGECHUTE

Daily Cleaning by the User (RemoveandWash/Rinse/Sanitize)

DISCHARGEPAN(CAUTION:HOTSURFACES,WEARINSULATEDGLOVESWHILECLEANING)

DISCHARGEHOOD X

DISCHARGEGREASEPANS X

MAINGREASEPANS X

DISCHARGEENDPANEL X

DISCHARGESCRAPER X

LOADER&TRAY(CAUTION:HOTSURFACES,WEARINSULATEDGLOVESWHILECLEANING)

DISCHARGECHUTE X

LOADERRAMP X

Weekly Cleaning by Qualified Service Personnel Only

FLAMEARRESTOR X X

BROILERFLIPPERDOOR X X

LOWERTUBEBURNER X X

CATALYST X X

Monthly Cleaning by the User

FLAMESENSOR(UPPERBURNERS) X X

FLAMESENSOR(LOWERBURNERS) X X

FLAMESENSORTUBE(UPPERBURNERS) X X

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C-1. Four (4) Hour CleaningAllcomponentsthatareincontactwithfoodproductmustbecleanedandsanitizedevery4hours.

Loader and Carriage: Remove loader fromcarriageandsanitize foodcontactareas.

Caution: Hot surface near door! Wear insulated gloves.

Discharge Chute: Withdischargehoodremoved,sanitizeoutsidechutesurface.

Caution: Hot surface! Wear insulated gloves.


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C-2. Daily CleaningDailycleaningshouldalsoincludeall itemslistedinthe4hourcleaningschedule.

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Discharge Hood and Chute: Removehoodandchutecompletely,cleanandreplace.

D i s c h a r g e P a n : Slide pan up andout of keyhole slots. Cleanandreplace.

Engage hooks on pins for reinstallation of chute

Discharge Grease Pan: Tilt up to un-hook andpull forward for removal.Cleanpan,areaandreplace.

Be sure to tilt up and push all the way back during re-installation!

Grease Pans:Removetop“V”panandlowercollectionpan.Cleanbothpans,areaandreplace.

Caution: Very Hot! Wait for pan to cool before removal.

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C-2. Daily Cleaning (cont’d)

Clean the top of the burner with the brush end of the “Tube

Burner Cleaning Tool”.

For heavy build-up, use the scraper end of the “Tube Burner

Cleaning Tool”.

Use the end of the tool to clean the discharge shaft of

the conveyor.

With the broiler cool, lift and remove the flipper door.

Clean and set aside.

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2

Lift and slide retaining bolt right.

12

Lift slightly and remove loader ramp as shown.

Disengage pin from pivot hole. Clean and set aside.

Discharge End Panel: Remove discharge accessories and lift panel up while swinging

out and down.

Discharge Scraper: Lift up and pull forward.

Discharge Scraper: Pull out removing locating pins from slots. Clean scraper and

area. Replace.


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C-3. Weekly Cleaning

With outer front panel removed, lift up the

combustion chamber panel.

Swing the right side of the panel out as shown.

Clean and set aside.

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Remove discharge panel and scraper as was performed for daily cleaning.

Remove burner shield.

12

Lift rear of burner out of saddle and continue to

hold it.

Orifice Hood

Pull burner off of orifice and through broiler wall. Remove from chamber. Clean,

empty any remaining water from the burner and replace.

Thoroughly dry out all burner ports!

Lift flame arrestor up to disengage tabs from slots. Tabs are located under the

front of the arrestor.

Pull flame arrestor out. Clean and reinstall.

Tab on the bottom of the flame arrestor drops into slot.

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Catalyst Guard

Catalyst Assembly

Front of Broiler

C-3. Weekly Cleaning (cont’d)

CLEANING CONSIDERATIONS

: Do not use soap, detergents, degreasers, silicone, sodium salts, bleaches, anti-oxidants or any other commercial cleaning agents to clean the catalyst. Use of these chemicals will damage the catalyst and render it inoperable

NOTE: Donotcleancatalystinadishwasherorultrasoniccleaner.Innocaseshouldanyabrasivematerialorabrasivescrubberbeusedforcleaning.

