Broaster 1600 Service Manual Download Page 115

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11-2

CONTROLLER TIPS (SOLID STATE)

COMPLAINT

CAUSE

REMEDY

Display reads FAIL

1. Faulty controller

1. Replace

Display reads HI

1. Faulty gas valve
2. Faulty contactor

1. Replace
2. Replace

Display reads PROBE

1. Wire polarity reversed
2. Faulty temperature sensor

probe

1. Rewire
2. Replace

Display reads CHEC

1. Gas valve OFF (1800GH)
2. Low gas pressure

(1800GH)

3. Poor air/gas mix (1800GH)
4. Main burner not on

(1800GH)

5. Loose gas valve wire

harness (1800GH)

6. Faulty flame sensor

(1800GH)

7. Faulty gas valve (1800GH)
8. Faulty contactor

(1600/1800E)

9. Faulty heating element(s)

(1600/1800E)

10. Open or faulty wall fuse

11. Pilot does not light

1. Turn ON
2. Check pressure

3. Adjust air shutter
4. See 5, 6, 7,8 and 11

5. Check connections

6. Replace

7. Replace
8. Replace

9. Replace

10. Check wall fuse or circuit

breaker

11. See GAS TIPS (1800GH)

broaster.com Manual #14680 3/99 Rev 5/14

Summary of Contents for 1600

Page 1: ... 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 Be sure ALL installers read understand and have access to this manual at all times SERVICE MANUAL BROASTER 1600 AND 1800 PRESSURE FRYER Manual 14680 3 99 Rev 9 14 ...

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Page 3: ...ations 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 papers contain ing cooking oil can catch fire if exposed to heat Laundering will ...

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Page 5: ...0GH 2 10 EXPORT 1600XP 1800EXP Mechanical 2 11 1600XP 1800EXP Solid State 2 15 1800GHXP 2 18 EU 1600CE Mechanical 2 19 1600CE 1800ECE Solid State 2 20 1800GHCE 2 21 United Kingdom 1600UK 1800EUK 2 22 1800GHUK 2 23 480V Units 1800E 480V Δ 2 24 1600XP 240 480V 2 25 1800XP 480V 2 27 3 1600 MECHANICAL CONTROL PANEL 3 1 FAMILIARIZATION 3 1 ACCESS FOR SERVICE 3 2 INDICATOR LIGHTS 3 3 COOK FILTER SWITCH ...

Page 6: ...ATURE SENSOR PROBE 4 12 5 POWER INPUT BOX 5 1 1600 1800E CONTACTORS 1600 1800E 5 2 FUSE 1600 1800E 5 3 HEATING ELEMENTS 1600 1800E 5 3 LIMIT SWITCH 5 5 RELAY 1600 1800E 5 6 1800GH TRANSFORMER 1800GH 5 7 1800GHCE IGNITION CONTROL 5 8 1800GHUK iGNITION CONTROL 5 9 TRANSFORMER 5 10 RELAYS 5 10 6 COVER AND YOKE 6 1 PROPER COVER OPERATION 6 1 FAMILIARIZATION 6 2 ADJUSTMENTS 6 3 REMOVAL 6 4 DISASSEMBLY ...

Page 7: ... 3 AIR SHUTTER 9 5 COMBUSTION CHAMBER 9 5 MAIN BURNER ORIFICE 9 7 PILOT BURNER ORIFICE 9 8 10 DRAIN VALVE AND FILTER SYSTEM 10 1 DRAIN VALVE 10 1 FILTER PAN 10 2 CHECK VALVE 10 3 MOTOR 10 4 PUMP 10 6 11 TROUBLESHOOTING 11 1 ELECTRICAL TIPS 11 1 CONTROLLER TIPS SOLID STATE 11 2 GAS TIPS 1800GH 11 3 COVER AND YOKE TIPS 11 3 PRESSURE SYSTEM TIPS 11 4 PRODUCT TIPS 11 5 FILTERING TIPS 11 7 FLOW CHART 1...

