Broaster 2400 Series Operation Manual Download Page 53

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11 - TROUBLESHOOTING

11-1

All adjustments and repairs shall be made by an authorized Broaster Company representative.

ELECTRICAL TIPS

COMPLAINT

CAUSE

REMEDY

POWER ON light not illu-
minated

Main power OFF

Cook/filter switch OFF

Hi-limit tripped

Unplugged

Turn ON.

Turn to COOK.

Turn cook/filter switch OFF.
Contact service person.

Plug in.

Timer will not time

Main power OFF

Cook/filter switch OFF

Solid state controller in
program mode

Pressure regulating valve
OPEN

Turn ON.

Turn to COOK.

Exit program mode.

CLOSE.

HEAT ON light not illumi-
nated

Main power OFF

Cook/filter switch OFF

Solid state controller in
program mode

Oil temperature has
reached programmed tem-
perature

Turn ON.

Turn to COOK.

Exit program mode.

Unit ready for cooking.

broaster.com Manual #15459 5/02 Rev: 2/14

Summary of Contents for 2400 Series

Page 1: ... Broaster Chicken Broaster Foods and Broasterie are registered trademarks Usage is available only to licensed operators with written authorization from the Broaster Company Be sure ALL installers read understand and have access to this manual at all times Design Certified By CSA NSF OPERATION MANUAL BROASTER 2400 PRESSURE FRYER Manual 15459 2 99 Rev 9 16 ...

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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 15459 5 02 Rev 10 15 ...

Page 5: ...LIARIZATION 6 1 CONTROLLER BASIC PROGRAMMING 6 2 Normal Operating Mode 6 2 Set Temperature 6 2 Set Time 6 2 Set AUTO COMP Automatic Time Compensation 6 2 Reset Cycle Counter 6 2 Preset Cook Mode Programming METHOD 1 6 3 Preset Cook Mode Programming METHOD 2 6 3 Choose Preset Cook Cycle 6 3 Change Cook Time 6 3 Change Cook Temperature 6 3 Activate Deactivate Auto Comp 6 4 Advance to Next Preset 6 4...

Page 6: ... COOKING WEIGHT TEMPERATURE AND TIME 7 1 FRESH PRODUCTS 7 1 INDIVIDUALLY QUICK FROZEN IQF CHICKEN FROZEN 7 2 BROASTER FOODS COOKING CHART FOR 2400 PRESSURE FRYER 7 3 8 COOKING OIL CARE AND FILTERING 8 1 OIL CARE 8 1 FILTERING 8 2 FILTERING HINTS 8 3 9 CLEANING 9 1 COOKING WELL 9 1 FOOD BASKET 9 2 UNIT SURFACES 9 2 CONDENSATE PAN 9 2 SLIDE RODS 9 2 COVER 9 2 SPLASH SHIELD 9 3 GAS SPRING COVERS 9 3 ...

Page 7: ...CONTROLLER TIPS 11 2 SMART TOUCH CONTROLLER TIPS 11 3 GAS TIPS 11 4 COVER YOKE AND LIFT TIPS 11 5 PRESSURE SYSTEM TIPS 11 6 PRODUCT TIPS 11 7 Fresh Chicken 11 7 Individually Quick Frozen IQF Chicken 11 8 FILTERING TIPS 11 9 broaster com Manual 15459 5 02 Rev 3 15 ...

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Page 9: ...aster Distributor from whom the pressure fryer was purchased Repairs will be made by The Broaster Company only Any freight charges and distributor labor costs to install the repaired cooking well as well as the cost of any other parts replaced will be the responsibility of the equipment owner Service under this warranty shall be furnished only by an authorized Company distributor The Company does ...

Page 10: ...1 2 Used Company equipment or Company equipment not purchased from an authorized distributor carries no warranty expressed or implied broaster com Manual 15459 5 02 Rev 6 15 ...

Page 11: ...T obstruct exhaust flue or open area around bottom of unit at the front back and sides which would restrict the flow of combustion and ven tilation air If you need replacement warning signs or manuals contact an authorized Broaster Company representative or the Broaster Company at 608 365 0193 The Customer Service Department at the Broaster Company should be contacted at the time of sale or dispos...

