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Service Manual 09/2008

1. 7 la xl MAIN 812 7 GAS VALVE E 3 gt FILTER m E MOTOR gt MOTOR PILOT m N PURPLE TUM s CONTROL BOX ET ose a ar 212 u gi See IGNITION MODULE a 5 HIGH LA i LIMIJ mMm V 1 3 10 11 16 tej DO 99 O 1 _ _ GREEN IGNITOR GRN YEL GREEN 2 SLE WHI PUR TUR eno BROWN 7 H WHI ORG SENSOR u NH BROWN BROWN ag mans ad za gt E BLACK BLUE BLUE BLUE 5 BLUE PURPLE m BROWN POWER BLUE INPUT BOX BROWN BROWN 5 BLACK PURPLE 111 PROVAL lt ADD 6 RANSF ORMER J 24VAC I JILI BLUE BLACK lt C CITUR a GRAY ale BLACK s P OWEN SWITCH YELLOW gt PROBE CONTROL PANEL 14709 2 23 Manual 14680 3 99 Rev 4 08 1600 MECHANICAL CONTROL PANEL FAMILIARIZATION 1 Timer Shows desired cooking time and time countdown during a cook cycle 2 Power Switch Upper position allows use of the function shown by the cook filter position Lower position is OFF Power On Indicator Light Illuminates when power switch is in the upper tion 4 Cook Filter Switch Has two posi tions COOK and FILTER 5 Valve Closed Indicator Light nates when pressure regulating va
2. a e 5 Q Manual 14680 3 99 Rev 3 06 1 10886 AMPS gt ksi SAD na N 7 MPS WIR N 2 SER SAFETY AND OPERATING INSTRUCTIONS DANGER 3 FAILURE TO COMPLY WITH THESE SAFETY AND OPERATING INSTRUCTIONS COULD CAUSE INJURY TO OPERATOR AND BYSTANDERS e Be familiar with the Operation Manual e Keep cover closed when cooker is not in use MAXIMUM WORKING 7 DO NOT attempt to heat water in fryer Never force cover open or closed PRESSURE 15 P s 9 Never overfill with shorting or product e Keep drain pail or filter under cooking well e Keep cover open when draining cooking well e Clean only as recommended DO NOT use soaps e Be sure cooking well is clean and free of Remove all pressure before making any repairs water before filling with shortening Disconnect electrical power before removing control panel NSF MADE IN U S A __ Item 2 Part 11027 T 5 5 CK US 5 3 S GAS 2 US 5 US 3 IR 3 NS gt RV 3 S gt lt x AS M 4 lt 5 lt NS gt lt X S s A I NS k Fu S NA ANDAR A 3 Part 414665 1800GH Only Manual 14680 3 99 1 5 _ MODEL 1800GH SP Item 7 Part 11028 FT SHE 0 1 US US J NU x Part 15777 1800G
3. U U u uu 4 1 ROTARY DIAL FAMILIAR TON en 4 1 CONTROLLER PROGRAMMING ee 4 2 DUAL DISPLAY FAMILIARIZATION en 4 3 CONTROLLER PROGRAMMING nee 4 4 PRESET PROGRAMMING 4 5 WARNING DISPLAY nur dae a e tie 4 6 DISPLAYING ACTUAL TEMPERATURE 47 CALIBRATION as ea ea ren are D DE 447 ACCESS FOR SERVICES ERI EARUM EE C 4 8 GOOKEILTER SWITCH u 4 9 EIELIMITGONTROLE Sn huie DE 4 9 POWER ON INDICATOR LIGHT ene 4 11 SOLID STATE CONTROLLER tarada idiota 4 11 TEMPERATURE SENSOR PROBE 4 12 5 POWER INPUT 5 1 1600 1800E CONTACTO 16001800E Saiten 5 2 FUSE 1600 1 adios 5 3 HEATING ELEMENTS 1600 1800 5 3 POTS a M ME un o ERE MUN 5 5 RELAY 1600 18006 A sed 5 6 1800GH TRANSFORMER 1800GH ene 5 7 1800GHCE IGNITION CONTRO arnt een 5 8 1800GHUK IGNITION CONTROL es 55556 5 10 TRANSFORMER O 5 11 a en M E 5 11 6 COVER AND YOKE nern ee 6 1 PROPER COVER OPERATION nn 6 1 FAMILIARIZATIONG INO PN AM 6 2 O 6 3 2121 VE EURE 6 4 DISAS ENBI en ms 6 4 PSS REY ti
4. 11 3 COVER AND YOKE TIPS a se 11 53 PRESSURE SYSTEM TIPS u na dea beste aia 11 4 PHODDGT 2 2 anra Ne 11 5 FILTERING Psoe 11 7 FLOW GHART 1600218008 etarra tia 11 8 FLOW CHART a 1800GH ee ees aa os 11 10 14680 3 99 Rev 3 08 1 WARNING SIGNS 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 If you need replacement warning signs or manuals contact an authorized Broaster Company representative or The Broaster Company Service Department at 608 365 0193 Manual 14680 3 99 Rev 3 06 1 Part 10773 SAFETY AND OPERATING INSTRUCTIONS DANGER gt FAILURE TO COMPLY WITH THESE SAFETY AND OPERATING INSTRUCTIONS COULD CAUSE INJURY TO OPERATOR AND BYSTANDERS Be familiar with the Operation Manual Keep cover closed when cooker is not in use MAXIMUM WORKING DO NOT attempt to heat water in fryer Never force cover open or closed PRESSURE 15 PSI Never overfill with shorting or product e Keep drain pail or filter under cooking well e Keep cover open when draining cooking well Clean only as recommended DO NOT use soaps Be sure cooking well is clean and free of Remove
5. Use repair kit 15279 1 Remove two allen screws which attach the valve assembly to the cooking well Remove valve from the unit Loosen locking nut 9 then remove valve control yoke 10 from the stem assembly 11 Remove entire stem assembly from the housing 12 by pushing on threaded end of the stem assembly Remove all components from the stem assembly 11 Clean then dry all metal components not replaced with hot water and a mild detergent Install new parts from the repair kit Lubricate all O rings and contacting surfaces with olive oil 1716 ADJUSTMENI b 27 Mount valve assembly back on cooking well with the allen screws SIA NTROL ROD I EL 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 pres sure port located on inside top of the cooking well Using a screwdriver turn stem assembly 11 either clockwise or counterclockwise to obtain this dis tance 10 Tighten locking nut Manual 14680 3 99 Rev 7 01 8 1800 PRESSURE SYSTEM DANGER DO NOT attempt to tighten repair or replace any fitting line or component unless main electric power is dis
6. s Ts PU 05 E gt E o MOTIJA MOVIE INN N ET 3sn4 ul 42 gt Q N _ m 9 SOLOW 331 la N Ah 72978 gt pe AA NEIN O ma 3 SA 2 _ u NZ NOLOVLINOI e gt 2 id gt LJ 7 O lt N m l Z gt 52 sy N gov K gt gt 7 5 HO Z a a amp tud 4 2 24 ane HILIMS YN 1491 9974 WIRE ONLY COPPER ER SE LARS 8 AWM USE 14611 MO geje UR LEAS JITABLE COMPANY K BRUASTE 1600 1800E Solid State 208 or 240VAC Effective SE6E401073 5 8 400951 o 0 e e gt gt 2 8 a A 2 2 6 Manual 14680 3 99 Rev 6 06 1600 1800E Solid State 208 or 240VAC Effective SE6A700013 SE8A700011 eee Yo 4 i ia 14680 8 07 1600 1800E Solid State 480VAC e 2 8 Manual 14680 3 99 Rev 12 05 1600 1800E Solid State 480VAC Effective January 04 40 eee Z lt A eee N 2 2 9 Manual 14680 3 99 Rev 06 06 1600 1800E Solid State 480VAC Effective November 06 K60 2 10 Manual 14680
7. 11 From inside the cooking well slide ele LIMIT SWITCH ment out and lift on end to remove Sgueeze slightly to clear neck of cook When the pressure regulating valve is ing well CLOSED switch supplies power to the tim ing circuit 1 See ACCESS FOR SERVICE 2 With needle nose pliers disconnect one wire from the switch 15 3 CLOSE pressure regulating valve Check between remaining wire and ter minal where other wire was discon nected with an ohmmeter Meter should indicate a closed circuit If not Install new element 8 in reverse order Use new O rings 17 located mounting bracket is out of adjustment between element and inside of the or switch is faulty cooking well Adjustment Install large element nut and tighten 1 See ACCESS FOR SERVICE Be sure all wire connections are secure and in their original location 2 With pliers bend mounting bracket 16 closer or further away from control rod 5 5 Manual 14680 3 99 Rev 12 05 Replacement 3 Check between 1 C and 2 NC with an ohmmeter Meter should indicate an 1 See ACCESS FOR SERVICE closed circuit If not relay is faulty 2 Remove wires from switch 4 Check between 1 C and 3 NO with an ohmmeter Meter should indicate a 3 Remove two mounting screws open circuit If not relay is faulty 4 Install new switch in reverse order 5 With needle nose pliers disconnect sure all wire connections are secure one wire from the coil
8. Action Press and hold AUTO COMP Button for 3 seconds Response Green light will toggle on or off Read Actual Temperature Action Press and hold Temp Button for 3 seconds Response Temp Display will show actual oil temperature and will vary as cooling and heating takes place Action Press Temp Button to return to set point display Reset Cycle Counter Action Press Reset Button twice in 5 seconds Response Display will return to a set ting of 00 Note If counter is not reset before reaching 99 Upon the next cycle completion the display will begin counting at 01 4 4 Manual 14680 3 99 Rev 9 05 TEMP N TIME FAMILIARIZATION Same as on page 4 2a CAUTION CHECK OIL LEVEL BEFORE OPERATING lt NOTE For single product programming see page 4 2b PRESET PROGRAMMING PROGRAMMING PROCEDURE PRESET MODE Choose Preset Cook Cycle Action Press and hold the TIME and Action Press a button O thru 9 corre TEMP buttons simultaneously for three sponding to the desired preset seconds Response The TIME display will show Response The TIME display and P _ X where X is the preset selected TEMP display will begin flashing The CYCLE COUNT display will show 0 Note If a button is not pressed in ten indicating that the preset 40 values are seconds the display will revert to the displayed The preset values for the previous display TIME TEMP and AUTO COMP will be shown
9. 1 See ACCESS FOR SERVICE 2 OPEN cover Drain cooking oil from cooking well 3 Disconnect wires from control 6 3 5 4 Remove capillary guard 13 from inside the cooking well 1 l 5 Remove small nut 14 then large cap illary 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 out of cooking well Bend in the 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 Continued Manual 414680 3 99 rev 3 08 10 Reconnect wires then mount new trol 11 Replace capillary guard 12 Return cooking oil into cooking well 13 Cook a load of product and check for leaks 14 Tighten smaller nut 14 if necessary THERMOSTAT Cooking oil temperature is maintained by the thermostat control Desired cooking oil temperature is indicated on the knob the hi limit has opened see HI LIMIT CONTROL and CONTACTORS for trou bleshooting If cooking oil temperature is above 400 F replace the thermostat contactor 1 See ACCESS FOR SERVICE 2 Turn thermostat knob clockwise until you hear the control click 3 With needl
