Broaster 2004E, Service Manual

Page 1: ...roasterie 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 ...

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Page 3: ...er 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 lo...

Page 4: ... 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 ...

Page 5: ...ING 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...

Page 6: ...ES 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...

Page 7: ...OUCH 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 ...

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Page 9: ...istence 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 608 365 0193 CAU TIO N BEFO RE OPE RA TI NG CHEC K OIL LE VEL 4 7 1 6 5 8 0 9 2 3 BEFORE OPERATING CHECK OIL LEVEL CAUTION 4 7 1 5 6 9 0 8 3 2 DO NOT OPERATE THIS FRYER WITHOUT FILTER PAN COVER IN PLACE CAUTION broaster ...

Page 10: ...ING 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 T...

Page 11: ...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 ...

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Page 13: ...rs 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 BLESHOOTIN...

Page 14: ...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 ...

Page 15: ...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 ...

Page 16: ...400EXP 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 ...

Page 17: ... 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 ...

Page 18: ... 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 ...

Page 19: ...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 ...

Page 20: ...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 ...

Page 21: ...2 9 MODEL 2400GH DOMESTIC MODEL 2400GHXP EXPORT broaster com Manual 15460 8 02 Rev 7 14 ...

Page 22: ...2 10 MODEL 2400GHCE EU broaster com Manual 15460 8 02 Rev 7 14 1 2 2 1 2 1 ...

Page 23: ...lating valve is CLOSED 6 Time Display Shows time count down during a cook cycle program values during programming and pro grammed time during idle period 7 Temp Display Shows set tempera ture and actual temperature on demand 8 Cook Temperature Button Initiates temperature programming and dis play actual temperature 9 Cook Time Button Initiates time pro gramming 10 Numerical Keypad Enters and adjus...

Page 24: ...se Programming mode has been entered Flashing Time Display reads time value ie 08 00 Action If desired press key pad numbers to change displayed value in minutes and seconds Press Cook Time Button once to enter new value into memory Response Controller returns to idle mode Set AUTO COMP Automatic Time Com pensation Action Press and hold AUTO COMP Button for 3 seconds Response Green light will togg...

Page 25: ...esponse The TEMP display will turn off and only the TIME display will flash Action Key in the desired cook time and press the TIME button to save the new setting If a button is not pressed in ten seconds the dis play will revert back to both the TIME and TEMP displays flashing Change Cook Temperature Action Press the TEMP button once Response The TIME display will turn off and the TEMP display wil...

Page 26: ...isabled during this condition Cause Temperature sensor prove faulty polarity of probe wires reversed or probe wire s loose CHEC Display will flash CHEC if cooking oil temperature does not rise 6 F within the first three minutes Audible alert will sound until cook filter switch is turned OFF All controller functions and heat source are disabled during this condition Cause Faulty controller heating ...

Page 27: ...oughly heat cooking oil When HEAT ON light goes out stir oil If HEAT ON light comes on allow unit to recover until light goes out This may have to be done several times 2 Press and hold cook temperature but ton for ten seconds until OFF then SET is displayed twice Release button 3 Uncalibrated cooking oil temperature is displayed Calibration must be per formed 4 Check cooking oil temperature one i...

Page 28: ...power supply 2 Remove condensate pan and screws from bottom of front panel Pull out and remove front panel 3 Remove screws holding controller 17 to the power input box Tilt panel down so back is visible broaster com Manual 15460 8 02 Rev 7 14 ...

Page 29: ...ew switch in reverse order Be sure small groove in threaded portion of switch is down Be sure all wire con nections are secure and in the original location HI LIMIT CONTROL When controller opens all controls are dis abled except the filter motor There are two ways to determine if the con trol is faulty Control open at cooking temperature Check cooking oil temperature 1 inch below oil surface in ce...

Page 30: ...oking well Bend in capillary must be large and smooth as possible 8 Install large capillary nut securely after applying teflon tape on threads 9 Install small capillary nut finger tight then tighten 1 4 turn with a wrench DO NOT over tighten Capillary may collapse or be cut in two 10 Reconnect wires then mount new con trol 11 Replace capillary guard 12 Return cooking oil to cooking well 13 Cook a ...

Page 31: ...D STATE CONTROLLER The controller regulates time and tempera ture Miscellaneous Remove F C jumper to display temperature in Celsius Replacement Note Within warranty controller should be replaced as a whole circuit board trans former speaker and control panel Out of warranty transformer and speaker are available separately 1 See ACCESS FOR SERVICE 2 Remove cook filter switch 3 Remove power on indic...

