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1800GHXP
Service Manual
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Broaster 1800, 1600, 1800EXP, 1800GHXP, 1800GH Service Manual

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1600 1800
SERVICE MANUAL
BROASTER® 1600 AND 1800
PRESSURE FRYER w/SMART TOUCH CONTROL
Be sure ALL installers read, understand, and have access to this manual at all times.
Genuine Broaster Chicken®, Broasted®, Broaster Chicken®, Broaster Foods®. and Broasterie® are registered
trademarks. Usage is available only to licensed operators with written authorization from the Broaster Company.
Design Certified By:
1600: CSA, NSF and UL 1800: CSA (AGA & CGA), NSF and UL
Broaster Company
608/365-0193 broaster.com
Manual #17270 10/13 Rev 9/16
© 2013 Broaster Company
Printed In U.S.A.
All adjustments and repairs shall be made
FOR YOUR SAFETY
Do not use or store gasoline or other flammable vapors
or liquids in the vicinity of this or any other appliance.
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:
Indicates an imminently hazardous situation which, if not avoided, could result in serious injury or death.
Indicates a potentially hazardous situation which, if not avoided, could result in serious injury or death.
Indicates a potentially hazardous situation which, if not avoided, could result in minor injury, property damage or both.
by an authorized Broaster Company repre­sentative.
when the cook/filter switch is moved to
If at any time the POWER ON light does not turn off
the OFF position, disconnect the power
If there is a power failure, turn cook/filter switch OFF. On the Model 2400GH, also slide switch on gas valve OFF. DO NOT
to the fryer and contact your local Broaster Company representative for service immediately.
attempt to operate unit during a power fail­ure.
DO NOT operate unit
without filter pan and filter Failure to read and understand this manual
completely could result in serious injury
pan cover in its proper position. Filter pan cover must be wiped clean after
each filtering cycle. or death. Be sure ALL operators read, understand and have access to this manual at all times.
Rags or paper containing
ports on bottom of cover are clear of any
oil or grease buildup.
Make sure Pressure Relief Valve and Pressure Gauge
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.
cont’d on next page
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broaster.com Manual #17270 10/13 Rev: 10/15
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.
Make sure a restraining
device is used that complies with the Standard for Commercial 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 #17270 10/13 Rev: 10/15
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TABLE OF CONTENTS
1 - WARNING SIGNS AND LABELS
1600 ........................................................................................................................ 1 - 1
1800 ........................................................................................................................ 1 - 2
Pictures .................................................................................................................... 1 - 3
2 - ELECTRIC POWER SUPPLY
WIRING DIAGRAMS
Electrical Connection - Single and Three Phase Power Connection ................. 2 - 1
DOMESTIC 1600/1800E ST ............................................................................... 2 - 2
EXPORT 1600XP ST .......................................................................................... 2 - 3
EXPORT 1800EXP ST ........................................................................................ 2 - 4
DOMESTIC 1800GH ST...................................................................................... 2 - 5
EXPORT 1800GHXP ST ..................................................................................... 2 - 6
3 - SMART TOUCH CONTROL PANEL
FAMILIARIZATION ......................................................................................................3 - 1
COOK TAB .................................................................................................................. 3 - 2
Cook Time Display ............................................................................................... 3 - 2
Temperature Display ............................................................................................. 3 - 2
Select Preset Display ........................................................................................... 3 - 3
Cycles Since last Filtered ..................................................................................... 3 - 3
FILTER TAB ................................................................................................................ 3 - 4
SETUP TAB ................................................................................................................ 3 - 5
PIN Number .......................................................................................................... 3 - 5
Setup Display ....................................................................................................... 3 - 5
Time & Date Adjustment ....................................................................................... 3 - 5
Temperature Adjustment ....................................................................................... 3 - 5
Energy Save Setting .............................................................................................3 - 6
Pin Maintenance ................................................................................................... 3 - 6
Presets ..................................................................................................................3 - 7
Name Edit ....................................................................................................... 3 - 7
Position Edit .................................................................................................... 3 - 7
Time & Temperature Edit ................................................................................. 3 - 7
Auto Comp On / Off ........................................................................................ 3 - 7
Active ..............................................................................................................
