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.
© 2015 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.
SERVICE MANUAL
BROASTER®2400
PRESSURE FRYER w/SmartTouch
Manual #17280 1/15 Rev 10/17

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 power 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 #17280 1/15 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 #17280 1/15 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
DUAL DISPLAY FAMILIARIZATION.............................................................................3 - 1
CONTROLLER BASIC PROGRAMMING ....................................................................3 - 2
WARNING DISPLAYS .................................................................................................3 - 4
DISPLAY ACTUAL TEMPERATURE ............................................................................3 - 4
CALIBRATION .............................................................................................................3 - 4
ACCESS FOR SERVICE..............................................................................................3 - 5
COOK/FILTER SWITCH ..............................................................................................3 - 6
HI-LIMIT CONTROL ....................................................................................................3 - 6
POWER ON INDICATOR LIGHT..................................................................................3 - 8
SOLID STATE CONTROLLER .....................................................................................3 - 8
TEMPERATURE SENSOR PROBE..............................................................................3 - 9
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 #17280 1/15

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 INFORMATION ............................................................................................7 - 1
GAS CONVERSION ....................................................................................................7 - 1
LIGHTING INSTRUCTIONS ........................................................................................7 - 1
VENTILATION ..............................................................................................................7 - 2
GAS VALVE POWER CHECK ......................................................................................7 - 3
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 #17280 1/15 Rev 12/15

iii
9 - TROUBLESHOOTING ..................................................................................................9 - 1
ELECTRICAL TIPS ......................................................................................................9 - 1
SMART TOUCH CONTROLLER TIPS ........................................................................9 - 2
GAS TIPS ....................................................................................................................9 - 3
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 #17280 1/15 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
DO NO T OP ERA TE THIS F RY ER WITHOU T FIL TE R P AN & CLEA N COVER IN PLACE CAUTION:
broaster.com Manual #17280 1/15

1-2
Item 1 - Part #11027
Item 2 - Part #15724
Item 4 - Part #15398
Item 3 - Part #16368
Item 5 - Part #10900
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 LATEST ADDITION
Item 6 - Part #15694
2400GH Only
CUS
R
BROASTER 2400GH
R
Item 6 - 2400GH Only
15667 Natural Gas
17421 LP gas
broaster.com Manual #17280 1/15

1-3
MODEL 2400G
Item 8 - Part #06375
Item 10 - Part #11028
Item 12 - Part #13396
Item 9 - Part #15785
DO NOT OPERATE THIS FRYER WITHOUT FILTER PAN & CLEAN COVER IN PLACE CAUTION:
Item 13 - Part #11746
2400GH Only
broaster.com Manual #17280 1/15
CAUTION
Item 11 - Part #15725

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
3-Phase
2400E 208 or 240 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 #17280 1/15 Rev 6/15
Three Phase Wiring: 2400E General Power
WIRING DIAGRAMS:

2-2
2400E 208 or 240VAC:
C
NO NC
broaster.com Manual #17280 1/15

2-3
2400GH
NO NC
C
broaster.com Manual #17280 1/15

3 - SMART TOUCH CONTROL PANEL
3-1
SMART TOUCH FAMILIARIZATION
and press the enter key. Repeat this action
for the Day, Year, Hours, Minutes, Seconds,
AM and PM boxes. When finished press the
green OK button in the bottom right corner
of the screen. The next display will ask you
if this date should be used to establish the
warranty start date. Press the green OK
button.
You will then see a display asking you to
verify the serial number of your fryer. Enter
the serial number using the keyboard and
press enter.
Note: The date/time display and the serial
number display will not appear again when
the power switch is turned off and back on.
If the CAUTION screen appears it is there to
remind you to check the oil level before the
heating elements or burner are activated. If
the oil is at the proper level, press the green
OK button in the bottom right corner of the
screen.
Along the top of the screen are four tabs
(Cook, Filter, Setup and Help) to help you
setup and use your fryer.
ON
OFF
HIGH
LIMIT
RESET
iyvhz{ly
jvtwhu
zthy{{v|jo
1. Power Switch: This switch has two
positions: ON or OFF.
2. Hi-Limit Control: Prevents oil tempera-
ture from exceeding 475°F. When this con-
trol trips, the power to the unit will be shut
down. Turn unit OFF and DO NOT attempt
to operate until it has been serviced by an
authorized Broaster Company representa-
tive.
It is possible for this con-
trol to trip during ship-
ment. If it does, fully depress red reset
button. If control “clicks” it was tripped.
If not, it is correctly reset.
3. Touch Control Screen: Touching this
screen controls the many options of the
fryer.
On initial power up you may be asked to
enter the current date and time, and verify
the Serial Number. Or the screen will have
the word CAUTION flashing on the screen.
If the date and time entry screen appears
press the box after “Month” and a keypad
will appear. Enter the number of the month
broaster.com Manual #17280 1/15 Rev 6/15

