Broaster 2400 Series User manual

Be sure ALL installers read, understand, and have access to this manual at all times.
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.
The Broaster Company
2855 Cranston Road, Beloit, WI 53511-3991
608/365-0193 broaster.com
Design Certified By:
CSA & NSF © 2014 the Broaster Company Printed In U.S.A.
15458 5/02 Rev 2/14
INSTALLATION MANUAL
BROASTER®2400
PRESSURE FRYER

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.
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.
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, 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.
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 #15458 5/02 Rev: 2/14

i
TABLE OF CONTENTS
1 - PRE-INSTALLATION ....................................................................................................1 - 1
LOCATION...................................................................................................................1 - 1
CLEARANCE...............................................................................................................1 - 1
USA & EU............................................................................................................1 - 1
Canada................................................................................................................1 - 1
LEVELING ...................................................................................................................1 - 1
RECOMMENDED VENTILATION REQUIREMENTS....................................................1 - 2
General Requirements ........................................................................................1 - 2
Hood Dimensions In Inches ................................................................................1 - 3
Hood Dimensions In Millimeters .........................................................................1 - 4
2 - FILTER PAN ASSEMBLY ..............................................................................................2 - 1
HARDWARE LIST........................................................................................................2 - 1
ASSEMBLY .................................................................................................................2 - 1
ADDITIONAL ADJUSTMENTS IF NEEDED.................................................................2 - 1
3 - INSTALLATION .............................................................................................................3 - 1
2400GH
GENERAL REQUIREMENTS.......................................................................................3 - 1
EU .......................................................................................................................3 - 1
US & Canada ......................................................................................................3 - 1
ELECTRICAL CHARACTERISTICS .............................................................................3 - 1
ELECTRICAL CONNECTIONS....................................................................................3 - 1
Wiring Diagrams..................................................................................................3 - 2
Domestic: 2400GH .......................................................................................3 - 2
Export: 2400GHXP .......................................................................................3 - 2
EU: 2400GHCE........................................................................................... 3 -2A
GAS CHARACTERISTICS...................................................................................3 - 3
BTU/HR Ratings..................................................................................................3 - 3
US & Canada............................................................................................3 - 3
EU.............................................................................................................3 - 3
Gas Pressure And Orifices ..................................................................................3 - 3
Gas Conversion ..................................................................................................3 - 3
USA & Canada .........................................................................................3 - 3
EU.............................................................................................................3 - 3
High Altitude .......................................................................................................3 - 3
GAS PIPING ................................................................................................................3 - 4
Unit Dimensions For Gas Hook-Up ....................................................................3 - 4
Example Of Piping System Design .....................................................................3 - 5
2400E
GENERAL REQUIREMENTS.......................................................................................3 - 6
ELECTRICAL CHARACTERISTICS .............................................................................3 - 6
ELECTRICAL CONNECTIONS....................................................................................3 - 6
2400E Suggested Wiring Capacity Table............................................................3 - 6
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ii
ELECTRICAL HOOK-UP .............................................................................................3 - 7
Access For Hook-up...........................................................................................3 - 7
Phase Wiring .......................................................................................................3 - 7
Unit Dimensions For Electrical Hook-up.............................................................3 - 7
Wiring Diagrams..................................................................................................3 - 8
Domestic: 2400E ..........................................................................................3 - 8
Export: 2400EXP ..........................................................................................3 - 9
EU: 2400ECE ..............................................................................................3 - 10
4 - OPERATIONAL CHECK-OUT ......................................................................................4 - 1
COVER ASSEMBLY ....................................................................................................4 - 1
INITIAL START-UP.......................................................................................................4 - 1
ELECTRIC ..........................................................................................................4 - 1
GAS ....................................................................................................................4 - 2
LIGHTING INSTRUCTIONS ........................................................................................4 - 2
Start-Up ..............................................................................................................4 - 2
Shut Down ..........................................................................................................4 - 3
MAIN BURNER FLAME ADJUSTMENT .............................................................4 - 3
broaster.com Manual #15458 5/02 Rev: 2/14

