Duke FBB-EO-208 User manual

Service Manual
FLEXIBLE BATCH
BROILER
MODELS
FBB-EO-208
FBB-EC-208
FBB-EO-230
FBB-EC-230
FBB-EO-240
FBB-EC-240
Please read this manual completely before attempting
to install, operate or service this equipment
This document is prepared for trained Duke service technicians. It is not to be used by anyone not
properly qualied to perform these procedures.
This Service Manual is not all encompassing. If you have not been trained on servicing this product,
be sure to read the manual completely before attempting servicing. Be sure all necessary tools,
test equipment, and skills are available. Those procedures for which you do not have the proper
skills and test equipment must be performed only by a qualied Duke trained service technician.
This manual is Copyright © 2010 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 177769A

Service Manual for Flexible Batch Broiler Units
2
IMPORTANT WARNING AND SAFETY INFORMATION
THIS MANUAL HAS BEEN PREPARED FOR PERSONNEL QUALIFIED TO INSTALL
ELECTRICAL EQUIPMENT, WHO SHOULD PERFORM THE INITIAL FIELD START-
UP AND ADJUSTMENTS OF THE EQUIPMENT COVERED BY THIS MANUAL.
READ THIS MANUAL THOROUGHLY BEFORE OPERATING, INSTALLING OR
PERFORMING MAINTENANCE ON THE EQUIPMENT.
Failure to follow all the instruc-
tions in this manual can cause property damage,
injury or death.
Improper installation, adjust-
ment, alteration, service or maintenance can
cause property damage, injury or death.
Electrical connections should
be performed only by a certied professional.
Electrical and grounding con-
nections must comply with the applicable por-
tions of the National Electric Code and/or all
local electric codes. Failure to comply with this
procedure can cause property damage, injury or
death.
Before connecting the unit to
the electrical supply, verify that the electrical and
grounding connections comply with the appli-
cable portions of the National Electric Code and/
or other local electrical codes. Failure to comply
with this procedure can cause property damage,
injury or death.
Before connecting the unit to
the electrical supply, verify that the electrical
connection agrees with the specications on the
data plate. Failure to comply with this procedure
can cause property damage, injury or death.
UL73 grounding instruc-
tions: This appliance must be connected to a
grounded, metal, permanent wiring system. Or
an equipment-grounding conductor must be run
with the circuit conductors and connected to
the equipment-grounding terminal or lead on the
appliance. Failure to comply with this procedure
can cause property damage, injury or death.
Appliances equipped with a
exible electric supply cord, are provided with a
grounding plug. It is imperative that this plug be
connected into a properly grounded receptacle.
Failure to comply with this procedure can cause
property damage, injury or death.
If the receptacle is not the
proper grounding type, contact an electrician. Do
not remove the grounding prong from the plug.
Failure to comply with this procedure can cause
property damage, injury or death.
Before performing any service
that involves electrical connection or disconnec-
tion and/or exposure to electrical components,
always perform the Electrical LOCKOUT/TA-
GOUT Procedure. Disconnect all circuits. Failure
to comply with this procedure can cause prop-
erty damage, injury or death.
Before removing any sheet
metal panels or servicing this equipment, al-
ways perform the Electrical LOCKOUT/TAGOUT
Procedure. Be sure all circuits are disconnected.
Failure to comply with this procedure can cause
property damage, injury or death.
Do not operate this equipment
without properly placing and securing all covers
and access panels. Failure to comply with this
procedure can cause property damage, injury or
death.
Do not use or store gasoline or
other ammable vapors or liquids in the vicinity
of this or any other appliance. Failure to comply
can cause property damage, injury or death.
In the event of a power failure,
do not attempt to operate this appliance. Failure
to comply can cause property damage, injury or
death.

