Duke FLEXIBLE BATCH BROILER Dokumentacja

Flexible Batch Broiler Flexible Batch Broiler

Broiler Operating Sequence Broiler Operating SequenceProduct Cooking-After the product is loaded the operator chooses the correct recipe menu on the c

Broiler Operating Sequence Broiler Operating SequencePrepping Next Load-The next product batch can now being placed on the loader tray. Being a batch

Broiler Operating Sequence Broiler Operating SequenceEnd of Cooking Cycle-When the cooking cycle is complete the conveyor will rotate the cook chain ½

SafetySafety¾ Observe all safety information in service manual¾ Review all information in service manual¾ No safeties have been bypassed¾ Properly ope

General SpecificationsGeneral Specifications

General SpecificationsGeneral Specifications

Subassemblies Troubleshooting/Operation Subassemblies Troubleshooting/Operation¾ Operating Controls¾ Loader Assembly¾Electrical System¾Gas System¾Conv

Operating Controls Controller Operating Controls Controller1-Power switch-Turns unit on/off-Self ignition system2-Product selection keys-Factory pre-p

Operating Controls Controller Operating Controls Controller3-Arrow keysUp Arrow-Displays current broiler tempwhen pressed in run mode. Used during pr

Operating Controls Controller Operating Controls Controller4-Display5-Enter Key-Used to enter into program mode.When in program mode used to enter par

AgendaAgenda¾Introduction¾Broiler Operation Sequence¾Safety/General Specifications¾Subassemblies¾10 Minute Break¾Electrical System¾Gas Burner System¾O

Operating Controls Basic Operation Operating Controls Basic OperationRefer to operating manual for complete operating instructions.The basic operation

Operating Controls Basic Operation Operating Controls Basic Operation¾ The cook light will be lit during the cooking cycle¾ Upon completion of cooking

Operating Controls Other Basic Functions Operating Controls Other Basic Functions¾ Fine cooking adjustment-allows to 30 seconds to beadded or subtract

Operating Controls Controller Programming Functions Operating Controls Controller Programming Functions¾ Always refer to service manual when gaining a

Operating Controls Recipe Programming Features Operating Controls Recipe Programming Features¾ Product Identifier-enter alphanumeric product name¾ Coo

Operating Controls Broiler Functionality Programming Operating Controls Broiler Functionality Programming¾ Idle temperature-temp set point during preh

Operating Controls Broiler Functionality Programming Operating Controls Broiler Functionality Programming¾ Reset Product Counts – Resets diagnostic re

Loader Assembly Basic Operation Loader Assembly Basic OperationThe loader assembly is a completely mechanical operation. After placing the product ont

Loader Assembly Major Components Loader Assembly Major Components¾ Loader Tray¾ LoaderLoaderLoader Tray/Loader

Loader Assembly Docking Plate/Loader Carriage Loader Assembly Docking Plate/Loader CarriageThe main issue with the loader not functioning correctly ot

PartneredWithTo Develop A RevolutionaryNew Flexible Batch BroilerExclusive To Burger King

Conveyor Assembly Basic Operation Conveyor Assembly Basic OperationThe conveyor assembly serves two purposes in the broiler. The cook chain provides t

Conveyor Assembly Major Components Conveyor Assembly Major ComponentsDrive Motor & CoverConveyor (Cook Chain)Sprockets & Drive ChainCapacitorM

Conveyor Assembly Drive Motor Conveyor Assembly Drive MotorPrior to checking the conveyor motor make sure the conveyor is not jammed with food product

Conveyor Assembly Drive Chain/Sprocket Conveyor Assembly Drive Chain/SprocketDrive chain is factory preset. Over time it may need to be adjusted and t

Conveyor Assembly Conveyor Conveyor Assembly ConveyorIndividual links on a conveyor (cook chain) can be replaced if damaged. A complete conveyor shoul

Conveyor Assembly Tips Conveyor Assembly Tips¾ Conveyor is also referred to as the cook chain.¾ Make sure the meat and ash scrapers are installed prop

Discharge Assembly Basic Operation Discharge Assembly Basic OperationWhen the cook cycle has completed the conveyor (cook chain) will discharge the pr

Discharge Assembly Major Components Discharge Assembly Major ComponentsProduct Pan ShelfDischarge HoodDischarge Chute(located under discharge hood)Dis

Discharge Assembly Tips Discharge Assembly TipsMost common issues with no dischargewould be the following: ¾ Jamme

10Minute Break 10Minute Break

Burger King Approached Duke Manufacturing With A ListOf DesignObjectives

Electrical System Major Subassemblies Electrical System Major Subassemblies¾ Controller Circuit¾ Conveyor Electrical System¾ Upper Burner Electrical S

Electrical System Controller Circuit Electrical System Controller CircuitMain ComponentsPower SwitchController Controller Wiring Harness24 Volt Transf

Electrical System Controller Circuit Electrical System Controller Circuit¾120VAC is supplied to the Broiler through the on/off switch ¾120 VAC is supp

Electrical System Conveyor Electrical System Electrical System Conveyor Electrical SystemMain ComponentsConveyor MotorConveyor Motor CapacitorConveyor

Electrical System Conveyor Electrical System Electrical System Conveyor Electrical System¾At the end of a cook cycle, the Controller outputs a 24 VACs

