RET Presenter 050903 by...Broilers 2 Introduction Different models/variations. Parts identification. Importance of chain speed. Gas Thermocouples. Gas flow/system. Cleaning/maintenance

Broilers

1BroilersBroilers

▲ Now we will talk about the single most important piece ofkitchen equipment.

▲ Who has had a broiler break down – what happened?▲ What % of sales mix goes through the broiler?▲ Identify whether you have electric or gas and deliver the

relevant training session.

Introduction▲ There are various different models/variations.▲ We will:

– Identify the various parts of the broiler.– Review the importance of chain speed.

Gas▲ Key areas of focus:

– Thermocouples.– Gas flow/system.– Cleaning/maintenance.

Electric▲ Key areas of focus:

– Operation.– Cleaning/maintenance.

General▲ There will be a trouble shooting exercise at the end to identify

common faults.

© 2003 Burger King Corporation. All rights reserved.

2BroilersBroilers

Introduction▲ Different models/variations.

▲ Parts identification.

▲ Importance of chain speed.

Gas▲ Thermocouples.

▲ Gas flow/system.

▲ Cleaning/maintenance.

Electric▲ Operation.

▲ Cleaning/maintenance.

General▲ Troubleshooting exercise.


3BroilersBroilers

▲ Identify with the learner(s) which sort of broiler you have.Remember when kitchen converts to Phase 1 the bun chainand sometimes platen may be removed.

▲ Review the relevant model with the learner(s).

Different Types of Nieco Broilers:980 8 gas burners – high output broiler flame-grills

meat and toasts buns.

960 and 950 6 gas burners or electric equivalent, flame-grillsmeat and toasts buns.

962 and 952 As above but return flow – stores meat in baserather than toasting buns.

930 4 gas burners or electric equivalent, flame-grillsmeat and toasts buns.

932 As above but return flow – stores meat in baserather than toasting buns.

922 Narrow broiler with 4 gas burners or electricequivalent – return flow so only flame-grills andholds meat.

Nieco Broiler


Model Number:

Gas/Electric:

Number of Burners/Elements:

What it does:

4BroilersBroilers

Nieco Broiler


Model Ideal Chain Speed< 75% “Close”

Action PointGas Pressure

950

960

980

930

26-28

links per minute

< 20

links per minute

3 low

5 high

26-28

links per minute

< 20

links per minute

3 low

5 high

17-19

links per minute

< 14

links per minute

3 low

5 high

32-34

links per minute

< 25

links per minute

3 low

5 high

5BroilersBroilers

▲ Ensure learner(s) understand that we must achieve bothappropriate chain speed and cook out temperature to ensuresafe cooking.

▲ We could get a patty to reach 70°C with only one burneroperating if the chain speed was slow enough but we wouldnot be certain that it would be a safe product.

▲ Identify with your learner(s) the meat chain speed yourbroiler should be operating at and check the meat chain linksper minute on your broiler.

▲ Burger King Corporation has carried out extensive testingon all broiler types in the system. Due diligence for the systemis provided as regards the “Time/Temperature Residence”of patties, proving that patties are cooked and achieve aninternal core temperature above 70°C for a minimum of 2minutes (or Temperature/Time equivalent); when cooked ina correctly operating broiler.

▲ We measure a correctly operating broiler by Cook Outtemperature achieved, combined with a correct chain speed(see table). Clearly if one of these critical factors is out ofspecification any defence under due diligence iscompromised.

▲ To check “links per minute”, stand at the feed end of thebroiler. Use a stopwatch to count the number of meat chainlinks that pass in 1 minute. “Links per minute” is not relatedto the speed on the speed dial.

Natural LPG

9 low

11 high

9 low

11 high

9 low

11 high

9 low

11 high


▲ Due diligence is provided by “Time/Temperature Residence” of

patties. Internal temperature is above 70°C for a minimum of 2

minutes (or Temperature/Time equivalent).

▲ We measure a correctly operating broiler by Cook Out temperature

achieved, combined with a correct chain speed. Clearly if one of

these critical factors is out of specification any defence under due

diligence is compromised.

