Broaster 2400 Series Service Manual
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Broaster 2400 Series Service Manual

Pressure fryer
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See also: Operating Manual , Installation Manual
SERVICE MANUAL
®
BROASTER
2400
PRESSURE FRYER
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:
© 2002 Broaster Company
Manual #15460 8/02 Rev 10/16
CSA & NSF
Printed In U.S.A.

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Summary of Contents for Broaster 2400 Series

  • 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 All adjustments and repairs shall be made If at any time the POWER by an authorized Broaster Company repre- ON light does not turn off sentative. when the cook/filter switch is moved to...
  • 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 #15460 8/02 Rev: 10/15...

  • Page 5: Table Of Contents

    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...
  • 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 #15460 8/02 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 #15460 8/02 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 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...
  • Page 11 Item 8 - Part #15725 CAUTION: DO NOT OPERATE THIS FRYER WITHOUT FILTER PAN & CLEAN COVER IN PLACE Item 9 - Part #15785 Item 10 - Part #16368 Item 11 - Part #11746 broaster.com Manual #15460 8/02 Rev 7/14...

  • Page 13: Electric Power Supply

    TROU- power supply. Be sure main circuit BLESHOOTING section. breaker is ON and main fuses are good. Wiring diagrams are located on inside front panel. WIRING DIAGRAMS: 2400E DOMESTIC 2400E EXPORT broaster.com Manual #15460 8/02 Rev 6/15...
  • Page 14 2400E 208 or 240VAC: broaster.com Manual #15460 8/02 Rev 7/14...
  • Page 15 2400E 208 or 240VAC: Effective SE4A700011 broaster.com Manual #15460 8/02 Rev 7/14...
  • Page 16 EXPORT: 2400EXP: 220/380 VAC to 240/415 VAC: broaster.com Manual #15460 8/02 Rev 7/14...
  • Page 17 EXPORT: 2400EXP: 220/380 VAC to 240/415 VAC: Effective SE4A700011 broaster.com Manual #15460 8/02 Rev 7/14...
  • Page 18 EU: 2400ECE 220/380VAC to 240/415VAC: broaster.com Manual #15460 8/02 Rev 7/14...
  • Page 19 EU: 2400ECE 220/380VAC to 240/415VAC: Effective SE4A700011 broaster.com Manual #15460 8/02 Rev 7/14...
  • Page 20 EU: 2400ECE 220/380VAC to 240/415VAC: Effective SE4F310031 broaster.com Manual #15460 8/02 Rev 7/14...

  • Page 21: Domestic

    MODEL 2400GH: DOMESTIC MODEL 2400GHXP: EXPORT broaster.com Manual #15460 8/02 Rev 7/14...
  • Page 22 MODEL 2400GHCE: EU 2-10 broaster.com Manual #15460 8/02 Rev 7/14...

  • Page 23: Control Panel

    13. Cycle Count Reset Button: Resets 6. Time Display: Shows time count- the cycle count display to “zero”. down during a cook cycle, program values during programming and pro- grammed time during idle period. broaster.com Manual #15460 8/02 Rev 6/16...

  • Page 24: Controller Programming

    “01”. Response: Programming mode has Normal operating programming can be been entered. Flashing Time Display done at any time without affecting presets. reads “##:##.” (##:## = time value ie: 08:00) broaster.com Manual #15460 8/02 Rev 6/16...
  • Page 25 Repeat the process as described. turn off and only the TIME display will After the presets for #9 are displayed, flash. pressing the RESET button again will cause the control to return to normal operation. broaster.com Manual #15460 8/02 Rev 6/16...

  • Page 26: Preset Cook Mode

    OFF. All controller functions and heat source are disabled during this condition. Cause: Faulty controller, heating ele- ment(s) (2400E Only) gas valve (2400GH Only), contactor (2400E Only), probe or loose wiring. broaster.com Manual #15460 8/02 Rev 6/16...

  • Page 27: Display Actual Temperature

    4. Check cooking oil temperature one inch below oil surface in the center of cooking well. 5. Using keypad, enter temperature to match controller display with calibrat- ing thermometer. 6. Press temp button to exit calibration. broaster.com Manual #15460 8/02 Rev 6/16...

  • Page 28: Access For Service

    Tilt panel down so back is visible. 1. Disconnect main power supply. 2. Remove condensate pan and screws from bottom of front panel. Pull out and remove front panel. broaster.com Manual #15460 8/02 Rev 7/14...

