Broaster 2400 Service Manual
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Broaster 2400 Service Manual

Pressure fryer w/smarttouch
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See also: Service Manual , Operating Manual
SERVICE MANUAL
®
BROASTER
2400
PRESSURE FRYER w/SmartTouch
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.
Broaster Company
2855 Cranston Road, Beloit, WI 53511-3991
608/365-0193 broaster.com
Design Certified By:
© 2015 Broaster Company
Manual #17280 1/15 Rev 10/17
CSA & NSF
Printed In U.S.A.

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  • Page 1 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. Broaster Company 2855 Cranston Road, Beloit, WI 53511-3991 608/365-0193 broaster.com...
  • Page 3 OFF position, disconnect the power to If there is a power failure, turn cook/filter the fryer and contact your local Broaster switch OFF. On the Model 2400GH, also Company representative for service slide switch on gas valve OFF.
  • Page 4 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...

  • Page 5: Table Of Contents

    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...
  • Page 6 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...
  • Page 7 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...

  • Page 9: Warning Signs

    Broaster be sure all safety devices and warning signs Company representative or the Broaster are in place and legible. If not, the Broaster Company Service Department at: Company should be notified in writing of the lack of warning signs and the existence (608) 365-0193 of an unsafe condition.
  • Page 10 INSTALL IN ACCORDANCE WITH AMERICAN NATIONAL STANDARD FUEL GAS CODE ANSI Z223. 1 LATEST ADDITION Item 6 - Part #15694 2400GH Only Item 3 - Part #16368 BROASTER 2400GH Item 4 - Part #15398 Item 6 - 2400GH Only 15667 Natural Gas 17421 LP gas Item 5 - Part #10900 broaster.com Manual #17280 1/15...
  • Page 11 Item 13 - Part #11746 2400GH Only Item 10 - Part #11028 CAUTION Item 11 - Part #15725 CAUTION: DO NOT OPERATE THIS FRYER WITHOUT FILTER PAN & CLEAN COVER IN PLACE Item 9 - Part #15785 broaster.com Manual #17280 1/15...

  • Page 13: Electric Power Supply

    If no component operates, check main power supply. Be sure main circuit Wiring diagrams are located on inside front breaker is ON and main fuses are good. panel. WIRING DIAGRAMS: Three Phase Wiring: 2400E General Power broaster.com Manual #17280 1/15 Rev 6/15...
  • Page 14 2400E 208 or 240VAC: broaster.com Manual #17280 1/15...
  • Page 15 2400GH broaster.com Manual #17280 1/15...

  • Page 17: Control Panel

    If the date and time entry screen appears (Cook, Filter, Setup and Help) to help you press the box after “Month” and a keypad setup and use your fryer. will appear. Enter the number of the month broaster.com Manual #17280 1/15 Rev 6/15...
  • Page 18 The right box displays “CUSTOM”. temperature. The word “CUSTOM” also replaces the tabs across the top of the display. “CUS- TOM” indicates you are in manual cooking mode. broaster.com Manual #17280 1/15 Rev 6/15...
  • Page 19 It is active and can be pressed All of the Broaster Company Products are at any time to go to the filter display except preloaded into the memory of the control during a cooking cycle.
  • Page 20 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. broaster.com Manual #17280 1/15 Rev 6/15...
  • Page 21 Help Temperature Units: Degrees F Time & Date Adjustment Language Selection Temperature Alert Settings Energy Save Setting Pin Maintenance Presets Shortening Management Exit Setup Pressing the Degrees box switches the units. Then press OK. broaster.com Manual #17280 1/15 Rev 8/15...
  • Page 22 When the OK button is pressed the display returns to the normal Cook Tab display and the temperature will be yellow and Low and the set temp will be alternating. DO NOT start cooking until the temp display is green. broaster.com Manual #17280 1/15 Rev 6/15...
  • Page 23 You can quickly tell when a product is not Creating a new product or deleting a prod- active because the name and number of the uct on the list will be described later. item will be greyed out. broaster.com Manual #17280 1/15 Rev 6/15...
  • Page 24 Smart Touch Remove the flash drive from the USB port. control. This is done from the Preset tab using the Load Menu and Export Menu but- tons along the top of the display. broaster.com Manual #17280 1/15 Rev 6/15...
  • Page 25 Shortening Changed Today Keypad Volume: It should be loud enough to hear while making changes in front of the Shortening Last Changed: fryer or when operating the fryer. Unknown broaster.com Manual #17280 1/15 Rev 6/15...
  • Page 26 After making the adjustments on this dis- play press the green OK button to save the entries. To go back to the Cook display either press the “Exit Setup” button or the “Cook” Tab. 3-10 broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 27: Access For Service

