Broaster 2400 Series User manual

Broaster Company
2855 Cranston Road, Beloit, WI 53511-3991
608/365-0193 broaster.com
Genuine Broaster Chicken®, Broasted®, Broaster Chicken®, Broaster Foods®. and Broasterie® are registered
trademarks. Usage is available only to licensed operators with written authorization from the Broaster Company.
© 2002 Broaster Company
Printed In U.S.A.
Design Certified By:
CSA & NSF
Be sure ALL installers read, understand, and have access to this manual at all times.
Manual #15460 8/02 Rev 10/16
SERVICE MANUAL
BROASTER®2400
PRESSURE FRYER

W-1
All adjustments and repairs shall be made
by an authorized Broaster Company repre-
sentative.
If there is a power failure, turn cook/filter
switch OFF. On the Model 2400GH, also
slide switch on gas valve OFF. DO NOT
attempt to operate unit during a power fail-
ure.
Failure to read and
understand this manual
completely could result in serious injury
or death. Be sure ALL operators read,
understand and have access to this
manual at all times.
Rags or paper containing
cooking oil can catch fire
if exposed to heat. Laundering will not
remove the oil. Dispose of all oil-soiled
papers and rags in a trash container that
is in a ventilated area away from all
cooking equipment or other heat
sources such as direct sunlight.
If at any time the POWER
ON light does not turn off
when the cook/filter switch is moved to
the OFF position, disconnect the power
to the fryer and contact your local
Broaster Company representative for
service immediately.
DO NOT operate unit
without filter pan and filter
pan cover in its proper position. Filter
pan cover must be wiped clean after
each filtering cycle.
Make sure Pressure Relief Valve and
Pressure Gauge ports on bottom of
cover are clear of any oil or grease
buildup.
Make sure Pressure Relief
Valve and Pressure Gauge
ports on bottom of cover are clear of any
oil or grease buildup.
2400GH: Post, in prominent locations,
instructions to be followed in the event that
the user smells gas. This information can be
obtained from your local gas supplier.
cont’d on next page
FOR YOUR SAFETY
Do not use or store gasoline or other flammable vapors
or liquids in the vicinity of this or any other appliance.
Improper installation, adjustments, alteration, service or maintenance can cause
property damage, injury or death. Read the installation, operating and mainte-
nance instructions thoroughly before installing or servicing this equipment.
For the sake of safety and clarity, the following words used in this manual are defined as follows:
Indicates an imminently hazardous situation which, if not avoided, could
result in serious injury or death.
Indicates a potentially hazardous situation which, if not avoided, could
result in serious injury or death.
Indicates a potentially hazardous situation which, if not avoided, could
result in minor injury, property damage or both.
broaster.com Manual #15460 8/02 Rev: 10/15

W-2
Make sure a restraining
device is used that
complies with the Standard for
Commercial Gas Ranges, ANSI Z83.11/
CSA 1.8 to guard against transmission of
strain to the gas connectors.
Failure to restrain the
fryer could allow it to
move, causing hot shortening to spill
out, or a possible break in the gas line
causing an explosive condition.
broaster.com Manual #15460 8/02 Rev: 10/15

