Duke FBB-XY-230-AAB User manual

Service Manual
FLEXIBLE BATCH
BROILER, CE VERSION
MODELS
FBB-XY-230-AAB
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 © 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
6/19/2014SM-BR-BR-0007

Service Manual for Flexible Batch Broiler, CE Version
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IMPORTANT WARNING AND SAFETY INFORMATION
IMPORTANT FOR YOUR SAFETY
THIS MANUAL HAS BEEN PREPARED FOR PERSONNEL QUALIFIED TO INSTALL
GAS EQUIPMENT. THE QUALIFIED INSTALLER SHOULD PERFORM THE INITIAL
FIELD START-UP AND ADJUSTMENTS OF THE EQUIPMENT COVERED BY THIS
MANUAL.
IMPORTANT
THE INSTRUCTIONS TO BE FOLLOWED IN THE EVENT THE SMELL OF GAS IS
DETECTED SHOULD BE POSTED IN A PROMINENT LOCATION. THIS INFORMATION
CAN BE OBTAINED FROM THE LOCAL GAS SUPPLIER.
IMPORTANT
IN THE EVENT A GAS ODOR IS DETECTED, SHUT DOWN BROILER AT MAIN
SHUTOFF VALVE AND CONTACT THE LOCAL GAS COMPANY OR GAS SUPPLIER
FOR SERVICE.
IMPORTANT FOR YOUR SAFETY
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS OR
LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
WARNING
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.
WARNING
IN THE EVENT OF A POWER FAILURE, DO NOT ATTEMPT TO OPERATE THIS
DEVICE.

Service Manual for Flexible Batch Broiler, CE Version
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How to Determine Manufacture Date from
Duke Equipment Serial Numbers
All units currently manufactured in St. Louis and Sedalia, Missouri (After 2/1/2013):
08 03 0202
Month Manufactured Sequential Number
Year Manufactured
(Example: 08030202 = Indicates the unit was manufactured in August of 2003)
Units Manufactured in St. Louis, Missouri (Before 2/1/2013):
30 IF AA 0123
Unit Identification Sequential Number
10 = 5/9
20 = 6/13 & E-Series
30 = 6/18 & 3/9
90 = FBB Month of Manufacture
94 = FWM JA = January
95 = IRHU JB = February
99 = Dry Channel JC = March
JD = April
Year of Manufacture JE = May
A = 1 JF = June
B = 2 JG = July
C = 3 JH = August
D = 4 (Examples) JI = September
E = 5 (JJ = 2000) AJ = October
F = 6 (JA = 2001) AA = November
G = 7 (JB = 2002) AB = December
H = 8
I = 9
J = 0

Service Manual for Flexible Batch Broiler, CE Version
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TABLE OF CONTENTS
INSTALLATION ............................................................................................................................................ 5
OPERATION................................................................................................................................................. 5
CLEANING ................................................................................................................................................... 5
CE SPECIFICATIONS.................................................................................................................................. 5
TOOLS ......................................................................................................................................................... 5
REMOVAL AND REPLACEMENT OF COMPONENTS ............................................................................... 6
COVERS AND PANELS......................................................................................................................... 6
Upper Lift Off Panel ......................................................................................................................... 6
PHU Pan Shelf ................................................................................................................................ 7
Discharge Hood............................................................................................................................... 7
Discharge Chute.............................................................................................................................. 7
Discharge Pan ................................................................................................................................. 8
Discharge Grease Pan .................................................................................................................... 8
Discharge Access Panel.................................................................................................................. 9
Main Grease Pan............................................................................................................................. 9
V Grease Pan .................................................................................................................................. 9
Loader Tray ................................................................................................................................... 10
Conveyor Drive Motor Cover ......................................................................................................... 10
Top Service Panel...........................................................................................................................11
Removing the Front Panel..............................................................................................................11
Removing the Rear Panel ..............................................................................................................11
COMPONENT REMOVAL.................................................................................................................... 12
Conveyor Drive Motor Assembly ................................................................................................... 12
Conveyor Drive Chain ................................................................................................................... 13
Conveyor Drive Motor Sprocket .................................................................................................... 13
Conveyor Drive Motor Capacitor ................................................................................................... 14
Blower Hose .................................................................................................................................. 15
Upper Flame Sensor Assemblies .................................................................................................. 15
Upper Igniter Assemblies............................................................................................................... 16
Lower Flame Sensor Assembly ..................................................................................................... 16
Lower Igniter Assembly ................................................................................................................. 17
Upper Infrared Burner Assembly ................................................................................................... 17
Lower J Burner Assembly.............................................................................................................. 18
Ignition Modules ............................................................................................................................ 19
Combo Gas Valves........................................................................................................................ 19
Cook Chamber Temperature Probe............................................................................................... 20
Control Board ................................................................................................................................ 21
Step-Down Transformers............................................................................................................... 22
Solid-State Relays ......................................................................................................................... 22
Main Power Switch ........................................................................................................................ 23
Blower Motor ................................................................................................................................. 23
Replacing Conveyor Links............................................................................................................. 24