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Page 13: ...ee Safety Relief Valve on page 4 3 DO NOT install unit where traffic areas are on either side or behind unit 2400GH Electrical Grounding Instructions The Model 2400GH is equipped with a three prong grounding plug to protect against shock hazard The plug must be plugged directly into a properly grounded three prong receptacle DO NOT cut or remove the grounding prong from this plug A gas shutoff val...

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Page 15: ...TING TO KNOW YOUR BROASTER PRESSURE FRYER BEFORE OPERATING CHECK OIL LEVEL CAUTION 9 8 7 0 6 3 4 1 5 2 CAU TION BEF OR E OP ER ATING CHE CK OIL LE VE L 4 7 1 6 5 8 0 9 2 3 broaster com Manual 15459 5 02 Rev 1 14 ...

Page 16: ...ube Directs conden sation from the exhaust tank into con densate pan 7 Countertop Drip Pan Collects con densate from the open cooking well and directs it to the Drip Pan Drain Line Drip Pan is removable for clean ing 8 Drip Pan Drain Line Directs counter top liquid toward Condensate Pan 9 Pilot Burner A small flame used to ignite the main burner 10 Manual Gas Shut Off Valve Shuts off gas flow to t...

Page 17: ... could cause serious burns Test valve once a month Also test before and after an extended shut down Using a hot mitt lift valve han dle during a cook cycle until pressure is released from cooking well Allow valve to snap closed 16 Pressure Gauge Indicates pressure within the cooking well Normal oper ating pressure is 12 14 PSI 17 Basket Lifter Used to raise and lower food basket into the cooking w...

Page 18: ...evel before turning cook filter switch to COOK 22 Exhaust Tank Steam and vapors are exhausted through this tank 23 Filter Pump and Motor When filter ing returns oil to cooking well 24 Basket Rest Holds and tilts basket for draining when removing cooked product from oil or loading uncooked product DO NOT rest basket on top flange of cooking well Damage to area in contact with O ring can cause leaki...

Page 19: ...e a high quality cooking medium manufactured for deep frying Check oil level before turning cook filter switch to COOK Danger of fire exists if the oil level is below the minimum level Using old oil reduces flash point increasing the risk of surge boiling Use care when handling hot oil Oil could splash causing serious burns Fill cooking well using one of the following methods Liquid Oil Use Broast...

Page 20: ... is high quality For best results chicken should be fresh trimmed for portion control and uni form in size A wide variety of Broaster Company monosodium glutamate free condiments are available They have all been tested for the best possible results in the unit If using Genuine Broaster breading and mari nades you can obtain a Trademark Authori zation allowing the use of the Broaster Company tradem...

Page 21: ...ermittent pilot burner This type of pilot lights when the control ler calls for heat and goes out when the controller is not calling for heat 5 To light pilot and main burners turn cook filter switch to COOK Shut Down 1 Turn cook filter switch OFF 2 Turn gas control switch 2 OFF 3 Turn gas shut off valve 1 OFF broaster com Manual 15459 5 02 Rev 2 14 This switch is not used on gas pressure fryers m...

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Page 23: ...ows time countdown during a cook cycle program values during programming and pro grammed time during idle period 7 Temp Display Shows set temperature and actual temperature on demand 8 Cook Temperature Button Initiates temperature programming and dis plays actual temperature 9 Cook Time Button Initiates time pro gramming 10 Numerical Keypad Enters and adjusts set point values 11 AUTO COMP Automati...

Page 24: ...y Response Controller returns to idle mode Set Time Action Press Cook Time Button twice within 5 seconds Response Programming mode has been entered Flashing Time Display reads time value in minutes seconds such as 08 00 Action If desired press keypad num bers to change displayed value in min utes and seconds Press Cook Time Button once to enter new value into memory Response Controller returns to ...

Page 25: ...nt PROGRAMMING PROCEDURE PRESET MODE Action Press and hold the TIME and TEMP buttons simultaneously for 3 seconds Response The TIME display and TEMP display begin flashing The CYCLE COUNT display 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...