10. 1 Turn cook filter switch manual gas shut off valve 1 and switch 2 OFF 2 Remove pressure tap 7 on gas valve 3 Install manometer 4 Turn gas shut off valve 1 ON Manuals 14680 3 99 5 Light pilot see MODEL 1800GH LIGHTING INSTRUCTIONS Turn gas valve switch 2 ON CAUTION Check cooking oil level before turning cook filter switch to 6 Turn cook filter switch to COOK 7 Remove regulator adjustment cover 8 Adjust pressure when main burner is on 8 cook filter switch manual gas shut off valve 1 and switch 2 OFF 9 Remove manometer Replace pres sure tap plug Use gas pipe sealer on threads Turn manual gas shut off valve 1 ON 11 Slide gas valve switch 2 ON Turn cook filter switch to COOK Check pressure tap with a soap and water solution when main burner is on Bubbles indicate a gas leak Pilot Burner Flame Adjustment Pilot burner flame must surround sensor 9 1 Remove screw 10 2 Adjust flame and replace screw Main Burner Flame Flame must be blue and sit on the burner surface During normal operation a slight whoosing sound may be heard when burner shuts off If you cannot adjust the flame correctly check the following 1 Air shutter adjustment See AIR SHUTTER Adjustment 2 Centered main burner orifice After installing a new gas valve or piping brackets can shift causing gas not to tr
11. Align holes in lifter box spacer block and cover Install new cover bolts but do not tighten Install slide rod through bearings on right hand side of yoke bar Place assembly onto counter top Place slide rod 13 into the rear sup port install bolt into front of the slide rod and install bolt on back of slide rod 1600 Pull cover forward If yoke latch 6 and latch columns 7 do not line up adjust slide rod 13 to the left or right Center cover within the cooking well See Centering Cover 6 6 PRESSURE GAUGE Gauge indicates pressure within the cooking well Operating pressure is 12 14 PSI Replacement 1 OPEN the pressure regulating valve then the cover Unscrew gauge 15 from the elbow 16 Use teflon tape on the threads Screw new gauge onto the elbow Manual 14680 3 99 Rev 9 08 SAFETY RELIEF VALVE The safety relief valve opens in the event pressure in the cooking well meets relief pressure rating of the valve DO NOT alter or attempt to repair this valve WARNING Keep away from safety A relief valve opening without heat and steam protective apparel Escaping steam could cause serious burns 1 See PROPER COVER OPERATION Replacement Note Replacement valve must have a 15 PSI relief pressure 1 OPEN cover and pressure regulating valve 2 Unscrew valve 1 from the cover 6 7 Note DO NOT install valve discharge opening in the direction of foo
12. 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 thoroughly 5 Clean silicone rubber from cover underside Seal cover with silicone during assembly 6 Clean all tubes 7 Replace grommet 6 if necessary 8 Assemble in reverse order EXHAUST TUBE gt Tube 4 directs steam and vapors from cooking well into the exhaust tank PRESSURE REGULATING VALVE Valve 6 is preset to maintain a maximum pressure of 12 14 psi during a cooking cycle Pressure may build slowly or remain low when cooking small loads Add one or two guartered potatoes with product to help build and maintain maximum pressure 8 3 Replacement 1 2 Disconnect main electric power supply Slide right hand sgueeze clamp on valve outlet to the left Pull silicone sleeve and exhaust tube 4 free of valve outlet Remove two allen screws mounting valve to the cooking well and remove valve See Repair Install silicone sleeve and exhaust tube onto the valve outlet Slide right hand squeeze clamp onto the valve outlet Manual 14680 3 99 Rev 9 08 Repair Prior to SE8D101763 and SG8D100830 11447 1 Remove two allen screws which attach the valve assembly to
13. Yes Does main burner flame Yes ignite Does ignitor Does filter Motor work Yes stop i Replace gas Is motor pokati Yes valve humming Yes once pilot is 9 lit Is thermal ignitor overload problem on ves 8 Check switch amp wiring connections Replace motor i if necessary Is pilot tube Replace gas and orifice Yes valve clear Clear and try again Check o ring and Does steam escape from filter pan stack assembly Remove blockage or Does steam replace valve cover Does pressure build properly Yes escape around No Problem Rebuild Replace cover o ring Check for enough product and high enough temperature Proper input gas pressure is below 7 WC for Natural Gas and below 14 WC for LP 11 11 Manual 14680 3 99 Rev 3 08 Can you use slot in back of motor to get it Yes started Separate pump from motor Still humming Remove face plate from pump and clean parts No Problem Replace motor SERVICE NOTES Manual 414680 3 99 SERVICE NOTES Manual 414680 3 99 SERVICE NOTES Manual 414680 3 99
14. compensate for fluctuations in the oil temperature Cycle Count Display Increases in increments of one every time a cooking cycle is completed Cycle Count Reset Button Resets the cycle count display to zero Manual 14680 3 99 Rev 9 05 CONTROLLER PROGRAMMING CAUTION Check oil level before turning cook filter switch to COOK Action Turn cook filter switch to COOK Response Temp Display alternates between number values for cook tem perature and LO idle mode LO will disappear when oil temperature has reached cook temperature value Time Display will show the set time in min utes and seconds Set Temperature Action Press Cook Temperature But ton twice within 5 seconds Response Programming mode has been entered Flashing Temp Display reads temperature value ie 360F Action If desired press keypad num bers 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 5 seconds Response Programming mode has been entered Flashing Time Display reads time value 08 00 Action If desired press key pad num bers to change displayed value in min utes 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
15. is not reversed If it is pilot burner will ignite but the flame sensor will not produce enough microvolts to verify a pilot flame As 41 2 result the gas valve will not open 1 See ACCESS FOR SERVICE 2 Connect main power supply l 3 Colors indicated below come from wire i 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 indi Continued 5 8 Manual 14680 3 99 Rev 12 05 5 With heat on light illuminated check voltage across blue and brown at the ter minal block 20 with a voltmeter Meter should indicate applied voltage If not check voltage supply loose connections or ignition control is faulty 5 9 Manual 14680 3 99 Rev 5 08 1800GHUK Pressure Fryer the United Kingdom POWER INPUT BOX 1800GHUK Ignition control 19 operates the gas solenoids and lights pilot burner Note Be sure polarity in main power supply is not reversed If it is pilot burner will ignite but the flame sensor will not produce enough microvolts to a pilot flame As a result the gas valve will not open 1 See ACCESS FOR SERVICE 2 Connect main power supply 3 Colors indicated below come from wire harness attached to the gas valve 4 Turn cook filter switch to COOK With HEAT ON light illuminated check voltage across blue a
16. l a 4 X EZ e 2 20 14680 3 99 4 08 EU 1800GHCE Solid State FILTER CONTROL BOX MOTOR OOOO LT Y TERMINAL IGNITION MODULE 2 1 BLICK 10 11 13 14 16 a O OOO O OO O m Y NT Y FA s 1 A F T E E I N IGNITOR 2 Y US Du GREEN J UN WHIZPUR FLAME V a gt WHI ORG SENSOR 5 KO STACK 24 1112 1 al A m SAWER t LJ gt LJ INPUT BOX W E m zl J ES m m ih 5 gt a IN O D BLUE ga BLUE J E Kass u CAPACITOR 2 LJ GRAY gt x URANGE o A A PA URANGE anit ul 21 o B JO kl ENS CONTROLLER 2 PUWER PUWER SWITCH LIGH CONTROL PANEL 2 21 Manual 14680 3 99 Rev 4 08 EU 1600UK 1800EUK Solid State ne S 2 22 Manual 14680 3 99 Rev 4 08 EU 1800GHUK Solid State
17. points 1 See ACCESS FOR SERVICE 2 Fully depress red reset button then release 3 With needle nose pliers disconnect one wire from control 4 Check across two terminals with an ohmmeter Meter should indicate a closed circuit If not control is faulty Manual 14680 3 99 Rev 9 05 Replacement ge NY 1 See ACCESS FOR SERVICE 2 OPEN cover Drain cooking oil from cooking well 3 Note where wires are connected Remove wires from control 3 4 Remove capillary guard 13 from inside cooking well 5 Remove small nut 14 then large cap nut 15 from outside cooking well 6 Pull control bulb 16 out of cooking well then remove control from control panel 7 Insert control 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 Reconnect wires then mount new con trol Replace capillary guard Return cooking oil to cooking well Cook a load and check for leaks Tighten smaller nut 14 if necessary Manual 14680 3 99 Rev 3 08 POWER ON INDICATOR LIGHT Illuminates when cook filter switch is turned to COOK Replacement 1 See
18. 18 and in their original location 6 Check between coil connections with RELAY 1600 1800E an ohmmeter Meter should indicate a closed circuit If not coil is faulty If C1 contactor is faulty the relay circuit pre vents the unit from being turned on after it has been turned off In this condition the fil ter motor will operate normally If the unit is off and the POWER ON light is illuminated replace C1 contactor See CONTACTORS 1600 1800E 1 2 See ACCESS FOR SERVICE With needle nose pliers disconnect wire from 1 C 5 6 Manual 14680 3 99 Rev 12 05 1800GH Pressure TRANSFORMER 1800GH 2 The transformer 20 supplies power to the gas control valve 1 See ACCESS FOR SEVICE 3 5 7 14680 3 99 Disconnect one wire from the primary black and white wires side and sec ondary yellow and blue wires side of the transformer Check between the two primary wires with an ohmmeter Meter should indi cate a closed circuit If not trans former is faulty Check between the two secondary wires with an ohmmeter Meter should indicate a closed circuit If not trans former 15 faulty 1800GHCE Pressure POWER INPUT BOX 1800GHCE cate applied voltage If not check voltage Ignition control 19 operates the gas valve supply loose connections or ignition con solenoids and lights pilot burner trol is faulty Note Be sure polarity in main power supply