SAFETY CONSIDERATIONS

Thecatalyticconverter(catalyst)isnormallypartofacombustionsystem,andthegeneralsafetypracticesobservedwithsuchsystemsshouldbepracticed.Thefollowing considerations are specific to the catalystportion.

A: Remove power: Before removing the catalyst,disconnectpowertothebroilerandallowtocooltoroomtemperature.Removethecatalystguardandsetasideforre-installationafterthecatalysthasbeencleaned.

B: Handlingcatalyst:Careshouldbetakensothatthecatalystisnotdroppedordamagedinhandling.If the unit is going to be handled soon after acookingcycle, care shouldbe taken toprotectone’shands fromanyhotsurfacesbywearingglovesdesignatedforthispurpose.Therearenomovingpartsorelectricalhookupsassociatedwiththecatalyst,thereforethereshouldbenodangerofashockhazardwhenwashingtheunit.Allowthecatalysttocooltoroomtemperaturebeforestartingthecleaningprocess.

C: Operation: Understand and follow the systeminstructionsprovidedwiththebroilerincludedintheinstallationandoperationsmanual.Itisveryimportantthatyoumakesurethattheductsabovethecookingappliancearecleanofanygrease,priortotheinitialoperationoftheappliancewiththe catalytic converter in place. IF NATURAL GAS IS PART OF THE EXHAUST STREAM, BE SURE THAT THE NATURAL GAS DOES NOT BUILD UP TO AN EXPLOSIVE MIXTURE IN THE EXHAUST SYSTEM.


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C-3. Weekly Cleaning (cont’d)

Gently tap frame of the catalyst while holding over a waste bin to dislodge any

loose ash/carbon particles.

Begin with a clean sink and remove all foreign matter from any wash basin used, before starting the

catalyst washing process.

Partially fill wash basin, that is large enough to accommodate the catalyst, with

enough clean hot water (100-130ºF) to completely cover the catalyst when placed into the basin. Agitate the catalyst up and

down in the water a few times and then let it soak for 20 minutes.

Remove the catalyst and shake out the excess water. Drain and clean the basin

thoroughly and then repeat the previous step.

Remove the catalyst and rinse thoroughly with a large volume of hot water. The typical restaurant dishwashing spray nozzle (low pressure, high volume) is perfect for this operation. Work the spray slowly over the entire

surface both front and back to assure the removal of any particles caught in the catalyst face or behind the frame. Shake the remaining water from the catalyst and then let it air dry overnight. The catalyst can then be reinstalled

in the broiler. Ensure that the catalyst guard is re-installed over the catalyst prior to turning on the broiler.

21


C-4. Monthly Cleaning

Locate the flame sensors for the upper burners.

Use caution and safely remove the sensor by holding onto the black

boot at the base of the sensor.

DO NOT REMOVE BY PULLING ON THE BRAIDED WIRE.

Retaining Clip

Using an alcohol swab, clean the entire metal portion of the sensor rod to remove any buildup. Clean

the white ceramic insulator using the alcohol swab until all residue has been

removed.Remove the back panel of the broiler and carefully remove

the sensor for the lower burner. Follow the same procedures as

those for the upper burners.

After the sensor is removed, use the T-handled cleaning tool by inserting it completely into the sensor tubes and remove.

Repeat the process at least five (5) times to remove any residue

inside the tube.

Once the cleaning procedures are complete, replace the sensors and panels. Wait at least 30 minutes before starting the broiler.

DO NOTLOAD

IF LIGHT ON

12

Remove top panel by lifting up and out.


22

D. TROUBLESHOOTING

SYMPTOM CAUSE REMEDY

Controldisplaydoesnotlightup Nopower Ensurebroilerispluggedintoapropervoltage/Hzreceptacle(pernameplaterating)andreceptacleaspower.Checkdedicated circuit breaker.

Raworundercookedproductwithnocontrollererrormessagesdisplayed.

Productnotloadedproperly. Reviewloadingtechnique.

Productbuttonwasdepressedpriortoloadingproduct.

Ensureproductbuttonisdepressedimmediatelyafterproductisloadedintobroiler.

Wrongproductbuttonwasdepressed. Ensureproperproductbuttonisbeingdepressed.