1 - PRE-INSTALLATION
1–1
LOCATION
For convenience and speed, location of the
unit should be given careful consideration.
If possible, locate the unit so the flow of
cooked product is in a straight line from
storage, in and out of the unit and to the
customer. Landing tables should be pro-
vided on at least one side of the unit.
• To avoid splashing of hot liquid, unit
must be restrained to prevent tipping.
This can be done by installing the unit in
a battery of appliances, in an alcove or
with adequate ties
• Provision must be made to eliminate
movement of the unit which might cause
strain on electrical and gas connections.
• DO NOT install unit where traffic areas
are on either side or in back of unit.
CLEARANCE
USA & EU:
Gas units are to be installed only in non-
combustible locations. Minimum clear-
ances for non-combustible construc-
tion is 0 inches from sides and 6 inches
from back.
CANADA:
Gas units are certified for installation on
a combustible floor. Minimum clear-
ances for combustible construction is 1
inch from sides and 6 inches from back.
LEVELING
Adjust front feet to level entire unit. Add
additional blocking if necessary on a slop-
ing floor.
broaster.com Manual #15458 5/02 rev 2/14

1–2
RECOMMENDED VENTILATION
REQUIREMENTS
Exhaust hood should comply with ANSI/
NFPA #96 or national, state and local
codes. All units must be under an adequate
power exhaust hood for ventilation of cook-
ing vapors and products of combustion.
Precautions should be taken in the design
of the exhaust hood to avoid interference
with operation of the unit. Consult a local
ventilation company for fire suppression,
design and installation of a hood.
DO NOT extend the
exhaust stack or exhaust
flue of any unit. Doing so may cause a neg-
ative back draft causing malfunction and
interference with burner operation on the
2400GH and improper exhausting of cook-
ing vapors on all models.
General Requirements:
1. Exhaust hood must conform to the
applicable national, state and local
codes in which it is installed.
2. In the absence of any such codes it is
recommended that requirements of
the National Fire Protection Associa-
tion (ANSI/NFPA), Standard No. 96 be
followed for the design, installation
and use of exhaust system compo-
nents. This includes hoods, grease
removal devices, exhaust ducts,
dampers, air moving devices, auxiliary
equipment and fire extinguishing
equipment for the exhaust system and
the cooking equipment used there-
with in commercial, industrial, institu-
tional and similar cooking applications.
3. Hood Size: The overhead canopy
type hood should be sized to com-
pletely cover the equipment it is
designed to ventilate plus an overhang
of at least 6 inches on all sides of
equipment not immediately adjacent
to walls or other construction extend-
ing above the cooking surface. Non-
canopy, prefabricated “backshelf”
type hoods should be sized according
to the manufacturers specifications.
4. Exhaust Air Volume (minimum):
Canopy hood open on all four sides:
1800 cu. ft./minute. Canopy hood
open on three sides or less: 1200 cu.
ft./minute.
5. Exhaust Air Velocity: All exhaust
ducts should be sized to provide an air
velocity in the ducts of at least 1500
ft./minute.
broaster.com Manual #15458 5/02 rev 2/14

1–3
Hood Dimensions In Inches:
broaster.com Manual #15458 5/02 rev 2/14
SAFETY AND OPE RATING INSTRUCTI ONS
BEFOR E OPER ATI NGCHECK OIL LE VELCAUT ION !
0
21
4
7
5
8
3
6
9
MAXI MU M WORK I NG
PRES SU RE 15 PSI
DANGER
NSF
CLOSED
OPEN

1–4
Hood Dimension In Millimeters:
broaster.com Manual #15458 5/02 rev 2/14

2 - FILTER PAN ASSEMBLY
2–1
HARDWARE LIST
(2) 00552 - Keps Nuts
(1) 15283 - Connector with ferrule
(3) 09883 - O-Ring
(1) 15559 - Riser Line
(2) 01596 - Washer
ASSEMBLY
1. From bag of hardware, install com-
pression nut then ferrule onto riser line
(1).
2. Install riser line onto pan. First install
line into fitting (2) on bottom center of
pan while the mounting plate fits over
studs (3) on front of pan.
3. Install washers and keps nuts onto
studs but do not tighten.
4. Tighten nut onto fitting (2).
5. Lubricate O-ring (4) with cooking oil.
Install O-ring into groove on riser line
(1).
6. Install filter pan under unit and align
riser line with suction line (5).
7. Tighten keps nuts mounting riser line
to filter pan.
8. See Operation Manual for additional
assembly.
ADDITIONAL ADJUSTMENTS
IF NEEDED
1. Loosen nut and bolt (6).
2. Push pan under unit. By hand, move
suction line (5) until riser line (1) is fully
inserted into suction line.
3. Tighten all nuts and bolts.
broaster.com Manual #15458 5/02 Rev 2/14