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TABLE OF CONTENTS (Cont.)
ADJUSTMENTS......................................................................................................................................... 25
COMBO GAS VALVE........................................................................................................................... 25
DRIVE CHAIN DEFLECTION ADJUSTMENT ..................................................................................... 25
CONVEYOR POSITION ADJUSTMENT ............................................................................................. 26
UPPER IR BURNER AIR SUPPLY ...................................................................................................... 27
LOWER BURNER AIR SUPPLY .......................................................................................................... 27
TROUBLESHOOTING ............................................................................................................................... 28
COMPONENT CHECK PROCEDURES.............................................................................................. 28
Checking the Power Switch........................................................................................................... 28
Checking the Control Board .......................................................................................................... 28
Checking the Conveyor Drive Motor.............................................................................................. 28
Testing the Conveyor Drive Motor ................................................................................................. 28
Checking Conveyor Drive Motor Capacitor ................................................................................... 29
Checking and Testing the Blower Motor ....................................................................................... 29
Testing the Relays ......................................................................................................................... 29
Testing the Transformers ............................................................................................................... 30
Voltage Test ................................................................................................................................... 30
Resistance Check.......................................................................................................................... 30
Lower Ignition Module Testing ....................................................................................................... 30
Upper Ignition Module ................................................................................................................... 30
Checking the Flame Sensors ........................................................................................................ 31
Checking the Igniters..................................................................................................................... 31
CUSTOMER ASSISTANCE........................................................................................................................ 39

Service Manual for Flexible Batch Broiler, CE Version
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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.
Model Number Information:
FBB-XY-230-AAB
X = 1 Reference Gas G31
X = 2 Reference Gas G20
X = 3 Reference Gas G30
X = 5 Reference Gas G25
Y = O No Catalyst
Y = C With Catalyst
AA = ISO 2 Digit Country Code
B = Future use
TOOLS
Standard
• Standard set of hand tools.
• VOM with AC current tester (Any quality VOM
with a sensitivity of at least 20,000 ohms per
volt can be used).
• Manometer
• Pyrometer
• Gas Leakage Tester or method to test for gas
leaks
• Conveyor Link Removal Pliers
• Duke Testing Harness
CE SPECIFICATIONS
G20 G25 G30 G31
ALTITUDE (MAXIMUM) 607 m 607 m 607 m 607 m
GROSS HEAT INPUT 26.4 KW 26.4 KW 26.4 KW 26.4KW
GAS PIP CONNECTION 12.7 mm BSPT 12.7 mm BSPT 12.7 mm BSPT 12.7 mm BSPT
Supply Pressure 20 mbar 25 mbar 28-30 mbar 37-50 mbar
IR burner Pressure 9.34 mbar 12.95 mbar 19.93 mbar 19.93 mbar
Lower Burner Pressure 9.34 mbar 12.95 mbar 19.93 mbar 19.93 mbar
ORIFICE – Front IR burner 2.35 2.35 1.40 1.55
ORIFICE – Rear IR Burner 2.50 2.50 1.51 1.61
ORIFICE – Lower Burner 3.05 3.05 2.00 2.00
SHIPPING WEIGHT 205 KG (450 lbs)
SHIPPING DIMENSIONS 121.9 cm x 99.1 cm x 172.7 cm (48" x 39" x68")
ELECTRICAL RATING 230 Volts 50 Hz 250 W