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Page 9: ...er Company should be notified in writing of the lack of warning signs and the existence of an unsafe condition If you need replacement warning signs or manuals contact an authorized Broaster Company representative or The Broaster Company Service Department at 608 365 0193 CAUTION broaster com Manual 14680 3 99 Rev 5 14 1600 Domestic and CE Labeling ...

Page 10: ...1 2 1600 French Canadian Labeling CAUTION broaster com Manual 14680 3 99 Rev 5 14 ...

Page 11: ...1 3 1800 Domestic and CE Labeling CAUTION CAUTION broaster com Manual 14680 3 99 Rev 5 14 ...

Page 12: ...1 4 1800 French Canadian Labeling CAUTION CAUTION broaster com Manual 14680 3 99 Rev 5 14 ...

Page 13: ...1 5 Item 1 Part 10733 Item 3 Part 10886 Item 2 Part 10959 Item 4 Part 10957 Item 5 Part 16368 Item 5a Part 17064 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 14: ...1 6 MADE IN U S A MAXIMUM WORKING PRESSURE 15 P S I NSF Item 6 Part 11027 FABRIQUE AUX E U NSF 2 Item 7 Part 15223 Item 8 Part 14463 Item 9 Part 11073 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 15: ...Item 12 Part 11028 Item 10 Part 06375 CAUTION Item 11 Part 15725 Item 13 Part 10900 Item 15 Part 15398 Domestic Only Item 16 Part 11746 1800GH Only Item 14 Part 13761 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 16: ...T DOWN START UP GAS Item 17 Part 14665 1800GH Only CAUTION Item 17 Part 15785 MODEL 1800GH C US R Item 18a 1800GH after July 2003 15777 for Nat Gas 16993 for LP Gas C US R MODELE 1800GH Item 19 Part 14730 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 17: ...BEFORE TURNING GAS VALVE ON 2 MOVE SLIDE SWITCH ON GAS VALVE TO ON 3 MOVE COOK FILTER SWITCH TO THE COOK POSITION SHUT DOWN 1 TURN COOK FILTER SWITCH TO OFF POSITION 2 MOVE SLIDE SWITCH ON GAS VALVE TO OFF 3 TURN THE MANUAL SHUT OFF VALVE TO THE OFF POSITION INSTALL IN ACCORDANCE WITH AMERICAN NATIONAL STANDARD FUEL GAS CODE ANSI Z223 1 LATEST ADDITION Item 22 Part 15694 Domestic Part 15795 CE MOD...

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Page 19: ...operates check main power supply Be sure main circuit breaker is ON and main fuses are good Correct voltage will be either 208 or 240V Perform the following if unit will not turn on 1 Disconnect main power supply 2 Be sure all connections are tight If power supply is proper see TROU BLESHOOTING section Wiring diagrams are located on inside front panel broaster com Manual 14680 3 99 Rev 5 14 WIRING...

Page 20: ...2 2 1600 Mechanical 208 or 240VAC broaster com Manual 14680 3 99 Rev 5 14 ...

Page 21: ...2 3 1600 Mechanical 208 or 240VAC Effective E16E401073 E18C401133 1 3 5 2 6 4 1 3 5 2 4 6 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 22: ...2 4 1600 Mechanical 208 or 240VAC Effective E16A700023 E18A700043 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 23: ...2 5 1600 Mechanical 208 or 240VAC Effective E16L700000 E18K700000 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 24: ...2 6 1600 1800E Solid State 208 or 240VAC broaster com Manual 14680 3 99 Rev 5 14 ...

Page 25: ...2 7 1600 1800E Solid State 208 or 240VAC Effective SE6E401073 5 6 5 6 1 3 2 4 1 3 2 4 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 26: ...2 8 1600 1800E Solid State 208 or 240VAC Effective SE6A700013 SE8A700011 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 27: ...2 9 1600 1800E Solid State 208 or 240VAC Effective SE8A213193 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 28: ...2 10 1800GH Solid State broaster com Manual 14680 3 99 Rev 9 14 ...