19. 1800GH Display reads CHEC 6 6 Replace 7 Faulty gas 1800GH 7 Replace 8 Faulty contactor 8 Replace 1600 1800E 9 Faulty heating element s 9 Replace 1600 1800E 10 Open or faulty wall fuse 10 Check wall fuse or circuit breaker 11 Pilot does not light 11 See GAS TIPS 1800GH 11 2 Manual 414680 3 99 Rev 7 01 GAS TIPS 1800GH COMPLAINT CAUSE REMEDY 1 Gas valve OFF 1 Turn ON 2 Air in gas line 2 Tighten Pilot burner light 3 Gas shut off valve OFF 3 Replace 4 Pilot burner flame too small 4 Adjust flame 5 Gas pressure too high 5 Install pressure regulator 1 Gas valve not ON 1 Turn On 2 Controller in program mode 2 Exit program mode Main burner will not turn on 3 No electrical power to the 3 Check circuit gas valve 4 Faulty gas valve 4 Replace COVER AND YOKE TIPS COMPLAINT CAUSE REMEDY 1 O ring groove and O ring 1 Clean and lubricate dry or dirty 2 Hard O ring 2 Replace Cover hard to CLOSE 3 Teflon bearing out of 3 Adjust or replace adjustment or worn 4 Cover not centered 4 Center 5 Lifter box dirty or dry 5 Clean and lubricate 1 O ring groove and O ring 1 Clean and lubricate Cover won t OPEN dry or dirty 2 Pressure not released 2 OPEN pressure regulating WARNING Never use valve force to OPEN cover 3 Pressure regulating valve 3 Adjust valve out of adjustment Cover hard to move from front 1 Yoke bearings and slide 1 Clea
20. ACCESS FOR SERVICE 2 Disconnect wires 3 Push down on light fixture 2 located behind control panel Slide fixture toward wire end until amber lens 11 is free of fixture 4 Install new light in reverse order Be sure all wire connections are secure and in the original location SOLID STATE CONTROLLER The controller regulates time and tempera ture Miscellaneous Remove F C jumper to dis play temperature in Celsius Replacement Note Within warranty controller should be replaced as a whole circuit board trans former speaker and control panel Out of warranty transformer and speaker are avail able separately 1 See ACCESS FOR SERVICE 2 Remove cook filter switch 3 Remove power on indicator light 4 Disconnect HEATER OUTPUT N O wires using needle nose pliers 5 Disconnect START SWITCH wires using needle nose pliers Continued Manual 14680 3 99 rev 9 05 6 Disconnect probe wires Note Be sure red and yellow wires are not reversed during replacement Controller will display PROB if polarity is reversed 7 Disconnect transformer wires within wire nuts 8 Remove controller 9 Assemble in reverse order 10 See CALIBRATION TEMPERATURE SENSOR PROBE This probe is a thermocouple It sends fluc tuating millivolts to the controller which is translated into degrees of temperature Replacement 1600 1800E 1 See ACCESS FOR SERVICE 2 Disconn
21. An American Tradition Since 1954 MODEL 1600 AND 1800 BROASTER PRESSURE FRYER SERVICE MANUAL Be sure ALL installers read understand and have access to this manual at all times 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 pone 6 608 365 0193 www broaster com Design Certified By 1600 NSF and UL 1800 8 and UL Printed in U S A 14680 3 99 Rev 9 08 Copyright 1999 The Broaster Company FOR YOUR SAFETY Do not use or store gasoline or other flammable vapors or liguids 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 mainte nance instructions thoroughly before installing or servicing this eguipment 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 c
22. Manuals 414680 3 99 Loosen brass fitting 24 and pull 1 4 gas supply line 25 brass fitting and pilot burner orifice 26 free of burner Loosen pipe union 6 While pulling on gas valve loosen air shutter and locknuts until they can be removed Remove main burner orifice 27 Assemble in reverse order Adjust air shutter See AIR SHUTTER Check all connections and pipes with a soap and water solution Bubbles indicate a gas leak PILOT BURNER ORIFICE Orifice 26 is located above brass fitting 24 Replacement 1 Remove condensate pan 2 Turn cook filter switch gas valve switch and manual gas shut 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 Manuals 414680 3 99 10 DRAIN VALVE AND FILTER SYSTEM DRAIN VALVE Used to drain oil from cooking well into filter pan or container made for handling hot oil A DANGER Never drain oil unless cook filter switch is OFF and pressure regulating valve is OPEN Hot oil could spray out under pressure causing ser
23. Remove piping from pump 19 4 Loosen three set screws 20 in neck of motor 18 which hold pump in place Remove pump 5 Assemble in reverse order using teflon tape on pipe threads Installation Hints 1 Loosen motor mounting bolts to help install piping 2 See MOTOR Installation Hints Manual 14680 3 99 Rev 7 01 Pump Cleaning Reassembly Hints Cleaning will be necessary if pump is seized 1 Pour olive oil or cooking oil on gears and tripping thermal overload on the motor and inside front cover bearing where gear shaft is installed Turn gears by 1 See PUMP Removal Remove pump hand for good oil coverage 2 Besure cover O ring is in place before tightening bolts 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 teflon tape on pipe threads Manual 14680 3 99 10 6 11 TROUBLESHOOTING Note Check all wire connections before replacing any part ELECTRICAL TIPS COMPLAINT CAUSE REMEDY 1 Hi limit trippe d 1 Resetor replac Sc not 2 Faulty light 2 Replace 3 Faulty cook filter switch 3 Replace 1 Controller in program mode 1 Exit program mod e 2 Pressure regulating valve 2 CLOSE OPEN Timer will not time 3 Microswitch faulty or out of 3 Replace or adjus t adjustment 4 Faulty cook filter switch 4 Replace 5 Faulty hi limi
24. button again will cause the control to return to normal operation WARNING DISPLAYS HI Display will flash HI if cooking oil tem perature exceeds 415 F Audible alert will sound until cook filter switch is turned OFF or hi limit trips All 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 controller func tions and heat source are disabled during this condition Cause Temperature sensor probe faulty polarity of probe wires reversed or probe wire s loose CHEC Display will flash CHEC if cooking oil temperature does not rise 6 F within the first three minutes Audible alert will sound until cook filter switch is turned OFF controller functions and heat source are dis abled during this condition Cause Faulty controller heating ele ment s 1600 1800E Only gas valve 1800GH Only contactor 1600 1800E Only probe or loose wiring Note CHEC could appear if cooking oil temperature is below 45 F Turn cook filter switch OFF then to COOK for another two minute heating period This may have to be repeated two or three times FAIL Display will flash FAIL if controller detects a fault within itself Audible alert will sound until cook filter sw
25. cook tem perature cook time and LO idle mode LO will disappear when oil temperature has reached cook temper ature value Action Press one of three program buttons once Response Display reads pro grammed value of button pressed Display will return to idle mode after five seconds Temperature Action Press cook temperature but ton twice within one second Response Programming mode has been entered Flashing display reads HHHF temperature value ie 360F Action If desired turn rotary knob to change displayed value Press cook temperature button to enter new value into memory Response Controller returns to idle mode Time Action Press cook time button twice within one second Response Programming mode has been entered Flashing display reads HEHH HHHH time value ie 08 00 Action desired turn rotary knob to change displayed value in fifteen sec ond increments Press cook time but ton to enter new value into memory Response Controller returns to idle mode AUTO COMP Automatic Time Compen sation Action Press AUTO COMP button twice within one second Response Programming mode has been entered Flashing display reads ON or OFF Action desired turn rotary knob to change displayed value Press AUTO COMP button to enter new value into memory Response Controller returns to idle mode WARNING DISPLAYSWARN ING DISPLAYS 4 2 Manual 14
26. on the display Action Press the same button again Change Cook Time Response The TIME display will show the preset time the AUTO COMP LED Action Press the TIME button once will turn on if enabled the TEMP dis play will show the preset setpoint and Response The TEMP display will turn the temperature will now regulate to off and only the TIME display will flash the new setpoint Action Key in the desired cook time and press the TIME button to save the new setting 4 5 Manual 14680 3 99 Rev 9 05 Note If a button is not pressed in ten seconds the display will revert back to both the TIME and TEMP displays flashing Change Cook Temperature Action Press the TEMP button once Response The TIME display will turn off and the TEMP display will be flash ing Action Key in the desired temperature setting and press the TEMP button to save the new setting Note If a button is not pressed in ten seconds the display will revert back to both the TIME and TEMP displays flashing Activate Deactivate Auto Comp Action Press the AUTO COMP button once Response AUTO COMP is enabled when the AUTO COMP LED is on and disabled when it is off Advance to Next Preset Action Press the RESET button once Response The CYCLE COUNT dis play will change to 1 and the presets for 1 will be displayed Repeat the process as described After the presets for 9 are displayed pressing the RESET
