Flexible Batch Broiler
Agenda ¾Introduction ¾Broiler Operation Sequence ¾Safety/General Specifications ¾Subassemblies ¾10 Minute Break ¾Electrical System ¾Gas Burner System ¾Operators Maintenance ¾Parts ¾10 Minute Break ¾Questions/Certification Test
Partnered With To Develop A Revolutionary New Flexible Batch Broiler Exclusive To Burger King
Burger King Approached Duke Manufacturing With A List Of Design Objectives
¾ Reduce Energy Costs ¾ Reduce Overall Floor Space ¾ Fit Under Existing Hood System ¾ Flexibility For Future New Menu Items ¾ Reduce Labor Costs ¾ Reduce Cleaning Down Time ¾ Single Step Loading/Unloading-Batch Cooking ¾ Eliminate Prep Work-Defrosting ¾ Increase Product Consistency ¾ Reduce Equipment Cost
What is a Batch Broiler? Allows the operator to cook product in batches to increase flexibility, cooks product faster, provide more consistent quality, provides faster product changeover while reducing labor and energy use.
Broiler Operating Sequence StartupAfter powering on the unit the broiler will go into a preheat mode to reach the proper operating temperature of 680 degrees F. The controller will read “rdY” for ready when the unit is properly up to temperature and the light above the controller will also go out to indicate the unit is ready to load.
Broiler Operating Sequence Product StagingOnce proper operating temperature is reached the product to be cooked is placed onto the loader. The product is placed frozen onto the loader. The cooking parameters of the controller are designed to operate with frozen product.
Broiler Operating Sequence Product LoadingThe product is loaded into the unit by pushing the loader forward in a steady motion. As the loader is pushed forward the loading door is opened. Once the loader is pushed forward all the way the handle on the loader is pushed down and loader pulled back in a steady motion with the handle in the down position to clear the product placed on the back row of the loader.
Broiler Operating Sequence Product CookingAfter the product is loaded the operator chooses the correct recipe menu on the controller and depresses the corresponding menu button. At this time the controller will cook the product in accordance to the parameters set for the menu item.
Broiler Operating Sequence Prepping Next LoadThe next product batch can now being placed on the loader tray. Being a batch broiler product can immediately be placed into the broiler after the prior load has completed the discharge cycle as the product is all cooked in the same cook cycle.
Broiler Operating Sequence End of Cooking CycleWhen the cooking cycle is complete the conveyor will rotate the cook chain ½ of a revolution. This will discharge the product out the side of the broiler and into a PHU (product holding unit) pan which is then directly loaded into the Duke Food Holding Unit. If the operator failed to hit a menu key for a cook cycle then the operator can hit menu #8 which is a manual discharge function.
Safety ¾ Observe all safety information in service manual ¾ Review all information in service manual ¾ No safeties have been bypassed ¾ Properly operating ventilation ¾ All panels installed SERVICE MANUAL CONTAINS STEP BY STEP SEQUENCE ON PARTS REPLACEMENT THESE INSTRUCTIONS MUST BE FOLLOWED!!!!!
General Specifications
General Specifications
Subassemblies Troubleshooting/Operation ¾ Operating Controls ¾ Loader Assembly ¾Electrical System ¾Gas System ¾Conveyor System ¾Discharge System
Operating Controls Controller 1-Power switch -Turns unit on/off -Self ignition system 2-Product selection keys -Factory pre-programmed for current products -Allows additional program recipes for future products -Number keys also used in programming mode
Operating Controls Controller 3-Arrow keys Up Arrow-Displays current broiler temp when pressed in run mode. Used during program mode to scroll backward through parameters. Down Arrow-Displays broiler set-point temp when pressed in run mode. Used during program mode to scroll backward through parameters. Left & Right Arrows-Moves between characters and parameters when in program mode also used as number 0 and 9 keys.
Operating Controls Controller 4-Display 5-Enter Key-Used to enter into program mode. When in program mode used to enter parameter and advance through the programming parameters. 6-Cook Light-Light is lit when broiler is in cooking mode. A warning label stating the following: “IF LIGHT IS ON DO NOT LOAD” NOTE: In a batch broiler all product is loaded at the same time.
