Duke FBB-10-230 User manual

Installation & Operation Manual
CE Version
BURGER KING
FLEXIBLE 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 63102
Phone: [phone]
Toll Free: 1-800-735-3853
Fax: [phone]
www.dukemfg.com
P/N 175820R

Installation & Operation Manual for Flexible Batch Broiler - CE Units
2
TABLE OF CONTENTS
I. General Information .....................................................................................................4
 A.BatchBroilerSpecications ...................................................................................4
A-1. Model Number Key ......................................................................................4
  A-2.BroilerDimensions......................................................................................5
II. Installation Instructions..............................................................................................6
 A.QualiedPersonnel................................................................................................6
 B.DeliveryandInspection..........................................................................................6
 C.BroilerAssembly ....................................................................................................8
 D.AdjustmentsatInstallation .....................................................................................9
  RaiseorLowerBroiler........................................................................................9
 E.LocationoftheBroiler ..........................................................................................10
 F.GasPiping ............................................................................................................10
 G.ElectricalConnections .........................................................................................10
 H.Ventilation ............................................................................................................10
  VentingtoaCanopyExhaustHood ..................................................................10
  MaintenanceofVentilationSystem ...................................................................10
III. Operation Instructions............................................................................................. 11
 A.BroilerControls .................................................................................................... 11
 B.CookingProduct .................................................................................................. 11
  B-1.0LightingtheBroiler................................................................................... 11
B-2.0 Cook Product ...........................................................................................12
B-3.0 Cook Cycle Complete ..............................................................................13
  B-4.0FineCookingAdjustment.........................................................................13
  B-5.0CancelaCookCycle ...............................................................................13
  B-6.0CheckingtheBroilerTemperature ...........................................................13
  B-7.0CheckingtheSetPointTemperature .......................................................13
  B-8.0ShutdowntheBroiler ...............................................................................13
 C.Cleaning...............................................................................................................13
  C-1.Four(4)HourCleaning..............................................................................15
  C-2.DailyCleaning ...........................................................................................16
  C-3.WeeklyCleaning........................................................................................18
  C-4.MonthlyCleaning......................................................................................21
 D.Troubleshooting ...................................................................................................22
IV. Service and Repair ...................................................................................................25
V. Replacement Parts List.............................................................................................26
VI. Wiring Schematic.....................................................................................................28

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Installation & Operation Manual for Flexible Batch Broiler - CE Units
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 ammable 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.

Installation & Operation Manual for Flexible Batch Broiler - CE Units
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I. GENERAL INFORMATION
A. Batch Broiler Specications
I2H/I2E(G20) I2L(G25) I3B/
P(G30) I3P(G31)
GROSSHEAT
INPUT 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
GASPIPE
CONNECTION
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
I2H/I2E(G20) I2L(G25) I3B/
P(G30) I3P(G31)
Supply
Pressure 20 mbar 20 mbar 20 mbar 25 mbar 25 mbar 25 mbar 30/50 mbar
37/50
mbar
37/50
mbar
37/50
mbar
37/50
mbar
IRBurner
Pressure
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
LowerBurner
Pressure
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
I2H/I2E(G20) I2L(G25) I3B/
P(G30) I3P(G31)
ORIFICE–
FrontIRBurner 2,35 2,35 2,35 2,35 2,35 2,35 1,40 1,55 1,55 1,55 1,55
ORIFICE–
RearIRBurner 2,50 2,50 2,50 2,50 2,50 2,50 1,51 1,61 1,61 1,61 1,61
ORIFICE–
LowerBurner 3,05 3,25 3,45 3,05 3,25 3,45 1,70 1,85 1,90 1,95 2,00
SHIPPING
WEIGHT 204Kg(450lbs)
SHIPPING
DIMENSIONS 121,9cmx99,1cmx172,7cm(48”x39”x68”)
ELECTRICAL
RATING 230V~ 50Hz 1,1A 250W
A-1. Model Number Key
XidentiesGasConguration Y=OwithoutCatalyst Y=CwithCatalyst
DESCRIPTION MODEL DESCRIPTION MODEL
X= 1 I3P(G31)gasw/oCatalyst FBB-10-230 I3P(G31)gaswithCatalyst FBB-1C-230
X = 2 I2H/I2E(G20)gasw/oCatalyst FBB-20-230 I2H/I2E(G20)gaswithCatalyst FBB-2C-230
X= 3 I3B/P(G30)gasw/oCatalyst FBB-30-230 I3B/P(G30)gaswithCatalyst FBB-3C-230
X= 5 I2L(G25)gasw/oCatalyst FBB-50-230 I2L(G25)gaswithCatalyst FBB-5C-230