Page 29: ...2 11 EXPORT 1600XP 1800EXP Mechanical broaster com Manual 14680 3 99 Rev 5 14 ...

Page 30: ...2 12 EXPORT 1600XP 1800EXP Mchanical Effective E16E401073 E18D401133 2 4 1 3 6 5 3 1 4 6 5 2 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 31: ...2 13 EXPORT 1600XP 1800EXP Mchanical Effective E16A700023 E18A700043 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 32: ...2 14 EXPORT 1600XP 1800EXP Solid State broaster com Manual 14680 3 99 Rev 5 14 ...

Page 33: ...2 15 EXPORT 1600XP 1800EXP Solid State Effective SE6A700013 SE8A700011 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 34: ...2 16 EXPORT 1800EXP Solid State 208 or 240VAC Effective SE8I213193 2 5 1 3 4 6 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 35: ...2 17 EXPORT 1800GHXP Solid State broaster com Manual 14680 3 99 Rev 9 14 ...

Page 36: ...2 18 TM M C2 C1 EU 1600CE Mechanical broaster com Manual 14680 3 99 Rev 5 14 ...

Page 37: ...2 19 C2 EU 1600CE 1800ECE Solid State broaster com Manual 14680 3 99 Rev 5 14 ...

Page 38: ...2 20 EU 1800GHCE Solid State 1 2 2 1 2 1 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 39: ...2 21 C2 C1 M R1 EU 1600UK 1800EUK Solid State broaster com Manual 14680 3 99 Rev 5 14 ...

Page 40: ...2 22 EU 1800GHUK Solid State broaster com Manual 14680 3 99 Rev 5 14 ...

Page 41: ...2 23 1800E Solid State 480VAC broaster com Manual 14680 3 99 Rev 6 14 ...

Page 42: ...2 24 3 6 4 1 2 5 4 6 3 1 2 5 EXPORT 1600XP 240 480VAC Solid State Effective SE6E401231 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 43: ...2 25 EXPORT 1600XP Solid State 240 480VAC Effective SE6A700013 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 44: ...2 26 3 6 4 1 2 5 4 6 3 1 2 5 EXPORT 1800EXP Solid State 480VAC Effective January 04 A40 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 45: ...2 27 EXPORT 1800EXP Solid State 480VAC Effective January 06 K60 broaster com Manual 14680 3 99 Rev 5 14 ...

Page 46: ...ator Light Illumi nates when power switch is in the upper position 4 Cook Filter Switch Has two posi tions COOK and FILTER 5 Valve Closed Indicator Light Illumi nates when pressure regulating valve is CLOSED 6 Hi Limit Control Prevents oil tem perature from exceeding 475 F 7 Temperature Control Regulates oil temperature 8 Heat On Indicator Light Illuminates when oil is being heated FAMILIARIZATION...

Page 47: ...onnect main power supply 2 Remove condensate pan and one screw from bottom of front panel 3 Remove two screws holding control panel 9 to the power input box Tilt panel down so back is visible broaster com Manual 14680 3 99 Rev 5 14 ...

Page 48: ...reverse order Be sure all wire connections are secure and in their original location COOK FILTER SWITCH AND POWER ON SWITCH 1 See ACCESS FOR SERVICE 2 Check all terminals and wire connec tions Refer to wiring diagram 3 Turn switch to COOK or ON position 4 With needle nose pliers disconnect center terminal from switch 5 Check across center terminal and lower terminal with an ohmmeter Meter should i...

Page 49: ...ter than zero 4 With needle nose pliers disconnect common COM wire terminal from microswitch 5 Check across COM and NC with an ohmmeter Meter should indicate a closed circuit If not timer is faulty 6 Check across COM and NO with an ohmmeter Meter should indicate an open circuit If not timer is faulty 7 Turn timer knob to zero 8 Check across COM and NC with an ohmmeter Meter should indicate an open...