▲ Stand at the feed end of the broiler. Use a stopwatch to count the

number of meat chain links that pass in 1 minute.

6BroilersBroilers

Model Ideal Chain Speed< 75% “Close”

Action PointGas Pressure


7BroilersBroilers

Broiler Chain Speed▲ As the meat is in the cook chamber of the broiler for a total of

only approximately 2 minutes we achieve the required 2minutes equivalent cook time by raising the meat temperatureto above 70°C. If the temperature reaches 80°C the timeequivalent is reached within 15 seconds.


8BroilersBroilers

Broiler Chain Speed▲ We achieve the required 2 minutes equivalent cook time by raising

the meat temperature to above 70°C.


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950 Gas Parts Identification▲ Overview all parts and their functions – the illustration is of

a 950 but most parts are common to the 960 and 980 series.

▲ Deliver this part of the session next to your broiler to allowyou to identify each part as you go.

▲ Temperature Probe – detects internal temperature of cookingchamber.

▲ Thermocouple – safety device which only allows gas to flowwhen a flame is detected.

Gas BroilersGas Broilers


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950 Gas Parts Identification



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▲ Patty feeder – position this as close as to the chain as possibleso that it allows only one patty through at a time.



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950 Gas Parts Identification



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Note:

If disposable burners are used, T-bar is replaced by two channelpieces between the three top burners. If Incendalyst is used,neither T-bar nor channel pieces are used.



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950 Gas Parts IdentificationNote: If Incendalyst is used, channel pieces are not used.



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▲ Refer back to solenoid session in Utilities.

▲ The thermocouple does not generate sufficient power to pullthe plunger back, but when hot does generate enough powerto hold it open once manually pushed back.

▲ Locate with your learner(s) the thermocouples on your broilerand which valves they are linked to.

▲ The pilot flame heats the thermocouple to hold the solenoid(red or blue button valve) open. Remember the thermocouplemay continue to hold valve open from radiated heat afterflame failure.

▲ The electricity produced is tiny – it is important to ensureflame is strong and thermocouple is clean.

Thermocouple

Pilot burner

Spark ignitor

Thermocouples



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▲ Hold Solenoid open by converting heat energy into electrical

current.

▲ The pilot flame heats the thermocouple to hold the solenoid (red or

blue button valve) open. Remember the thermocouple may continue

to hold valve open from radiated heat after flame failure.

▲ The electricity produced is tiny – it is important to ensure flame

is strong and thermocouple is clean.Thermocouple

Pilot burner

Spark ignitor

Thermocouples



Low Gas

Regulator

High Gas

Solenoid

High Gas

Regulator

Main Gas

Solenoid

Gas

Tap

Lower Pilot Assembly

Upper Pilot Assembly

Burner Manifold

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▲ Deliver this section of the training besideyour broiler.

▲ Recent models will house all the regulatorsand solenoids in one combined assembly andmay not have a manual gas tap fitted.

▲ Exact layout of components will differ but theconcepts remain the same.

▲ Lighting Procedure:

– Open gas tap, gas flows to the main gassolenoid.

– Switch main electric switch on, gas flowsto lower red button valve (high gassolenoid opens because low temperaturedetected).

– Manually open red button valveby pushing in button and ignite. Holdbutton for 20 seconds. When released,thermocouple will hold open valve.

– Gas travels to upper red button valve.

– Manually open upper red button valve (asabove).

– Once second thermocouple heats up, gasflows to burner manifold.

– Gas/air mix from burners is ignited bypilot burners and carryover burners.



Low Gas

Regulator

High Gas

Solenoid

High Gas

Regulator

Main Gas

Solenoid

Gas

Tap

Lower Pilot Assembly

Upper Pilot Assembly

Burner Manifold

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▲ Exact layout of components will differ but the

concepts remain the same.

▲ Lighting Procedure:

– Open gas tap, gas flows to the main gas

solenoid.

