Broaster 1600XP Installation Manual

“An American Tradition Since 1954!”

MODEL 1600XP AND 1800XP

BROASTER

®

PRESSURE FRYER

OPERATION MANUAL

Be sure ALL installers read, understand, and have access to this manual at all times.

Printed in U.S.A.

Broaster®, Broasted®, Broasted Chicken®, Broaster Foods®. and Broasterie® are registered trademarks.
Usage is available only to licensed opertors with written authorization from The Broaster Comany.

The Broaster Company

2855 Cranston Road, Beloit, WI 53511-3991

608/365-0193 www.broaster.com

Manual #16284 Rev 5/10

Copyright 2005 The Broaster Company

FOR YOUR SAFETY

Do not use or store gasoline or other flammable vapors

or liquids in the vicinity of this or any other appliance.

WARNING: Improper installation, adjustments, alteration, service or maintenance can
cause property damage, injury or death. Read the installation, operating and mainte­nance instructions thoroughly before installing or servicing this equipment.

For the sake of safety and clarity, the following words used in this manual are defined as follows:

DANGER: Indicates an imminently hazardous situation which, if not avoided, could result
in serious injury or death.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result
in serious injury or death.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, could result in
minor injury, property damage or both.

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

If there is a power failure, turn cook/filter
switch OFF. On the Model 1800GH, also
slide switch on gas valve OFF. DO NOT
attempt to operate unit during a power fail­ure.

1800GH: Post, in prominent locations,
instructions to be followed in the event that
the user smells gas. This information can
be obtained from your local gas supplier.

WARNING: 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.

WARNING: 1600 Mechanical Controls: If

at any time the unit fails to operate prop­erly when the cook/filter switch is moved to the
cook position, contact your local Broaster Com­pany representative for service immediately.
1600/1800E Solid State Controls: If at any time
the POWER ON light does not turn off when the
cook/filter switch is moved to the OFF position,
contact your local Broaster Company represen­tative for service immediately.

WARNING: 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.

WARNING: DO NOT operate unit without

filter pan and filter pan cover in its proper
position. Filter pan cover must be wiped clean
after each filtering cycle.

Manual #16284 8/05 Rev: 5/10

NEW OWNER OR RELOCATION NOTIFICATION

If you are a new owner of a used unit or
have relocated your Broaster Pressure
Fryer, please take a minute to fill out one of
the cards below. It is NOT a warranty regis­tration.

PLEASE PRINT: 2

Business Name:

This card enables The Broaster Company to
better serve you and keep you informed of
changes in equipment, condiments, or ser­vice bulletins.

Address:
City: State: Zip Code:
Owner’s Name:
County:
Phone:
Model:
Serial Number:

PLEASE PRINT: 1

Business Name:
Address:
City: State: Zip Code:
Owner’s Name:
County:
Phone:

Manual #16284 8/05

Model:
Serial Number:

The Broaster Company
2855 Cranston Road
Beloit, WI 53511

The Broaster Company
2855 Cranston Road
Beloit, WI 53511

Manual #16284 8/05

TABLE OF CONTENTS

1 - OWNER’S RESPONSIBILITY ....................................................................................1 - 1

2 - INSTALLATION INSPECTION....................................................................................2 - 1

3 - GETTING TO KNOW YOUR BROASTER PRESSURE FRYER................................3 - 1

4 - PRE-COOKING PREPARATIONS..............................................................................4 - 1

O-RING LUBRICATION............................................................................................4 - 1

COVER CHECK.......................................................................................................4 - 1

COOKING OIL..........................................................................................................4 - 1

Liquid Oil ..........................................................................................................4 - 1

Solid Shortening...............................................................................................4 - 1

OIL LEVEL................................................................................................................4 - 2

FOOD AND CONDIMENTS .....................................................................................4 - 2

1800GH LIGHTING INSTRUCTIONS......................................................................4 - 3

Start Up ............................................................................................................4 - 3

Shut Down........................................................................................................4 - 3

5 - 1600 MECHANICAL CONTROL PANEL....................................................................5 - 1

FAMILIARIZATION...................................................................................................5 - 1

6 - SOLID STATE CONTROL PANEL .............................................................................6 - 1

ROTARY DIAL FAMILIARIZATION.............................................................................6 - 1

CONTROLLER PROGRAMMING.........................................................................6 - 2

Set Temperature...............................................................................................6 - 2

Set Time...........................................................................................................6 - 2

Set AUTO COMP (Automatic Time Compensation).........................................6 - 2

DUAL DISPLAY FAMILIARIZATION ...........................................................................6 - 3

CONTROLLER PROGRAMMING.........................................................................6 - 4

Set Temperature...............................................................................................6 - 4

Set Time...........................................................................................................6 - 4

Set AUTO COMP (Automatic Time Compensation).........................................6 - 4

Read Actual Temperature.................................................................................6 - 4

Reset Cycle Counter........................................................................................6 - 4