Page 32: ...rees of temperature Replacement 2400GH 1 See ACCESS FOR SERVICE 2 Disconnect probe 23 wires 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 7 Remove reducer fitting 20 from out side cooking well 8 Carefully pull probe 24 out of cooking well 9 Install new pro...

Page 33: ...king well Close drain valve 4 Remove capillary guard 18 inside of cooking well 5 Remove basket guide 27 inside of cooking well 6 Slide item 27 off of Temperature Sen sor probe 28 Note where probe bend is located Placement is important 7 Loosen compression nut 25 8 Remove fitting 26 from reducer fitting 20 9 Remove reducer fitting 20 from out side of the cooking well 10 Carefully pull probe out of ...

Page 34: ...pe 13 Tighten compression nut 25 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 18 See CALIBRATION 19 Cook a load and check for leaks 20 Tighten compression nut 25 if neces sary Fig 1 broaster com Manual 15460 8 02 Rev 7 14 ...

Page 35: ...g 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 Timer Switch Adjustment 1 See ACCESS FOR SERVICE 2 With pliers bend mounting bracket 2 closer or further away from control rod Timer Switch Replacement 1 See ACCESS FOR SERVICE 2 Remove wires fr...

Page 36: ... Drain Valve Interlock 4 by removing screw 5 and nut 6 2 Remove Bridge Pin 7 from Control Rod just below countertop 3 Pull Button Pin 8 from top of Control 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: ...e primary black and white wires side and sec ondary yellow and blue wires side of the transformer 3 Check between the two primary wires with an ohmmeter Meter should indi cate a closed circuit If not trans 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 2400GH Pressure Fryer broaster com Manual 15460 8 0...

Page 38: ...is controlled by the preheat relay circuit 1 See ACCESS FOR SERVICE Check oil level before turning cook filter switch to COOK 2 Connect main power supply 3 Turn cook filter switch to COOK You should hear an audible snap followed by another shortly after the first 4 Check voltage through Primary Con tactor 13 using a voltmeter For three phase check across any two of three connections Meter should i...

Page 39: ...tri cally check coil 20 with an ohmme ter With needle nose pliers disconnect wire s from one side of the coil Meter should indicate a closed circuit If not coil is faulty Contactor Replacement 1 See ACCESS FOR SERVICE 2 Remove all wires from the contactor 3 Remove two mounting screws Remove contactor 4 Install new contactor in reverse order Be sure all wire connections are secure and in their orig...

Page 40: ...ar of the panel that screws up into the frame from the bottom edge of the panel 4 Pull the panel straight down until the top of the panel is visible below the edge of the countertop 5 Separate the rear edge of the panel from the frame then push the panel forward off of the front of the frame 6 Remove the control rod SEE CON TROL ROD REMOVAL page 4 2 7 Remove the solid state control panel 8 Remove ...

Page 41: ...lide ele ment out lift and rotate on end to remove 15 Install new elements using new gas kets 27 located between element and inside of the cooking well bulkhead 16 Loosely attach basket guides 25 and capillary guard 26 17 Apply bead of 94622 Silicone to threads of element at the bulkhead fit ting 18 Loosely attach washers 19 and large nuts 18 19 Tighten large nuts 18 20 Tighten basket guides 25 an...

Page 42: ...termi nal 2 with an ohmmeter Meter should indicate a open circuit If not relay is faulty 1 3 6 5 2 4 5 With needle nose pliers disconnect one wire from the coil terminals Termi nal 1 or 3 6 Check between coil connections with an ohmmeter Meter should indicate a closed circuit If not coil is faulty Relay Effective S N SE4A700011 7 With needle nose pliers disconnect wire from terminal 1 8 Check betw...

Page 43: ...ohmmeter Meter should indicate a closed circuit If not coil is faulty TDR RELAY The TDR relay controls the power to the C3 contactor When the oil temperature has reached set point and the HEAT ON light goes out for 10 seconds or more the TDR relay is faulty if the C3 contactor does not energize when the HEAT ON light is illumi nated again 1 See ACCESS FOR SERVICE 2 With needle nose pliers disconne...

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Page 45: ...5 COVER YOKE AND LIFT 5 1 FAMILIARIZATION broaster com Manual 15460 8 02 Rev 9 14 ...

Page 46: ...ced Always fully rotate cover handle 2 OPEN or CLOSED 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 When the cover is raised the gas springs 17 compensate for the weight of the cover and lift assembly This reduces the fo...