Add New ......................................................................................................... 3 - 8
Menu Transfer ................................................................................................. 3 - 8
Export Menu .............................................................................................. 3 - 8
Load Menu ................................................................................................. 3 - 9
Shortening Management ................................................................................ 3 - 9
Language Selection ........................................................................................ 3 - 9
Alert Settings ..................................................................................................3 - 9
HELP TAB ................................................................................................................ 3 - 10
CALIBRATION ........................................................................................................... 3 - 11
3 - 7
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4 - POWER INPUT BOX
1600/1800E
CONTACTORS (1600/1800E)............................................................................ 4 - 2
FUSE (1600/1800E) ...........................................................................................4 - 3
HEATING ELEMENTS (1600/1800E).................................................................4 - 3
LIMIT SWITCH ...................................................................................................4 - 5
1800GH
TRANSFORMER (1800GH)...............................................................................4 - 6
5 - COVER AND YOKE
PROPER COVER OPERATION ..............................................................................5 - 1
FAMILIARIZATION...................................................................................................5 - 2
ADJUSTMENTS.......................................................................................................5 - 3
REMOVAL................................................................................................................ 5 - 4
DISASSEMBLY........................................................................................................5 - 4
ASSEMBLY..............................................................................................................5 - 5
PRESSURE GAUGE ...............................................................................................5 - 6
SAFETY RELIEF VALVE..........................................................................................5 - 7
6 - 1600 PRESSURE SYSTEM
SYSTEM FAM ILIARIZATION................................................................................... 6 - 1
EXHAUST DRAIN TUBE ......................................................................................... 6 - 2
EXHAUST TANK...................................................................................................... 6 - 2
EXHAUST TUBE......................................................................................................6 - 3
PRESSURE REGULATING VALVE.........................................................................6 - 4
7 - 1800 PRESSURE SYSTEM
SYSTEM FAM ILIARIZATION................................................................................... 7 - 1
EXHAUST DRAIN TUBE ......................................................................................... 7 - 2
EXHAUST TANK...................................................................................................... 7 - 2
EXHAUST TUBE......................................................................................................7 - 3
PRESSURE REGULATING VALVE.........................................................................7 - 3
8- 1800GH MAIN BURNER SYSTEM ............................................................................. 8 - 1
MODEL 1800GH LIGHTING INSTRUCTIONS........................................................8 - 1
GAS CONVERSION ................................................................................................ 8 - 1
HIGH ALTITUDE...................................................................................................... 8 - 1
VENTILATION..........................................................................................................8 - 2
GAS VALVE.............................................................................................................. 8 - 2
FLAME ADJUSTMENTS..........................................................................................8 - 4
AIR SHUTTER.........................................................................................................8 - 5
COMBUSTION CHAMBER...................................................................................... 8 - 6
MAIN BURNER ORIFICE ........................................................................................ 8 - 7
PILOT BURNER ORIFICE....................................................................................... 8 - 8
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9 - DRAIN VALVE AND FILTER SYSTEM
DRAIN VALVE........................................................................................................... 9 - 1
FILTER PAN.............................................................................................................. 9 - 2
CHECK VALVE ......................................................................................................... 9 - 3
MOTOR .................................................................................................................... 9 - 4
PUMP....................................................................................................................... 9 - 6
10 - TROUBLESHOOTING
ELECTRICAL TIPS ................................................................................................. 10 - 1
SMART TOUCH CONTROLLER TIPS ................................................................... 10 - 2
GAS TIPS (1800GH) ............................................................................................... 10 - 3
COVER AND YOKE TIPS .......................................................................................10 - 4
PRESSURE SYSTEM TIPS .................................................................................... 10 - 4
PRODUCT TIPS .....................................................................................................10 - 5
FILTERING TIPS ..................................................................................................... 10 - 7
FLOW CHART - 1600 & 1800E .............................................................................. 10 - 8
FLOW CHART - 1800GH ....................................................................................... 10 - 9
broaster.com Manual #17270 10/13 Rev 3/16
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1 - WARNING SIGNS
CAUTION
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When servicing a Broaster
® Pressure Fryer,
be sure all safety devices and warning signs are in place and legible. If not, The Broaster Company should be notified in writing of the lack of warning signs and the existence of an unsafe condition.