27. t 5 Replace 1 Controller in program mode 1 Exit program mod e 2 Faulty light or controller 2 Replace controller HEAT ON light not 3 Faulty cook filter switch 3 Replace iluminated 4 Faulty hi limi t 4 Replace 5 Faulty temperature control 5 Replace 1600 mechanical 1 Cooking oil temperature too 1 Allow oil to cool approxi Hi limit will not reset high mately 100 F 2 Faulty hi limit 2 Replace 1 Controller in program mode 1 Exit program mod e 2 Faulty element s 2 Replace Heating element s won t heat 3 Faulty contactor 3 Replace 1600 1800E 4 Faulty cook filter switch 4 Replace 5 Faulty hi limit 5 Replace 1600 1800E Cooking oil temperature too hot or too cold Manual 14680 3 99 Controller in program mode Controller needs calibrating Faulty contactor Faulty controller Faulty gas valve Faulty temperature sensor probe 11 1 CONTROLLER TIPS SOLID STATE COMPLAINT CAUSE REMEDY Display reads FAIL 1 Faulty controller 1 Replace 1 Faulty gas valve 1 Replace Display Teads HI 2 Faulty contactor 2 Replace 1 Wire polarity reversed 1 Rewire Display reads PROBE 2 Faulty temperature sensor 2 Replace probe 1 Gas valve OFF 1800GH 1 Turn ON 2 Low gas pressure 2 Check pressure 1800GH 3 Poor air gas mix 1800GH 3 Adjust air shutter 4 Main burner not on 4 See 5 6 7 8 and 11 1800GH 5 Loose gas valve wire 5 Check connections harness
28. 3 99 Rev 4 08 1800GH Solid State 2541 Manual 14680 3 99 Rev 4 08 EXPORT 1600 1800E Mechanical 2 12 Manual 14680 3 99 Rev 4 08 3Ph 50 60Hz 1Ph 50 60Hz 1600XP 1800EXP Mchanical Effective E16E401073 E18D401133 o j 9 4 8 l eco 1 i 2H09 0S 2 13 Manual 14680 3 99 Rev 4 08 EXPORT 1600XP 1800EXP Mchanical Effective E16A700023 E18A700043 2 14 Manual 14680 8 07 4 08 1Ph 50 60Hz 3Ph 50 60Hz EXPORT 1600XP 1800EXP Solid State STAR o 0 1 1 RB Y U 2 15 Manual 14680 3 99 Rev 4 08 EXPORT 1600XP 1800EXP Solid State Effective SE6E401231 SE8C400951 eee Ln i d eee V yov gt 1 ii e e e e 2 16 Manual 14680 3 99 Rev 4 08 EXPORT 1600XP 1800EXP Solid State Effective SE6A700013 SE8A700011 e DN 2 17 Manual 14680 8 07 Rev 4 08 1800GH Solid State 8 e me e Ve 2 18 Manual 14680 3 99 Rev 4 08 EU 1600CE Mechanical o Y 5 R lt a i A 1 A gt i 2 19 Manual 14680 3 99 Rev 4 08 EU 1600 1800 Solid State 579 eee 141 V eee 1 gt o lt e
29. 6 TABLE OF CONTENTS 1 WARNING SIGNS I uu 1 1 A A 1 1 A AN m na 1 4 2 ELECTRIC POWER SUPPLY a 2 1 WIRING DIAGRAMS Single and Three Phase Power Connecltion 2 1 DOMESTIC 1600 Mechanic luci n nic 2 2 16001 BODE Solid State iii 2 5 1800GH A 2 11 EXPORT 1600XP 1800EXP Mechanical 2 12 1600XP 1800EXP Solid SIG oe i c Facta e cea aka 2 15 AS 2 18 EU 1600CE Mechanical a 2 19 1600CE 1800ECE Solid State 2 20 PS GA CE NN EP 2 21 United Kingdom AS 2 22 o A 2 23 3 1600 MECHANICAL CONTROL PANIL 3 1 3 1 ACCESS FOR SERVICE cosida 3 2 INDICATOR LIGHTS 3 3 COOK FILTER SWITCH AND POWER ON 3 3 UMER MI V una mi ona mnm 3 4 A A 3 5 TAE RMO SA ee ERE A RR RR 3 6 14680 3 99 Rev 4 08 4 SOLID STATE CONTROL PANEL
30. 680 3 99 DUAL DISPLAY FAMILIARIZATION BEFORE OPERATING Cook Filter Switch Has three posi tions COOK OFF and FILTER Power On indicator Light when cook filter switch is in COOK position Hi Limit Control Prevents oil tempera ture from exceeding 475 F Turn unit OFF and DO NOT attempt to operate until it has been serviced by an autho rized Broaster Company representa tive Note It is possible for this control to trip during shipment If it does fully depress red reset button If control clicks it was tripped If not it is correctly reset 4 Heat On Indicator Light when oil is being heated Valve Closed Indicator Light Illumi nates when pressure regulating valve is CLOSED Time Display Shows time countdown during a cook cycle program values during programming and programmed time during idle period 4 3 10 11 12 13 14 15 16 Temp Display Shows set temperature and actual temperature on demand Cook Temperature Button Initiates temperature programming and display actual temperature Cook Time Button Initiates time pro gramming Numerical Keypad Enters and adjusts set point values AUTO COMP Automatic Time Com pensation Set Button and Light Indi cates timing method When OFF controller operates as a regular timer When ON controller monitors oil tem perature and adjusts time down rate to
31. Float basket while loading p 2 Food basket overloaded 2 Decrease load size Dark spots 1 Dirty oil 1 Filter or replace Manual 14680 3 99 11 6 FILTERING TIPS COMPLAINT Motor will not start A WARNING Turn cook filter switch to OFF position to avoid splashing of oil when motor protector reset button is pushed CAUSE Overload tripped Cook filter switch OFF Open or faulty wall fuse or circuit breaker Co REMEDY for overload to cool Push red motor protector reset button located on rear of motor Turn to FILTER Check wall fuse or circuit breaker Motor hums but will not start Solidified shortening in pump Crumbs in pump Turn cook filter switch OFF Clean pump Turn cook filter switch OFF Clean pump Motor starts but will not pump Filter pan not completely installed O ring on riser line not installed Solidified shortening in piping or filter pan Firmly push filter pan in See FILTERING Turn cook filter switch OFF Contact service person Motor starts but will not pump or stops at any level Filter paper or hold down improperly installed Not using enough Broaster filtering com pound See COOKING OIL CARE AND FILTERING Next filtering cycle make sure proper amount of Broaster filtering com pound is used Motor starts but stops pumping when oil is level with top of hol
32. H after July 2003 8 Part 06375 4 Part 11746 1800GH Only NTS BACK 5 Part 10900 9 Part 14463 Item 6 Part 11073 1800GH Only 1 6 Manual 14680 3 99 rev 10 04 10 415725 CAUTION bo NOT OPERATE THIS FRYER WITHOUT FILTER PAN 8 CLEAN COVER IN PLACE 11 Part 415785 Item 12 Part 15846 1800GHCE Only WARNING Rags or papers 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 ADVERTENCIA Trapos o papeles conteniendo aceite de cocinar pueden incendiar fuego si est n expuestos al calor Trapos de limpieza no son suficientes para remover el aceite completamente Dispongan todo el aceite papel y trapos con lodo en una basura que esta en un lugar ventilado lejos de todos los equipos de cocinar y lejos de otros lugares que pueden incendiar fuego como directo al pasadillo de luz del sol 8 Part 16368 1 7 Manual 14680 3 99 Rev 3 06 2 ELECTRIC POWER SUPPLY DANGER Many sections in this man A ual pertain to checking and repairing electrical components High voltage will be encountered in several instances Only per sons trained and equipped for checking high voltage sha
33. RNING Keep away from safety A relief valve opening without heat and steam protective apparel Escaping steam could cause serious burns CLUSED 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 unit Using a hot mitt 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 When handle is rotated cam 3 moves cover 4 in or out of the cooking well Cam and spacer block 5 lock the cover when pressure in cooking well pushes up on the cover 6 1 Manual 14680 3 99 Rev 7 01 FAMILIARIZATION Manual 14680 3 99 Rev 7 01 ADJUSTMENTS Height Adjustment Proper alignment of the left side yoke latch 6 and latch column 7 is essential Remove black cover and turn set screw in or out to raise or lower the yoke latch r SET SCREW UNDER BLACK COVER MODE O E Manuals 14680 3 99 Centering Cover This is important for prevention of steam le
34. VAC Controller present at 15 Does it shut off and red open glow wires Replace Open and gas valve try again Replace Transformer Is 24VAC Reset present at Is High Limit ahd valve biue Replace Yes tripped Yes Controller Monitor and yellow wires Check Switch and connections Transformer Check Switch and connections Yes Does Temperature exceed limit Yes rating Did Heat On light stay on Check controller and Temp Sensor Probe Was Did Burner stay on 24VAC when Heat On present at light was off red and blue wire Does Hi Limit trip Yes again Replace Controller No Replace gas valve Start over Controller Alarms HI CHEC PROB FAIL Temperature exceeded 415 degrees Check actual trmperature controller gas valve Temperature didn t rise 6 degrees in 3 minutes Check controller gas valve wiring and connections Problem with temperature sensing Check controller probe speaker Internal fault detected or temperature fluctuation Check controller or probe 11 10 Manual 14680 3 99 Rev 3 08 1800GH Troubleshooting Flow Chart Sheet 2 Is Proper input pressure applied Install regulator and adjust for proper gas pressure Does oil pump Yes No 15 suction present at filter line Blockage in filter lines or check valve Yes No Replace pump
35. a closed circuit If not timer is faulty Check across COM and NO with an ohmmeter Meter should indicate an open circuit If not timer is faulty Turn timer knob to zero Check across COM and NC with an ohmmeter Meter should indicate an open circuit If not timer is faulty Check across COM and NO with an ohmmeter Meter should indicate a closed circuit If not timer is faulty With needle nose pliers disconnect one timer motor wire Check across two motor wires with an ohmmeter Meter should indicate a closed circuit If not timer is faulty Replacement 1 2 See ACCESS FOR SERVICE With needle nose pliers remove wires from timer 1 With an allen wrench remove timer knob Remove timer mounting screws Install new timer in reverse order Be sure all wire connections are secure and in their original location HI LIMIT CONTROL When the control opens all controls are dis abled Check cooking oil temperature one inch below oil surface in center of cooking well If oil temperature is close to the desired cooking temperature check for a faulty control Electricity cannot travel across faulty points 1 See ACCESS FOR SERVICE 2 Fully depress red reset button then release 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