Lowerburnernotlightingproperly. (Observebottomburnerthroughslitsinlowergreasetray)

Ifbroilerishot,attempttocleanburnerinplacewithbroilercleaningtool.

Ifbroileriscoldorallowedtocooldown,removelowerburnerbyremovingaccesspanels,clean,andreinstall.Removelowerflamesensorandcleanwithasoftcloth&isopropylalcohol.

Infraredburnersnotlightingproperly.(ObserveInfraredthroughdischargeendofbroiler.Note:Burnersshouldremainlitinidle mode

Removeuppercontrolcompartmentpanelandclean2upperflamesensorswithasoftcloth&isopropylalcohol.

Cleanflamesensortubewithflamesensingtubecleaningbrush.

Conveyorbeltwillnotmovetodischargeproduct.

Conveyorbeltisbeingobstructed Observeforobstructionsbymanuallyrotatingconveyorbeltfromdischargeendofbroilerusingbroilercleaningtool.

Ensuredischargescraperisproperlyinplace.

Ensuredockingplateisproperlyinplace.

Ensureflamearrestorisproperlyinplace.

Loaderisnotabletobepushedcompletelyintocookingchamber

Dockingplateisnotproperlyinplace.

Ensuredockingplateandlockingtabarecorrectlyinplace.

Productisgettingstuckormangleduponloading

Dockingplateisnotproperlyinplace Ensuredockingplateandlockingtabarecorrectlyinplace.

Flamearrestorisnotproperlyinplace Ensureflamearrestoriscorrectlyinplaceandtabsareslottedcorrectly.

23



Controldisplayisreading“Hi” ContactDukeManufacturingCo.oraDukeAuthorizedServiceagent.

Controldisplayisreading“Lo” Lowerburnernotlightingproperly.(Observebottomburnerthroughslitsinlowergreasetray)



Infraredburnersnotlightingproperly.(ObserveInfraredthroughdischargeendofbroiler.Note:Burnersshouldremainlitinidlemode)



Greasepanisnotinstalled Installgreasepan

Impedancepanorcatalystisnotinstalled. Installimpedancepanorcatalyst

Controldisplayisreading“Prob” ContactDukeManufacturingCo.oraDukeAuthorizedServiceagent.

ControlDisplayisreading“tESt Prod”

Lowerburnernotlightingproperly.(Observebottomburnerthroughslitsinlowergreasetray)




Removeuppercontrolcompartmentpanelandclean2upperflamesensorswithasoftcloth&isopropylalcohol. Cleanflamesensortubewithflamesensingtubecleaningbrush.


24


Controldisplayisreading“gAS toP”

Broilernotreceivinggassupply. Ensurethatgasvalve(s)inlinewiththebroilerareintheONposition.


Removeuppercontrolcompartmentpanelandclean2upperflamesensorswithasoftcloth&isopropylalcohol. Cleanflamesensortubewithflamesensingtubecleaningbrush.

Controldisplayisreading“gAS bot”

Broilernotreceivinggassupply. Cyclebroileroffandbackon.Ifthiserrorpersists,proceedwiththenextsteps.

Ensurethatgasvalve(s)inlinewiththebroilerareintheONposition.




Controldisplayisreading“gAS SEnt”




Controldisplayisreading“gAS SEnb”




25


Periodicserviceandmaintenanceofthebroilerisnotrequiredbeyondtheuser’sdailyandweeklycleaningschedule defined in Sections C-1 to C-4. Qualifiedservice personnel must perform service or repairshouldthebroilerdevelopafaultotherthancleaningmaintenance.

Qualified service personnel are individuals, firms,companies,orcorporationswhoareknowledgeablein and responsible for compliance with jurisdictionauthorities concerning service of commercial foodpreparationequipment.ContacttheDukeManufacturingCompanyServiceDepartmentattheUSAworldwideheadquarters (telephone: 011-800-735-3853) forassistancewithselectingqualifiedservicepersonnel.

WARNINGStoqualifiedservicepersonnel:

: Disconnect the power supply to the appliance before servicing.

: Units provided with casters have a restraint to limit the movement that must be reconnected after servicing and installed in the original position.