3 - INSTALLATION
3–1
2400GH
GENERAL REQUIREMENTS
• When installing or servicing the unit,
always check the dataplates, located
toward the rear of the countertop. This
will make certain proper parts are used
and the correct service rendered. DO
NOT apply a voltage to this unit other
than that shown on the dataplate. If in
doubt, consult your local power com-
pany.
• A remote circuit breaker or fuse should
be installed in main power supply
located in a path of exit and clearly iden-
tified.
• A gas shutoff valve, installed in gas sup-
ply line, should be located in a path of
exit and clearly identified.
• Keep burner area free and clear of all
combustible materials.
• DO NOT obstruct exhaust flue or open
area around bottom of unit at the front,
back and sides which would restrict the
flow of combustion and ventilation air.
• Consult a local ventilation company to
insure an adequate air supply for all gas
fired equipment.
•EU:
Installation must conform with
National and Local Codes of the country
in which installation is made.
• US & Canada: Installation must conform
with local codes, or in the absence of
local codes, with the National Fuel Gas
Code, ANSI Z223.1, Natural Gas Instal-
lation Code, CAN/CGA-B149.1, or the
Propane Installation code, CAN/CGA-
B149.2, as applicable.
• The unit and its individual shut-off valve
must be disconnected from the gas sup-
ply piping system during any pressure
testing of that system at test pressures
in excess of 1/2psi(3.45kPa).
• The unit must be isolated from the gas
supply piping system by closing its indi-
vidual manual shut-off valve during any
pressure testing of the gas supply piping
system at test pressures equal to or less
than 1/2psi(3.45kPa).
ELECTRICAL CHARACTERISTICS
The unit is available for 120VAC applied
voltage, 15 amp, 60Hz, 1 phase electrical
connection in the USA and Canada.
220VAC applied voltage, 50/60Hz, 1 phase
connection in the European Union.
• When installed, the unit must be electri-
cally grounded in accordance with local
codes, or in the absence of local codes,
with the National Electrical Code, ANSI/
NFPA 70, or the Canadian Electrical
Code, CSA C22.2, as applicable.
ELECTRICAL CONNECTIONS
• Applied voltage should match dataplate
listed voltage.
Electrical Grounding
Instructions - The unit is
equipped with a three-prong (grounding)
plug for your protection against shock haz-
ard and should be plugged directly into a
properly grounded three-prong receptacle.
DO NOT cut or remove grounding prong
from this plug.
broaster.com Manual #15458 5/02 Rev 2/14

3–2
Wiring diagrams:
GRAY
CONTROLLER
PROBE
SWITCH
START
JUMPER
F°-C°
XFRM
OUTPUT
POWER "ON" LIGHT
SPEAKER
HI-LIMIT
COOK
POWER SW
FILTER
OFF
BLUE
YELLOW RED
RED
RED
ORANGE ORANGE
GAS
VALVE
HEATER
120VAC 220VAC
120VAC 220VAC
24VAC
5VA
48VA 24VAC
12VAC
M
220V PURPLE
BLACK
GRAY
YELLOW
BROWN #2
BROWN #1
BLACK
BLACK
WHITE
240/480VAC
120/240VAC
COOK
BLACK PURPLE
BLACK
FILTER
POWER SW
OFF
JUMPER
RED
12VAC
RED
VALVE
GAS BLUE
HI-LIMIT
YELLOW
RED
START
SWITCH
CONTROLLER
B
ORANGE ORANGE
HEATER
OUTPUT
F°-C°
PROBE XFRM
24VAC
220VAC 120VAC
FILTER MOTOR
POWER "ON"
24VAC
220VAC 120VAC
48VA
GRAY
5VA
M
LIGHT
SPEAKER
WHITE
120VAC
MODEL 2400GH: DOMESTIC
MODEL 2400GHXP: EXPORT
broaster.com Manual #15458 5/02 Rev 2/14