– Switch main electric switch on, gas flows to

lower red button valve (high gas solenoid

opens because low temperature detected).

– Manually open red button valve by pushing in

button and ignite. Hold button for 20 seconds.

When released, thermocouple will hold open

valve.

– Gas travels to upper red button valve.

– Manually open upper red button valve (as

above).

– Once second thermocouple heats up, gas flows

to burner manifold.

– Gas/air mix from burners is ignited by pilot

burners and carryover burners.



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▲ Leave to operate for 10 minutes after last product cooked.

Why operate empty for 10 minutes?

– Burn off excess grease.

– Allow grease to drain to pan.

▲ Once off, allow to cool for 30 minutes.

Why cool for 30 minutes?

– Safety.

– Reduce risk of metal buckling when cooling.

▲ Check condition of heat resistant gloves and rubber gauntletsif using soak tank/decarboniser.

▲ Remove and clean all exterior panels and grease collectionparts.

▲ Remove and clean bottom burner shields.

▲ Identify with your learner(s) all parts on your broiler to becleaned on a daily basis and how they are removed.

Daily Maintenance

Bottom burner shield



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▲ PPE:

– Heat resistant gloves.

– Rubber gauntlets - soak tank/decarboniser.

▲ Remove and clean all exterior panels and grease collection parts.

▲ Remove and clean bottom burner shields.

Daily Maintenance

Bottom burner shield



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▲ Review with learner(s) all cleaning tools.– Bristle brush.– Venturi brush.– Drive shaft cleaning tool.– Jet cleaning tool.

▲ Remove and clean all burners including distributor screens(face down with bristle brush). Do not immerse burnerassembly in water, distributor screen must remain dry.

▲ Demonstrate how to brush burner screen with screen facingfloor so any loose particles fall away from it rather than backinto the mesh.

▲ Clean burner venturi using venturi brush.

▲ Demonstrate correct cleaning of venturi.

▲ Clean reverberators.

▲ Demonstrate correct cleaning of reverberators. Wash in sink.

Weekly Maintenance▲ Clean main burner jets.

▲ Demonstrate location and correct cleaning of main burnerjets – use correctly sized brush.

▲ Clean teflon sheets (if used).

▲ Demonstrate correct cleaning of teflon sheets – wash, rinse,sanitise (if applicable).

▲ Clean drive shaft.

▲ Demonstrate correct cleaning of drive shaft.

▲ Remove and clean bun chain (if used).

▲ Demonstrate correct procedure for the removal of the bunchain – direction that chain knuckles should face and whatthe open or split link looks like.

▲ Demonstrate correct cleaning – wash, rinse, sanitise and airdry – of bun chain.

Drive shaftcleaning tool

Jet cleaning brushJet cleaningReverberatorCleaning burnerscreen

Cleaning burner venturi



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▲ Remove and clean all burners including

distributor screens (face down with bristle

brush). Do not immerse burner assembly in

water, burner screen must remain dry.

Weekly Maintenance▲ Clean burner venturi using venturi brush.

▲ Clean reverberators.

▲ Clean main burner jets.

Cleaning burner venturi

Drive shaft

cleaning tool


▲ Clean drive shafts.


Cleaning burner screen

Reverberator

Jet cleaning

Jet cleaning brush



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Incendalyst

Carryover burner

Pilot burner

Thermocouple

Main jet (bottom burner)

▲ Identify if Incendalyst is used.

▲ Show learner(s) where soak tank for Incendalyst islocated.

▲ Show where Automatic Temperature Control (ATC)is located. Explain importance of correctly setting theATC – if set wrongly or fiddled with/tweaked, it willprevent the broiler from operating correctly.

▲ Clean all pilot burners using dry scouring pad.

▲ Clean carryover burners.

▲ Clean thermocouples using damp cloth.

▲ Inspect teflon bearings for wear.

▲ Clean incendalyst (soak in clean water – air/drip dry).

▲ Set ATC (see next page).

Monthly Maintenance



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▲ Clean all pilot burners using dry scouring pad.

▲ Clean carryover burners.