1600 Domestic Labeling
If you need replacement warning signs or manuals, contact an authorized Broaster Company representative or The Broaster Company Service Department at 608/365-
0193.
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1800 Domestic Labeling
DO NOT OPERATE THIS FRYER WITH OUT FILTER PAN & COVER IN PLACE
CAUTION:
CAUTION
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broaster.com Manual #17270 10/13 Rev 12/14
Item 1 - Part #10733
Item 2 - Part #10886
Item 3 - Part #11027
Item 4- Part #16368
Item 5 - Part #11073
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broaster.com Manual #17270 10/13 Rev 12/14
Item 6 - Part #06375
CAUTION
DO NOT OPERATE THIS FRYER WITHOUT FILTER PAN & COVER IN PLACE
CAUTION:
MODEL 1800GH
C US
R
Item 11 - Part #15398 Domestic Only
Item 7 - Part #15725
Item 8 - Part #11028
Item 12 - Part #11746 (1800GH Only)
Item 13 - (1800GH after July 2003)
#15777 for Nat Gas
#16993 for LP Gas
Item 9 - Part #10900
Item 10 - Part #15785
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OPERATING 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 THE "OFF" POSITION.
INSTALL IN ACCORDANCE WITH AMERICAN NATIONAL STANDARD FUEL GAS CODE ANSI Z223. 1 LATEST ADDITION
Item 14 - Part #15694 Domestic
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2 - ELECTRIC POWER SUPPLY
3Ph 50/60Hz
1Ph. 50/60Hz
Many sections in this
manual pertain to check­ing and repairing electrical components. High voltage
will be encountered in sev­eral instances. Only persons trained and equipped for checking high voltage shall undertake such repairs.
If no component 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.
WIRING DIAGRAMS
Three and Single Phase Wiring Connections:
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 TROU­BLESHOOTING section.
Wiring diagrams are located on inside front panel.
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NO
C
DOMESTIC - 1600 and 1800E SmartTouch
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EXPORT 1600XP SmartTouch
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EXPORT 1800EXP SmartTouch
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DOMESTIC - 1800GH SmartTouch
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EXPORT - 1800GHXP SmartTouch
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3 - SMART TOUCH CONTROL PANEL
ON
OFF
HIGH LIMIT
RESET
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SMART TOUCH FAMILIARIZATION
1. Power Switch: This switch has two posi-
tions: ON or OFF.
2. Hi-Limit Control: Prevents oil tempera­ture from exceeding 475°F. When this con­trol trips, the power to the unit will be shut down. Turn unit OFF and DO NOT attempt to operate until it has been serviced by an authorized Broaster Company representa­tive.
It is possible for this con-
trol to trip during ship­ment. If it does, fully depress red reset button. If control “clicks” it was tripped. If not, it is correctly reset.
3. Touch Control Screen: Touching this
screen controls the many options of the fryer.
On initial power up you may be asked to enter the current date and time, and verify the Serial Number. Or the screen will have the word CAUTION flashing on the screen.
If the date and time entry screen appears 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 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 the serial number using the keyboard and press enter.
The date/time display and the serial number display
will not appear again when the power switch is turned off and back on.
If the CAUTION screen appears it is there to remind you to check the oil level before the heating elements or burner are activated. If the oil is at the proper level, press the green OK button in the bottom right corner of the screen.
Along the top of the screen are four tabs (Cook, Filter, Setup and Help) to help you setup and use your fryer. This tab is the main working screen. From
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COOK TAB
05:00
Auto Comp ON
360F
Heat ON
Set
Select Preset
Select Preset
01
Cycles Since Last Filtered
Cook Filter Setup Help
05:00
Auto Comp ON
360F
Heat ONSet
At the end of the cycle the left box alter­nates between red and white, the alert sounds and continues until the exhaust valve is opened by turning the small handle on the Counter Top, 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 off and green if Auto­Comp is on.
this screen can be set the Cook Cycle Time, Cook Temperature, Product Preset and the number of loads cooked since the last time the oil was filtered.