: Proper clearances must be maintained during servicing and when installed in the original position.

IV. SERVICE AND REPAIR


26

V. REPLACEMENT PARTS LISTPartsthatwilllikelyrequirereplacementduringthelifeofthebroilerareidentifiedwitha“ ”intheReplacementPartsList.The“ ”symbolinthelistidentifiespartsthatareprotectedandshallnotbeorcannotbeadjustedbytheuser.Partsidentifiedwitha“-”shouldnotrequireadjustmentorreplacementduringthebroilerlife,butarelistedtoassistqualifiedservicepersonnelifreplacementisnecessary.

P/N DESCRIPTION

175503 SWITCH,LIGHTED,DPST -

175780 BURNER,INFRARED ,

176350 KIT,BURNER,ADJUSTABLE ,

175875 MOTOR-CONVEYOR -

175517 SPROCKET,B21X3/8BORE(MOTOR)

175037 SHAFT,DISCHARGESIDE

175038 SHAFT,RIGHTSIDE

175802 CAPACITOR,MOTOR-CONVEYOR

175876 MODULEIGNITION(7-5-3)CE(PROPANE,LOWERBURNERONLY)

175877 MODULEIGNITION(24-5-3)CE ,

175765 TRANSFORMER,40VA,230VAC-24VAC

175977 PROBE,TEMP.,C-CHAMBER

175550 LIGHT,COOK -

175870 RELAY-SOLIDSTATE ,

175551 CHAIN,DRIVE

175918 CONTROLLER

175510 GASKET,CONTROLBEZEL -

175511 GASKET,BLOWERINLET -

176186 BLOWER,230V50HZW/CENTRIFUGALSWITCH ,

175189 HOSE,BLOWER ,

175542 ORIFICEHOLDER,IR -

175182 KIT,VALVECEWITH90°FITTING ,

175935 ORIFICE,3.26mm,LOWERBURNER(I2H/I2E(G20),I2L(G25))

176388 ORIFICE,2.00mm,LOWERBURNER(I3P(G31))

175952 ORIFICE,1.70mm,LOWERBURNER(I3B/P(G30))

175814 ORIFICE,IRFRONT,2.35mm,GI2H/I2E(G20)&I2L(G25)

175815 ORIFICE,IRREAR,2.50mm,GI2H/I2E(G20)&I2L(G25)

175816 ORIFICE,IRFRONT,1.55mm,I3P(G31)

175817 ORIFICE,IRREAR,1.61mm,I3P(G31)

175818 ORIFICE,IRFRONT,1.40mm,I3B/P(G30)

175819 ORIFICE,IRREAR,1.51mm,I3B/P(G30)

176368 ORIFICEHOLDER3/8COMP.STRGHTXBULKHEAD

175476 TUBING-TEETOIR,KIT

175477 TUBING-TEETOVALVE,KIT

175178 TUBING-LOWERVALVETOORIFICEKIT

27


P/N DESCRIPTION

175534 SENSOR-LOWERBURNER ,

175535 SENSOR-IRBURNER ,

175536 IGNITER ,

175537 IGNITIONSUPPRESSIONCABLE-IR -

175538 IGNITIONSUPPRESSIONCABLE-LOWER -

175674 CHAIN,COOK ,

175525 BUSHINGBLOCK,CONVEYOR ,

175430 LOADERTRAY -

175438 LOADERMOUNTINGBRACKET -

175444 LOADER -

175741 LOADERRAMP -

175429 DOOR -

175293 FLAMEARRESTOR ,

176349 BURNERSHIELD ,

175340 DISCHARGECHUTE -

175778 DISCHARGEHOOD -

175363 PRODUCTPANSHELF -

175358 DISCHARGEPAN -

175329 MAINGREASEPAN -

175325 “V”GREASEPAN -

175357 SIDE,GREASEPAN -

175150 PIVOTASHSCRAPER -

175305 REARPANEL -

175300 FRONTPANEL -

175392 PANEL,UPPER,LIFTOFF -

175383 PANEL,ACCESSELECTRICALLWB -

175250 PANEL,ACCESSDISCHARGE -

175226 IMPEDANCEPAN(IFNOOPTIONALCATALYST) ,