36. across center terminal and lower terminal with an ohmmeter Meter should indicate a closed circuit If not switch is faulty Turn switch to FILTER or OFF Check across center terminal and upper terminal with an ohmmeter Meter should indicate a closed circuit If not switch is faulty Replacement 1 See ACCESS FOR SERVICE Continued 2 With needle nose pliers all wires from switch 2 or 4 Loosen hex nut 11 on rear of control panel Remove small knurled nut 12 from front of switch Install new switch in reverse order Locate small groove in threaded por tion of the switch toward bottom of the control panel Be sure all wire connec tions are secure and in their original location TIMER The timer will begin time countdown when the following conditions are present COOK FILTER switch is in the COOK position POWER ON switch 15 on Pressure regulating valve 15 CLOSED Note If the buzzer sounds when timer 1 is activated the normally open NO and normally closed NC wire terminals on microswitch may be touching 1 2 See ACCESS FOR SERVICE Check all terminals and wire connec tions Refer to wiring diagram Manual 414680 3 99 10 11 Turn timer knob to any number greater than zero With needle nose pliers disconnect common COM wire terminal from microswitch Check across COM and NC with an ohmmeter Meter should indicate
37. ait five minutes before turning gas control ON 4 Slide switch 2 on top of gas valve to ON Note The Model 1800GH has an intermit tent pilot burner This type of pilot lights when the controller calls for heat and goes out when the controller is not calling for heat 5 Tolight pilot and main burners turn cook filter switch to COOK Manuals 14680 3 99 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 orifice and two specification plates Notify The Broaster Company Service Department of a conversion in writing Main Burner Orifice Sizes Up To 2000 Feet Above Sea Level Natural Gas 24 Propane 41 HIGH ALTITUDE Standard gas units operate up to 2000 feet above sea level Installations above this require a special main burner orifice Con tact The Broaster Company for orifice siz ing VENTILATION EXHAUST FLUE e Never modify exhaust flue Back pres sures from added extensions can cause high ambient temperatures near the con trols Make sure unit is correctly ventilated Restrictions drafts or other adverse con ditions might affect proper operation of the burner and combustion assemblies GAS VALVE Regulates gas supply The gas valve has a two posi
38. aks and keeping O ring wear to a mini mum Note It is important warning sign 8 be placed back into its original position and screw replaced after making this adjust ment 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 in CLOSED posi tion tighten each cover bolt a little at a time while alternating between the two REMOVAL DISASSEMBLY To remove complete cover and yoke assem bly 1 OPEN cover and push assembly to the rear CLOSE cover so it rests on the counter top LT G D 9 OL 2 Remove front panel 11 Remove bolt 12 from bottom of slide rod remove bolt from back of slide rod 1600 and remove rod 13 Complete assembly can now be removed from the unit Manuals 14680 3 99 M Em e Note If warning sign 8 becomes worn illegible it must be replaced immediately 1 Rotate cover handle 2 to a centered position 2 Loose
39. all pressure before making any repairs water before filling with shortening Disconnect electrical power before removing control panel e NSE MADE IN U S A Item 2 Part 411027 Item 3 Part 10900 DI V n 4 Part 11073 1 2 14680 3 99 3 06 WARNING SHURTENING DO NI JSE HIS CONTAINER RANSPLIR N HOT SHORTENING 4 5 Part 411028 7 Part 414463 NEVER OPEN PO RAIN ida nm AG s or papers containing cooking oil WHILE UNDER PRESSURE can catch fre 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 uipment or other Item 6 Part 06375 heat e M such as direct ADVERTENCIA Trapos o papeles conteniendo aceite de cocinar pueden incendiar fuego si est n expuestos al calor Trapos de limpieza no son suficientes para remover el aceite completamente Dispongan todo el aceite papel y trapos con lodo en una basura que esta en un lugar ventilado lejos de todos los equipos de cocinar y lejos de otros lugares que pueden incendiar fuego como directo al pasadillo de luz del sol Item 8 Part 16368 1 3 Manual 14680 3 99 Rev 3 06 1800 DEL
40. as 6 5 PRESSURE GAUGE 6 6 SAFETY BELIEF VALVE vince eo cos 6 7 7 1600 PRESSURE SYSTEM II 7 1 EXHAUST DRAIN TUBE a UE 7 2 TF TANK uq ee M m 7 2 EXHAUST TUBE un 128 PRESSURE REGULATING VALVE 7 3 14680 3 99 Rev 12 05 8 1800 PRESSURE SYSTEM nennen 8 1 EXHAUST DRAIN TUBE anta 8 2 EXHAUST TANK een aita an 8 2 EXHAUST A 8 3 PRESSURE REGULATING VALE 8 3 9 1800GH MAIN BURNER SYSTEM 9 1 MODEL 1800GH LIGHTING INSTRUCTIONS enne 9 1 GAS CONVERSION area ume Net 9 1 TN VERNA 9 1 VENTILATION ee e dett 9 2 GAS VALVE ipae MD ER UM iu ei pied 9 2 FLAME ADJUSTMENTS Ro ad he 9 3 AIR STE ee ee 9 4 COMBUSTION CHAMBER ene 9 5 MAIN BURNER ORIFICE a nn aed caida 9 6 PILOT BURNER ORIFICE een 9 7 10 DRAIN VALVE AND FILTER SYSTEM 10 1 EI O Na 10 1 FILTER PAN A OO ooo 10 2 CHECK VALVE nannte tendieren 10 3 MOTOR A lee p he 10 4 PM ee ee een en ig CE 10 5 11 TROUBLESHOOTING cin rra 11 1 ELECTRICAL TIP see ro 11 1 CONTROLLER TIPS SOLID TTD ida 11 2 GAS TIPS 1800GH
41. avel down center of the venturi A bad air gas mixture 15 the result 3 Drafts on floor can affect combustion Drafts can be caused by open doors fans and ventilation systems See VENTILATION 4 Incorrect ventilation can affect com bustion See VENTILATION 5 Gas pressure is a main factor for good operation Be sure correct water col umn 15 present See Gas Pressure Adjustment under FLAME ADJUST MENTS 6 Loose venturi 11 or bad gasket 12 can affect combustion Tighten or replace gasket Manuals 14680 3 99 AIR SHUTTER Maintains air gas mixture for good combus tion Start with a 1 4 gap after installing a new gas valve or piping Adjustment will be necessary if main burner flame is mostly orange or yellow If flame is out of adjustment check combustion cham ber and flue for soot build up WARNING soot is present DO NOT operate unit until all soot is removed and correction made Soot is black and powdery to the touch See COM BUSTION CHAMBER Adjustment 1 Loosen locknut 13 which locks air shutter 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 com
42. bustion cham ber 16 exhaust flue 15 and cooking well 17 Soot is identified as black and pow dery to the touch WARNING f soot is present DO NOT operate unit until all soot is removed and corrections made WARNING Allow combustion cham ber parts to cool before servicing Hot metal may cause serious burns Cleaning 1 Turn cook filter switch gas valve switch and manual gas shut off valve OFF 2 Turn main gas supply OFF Disconnect main electric supply Remove condensate pan Remove left and right hand side pan els Remove exhaust flue mounting screws 18 from combustion chamber Remove upper mounting nuts inside upper flue opening and remove flue 15 Remove outer wall clamp 19 Remove screw 20 on top of outer wall weldments Remove screws 21 on both sides of outer walls and remove Remove screws 22 on both sides of inner jackets and remove Clean exhaust flue inner jacket outer wall and cooking well Assemble in reverse order Manual 14680 3 99 Rev 7 01 MAIN BURNER ORIFICE Replacement 1 cook filter switch gas valve switch and manual gas shut off valve OFF Turn main gas supply OFF Disconnect main electric supply Remove condensate pan Facing the front of unit remove left hand side panel if possible Loosen two locknuts 23 behind air shutter 14 Screw air shutter and locknuts away from gas valve as far as possible
43. connected pressure regulating valve 15 OPEN and cooking oil has cooled Hat oil could spray out under pressure caus ing serious burns The following operator habits may cause the pressure system to become faulty cooking well with oil See operation manual for correct oil level Manual 414680 3 99 Overloading basket with product level will raise too high Breading then dropping Excess coating can collect in pressure regulating valve and exhaust tank See operation man ual for coating instructions Opening pressure regulating valve guickly at the end of a cooking cycle Excess coating can collect in pressure regulating valve and exhaust tank EXHAUST DRAIN TUBE Tube 1 drains condensation from exhaust tank into the condensate pan EXHAUST TANK Steam and vapors are exhausted through this tank 8 See mentioned operator habits Tank 2 can become obstructed The obstruction usually forms on the bottom of tank where exhaust drain tube 1 is con nected Tank will then become filled with lig uid Liquid may be forced up the stack 3 when pressure is released at the end of a cooking cycle Manual 414680 3 99 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
44. d down approximately 1 inch of oil in bottom Filter paper improperly installed or crumbs under filter paper or hold down 1027 Manual 14680 3 99 Rev 9 05 See COOKING OIL CARE AND FILTERING 1600 1800E Troubleshooting Flow Chart Sheet 1 Does C2 15 Power Does Light Controller 9 Yes Closed Yes Yes Heat Yes 2 em light Come on No Applied Voltage Replace present at Yes C1 coil Does C2 and Controller chatter and C1 chattering No Yes Yes Is controller Replace R2 wiring and connections Does Filter Is High Limit Is applied voltage at coil Reset and Motor Yes Yes Monitor Yes Yes work Replace Controller tripped 20 30 VAG from Transformer No Replace Controller switch and connections Replace Transformer Replace blown Yes Fuse No Check Did Heat On controller and Does Temperature exceed limit Yes Is proper rating Probe power applied Yes connections a x iS Did C2 stay Was applied Does limit closed when voltage Heat On light Yes present at Repair was off coil No No Controller Alarms HI Temperature exceeded 415 degrees Check actual trmperature controller C2 Temperature didn t rise 6 degrees in 3 minutes Check controller C2 wiring and connections PROB Problem with temperature sensing Check contro