Service Manual for Flexible Batch Broiler, CE Version
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COVERS AND PANELS
WARNING
DISCONNECT THE ELECTRICAL
POWER TO THE BROILER AND
FOLLOW LOCKOUT / TAGOUT
PROCEDURES.
Caution: If the broiler has been operating,
broiler panels and components
may be hot. Use PROPER
PROTECTION.
Upper Lift Off Panel
The Upper Lift Off Panel provides access to the
Upper Flame Sensors, Igniters and Blower Hose.
1. Remove Upper Lift Off Panel by lifting up
and removing from broiler.
2. Install Upper Lift Off Panel by lowering
into the side grooves.
Control Side
Access Panel
Upper Lift Off Panel
REMOVAL AND REPLACEMENT OF COMPONENTS
Lower Control Side Service Panel
The Lower Control Side Service Panel
provides access to the Combo Gas Valves,
Ignition Modules, Transformers, Blower Motor,
Conveyor Motor Capacitor, and electrical
connections to the Control Board.
1. Remove the six screws securing the
Lower Control Side Service Panel.
2. Remove the panel from the broiler.
3. Reverse procedure to install the Lower
Control Side Service Panel.
Control Side
Service Panel
Screws
Lower Control Side Service Panel

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PHU Pan Shelf
The PHU Pan Shelf is located on the discharge side
of the broiler and holds the unused holding pans.
1. Lift the pan shelf up and remove.
2. To install the pan shelf, slide the keyholes
over the two screws and slide pan shelf
down.
PHU
Pan
Shelf
Discharge
Hood
PHU Pan Shelf and Discharge Hood
Discharge Hood
The Discharge Hood is located on the discharge
side of the broiler under the PHU Pan Shelf.
1. Remove the PHU Pan Shelf.
2. Remove the Discharge Hood by lifting out.
3. Install Discharge Hood by lowering into the
side grooves.
4. Reinstall the PHU Pan Shelf.
Discharge Chute
The Discharge Chute is located under the
Discharge Hood and guides the patties from the
conveyor into the Discharge Pan.
1. Remove PHU Pan Shelf.
2. Remove the Discharge Hood.
3. Remove Discharge Chute by lifting off of the
two side pins.
4. Reverse procedure to install Discharge Chute,
being sure to rest the hooks onto the pins on
both sides.
Discharge
Chute Hook
Pin
Pin
Discharge Chute

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Discharge Pan
The Discharge Pan is located on the discharge
side of the broiler below the Discharge Hood
and is used to support the PHU Holding Pan (not
supplied).
1. Remove the PHU Holding Pan if present.
2. Slide Discharge Pan up and out of keyhole
slots.
3. Install Discharge Pan by lowering it into the
thumbscrews.
Discharge
Pan
Discharge Pan
Discharge Grease Pan
The Discharge Grease Pan is located below the
Discharge Pan and catches any grease drippings.
1. Tilt Discharge Grease Pan up to unhook and
pull forward to remove.
2. When installing the Discharge Grease Pan,
be sure to tilt up and push all the way back.
NOTE: Correct positioning will not allow pan
removal without upward tilt.
Discharge
Grease
Pan
1
2
Discharge Grease Pan

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Discharge Access Panel
1. Remove the PHU Pan Shelf.
2. Remove Discharge Hood.
3. Remove Discharge Chute.
4. Remove Discharge Pan.
5. Remove Discharge Grease Pan.
6. Remove Discharge Access Panel by lifting it
up and out.
7. Reverse procedure to install DischargeAccess
Panel.
Discharge
Side
Access
Panel
Discharge
Side
Access
Panel
Discharge Access Panel
Main Grease Pan
The Main Grease Pan is located on the front of
the broiler under the V Grease Pan.
Remove the Main Grease Pan by sliding straight
out of broiler.
V Grease Pan
The V Grease Pan is located on the front of the
broiler under the Loader Tray.
Remove pan by sliding straight out from broiler.
Main
Grease Pan
Grease
V-Pan
V Grease Pan and Main Grease Pan