Page 50: ...cement 1 See ACCESS FOR SERVICE 2 OPEN cover Drain cooking oil from cooking well 3 Disconnect wires from control 6 4 Remove capillary guard 13 from inside the cooking well 5 Remove small nut 14 then large capil lary nut 15 from outside the cooking well 6 Pull control bulb 16 out of cooking well then remove control from control panel 7 Insert new control bulb as shown above Pull excess capillary 17...

Page 51: ...L and CONTACTORS for trou bleshooting If cooking oil temperature is above 400 F replace the thermostat or contactor 1 See ACCESS FOR SERVICE 2 Turn thermostat knob clockwise until you hear the control click 3 With needle nose pliers disconnect one wire from the control 4 Check across two terminals with an ohmmeter Meter should indicate a closed circuit If not the control is faulty Replacement 1 Se...

Page 52: ...capillary must be large and smooth as possible 9 Install large capillary nut securely after applying teflon tape on threads 10 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 11 Reconnect wires then mount new con trol 12 Replace thermostat knob 13 Replace capillary guard 14 Return cooking oil into cooking well...

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Page 54: ... when oil is being heated 5 Valve Closed Indicator Light Illumi nates when pressure regulating valve is CLOSED 6 Display Shows time countdown dur ing a cook cycle program values dur ing programming and programmed time and temperature during idle period 7 Program Buttons Displays program values initiates programming stores desired program values and exits pro gramming mode Cook Temperature Button C...

Page 55: ...tary knob to change displayed value Press cook temperature button to enter new value into memory Response Controller returns to idle mode Set Time Action Press cook time button twice within one second Response Programming mode has been entered Flashing display reads time value ie 08 00 Action If desired turn rotary knob to change displayed value in fifteen sec ond increments Press cook time but to...

Page 56: ...time count down during a cook cycle program values during programming and pro grammed time during idle period 10 Temp Display Shows set tempera ture and actual temperature on demand 11 Cook Temperature Button Initiates temperature programming and dis play actual temperature 12 Cook Time Button Initiates time pro gramming 13 Numerical Keypad Enters and adjusts set point values 14 AUTO COMP Automati...

Page 57: ... twice within 5 seconds Response 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 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 Respo...

Page 58: ...URE PRESET MODE Action Press and hold the TIME and TEMP buttons simultaneously for three seconds Response The TIME display and TEMP display will begin flashing The CYCLE COUNT display will show 0 indicating that the preset 0 values are displayed The preset values for the TIME TEMP and AUTO COMP will be shown on the display Change Cook Time Action Press the TIME button once Response The TEMP displa...

Page 59: ...ll controller functions and heat source are disabled during this condi tion Cause Faulty controller gas valve 1800GH Only or contactor 1600 1800E Only PROB Display will flash PROB if there is a problem with temperature sensor probe Audible alert will sound until cook filter switch is turned OFF All controller functions and heat source are disabled during this condition Cause Temperature sensor pro...

Page 60: ...T ON light comes back 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 inch below oil surface in the center of cooking well 5 Rotary D...

Page 61: ...er supply 2 Remove condensate pan and screw s from bottom of front panel Pull out and down on bottom to remove 3 Remove screws holding controller 12 to the power input box Tilt panel down so back is visible broaster com Manual 14680 3 99 Rev 5 14 ...

Page 62: ...ontrol panel Remove small knurled nut 10 from front of switch 4 Install new 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...

Page 63: ...ntrol bulb as shown in picture at right Pull excess capillary 17 out of cooking 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 1...

Page 64: ...TE CONTROLLER The controller regulates time and tempera ture Miscellaneous Remove F C jumper to display temperature in Celsius Replacement Within warranty control ler should be replaced as a whole circuit board transformer speaker and control panel Out of war ranty transformer and speaker are avail able separately 1 See ACCESS FOR SERVICE 2 Remove cook filter switch 3 Remove power on indicator lig...