Page 26: ...disabled when it is off Advance to Next Preset Action Press the RESET button once Response The CYCLE COUNT dis play changes to 1 and the presets for 1 are displayed Repeat the process as described After the presets for 9 are displayed pressing the RESET button again causes the control to return to normal operation broaster com Manual 15459 5 02 Rev 9 16 ...

Page 27: ... the month and press the enter key Repeat this action for the Day Year Hours Minutes Seconds AM and PM boxes When finished press the green OK button in the bottom right corner of the screen The next display will ask you if this date should be used to establish the warranty start date Press the green OK button You will then see a display asking you to verify the serial number of your fryer Enter th...

Page 28: ...oss the top of the display CUS TOM indicates you are in manual cooking mode At the end of the cycle the left box alter nates between red and white the alert sounds and continues until the exhaust valve is opened by turning the small handle on the countertop from CLOSED to OPEN Auto Comp In the upper right corner of the cook time display is the Auto Comp indicator It will be black if Auto Comp is o...

Page 29: ...et If the wrong product comes up don t worry Tap the preset box again and the menu will reappear When the item has been selected a picture of the item will appear in the left box and a description of the item will appear in the right box When a cook cycle is started the left box turns yellow and the time remaining in the cycle is displayed The picture moves to the right box If the menu item to be ...

Page 30: ... it DO NOT press the Stop Pump button Cook Filter Setup Help Check Filter Pan Components Stir Oil Before Opening Drain Valve Start Pump Stop Pump X Start Stop Filter Pump Filter Pump Running 00 00 Press STOP PUMP after the oil is com pletely returned to the cooking well or you can leave the pump running and it will auto matically stop when the counter says 10 00 minutes See display below To return...

Page 31: ...ment Pressing this option opens the Set Date Time display To set the date and time press the box after Month and a keypad will appear Enter the number of the month and press the enter key Repeat this action for the Day Year Hours Minutes Seconds AM and PM boxes When finished press the green OK button To leave this display without making a change press the red X or the green OK Temperature Pressing...

Page 32: ...emperature will be yellow and Low and the set temp will be alternating DO NOT start cooking until the temp display is green X Energy Saving Settings OK Set Energy Save Timer HH MM 00 00 Set Auto Shut Off Timer HH MM 00 00 Setting Either Timer to 00 00 will disable the function OK Energy Save Mode Set temperature is 270F Allow temperature to recover before cooking Option 2 Auto Shut Off Timer When ...

Page 33: ...duct press the Edit Enter Preset Name bar and a typewriter keyboard will appear The curser will be at the end of the name To change the name press the BACK button and the cursor will delete the name one let ter each time the BACK button is pressed Delete the letters until you get to the place where you want to start making the change To get the numbers and symbols to come up press the Symbol key W...

Page 34: ...e 000F 1 00 00 On Yes 000F 2 00 00 3 00 00 000F EXPORT MENU When you make changes to the menu on one fryer and want to put the same menu on other fryers with the Smart Touch Con trol you can export the revised menu from this fryer to the Flash Drive and load it unto the other fryers Plug the flash drive into the USB port in the front panel above the control panel Press the Export Menu button on th...

Page 35: ...ounter to 00 on the Cook Tab X Shortening Settings OK Liquid Shortening Type Selected Shortening Changed Today Shortening Last Changed Unknown LANGUAGE SELECTION Pressing this option will allow you to change the language used in all displays This option is not yet active ALERT SETTINGS Pressing this option allows you to set con ditions for several features The numbers left of the boxes indicate th...

Page 36: ...pear will alert you to stir the oil to get it to a uniform temperature 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 HELP TAB This display provides instructions for the items in the boxes They are available at any time to help you set up the control to cook product Cook F...