Electrical System Upper Burner Electrical System Electrical System Upper Burner Electrical SystemUpper Ignition ModuleUpper Gas ValveBlower MotorFlame

Electrical System Upper Burner Electrical System Electrical System Upper Burner Electrical System¾The Controller initiates a call for ignition of the

Electrical System Lower Burner Electrical System Electrical System Lower Burner Electrical SystemMain ComponentsLower Gas ValveLower Ignition ModuleSp

Electrical System Lower Burner Electrical System Electrical System Lower Burner Electrical System¾The Controller initiates a call for ignition of the

Gas Burner Assembly Upper Burner System-Major Components Gas Burner Assembly Upper Burner System-Major ComponentsUpper Ignition ModuleUpper Gas ValveB

¾ Reduce Energy Costs¾ Reduce Overall Floor Space¾ Fit Under Existing Hood System¾ Flexibility For Future New Menu Items¾ Reduce Labor Costs¾ Reduce C

Gas Burner Assembly Upper Burner System-Operational Sequence Gas Burner Assembly Upper Burner System-Operational Sequence¾With ignition present on the

Gas Burner Assembly Lower Burner System-Major Components Gas Burner Assembly Lower Burner System-Major ComponentsLower Gas ValveLower Ignition ModuleI

Gas Burner Assembly Lower Burner System-Operational Sequence Gas Burner Assembly Lower Burner System-Operational Sequence¾With ignition present on the

TroubleshootingTroubleshooting

Troubleshooting Step 1 Components Troubleshooting Step 1 ComponentsFaulty SwitchInput Voltage Check: 120 vac across wires 1 & 2Output Voltage Chec

Troubleshooting Type 2 Components Troubleshooting Type 2 ComponentsLower IgniterMeasure spark gap

Troubleshooting Step 2 Components Troubleshooting Step 2 ComponentsFaulty ControllerThermocouple input1 (30) 4 (20) 7 (11)2 (31) 5 (21) 8 (32)3 (13) 6

Troubleshooting Step 2 Components Troubleshooting Step 2 ComponentsIgnition Cable-Check for continuitythrough lower ignition cableLower Ignition Modul

Troubleshooting Step 2 Components Troubleshooting Step 2 ComponentsLower Gas ValveInput Voltage Check24 VAC across each solenoid from lower ignition m

What is a Batch Broiler?What is a Batch Broiler?Allows the operator to cook product in batches to increase flexibility, cooks product faster, provide

Troubleshooting Step 3 Components Troubleshooting Step 3 ComponentsUpper IgniterMeasure spark gap

Troubleshooting Step 3 Components Troubleshooting Step 3 ComponentsFaulty ControllerThermocouple input1 (30) 4 (20) 7 (11)2 (31) 5 (21) 8 (32)3 (13) 6

Troubleshooting Step 3 Components Troubleshooting Step 3 ComponentsIgnition Cable-Check for continuitythrough upper ignition cableUpper Ignition Modul

Troubleshooting Step 3 Components Troubleshooting Step 3 ComponentsUpper Gas ValveInput Voltage Check 24 VAC across each solenoid from lower ignition

Troubleshooting Step 4 Components Troubleshooting Step 4 ComponentsTemperature (Thermocouple) ProbeTest for open or shorted conditionController- Lower

Troubleshooting Step 6 Components Troubleshooting Step 6 ComponentsUpper Igniter-Controller-Upper Ignition Cable-Upper Ignition Module-Upper Gas Valve

Broiler Operating Sequence Broiler Operating SequenceStartup-After powering on the unit the broiler will go into a preheat mode to reach the proper op

Troubleshooting Step 7 Components Troubleshooting Step 7 ComponentsController-See slide #74 or #79Conveyor Motor RelayInput Voltage Check 24 VDC acros

Troubleshooting Step 7 Components Troubleshooting Step 7 ComponentsConveyor MotorInput Voltage Test 120 VAC across motor leadsOutput Voltage Test With

Troubleshooting Upper Flame Sensor Check Troubleshooting Upper Flame Sensor CheckUpper Flame SensorContinuity from rod tip to terminal-closed

Troubleshooting Lower Flame Sensor Check Troubleshooting Lower Flame Sensor CheckLower Flame SensorContinuity from rod tip to terminal-closed

Operator MaintenanceOperator MaintenanceOne of the most important aspects for proper operation of the batch broiler is operator maintenance.

Broiler Operating Sequence Broiler Operating SequenceProduct Staging-Once proper operating temperature is reached the product to be cooked is placed o

PartsPartsBurger King is offered an optional spare parts kits for the restaurants use in case of emergency or out of warranty repairs. These parts are

Recommended Spare Parts Truck Stock Recommended Spare Parts Truck Stock Critical Burger King Broiler Parts List Minimum Truck Sto

Recommended Spare Parts “GRAB & GO BOX” Recommended Spare Parts “GRAB & GO BOX” Critical Burger King Broiler Parts List

Recommended Spare Parts Service Warehouse Stock Recommended Spare Parts Service Warehouse Stock Critical Burger King Broiler Parts List Minim

10 Minute Break10 Minute Break

ReviewReviewBK BroilerInteractive Training CD

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Test Time 30 Minutes Test Time 30 Minutes

Broiler Operating Sequence Broiler Operating SequenceProduct Loading-The product is loaded into the unit by pushing the loader forward in a steady mot

CertificationCertification