Page 65: ...r which is translated into degrees of temperature Replacement 1600 1800E 1 See ACCESS FOR SERVICE 2 Disconnect probe 18 wires 3 OPEN cover Drain cooking oil from cooking well Close drain valve 4 Remove capillary guard 13 inside of cooking well 5 Remove basket guides 22 inside of cooking well 6 With a dull tool such as a crescent wrench handle pry top heating ele ment inward far enough to slide bra...

Page 66: ...for leaks 20 Tighten smaller nut 14 if necessary Replacement 1800GH 1 Follow steps 1 through 4 under Replacement 1600 1800E 2 Loosen compression nut 14 3 Remove fitting 23 from outside of the cooking well Leave reducer fitting 15 in place 4 It may be necessary to move top heat ing element up or down slightly to get temperature sensor probe out from behind element 5 Carefully pull probe out of cook...

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Page 68: ...5 POWER INPUT BOX 5 1 1600 Pressure Fryer 1800E Pressure Fryer broaster com Manual 14680 3 99 Rev 5 14 ...

Page 69: ... limit open or power cord may be faulty 5 Check voltage between any two of the three connections opposite element wires on secondary contactor 2 Any great drop in voltage indicates a poor connection or dirty contact within the contactor 6 Secondary contactor 2 will close when HEAT ON light is illuminated Make same checks as in step 4 between any two of the three connec tions on element wire side o...

Page 70: ...should indicate a closed circuit If not fuse may be faulty Fuse Replacement 1 Remove end cap 5 and replace fuse 6 HEATING ELELEMENTS 1600 1800E All elements heat the oil when thermostat 1600 mechanical or the solid state control ler calls for heat If HEAT ON light is illumi nated for long periods of time this may indicate a faulty element or wire connec tion 1 See ACCESS FOR SERVICE 1600 1800E Con...

Page 71: ...secure elements to the cooking well 4 Remove capillary guard 10 5 Remove element wires 7 large nut 11 and washer 12 from element s 6 To remove bottom or center element remove element or elements above it 7 Position element to allow removal of probe bracket 13 Lightly pry inward on top element if necessary Slide probe bracket off the temperature sen sor probe 14 8 From inside the cooking well slide...

Page 72: ... from the switch 15 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 Adjustment 1 See ACCESS FOR SERVICE 2 With pliers bend mounting bracket 16 closer or further away from control rod Replacement 1 See ACCESS FOR SERV...

Page 73: ...e ACCESS FOR SERVICE 2 With needle nose pliers disconnect wire from 1 C 3 Check between 1 C and 2 NC with an ohmmeter Meter should indicate an closed circuit If not relay is faulty 4 Check between 1 C and 3 NO with an ohmmeter Meter should indicate a open circuit If not relay is faulty 5 With needle nose pliers disconnect one wire from the coil 18 6 Check between coil connections with an ohmmeter ...

Page 74: ...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 1800GH Pressure Fryer broaster com Manual 14680 3 99 Rev 5 14 ...

Page 75: ...ome from wire harness attached to the gas valve 4 Turn cook filter switch to COOK With HEAT ON light illuminated check voltage across blue and black at the terminal block 20 with a voltmeter Meter should indicate applied voltage If not check voltage supply loose connections or igni tion control is faulty 5 With heat on light illuminated check voltage across blue and brown at the ter minal block 20...

Page 76: ...tached to the gas valve 4 Turn cook filter switch to COOK With HEAT ON light illuminated check voltage across blue and black at the terminal block 20 with a voltmeter Meter should indicate applied voltage If not check voltage supply loose connections or igni tion control is faulty 5 With heat on light illuminated check voltage across blue and brown at the ter minal block 20 with a voltmeter Meter ...