Operating Controls Basic Operation Refer to operating manual for complete operating instructions.
Operating Controls Basic Operation ¾ The cook light will be lit during the cooking cycle ¾ Upon completion of cooking cycle the product will discharge into the holding pan and alarm will sound (if programmed for the alarm feature). ¾ After the cycle is completed the display will show “RDY” (ready), loaded program lights turn green and cook light is off.
Operating Controls Other Basic Functions ¾ Fine cooking adjustment-allows to 30 seconds to be added or subtracted to a program ¾ Cancel a cook cycle-will stop a cook cycle and discharge all product in broiler ¾ Check broiler temperature ¾ Check broiler temperature set point
Operating Controls Controller Programming Functions ¾ Always refer to service manual when gaining access to the programming functions ¾ Two levels of programming -Recipe related programming -Broiler functionality programming ¾ Diagnostic feature to record failures ¾ All programs are pre-loaded at factory including replacement Controllers ¾ All programs and parameters must not deviate from Burger King Corporate or Duke Manufacturing specifications
Operating Controls Recipe Programming Features ¾ Product Identifier-enter alphanumeric product name ¾ Cook temperature-all cook profiles have only one temperature per cycle ¾ Cooking profile -defines cycle parameter for upper burner on/off cycle -overall cook time is the total sum of on/off cycles -up to 6 cook segments can be loaded per program example: Segment 1 On 2:30 Off 1:00 Segment 2 On 1:30 Off 1:00 Segment 3 On 1:30 Off 1:00 Total Cook Time 8 minutes 30 seconds
Operating Controls Broiler Functionality Programming ¾ Idle temperature-temp set point during preheat and idle cycles -range 500-900 degrees F -factory preset 680 degrees F ¾ Offset parameter-Difference between measured temp and display temp -Positive offset-display temp will be below measured temp -Negative offset-display temp will be above measured temp ¾ Chain drive time-time required for chain to complete ½ rotation -range 1-10 seconds -factory default 6 seconds -factory default right to left
Operating Controls Broiler Functionality Programming ¾ Reset Product Counts – Resets diagnostic record of how many times each product key has been depressed ¾ Reset Failure Counts – Resets diagnostic record of how many times a failure to sense flame occurred ¾ Hitting the ► key will return to the first parameter ¾ Hitting the “enter” key will save all new entries into the controller
Loader Assembly Basic Operation The loader assembly is a completely mechanical operation. After placing the product onto the loader the operator pushes the loader forward into the broiler, pushes down on the handle and pulls the loader back. There are limits to the amount of product that can be loaded into the unit (per Burger King specs) however less product can be loaded. It is important that mixed product batches never be cooked as the programs are different for each product.
Loader Assembly Major Components ¾ Loader Tray ¾ Loader Loader Loader Tray/Loader
Loader Assembly Docking Plate/Loader Carriage The main issue with the loader not functioning correctly other than a damaged loader or loader tray would be an improperly installed loader ramp. Ensure loader tray is installed and latched correctly. It must sit on to top of the cook chain.
Conveyor Assembly Basic Operation The conveyor assembly serves two purposes in the broiler. The cook chain provides the score “char” markings on the product as it is superheated to approximately 750 degrees F. The conveyor also discharges the product automatically into the PHU pans at the end of the cook cycle by rotating a half of a revolution.
Conveyor Assembly Major Components Capacitor Drive Motor & Cover Conveyor (Cook Chain) Motor Relay Sprockets & Drive Chain
Conveyor Assembly Drive Motor Prior to checking the conveyor motor make sure the conveyor is not jammed with food product-refer to troubleshooting guide on how to check for jammed product. If conveyor chain is not jammed check the motor resistance following the instructions provided in the service manual. Normal Motor Resistance Wires to Test Resistance Black and Brown 24.2Ω Black and Orange 24.2Ω Brown and Orange 49.
Conveyor Assembly Drive Chain/Sprocket Drive chain is factory preset. Over time it may need to be adjusted and the chain deflection should set to 3/16”. Moving the bracket up will loosen the chain while moving the bracket down will tighten the chain. Should the chain and/or sprocket need to be replaced follow the replacement procedures as outlined in the service manual. Remove the motor cover.