CookTime Display:
The cook time is indicated in the box next to the clock face. To change the time press the time display twice and a keypad will appear.
Enter the cook time for the product you are cooking, as you enter the time it will appear above the keypad. To save this time press the enter key the new time will be entered and the keypad will disappear.
If no entry is made or the enter key is not pressed with in 25 seconds, no change is made to the time.
When a cooking cycle is started the box below the cook time turns yellow and shows the amount of time remaining in the cycle. The right box displays “CUSTOM”. The word “CUSTOM” also replaces the tabs across the top of the display. “CUS­TOM” indicates you are in manual cooking mode.
To turn Auto Comp on or off press the cook time display twice. When the keypad appears the Auto Comp toggle switch is in the upper right corner of the keypad. If the button is red Auto Comp is off, if it is green Auto Comp is on. Press the Auto Comp button to change it then press the enter key.
Our recommendation is that Auto Comp should be on when cooking a load of prod­uct.
Temperature Display:
The temperature is indicated next to the thermometer.
When the fryer is turned on in the morning this box will be yellow and “Heat On” will be displayed. The temperature will alternate between “LOW” and the set temperature until the oil temperature reaches the set temperature.
There are other times when this will occur;
1. Anytime the temperature is changed.
2. After a filtering cycle.
3. When a preset is selected and the oil temperature is not at the preset tempera­ture.
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In any of these cases when the oil tempera-
Select Preset
01
Cycles Since Last Filtered
ture reaches the set temperature the box turns green indicating the oil is up to the set temperature.
The temperature shown in this box can be either the “Set” temperature of the “Actual” temperature as indicated above the ther­mometer. To change from one to the other press anywhere in the box for 3 seconds. An alert will sound when you press the box and a second alert will sound when the change is made.
To set the temperature, press the tempera­ture box twice and a keypad will appear. Enter the temperature for the product you want to cook, as you enter the temperature, it will appear above the keypad. To save this temperature press the enter key.
Select Preset Display:
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 cooked uses a differ­ent temperature the temperature box will either remain green meaning it is all right to start a cook cycle or it will turn yellow meaning the temperature is too low to start a load. Wait to start a cook cycle until the temperature is green.
When the temperature is green. Load the product as recommended and move the small handle on the top of the fryer from open to close. This will start the cycle timer counting down. When the load is done an alert will signal that the cooking cycle is complete.
There are 2 “Select Preset” boxes.
All of the Broaster Company Products are preloaded into the memory of the control and can be selected when you want to cook that product. The cook time and cook temperature for that product will be auto­matically entered in the Time and Tempera­ture displays.
To select a product, press either preset box and a menu of the products will be dis­played. Tap the product you wish to select.
If the wrong product comes up, don’t worry! Tap the preset box again and the menu will appear.
Cycles Since Last Filtered:
It is recommended the oil should be filtered every 5 loads.
This box indicates how many cook cycles have been done since the last time the oil was filtered. It is active and can be pressed at any time to go to the filter display except during a cooking cycle. Once you reach a preset number of cycles, you will be shown a filter options screen. If a filter cycle is bypassed the next cycle will turn red and start flashing.
This number can be changed and the pro­cedure will be explained in the Setup Tab section.
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Stop
Pump
X
Start / Stop Filter Pump
Filter Pump Running
00:00
FILTER TAB
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
Close Drain Valve
Start
Pump
X
Start / Stop Filter Pump
Filter Pump Run Time
10:00
Limit Reached
This tab is the filter motor control and has two buttons; a Start Pump button and a Alert Silence button.
There are also two reminders to observe before filtering the oil. SEE SECTION 9 ­COOKING OIL CARE AND FILTERING before starting the pump motor.
The pump will continue to run and will auto­matically stop when the counter says 10:00 minutes. You will see the display below.
When the Start Pump button is pressed the filter running display appears as shown below.
The timer in the middle of the screen starts counting up. When it reaches 5:00 minutes an alert sounds and a reminder flashes (see below) to close the drain valve. To silence the alert press the button with the speaker on it. DO NOT press the Stop Pump button.
To return to the Cook Tab, press the red X in the upper left corner. The Caution Display will appear advising the oil level be checked. If the oil level is OK press the green OK button.
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