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Installation & Operation Manual for Flexible Batch Broiler - CE Units
21,6
8 1/2"
88,4
34 3/4"
100,3
39 1/2"
128
50 3/8"
111,9
44"
52,9
20 3/4"
161,7
63 5/8"
136,1
53 5/8"
GAS CONNECTION
3/4" BSPT FEMALE
115,8
45 5/8"
141,4
55 5/8"
HIGH POSITION
LOW POSITION
A-2. Broiler Dimensions
Note: Dimensionshownincentimeters,bracketed[]areininches

Installation & Operation Manual for Flexible Batch Broiler - CE Units
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A. QUALIFIED PERSONNEL
These installation instructions are for the use of
qualied installation and service personnel only.
Installationorservicebyotherthanqualiedpersonnel
mayresultindamagetothebroilerand/orinjurytothe
operator.
Qualiedinstallationpersonnelarethoseindividuals,
rms,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 sufcient
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.
• Thisapplianceisnotintendedforuseby
persons(includingchildren)withreduced
physical,sensoryormentalcapabilities,orlack
ofexperienceandknowledge,unlesstheyhave
beengivensupervisionorinstructionconcerning
useoftheappliancebyapersonresponsiblefor
theirsafety.
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.
Caution: The Broiler is very heavy!
Use adequate help for lifting.
II. INSTALLATION INSTRUCTIONS

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Installation & Operation Manual for Flexible Batch Broiler - CE Units
1. Using a utility knife, cut away plastic wrap (not
shown).
2. Removethetopcardboardandinnercap.
3. RemoveTrainingMaterialbox.
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and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its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oorto
avoiddamagetocasters.
10. Removeprotectivebluetapefrombroilerpanels,
doublecheckingthatnotaperemains.
• Checkforconcealeddamage.Thecarriermustbe
notiedwithinfteen(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lingyourclaim.
2
3
5
4
6
7
4
4
5
8

Installation & Operation Manual for Flexible Batch Broiler - CE Units
8
C. BROILER ASSEMBLY
Beforeassemblingandinstallingthebroiler,pleasecheck
tomakesurethatallnecessarypartsarepresent.
ITEM # PART NAME PART #
1PRODUCTPANSHELF 175353
2DISCHARGECHUTE 175340
3DISCHARGEHOOD 175362
4DISCHARGEPANHOLDER 175358
5DISCHARGEGREASEPAN 175357
6“V”GREASEPAN 175325
7MAINGREASEPAN 175329
8LOADER 175444
9LOADER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
Loader Install Tool
(Included with Broiler Tools Kit)
12
13 15
11
10
9
8
7
6
5
4
3
2
1
16
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.)
OPTIONAL SERVICE PARTS & ACCESSORIES
PARTSKIT–I2H/I2E(G20)&I2L(G25)(w/
Controller&CookChain) 176351 PARTSKIT-
(Burner,Arrestor,Loader,&Burner
Shield)
176353
PARTSKIT–I3B/P(G30)&I3P(G31) (w/
Controller&CookChain) 176352 KIT–CEGASHOSECONNECTOR 175831
PARTSKIT-(Burner&FlameArrestor) 176354 KIT–CEGASHOSECONNECTOR-UK 175827

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Installation & Operation Manual for Flexible Batch Broiler - CE Units
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.
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 ow
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ow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specications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
Support broiler here
Screw
Screw
Slide Leg.
Reinstall screws.
Plastic Hole Plug

Installation & Operation Manual for Flexible Batch Broiler - CE Units
10
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specicbelow:
COMBUSTIBLE SURFACE SPACING
DischargeEnd(leftside) 305 mm
AccessPanelEnd(rightside) 76 mm
Rear 102 mm
Floor/Table 0 mm
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sufcient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 xed 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
Yourbroilermustbesuppliedfroma230Volt50Hz,
groundedcircuitwithasupplycordforeachcountry’s
requirements.Awiringdiagramisattachedtothebroiler
controlcompartmentandwiththismanual.
The Main Supply safety / earth ground wire must
be longer than main conductors at the unit's
interconnectionstopreventstressunderpull.
Ifthesupplycordisdamaged,itmustbereplacedby
themanufacture,it'sserviceagentorsimilarlyqualied
personsinordertoavoidahazard.
EXTERNAL EQUIPOTENTIAL
Terminal provides a connection for bonding to
equipmentenclosure.
: 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 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 specied
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Qualied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.
: 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 airow through the unit—
resulting in poor cooking performance.