Conveyor Assembly Conveyor Individual links on a conveyor (cook chain) can be replaced if damaged. A complete conveyor should only be replaced in the rare occurrence that multiple links have been damaged. Should more than a couple need to be replaced then the entire conveyor (cook chain) must be replaced.
Conveyor Assembly Tips ¾ Conveyor is also referred to as the cook chain.
Discharge Assembly Basic Operation When the cook cycle has completed the conveyor (cook chain) will discharge the product out of the side of the unit into a PHU pan by turning one half of a revolution.
Discharge Assembly Major Components Product Pan Shelf Discharge Hood Discharge Chute(located under discharge hood) Discharge Pan Holder (PHU pan placed here) Discharge Grease Pan
Discharge Assembly Tips Most common issues with no discharge would be the following: ¾ Jammed conveyor (cook chain) ¾ Operator did not hit a program key ¾ Defective controller ¾ Defective motor or relay
10 Minute Break
Electrical System Major Subassemblies ¾ Controller Circuit ¾ Conveyor Electrical System ¾ Upper Burner Electrical System ¾ Lower Burner Electrical System Refer to the troubleshooting flow chart for operational sequence and troubleshooting component guide for individual component testing procedure
Electrical System Controller Circuit Main Components Power Switch Controller 24 Volt Transformer Controller Wiring Harness Thermocouple Probe
Electrical System Controller Circuit ¾120VAC is supplied to the Broiler through the on/off switch ¾120 VAC is supplied to primary winding of both transformers. ¾24 VAC on secondary winding of left-side transformer. ¾24 VAC supplies power to the Control. ¾The Control senses cook chamber temperature through a Type K thermocouple which is located behind the rear panel.
Electrical System Conveyor Electrical System Main Components Conveyor Motor Capacitor Conveyor Motor Conveyor Motor Relay
Electrical System Conveyor Electrical System ¾At the end of a cook cycle, the Controller outputs a 24 VAC signal to a solid state relay which closes. ¾The output of the solid state relay allows 120 VAC to reach the conveyor motor and start capacitor. ¾The Controller ceases to output the 24 VAC signal after the cook chain has rotated a ½ of a revolution.
Electrical System Upper Burner Electrical System Igniter (2 units under cover) Igniter Wires (Rubber) Flame Sensor Wires (Braided) Flame Sensor (2 units) Blower Motor Upper Gas Valve Upper Ignition Module
Electrical System Upper Burner Electrical System ¾The Controller initiates a call for ignition of the upper burners. (LED dot can be seen at the top of the Controller display) ¾The Controller supplies a 24VAC signal to the upper ignition module. ¾The Controller also supplies a 24VAC signal to the blower motor relay which closes and allows 120VAC to the blower motor. ¾The upper ignition module supplies a 24VAC signal to the upper gas valve solenoid which allows the gas valve to open.
Electrical System Lower Burner Electrical System Main Components Ignition Wire Lower Gas Valve Spark Rod Assy Lower Flame sensor & wire located by removing rear cover Lower Ignition Module
Electrical System Lower Burner Electrical System ¾The Controller initiates a call for ignition of the lower burner. (A separate LED dot can be seen at the top of the Controller display) ¾The Controller supplies a 24VAC signal to the lower ignition module. ¾The lower ignition module supplies a 24VAC signal to the lower gas valve solenoid which allows the gas valve to open. ¾The lower ignition module then supplies a high voltage to the igniter to produce spark.
Gas Burner Assembly Upper Burner System-Major Components Igniter (2 units under cover) Igniter Wires (Rubber) Flame Sensor Wires (Braided) Infrared Burner (2 units) Flame Sensor (2 units) Blower Motor Upper Gas Valve Blower Motor Relay 24V Transformer Upper Ignition Module
Gas Burner Assembly Upper Burner System-Operational Sequence ¾With ignition present on the upper burners, the upper ignition module must sense that flame is present. ¾This is accomplished through flame rectification. ¾The upper ignition module applies a voltage between the flame sensor and ground (the burner). With a flame present between the flame sensor and ground, the flame completes the circuit’s path. Rectification occurs through the flame and a small DC current can be sensed.
