Duke FBB-NO-120 Owner's manual

Installation and
Operation Manual
BURGER KING
FLEXIBLE
BATCH BROILER -
LOWER BURNER
UPGRADE
Please read this manual completely before attempting
to install, operate or service this equipment
This manual is Copyright © 2014 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 176483C
10/1/2014

Installation and Operation of Flexible Batch Broiler
2
TABLE OF CONTENTS
IMPORTANT WARNING AND SAFETY INFORMATION ..................................................4
I. GENERAL INFORMATION.............................................................................................5
A. BATCH BROILER SPECIFICATIONS...................................................................5
A-1.0 Model Number Key ...................................................................................5
A-2.0 Broiler Dimensions ...................................................................................6
II. INSTALLATION INSTRUCTIONS .................................................................................7
A. QUALIFIED PERSONNEL....................................................................................7
B. DELIVERY AND INSPECTION .............................................................................8
C. BROILER ASSEMBLY ..........................................................................................9
Setup .................................................................................................................10
D. ADJUSTMENTS AT INSTALLATION ..................................................................10
Raise or Lower Broiler....................................................................................... 11
E. LOCATION OF THE BROILER ........................................................................... 11
F. GAS PIPING........................................................................................................ 11
NOTICE TO INSTALLER:..................................................................................12
G. ELECTRICAL CONNECTIONS ..........................................................................12
H. VENTILATION.....................................................................................................12
Venting to a Canopy Exhaust Hood ..................................................................12
Maintenance of Ventilation System ...................................................................12
III. OPERATION INSTRUCTIONS...................................................................................13
A. BROILER CONTROLS .......................................................................................13
B. COOKING PRODUCT ........................................................................................14
B-1.0 Lighting the Broiler..................................................................................14
B-2.0 Cook Product ..........................................................................................14
B-3.0 Cook Cycle Complete .............................................................................15
B-4.0 Fine Cooking Adjustment........................................................................15
B-5.0 Cancel a Cook Cycle ..............................................................................15
B-6.0 Checking the Broiler Temperature ..........................................................15
B-7.0 Checking the Set Point Temperature ......................................................15
B-8.0 Shutdown the Broiler ..............................................................................15
C. CLEANING .........................................................................................................16
C-1. Four (4) Hour Cleaning.............................................................................18
C-2. Daily Cleaning ..........................................................................................19
C-3. Weekly Cleaning.......................................................................................21
CLEANING CONSIDERATIONS..............................................................22
SAFETY CONSIDERATIONS ..................................................................22
C-4. Monthly Cleaning......................................................................................24
D. PROGRAMMING THE CONTROL .....................................................................25
D-1.0 Entering Program Mode .........................................................................25
D-2.0 Navigating the Programming Screens....................................................25
D-3.0 Level 1 Programming .............................................................................25
  D-3.1ProductIdentierAbCd..........................................................................25

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Installation and Operation of Flexible Batch Broiler
D-3.2 Cook Temperature “Sett” .......................................................................25
  D-3.3CookingProle“on1”,“oFF1”,“on2”,“oFF2”........................................25
D-3.4 Exit Program Mode.................................................................................26
D-4.0 Level 2 Programming .............................................................................26
D-4.1 ºF or ºC Parameter “dEg” .......................................................................26
D-4.2 Change the Idle Temperature “Sett” .......................................................26
D-4.3 Additional Factory Parameters ...............................................................26
D-4.4 Exit Program Mode.................................................................................26
E. TROUBLESHOOTING.........................................................................................27
IV. SERVICE AND REPAIR .............................................................................................29
V. REPLACEMENT PARTS LIST ....................................................................................30
VI. ELECTRICAL SCHEMATIC .......................................................................................32

Installation and Operation of Flexible Batch Broiler
4
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.

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Installation and Operation of Flexible Batch Broiler
I. GENERAL INFORMATION
A. Batch Broiler Specications
FLEXIBLE BATCH BROILER SPECIFICATIONS
NATURAL GAS PROPANE
ALTITUDE (MAXIMUM) 2000 FT 607 m 2000 FT 607 m
GAS PIPE CONNECTION 3/4" F-NPT 3/4" F-NPT
INLET PRESSURE RANGE 7" – 12" W.C. 10" – 12” W.C.
MANIFOLD PRESSURE MANIFOLD PRESSURE
INFRARED BURNERS (TOP) 3.75" W.C. 0.93 kPa 8.0" W.C. 2.0kPa
LOWER BURNER 3.75" W.C. 0.93 kPa 8.0" W.C. 2.0kPa
TOTAL ENERGY RATE 94,000–100,000
BTU/HR
27.5 – 29.3
kW
94,000–100,000
BTU/HR
27.5 – 29.3
kW
BURNER ORIFICE SIZE BURNER ORIFICE SIZE
FRONT INFRARED BURNER #40 2.49mm #52 1.61mm
BACK INFRARED BURNER #36 2.70mm #51 1.70mm
LOWER BURNER #30 3.26mm #46 2.06mm
SHIPPING WEIGHT: 482 lbs (219 Kg)
SHIPPING DIMENSIONS: 47” x 34” x 68” (119.4 x 86.4 x 172.7 cm)
MODEL NUMBER ELECTRIC NATURAL & LP GAS
FBB-NO-120 120VAC,2A,60Hz 94,000–100,000BTU/HR
FBB-NC-120 120VAC,2A,60Hz 94,000–100,000BTU/HR
FBB-PO-120 120VAC,2A,60Hz 94,000–100,000BTU/HR
FBB-PC-120 120VAC,2A,60Hz 94,000–100,000BTU/HR
A-1.0 Model Number Key
FBB-X Y -120
X = N (NATURAL GAS) OR P (PROPANE / LP GAS)
Y = O (NO CATALYST) OR C (CATALYST)
120 = 120 VOLTS