Page 47: ... steam leaks and keeping O ring wear to a mini mum It is important warning sign 8 be placed back into its original position and screw replaced after making this adjustment If this sign becomes worn or illegible it must be replaced immediately 1 Remove screw from left side of warn ing sign 8 and swing out toward the right 2 Loosen but do not remove two cover bolts 12 in top of splash shield 10 3 Op...

Page 48: ...p on cover until the two outer gas springs are at their full extension While holding the cover up pop them off the ballstuds at the large end of both springs Then raise the cover fur ther until the center gas spring is at its full extension and pop it off also 7 Lower cover to the support block holding it in the up position When performing the next step be extremely careful so that the support doe...

Page 49: ... order COVER AND YOKE DISASSEMBLY 1 Remove two cover bolts 12 2 Lift yoke bar up The cover 4 and spacer block 5 will remain 3 Remove lifter box 13 4 Rotate cover handle to the OPEN position 5 Locate grooved pin 14 hole in the flat of the cam 3 Be sure to note how the handle and cam are removed Use a stiff wire to tie the han dle and cam together after removal 6 Use a 1 8 inch punch to remove groov...

Page 50: ...nstall 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 8 Align holes in lifter box spacer block and cover 9 Install new cover bolts but do not tighten Bolts will be tightened when centering cover at reassembly see Centering Cover under ADJUSTMENTS CHECK CAM OPERATION When handle is rotated cam 3 moves cover 4 in or out ...

Page 51: ... the cover mount block 22 toward the outside of the unit 4 Slide the lift assembly toward the out side of the unit thereby disengaging the lift hinge bar 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: ...from the lift assembly 20 DO NOT allow the sliding rod bar to be damaged It may not be able to be reinserted into the lift assembly 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: ... or attempt to repair this valve 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 1 OPEN the pressure regulating valve then the cover 2 Unscrew valve 1 from the cover DO NOT install valve dis charge opening in the direction of fo...

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Page 55: ...the pressure system to become faulty Overfilling cooking well with oil See operation manual for correct oil level Overloading basket with product Oil level will raise too high Breading then dropping Excess coat ing can collect in pressure regulating valve and exhaust tank See operation manual for coating instructions Opening pressure regulating valve quickly at the end of a cooking cycle Excess co...

Page 56: ...ooking cycle Cleaning 1 Remove exhaust drain tube 1 from bottom of the tank 2 2 Remove three screws from the stack 3 which mounts tank to the unit 3 Remove Exhaust tube 4 from end of tank and pull tank away from the frame 4 Loosen two latches holding cover 3 to the tank then remove cover Remove rubber grommet 6 on end of the muffler Set the tank in a sink and clean thoroughly 5 Inspect gasket Repl...

Page 57: ...otatoes with product to help build and maintain maximum pressure Replacement 1 Disconnect main electric power sup ply 2 Slide right hand squeeze clamp on valve outlet to the left 3 Pull silicone sleeve and exhaust tube 4 free of valve outlet 4 Remove two allen screws mounting valve to the cooking well and remove valve 5 See Repair 6 Install silicone sleeve and exhaust tube onto the valve outlet 7 ...

Page 58: ...a mild detergent 7 Install new parts from the repair kit Lubricate all O rings and contacting surfaces with olive oil 8 Mount valve assembly back on cook ing well with the allen screws With open end of yoke pointing to the left 9 With control arm in the CLOSED position a distance of 1 16 should be maintained between the control yoke 10 and control rod While locking nut 9 is loose adjust distance i...

Page 59: ...t burner orifice main burner ori fice and gas data plate Notify Broaster Company Service Department of a conver sion in writing LIGHTING INSTRUCTIONS Start Up 1 Turn power switch OFF 2 See OIL LEVEL in the operation man ual 3 Turn gas shut off valve 1 ON Wait five minutes before turning gas control ON 4 Slide switch 2 on top of gas valve to ON The unit has an intermit tent pilot burner This type o...

Page 60: ...on the valve Replacement 1 Turn power switch manual gas shut off valve 1 and switch 2 OFF 2 Turn main gas supply OFF 3 Disconnect main electric supply 4 Remove condensate pan and front panel 5 Disconnect gas valve wire harnesses 3 6 Loosen fitting 4 that mounts pilot burner gas supply line to gas valve 7 Loosen brass union elbow 5 8 Loosen pipe union 6 9 Remove piping from gas valve Be sure pilot ...

Page 61: ...ure after a new gas valve installation Check pressure when other gas equipment is also operating This will ensure adequate pressure during peak operating times There is a pressure tap in output side of the gas valve for manometer hook up Correct output gas pressures in Water Column are Natural G20 Gas 4 0 wc 10mbar Propane G31 Gas 10 0 wc 25mbar 1 Turn power switch manual gas shut off valve 1 and ...