Page 77: ...ure all wire connections are secure and in their original location See wiring diagrams RELAYS Relay 23 24VDC coil is energized when the solid state controller calls for heat 220 volts is then supplied to the ignition module 19 Relay 22 24VAC coil is energized when cook filter switch is turned to FILTER 220 volts is then supplied to the filter motor 1 See ACCESS FOR SERVICE 2 With needle nose plier...

Page 78: ... and 4 8 using a voltmeter Meter should indicate applied voltage If not check for loose connections or relay is faulty Replacement 1 See ACCESS FOR SERVICE 2 Remove all wires from relay 3 Remove two mounting screws from relay 4 Install new relay in reverse order Be sure all wire connections are secure and in their original location See wiring dia grams broaster com Manual 14680 3 99 Rev 5 14 ...

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Page 80: ...tt lift safety relief valve 1 handle If pressure is released do not attempt to open the cover Do not attempt to operate the unit until it has been serviced Always fully rotate cover handle 2 OPEN or CLOSED To CLOSE cover slide cover forward then rotate the handle 2 counterclockwise To OPEN cover push down on cover handle then slowly rotate the handle clockwise Slide cover toward the rear of the un...

Page 81: ...6 2 FAMILIARIZATION broaster com Manual 14680 3 99 Rev 5 14 ...

Page 82: ... 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 9 in top of splash shield 10 3 Open and close cover several times in cooking well to let cover seek its own center With cover...

Page 83: ...back of slide rod 1600 and remove rod 13 Complete assembly can now be removed from the unit DISASSEMBLY If warning sign 8 becomes worn or illegi ble it must be replaced immediately 1 Rotate cover handle 2 to a centered position 2 Loosen screws 9 attaching splash guard 10 to back panel assembly 11 3 Slide splash guard 10 forward and up towards the end of the cover handle 2 Continued broaster com Ma...

Page 84: ... pin Remove handle and cam 10 Clean lifter box handle cam and yoke bar where lifter box slides up and down ASSEMBLY 1 Install cam 3 into yoke bar 2 Install handle 2 through splash guard into yoke bar then into the cam 3 Align holes in handle and cam then install a new grooved pin 14 Be sure the grooved pin is installed flush with the cam 4 Lubricate inside of yoke bar where lifter box slides up an...

Page 85: ...ide rod and install bolt on back of slide rod 1600 12 Pull cover forward If yoke latch 6 and latch columns 7 do not line up adjust slide rod 13 to the left or right 13 Center cover within the cooking well See Centering Cover PRESSURE GAUGE Gauge indicates pressure within the cook ing well Operating pressure is 12 14 PSI Replacement 1 OPEN the pressure regulating valve then the cover 2 Unscrew gaug...

Page 86: ... steam could cause serious burns 1 See PROPER COVER OPERATION Replacement Replacement valve must have a 15 PSI relief pres sure 1 OPEN cover and pressure regulating valve 2 Unscrew valve 1 from the cover DO NOT install valve dis charge opening in the direction of foot traffic areas 3 Apply teflon tape to threads Screw new valve into the cover with valve discharge opening facing the rear at an angl...

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Page 88: ...se 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 coating 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 ...

Page 89: ...e obstructed The obstruction usually forms where exhaust drain tube 1 meets tank 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 Cleaning 1 Remove two screws cover 4 and seal 5 from tank 2 Scrape inside of tank clean 3 Replace seal 5 and grommet 6 if necessary 4 Assemble in reverse order broaster com Manual 14680 ...

Page 90: ...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 7 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 91: ...m the repair kit Lubricate all O rings and contacting surfaces with olive oil Be sure flat end of spacer 13 is against piston 14 8 Mount valve assembly back on cook ing well with the allen screws With the open end of the 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 loos...

Page 92: ...t 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 the open end of the 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 in the p...

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Page 94: ...se 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...

Page 95: ... is released at the end of a cooking cycle Cleaning 1 Remove exhaust drain tube 1 from bottom of the tank 2 2 Remove two screws from the stack 3 which mounts tank to the unit 3 Pull tank away from the frame Exhaust tube 4 will separate from the tank 4 Remove two screws holding cover 5 to the tank then remove cover Remove rubber grommet 6 on side of the tank Set the tank in a sink and clean thoroug...