    3. CLOSE pressure regulating valve. Check between remaining wire and terminal where other wire was discon- nected with an ohmmeter. Meter should indicate a closed circuit. If not, mounting bracket is out of adjustment or switch is faulty. broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 28: Control Rod

    Rod and remove Cover Interlock (9). 4. Remove E-Clip (10) which hold Control Rod to countertop. 5. Pull Control Rod straight up from countertop. Be sure to retain o-ring (11) to use at reassembly. broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 29: 2400Gh Pressure Fryer

    If not, trans- 1. See ACCESS FOR SEVICE. former is faulty. 4. Check between the two secondary wires with an ohmmeter. Meter should indicate a closed circuit. If not, trans- former is faulty. broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 30: 2400E Pressure Fryer

    Secondary Contactor (14). See ACCESS FOR SERVICE. Any great drop in voltage indicates a poor connection or dirty contact within Check oil level before the contactor. turning cook/filter switch to COOK. Connect main power supply. broaster.com Manual #17280 1/15 Rev 10/17...

  • Page 31: Fuse (2400E)

    See ACCESS FOR SERVICE. should indicate a closed circuit. If not, fuse may be faulty. Remove all wires from the contactor. Fuse Replacement: Remove two mounting screws. Remove contactor. Remove end cap (22) and replace fuse (21). broaster.com Manual #17280 1/15 Rev 10/17...

  • Page 32: Heating Element (2400E)

    Pull the panel straight down until the top of the panel is visible below the edge of the countertop. broaster.com Manual #17280 1/15 Rev 10/17...
  • Page 33 (26). 21. Be sure all wire connections are secure and in their original location. 15. Install new elements using new gas- kets (27) located between element and inside of the cooking well bulkhead. broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 34: Relay (2400E)

    5. With needle nose pliers, disconnect one wire from the coil terminals (Termi- nal 7 or 8). 6. Check between coil connections with an ohmmeter. Meter should indicate a closed circuit. If not, coil is faulty. broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 35: Cover, Yoke, & Lift

    5 - COVER, YOKE, AND LIFT FAMILIARIZATION broaster.com Manual #17280 1/15...

  • Page 36: Proper Cover Operation

    To CLOSE cover, lower cover, slide cover forward then rotate the handle (2) counter- clockwise. To OPEN cover, push down on cover handle then slowly rotate the handle clockwise. Slide cover toward the rear of the unit and raise cover. broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 37: Gas Springs

    With cover in CLOSED posi- tion, tighten each cover bolt a little at a time while alternating between the two. 4. Using a torque wrench, tighten each bolt to a maximum torque of 180 in/lbs or 15 ft/lbs. broaster.com Manual #17280 1/15 Rev 9/15...