175480 CATALYST(OPTIONAL) -

175482 CATALYST,GUARD -

175485 TUBEBURNERCLEANINGTOOL ,

175701 FLAMERODTUBECLEANER ,

175705 BRUSH,FLAMERODTUBECLEANER ,

175184 RELAY,10A,24VAC ,


28

VI. WIRING SCHEMATIC

T1L1+ S

olid

stat

e R

elay

T1L1+ So

lidst

ate

Rel

ay

PRIMARY

SECONDARY

PRIMARY

SECONDARY

Sens

or –

Rea

r IR

Bur

ner

Igni

ter –

Fron

t IR

Bur

ner

Igni

te –

Rea

r IR

Bur

ner

ON/OFF Switch

Sens

or –

Fron

t IR

Bur

ner

Capacitor 4uF

Con

veyo

r Mot

or

Sens

or –

Low

er B

urne

r

Igni

ter –

Low

er B

urne

r

1 2

1 2

2 1 1 2

1 2

1 1

3 2 1

Igni

tion

Xfm

r.

J 6J 5

J 4 J 3

BLK 11

WHT 11BLU 11

BRN 11

BRN 12

BRN 13

BRN 14

BLU 11

BLU 15

BLU 13

BRN 13

BLK

BLK

GR

N/Y

EL

BRN 12

BLU 12

BRN

15

RED

15

RED 15

BLU 14

BLKBL

K

BLK

BRN

ORG

BLK

BR

NO

RG

BLUBLU

BLU

BLU

BLU

7

OR

G 7

OR

G 6

GRN 4

GRN 0GRN 3

GRN 8GRN 2

GRN 7

GRN 9

GRN 1

BLK 6

BLK 5

BLU 7

BRN 8

RED 2

YEL 1

ORG 4

BLU 6

ORG 6

OR

G 8

YEL 1

RED 5

RED

3

RE

D 3

WHT 8

RED 4

GRN 7

GR

N 2

GR

N 1

GR

N 9

WH

T 8

BLU

4

BLU

4GR

N 8

GR

N 3

J1 & J 2 View

BLU

6

Power Cord Inlet

☼

24V

Con

trolle

r Xf

mr 24V

Relay –Conveyor Motor

BLK 11 WHT 11

BLU 11BRN 11

ON/OFF Switch Connections(Note: Indicator light Brn11 to Blu11)

ORG 8

BRN 8

2 1

2 1

+

Gas Valve – IR Burners

BLU

4GR

N 8

Gas Valve –Lower Burner

OR

G 7

GR

N 8

BLU

4

WH

T 8

RE

D 4

GRN 4

S1V

2 G

ND

V1TH

FC-

FC+S

1V2 G

ND

V1TH

FC-

FC+S1

V2 G

ND

V1

TH

FC-

FC+

Thermocouple

1

2

3

4

5

6

7

8

9

10

11

12

1

2

3

4

5

6

7

8

9

2 1

3 2 1

J 1

J 2

Con

trolle

r PC

Boa

rd

Load Light

Note: Warranty is voided when water sensitive stickers have changed color to red.

ELECTRICAL SCHEMATIC – CE FLEXIBLE BATCH BROILERDUKE MFG. 175806 Rev.E

BLU

5

ORG 5ORG 4

1 2

1 2

BLK 14

BLU 15

IR Blower Motorw/Centrifugal

Switch

DPST Relay

12

34

5

32

45

1

DPST Relay

ORG 3

RED

RED

OR

G

OR

G

BLU 5

BLU 101 BLU 102

RED 103

RED 104

RED 102

RED 2

N.O.

N.C.

N.O.

N.C.

ORG 5

RED 5

Igni

tion

Con

trol M

odul

eLo

wer

Bur

ner

Igni

tion

Con

trol M

odul

eFr

ont I

R B

urne

r

Igni

tion

Con

trol M

odul

eR

ear I

R B

urne

r

29


NOTES:


30

NOTES:

31


NOTES:


32

Duke Manufacturing Co.2305 N. Broadway

St. Louis, MO 63102Phone: 314-231-1130

Toll Free: 1-800-735-3853Fax: 314-231-5074

www.dukemfg.com

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