i
TABLE OF CONTENTS
1 - WARNING SIGNS .........................................................................................................1 - 1
2 - ELECTRIC POWER SUPPLY .......................................................................................2 - 1
WIRING DIAGRAMS ELECTRIC
DOMESTIC ......................................................................................................2 - 1
EXPORT ..........................................................................................................2 - 4
EU ....................................................................................................................2 - 6
WIRING DIAGRAMS GAS
DOMESTIC ......................................................................................................2 - 9
EXPORT ..........................................................................................................2 - 9
EU ..................................................................................................................2 - 10
3 - CONTROL PANEL ........................................................................................................3 - 1
TEMP-N-TIME FAMILIARIZATION ..............................................................................3 - 1
CONTROLLER PROGRAMMING................................................................................3 - 2
PRESET COOK MODE................................................................................................3 - 3
PROGRAMMING METHOD 1 ................................................................................3 - 3
PROGRAMMING METHOD 2 ................................................................................3 - 4
WARNING DISPLAYS .................................................................................................3 - 4
DISPLAY ACTUAL TEMPERATURE ............................................................................3 - 5
CALIBRATION .............................................................................................................3 - 6
ACCESS FOR SERVICE..............................................................................................3 - 5
COOK/FILTER SWITCH ..............................................................................................3 - 7
HI-LIMIT CONTROL ....................................................................................................3 - 7
POWER ON INDICATOR LIGHT..................................................................................3 - 9
SOLID STATE CONTROLLER .....................................................................................3 - 9
TEMPERATURE SENSOR PROBE............................................................................3 - 10
4 - POWER INPUT BOX.....................................................................................................4 - 1
TIMER SWITCH...........................................................................................................4 - 1
CONTROL ROD ..........................................................................................................4 - 2
2400GH PRESSURE FRYER.......................................................................................4 - 3
TRANSFORMER (2400GH) .........................................................................................4 - 3
2400E PRESSURE FRYER..........................................................................................4 - 4
CONTACTORS (2400E) ...............................................................................................4 - 4
FUSE (2400E) ..............................................................................................................4 - 5
HEATING ELEMENT (2400E).......................................................................................4 - 6
RELAY (2400E) ............................................................................................................4 - 8
PRE-HEAT RELAYS (2400E)........................................................................................4 - 8
broaster.com Manual #15460 8/02 Rev 6/16

ii
5 - COVER, YOKE, & LIFT .................................................................................................5 - 1
FAMILIARIZATION.......................................................................................................5 - 1
PROPER COVER OPERATION ...................................................................................5 - 2
GAS SPRINGS ............................................................................................................5 - 3
ADJUSTMENTS ..........................................................................................................5 - 3
COVER AND YOKE REMOVAL ...................................................................................5 - 4
COVER AND YOKE DISASSEMBLY ...........................................................................5 - 5
COVER AND YOKE ASSEMBLY .................................................................................5 - 6
CHECK CAM OPERATION..........................................................................................5 - 6
LIFT REMOVAL ...........................................................................................................5 - 7
SLIDE ROD AND BEARING REPLACEMENT .............................................................5 - 8
PRESSURE GAUGE....................................................................................................5 - 9
SAFETY RELIEF VALVES ............................................................................................5 - 9
6 - PRESSURE SYSTEM ...................................................................................................6 - 1
EXHAUST DRAIN TUBE..............................................................................................6 - 2
EXHAUST TANK..........................................................................................................6 - 2
EXHAUST TUBE..........................................................................................................6 - 3
PRESSURE REGULATING VALVE...............................................................................6 - 3
7 - MAIN BURNER SYSTEM .............................................................................................7 - 1
BURNER INFORMATON .............................................................................................7 - 1
GAS CONVERSION ....................................................................................................7 - 1
LIGHTING INSTRUCTIONS ........................................................................................7 - 1
VENTILATION ..............................................................................................................7 - 2
GAS VALVE .................................................................................................................7 - 2
FLAME ADJUSTMENTS .............................................................................................7 - 3
MAIN BURNER FLAME ADJUSTMENT .....................................................................7 - 5
MAIN BURNER ORIFICE.............................................................................................7 - 6
PILOT BURNER ORIFICE ...........................................................................................7 - 7
COMBUSTION CHAMBER .........................................................................................7 - 8
8 - DRAIN VALVE AND FILTER SYSTEM..........................................................................8 - 1
DRAIN VALVE ..............................................................................................................8 - 1
FILTER PAN.................................................................................................................8 - 2
CHECK VALVE ............................................................................................................8 - 3
MOTOR .......................................................................................................................8 - 4
PUMP..........................................................................................................................8 - 5
broaster.com Manual #15460 8/02 Rev 12/15