Page 37: ...ase the amount of surge boiling in the cooking well PRODUCT WEIGHT THICKNESS TEMPERATURE TIME Fresh Chicken 8 or 9 Piece Cut 0 90 1 02 kg 2 00 2 25 lb 1 02 1 13 kg 2 25 2 50 lb 1 13 1 25 kg 2 50 2 75 lb 1 25 1 36 kg 2 75 3 00 lb 1 36 1 47 kg 3 00 3 25 lb 1 47 1 59 kg 3 25 3 50 lb 182 C 360 F 182 C 360 F 182 C 360 F 182 C 360 F 182 C 360 F 182 C 360 F 7 15 7 45 minutes 7 45 8 15 minutes 8 15 9 00 m...

Page 38: ...ish 155 F Keep uncooked product frozen at 0 F or below at all times Maximum Load Size 6 chickens 48 pieces PRODUCT MAXIMUM LOAD TEMPERATURE TIME Thighs 30 pieces 168 C 335 F 15 00 17 00 min Legs 48 pieces 168 C 335 F 15 00 17 00 min Breasts 24 pieces 168 C 335 F 17 00 19 00 min Wings 60 pieces 168 C 335 F 12 00 14 00 min Mixed Load 48 pieces 168 C 335 F 17 00 19 00 min broaster com Manual 15459 5 ...

Page 39: ... Packed 96661 10 Thawed 7 8 Min 168 C 335 F 91 kg 2 lb 5 44 kg 12 lbs Jumbo Corn Dogs Bulk Packed 96661 10 Frozen 13 14 Min 168 C 335 F 91 kg 2 lb 5 44 kg 12 lbs Pork Tenderloin Bulk Packed 96313 9 75 3 3 5 Min 182 C 360 F 91 kg 2 lb 1 81 kg 4 lbs Deluxe Pizza Burritos 48 in 7 trays 96316 15 6 5 7 5 Min 182 C 360 F 91 kg 2 lb 1 81 kg 4 lbs Deluxe Beef n Bean Burritos 48 in 7 trays 96317 15 5 5 6 5...

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Page 41: ...tween business rushes will extend useful oil life Volume The more product cooked the more often oil will need filtering and replac ing Type of Coating and Seasoning Used Ingredients in some coatings can affect product appearance and shorten the useful oil life Amount of Care and Filtering Oil Receives DO NOT leave any crumb buildup in oil on cooking well or on food basket See FILTERING Oil will ne...

Page 42: ...s will aid in draining crumbs Lower cover pull over cook ing well and open drain valve slowly If valve becomes obstructed with crumbs use ramrod to unblock valve DO NOT allow ramrod point to hit bottom of filter pan Point of ramrod can penetrate filter paper allowing crumbs and filter compound to pass through filter lines 3 When oil is drained remove basket support grate if present and clean separ...

Page 43: ...er Rags or paper containing cooking oil can catch fire if exposed to heat Laundering will not remove the oil Dispose of all oil soiled papers and rags in a trash container that is in a ventilated area away from all cooking equipment or other heat sources such as direct sunlight DO NOT operate unit without filter pan and filter pan cover in its proper position Filter pan cover must be wiped clean a...

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Page 45: ...ch column Cleaning flag is supplied with each new unit and in cooking well cleaner Additional cleaning flags can be ordered COOKING WELL Cover and Splash Shield cleaning should be completed before cooking well is cleaned 1 Turn power switch OFF and discon nect main power supply 2 Remove filter pan if unit has one from under unit 3 Drain and discard used oil 4 OPEN cover and install cleaning flag 1...

Page 46: ...il Dispose of all oil soiled papers and rags in a trash container that is in a ventilated area away from all cooking equipment or other heat sources such as direct sunlight CONDENSATE PAN Check liquid level several times daily Empty as needed Water and hot oil DO NOT mix DO NOT pour contents into cooking well or filter pan Hot oil could splash causing serious burns SLIDE RODS Clean daily along wit...

Page 47: ...3 4 4 Slide splash shield 4 forward and up toward the end of the cover handle 1 5 Clean the top and underside of splash shield and top of the cover Ensure back splash shield 3 and splash shield 4 are assembled correctly after cleaning The cover may not close correctly if they are not 6 Assemble in reverse order GAS SPRING COVERS Allow cover assembly to cool before cleaning Hot surfaces could cause...