Page 96: ...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 97: ...pair kit Lubricate all O rings and contacting surfaces with olive oil Be sure flat end of spacer 11 is against piston 12 8 Mount valve assembly back on cook ing well with the allen screws With the open end of the 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 8 and control rod While locking nut 7 is loose adjust ...

Page 98: ...tall 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 When the open end of the 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 in the pressure...

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Page 100: ...n cook filter switch to COOK Shut Down 1 Turn cook filter switch OFF 2 Turn gas valve switch 2 OFF 3 Turn gas shut off valve 1 OFF GAS CONVERSION To convert from one type of gas to another five components must be changed gas valve pilot burner orifice main burner ori fice and gas data plate Notify the Broaster Company Service Department of a conver sion in writing Main Burner Orifice Sizes Up To 2...

Page 101: ...gas flow and ON allows gas flow to pilot and main burners as needed Adjustment for gas pressure and gas flow to pilot burner are also found on the valve Replacement 1 Turn cook filter 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...

Page 102: ...LOW CHART on page 11 10 if there is no voltage at either or both places FLAME ADJUSTMENTS Gas Pressure Adjustment Always check gas pressure 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 pressur...

Page 103: ...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 Air shutter adjustment See AIR SHUT TER Adjustment 2 Centered main burner orifice After installing a new gas valve or piping brackets can shift causing gas not to ...

Page 104: ... 2 Screw shutter 14 in or out to obtain a blue flame Flame should start burning slightly above main burner 3 Tighten locknut COMBUSTION CHAMBER Combustion chamber directs heat from main burner flame across fins on cooking well and out the exhaust flue 15 If main burner flame is not adjusted correctly soot deposits can form on the combustion chamber 16 exhaust flue 15 and cooking well 17 Soot is id...

Page 105: ...nting nuts inside upper flue opening and remove flue 15 7 Remove outer wall clamp 19 8 Remove screw 20 on top of outer wall weldments 9 Remove screws 21 on both sides of outer walls and remove 10 Remove screws 22 on both sides of inner jackets and remove 11 Clean exhaust flue inner jacket outer wall and cooking well 12 Assemble in reverse order broaster com Manuals 14680 3 99 Rev 5 14 ...

Page 106: ...w air shutter and locknuts away from gas valve as far as possible 8 Loosen brass fitting 24 and pull 1 4 gas supply line 25 brass fitting and pilot burner orifice 26 free of burner 9 Loosen pipe union 6 10 While pulling on gas valve loosen air shutter and locknuts until they can be removed 11 Remove main burner orifice 27 12 Assemble in reverse order Adjust air shutter See AIR SHUTTER Check all co...

Page 107: ...off valve OFF 3 Loosen brass fitting 24 from pilot burner 4 Pull 1 4 gas supply line 25 and brass fitting free of burner It may be neces sary to loosen gas valve side of gas supply line 5 Remove orifice 26 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 14680 3 99 Rev 5 14 ...

Page 108: ... serious 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 nut 1 screw 2 and interlock 3 4 Remove nut mounting handle 4 to the drain valve 5 5 Remove nipple 7 from drain valve 6 Unscrew drain valve from the cooking well 6 7 Assemble in reverse order using 15820 Primer 1...

Page 109: ...t oil could splash causing serious burns 1600 1800 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 one cup 1600 or two cups 1800 of Broaster filtering compound on top of filter paper and cover 10 on filter pan broaster com Manual 14680 3 99 Rev 5 14 ...

Page 110: ... area away from all cooking equipment or other heat sources such as direct sun light 2 Be sure the O ring 12 1600 located in suction line is in good condition lubricated with cooking oil and installed correctly CHECK VALVE Prevents cooking oil from draining into the filter pan from cooking well Replacement 1 Disconnect main electric power sup ply 2 Drain cooking oil from the cooking well and into ...