▲ Clean thermocouples using damp cloth.


▲ Clean incendalyst (soak in clean water – air/drip dry).

▲ Set ATC (see next page).

Monthly Maintenance

Carryover burner

Pilot burner

Thermocouple

Main jet (bottom burner)

Incendalyst



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Monthly Maintenance (Set ATC)▲ Review step by step process with managers responsible for

setting the ATC.

▲ Ensure all cleaning tasks are complete and that the broiler iscorrectly assembled.

▲ Set ATC to 600°F.

▲ Light broiler (high gas will be on at first).

▲ Leave broiler to heat up for 40 minutes (high gas will notbe on).

▲ Turn ATC knob clockwise until high gas clicks in.

▲ Stop and turn knob back 10°F and tighten locking screw.

Automatic Temperature Control



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▲ Ensure all cleaning tasks are complete and that the broiler is

correctly assembled.

▲ Set ATC to 600°F.

▲ Light broiler (high gas will be on at first).

▲ Leave broiler to heat up for 40 minutes (high gas will not be on).

▲ Turn ATC knob clockwise until high gas clicks in.

▲ Stop and turn knob back 10°F and tighten locking screw.

Monthly Maintenance (Set ATC)

Automatic Temperature Control



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950 Electric Parts Identification▲ Overview all parts and their functions.

▲ Deliver this part of the session next to your broiler toallow you to identify each part as you go.

▲ Temperature Probe – detects internal temperature ofcooking chamber.

Electric BroilersElectric Broilers


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950 Electric Parts Identification



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▲ Deliver this part of the session next to your broiler toallow you to identify each part as you go.

▲ Patty feeder – position this as close as to the chain as possibleso that it allows only one patty through at a time.



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31





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33Electric BroilersElectric Broilers

▲ Identify with the learner(s) the Broil Stabilizer Control (BSC)display – one display is set point which can be adjusted andsecond display is actual measured temperature.

▲ Explain that:

– Meat cooked by U shaped electrical elements(six above and six below the chain).

– Temperature controlled by Broil Stabilizer Control (BSC).

▲ Identify which elements are controlled by BSC and whichare on continuously i.e. front 2 top and front 2 bottom arecontrolled by BSC.

▲ Check with the learner(s) the condition of elements (whencold) and that they are all glowing evenly when hot.



▲ Meat cooked by U shaped electrical elements

(six above and six below the chain).

▲ Temperature controlled by Broil Stabilizer Control (BSC).

▲ Front top 2 and bottom 2 elements connected to BSC/other

eight continuously on.

▲ Front top 2 and bottom 2 elements pulsed on and off by BSC

to control temperature.




Why operate empty for 10 minutes?

– Burn off excess grease.

– Allow grease to drain to pan.


Why cool for 30 minutes?

– Safety.

– Reduce risk of metal buckling when cooling.

▲ Check condition of heat resistant gloves and rubber gauntletsif using soak tank/decarboniser.

▲ Remove and clean all exterior panels and grease collectionparts.

▲ Identify with your learner(s) all parts on your broiler to becleaned on a daily basis and how they are removed.

Daily Maintenance





▲ PPE:

– Heat resistant gloves.

– Rubber gauntlets - soak tank/decarboniser.

▲ Remove and clean all exterior panels and grease collection parts.

Daily Maintenance



▲ Review with learner(s) all cleaning tools.

– Bristle brush.– Drive shaft cleaning tool.

▲ Clean reflectors.

▲ Demonstrate correct cleaning of reflectors.

▲ Clean drive shaft.

▲ Demonstrate correct cleaning of drive shaft.


▲ Demonstrate correct cleaning of teflon sheets – wash, rinse,sanitise (if applicable).


▲ Demonstrate correct procedure for the removal of the bunchain – direction that chain knuckles should face and whatthe open or split link looks like.

▲ Demonstrate correct cleaning – wash, rinse, sanitise and airdry – of bun chain.

Drive shaft cleaning tool

Weekly Maintenance



▲ Clean reflectors.