iii
9 - TROUBLESHOOTING ..................................................................................................9 - 1
ELECTRICAL TIPS ......................................................................................................9 - 1
SOLID STATE CONTROLLER TIPS ............................................................................9 - 2
SMART TOUCH CONTROLLER TIPS ........................................................................9 - 3
GAS TIPS ....................................................................................................................9 - 4
COVER, YOKE, AND SLIDE TIPS ...............................................................................9 - 4
PRESSURE SYSTEM TIPS .........................................................................................9 - 5
PRODUCT TIPS ..........................................................................................................9 - 6
FRESH CHICKEN ...............................................................................................9 - 6
FROZEN IQF CHICKEN .....................................................................................9 - 7
FILTERING TIPS.............................................................................................................9 - 8
TROUBLESHOOTING FLOW CHART - 2400GH.........................................................9 - 10
TROUBLESHOOTING FLOW CHART - 2400E............................................................9 - 12
broaster.com Manual #15460 8/02 Rev 3/16

1 - WARNING SIGNS
1-1
When servicing a Broaster®pressure fryer,
be sure all safety devices and warning signs
are in place and legible. If not, the Broaster
Company should be notified in writing of
the lack of warning signs and the existence
of an unsafe condition.
If you need replacement warning signs or
manuals, contact an authorized Broaster
Company representative or the Broaster
Company Service Department at:
[phone]
CAUTION!BEF
OREOPER
ATING
CHECKOILLEVEL
4
7
1
6
5
8
0
9
23
BEFORE OPER ATIN GCHEC K O I L LEVE LCAUTION!
4
7
1
56
9
0
8
32
DO NOT OPERATE THISFRYER WITHOUT FILTER PAN & COVERIN PLACE CAUTION :
broaster.com Manual #15460 8/02 Rev 7/14

1-2
COVER CLOSED COVER OPEN
MODEL 2400
DO NOT OPEN COVER
UNLESS PRESSURE IS AT ZERO P.S.I.
MANUFACTURED BY THE BROASTER COMPANY
DANGER
PELIGRO
Item 1 - Part #15724
FAILURE TO COMPLY WITH THESE SAFETY AND OPERATING INSTRUCTIONS COULD CAUSE INJURY TO OPERATOR AND BYSTANDERS.
DANGER
MAXIMUM WORKING
MADE IN U.S.A.
SAFETY AND OPERATING INSTRUCTIONS
PRESSURE 15 PSI
Item 2 - Part #11027
OPERATING INSTRUCTIONS
START UP
YOU ARE NOT REQURIED TO PHYSICALLY LIGHT THE PILOT ON THIS UNIT.
1. TURN THE MANUAL SHUT-OFF VALVE TO THE "ON" POSITION. WAIT
5 MINUTES BEFORE TURNING GAS VALVE ON.
2. MOVE SLIDE SWITCH ON GAS VALVE TO "ON"
3. MOVE COOK / FILTER SWITCH TO THE "COOK" POSITION.
SHUT DOWN
1. TURN COOK / FILTER SWITCH TO "OFF" POSITION.
2. MOVE SLIDE SWITCH ON GAS VALVE TO "OFF".
3. TURN THE MANUAL SHUT-OFF VALVE TO THE "OFF" POSITION.
INSTALL IN ACCORDANCE WITH AMERICAN NATIONAL STANDARD FUEL GAS CODE ANSI Z223. 1 LASTEST ADDITION
Item 3 - Part #15694
2400GH Only
broaster.com Manual #15460 8/02 Rev 7/14

1-3
MODEL 2400G
MODEL 2400G
Item 4 - Part #15667
2400GH Only
Item 5 - Part #10900
Item 6 - Part #11028
Item 7 - Part #06375
Item 8 - Part #15725
Item 9 - Part #15785
CAUTION
DO NOT OPERATE THIS FRYER WITHOUT FILTER PAN & CLEAN COVER IN PLACE CAUTION:
Item 10 - Part #16368 Item 11 - Part #11746
broaster.com Manual #15460 8/02 Rev 7/14

