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Duke FBB-XY-230-AAB, Service Manual

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Duke FBB-XY-230-AAB Service Manual Download Page 40

Service Manual for Flexible Batch Broiler, CE Version

40

6/19/2014

SM-BR-BR-0007

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Summary of Contents for FBB-XY-230-AAB

Page 1: ...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 equ...

Page 2: ...CATION 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 SUPPL...

Page 3: ...red 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...

Page 4: ...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 Con...

Page 5: ...ING 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 C...

Page 6: ...ster 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 Ha...

Page 7: ...g 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...

Page 8: ...ed 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 Reins...

Page 9: ...n 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 DischargePanand...

Page 10: ...7 ReverseproceduretoinstallDischargeAccess 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 broil...

Page 11: ...Loader Tray from keepers on the Loader Brackets 3 Install Loader Tray by sliding it into bracket and engaging ears with keepers Loader Carriage Loader Bracket Ear Loader Tray Conveyor Drive Motor Cov...

Page 12: ...anel Flue Restrictor Top Service Panel Removing the Front Panel 1 Slide the Loader out of the Loader Tray 2 Unlatch the Loader Tray and slide it out of the Loader Tray Mounting Brackets 3 Pull the Mai...

Page 13: ...ecuring motor to mounting plate and remove motor 5 Raisemotormountingplatetodisengagedrive chain from motor pulley 6 Remove sprocket from motor shaft Sprocket is secured to motor shaft by two set scre...

Page 14: ...alling the new chain be sure to engage the chain on the motor sprocket and conveyor sprocket Then adjust the tension on the chain to allow 4 763 mm chain deflection as described in the procedure DRIVE...

Page 15: ...VE CHAIN DEFLECTION ADJUSTMENT in the ADJUSTMENT Section before tightening the motor mounting plate screws Conveyor Drive Motor Capacitor WARNING DISCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOL...

Page 16: ...Panel Each upper burner has a corresponding Flame Sensor Assembly WARNING DISCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT TAGOUT PROCEDURES 1 RemovetheControlSideAccessPanel Refer to...

Page 17: ...the Air Box Cover and remove the Air Box Cover 7 Remove the Sensor Igniter Support Bracket 8 Remove the nut securing the Igniter 9 Reverse procedure to install a new Upper Igniter ensuring the replac...

Page 18: ...e Infrared Burners can be accessed by removing the Top Service Panel and Impedance Pan WARNING DISCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT TAGOUT PROCEDURES WARNING SHUT OFF THE...

Page 19: ...ve the Discharge Grease Pan 6 Remove the Discharge Access Panel Refer to the COVERS and PANELS section of the manual 7 Remove the Ash Scraper by pulling thetop of the Ash Scrapper out away from the br...

Page 20: ...he Flame Sensor wire s 4 Remove the two screws attaching Ignition Module to frame and remove the module 5 Reverse this procedure to replace an Ignition Module Lower Ignition Module Upper Ignition Modu...

Page 21: ...lve Incoming Pressure Tap Outgoing Pressure Tap Outgoing Pressure Adjustment Combo Gas Valves Cook Chamber Temperature Probe The Cook ChamberTemperature Probe connects to the bottom of the Control Boa...

Page 22: ...NNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT TAGOUT PROCEDURES 1 RemovetheLowerControlSideServicePanel Refer to the COVERS and PANELS section of the manual 2 Disconnect the Cook Chambe...

Page 23: ...ngTransformertoframe 4 Remove Transformer 5 Reverse procedure to install a Transformer Control Board Step Down Transformer Ignition Module Step Down Transformer Step Down Transformers Solid State Rela...

Page 24: ...ower Motor The Blower Motor is located on the Control Board side of the broiler and is accessed by removal of the Upper Lift Off and Lower Control Side Service Panels WARNING DISCONNECT THE ELECTRICAL...

Page 25: ...the front operator parts and panels Refer to the COVERS and PANELS section of the manual 3 SpreadthedamagedlinkwithLinkToolatboth ends 4 Remove the damaged link 5 Install the new link 6 Use pliers to...