Page 62: ...w 10 2 Adjust flame and replace screw Main Burner Flame Flame must be blue and sit on the burner surface During normal operation a slight whoosing sound may be heard when burner shuts off If you cannot adjust the flame correctly check the following 1 Centered main burner orifice After installing a new gas valve or piping brackets can shift causing gas not to travel down center of the venturi A bad...

Page 63: ...e support bracket 2 While observing the flame slowly slide the gas pipe from front to back in the support bracket When the flame is as blue as it can get re tighten the clamps on each side of the support bracket to hold the pipe in position Is the flame blue and settled on the face of the burner If it is no further adjust ment is necessary otherwise continue 3 Remove the LH side panel 4 Using an a...

Page 64: ... Remove condensate pan 5 Facing the front of unit remove left and side panel if possible 6 Loosen union elbow 5 and remove locknut 13 7 Remove orifice holder and union elbow from mixer 8 Remove main burner orifice 14 9 Assemble in reverse order Check all connections and pipes with a soap and water solution Bubbles indicate a gas leak broaster com Manuals 17280 1 15 Rev 12 15 ...

Page 65: ...alve switch and manual gas shut off valve OFF 3 Loosen brass fitting 15 from pilot burner 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: ...us burns Cleaning 1 Turn cook filter switch gas valve switch and manual gas shut off valve OFF 2 Turn main gas supply OFF 3 Disconnect main electric supply 4 Remove condensate pan 5 Remove left and right hand side pan els 6 Remove exhaust flue mounting screws 22 from combustion chamber Remove upper mounting nuts inside upper flue opening and remove flue 19 7 Remove outer wall clamp 23 8 Remove scr...

Page 67: ...burns Replacement 1 Disconnect main electric supply 2 Remove filter pan from under the unit Drain cooking oil from cooking well into a container made for handling hot oil 3 Remove splash disc 21 and bushing 22 2400GH only 4 Remove nut 1 screw 2 and interlock 3 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 P...

Page 68: ...per 8 filter hold down 9 3 cups of Broaster filtering compound on top of filter paper and cover 10 on filter pan Preventive Maintenance 1 Use a clean cloth or paper towel to wipe crumbs from filter hold down and the filter pan interior before replacing filter paper This will help prevent crumbs from causing a poor seal or entering the riser line 11 and pump 2 Be sure the O ring 12 is in good con d...

Page 69: ...ain cooking oil from the cooking well and into a container made for handling hot oil then close the drain valve 3 Remove left hand side panel 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 Installation hint 1 When installing a fitting or pipe nipple into...

Page 70: ... ply 2 Disconnect conduit wires and conduit from the motor 3 Loosen three set screws 18 in neck of motor 16 which hold pump in place 4 Remove motor mounting bolts and remove motor 5 Install in reverse order Installation Hints 1 Be sure pump is fully installed into the motor neck before tightening set screws 2 Tighten three set screws in neck a little at a time in sequence around neck until tight T...

Page 71: ...main electric power sup ply 2 Drain cooking oil from cooking well into a container made for handling hot oil and close drain valve 3 Remove piping from pump 17 4 Loosen three set screws 18 in neck of motor 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...

Page 72: ...ean gears and covers 5 Replace O ring and shaft seal if neces sary 6 Install in reverse order using 15820 Primer 15359 Sealant on pipe threads Reassembly Hints 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 ...

Page 73: ...r controller 3 Faulty temperature control 1 Exit program mode 2 Replace controller 3 Replace Hi limit will not reset 1 Cooking oil temperature too high 2 Faulty hi limit 1 Allow oil to cool approxi mately 100 F 2 Replace Heating element s won t heat 1 Controller in program mode 2 Faulty element s 3 Faulty contactor 1 Exit program mode 2 Replace 3 Replace Cooking oil temperature too hot or too cold...

Page 74: ...reads CHEC 1 Gas valve OFF 2400GH 2 Low gas pressure 2400GH 3 Poor air gas mix 2400GH 4 Main burner not on 2400GH 5 Pilot does not light 2400GH 6 Loose gas valve wire har ness 2400GH 7 Faulty flame sensor 2400GH 8 Faulty gas valve 2400GH 9 Faulty contactor 2400E 10 Faulty heating element s 2400E 11 Open or faulty wall fuse 2400GH 2400E 1 Turn ON 2 Check pressure 3 Adjust air shutter 4 See GAS TIPS...