2 - ELECTRIC POWER SUPPLY
2-1
The 2400E is designed to
operate on 3-phase input
ONLY. DO NOT connect to 1-phase
power.
Many sections in this
manual pertain to check-
ing and repairing electrical components.
High voltage will be encountered in sev-
eral instances. Only persons trained and
equipped for checking high voltage shall
undertake such repairs.
If no component operates, check main
power supply. Be sure main circuit
breaker is ON and main fuses are good.
Correct voltage:
1-Phase
2400GH 120 VAC
2400GH Export 220 VAC
3-Phase
2400E 208 or 240 VAC
2400E Export & CE 220/380 VAC
220/415 VAC
Perform the following if unit will not turn on:
1. Disconnect main power supply.
2. Be sure all connections are tight. If
power supply is proper, see TROU-
BLESHOOTING section.
Wiring diagrams are located on inside front
panel.
broaster.com Manual #15460 8/02 Rev 6/15
2400E DOMESTIC
WIRING DIAGRAMS:
2400E EXPORT

2-2
2400E 208 or 240VAC:
USE #6 AWM. OR LARGER COPPER WIRE ONLY. SUITABLE FOR AT LEAST 75°C
MODEL 2400E
THE BROASTER CO. BELOIT, WI 53511
3
6
4 3 4
6
1
2 5
1
2 5
A B
broaster.com Manual #15460 8/02 Rev 7/14

2-3
2400E 208 or 240VAC: Effective SE4A700011
USE #6 AWM. OR LARGER COPPER WIRE ONLY. SUITABLE FOR AT LEAST 75°C
MODEL 2400E
THE BROASTER CO. BELOIT, WI 53511
A B
broaster.com Manual #15460 8/02 Rev 7/14

2-4
EXPORT: 2400EXP: 220/380 VAC to 240/415 VAC:
USE #6 AWM. OR LARGER COPPER WIRE ONLY. SUITABLE FOR AT LEAST 75°C
MODEL 2400EXP
THE BROASTER CO. BELOIT, WI 53511
2
4
6
3
5
1
6
4
3
5
2
1
N
A B
broaster.com Manual #15460 8/02 Rev 7/14

2-5
EXPORT: 2400EXP: 220/380 VAC to 240/415 VAC: Effective SE4A700011
USE #6 AWM. OR LARGER COPPER WIRE ONLY. SUITABLE FOR AT LEAST 75°C
MODEL 2400EXP
THE BROASTER CO. BELOIT, WI 53511
N
A B
broaster.com Manual #15460 8/02 Rev 7/14

2-6
USE #6 AWM. OR LARGER COPPER WIRE ONLY. SUITABLE FOR AT LEAST 75°C
MODEL 2400ECE
THE BROASTER CO. BELOIT, WI 53511
4 2
6
3
5
1
6
4 3
5 2
1
N
A B
EU: 2400ECE 220/380VAC to 240/415VAC:
broaster.com Manual #15460 8/02 Rev 7/14

2-7
EU: 2400ECE 220/380VAC to 240/415VAC: Effective SE4A700011
USE #6 AWM. OR LARGER COPPER WIRE ONLY. SUITABLE FOR AT LEAST 75°C
MODEL 2400ECE
THE BROASTER CO. BELOIT, WI 53511
N
A B
broaster.com Manual #15460 8/02 Rev 7/14

2-8
EU: 2400ECE 220/380VAC to 240/415VAC: Effective SE4F310031
broaster.com Manual #15460 8/02 Rev 7/14
USE #6 AWM. OR LARGER COPPER WIRE ONLY. SUITABLE FOR AT LEAST 75°C
MODEL 2400ECE
THE BROASTER CO. BELOIT, WI 53511
N
A B