INSTALLATION INSTRUCTIONS

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1 INSTALLATION INSTRUCTIONS NATURAL GAS LOWER BURNER UPGRADE KIT INSTRUCTIONS DUKE KIT#s: (Style 1) and (Style 2) A B C This kit contains: A. (1) V-Shaped Pan B. (1) Main Grease Pan C. (2) Burner, Lower, Center Air Flow * 1 installed/1 spare D. (1) Orifice, Lower Burner # E. (1) Assembly, Mounting, Grease Pan Stop Style Style F. (1) Stop, V-Pan Style Style G. (2) Nut, 1/ H. (2) Screw, #8-32 x 1/2" I. (2) Nut, # J. (1) Label, Gas Rating K. (1) Configuration/Recipe Update Sheet L. (1) Overlay, Name Plate D E Style 1 Style 2 F Style 1 Style 2 Items required for this installation: 1/2" deep well socket and ratchet or 1/2" wrench 5/8" deep well socket and ratchet or 5/8" wrench 7/16" wrench 11/32" wrench Cross Tip Screwdriver This manual is Copyright 2012 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 N. Broadway St. Louis, MO Phone: Toll Free: Fax: P/N C

2 Natural Gas Lower Burner Upgrade Kit CAUTION: THESE INSTALLATION INSTRUCTIONS ARE FOR THE USE OF QUALIFIED INSTALLATION AND SERVICE PERSONNEL ONLY. INSTALLATION OR SERVICE BY OTHER THAN QUALIFIED PERSONNEL MAY RESULT IN SEVERE PERSONAL INJURY TO THE OPERATOR OR OTHERS, DAMAGE TO THE BROILER, OR OTHER PROPERTY DAMAGE. WARNING FOR YOUR SAFETY, THESE INSTRUCTIONS MUST BE FOLLOWED TO MINIMIZE THE RISK OF FIRE OR EXPLOSION, ELECTRIC SHOCK, AND TO PREVENT PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. A. Qualified Personnel: Qualified installation personnel are those individuals, firms, 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. Qualified 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. 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 1/2 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 1/2 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. Detailed broiler installation instructions are available in the Flexible Batch Broiler Installation and Operation Manual. If the manual is missing you must request one using the contact information on page 12. 2

3 B. Procedure 1. Turn the broiler off and unplug the broiler from electrical power. Close the main gas supply valve and disconnect supply line. Natural Gas Lower Burner Upgrade Kit 3. Remove Discharge Chute Pin Hook Discharge Chute Hook Pin 4. Remove lower main grease pan and V-Shaped pan. 2. Remove discharge end components. NOTE: REMOVE AND DISCARD OLD V-SHAPED PAN AND MAIN GREASE PAN COMPLETELY FROM RESTAURANT. THEY ARE NOT COMPATIBLE WITH NEW COMPONENTS. Grease V-Pan Main Grease Pan 3

4 Natural Gas Lower Burner Upgrade Kit 5. Remove loader, loader tray and front panel. 7. Remove ash scraper on discharge end. 6. Lift up lower burner panel and rotate outward to remove from hanger bracket. 8. Remove lower burner shield. 4

5 9. Remove lower burner and DISCARD. Locate and DISCARD any spare burners as well. Natural Gas Lower Burner Upgrade Kit 10. Remove and DISCARD lower orifice (#31) using a 1/2" deep well socket or 1/2" wrench. NOTE: REMOVE AND DISCARD ALL OLD BURNERS (INCLUDING ANY SPARE BURNERS THAT ARE LOCATED) AND THE ORIFICE COMPLETELY FROM THE RESTAURANT. THEY ARE NOT COMPATIBLE WITH NEW COMPONENTS. 11. Using a 5/8" deep well socket or 5/8" wrench, replace lower orifice with orifice provided in kit per the table below. NOTE: EXCESSIVE OVER-TIGHTENING OF ORIFICE DOWN ON TO ORIFICE HOLDER CAN CAUSE HOLDER TO BREAK. Orifice sizing (color code) Natural Gas #30 (green) 5

6 Natural Gas Lower Burner Upgrade Kit 12. Replace lower burner with new lower burner provided in kit. Provide additional spare burner to restaurant manager. 14. Replace ash scraper on discharge end. 15. Replace lower burner panel. 13. Replace lower burner shield. 6

7 16. Replace front panel, loader, and loader tray. Natural Gas Lower Burner Upgrade Kit 18. Determine whether your Stop Assembly is Style 1 or Style 2, and install as shown. STYLE 1 STYLE Remove back panel. STYLE 1: Install with #8-32 screws and nuts. 7

8 Natural Gas Lower Burner Upgrade Kit STYLE 2: NOTE: The stop bracket flange is fitted behind the existing cavity bracket flange. 19. Adjust and tighten Stop Bracket. (Ensure bracket is tightly against Broiler Bracket Flange, NO GAP). STYLE 1: NO GAP A. If the mounting holes are open: Install with #8-32 screws and nuts. STYLE 2: NO GAP OR 20. Replace back panel. B. If there are rivets in the mounting holes: The bracket simply is fitted over the clenched rivets. 8

9 21. Install new V-shaped pan and main grease pan provided in kit. 24. Remove Electrical Panel Cover. Natural Gas Lower Burner Upgrade Kit 22. Replace Discharge Chute 25. Remove Electrical Service Panel Cover. Pin Hook Discharge Chute Hook Pin 23. Replace discharge end components. 26. Remove Gas Ratings label. 9

10 Natural Gas Lower Burner Upgrade Kit 27. Apply new Gas Ratings label. 30. Re-Install Electrical Service Panel Cover. 28. Install Nameplate Overlay (clear protective sheet). 31. Upon supplying electrical power, gas supply, and turning the unit on, a gas leakage test should be performed where the orifice meets the orifice holder. 29. Re-Install Electrical Panel Cover. 32. Reprogram the broiler per the Configurations/ Settings Update Sheet included in the upgrade kit. 10

11 NOTE: ELECTRONIC LEAK DETECTORS WILL GIVE FALSE READINGS ON TOP OF THE BROILER NEAR THE IR ORIFICES AND GAS PIPING. THIS IS DUE TO PRODUCTS OF COMBUSTION NEAR THE FLUE. USE A LEAK CHECK FLUID OR SOAP SOLUTION IN THIS AREA. Natural Gas Lower Burner Upgrade Kit NOTE: REMOVE AND DISCARD ALL OLD COMPONENTS FROM THE RESTAURANT. THEY ARE NOT COMPATIBLE WITH THE NEW COMPONENTS. THESE COMPONENTS ARE: V-SHAPED PAN MAIN GREASE PAN ORIFICE ALL BURNERS (INCLUDING SPARES) 11

12 Natural Gas Lower Burner Upgrade Kit Duke Manufacturing Co. Duke Corporate, Canada, Latin America 2305 N. Broadway St. Louis, MO Phone: Toll Free: Fax: Duke EMEA - Europe, Middle East, Africa, Russia Duke Manufacturing CR, s.r.o. Zdebradska 92 Jazlovice, Ricany Building number DC 4 on the ProLogis Park Prague D1 West Prague Czech Republic Phone: Fax: Duke EMEA UK, Ireland, Nordic Countries Duke Manufacturing UK Ltd. Unit 10, Greendale Business Park Woodbury Salterton Exeter, EX5 1EW Phone: +44 (0) Fax: +44 (0) Duke Asia Pacific Duke Manufacturing No.3 Building Lane 28, Yu Lv Road Malu Town, Jiading District Shanghai , China Phone: / Fax:

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