  • Page 29: Cook/Filter Switch

    3. Note where wires are connected. of switch is down. Be sure all wire con- Remove wires from control (3). nections are secure and in the original location. broaster.com Manual #15460 8/02 Rev 7/14...
  • Page 30 10. Reconnect wires then mount new con- trol. 11. Replace capillary guard. 12. Return cooking oil to cooking well. 13. Cook a load and check for leaks. 14. Tighten smaller nut (19) if necessary. broaster.com Manual #15460 8/02 Rev 7/14...

  • Page 31: Power On Indicator Light

    4. Install new light in reverse order. Be sure all wire connections are secure 4. Disconnect HEATER OUTPUT (N.O.) and in the original location. wires using needle nose pliers. 5. Disconnect START SWITCH wires using needle nose pliers. Continued: broaster.com Manual #15460 8/02 Rev 7/14...

  • Page 32: Temperature Sensor Probe

    3. OPEN cover. Drain cooking oil from cooking well. Close drain valve. 4. Remove capillary guard (18) inside of cooking well. 5. Loosen compression nut (25). 6. Remove fitting (26) from reducer fitting (20). 3-10 broaster.com Manual #15460 8/02 Rev 7/14...
  • Page 33 10. Carefully pull probe out of cooking well. 11. Install new probe in the same location as old probe. Slide guide (27) onto probe and assemble noting dimen- sions for locating probe (28). See Fig.1 below. 3-11 broaster.com Manual #15460 8/02 Rev 7/14...
  • Page 34 13. Tighten compression nut (25). sary. 14. Reconnect red and yellow wires (23). 15. Replace controller, front panel and condensate pan. 16. Replace capillary guard. 17. Return cooking oil to cooking well. Fig. 1 3-12 broaster.com Manual #15460 8/02 Rev 7/14...

  • Page 35: Power Input Box

    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 #15460 8/02 Rev 6/15...

  • Page 36: 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 #15460 8/02 Rev 6/15...

  • Page 37: 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 #15460 8/02 Rev 6/15...

  • Page 38: 2400E Pressure Fryer

    Secondary Contactor (14). Any great drop in voltage indicates a 1. See ACCESS FOR SERVICE. poor connection or dirty contact within the contactor. Check oil level before turning cook/filter switch to COOK. broaster.com Manual #15460 8/02 Rev 6/15...

  • Page 39: Fuse (2400E)

    If not, 2. Remove all wires from the contactor. fuse may be faulty. 3. Remove two mounting screws. Fuse Replacement: Remove contactor. 1. Remove end cap (22) and replace fuse (21). broaster.com Manual #15460 8/02 Rev 6/15...

  • Page 40: Heating Element (2400E)

    4. Pull the panel straight down until the top of the panel is visible below the edge of the countertop. broaster.com Manual #15460 8/02 Rev 6/15...
  • Page 41 (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 #15460 8/02 Rev 6/15...

  • Page 42: Relay (2400E)

    11. Check between coil connections with nal 2 with an ohmmeter. Meter should an ohmmeter. Meter should indicate a indicate a open circuit. If not, relay is closed circuit. If not, coil is faulty. faulty. broaster.com Manual #15460 8/02 Rev 6/15...

  • Page 43: Pre-Heat Relays (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 #15460 8/02 Rev 6/15...

  • Page 45: Cover, Yoke, & Lift

    5 - COVER, YOKE, AND LIFT FAMILIARIZATION broaster.com Manual #15460 8/02 Rev 9/14...

  • Page 46: 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 #15460 8/02 Rev 6/15...

  • Page 47: 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 #15460 8/02 Rev 9/16...

  • Page 48: 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 #15460 8/02 Rev 6/15...

  • Page 49: 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 #15460 8/02 Rev 6/15...

  • Page 50: Cover And Yoke Assembly

    6. Lower assembly over the cover (4) and spacer block (5). 7. Rotate cover handle to the CLOSED position. 8. Align holes in lifter box, spacer block and cover. broaster.com Manual #15460 8/02 Rev 6/15...

  • Page 51: 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 #15460 8/02 Rev 6/15...

  • Page 52: Slide Rod And Bearing Replacement

    3. Drive out old bearings using a bar 1/4” Dia. x 15” long. (See diagram). 4. Install new bearings. 5. Reassemble in reverse order. broaster.com Manual #15460 8/02 Rev 6/15...

  • Page 53: 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 #15460 8/02 Rev 6/15...