3-2
This tab is the main working screen. From
this screen you can set the Cook Cycle
Time, Cook Temperature or select a Prod-
uct Preset.
CookTime Display:
The cook time is indicated in the box next
to the clock face. To change the time press
the time display twice and a keypad will
appear.
Enter the cook time for the product you are
cooking, as you enter the time it will appear
above the keypad. To save this time press
the enter key the new time will be entered
and the keypad will disappear.
If no entry is made or the enter key is not
pressed with in 25 seconds, no change is
made to the time.
When a cooking cycle is started the box
below the cook time turns yellow and
shows the amount of time remaining in the
cycle. The right box displays “CUSTOM”.
The word “CUSTOM” also replaces the
tabs across the top of the display. “CUS-
TOM” indicates you are in manual cooking
mode.
05:00
Auto Comp ON
At the end of the cycle the left box alter-
nates between red and white, the alert
sounds and continues until the exhaust
valve is opened by turning the small handle
on the countertop from “CLOSED” to
“OPEN”.
Auto Comp
In the upper right corner of the cook time
display is the Auto Comp indicator. It will be
black if Auto Comp is off and green if Auto-
Comp is on.
To turn Auto Comp on or off press the cook
time display twice. When the keypad
appears the Auto Comp toggle switch is in
the upper right corner of the keypad. If the
button is red Auto Comp is off, if it is green
Auto Comp is on. Press the Auto Comp
button to change it then press the enter key.
Our recommendation is that Auto Comp
should be on when cooking a load of prod-
uct.
Temperature Display:
The temperature is indicated next to the
thermometer.
When the fryer is turned on in the morning
this box will be yellow and “Heat On” will be
displayed. The temperature will alternate
between “LOW” and the set temperature
until the oil temperature reaches the set
temperature.
360F
Heat ONSet
COOK TAB
05:00
Auto Comp ON
360F
Heat ON Set
Select Preset Select Preset
01 Cycles Since Last Filtered
Cook Filter Setup Help
broaster.com Manual #17280 1/15 Rev 6/15

3-3
There are other times when this will occur;
1. Anytime the temperature is changed.
2. After a filtering cycle.
3.When a preset is selected and the oil tem-
perature is not at the preset temperature.
In any of these cases when the oil tempera-
ture reaches the set temperature the box
turns green indicating the oil is up to the set
temperature.
The temperature shown in this box can be
either the “Set” temperature or the “Actual”
temperature as indicated above the ther-
mometer. To change from one to the other
press and hold anywhere in the box for 3
seconds. An alert will sound when you
press the box and a second alert will sound
when the change is made.
To set the temperature, press the tempera-
ture box twice and a keypad will appear.
Enter the temperature for the product you
want to cook, as you enter the temperature,
it will appear above the keypad. To save this
temperature press the enter key.
Select Preset Display:
There are 2 “Select Preset” boxes.
All of the Broaster Company Products are
preloaded into the memory of the control
and can be selected when you want to
cook that product. The cook time and cook
temperature for that product will be auto-
matically entered in the Time and Tempera-
ture displays.
To select a product, press either preset box
and a menu of the products will be dis-
played. Tap the product you wish to select.
Select Preset
If the wrong product comes up, don’t worry!
Tap the preset box again and the menu will
reappear.
When the item has been selected a picture
of the item will appear in the left box and a
description of the item will appear in the
right box. When a cook cycle is started the
left box turns yellow and the time remaining
in the cycle is displayed. The picture moves
to the right box.
If the menu item to be cooked uses a differ-
ent temperature the temperature box will
either remain green meaning it is all right to
start a cook cycle or it will turn yellow
meaning the temperature is too low to start
a load. Wait to start a cook cycle until the
temperature is green.
When the temperature is green. Load the
product as recommended and move the
small handle on the top of the fryer from
open to close. This will start the cycle timer
counting down. When the load is done an
alert will signal that the cooking cycle is
complete.
Cycles Since Last Filtered:
It is recommended the oil should be filtered
every 5 loads.
This box indicates how many cook cycles
have been done since the last time the oil
was filtered. It is active and can be pressed
at any time to go to the filter display except
during a cooking cycle. Once you reach a
preset number of cycles, you will be shown
a filter options screen. If a filter cycle is
bypassed the next cycle will turn red and
start flashing.
This number can be changed and the pro-
cedure will be explained in the Setup Tab
section.
01
Cycles Since Last Filtered
broaster.com Manual #17280 1/15 Rev 6/15

3-4
This tab is the filter motor control and has
two buttons; a Start Pump button and an
Alert Silence button.
There are also two reminders to observe
before filtering the oil. SEE SECTION 9 -
COOKING OIL CARE AND FILTERING
before starting the pump motor.
When the Start Pump button is pressed the
filter running display appears as shown
below.
The timer in the middle of the screen starts
counting up. When it reaches 5:00 minutes
an alert sounds and a reminder flashes (see
below) to close the drain valve. To silence
the alert press the button with the speaker
on it. DO NOT press the Stop Pump button.
Stop
Pump
X
Start / Stop Filter Pump
Filter Pump Running
00:00
Press STOP PUMP after the oil is com-
pletely returned to the cooking well or you
can leave the pump running and it will auto-
matically stop when the counter says 10:00
minutes. See display below.
To return to the Cook Tab, press the red X in
the upper left corner. The Caution Display
will appear advising the oil level be
checked. If the oil level is OK press the
green OK button.
Stop
Pump
X
Start / Stop Filter Pump
Filter Pump Running
00:00
Close Drain Valve
Start
Pump
X
Start / Stop Filter Pump
Filter Pump Run Time
10:00
Limit Reached
FILTER TAB
Cook Filter Setup Help
* Check Filter Pan & Components
* Stir Oil Before Opening Drain Valve
Start
Pump
broaster.com Manual #17280 1/15 Rev 6/15