Installation and Operation of Flexible Batch Broiler
6
A-2.0 Broiler Dimensions
39 1/2"
(100.3 cm)
34 3/4"
(88.4 cm)
53 5/8"
(136.1 cm)
20 3/4"
(52.9 cm)
63 5/8"
(161.7 cm)
45 5/8"
(115.8 cm)
55 5/8"
(141.4 cm)
44"
(111.9 cm)
8 1/2"
(21.6 cm)
50 3/8"
(128 cm)

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Installation and Operation of Flexible Batch Broiler
II. INSTALLATION INSTRUCTIONS
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:
• The installation or replacement of gas piping or
theconnection,installation,repairorservicingof
equipment, who are experienced in such work,
familiar with all precautions required, and have
complied with all requirements of state and local
authorities having jurisdiction. See: National Fuel
Gas Code NFPA 54 (ANSI Z223.1).
• The installation of electrical wiring from the electric
meter, main control box or service outlet to the
electricalappliance.Qualiedinstallationpersonnel
must be familiar with all precautions required and
have complied with all requirements of state and
local authorities having jurisdiction. See: National
ElectricalCode,ANSI/NFPA70.
• 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.
Theinstallationmustconformwithlocalcodes,orin
theabsenceoflocalcodes,withtheNationalFuelGas
Code,ANSIZ223.1/NFPA54,ortheNaturalGasand
PropaneInstallationCode,CSAB149.1asapplicable,
including:
• The appliance and its individual shutoff valve must
be disconnected from the gas supply piping system
during any pressure testing of that system at test
pressures in excess of ½ psi (3.5 kPa).
• The appliance must be isolated from the gas supply
piping system by closing its individual manual
shutoff valve during any pressure testing of the
gas supply piping system at test pressures equal
to or less than ½ psi (3.5 kPa).
For a broiler mounted on casters, the installation
shall be made with a connector that complies with the
StandardforConnectorsforMovableGasAppliances,
ANSI Z21.69/CSA 6.16 and a quick-disconnect device
that complies with the Standard for Quick-Disconnect
DevicesforUsewithGasFuel,ANSIZ21.4/CSA6.9.
When installing the broiler with casters and quick-
disconnecthose,adequatemeansmustbeprovided
to limit the movement of the broiler without depending
on the connector and the quick disconnect device or
its associated piping to limit the broiler movement. A
means for restraining may be attached to the vertical
portion of the base frame in the rear of the broiler.

Installation and Operation of Flexible Batch Broiler
8
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.
• 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inlingyourclaim.
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Caution: The broiler is very heavy!
Use adequate help when lifting.
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 & 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 it’s 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.

9
Installation and Operation of Flexible Batch Broiler
C. BROILER ASSEMBLY
Beforeassemblingandinstallingthebroiler,pleasecheck
to make sure that all necessary parts are present.
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16
ITEM PART NAME PT.NO.
1 PRODUCT PAN SHELF 175353
2 DISCHARGE CHUTE 175340
3 DISCHARGE HOOD 175778
4 DISCHARGE PAN HOLDER 175358
5 DISCHARGE GREASE PAN 175357
6 “V” GREASE PAN 176397
7 MAIN GREASE PAN 176398
8 LOADER 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
17 KIT,CLEANINGTOOLS/
INSTALLATION TOOL CLEANING
– LOWER BURNER FLAME ROD
TUBECLEANERBRUSH,TUBE
CLEANER TOOL– LOADER INSTALL
WRENCH,ALLEN,3/16”
175700
18 KIT–BROILERSVC.PARTS,NAT.
GAS W/ CONTROLLER W/COOK
CHAIN (OPTIONAL)
600310
19 KIT–BROILERSVC.PARTS,
PROPANE,W/CONTROLLERW/
COOK CHAIN (OPTIONAL)
600314
ITEM PART NAME PT.NO.
20 KIT–USERREPLACEABLE,
BOTTOMBURNER,FLAME
ARRESTOR,LOADER&BURNER
SHIELD (OPTIONAL)
600311
21 KIT–USERREPLACEABLE,
BOTTOM BURNER & FLAME
ARRESTOR (OPTIONAL)
600312
22 KIT – GAS HOSE CONNECTOR
ASSEMBLY (OPTIONAL)
175690
23 KIT – HIGH SUPPLY GAS
PRESSURE REGULATOR
(OPTIONAL)
175689
24 KIT–BROILERSVC.PARTS,NAT.
GAS,W/CONTROLLERW/COOK
CHAIN(OPTIONAL),ADJUSTABLE
– FOR HIGH ALTITUDE &
INTERNATIONAL UNITS
600331
25 KIT–USERREPLACEABLE,
BOTTOMBURNER,FLAME
ARRESTOR,LOADER&BURNER
SHIELD (OPTIONAL) – FOR HIGH
ALTITUDE & INTERNATIONAL
UNITS
600332
26 KIT–USERREPLACEABLE,
BOTTOM BURNER & FLAME
ARRESTOR (OPTIONAL) – FOR
HIGH ALTITUDE & INTERNATIONAL
UNITS
600333
27 KIT–BROILERSVC.PARTS,
PROPANE,W/CONTROLLERW/
COOK CHAIN (OPTIONAL) – FOR
HIGH ALTITUDE & INTERNATIONAL
UNITS
600334

Installation and Operation of Flexible Batch Broiler
10
Setup
Install all items as shown below.
Loader Install Tool
(Included with Broiler Tools Kit)
Install loader bracket with (4) 1/4-20 nuts.
Use supplied extension tool to remove and reinstall nuts.
(Nuts are shipped installed on loader mounting studs.)
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qualied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.