3–3
ORANGE
ORANGE
CONTROLLER
SWITCH
POWER LIGHT
POWER
XFMR
HIGH BLOCK
TERMINAL
GAS
BLACK
BLUE
BROWN
YEL/GRN
CONTROL PANEL
HEAT OUT
NO C
NC
BROWN
CAPACITOR
TO IGNITOR
IGNITION MODULE
CONTROL BOX
WHI/ORG
WHI/PUR
BLACK
GREEN
13510 11 13 14
SENSOR
TO FLAME
16
VALVE
FILTER
MOTOR
BLUE
GRN/YEL
BLUE
PURPLE
GREEN
LIMIT
1
22
1
2
1
BLUE #1
BLUE #2
BROWN
PURPLE
24VAC
220VAC
BROWN GRAY
BLUE
BLUE
BLUE
BLUE
GRAY
BLUE
BLUE
POWER
INPUT
BOX
BLUE
GRAY
GRAY
50/60 Hz.
220VAC
MODEL 2400GHCE: EU
broaster.com Manual #15458 5/02 Rev 2/14

3–4
GAS CHARACTERISTICS
All gas units are tested using local gas sup-
ply. Your unit may or may not operate cor-
rectly on your type of gas. Therefore, the
unit should be checked and corrected if
necessary. See service manual.
DO NOT attempt to use
any other gas than that
specified on dataplate located on the front
panel.
BTU/HR Ratings:
US & Canada:
Natural Gas: 100,000
Propane: 100,000
EU:
G20: 26.4 KW gross
G31: 26.4 KW gross
Gas Pressure and Orifices:
• If adjustment of the regulator does not
deliver the correct BTU per hour or if
another type of gas is to be used, con-
tact your local gas supply company for
correct gas pressure and orifice sizing.
Maximum gas supply line pressure:
Natural (G20) Gas: 7” wc (20mbar)
Propane (G31) Gas: 14” wc (37 mbar)
Manifold pressure at test fitting:
Natural (G20) Gas: 4.0” wc (10 mbar)
Propane (G31) Gas: 10.0” wc (25 mbar)
Main burner orifice size:
Natural (G20) Gas: #14 (4.50mm)
Propane (G31) Gas: #32 (2.87mm)
Pilot burner orifice size:
Natural (G20) Gas: .018 (.46mm)
Propane (G31) Gas: .011 (.27mm)
Gas Conversion:
USA & Canada
• Contact your local Broaster Company
representative for converting from one
type of gas to another.
EU
• Units manufactured for use in the EU are
not convertible from one type of gas to
another.
High Altitude:
• For operation at elevations above 2,000
feet above sea level, gas input must be
reduced 4% for each 1,000 feet. Con-
tact your local Broaster Company repre-
sentative for correct orifice sizing.
broaster.com Manual #15458 5/02 Rev 2/14

3–5
GAS PIPING
• The unit is equipped with a 1/2” pipe for
gas connection. Shipped with each
unit, for 3/4” gas connection, is one
each of the following:
P/N 00743 - Bushing Hex Reducer
3/4 to 1/2
P/N 01319 - Coupling 3/4 Pipe
• 3/4 NPT minimum supply piping recom-
mended.
• Use only black steel pipe and malleable
fittings for gas connections.
• Pressure loss in the piping must not
exceed 0.3” W.C.
• Be sure gas supply piping is of the
proper size for the BTU input. Take into
consideration all other gas appliances
which must operate from the same gas
supply. Be sure piping will not interfere
with drain pails or valves.
• A compound resistant to the action of
liquified petroleum gas should be used
on the threads of gas supply piping
joints. Check all connections and pipes
with a soap and water solution. Bubbles
indicate a gas leak. DO NOT use an
open flame to check for gas leaks.
Unit Dimensions For Gas Hook-Up:
broaster.com Manual #15458 5/02 Rev 2/14