▲ Clean drive shafts.



Weekly Maintenance

Drive shaft cleaning tool



▲ Identify if Incendalyst is used.

▲ Show learner(s) where soak tank for Incendalyst is located.

▲ Show where BSC is located. Explain importance of correctlysetting the BSC – if set wrongly or fiddled with/tweaked itwill prevent the broiler from operating correctly.

▲ Clean temperature probe.


▲ Clean Incendalyst (soak in clean water – air/drip dry).

▲ Set Broil Stabiliser Control (see next page).

Incendalyst

Monthly Maintenance



▲ Clean temperature probe.


▲ Clean Incendalyst (soak in clean water – air/drip dry).

▲ Set Broil Stabiliser Control (see next page).

Monthly Maintenance

Incendalyst



Monthly Maintenance▲ Review step by step process with managers responsible for

setting the BSC.

▲ Ensure all cleaning tasks are complete and that the broiler iscorrectly assembled.

▲ Turn the broiler on and set BSC to 200°F or 100°C (dependingon display).

▲ Allow broiler to heat up for 40 minutes.

▲ Note actual temperature on BSC display and adjust set pointto 200°F/100°C above the indicated actual temperaturedisplay.

▲ Leave for further 10 minutes before use.

Broil Stabiliser Control



▲ Ensure all cleaning tasks are complete and that the broiler is

correctly assembled.

▲ Turn the broiler on and set BSC to 200°F or 100°C.

▲ Allow broiler to heat up for 40 minutes.

▲ Note actual temperature on BSC display and adjust set point to

200°F/100°C above the indicated actual temperature display.

▲ Leave for further 10 minutes before use.

Monthly Maintenance

Broil Stabiliser Control


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▲ When troubleshooting broiler problems, particularly if thebroiler is running but not at the correct chain speed, you needto look at two possible areas:

– Amount of heat generated and

– Amount of heat escaping.

If too little heat is generated it will run slow or, if too muchheat can escape, it will again run slow.

▲ Amount of heat generated is affected by:

– Gas pressure.

– Gas jets.

– Burners.

– Condition of elements.

▲ Amount of heat escaping is affected by:

– Correct assembly.

– Missing parts.

– Reflectors.

– Extract rate.

Broilers – Common ProblemsBroilers – Common Problems

What Affects Broiler Temperature?


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▲ Amount of heat generated is affected by:

– Gas pressure.

– Gas jets.

– Burners.

– Condition of elements.

▲ Amount of heat escaping is affected by:

– Correct assembly.

– Missing parts.

– Reflectors.

– Extract rate.

What Affects Broiler Temperature?



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▲ Discuss how the following problems may cause incorrectoperation of the broiler.

▲ Blocked main jets – correct gas flow is not allowed into theburner assembly.

▲ Blocked burner distributor screens:

– If water is allowed onto the screen, limescale will blockthe screens.

– If chemicals are on the screen, these will block the screens.

▲ Non-original burners – not as efficient.

▲ Incorrect gas pressure – correct pressure (3wci/5wci high).

▲ Damaged gas hose – this will lead to incorrect gas pressure.

▲ Gas tap not fully open – this will lead to incorrect gas pressure.

▲ Damaged elements – not as efficient.


Heat Generation


46Broilers – Common ProblemsBroilers – Common Problems

▲ Blocked main jets.

▲ Blocked burner distributor screens:

– Water.

– Chemical.

▲ Non-original burners.

▲ Incorrect gas pressure.

▲ Damaged gas hose.

▲ Gas tap not fully open.

▲ Damaged elements.

Heat Generation



Heat Escaping▲ Feed end reflector too high.

Feed end reflector should be set just high enough to allow aWHOPPER® or burger to pass beneath it but no higher.

▲ Burner channels/spacers missing (if no Indendalyst).

Check that you have the burner channels in place – if missingexcess heat will be able to escape between the burners.

▲ Non original reverberators.

Non-original parts may not always operate correctly – e.g.reverberators which are not as deep as originals will not bringthe heat close enough to the top surface of the burger patty.In addition, this is unsafe and illegal.