45. e connections are secure and in their original location See wiring diagrams 3 Check across coil with an ohmmeter Meter should indicate a closed circuit not relay is faulty 4 Replace coil wire s 4 CAUTION Check oil level before turning cook filter switch to COOK 5 Connect main power supply Continued 5 11 Manual 14680 3 99 Rev 12 05 6 cook filter switch to COOK to check relay 23 You should hear a faint audible snap when HEAT ON light illumi nates Turn switch to FILTER to check relay 22 Check across terminals 2 8 6 and 4 8 8 using a voltmeter Meter should indicate applied voltage If not check for loose connections or relay is faulty e 1 1 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 sure all wire connections are secure and in their original location See wiring dia grams 5 12 Manual 14680 3 99 Rev 12 05 6 COVER AND YOKE PROPER COVER OPERATION Note Always fully rotate cover handle 2 OPEN or CLOSED Never use force to OPEN the cover OPEN only when no pressure is present in the cooking well Ce e If cover will not open easily be sure the pressure regulating valve is OPEN cover will not OPEN turn cook filter switch OFF WA
46. e 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 Manual 414680 3 99 Replacement 1 See ACCESS FOR SERVICE 2 OPEN cover Drain cooking oil from cooking well 3 Disconnect wires from control 7 4 Remove thermostat knob Continued 5 Remove capillary guard 13 from 7 Pull control bulb 16 out of cooking inside the cooking well well then remove control C 8 Insert new control bulb in same posi tion as the original Pull excess capil lary 17 out of cooking well Bend in the capillary must be large and smooth as possible A 9 Install large nut securely after applying teflon tape on threads gt 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 15 Cook a load of product and check for 6 Remove small nut 14 then large cap leaks illary nut 15 from outside the cooking well 16 Tighten smaller nut 14 if necessary Manual 14680 3 99 3 7 4 SOLID STATE CONTROL PANEL ROTARY DIAL FAMILIARIZATION 1 Cook Filter Switch Has three posi tions COOK OFF and FILTER 2 Power O
47. e power input box Tilt panel down so back 15 visible 1 Disconnect main power supply 2 Remove condensate pan and screw s from bottom of front panel Pull out and down on bottom to remove 4 8 Manual 14680 3 99 Rev 9 05 COOK FILTER SWITCH See ACCESS FOR SERVICE Check all terminals and connections Refer to wiring diagram With needle nose pliers disconnect center terminal from switch Turn switch to COOK Check across center terminal and lower terminal with an ohmmeter Meter should indicate a closed circuit If not switch is faulty Turn switch to FILTER Check across center terminal and upper terminal Meter should indicate a closed circuit If not switch is faulty Replacement See ACCESS FOR SERVICE Note where wires are connected With needle nose pliers remove all wires from switch 1 Loosen hex nut 9 on rear of control panel Remove small knurled nut 10 from front of switch 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 4 9 HI LIMIT CONTROL When controller opens all controls are dis abled except the filter motor There are two ways to determine if the con trol is faulty Control open at cooking temperature Check cooking oil temperature 1 inch below oil surface in center of cooking well Electricity cannot travel across faulty
48. ect probe 18 wires 3 OPEN cover Drain cooking oil from cooking well Close drain valve 4 19 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 bracket 21 away from temperature sensor probe 19 Note where probe bracket is located Placement is important Continued Manual 414680 3 99 rev 9 05 Loosen compression nut 14 Remove fitting 23 from outside of the cooking well Leave reducer fitting 15 in place may be necessary to move top heat ing element up or down slightly to get temperature sensor probe out from behind element Carefully pull probe out of cooking well Install new probe in the same location as old probe Relocate probe bracket Use teflon tape new fitting 23 and tighten fitting 23 into fitting 15 Tighten compression nut 14 Reconnect red and yellow wires 20 Replace controller front panel and condensate pan Replace capillary guard and basket guides Return cooking oil to cooking well See CALIBRATION Cook a load and check for leaks Tighten smaller nut 14 if necessary Replacement 1800GH lk 12 4 13 Follow steps 1 through 4 under Replacement 1600 1800E Loosen compression nut 14 Remove fitting 23 from outside of the cooking well Leave red
49. g cooking oil can catch fire if exposed to heat Laundering will not remove the oil Dispose of all oil soiled papers and rags a trash container that is in a ventilated area away from all cooking equipment or other heat sources such as direct sunlight 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 supply 2 Drain cooking oil from the cooking well and into a container made for handling hot oil then close the drain valve 3 Remove left hand side panel 1800 1600 1800 4 Loosen fitting 13 motor mounting bolts remove pipe 14 and 15 1800 slide motor back to remove pipe Continued Manual 14680 3 99 Rev 5 08 5 Unscrew valve 16 6 Remove any fittings from the valve 7 Install in reverse order using teflon tape on pipe threads Installation hint 1 When installing a fitting or pipe nipple into the valve be sure to place wrench on the same side of valve into which fit ting or nipple is being installed DO NOT tighten across the valve Distor tion of valve seat could occur 2 When installing compression fittings on tubing tighten nut finger tight then turn 1 1 4 turns more MOTOR Motor 18 turns pump 19 which returns cooking oil from filte
50. il when thermostat 1600 mechanical or the solid state control 1 See ACCESS FOR SERVICE ler calls for heat If HEAT ON light is illum minated for long periods of time this may indicate a faulty element or wire connection 1 See ACCESS FOR SERVICE 1600 SY C SEY XS SE SED 1800E 2 With needle nose pliers disconnect r u wire s from one end of holder 4 NOS gda 3 Check between two terminals of fuse E N holder with an ohmmeter Meter should indicate closed circuit If not fuse may be faulty Fuse Replacement 1 Remove end cap 5 and replace fuse 6 Continued 5 3 Manual 14680 3 99 2 Disconnect one wire 7 from sus pected element 8 3 Check across two connections of ele ment with an ohmmeter Meter should indicate a closed circuit If not ele ment is faulty Replacement 1 See ACCESS FOR SERVICE 2 Drain cooking oil from the cooking well 1600 1800E 3 Remove three brackets 9 from inside cooking well that 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 Continued Manual 14680 3 99 8 10
51. ious burns Replacement 1 2 Disconnect main electric supply Remove filter pan from under the unit Drain cooking oil from cooking well into a container made for handling hot oil Remove nut 1 2 and inter lock 3 Remove nut mounting handle 4 to the drain valve 5 Unscrew drain valve from the cooking well 6 Assemble in reverse order using teflon tape on cooking well threads Manual 14680 3 99 Rev 7 01 10 1 CONTROL ROD SHOWN CLOSED POSITION CORRECTLY INSTALLED DRAIN VALVE INTERLOCK FOOT SHOWN IN VALVE CLOSED POSITION FILTER PAN 1800 See Operation Manual for detailed filtering procedures Filter Pan Assembly WARNING DO NOT use the filter pan to transport hot oil Hot oil could splash causing serious burns 1600 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 10 2 Manual 14680 3 99 Rev 9 05 Preventive Maintenance 1600 1800 1 Use a clean cloth or paper towel to wipe crumbs from filter hold down and the filter pan interior before replacing filter paper This will help prevent crumbs from causing a poor seal or entering the riser line 11 and pump WARNING Rags or papers con tainin
52. itch is turned OFF All controller functions and heat source are disabled during this condition Cause Faulty controller Manual 14680 3 99 Rev 9 05 DISPLAY ACTUAL TEMPERATURE Action Press and hold cook tempera ture button for two seconds Response Display will show actual temperature and will vary as cooling and heating takes place Action Press cook temperature but ton again to return to idel mode CALIBRATION Calibration will be necessary when tempe ture sensor probe or controller is replaced Calibrate using an accurate non mercury test thermometer 1 Thoroughly heat cooking oil When HEAT ON light goes out stir oil HEAT ON light comes back on allow unit to recover until light goes out This may have to be done several times Press and hold cook temperature but ton for ten seconds until OFF then SET is displayed twice Release button Uncalibrated cooking oil temperature 15 displayed Calibration must be per formed Check cooking oil temperature one inch below oil surface in the center of cooking well Rotary Dial Controller Turn rotary knob to match controller display with calibrating thermometer OR Dual Display Controller Using key pad enter temperature to match con troller display with calibrating thermometer 4 7 7 Press temp button to exit calibration Manual 14680 3 99 Rev 4 08 ACCESS FOR SERVICE 3 Remove screws holding controller 12 to th
53. kit 11447 1 Remove two allen screws which attach the valve assembly to the cooking well Remove valve from the unit Loosen locking nut 9 then remove valve control yoke 10 from the stem assembly 11 Remove entire stem assembly from the housing 12 by pushing on threaded end of the stem assembly Remove all components from the stem assembly 11 Clean then dry all metal components not replaced with hot water and a mild detergent Install new parts from the repair kit Lubricate all O rings and contacting surfaces with olive oil SLOT FOR 1 16 ADJUSTMENT m z Note Be sure flat end of spacer 13 is against piston 14 8 Mount valve assembly back on cooking well with the allen screws 1 16 CONTROL RUD 1 NES 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 pres sure port located on inside top of the cooking well Using a screwdriver turn stem assembly 11 either clockwise or counterclockwise to obtain this dis tance 10 Tighten locking nut 7 2 Manual 14680 3 99 Rev 7 01 Repair Effective 5 60100613