Page 48: ...o much force in this area may damage the hi limit capillary or the temperature sen sor probe If either of these components are damaged the unit will be inoperable until the component is replaced 4 Leaving the probe guard and basket guides off fill the cooking well with cleaning solution and clean normally The probe guard and basket guides can be placed in the cooking well while soaking 5 After dra...

Page 49: ...ooking Well X Clean Condensate Pan X Clean Oil Build up Under Unit X Clean Pressure Relief Valve port Pressure Gauge Port X Clean Cover and Splash Guard X Clean Food Basket X Clean Temperature Sen sor X Clean Filter Pan Cover After each fil tering cycle Filter Cooking Oil See FILTER ING Clean and Lubricate O Ring X Slide Rods X Gas Spring Cover X Probe Guard Basket Guides X broaster com Manual 154...

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Page 51: ...il and crumbs from unit surfaces with a clean cloth 5 Clean food basket 6 Clean condensate pan SEASONAL Rags or paper containing cooking oil can catch fire if exposed to heat Laundering will not remove the oil Dispose of all oil soiled papers and rags in a trash container that is in a ventilated area away from all cooking equipment or other heat sources such as direct sunlight 1 See Cooking Oil Ca...

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Page 53: ...tch OFF Contact service person 4 Plug in Timer will not time 1 Main power OFF 2 Cook filter switch OFF 3 Solid state controller in program mode 4 Pressure regulating valve OPEN 1 Turn ON 2 Turn to COOK 3 Exit program mode 4 CLOSE HEAT ON light not illumi nated 1 Main power OFF 2 Cook filter switch OFF 3 Solid state controller in program mode 4 Oil temperature has reached programmed tem perature 1 ...

Page 54: ...e person Display reads PROB 1 There is a temperature sen sor probe failure 1 Turn cook filter switch OFF Contact service person Display reads CHEC 1 Gas valve not ON 2400GH 2 Pilot light will not light 2400GH 3 Open or faulty wall fuse 4 Oil temperature not rising properly 1 Turn ON 2 Turn ON manual gas shut off valve 3 Check wall fuse or circuit breaker 4 Turn cook filter switch OFF Contact servi...

Page 55: ... 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 56: ... INSTRUCTIONS on page 5 3 3 Turn ON 4 Install regulator to control gas pressure Main burner will not ignite 1 Pilot burner not lit 2 Gas control OFF 3 Controller in program mode 4 Cook filter switch OFF 5 Hi limit tripped 1 See 2400GH LIGHTING INSTRUCTIONS on page 5 3 2 Turn ON 3 Exit program mode 4 Turn to COOK 5 Turn cook filter switch OFF Contact service person broaster com Manual 15459 5 02 Re...

Page 57: ...e 4 OPEN pressure regulat ing valve 5 Contact service person O ring Break DO NOT rest basket on top flange of cooking well Damage to area in contact with O ring can cause leak ing under pressure or O ring failure 1 O ring groove dirty 2 Nicks in cooking well or cover 1 Clean 2 Remove Cover will not stay in raised position 1 Weak gas spring 1 Contact service person Pressure Gauge does not indicate ...

Page 58: ...uld spray out under pressure causing serious burns COMPLAINT CAUSE REMEDY No pressure 1 Pressure regulating valve OPEN 2 Pressure regulating valve dirty or blocked open 3 Leaks around cover O ring 1 CLOSE 2 Contact service person 3 Replace O ring Excess pressure 1 Turn cook filter switch OFF Contact service person broaster com Manual 15459 5 02 Rev 3 16A ...

Page 59: ...eaded too wet 1 Check cook temperature 2 Check procedures 3 Discard 4 Change oil 5 Drain thoroughly prior to breading 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 Improper marination 1 Check procedures White spots 1 Product stuck together 2 Food basket overloaded 1 Float basket while ...

Page 60: ...heck cook 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 Food basket overloaded 1 Float basket while loading 2 Decrease ...

Page 61: ...tarts 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 per son 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...

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Page 64: ...Broaster Company 2855 Cranston Road Beloit WI 53511 3991 608 365 0193 broaster com ...

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