Page 75: ... it again until it moves to the lower left corner then touch it again until it disappears Controller will reboot Call for service Display doesn t respond when touched Display reads PROBE FAULT Probe circuit is open or shorted Probe wires are connected in reverse Temperature changes more than 100F in two seconds Call for service Call for service Display reads HI TEMP FAULT Temp reaches 415F Call fo...

Page 76: ...and O ring dry or dirty 2 Hard O ring 3 Teflon bearing out of adjustment or worn 4 Cover not centered 5 Lifter box dirty or dry 1 Clean and lubricate 2 Replace 3 Adjust or replace 4 Center 5 Clean and lubricate Cover won t OPEN Never use force to OPEN cover 1 O ring groove and O ring dry or dirty 2 Pressure not released 3 Pressure regulating valve out of adjustment 1 Clean and lubricate 2 OPEN pre...

Page 77: ...or blocked open 3 Leaks around cover O ring 4 Cover cold 5 Low cooking oil temperature 6 Faulty safety relief valve 7 Pressure valve out of adjustment 8 Faulty pressure gauge 1 CLOSE 2 Use repair kit 3 Replace O ring and center cover 4 Pre heat cover 5 Check programmed temperature 6 Replace 7 Adjust 8 Replace Excess pressure 1 Restriction in exhaust system 2 Overloaded with fresh product 3 Faulty ...

Page 78: ...ng 5 Dirty cooking oil 1 Check cook temperature 2 Decrease time 3 Check procedures 4 Rinse then recoat 5 Filter or replace Product not done 1 Low cooking oil temperature 2 Food basket overloaded 3 Cook time too short 4 Frozen product 1 Check cook temperature 2 Decrease product load 3 Increase cook time 4 Increase cook time No flavor 1 Improper marination 1 Check procedures White spots on product 1...

Page 79: ...emperature 2 Decrease cook time 3 Change oil 4 Keep product at 0 F or below Product not done 1 Low oil temperature 2 Food basket overloaded 3 Cook time too short 1 Check cook temperature 2 Decrease load 3 Increase cook time No flavor 1 Overcooked 2 Old product 1 Check cook time 2 Discard White spots 1 Product stuck together 2 Food basket overloaded 1 Float basket while load ing 2 Decrease load siz...

Page 80: ...e motor Motor starts but will not pump 1 Filter pan not completely installed 2 O ring on riser line not installed 3 Solidified shortening in piping or filter pan 1 Firmly push filter pan in 2 See FILTERING 3 Turn cook filter switch OFF Contact service person Motor starts but will not pump or stops at any level 1 Filter paper or hold down improperly installed 2 Not using enough Broaster filtering c...

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Page 82: ...Transformer Replace Controller Is 24VAC present at valve blue and red wires 1 Is manual shut off open Open and try again Did Burner stay on when Heat On light was off Plug in new ignitor Does it glow 2 Replace Controller Was 24VAC present at red and blue wire Replace gas valve Replace Controller Does pilot flame ignite Is Power On Light On Does Filter Motor work Is Proper power applied Does Contro...

Page 83: ...lame ignite Does ignitor stop glowing once pilot is lit Replace ignitor problem solved Replace gas valve Can you use slot in back of motor to get it started Separate pump from motor Still humming Remove face plate from pump and clean parts Replace motor No Problem Replace gas valve Does steam escape around cover Replace pump Check for enough product and high enough temperature Rebuild pressure val...

Page 84: ...troller Does C2 close W Heat On light Was applied voltage present at coil Replace R3 Reset and Monitor Replace C2 Check controller and Temp Sensor Probe Replace R2 Does C2 and Controller chatter Is applied voltage at C2 coil Is applied voltage at R3 coil Replace Controller Did C2 stay closed when Heat On light was off Are fuses Blown Is proper power applied Monitor Repair Replace C2 Start Over Is ...

Page 85: ... necessary Reset Can you use slot in back of motor to get it started Separate pump from motor Still humming Is thermal overload tripped Remove faceplate from pump and clean parts Is applied voltage at TDR coil Is applied voltage at C3 Coil 3 4 Does filter motor run Is motor humming Replace R3 Replace C3 Replace TDR Does bottom element heat Does top element start heating Check element and connectio...

Page 86: ...ape from around cover Check o ring and filter pan assembly Is suction present at filter line Blockage in filter lines or check valve Remove blockage or replace valve 2 Check for enough product and high enough temperature Does pressure build properly Replace cover o ring Does oil pump 3 4 No Problem Replace Motor Replace pump broaster com Manual 15460 8 02 Rev 3 16 ...

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Page 92: ...Broaster Company 2855 Cranston Road Beloit WI 53511 3991 608 365 0193 broaster com ...