3
Service Manual for Flexible Batch Broiler Units
TABLE OF CONTENTS
INTRODUCTION ..................................................................................................................................5
INSTALLATION ...............................................................................................................................5
OPERATION ...................................................................................................................................5
CLEANING .....................................................................................................................................5
SPECIFICATIONS ................................................................................................................................6
MODEL NUMBER KEY ..................................................................................................................6
TOOLS............................................................................................................................................6
REMOVAL AND REPLACEMENT OF COMPONENTS .......................................................................7
COVERS AND PANELS .................................................................................................................7
Fuse Access Panel ...................................................................................................................7
Element Connection Access Panel ...........................................................................................7
Electrical Access Panel .............................................................................................................7
Product Pan Shelf .....................................................................................................................8
Discharge Hood ........................................................................................................................8
Discharge Chute .......................................................................................................................8
Discharge Pan ..........................................................................................................................8
Discharge Grease Pan .............................................................................................................9
Discharge Access Panel ...........................................................................................................9
Main Grease Pan ....................................................................................................................10
Grease V-Pan .........................................................................................................................10
Loader Tray .............................................................................................................................10
Conveyor Drive Motor Cover ..................................................................................................11
Top Service Panel ...................................................................................................................11
Removing the Front Panel ......................................................................................................12
Removing the Rear Panel .......................................................................................................12
Removing the Element Cover Panel .......................................................................................12
COMPONENT REMOVAL ............................................................................................................13
Conveyor Drive Motor Assembly ............................................................................................13
Conveyor Drive Chain .......................................................................................................14
Conveyor Drive Motor Sprocket ........................................................................................14
Conveyor Drive Motor Capacitor ......................................................................................15
Cook Chamber Temperature Probe ........................................................................................16
Control Board ..........................................................................................................................17
Step-Down Transformer ..........................................................................................................17
Solid-State Relays ..................................................................................................................18
Main Power Switch .................................................................................................................18
Mechanical Relays ..................................................................................................................19
Replacing Conveyor Links ......................................................................................................19
HEATING ELEMENTS..................................................................................................................20
FUSE REPLACEMENT ................................................................................................................22
ADJUSTMENTS .................................................................................................................................23
DRIVE CHAIN DEFLECTION ADJUSTMENT ..............................................................................23
CONVEYOR POSITION ADJUSTMENT ......................................................................................23
ASH SCRAPER BRACKET ADJUSTMENT .................................................................................24
LOADER DOOR SEAL BRACKET ...............................................................................................24
PRODUCT STOP BRACKET ADJUSTMENT ..............................................................................25

Service Manual for Flexible Batch Broiler Units
4
SEQUENCE OF OPERATION .......................................................................................................... 26
TROUBLESHOOTING .......................................................................................................................27
COMPONENT CHECK PROCEDURES ......................................................................................27
Checking the Power Switch ....................................................................................................27
Checking the Control Board ....................................................................................................27
Testing the Temperature Probe ...............................................................................................27
Checking the Conveyor Drive Motor .......................................................................................27
Testing the Conveyor Drive Motor ..........................................................................................28
Checking Conveyor Drive Motor Capacitor ............................................................................28
Testing the Relays ..................................................................................................................28
Testing the Transformers ........................................................................................................29
Voltage Test ......................................................................................................................29
Resistance Check .............................................................................................................29
Testing the Mechanical Relays ...............................................................................................29
Continuity Test ..................................................................................................................29
Testing the Contactors ............................................................................................................29
Voltage Test ......................................................................................................................29
CONTROL DIAGNOSTICS ..........................................................................................................30
Programming ..........................................................................................................................30
Diagnostics .............................................................................................................................30
TROUBLESHOOTING CHART ....................................................................................................32
PREVENTIVE MAINTENANCE ..........................................................................................................35
ELECTRICAL SCHEMATIC – FLEXIBLE BATCH BROILER .............................................................36
CUSTOMER ASSISTANCE ................................................................................................................39

5
Service Manual for Flexible Batch Broiler Units
INSTALLATION
For detailed installation instructions, refer to the
Installation and Operation Manual.
OPERATION
For specic operating instructions, refer to the
Installation and Operation Manual.
INTRODUCTION
CLEANING
For specic cleaning instructions, refer to the
Installation and Operation Manual.