Page 26: ...chain 6 Secure the motor mount in place by tightening the four motor mount screws 7 Install Conveyor Drive Motor Cover 8 Install Discharge Access Panel ADJUSTMENTS COMBO GAS VALVE The two Combo Gas Va...

Page 27: ...thebearing assembly and the frame 5 Check Conveyor position NOTE Leading edge of Discharge Chute should be about an 3 175 mm above the center line of the Conveyor shaft When correctly adjusted the Con...

Page 28: ...er Lift Off Panel 2 Iffoundloose itmaybenecessarytore adjust and re tighten the locking nuts which secure the air adjustment screws Air Adjustment Screws IR Burner Air Adjustment Screws LOWER BURNER A...

Page 29: ...eControl Board TryrunningtheControlBoardthroughacouple of different cook cycles NOTE If the Control Board is still not performing properly try these procedures 1 Turn the broiler off 2 Remove the Cont...

Page 30: ...e WARNING DISCONNECT THE ELECTRICAL POWER TO THE BROILER AND FOLLOW LOCKOUT TAGOUT PROCEDURES 1 Make sure the broiler is off and unplugged 2 RemovetheLowerControlSideServicePanel Refer to the COVERS a...

Page 31: ...diagnosticcheck Afterthediagnostic theLower Ignition Module is activated 24VAC is applied across terminal V1 opening the Lower Combo Gas Valve High voltage spark is generated at terminal HV When the F...

Page 32: ...bris between the Flame Sensor tip and burner Adjust the Flame Sensor if the tip is touching ground MakesurealloftheFlameSensorconnections are tight Checking the Igniters Another item to check if the b...

Page 33: ...and Prod SEnt Display flashing gAS and toP SEnb bot Display showing Hi Display showing Prob Define the Problem STEP 2 STEP 3 STEP 2 STEP 3 1 5 4 3 2 Consult STEP Faulty Probe Test and replace probe ST...

Page 34: ...nt at lower burner but no ignition YES Is there spark and ignition present but burner does not stay lit NO NO NO Faulty ignition cable Ensure continuity through ignition cable Dirty burner Ensure lowe...

Page 35: ...sure gas valve solenoid energizes and gas is present at the upper burners Consult next page YES Faulty Controller Ensure Controller signals blower motor relay to close Faulty blower motor or relay Ens...

Page 36: ...lashing gAS and YES Display flashing Prob Display flashing Hi or Lo NO NO Display flashing tESt Prod NO YES YES YES See Step 2 3 and 6 See Step 2 Faulty Probe Test and replace temperature probe SEE ST...

Page 37: ...spark gap Ensure upper igniters have sufficient spark gaps and spark is not arcing elswehere Faulty Controller Ensure Controller signals for heat to the upper ignition module Faulty ignition cable Ens...

Page 38: ...r Test conveyor motor capacitor for fault Faulty relay Ensure conveyor motor relay is closing Replace relay if conveyor motor running nonstop Faulty Controller Ensure Controller is signaling to energi...

Page 39: ...T 8 BLU 4 BLU 4 GRN 8 GRN 3 J1 J 2 View BLU 6 Power Cord Inlet 24V Controller Xfmr 24V Relay Conveyor Motor BLK 11 WHT 11 BLU 11 BRN 11 ON OFF Switch Connections Note Indicator light Brn11 to Blu11 OR...

Page 40: ...Service Manual for Flexible Batch Broiler CE Version 40 6 19 2014 SM BR BR 0007...

Page 41: ...emfg com DUKE ASIA PACIFIC Duke Manufacturing No 3 Building Lane 28 Yu Lv Road Malu Town Jiading District Shanghai 201801 China Phone 86 21 59153525 59153526 Fax 86 21 33600628 service asiapac dukemfg...

Page 42: ...Service Manual for Flexible Batch Broiler CE Version 42 6 19 2014 SM BR BR 0007...

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