TEMP-N-TIME FAMILIARIZATION.............................................................................6 - 5

CONTROLLER BASIC PROGRAMMING .............................................................6 - 6

Normal Operating Mode

Set Temperature...............................................................................................6 - 6

Set Time...........................................................................................................6 - 6

Set AUTO COMP (Automatic Time Compensation)........................................ 6 - 6

Read Actual Temperature.................................................................................6 - 6

Reset Cycle Counter........................................................................................6 - 6

Multi-Program Feature

Preset Cook Mode............................................................................................6 - 7

Chose Preset Cook Cycle................................................................................6 - 7

Manual #16284 8/05

Programming Procedure (Preset Mode)................................................................6 - 7

Change Cook Time................................................................................................6 - 7

Change Cook Temperature....................................................................................6 - 7

Activate/Deactivate Auto Comp .............................................................................6 - 7

Advance To Next Preset ........................................................................................6 - 7

7 - COOKING WEIGHT, TEMPERATURE AND TIME ..........................................................7 - 1

FRESH PRODUCTS......................................................................................................7 - 1

FROZEN IQF CHICKEN................................................................................................7 - 2

8 - PRODUCT PREPARATION AND COOKING...................................................................8 - 1

PREPARING GENUINE BROASTER CHICKEN...........................................................8 - 1

COOKING......................................................................................................................8 - 1

MSG FREE CONDIMENT LIST FOR FRESH PRODUCT ............................................8 - 2

Broaster Marinades................................................................................................8 - 2

Broaster Coatings and Batters...............................................................................8 - 2

Other Broaster Food Recipes ................................................................................8 - 3

9 - COOKING OIL CARE AND FILTERING ..........................................................................9 - 1

OIL CARE....................................................................................................................9 - 1

FILTERING..................................................................................................................9 - 2

FILTERING HINTS...................................................................................................... 9 - 3

10 - CLEANING ...................................................................................................................10 - 1

COOKING WELL.......................................................................................................10 - 1

FOOD BASKET.........................................................................................................10 - 2

UNIT SURFACES......................................................................................................10 - 2

CONDENSATE PAN..................................................................................................10 - 2

SLIDE ROD...............................................................................................................10 - 2

COVER......................................................................................................................10 - 2

SPLASH SHIELD ......................................................................................................10 - 3

PROBE GUARD........................................................................................................10 - 4

MINIMUM PREVENTIVE MAINTENANCE REQUIREMENTS .................................10 - 5

11 - NIGHTLY SHUTDOWN.................................................................................................11 - 1

12 - SEASONAL SHUTDOWN............................................................................................12 - 1

13 - TROUBLESHOOTING..................................................................................................13 - 1

ELECTRICAL TIPS ...................................................................................................13 - 1

SOLID STATE CONTROLLER TIPS.........................................................................13 - 2

1800GH GAS TIPS....................................................................................................13 - 3

COVER AND YOKE TIPS......................................................................................... 13 - 4

PRESSURE SYSTEM TIPS......................................................................................13 - 4

PRODUCT TIPS........................................................................................................13 - 5

Fresh Chicken...................................................................................................13 - 5

Frozen IQF Chicken..........................................................................................13 - 6

FILTERING TIPS.......................................................................................................13 - 7

Manual #16284 8/05 Rev 11/08

1 - OWNERS RESPONSIBILITY

It is the owner’s responsibility to:

®

• Insure the Broaster

Pressure Fryer is

properly maintained.

• Insure all safety devices and warning
signs are in their original location and
are legible.

• Allow only properly trained personnel to
operate, clean and maintain a Broaster

®

Pressure Fryer.

• Retain this manual for future reference.

• Insure main power supply is discon­nected before the unit is serviced.

• When you sell, trade, dispose of or give
away your Broaster® Pressure Fryer,

you must make sure that all safety
devices and warning signs are intact and
legible and the operation manual is
included with the unit.

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 disposal of the Broaster®
Pressure Fryer so records may be updated.

• 1800GH: Keep burner area free and
clear of all combustible materials.

• 1800GH: DO NOT obstruct exhaust flue
or open area around bottom of unit at the
front, back and sides which would
restrict the flow of combustion and venti­lation air .

Manual #16284 8/05 Rev 5/08

1 - 1

2 - INSTALLATION INSPECTION

Before operating unit, be sure installation
meets all requirements in the Installation
Manual provided with your unit.

CAUTION: Follow cleaning instruc-

tions as outlined in this manual before
operating the first time. See section 11 ­CLEANING.

• A remote circuit breaker or fuse should

be installed in the main power supply
located in a path of exit and clearly iden­tified.

• To avoid splashing of hot liquid, unit

must be restrained to prevent tipping.
This can be done by installing the unit in
a battery of appliances, in an alcove or
with adequate ties.

• See Safety Relief Valve under GET-

TING TO KNOW YOUR BROASTER®
PRESSURE FRYER. DO NOT install
unit where traffic area’s are on either
side or in back of unit.