  • Page 38: Cover And Yoke Removal

    Serious injury or damage to the unit may result. 3. Raise the cover to its full open position and place a solid support under the lift to keep it in raised position. broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 39: Cover And Yoke Disassembly

    6. Use a 1/8 inch punch to remove 14. Reassemble in reverse order. grooved pin. Remove handle and cam. 7. Clean lifter box, handle, cam and yoke bar where lifter box slides up and down. broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 40: Cover And Yoke Assembly

    5. Lubricate lifter box then install lifter box into the yoke bar. 6. Lower assembly over the cover (4) and spacer block (5). 7. Rotate cover handle to the CLOSED position. broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 41: Lift Removal

    (26) from the opposite cover mount block. DO NOT allow the lift hinge bar to be damaged. It may not allow the lift assembly to be reattached to the unit. 5. Reassemble in reverse order. broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 42: Slide Rod And Bearing Replacement

    3. Drive out old bearings using a bar 1/4” Dia. x 15” long. (See diagram below). 4. Install new bearings. 5. Reassemble in reverse order. broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 43: Pressure Gauge

    See PROPER COVER OPERATION. Keep away from safety relief valve opening with- out heat and steam protective apparel. Escaping steam could cause serious burns. Replacement: Replacement valve must have a 15 PSI relief pres- sure. broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 45: Pressure System

    Excess coating can collect in pressure regulating valve and exhaust tank. • Overfilling cooking well with oil: See operation manual for correct oil level. broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 46: Exhaust Drain Tube

    (1) is con- nected. Tank will then become filled with liquid. Liquid may be forced up the stack (3) when pressure is released at the end of a cooking cycle. broaster.com Manual #17280 1/15...

  • Page 47: Exhaust Tube

    Valve (7) is preset to maintain a maximum pressure of 12-14 psi during a cooking cycle. Pressure may build slowly or remain low when cooking small loads. Add one or two quartered potatoes with product to help build and maintain maximum pressure. broaster.com Manual #17280 1/15...
  • Page 48 Using a screwdriver, turn stem assembly (11) either clock- 7. Install new parts from the repair kit. wise or counterclockwise to obtain this Lubricate all O-rings and contacting distance. surfaces with olive oil. 10. Tighten locking nut. broaster.com Manual #17280 1/15...

  • Page 49: Main Burner System

    COOK. four components must be changed: gas Shut Down: valve, pilot burner orifice, main burner ori- fice and gas data plate. Notify Broaster 1. Turn power switch OFF. Company Service Department of a conver- sion in writing.

  • Page 50: Ventilation

    Adjustment for connections and pipes with a soap gas pressure and gas flow to pilot burner and water solution. Bubbles indicate a are also found on the valve. gas leak. broaster.com Manuals #17280 1/15 Rev 12/15...

  • Page 51: Gas Valve Power Check

    3. Install manometer. 4. Turn gas shut off valve (1) ON. 5. Turn gas valve switch (2) ON. Check cooking oil level before turning cook/filter switch to COOK. (continued) broaster.com Manuals #17280 1/15 Rev 12/15...
  • Page 52 If soot is present, DO NOT operate unit until all soot is removed and correction made. Soot is black and powdery to the touch. See COMBUSTION CHAMBER. 2. Drafts on floor can affect combustion. broaster.com Manuals #17280 1/15 Rev 12/15...

  • Page 53: Main Burner Flame Adjustment

    5. Replace the side panel. Loose venturi (11) or bad gasket (12) To get the best flame sev- can affect combustion. Tighten or eral adjustments, both up replace gasket. and down and front and back, may be necessary. broaster.com Manuals #17280 1/15 Rev 12/15...

  • Page 54: Main Burner Orifice

    Bubbles indicate a gas leak. 6. Loosen union elbow (5) and remove locknut (13). 7. Remove orifice holder and union elbow from mixer. 8. Remove main burner orifice (14). broaster.com Manuals #17280 1/15 Rev 12/15...

  • Page 55: Pilot Burner Orifice

    4. Pull 1/4” gas supply line (16) and brass fitting free of burner. 5. Remove orifice (17). 6. Install new orifice in reverse order. Check all gas connections with a soap and water solution. Bubbles indicate a gas leak. broaster.com Manuals #17280 1/15 Rev 12/15...