3–6
Example of Piping System Design:
Determine the required pipe size of each
section and outlet of the piping system
shown in Solution, with a designated pres-
sure drop of 0.30 inch water column. Gas
to be used has 0.60 specific gravity and a
heating value of 1,000 BTU per cubic foot.
Maximum capacity of pipe in cubic feet of
gas per hour (based upon a pressure drop
of 0.3 inch water column and 0.6 specific
gravity gas):
consumption (rating plate input or pipe cap. if necessary)
BTU of gas =
30,000 BTU per hour rating
1,000 BTU per cubic foot = 30 cubic feet per hour (30cfh)
Maximum gas demand for outlet B:
consumption
BTU of gas
Solution:
Maximum gas demand for outlet A:
=3,000
1,000 = 3cfh
Maximum gas demand for outlet C:
consumption
BTU of gas
75,000
1,000
== 75cfh
Maximum gas demand for outlet D:
consumption
BTU of gas
136,000
1,000
== 136cfh
Length
in
Feet
Nominal Iron Pipe Size, Inches
1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4
10 132 278 520 1,050 1,600 3,050 4,800 8,500 17,500
20 92 190 350 730 1,100 2,100 3,300 5,900 12,000
30 73 152 285 590 890 1,650 2,700 4,700 9,700
40 63 130 245 500 760 1,450 2,300 4,100 8,300
50 56 115 215 440 670 1,270 2,000 3,600 7,400
60 50 105 195 400 610 1,150 1,850 3,250 6,800
70 46 96 180 370 560 1,050 1,700 3,000 6,200
80 43 90 170 350 530 990 1,600 2,800 5,800
90 40 84 160 320 490 930 1,500 2,600 5,400
100 38 79 150 305 460 870 1,400 2,500 5,100
125 34 72 130 275 410 780 1,250 2,200 4,500
150 31 64 120 250 380 710 1,130 2,000 4,100
175 28 59 110 225 350 650 1,050 1,850 3,800
200 26 55 100 210 320 610 980 1,700 3,500
broaster.com Manual #15458 5/02 Rev 2/14

3–7
2400E
GENERAL REQUIREMENTS
• When installing or servicing the unit,
always check the dataplates, located
toward the rear of the countertop. This
will make certain proper parts are used
and the correct service rendered. DO
NOT apply a voltage to this unit other
than that shown on the dataplate. If in
doubt, consult your local power com-
pany.
• A remote circuit breaker or fuse should
be installed in main power supply
located in a path of exit and clearly iden-
tified.
ELECTRICAL CHARACTERISTICS
These models are available for either 208 or
240 applied voltage, 60Hz, 3 phase electri-
cal connection in the USA. 220 or 240
applied voltage, 50/60Hz, 3 phase connec-
tion in the European Union.
Be sure to check the wiring diagram located
inside the front panel. It shows electrical
circuits and connections. See Access For
Hook-Up under ELECTRICAL HOOK-UP.
• When installed, the unit must be electri-
cally grounded in accordance with local
codes, or in the absence of local codes,
with the National Electrical Code, ANSI/
NFPA 70, or the Canadian Electrical
Code, CSA C22.2, as applicable.
ELECTRICAL CONNECTIONS
• Use copper wire only for connections.
• If power run is over 50 feet, use next
larger size wire.
2400E Suggested Wiring Capacity Table:
Phase Volts Amps Wire Breaker
or Fuse
3 240 40 #8 50
3 208 42 #8 60
3 220/380 29.5 #8 40
3 230/400 25.2 #8 35
3 240/415 26.3 #8 35
broaster.com Manual #15458 5/02 Rev 2/14

3–8
ELECTRICAL HOOK-UP
Disconnect main power
supply and turn unit OFF
before installing power supply to the unit.
High voltage may be encountered. Only
persons trained and equipped for checking
high voltage shall perform electrical con-
nections.
Access For Hook-Up:
1. Disconnect main power supply.
2. Remove condensate pan and two
screws from bottom of front panel.
Pull out and down on bottom to
remove.
Phase Wiring:
Phase wiring diagram is located inside the
front panel.
Electric units are shipped from the factory
wired for 3 phase. In this case, applied
voltage must be connected to L1, L2 and
L3 of contactor C1 and a ground wire to the
GND connector.
Unit Dimensions For Electrical Hook-Up:
Note: Check all contactor screw connec-
tions to be sure they are fully tightened for
proper electrical continuity.
broaster.com Manual #15458 5/02 Rev 2/14