Gas Burner Assembly Lower Burner System-Major Components Ignition Wire Igniter Lower Burner Lower Flame sensor & wire located by removing rear cover Lower Ignition Module Lower Gas Valve
Gas Burner Assembly Lower Burner System-Operational Sequence ¾With ignition present on the lower burner, the lower ignition module must sense that flame is present. ¾This is accomplished through flame rectification. ¾The lower ignition module applies a voltage between the flame sensor and ground (the burner). With a flame present between the flame sensor and ground, the flame completes the circuit’s path. Rectification occurs through the flame and a small DC current can be sensed.
Troubleshooting
Troubleshooting Step 1 Components Faulty Switch Input Voltage Check: 120 vac across wires 1 & 2 Output Voltage Check: 120 vac across wires 3 & 4 Back of Switch Transformer Primary Winding Voltage 120 vac Resistance Approx.21.8 ohms Secondary Winding Voltage 24 vac Resistance Approx. 0.
Troubleshooting Type 2 Components Lower Igniter Measure spark gap
Troubleshooting Step 2 Components Faulty Controller BACKSIDE - TOP 1 (30) 4 (20) 7 (11) 2 (31) 5 (21) 8 (32) 3 (13) 6 (33) 9 (12) 12 9 6 (15) 3 11 8 5 10 7 (18) 4 2 1 (14) Thermocouple input BACKSIDE - BOTTOM Wires 11 & 12 - Input Power 24 VAC Wires 14 & 18 - Input Detect Lower Valve Open Signal 24 VAC Wires 14 & 15 - Input Detect Upper Valve Open Signal 24 VAC Wires 13 & 14 - Input Detect Upper Ignition Module Power 24 VAC Wires 30 & 33 - Output Cook Light 24 VDC Wires 30 & 31 - Output Convey
Troubleshooting Step 2 Components Ignition Cable-Check for continuity through lower ignition cable Lower Ignition Module Input Voltage Check Power - 24 VAC across TH & GND from controller Output Voltage Check 24 VAC across V1 & V2 to lower gas valve -- Diagnostic LED Flash indication will occur once immediately after the failure. 2 flashes = Have flame, but no call from heat across TH & GND 3 flashes = Ignition Lockout ( only after 3 unsuccessful attempts to ignite and sense flame).
Troubleshooting Step 2 Components Lower Gas Valve Input Voltage Check 24 VAC across each solenoid from lower ignition module Output Voltage Check Test pressure tap for open valve with manometer
Troubleshooting Step 3 Components Upper Igniter Measure spark gap
Troubleshooting Step 3 Components Faulty Controller BACKSIDE - TOP 1 (30) 4 (20) 7 (11) 2 (31) 5 (21) 8 (32) 3 (13) 6 (33) 9 (12) 12 9 6 (15) 3 11 8 5 10 7 (18) 4 2 1 (14) Thermocouple input BACKSIDE - BOTTOM Wires 11 & 12 - Input Power 24 VAC Wires 14 & 18 - Input Detect Lower Valve Open Signal 24 VAC Wires 14 & 15 - Input Detect Upper Valve Open Signal 24 VAC Wires 13 & 14 - Input Detect Upper Ignition Module Power 24 VAC Wires 30 & 33 - Output Cook Light 24 VDC Wires 30 & 31 - Output Convey
Troubleshooting Step 3 Components Ignition Cable-Check for continuity through upper ignition cable Upper Ignition Module Input Voltage Check Power - 24 VAC across R & GND from right side transformer Output Voltage Check 24 VAC across V1 & V2 to upper gas valve -- Diagnostic LED Flash indication will occur once immediately after the failure.
Troubleshooting Step 3 Components Upper Gas Valve Input Voltage Check 24 VAC across each solenoid from lower ignition module Output Voltage Check Test pressure tap for open valve with manometer Input Voltage Check 120 VAC across motor leads Output Voltage Check Running motor Blower Motor Resistance Check-Approx 22.