1800GH:

WARNING: Electrical Grounding

Instructions - The Model 1800GH is
equipped with a three-prong (grounding)
plug for your protection against shock haz­ard and should be plugged directly into a
properly grounded three-prong receptacle.
DO NOT cut or remove grounding prong
from this plug.

• A gas shutoff valve, installed in gas sup-

ply line, should be located in a path of
exit and clearly identified.

Gas Conversion: Contact your local
Broaster Company representative for con­verting from one type of gas to another.

2 - 1

Manual #16284 8/05 Rev 9/05

Model 1600:

3 - GETTING TO KNOW YOUR

®

BROASTER

PRESSURE FRYER

3 - 1

Manual #16284 8/05

Model 1800:

3 - 2

Manual #16284 8/05

1. Pressure Regulating Valve: Opens
and closes pressure regulating valve.
When cover and valve are CLOSED,
this valve seals the cooking well allow­ing pressure to build up. Valve is pre­set to maintain pressure at 12-14 PSI
during a cooking cycle. When OPEN,
all pressure is exhausted and timer
stops timing.

2. Cooking Well: Holds cooking oil.

3. Basket Lifter Holder: Holds basket
lifter when not in use.

4. Condensate Pan: Holds condensation
drained from exhaust tank. Check liq­uid level several times daily. Empty as
needed.

WARNING: Water and hot oil DO

NOT mix. DO NOT pour contents of
condensate pan into cooking well or filter
pan. Hot oil could splash causing serious
burns.

8. Model 1800GH Manual Gas Shut Off
Valve: Shuts off gas flow to the gas
valve. Gas will flow when handle is in
line with pipe. Turning handle cross­wise to the pipe will stop gas flow.

9. Model 1800GH Gas Valve: Regulates
gas supply. The valve has a two posi­tion switch: OFF to stop all gas flow
and ON allows gas flow to pilot and

main burner as needed.

5. Filter Pan: Holds filter components
and filtering compound used to filter
hot oil.

CAUTION: HOT!

WARNING: Hot shortening! DO NOT

use this container to transport hot
shortening. Hot shortening could splash
causing serious burns.

6. Exhaust Drain Tube: Directs conden­sation from the exhaust tank into con­densate pan.

7. Model 1800GH Pilot Burner: A small
flame used to ignite the main burner.

10. Drain Valve: Used to drain cooking oil
from cooking well into filter pan or con­tainer made for handling hot oil.

DANGER: Never drain oil unless

cook/filter switch is OFF and pressure
regulating valve is OPEN. Hot oil could
spray out under pressure causing serious
burns.

1 1. Drain V alve Handle: Opens and closes

drain valve. When handle is horizon­tal, valve is closed. When vertical,
valve is open.

3 - 3

Manual #16284 8/05 Rev 9/08

12. Cover O-Ring: Forms a seal when
cover is lowered into the cooking well.

13. Safety Relief Valve: This valve will
open in the event pressure in the cook­ing well meets relief pressure of valve.
A properly installed valve has the outlet
facing toward rear corner of the coun­tertop. DO NOT use valve to release
pressure at the end of a cooking cycle.
If valve leaks during normal operation,
DO NOT operate your unit until valve is
replaced by an authorized Broaster
Company representative.

WARNING: Keep away from safety

relief valve opening without heat and
steam protective apparel. Escaping steam
could cause serious burns.

Test valve once a month. Also test
before and after an extended period of
non-service. Using a hot mitt, lift valve
handle during a cook cycle until pres­sure is released from cooking well.
Allow valve to snap closed.

15. Basket Lifter: Used to raise and lower
food basket into the cooking well.

16. Food Basket: Holds product for cook­ing.

17. Hot Oil Level: Indicates proper level
when oil is at operating temperature.

Model 1600:

Model 1800:

14. Pressure Gauge: Indicates pressure
within the cooking well. Normal oper­ating pressure is 12-14 PSI.

Manual #16284 8/05 Rev 9/08

3 - 4

18. Pressure Port: When cover is
CLOSED while cooking, all steam
passes through this port into the pres­sure regulating valve.

19. Capillary Guard: This guard protects
temperature sensor probe, hi-limit bulb
and capillary from damage.

CAUTION: Check oil level before
turning cook/filter switch to COOK.

20. 1600/1800E Hot Oil Level: Indicates
proper level when oil is at operating
temperature. 1800GH: HOT OIL
LEVEL is stamped on capillary guard.

Model 1600:

Model 1800:

21. Exhaust Tank: Steam and vapors are
exhausted through this tank.

22. Filter Pump and Motor: Used to return
oil to cooking well when filtering.

23. Basket Rest: Used to hold and tilt bas­ket for draining whenremoving cooked
product from oil or loading product
before lowering into oil.

CAUTION: DO NOT rest basket on

top flange of cooking well. Damage to
area in contact with o-ring can cause leak­ing under pressure or o-ring failure.

3 - 5

Manual #16284 8/05