54. ll 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 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 Ns T TAAN AA Z AA N N AA AS ZN N N ki 2 1 14680 3 99 1600 Mechanical 208 or 240VAC 2 2 Manual 14680 3 99 1600 Mechanical 208 or 240VAC Effective E16E401073 E18C401133 eee eee e e 2 3 Manual 14680 3 99 Rev 6 06 1600 Mechanical 208 or 240VAC Effective 16 700023 E18A700043 Manual 14680 8 07 1600 1800E Solid State 208 240VAC Z 2 amp 208 240 83 1110441 2 5 Manual 14680 3 99 Rev 7 05 REN Ps 5 K N au e m p 4 y lt lt hy No D 5 lt lt lt 3 f 2 gt 2 A QU 1 4 lt 49
55. ller probe speaker FAIL Internal fault detected or temperature fluctuation Check controller or probe 11 8 Manual 14680 3 99 Rev 3 08 Replace Controller Replace C2 Replace Controller Do elements Pg 2 heat Yes 1 Check elements connections Page 1 1600 1800E Troubleshooting Flow Chart Sheet 2 Does Does filter Motor Does oil pressure No work Yes pump Yes build Yes problem properly No Rebuild pressure valve Is suction present at Check o ring Does steam and filter pan escape from assembly stack Can you use slot in back of motor Is motor humming Yes Yes Yes filter line No problem to get it started Does steam escape around Yes cover Remove blockage or replace valve Replace cover ring Is thermal Separate pump Blockage in overload Reset from motor Still filter lines or tripped Yes humming check 99 No Replace Check for Remove face pump enough product and plate from pump Check switch amp wiring connections high enough temperature Replace motor if necessary and clean parts 11 9 Manual 14680 3 99 Rev 3 08 1800GH Troubleshooting Flow Chart Sheet 1 Is Power On Light On Does Filter Motor work Is Proper power applied Does Controller come on Does pilot Does pilot ignitor flame glow ignite Yes Yes 10 20 from transformer Yes Is 24
56. lve is CLOSED 3 1 Hi Limit Control Prevents oil tempera ture from exceeding 475 F Temperature Control Regulates oil temperature Heat On Indicator Light Illuminates when oil is being heated Manual 14680 3 99 Rev 9 05 ACCESS FOR SERVICE 3 Remove two screws holding control panel 9 to the power input box Tilt 1 Disconnect main power supply panel down so back is visible 2 Remove condensate pan and one screw from bottom of front panel Manual 414680 3 99 3 2 INDICATOR LIGHTS There are three indicator lights on the con trol panel Indicator lights will respectively when the POWER ON switch is on COOK FILTER switch is in COOK posi tion and unit is heating and when the pres sure regulating valve is CLOSED Replacement 1 See ACCESS FOR SERVICE 2 Disconnect wires 3 Push down on light fixture 3 5 8 8 located behind the control panel Slide fixture toward the wire end of fixture until amber lense 10 is free of fixture 4 Install new light in reverse order Be sure all wire connections are secure and in their original location Manual 414680 3 99 3 3 COOK FILTER SWITCH AND POWER ON SWITCH 2 See ACCESS FOR SERVICE Check all terminals and wire connec tions Refer to wiring diagram Turn switch to COOK or ON position With needle nose pliers disconnect center terminal from switch Check
57. n of the unit to the rear rod dirty O ring breaking 1 Dirty O ring groove 1 Clean 2 Nicks in cooking well or 2 Remove nicks CAUTION DO NOT A rest basket on top flange of cooking well Dam age to area in contact with o ring can cause leaking under pressure or O ring failure cover 11 3 Manual 14680 3 99 Rev 6 04 PRESSURE SYSTEM TIPS DANGER DO NOT attempt to tighten repair or replace any fitting line or component when there is pressure in the cooking well Hot oil could spray out under pressure caus ing serious burns COMPLAINT CAUSE Pressure regulating valve OPEN REMEDY CLOSE 2 Pressure regulating valve 2 Use repair kit dirty or blocked open 3 Leaks around cover O ring 3 Replace O ring and center cover No pressure 4 Cover cold 4 Pre heat cover 5 Low cooking oil 5 Check programmed temperature temperature 6 Faulty safety relief valve 6 Replace 7 Pressure valve out of 7 Adjust adjustment 8 Faulty pressure gauge 8 Replace 1 Restriction in exhaust 1 Locate remove then clean system Excess pressure 2 Overloaded with fresh 2 Decrease load product 3 Faulty pressure gauge 3 Replace 11 4 Manual 414680 3 99 Rev 7 01 PRODUCT TIPS COMPLAINT CAUSE REMEDY 1 Low cooking oil 1 Check cook temperature temperature 2 Wrong coating 2 Check procedures 3 No coating 3 Check procedures 4 Not done 4 Increase cook time 5 Food basket
58. n Indicator Light Illuminates when cook filter switch is in COOK position 3 Hi Limit Control Prevents oil tempera ture from exceeding 475 F Turn unit OFF and DO NOT attempt to operate until it has been serviced by an autho rized Broaster Company representa tive Note It is possible for this control to trip during shipment If it does fully depress red reset button If control clicks it was tripped If not it is correctly reset 4 Heat On Indicator Light Illuminates when oil is being heated 5 Valve Closed Indicator Light Illumi nates when pressure regulating valve is CLOSED Display Shows time countdown dur ing a cook cycle program values dur ing programming and programmed time and temperature during idle period Program Buttons Displays program values initiates programming stores desired program values and exits pro gramming mode Cook Temperature Button Cook Time Button AUTO COMP Automatic Time Com pensation Button Indicates timing method When OFF controller oper ates as a regular timer When ON controller monitors oil temperature and adjusts time down rate to compensate for fluctuations in the oil temperature Rotary Knob Changes program val ues Manual 14680 3 99 Rev 9 05 CONTROLLER PROGRAMMING CAUTION Check oil level before turning cook filter switch to COOK Action Turn cook filter switch to COOK Response Display alternates between number values for
59. n 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 4 Remove two cover bolts 12 5 Lift yoke bar up The cover 4 and spacer block 5 will remain 6 Remove lifter box 13 7 Rotate cover handle to the OPEN posi tion 8 Locate grooved pin 14 hole in the flat of the cam 3 Note Be sure to note how the handle and cam are removed Use stiff wire to tie the handle and cam together after removal 9 Usea 1 8 inch punch to remove grooved pin Remove handle and cam 10 Clean lifter box handle cam and yoke bar where lifter box slides up and down Manuals 14680 3 99 ASSEMBLY 1 Install cam 3 into yoke bar f o D uec 5222 2 Install handle 2 through splash guard into yoke bar then into the cam Align holes in handle and then install a new grooved pin 14 Be sure the grooved pin 15 installed flush with the cam 4 Lubricate inside of yoke bar where lifter box slides up and down 5 Lubricate lifter box then install lifter box into the yoke bar 6 Lower assembly over the cover 4 and spacer block 5 Continued Rotate cover handle to the CLOSED position
60. nd black at the terminal block 20 with a voltmeter Meter should indi 24VAC RELAY 24VDC RELAY cate applied voltage If not check voltage supply loose connections or ignition con trol is faulty Continued 5 10 Manual 14680 3 99 Rev 12 05 5 With heat on light illuminated check voltage across blue and brown at the ter minal block 20 with a voltmeter Meter should indicate applied voltage If not check voltage supply loose connections or ignition control is faulty 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 TRANSFORMER The transformer 21 supplies 24 volts AC to both relay coils power on light cook filter switch and solid state controller 1 See ACCESS FOR SERVICE 2 With needle nose pliers disconnect wire s from one side of the coil 1 See ACCESS FOR SERVICE 2 With needle nose pliers disconnect wire s from suspected coil 3 Check across with an ohmmeter Meter should indicate a closed circuit not transformer is faulty Replacement 1 See ACCESS FOR SERVICE 2 Remove all wires from transformer 3 Remove mounting screws and remove transformer 4 Install new transformer in reverse order Be sure all wir
61. nections opposite applied voltage wires Meter should indicate 208 or 240 volts For three phase check across any two of three connections Meter should indicate 208 or 240 volts across all combinations If not cook filter switch contactor main power supply hi 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 of contactor Any drop in voltage indicates a poor or dirty contact within the contactor 7 Disconnect main power supply 8 If either contactor will not close electri cally check coil 3 with an onmmeter With needle nose pliers disconnect wire s from one side of the coil Meter should indicate a closed circuit If not coil is faulty Replacement 1 See ACCESS FOR SERVICE 2 Remove all wires from the contactor 3 Remove two mounting screws Remove contactor 4 Install new contactor in reverse order Be sure all wire connections are secure and in their original location See wiring diagram Manual 14680 3 99 FUSE 1600 1800 HEATING ELELEMENTS 1600 1800E Two 15 amp fuses protect the control and fil ter circuits elements heat the o