Troubleshooting Step 4 Components Temperature (Thermocouple) Probe Test for open or shorted condition ControllerLower Ignition ModuleUpper Ignition ModuleLower Gas ValveUpper Gas ValveBlower MotorBlower Motor Relay- See prior pages for component troubleshooting
Troubleshooting Step 6 Components Upper IgniterControllerUpper Ignition CableUpper Ignition ModuleUpper Gas ValveBlower MotorBlower Motor Relay- See prior page for component troubleshooting
Troubleshooting Step 7 Components Controller-See slide #74 or #79 Conveyor Motor Relay Input Voltage Check 24 VDC across wires 30 & 31 from controller Output Voltage Check 120 VAC across wires 4 & 5 Other Relay Tests -With 24 VDC input there should be 120 VAC across the output -With 0 VDC input there should be approx. 0 VAC across output Motor Capacitor Test: Discharge capacitor.
Troubleshooting Step 7 Components Conveyor Motor Input Voltage Test 120 VAC across motor leads Output Voltage Test With motor free from drive chain motor should run Resistance Checks Approx. Readings: Black-Orange = 24.2 ohms Black-Brown = 24.2 ohms Orange-Brown = 49.
Troubleshooting Upper Flame Sensor Check Upper Flame Sensor Continuity from rod tip to terminal-closed
Troubleshooting Lower Flame Sensor Check Lower Flame Sensor Continuity from rod tip to terminal-closed
Operator Maintenance One of the most important aspects for proper operation of the batch broiler is operator maintenance.
Parts Burger King is offered an optional spare parts kits for the restaurants use in case of emergency or out of warranty repairs. These parts are not to be used under warranty unless first approved by Duke Mfg. For warranty purposes Duke Mfg. requires all authorized service agents to use company stock. The purpose of offering a spare parts kits is for out of warranty repair or in cases where the restaurant has caused non warranty related damage to the broiler.
Recommended Spare Parts Truck Stock Qty 1 1 1 1 1 1 1 2 1 1 1 1 2 2 1 1 Critical Burger King Broiler Parts List Minimum Truck Stock Inventory Part # Description 175503 Switch, Lighted, DSPT 16GA@125V 175506 Motor, Conveyor 175507 Capacitor, Motor-Conveyor 175508 Module, Ignition (Lower) 175509 Module, Ignition (Upper BRN) 175516 Transformer, 40VA, 120 VAC-24 VAC 175518 Probe, Temp, C-Chamber 175519 Relay-Solid State 175575 Control (FAS16) (RoHS) 175524 Blower, Dayton 60 Hz 115v 175531 Valve, Nat-Gas Combo
Recommended Spare Parts “GRAB & GO BOX” Critical Burger King Broiler Parts List Grab and Go Box Qty Part # Description 1 175503 Switch, Lighted, DSPT 16GA@125V 1 175506 Motor, Conveyor 1 175507 Capacitor, Motor-Conveyor 1 175508 Module, Ignition (Lower) 1 175509 Module, Ignition (Upper BRN) 1 175516 Transformer, 40VA, 120 VAC-24 VAC 1 175518 Probe, Temp, C-Chamber 2 175519 Relay-Solid State 1 175575 Control (FAS16) (RoHS) 1 175524 Blower, Dayton 60 Hz 115v 1 175531 Valve, Nat-Gas Combo 120v 1 175534 Sensor
Recommended Spare Parts Service Warehouse Stock Critical Burger King Broiler Parts List Minimum Service Agency Warehouse Inventory Qty Part # Description 1 175503 Switch, Lighted, DSPT 16GA@125V 1 175504 Burner, Infrared 1 175505 Burner, Tube, J Style 1 175506 Motor, Conveyor 1 175507 Capacitor, Motor-Conveyor 1 175508 Module, Ignition (Lower) 1 175509 Module, Ignition (Upper BRN) 1 175516 Transformer, 40VA, 120 VAC-24 VAC 1 175518 Probe, Temp, C-Chamber 2 175519 Relay-Solid State 1 175551 Chain, Drive 1 17
10 Minute Break
Review BK Broiler Interactive Training CD
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Test Time 30 Minutes
Certification