  • Page 55: 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 #15460 8/02 Rev 6/15...

  • Page 56: Exhaust Drain Tube

    (1) is con- 8. Assemble in reverse order. 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 #15460 8/02 Rev 9/14...

  • Page 57: Exhaust Tube

    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 #15460 8/02 Rev 12/14...
  • Page 58 (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 #15460 8/02 Rev 6/15...

  • Page 59: 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 60: 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 61: Flame Adjustments

    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 62 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 63: Main Burner Flame Adjustment

    To get the best flame sev- eral adjustments, both up 5. Loose venturi (11) or bad gasket (12) and down and right and left, may be nec- can affect combustion. Tighten or essary. replace gasket. broaster.com Manuals #15460 8/02 Rev 10/16...

  • Page 64: 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 65: 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 66: 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 67: 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 #15460 8/02 Rev 6/15...

  • Page 68: 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 69: Check Valve

    DO NOT tighten across the valve! Distor- tion of valve seat could occur. 2. When installing compression fittings on tubing, tighten nut finger tight then turn 1-1/4 turns more. broaster.com Manual #15460 8/02 Rev 12/14...

  • Page 70: 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 #15460 8/02 Rev 6/15...

  • Page 71: Pump

    (16) which hold pump in place. Remove pump. 5. Assemble in reverse order using #15820 Primer & #15359 Sealant on pipe threads. Installation Hints: 1. Loosen motor mounting bolts to help install piping. 2. See MOTOR Installation Hints. broaster.com Manual #15460 8/02 Rev 6/15...
  • Page 72 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 #15460 8/02 Rev 12/14...

  • Page 73: 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 #15460 8/02 Rev 6/15...

  • Page 74: Solid State Controller Tips

    7. Replace (2400GH) 8. Faulty gas valve (2400GH) 8. Replace 9. Faulty contactor (2400E) 9. Replace 10. Faulty heating element(s) 10. Replace (2400E) 11. Open or faulty wall fuse 11. Replace (2400GH & 2400E) broaster.com Manual #15460 8/02 Rev 3/16...

  • Page 75: 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 #15460 8/02 Rev 3/16...

  • Page 76: 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 #15460 8/02 Rev 3/16...

  • Page 77: 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 #15460 8/02 Rev 3/16...

  • Page 78: 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 #15460 8/02 Rev 3/16...

  • Page 79: 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 #15460 8/02 Rev 3/16...

  • Page 80: 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 #15460 8/02 Rev 3/16...
  • Page 81 This page intentionally left blank broaster.com Manual #15460 8/02 Rev 3/16...
  • Page 82 Temperature didn't rise 6 degrees in 3 minutes. Check controller, gas valve, wiring and connections. CHEC: Problem with temperature sensing. Check controller, probe, speaker. PROB: Internal fault detected or temperature fluctuation. Check controller or probe. FAIL: 9-10 broaster.com Manual #15460 8/02 Rev 3/16...
  • Page 83 Check for enough product Replace pump and high enough temperature. *Proper input gas pressure is below 7"WC for Natural Gas and below 14"WC for LP 9-11 broaster.com Manual #15460 8/02 Rev 3/16...
  • Page 84 Temperature didn't rise 6 degrees in 3 minutes. Check controller, C2, wiring and connections. CHEC: Problem with temperature sensing. Check controller, probe, speaker. PROB: Internal fault detected or temperature fluctuation. Check controller or probe. FAIL: 9-12 broaster.com Manual #15460 8/02 Rev 3/16...
  • Page 85 Replace C3 Remove Coil? Check switch faceplate & wiring from pump connections. and clean Replace motor parts. if necessary. Is applied voltage at Replace TDR TDR coil? Replace R3 Continued on next page 9-13 broaster.com Manual #15460 8/02 Rev 3/16...
  • Page 86 Blockage in Remove Does steam Replace Replace filter lines blockage or escape from cover Motor or check replace valve. around cover? o-ring valve? Check for Replace enough pump product and high enough temperature. 9-14 broaster.com Manual #15460 8/02 Rev 3/16...
  • Page 87 SERVICE NOTES broaster.com Manual #15460 8/02...
  • Page 88 SERVICE NOTES broaster.com Manual #15460 8/02...
  • Page 89 SERVICE NOTES broaster.com Manual #15460 8/02...
  • Page 92 Broaster Company 2855 Cranston Road, Beloit, WI 53511-3991 608/365-0193 broaster.com...

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