62. 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 Manual 14680 3 99 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 EXHAUST TUBE Tube 7 directs steam and vapors from cooking well into the exhaust tank PRESSURE REGULATING VALVE Valve 8 is preset to maintain a maximum pressure of 12 14 psi during a cooking cycle Pressure may build slowly or remain low when cooking small loads Add one or two guartered potatoes with product to help build and maintain maximum pressure 7 3 Replacement 1 2 Disconnect main electric power supply Slide right hand sgueeze clamp on valve outlet to the left Pull silicone sleeve and exhaust tube 7 free of valve outlet Remove two allen screws mounting valve to the cooking well and remove valve See Repair Install silicone sleeve and exhaust tube onto the valve outlet Slide right hand squeeze clamp onto the valve outlet Manual 414680 3 99 9 08 Repair Prior to 5 60100613 Use repair
63. ould result in minor injury property damage or both All adjustments and repairs shall be made by an authorized Broaster Company repre sentative 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 fail ure 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 A 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 A at any time the unit fails to operate prop erly when the cook filter switch is moved to the cook position contact your local Broaster Com pany representative for service immediately 1600 1800E Solid State Controls f 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 represen tative for service immediately A WARNING Rags or papers containing cooking oil can catch fire if exposed to heat Laundering will not remove the oil Dis pose 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 Manual 14680 3 99 Rev 3 0
64. overloaded 5 Decrease product load 1 High cooking oil 1 Check cook temperature temperature 2 Product cooked too long 2 Decrease time Product too dark 3 Wrong coating 3 Check procedures 4 Coated product held in 4 Rinse then recoat refrigeration too long 5 Dirty cooking oil 5 Filter or replace 1 Low cooking oil 1 Check cook temperature temperature Product not done 2 Food basket overloaded 2 Decrease product load 3 Cook time too short 3 Increase cook time 4 Frozen product 4 Increase cook time No flavor 1 Improper marination 1 Check procedures 1 Product stuck together 1 Float food basket while White spots on product while loading loading 2 Food basket overloaded 2 Decrease load size Dark spots on product Manual 414680 3 99 Dirty oil 11 5 Filter or replace Frozen IQF Chicken COMPLAINT CAUSE REMEDY 1 Low oil temperature 1 Check cook temperature Product too light 2 Not done 2 Increase cook time 3 Food basket overloaded 3 Decrease load 1 High oil temperature 1 Check cook temperature 2 Overcooked 2 Decrease cook time Product too dark 3 Oil old 3 Change oil 4 Thawed and refrozen 4 Keep product at 0 or below 1 Low oil temperature 1 Check cook temperature Product not done 2 Food basket overloaded 2 Decrease load 3 Cook time too short 3 Increase cook time No aver 1 Overcooked 1 Check cook time 2 Old product 2 Discard White spots 1 Product stuck together 1
65. r pan to the cooking well WARNING Turn cook filter switch OFF before resetting manual reset thermal overload Motor has a manual reset thermal over load If overload trips push red reset button on back after motor has cooled Replacement Disconnect main electric power supply 2 Disconnect conduit wires and conduit from the motor Loosen three set screws 20 in neck of motor 18 which hold pump in place Remove motor mounting bolts and remove motor Install in reverse order Manual 14680 3 99 Rev 7 01 Installation Hints 1 Be sure pump is fully installed into the motor neck before tightening set screws 2 Tighten three set screws in neck alittle at_a time in sequence around neck until tight This will prevent any unnec essary binding on shafts of the pump and motor 3 Besure motor is wired for correct volt age Motor wires are numbered for 120 or 208 240V connection 120V 208 240V LOW VOLTAGE HIGH VOLTAGE P1 P2 13 18 12 14 15 P1 P2 12 13 T8 15 CCW ROTATION FACING LEAD END AS SHOWN INTERCHANGE LEADS 5 AND T8 FOR Note The dots represent wire nuts Note 1600 Rotates clockwise 1800 Rotates counterclockwise PUMP Pumps cooking oil from filter pan to the cooking well Removal 1 Disconnect main electric power supply 2 Drain cooking oil from cooking well into a container made for handling hot oil and close drain valve 3
66. rews which attach the valve assembly to the cooking well Remove valve from the unit Loosen locking nut 9 then remove valve control yoke 10 from the stem assembly 11 Remove entire stem assembly from the housing 12 by pushing on threaded end of the stem assembly Remove all components from the stem assembly 11 Clean then dry all metal components not replaced with hot water and a mild detergent Install new parts from the repair kit Lubricate all O rings and contacting surfaces with olive oil 8 F DJUSTMENI Mount valve assembly back on cooking well with the allen screws SIA NTROL ROD I 10 EL 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 pres sure port located on inside top of the cooking well Using a screwdriver turn stem assembly 11 either clockwise or counterclockwise to obtain this dis tance Tighten locking nut Manual 14680 3 99 Rev 7 01 9 1800GH MAIN BURNER SYSTEM MODEL 1800GH LIGHTING INSTRUCTIONS Start Up 1 Turn cook filter switch OFF 2 See OIL LEVEL in the operation man ual 3 Turn gas shut off valve 1 ON W
67. t traffic areas 3 Apply teflon tape to threads Screw new valve into the cover with valve dis charge opening facing the rear at an angle away from foot traffic as shown below SAFETY VALVE 1 Manual 14680 3 99 Rev 7 01 7 1600 PRESSURE SYSTEM k DANGER DO NOT attempt to tighten repair or replace any fitting line or component unless main electric power is disconnected pressure regulating valve is OPEN and cocking oil has cooled Hol oil could spray out under pressure caus ing serious burns The following operator habits may cause the pressure system to become faulty cooking well with oil See operation manual for correct oil level Manual 14680 3 99 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 man ual for coating instructions Opening pressure regulating valve quickly at the end of a cooking cycle Excess coating can collect in pressure regulating valve and exhaust tank EXHAUST DRAIN TUBE Tube 1 drains condensation from exhaust tank into the condensate pan EXHAUST TANK Steam and vapors are exhausted through this tank See previously mentioned operator habits Tank 2 can become
68. the cooking well Remove valve from the unit Loosen locking nut 7 then remove valve control yoke 8 from the stem assembly 9 Remove entire stem assembly from the housing 10 by pushing on threaded end of the stem assembly Remove all components from the stem assembly 9 Clean then dry all metal components not replaced with hot water and a mild detergent Install new parts from the repair kit Lubricate all O rings and contacting surfaces with olive oil SLUT FOR 1 15 ADJUSTME Note Be sure flat end of spacer 11 is against piston 12 8 Mount valve assembly back on cooking well with the allen screws a CONTR ID 1 CLOSED POSITION Y 6 A 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 distance in the pres sure port located on inside top of the cooking well Using a screwdriver turn stem assembly 9 either clockwise or counterclockwise to obtain this dis tance 10 Tighten locking nut 8 4 Manual 14680 3 99 Rev 7 01 Repair Effective SE8D101763 and SG8D100830 Use repair kit 15279 1 Remove two allen sc
69. tion switch OFF to stop all 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 Manuals 14680 3 99 Replacement 1 Turn cook filter switch manual gas shut off valve 1 and switch 2 OFF 2 main gas supply OFF 3 Disconnect main electric supply 4 Remove condensate pan and front panel 5 Disconnect gas valve wire harnesses 3 6 Loosen fitting 4 that mounts pilot burner gas supply line to gas valve 7 Loosen brass union nut 5 8 Loosen pipe union 6 9 Remove piping from gas valve Continued WARNING Be sure pilot burner gas A supply line is fully installed into gas valve fitting during installation If not a gas leak may be the result 10 Install in reverse order Use gas pipe sealer on pipe threads Checkall gas connections and pipes with a soap and water solution Bubbles indicate a gas leak FLAME ADJUSTMENTS Gas Pressure Adjustment Always check gas pressure after a new gas valve installation Check pressure when other gas eguipment is also operating This will ensure adeguate pressure during peak operating times There is a pressure tap in output side of the gas valve for manometer hook up Correct output gas pressures in Water Column are Natural Gas 3 5 W C Propane Gas 10 0 W C
70. ucer fitting 15 in place It may be necessary to move top heat ing element up or down slightly to get temperature sensor probe out from behind element Carefully pull probe out of cooking well Install new probe in the same location as old probe Relocate probe bracket Use teflon tape new fitting 23 and tighten fitting 23 into fitting 15 Tighten compression nut 14 Reconnect red and yellow wires Replace controller front panel and condensate pan Replace capillary guard and basket guides Return cooking oil to cooking well Manual 14680 3 99 rev 9 05 13 See CALIBRATION 14 Cook aload and check for leaks 15 Tighten smaller nut 14 if necessary 4 14 Manual 414680 3 99 rev 9 05 5 POWER INPUT BOX 1600 Pressure Fryer 1800E Pressure Fryer gg 5 1 Manual 14680 3 99 CONTACTORS 1600 1800 Primary contactor 1 is controlled by the cook filter switch This contactor opens if hi limit opens Secondary contactor 2 is con trolled by the thermostat control 1600 mechanical or the solid state controller 1 See ACCESS FOR SERVICE CAUTION Check oil level before turning cook filter switch to COOK 2 Connect main power supply 3 Turn cook filter switch to COOK You should hear an audible snap followed by another shortly after the first 4 Check voltage through primary contac tor 1 using a voltmeter For single phase check across two outside con

Service Manual 09/2008

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