▲ Missing reflectors.

Reflectors are designed to reflect heat back into the cookingchamber. Missing reflectors will allow heat to escape.

▲ Extract rate too high/hood too tight on broiler.

If the extract rate is too high it will pull the heat straight outof the broiler. If an end shield is fitted to the hood, tryremoving and see if the chain speed can be increased.

▲ Broiler placement under hood.

The broiler must be within the footprint of the hood – if thefeed end or discharge end reflectors project beyond the hood,it may affect the air flow.

▲ Incendalyst reflectors fitted but Incendalyst no longer used.

▲ Discharge end reflector.

Check the tabs are flat onto the broiler frame and not bent.


Heat Escaping


▲ Feed end reflector too high.

▲ Burner channels/spacers missing.

▲ Non original reverberators.

▲ Missing reflectors.

▲ Extract rate too high/hood too tight on broiler.

▲ Broiler placement under hood.

▲ Incendalyst reflectors fitted but Incendalyst no longer used.

▲ Discharge end reflector.


49Broilers – TroubleshootingBroilers – Troubleshooting

▲ Conveyer chain won’t run.

– are all switches “ON” and speed dial set– something stuck in conveyor– chain jammed– 5 amp fuse blown– SCR loose or defective– drive sprocket loose– electric motor faulty.

▲ Pilot won’t light.

– power supply “OFF”– manual gas valve not open– quick disconnect not properly connected– solenoid valve defective– pilot burner dirty (burner and jet)– red push button gas valve faulty including thermocouple.

Work through these troubleshooting exercises:▲ Pilot won’t stay lit.

– air draught – try lighting again– thermocouple (dirty, loose, bad)– pilot burner weak flame (burner and orifice)– red push button gas valve defective.

▲ Meat not cooking properly.

– main burners obstructed– dirty or damaged jets– dirty or missing shields– reverberators damaged, missing or incorrect– ATC not properly calibrated– burner channels properly installed (if no Incendalyst)– gas pressures incorrect.

▲ Burners backfire.

– dirty or defective wire mesh (burnt through more than 3layers)

– dirty venturi– dirty or damaged jet– gas pressure set too high– damaged or loose venturi– overheating due to blocked Incendalyst.


50Broilers – TroubleshootingBroilers – Troubleshooting

▲ Conveyer chain won’t run.

▲ Pilot won’t light.

▲ Pilot won’t stay lit.

▲ Meat not cooking properly.

▲ Burners backfire.

What may be the cause of the following problems?


51BroilersBroilers

▲ Read through the following with the learner(s) – explain whois responsible for gas or electrical repairs, how to call themout if required and who is responsible for calling them out.

▲ Only qualified engineers may work on gas or electricalsystems.

▲ If in doubt ask an engineer.

▲ Ask yourself what could go wrong - what would happen ifsomeone else was injured on equipment you or one of yourstaff tried to work on.

▲ This workshop is to enable you to understand how theequipment in the restaurant works and allow you to givebetter information to engineers you call out – it will not makeyou an engineer!

▲ Remember the ultimate responsibility will lie with the lastperson to work on the equipment and the manager who wascontrolling that work.

The Day’s Most Important Learning Point – THINK SAFETY


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▲ Only qualified engineers may work on gas or electrical systems.

▲ If in doubt ask an engineer.

▲ Ask yourself what could go wrong - what would happen if someone

else was injured on equipment you or one of your staff tried to

work on.

▲ This workshop is to enable you to understand how the equipment in

the restaurant works and allow you to give better information to

engineers you call out – it will not make you an engineer!

▲ Remember the ultimate responsibility will lie with the last person

to work on the equipment and the manager who was controlling that

work.

BroilersBroilers

The Day’s Most Important Learning Point – THINK SAFETY


Documents

RET Presenter 050903 by...Broilers 2 Introduction Different models/variations. Parts identification. Importance of chain speed. Gas Thermocouples. Gas flow/system. Cleaning/maintenance