Page 111: ...cooking well Turn cook filter switch OFF before resetting manual reset thermal overload Motor has a manual reset thermal overload If overload trips push red reset button on back after motor has cooled Replacement 1 Disconnect main electric power sup ply 2 Disconnect conduit wires and conduit from the motor 3 Loosen three set screws 20 in neck of motor 18 which hold pump in place 4 Remove motor mou...

Page 112: ...10 5 Be sure motor is wired for correct voltage and correct direction See below for correct wire connections MOTOR WIRING WIRENUT DOMESTIC EXPORT EUROPEAN UNION broaster com Manual 14680 3 99 Rev 5 14 ...

Page 113: ...elp install piping 2 See MOTOR Installation Hints Pump Cleaning Cleaning will be necessary if pump is seized and tripping thermal overload on the motor 1 See PUMP Removal Remove pump 2 Remove four bolts 21 and cover 22 3 Remove interior gears 4 Clean 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...

Page 114: ... controller 3 Faulty temperature Control 1600 mechanical 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 1600 1800E 1 Controller in program mode 2 Faulty element s 3 Faulty contactor 1 Exit program mode 2 Replace 3 Replace Cooking oil tempe...

Page 115: ...2 Low gas pressure 1800GH 3 Poor air gas mix 1800GH 4 Main burner not on 1800GH 5 Loose gas valve wire harness 1800GH 6 Faulty flame sensor 1800GH 7 Faulty gas valve 1800GH 8 Faulty contactor 1600 1800E 9 Faulty heating element s 1600 1800E 10 Open or faulty wall fuse 11 Pilot does not light 1 Turn ON 2 Check pressure 3 Adjust air shutter 4 See 5 6 7 8 and 11 5 Check connections 6 Replace 7 Replac...

Page 116: ...lean 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 pressure regulating valve 3 Adjust valve Cover hard to move from front of the unit to the rear 1 Yoke bearings and slide rod dirty 1 C...

Page 117: ... 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 118: ...irty 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 Produ...

Page 119: ...temperature 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 si...

Page 120: ...arts 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 com pound 1 See C...

Page 121: ...r Probe Do elements heat Check elements and connections Repair Does C2 close w Heat On light Does C2 and Controller chatter Replace Controller Replace R2 Did Heat On light stay on Did C2 stay closed when Heat On light was off Monitor Replace Controller Is applied voltage at coil Does limit trip again Replace Hi Limit Is proper power applied Does Temperature exceed limit rating Replace C1 Check swi...

Page 122: ... pump Check o ring and filter pan assembly Remove blockage or replace valve No problem Separate pump from motor Still humming Replace motor Remove face plate from pump and clean parts Does steam escape around cover Does pressure build properly Is thermal overload tripped Check switch wiring connections Replace motor if necessary Reset Is motor humming Can you use slot in back of motor to get it st...

Page 123: ...epair Replace ignitor Check controller and Temp Sensor Probe Does pilot flame ignite Is Power On Light On Does Filter Motor work Is Proper power applied Does Controller come on 10 20 VAC from transformer Is High Limit tripped 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 ...

Page 124: ...lace gas valve Does filter Motor work Is motor humming Is thermal overload tripped Check switch wiring connections Replace motor if necessary 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 Does steam escape from stack Does steam escape around cover Replace pump Check for enough product ...

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Page 126: ...broaster com Manual 14680 3 99 Rev 5 14 SERVICE NOTES ...

Page 127: ...broaster com Manual 14680 3 99 Rev 5 14 SERVICE NOTES ...

Page 128: ...broaster com Manual 14680 3 99 Rev 5 14 SERVICE NOTES ...

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Page 131: ...The Broaster Company 2855 Cranston Road Beloit WI 53511 3991 608 365 0193 broaster com ...

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Broaster 1600, Service Manual

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