  • Page 56: Combustion Chamber

    11. Clean exhaust flue (19), inner jackets switch and manual gas shut off valve (20), outer walls (27) and cooking well OFF. (21). 2. Turn main gas supply OFF. 12. Assemble in reverse order. 3. Disconnect main electric supply. broaster.com Manuals #17280 1/15 Rev 12/15...

  • Page 57: Drain Valve And Filter System

    5. Remove nut mounting handle (4) to the drain valve (5). 6. Unscrew drain valve from the cooking well (6). 7. Assemble in reverse order using #15820 Primer & #15359 Sealant on cooking well threads. broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 58: Filter Pan

    Be sure filter components are assembled correctly. Correct order is filter screen (7) on bottom of filter pan, filter paper (8), filter ® hold-down (9), 3 cups of Broaster filtering compound on top of filter paper and cover (10) on filter pan.

  • Page 59: Check Valve

    4. Loosen fittings (13), remove return tube (21), remove pipe assembly (14) from pump. 5. Remove any fittings from the valve (15). 6. Install in reverse order using #15820 Primer & #15359 Sealant on pipe threads. broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 60: Motor

    2. Tighten three set screws in neck a little at a time, in sequence, around neck until tight. This will prevent any unnec- essary binding on shafts of the pump and motor. Continued next page broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 61: Pump

    The dots represent wire nuts. Wire 2400 pump motor as shown above. 3. Remove piping from pump (17). 4. Loosen three set screws (18) in neck of motor (16) which hold pump in place.
  • Page 62 1. Pour olive oil or cooking oil on gears and inside front cover bearing where gear shaft is installed. Turn gears by hand for good oil coverage. 2. Be sure cover O-ring is in place before tightening bolts. broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 63: Troubleshooting

    3. Replace Cooking oil temperature too 4. Faulty controller 4. Replace hot or too cold 5. Faulty temperature sensor probe 5. Replace 6. Faulty gas valve (2400GH) 6. Replace 7. Faulty element(s) (2400E) 7. Replace broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 64: Smart Touch Controller Tips

    Display reads Internal fault detected * Call for service * Call for service INTERNAL FAULT Display reads C1 contactor is stuck in * Call for service * Call for service the closed position C1 FAULT broaster.com Manual #17280 1/15 Rev 3/16...

  • Page 65: Gas Tips

    Dam- age to area in contact with o- ring can cause leaking under pressure or 0-ring failure. Cover won’t remain in raised 1. Weak gas spring 1. Replace position broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 66: Pressure System Tips

    7. Adjust adjustment 8. Faulty pressure gauge 8. Replace 1. Restriction in exhaust 1. Locate, remove then clean system Excess pressure 2. Overloaded with fresh 2. Decrease load product 3. Faulty pressure gauge 3. Replace broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 67: Product Tips

    1. Product stuck together 1. Float food basket while White spots on product while loading loading 2. Food basket overloaded 2. Decrease load size Dark spots on product 1. Dirty oil 1. Filter or replace broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 68: Frozen Iqf Chicken

    No flavor 2. Old product 2. Discard 1. Product stuck together 1. Float basket while load- White spots 2. Food basket overloaded 2. Decrease load size Dark spots 1. Dirty oil 1. Filter or replace broaster.com Manual #17280 1/15 Rev 6/15...

  • Page 69: Filtering Tips

    1. Filter paper improperly 1. See COOKING OIL CARE pumping when oil is level installed or crumbs under AND FILTERING with top of hold down, filter paper or hold down approximately 1 inch of oil in bottom broaster.com Manual #17280 1/15 Rev 6/15...
  • Page 71 SERVICE NOTES broaster.com Manual #17280 1/15...
  • Page 72 SERVICE NOTES broaster.com Manual #17280 1/15...
  • Page 73 SERVICE NOTES broaster.com Manual #17280 1/15...
  • Page 74 SERVICE NOTES broaster.com Manual #17280 1/15...
  • Page 76 Broaster Company 2855 Cranston Road, Beloit, WI 53511-3991 608/365-0193 broaster.com...

This manual is also suitable for:

2400gh2400e

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